Automation System TROVIS 6400

Compact Controller
TROVIS 6493

Mounting and
operating instructions

EB 6493 EN
Firmware version 2.0 and 3.0
Edition January 2001
 Firmware version 2.0, 3.0

Modifications of firmware version 2.0 and 3.0

The TROVIS 6493 Compact controller has been extended by the version 6493-02 (Firmware
version 3.0). This version’s hardware is different from version 6493-01 (Firmware version
2.0) as regards to the In2 input. The version 6493-02 has two mA inputs. The result is a
change of function IN2 in the main group (IN), see chapter 3.2.2.

The software has also been extended for both version of the compact controller:
 6493-01 Firmware version 2.0
 6493-02 Firmware version 3.0.
A new main group, PAR, has been implemented. This group allows faster setting of Kp, Tn
and Tvs parameters (see chapter 3.1).
The main group, AUX, has been supplemented with the function DP. This function allows the
user to determine how many decimal places for the analog input variables are indicated in
the display (see chapter 3.7.6).
In the main group, I-O, the serial number of the device is now indicated under S-No (see
chapter 3.9.2).
Moreover, the factory settings of several parameters have been changed (see Table
Appendix A).
In the parameter level, the selector key has been given a special function to allow even faster
modifiation of the parameters: each time you press the key, the indicated value is multiplied
by 10 until the end of the value range is reached for that parameter. When the key is pres-
sed again, the display jumps to the start of value range of the same parameter.
Contents
1 Notes............................................................................................................ 3
2 Operation ..................................................................................................... 4
2.1 Display...........................................................................................................4
2.2 Key ............................................................................................................5
2.3 Operating level...............................................................................................6
2.4 Setup level......................................................................................................7
2.5 Key number ....................................................................................................8
2.6 Example for configuration and parameterization.............................................10
3 Functions of the compact controller .............................................................. 14
3.1 PAR Fast setting of Kp, Tn, Tv parameters........................................................14
3.2 IN Input functions ..........................................................................................14
3.2.1 IN1 Input signal range IN1 ................................................................. 16
3.2.2 IN2 Input signal range IN2 ................................................................. 16
3.2.3 MEAS Measuring range monitoring for analog input 1 and 2 .............. 17
3.2.4 MAN Changeover to manual mode upon transmitter failure .................. 17
3.2.5 CLAS Assignment of X and WE ........................................................... 18
3.2.6 DI.FI Filtering of X and WE ................................................................. 18
3.2.7 SQR Root extraction ........................................................................... 18
3.2.8 FUNC Function generation of X and WE.............................................. 19
3.3 SETP Reference variable ................................................................................20
3.3.1 SP.VA ............................................................................................... 22
3.3.2 SP.FU ................................................................................................ 23
3.4 CNTR Controller structure and functions ..........................................................24
3.4.1 C.PID Dynamic behavior of controller output ........................................ 24
3.4.2 SIGN Inversion of error Xd.................................................................. 26
3.4.3 D.PID Assignment of controller output D element................................... 26
3.4.4 CH.CA Control mode changeover P(D)/PI(D) ....................................... 27
3.4.5 M.ADJ Operating point adjustment in manual mode for YPID ................. 28
3.4.6 DIRE Operating direction of output variable ......................................... 28
3.4.7 F.FOR Feedforward control ................................................................. 28
3.4.8 AC.VA Increase, decrease of actual value............................................ 29
3.5 OUT Output definition ...................................................................................30
3.5.1 SAFE Initialization of 2nd output variable Y1K1 for YPID ....................... 30
3.5.2 MA.AU Manual/automatic transfer ..................................................... 30
3.5.3 Y.LIM Output signal limitation YPID....................................................... 32
3.5.4 RAMP Output ramp or limitation of rate of output changes YPID ............. 32
3.5.5 BLOC Locking of output signal YPID ...................................................... 34
3.5.6 FUNC Function generation of output variable ....................................... 34

EB 6493 EN 1
3.5.7 Y.VA Output signal range................................................................... 34
3.5.8 Y.SRC Assignment of continous output ................................................. 35
3.5.9 CALC Mathematical adaptation of continuous output Y ........................ 35
3.5.10 C.OUT Configuration of two-step or three-step output .......................... 36
3.5.11 B.OUT Configuration of binary outputs BO1 and BO2 .......................... 45
3.6 ALRM Alarm functions ..................................................................................46
3.6.1 LIM1 Limit relay L1 ............................................................................. 47
3.6.2 LIM2 Limit relay L2 ............................................................................. 47
3.7 AUX Additional functions ..............................................................................48
3.7.1 RE.CO Restart conditions upon power failure ....................................... 48
3.7.2 ST.IN Resetting to factory default ......................................................... 48
3.7.3 KEYL Operator keys ........................................................................... 49
3.7.4 VIEW Setting of display contrast.......................................................... 49
3.7.5 FREQ Power frequency ....................................................................... 49
3.7.6 DP Decimal point setting ..................................................................... 50
3.8 TUNE Start-up adaptation .............................................................................50
3.8.1 ADAP Start-up adaptation .................................................................. 50
3.9 I-O View process data...................................................................................53
3.9.1 CIN Firmware .................................................................................... 53
3.9.2 S-No Serial number ........................................................................... 53
3.9.3 ANA View values of analog inputs...................................................... 53
3.9.4 BIN Status of binary input and outputs ................................................. 53
3.9.5 ADJ Adjusting the analog inputs and output......................................... 54
4 Practical examples ...................................................................................... 55
4.1 Fixed set point control ...................................................................................55
4.2 Follow-up control ..........................................................................................56
4.3 Follow-up control with function generation ......................................................58
5 Start-up ...................................................................................................... 60
5.1 P controller ...................................................................................................60
5.2 PI controller ..................................................................................................60
5.3 PD controller.................................................................................................61
5.4 PID controller ................................................................................................61
6 Installation .................................................................................................. 62
7 Electrical connections................................................................................... 64
8 Technical data ............................................................................................. 66
Appendix A Function and parameter table .................................................................. 68
Appendix B Error messages ........................................................................................ 88
Appendix C Checklist.................................................................................................. 89
Index .......................................................................................................... 93

2 EB 6493 EN
 1 Notes

1 Notes
The TROVIS 6493 Compact Controller is a microprocessor-based controller with a flexible
software design for automating industrial process plants. It is suitable for single control loops
as well as for complex control tasks. The flexible software design gives you the power to con-
figure control circuits without changing the hardware. The fixed-programmed functions can
be adapted to your specific plant configuration.
These Mounting and operating instructions (EB) describe the controller’s powerful capabili-
ties. To give you a good start, we make you familiar with the convenient operation. All the
functions and parameters are described in chapter 3. Then some practical examples are gi-
ven in chapter 4 to show you which settings are needed for which task. Chapters 6 and 7 ex-
plain the electrical connections and the installation. At the end, the index gives you direct
reference in case you have specific questions or problems.

Caution!
! Assembly, start-up and operation of the device may only be performed by
trained and experienced personnel familiar with this product.

EB 6493 EN 3
 2 Operation 2.1 Display

2 Operation
In this chapter, you learn how to operate the controller. First, open the folded back cover of
this EB. You can see now the controller’s front panel with its display and six keys.
Principally, there are two levels which provide different key functions and different displays:
these are the operating level and the setup level. The functions of the controller are defined
by configuration and parameterization procedures. A table containing all the details necessa-
ry for parameterization and configuration is provided in Appendix A. In addition, we will
give you a suitable example in chapter 2.6 to show you how to use this table.

2.1 Display
Depending on the selected level, the display shows the following variables and operating sta-
tuses (see folded back cover):
Item Operating level Setup level

1 Controlled variable X Designations, settings and

values of functions,
2 Value assumed by W, W2, WE, Y or Xd parameters;
abbreviations are listed in
Appendix A

3 Limit relay L2 active Not displayed

4 Three-step output − Not displayed

5 Limit relay L1 active Not displayed

6 Three-step output + or two-step output Not displayed

7 Alarm messages See chapter 3.2.3 Not displayed

8 Hand symbol appears when in manual mode Not displayed

No symbol when in automatic mode

9 and are used for

Press the key to display W, W2, WE, Y or
minimum and maximum
Xd% in sequence. The associated value
values of different
appears in (2).
parameters.
W2 and WE only when they have been activated, see chapter3.3.1

10 Bar graph display of Xd in percent Not displayed

4 EB 6493 EN
 2.2 Keys 2 Operation

2.2 Keys
You operate the compact controller via six keys whose functions depend on the selected level.

Key Function in operating level Function in setup level

Program- Provides access to setup level. Activates functions and

ming key parameters to be changed
(yellow) Activates a new reference variable, (display is blinking).
provided that its symbol (W, W2 Acknowledges new setting of
or WE) is blinking on the display (9). functions or parameters
(display stops blinking).

Selector key Changes the lower display section: Provides access to parameter
W internal reference variable 1, level.
W2* internal reference variable 2,
WE* external reference variable, Jump within the value range
Y continuous output variable, in the parameter level.
Xd% error.
* Only when selected, see p.22.

Manual/auto Changes from manual to automatic mode No function

transfer key and vice versa.
In manual mode, the symbol appears.

Cursor keys Change the value of W or W2 provided that Browse within the main
they are displayed on the lower display groups, the functions, settings
section. and parameters.
Change the controller output when in manual Change function settings and
mode and when Y is indicated on the lower parameter values.
display section.

Reset key Displays the current reference variable. Return to preceeding level up
to the operating level.

No key After approx. 5 minutes, display changes to Changes to operating level

pressed current reference variable. after approx. 5 minutes.
Exception: in manual mode and display of output variable

EB 6493 EN 5
 2 Operation 2.3 Operating level

2.3 Operating level

In the operating level, Press Note!

you can

view different variables: W, selector key repeatedly W2 and WE are only

W2, WE, Y, Xd. until the desired displayed when you have
variable appears on activated them in SETP,
the display. see chap. 3.3.1.

select another reference selector key repeatedly When the reference variables
variable. until the desired are inactive, W, W2 or WE
reference variable (W, are blinking. Whereas they
W2 or WE) appears on are not blinking when active.
the display.
Finally, activate the
programming key.

change the value of the inter- selector key repeatedly New value is accepted at
nal reference variable W or until W or W2 appears, once.
W2. then change the value No acknowledgement
using the cursor keys. required.

switch to manual mode. manual/auto transfer In manual mode, use the

key. cursor keys to determine the
output variable.

change the output variable. manual/auto transfer

key, to display Y.
Change its value using
the cursor keys.

enter the setup level for programming key. Do not use it when W, W2 or
configuration and para- WE are blinking, otherwise
meterization. you activate a new reference
variable!

6 EB 6493 EN
 2.4 Setup level 2 Operation

2.4 Setup level

This level is the platform for configuration and parameterization. You can enter the setup le-
vel from the operating level by pressing the programming key once. Here, you can adapt
preset functions to your specific needs (configure) and change parameters. The functions are
part of nine so-called main groups:
 PAR (fast setting of Kp, Tn and Tv parameters)
 IN (input functions)
 SETP (reference variable)
 CNTR (control structure and functions)
 OUT (output functions)
 ALRM (alarm functions)
 AUX (additional functions)
 TUNE (start-up adaptation)
 I-O (view process data)
The parameters are always connected to the function they are assigned to. This means that
pressing the selector key allows you to access only the parameters that are relevant for
the particular function you have chosen.
Appendix A lists all the functions and parameters provided by the compact controller. The ta-
ble includes the main groups and their functions with the setting options in the left column,
and the associated parameters in the right column. This table will be a great help in learning
how to operate the controller. You just have to keep in mind the following:
To move from the left to the right (in columns), use the programming key .
To move in the reverse direction (from the right to the left), use the reset key .
The key number (KEY) will be prompted in the setup level only for the first change of a
function or parameter.
The right column of the table, i.e. the parameters, can be accessed by pressing the selector
key . Then press again the programming key to move forward in columns.
To move in rows from top to bottom, press the cursor key .
Moving in the reverse direction is done by pressing the cursor key . Confirm the new set-
ting or the new value by pressing the programming key .
How to configure and parameterize properly will show an example in chapter 2.6.
Note: The display changes from the setup level into the operating level after 5 minutes if
no key is pressed!

EB 6493 EN 7
 2 Operation 2.5 Key number

2.5 Key number

You are prompted to enter the key number when you want to change the setting of
functions or parameters.
The compact controller can be operated with or without a key number. Factory default is
without key number. Each time you prepare to change a function or a parameter in the setup
level for the first time, the key number is prompted. Then perform the following steps:
Press! Display shows Comment

KEY is blinking. You must now enter the key

number.

Omit the following step for operation without

key number.

Note: With this display, the key number can

always be changed, see following section.

KEY is blinking.
Enter the valid key number. In this example, it
or
is 12.

If you have entered the correct key number, the selected function is blinking on
the display. If not, the key number is prompted once more and 1 appears in the
upper display section, meaning the controller operates with key number.
Enter the key number again or cancel by pressing the reset key .

Changing the key number

You can define a new key number or set up the controller to operate without key number.
When defining a new key number, you first need to know the service key number which you will
find on page 95. To prevent any misuse, you should cut it out or make it unreadable.
Proceed as described on the next page to define a new key number:

8 EB 6493 EN
 2.5 Key number 2 Operation

Press! Display shows Comment

You are in the operating level.

The display looks like this.

KEY is blinking.
3x
Note: When you see this display, the key
number can always be changed.

KEY is blinking.
Enter the service key number. See page 95.
or

You have acknowledged the service key

number. You now see KEYP which stands for
key number programming. The upper display
section shows the current key number. The
four dashes stand for "no key number".

Enter the new key number ( - - - - for "no key

number"). We have chosen 12 in this
example.

EB 6493 EN 9
 2 Operation 2.6 Example for configuration and parameterization

Press! Display shows Comment

You have acknowledged the new key number

and return to the selected function or
parameter. In our example, we return to the
Kp value.

2.6 Example for configuration and parameterization

We will use the "Function and parameter table" provided in Appendix A to learn configura-
tion and parameterization procedures. The exercise consists of setting up the controller to be
a PID controller and adjusting the controller parameters accordingly.
The biggest problem to solve is of course where to find the appropriate function and what to
change in this function. There are two ways to proceed. You may search for the function in
the table in Appendix A where you also find some reference to further details, or you may
look it up in the index. With PID controller, you will find the function C.PID which is part of
the main group CNTR. As you know now which main group to activate and which function
to change, carry out the following steps:
Press! Display shows What happens!

You are in the operating level.

You have entered the setup level. The display

shows the first main group IN.
Main groups are always displayed in a single
line. You are now in the first column of the
table in Appendix A.
Note: If you press the programming key
again, you reach Kp, see page 12.

10 EB 6493 EN
 2.6 Example for configuration and parameterization 2 Operation

Press! Display shows What happens!

You browse through the main groups [in the

repeatedly
table in Appendix A you move from top to
until CNTR
bottom] until you reach the main group CNTR.
appears!
Here, you adjust the dynamic behavior of the
controller output.

You have entered the main group CNTR

[moved to the right in the table] and arrived at
the functions. Functions are always marked
with -CO- for configuration.
The display shows the first function C.PID,
"Dynamic behavior of controller output ", in our
case the function we have been looking for.

You have moved again one column to the right

and see now the current setting of the function:
PI action. This setting is to be changed to PID
action.

Now you have to enter the key number (KEY).

The prompt appears when you, upon entering
KEY is blinking
of the setup level, change a function for the
first time. You will not be prompted for the
following changes.
If you do not use a key number, leave out the
next step.

Use the cursor keys to enter the key number. In

our example, this is 27.
or

EB 6493 EN 11
 2 Operation 2.6 Example for configuration and parameterization

Press! Display shows What happens!

After having entered the correct key number,

the display looks like this. If not, the prompt
will be repeated. The upper section is
blinking, meaning that you may change the
setting of the function. In the table, you have
moved another column to the right and
reached "Setting options".

The upper section is blinking!

Use the cursor keys to choose the desired
or
setting, which is in our example PId standing
for PID action of the controller output.

You have acknowledged the new setting. The

upper display section stops blinking.
Bravo! The first part of the task is completed.
Now change the control parameters KP, TN
and TV. To do so, you need to enter the
parameter level.

Press the selector key to open the parameter

level. In the table, you have jumped to the first
column on the right page.
The lower display section shows C.PID and
CP.YP in turn.

The first parameter Kp is displayed.

Note: You can go directly from the PAR

display to this display if you press the
programming key (yellow key) once. You can
just change the KP, TN and TV parameters.

12 EB 6493 EN
 2.6 Example for configuration and parameterization 2 Operation

Press! Display shows What happens!

KP is blinking, i.e. you can change this

parameter.

Adjust a new value for KP.

For our example, this would be 1.5.
or
The upper section continues blinking.

You have acknowledged the new value for Kp.

The upper section now stops blinking.

The next parameter is displayed.

To change this and other parameters, proceed
in the same way as for KP, i.e. repeat the steps
in the shadowed fields.

You are now back in the operating level! The

repeatedly
symbol indicates that the compact
until the display
controller is in manual mode.
looks like this!

EB 6493 EN 13
 3 Functions of the compact controller 3.1 PAR Fast setting of Kp, Tn, Tv parameters

3 Functions of the compact controller

This chapter describes each function of the setup level. We assume that you are familiar with
the operation of this controller and know how to change functions and parameters.
The compact controller contains nine main groups: PAR, IN, SETP, CNTR, OUT, ALRM, AUX,
TUNE and I-O. Each of the chapters 3.2 to 3.9 is dedicated to one of the main groups. The
main groups have different functions that can be identified by - C O - displayed in the
upper display section. The functions are explained in the subchapters (e.g. 3.2.1) where you
can already derive the type of function from the headline. Almost every function provides dif-
ferent setting options from which you can choose one to adapt this function to your specific
needs. The setting options of the functions are marked with a small grey square in this EB.
If you need to additionally adjust parameters for your function, they will be specified and ex-
plained as necessary. The value range of the parameters and factory default can be found in
Appendix A.

3.1 PAR Fast setting of Kp, Tn, Tv parameters

This main group fulfills a special purpose. In contrast to all other main groups, it does not in-
clude any functions. When you open this level, it immediately jumps to the parameter level
where you can set the Kp, Tn and Tv control parameters.
This main group allows you to quickly set the control parameters. You can also carry out the
same settings in the main group CNTR, function C.PID.

3.2 IN Input functions

This main group defines all the functions of the two analog inputs In1 and In2. You can speci-
fy the input signal range and assign the analog inputs to the controlled variable X or the ex-
ternal reference variable WE. In addition, you can determine the measuring range of both
signals. You may also perform measuring range monitoring and filter as well as generate a
function of the input signal.

14 EB 6493 EN
 IN I–O IN I–O IN ALRM

Fig. 1 : Main group IN

3.2 IN Input functions

IN1
Input Root LIM1 LIM2
assignment Dig. filter extraction Function generation
A
WE
D F WE
IN1 WE.VA LIM1[L1.WE] LIM2[L2.WE]
CLAS[WE] DI.FI[WE] SQR[WE] FUNC[WE]

A
X
D F X
IN2
CLAS[X] DI.FI[X] SQR[X] FUNC[X]
Measuring range IN2
monitoring
LIM1 LIM2

CO.VA LIM1[L1.X] LIM2[L2.X]

MEAS MAN

EB 6493 EN
3 Functions of the compact controller

15
 3 Functions of the compact controller 3.2 IN Input functions

3.2.1 IN1 Input signal range IN1

This function enables you to define the input signal type and range for the analog input In1.
The parameters lower and upper range value must be given in absolute values.
Choose between:
0-20 mA 0 to 20 mA input
4-20 mA 4 to 20 mA input
0-10 V 0 to 10 V input
2-10 V 2 to 10 V input
Parameters to be set
IN1 Lower range value as absolute value
IN1 Upper range value as absolute value

3.2.2 IN2 Input signal range IN2

Please note that there are two hardware versions for the analog input In2: controller version
6493-01 (model no. on the nameplate) has a temperature sensor or potentiometer input,
whereas, controller version 6493-02 has a mA input.

IN2 for controller version 6493-01

This function enables you to define the input signal type and range for the analog input In2.
The measuring range must be specified with the parameters IN2 and IN2. Make sure that
the span is not smaller than 100 °C.
Choose between:
100 PT Pt 100 resistance thermometer −100 to 500 °C
1000 PT Pt 1000 resistance thermometer −100 to 500 °C
100 NI Ni 100 resistance thermometer −100 to 500 °C
1000 NI Ni 1000 resistance thermometer −60 to 250 °C
0-1 KOHM 0 to 1000 Ω input
Parameters to be set
IN2 Lower range value as absolute value
IN2 Upper range value as absolute value

IN2 for controller version 6493-02

This function enables you to define the input signal type and range for the analog input In2.
Enter the parameters lower range and upper values as absolute values of the size you require.

16 EB 6493 EN
 3.2 IN Input functions 3 Functions of the compact controller

Choose between:
0-20 mA 0 to 20 mA input
4-20mA 4 to 20 mA input
Parameters to be set
IN2 Lower range value as absolute value
IN2 Upper range value as absolute value

3.2.3 MEAS Measuring range monitoring for analog input 1 and 2

This function enables you to define whether the measuring values of the analog inputs are to
be monitored either for exceeding or falling below the measuring range.
Choose between :
oFF ME.MO No measuring range monitoring
In1 ME.MO Measuring range monitoring of analog input IN1
In2 ME.MO Measuring range monitoring of analog input IN2
ALL ME.MO Measuring range monitoring of both analog inputs IN1 and IN2

When values exceed or fall below the measuring range, this is signalized on the display by
the alarm message symbol , and the binary output is set. In addition, "__o1" is blinking
on the upper display section when values exceed the measuring range and "__u1" when va-
lues fall below the measuring range of the analog input 1, or analog inputs 1 and 2. When
the analog input 2 exceeds or falls below the measuring range, " __o2" or "__u2" appears
on the display. Whenever values exceed or fall below the measuring range, the compact con-
troller can change over to manual mode, see chapter 3.2.4.

3.2.4 MAN Changeover to manual mode upon transmitter failure

This function enables you to define whether the controller switches manual mode and which
output value is generated when the measuring range is exceeded or not reached. This
function becomes effective only when measuring range monitoring has previously been acti-
vated in the function MEAS, see the preceeding chapter 3.2.3. Manual mode is easily recog-
nized by the symbol on the display.
Choose between:
oFF FAIL No changeover to manual mode upon transmitter failure
F01 FAIL Changeover to manual mode with 2nd output variable Y1K1
F02 FAIL Changeover to manual mode with last received output value
Parameter to be set
Y1K1 2nd output value
Note: When values exceed or fall below the measuring range, Y1K1 becomes effective only
when the compact controller is in automatic mode.

EB 6493 EN 17
 3 Functions of the compact controller 3.2 IN Input functions

The parameter Y1K1 can also be set in the main group OUT via the function SAFE as well as
in the main group AUX via the function RE.CO, see chapters 3.5.1 and 3.7.1.

3.2.5 CLAS Assignment of X and WE

The compact controller operates internally with the analog input signals X and WE. The
function CLAS is used to assign these signals to the analog inputs IN1 or IN2. Principally, X
is assigned to the analog input IN2 and WE to the analog input IN1.
Assignment of X
IN1 X X assigned to analog input IN1
IN2 X X assigned to analog input IN2
Assignment of WE
IN1 WE WE assigned to analog input IN1
N2 WE WE assigned to analog input IN2

3.2.6 DI.FI Filtering of X and WE

This function enables you to determine whether X and/or WE are to be filtered.
The first-order filter (low-pass filter or Pt1 behavior) smoothes the selected signals and sup-
presses input signal interferences of higher frequency.
The time constant of the Pt1 element is defined by the parameter TS.X for the input signal
X, and by TS.WE for the input signal WE. The time constant is given in seconds.
Filtering of input variable X
oFF X Filtering of input variable X deactivated
on X Filtering of input variable X activated
Filtering of input variable WE
oFF WE Filtering of input variable WE deactivated
on WE Filtering of input variable WE activated

Parameters to be set
TS.X Time constant X filter, in seconds
TS.WE Time constant WE filter, in seconds

3.2.7 SQR Root extraction

This function enables you to root-extract the signals X as well as WE. So you have the possi-
bility to easily calculate, for example, the flow rate of the differential pressure.
Choose :
Root extraction X
oFF X No root extraction of signal X
on X Root extraction of X

18 EB 6493 EN
 3.2 IN Input functions 3 Functions of the compact controller

Root extraction WE
oFF WE No root extraction of signal WE
on WE Root extraction of WE

3.2.8 FUNC Function generation of X and WE

You may apply function generation to the signal X as well as WE.
Choose between:
Function generation of X
oFF X No function generation of signal X
on X Function generation of X
Function generation of WE
oFF WE No function generation of signal WE
on WE Function generation of WE
Function generation means that a signal is re-evaluated to be further processed. This allows
adapting auxiliary, reference or equivalent variables which are necessary for measuring and
control to your specific con-
trol loop. For this purpose,
E' you need to plot 7 points to
characterize the relationship
MAX between the signal to be
K7.Y function-generated E (X or
E E' WE) and the desired new
K5.Y
output signal E’ (X’or WE’).
This relationship is known to
you from physical laws, ex-
perience or calculated valu-
K1.Y
MIN es, as it is the case for the
K1.X K5.X K6.X K7.X E relationship between steam
MBA MBE pressure and temperature.
We recommend that you eit-
MBA Lower range value MBE Upper range value
her construct a table or cre-
Fig. 2 : Example for function generation ate a curve in a Cartesian
coordinate system. Choose
the 7 points in such a way that a curve can be easily created by drawing straight lines be-
tween two adjacent points.
The points for the input signal are entered via the parameters K1.X to K7.X, for the output si-
gnal, they are entered via the parameters K1.Y to K7.Y. The values are fixed as absolute va-
lues, i.e. in units of measurement comprehensible for the user (in °C, bar or %).

EB 6493 EN 19
 3 Functions of the compact controller 3.3 SETP Reference variable

Even when the signal curve can be sufficiently characterized by less than 7 points, you al-
ways have to plot 7 points. As appropriate, you may define the seventh point to be located
in the same position as the last point.
The parameters MIN and MAX are used to determine the measuring range of the output si-
gnal E’. It corresponds to that of the not function-generated signal E with reference to the
output signal E’. By entering these two parameters you create the proper basis for the per-
centage calculation performed by the software.
If K1.Y or K7.Y do not agree with MIN and MAX, the output values for the function-generated
signal which are below or above these limits are constantly set to K1. Y or K7.Y. The com-
pact controller completes in this way the polygonal curve by generating straight lines (see
Fig. 2).
If you have entered an output value greater than MAX or smaller than MIN, it will be set to
the value of MAX or MIN.
You will find an application example of function generation in chapter 4.3.

Note:
The course of the polygonal curve is not limited by the software. Polygonal curves with more
than one maximum or minimum are possible. However, make sure that you assign only one
ordinate value to one abscissa value. Otherwise you risk to lose clear assignment of the input
signal.

Parameters to be set
MIN Lower range value of output signal
MAX Upper range value of output signal
K1.X bis K7.X Input values for points 1 to 7
K1.Y bis K7.Y Output values for points 1 to 7

3.3 SETP Reference variable

This main group enables you to determine one or more reference variables and you can
change from one to another as required. The compact controller has two internal reference
variables W and W2 for fixed set point control, however, W2 must be activated by you.
Standard setting of the controller is fixed set point control. To obtain follow-up control, you
just have to activate the external reference variable WE. However, the input WE can also be
used for fixed set point control, serving then as input for position transmission with a three-
step output and external position feedback, or for feedforward control. If you want to activate
one of these other control modes, you have to fix this here. Moreover, you can select a set
point ramp with various starting conditions.

20 EB 6493 EN
 Fig. 3 : Main group SETP
3.3 SETP Reference variable

I–O SETP I–O

FE.CO

SP.CO
Reference variable selection
Set point
WE ramp
WE

W W

W2 W2
RAMP
BI SP.FU
CH.SP W/W2/WE

SP.FU SP.VA

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3 Functions of the compact controller

21
 3 Functions of the compact controller 3.3 SETP Reference variable

3.3.1 SP.VA
This function enables you to define which reference variables are active: W, W2 or/and
WE. When you activate WE, follow-up control will automatically be in effect, except that you
use WE as input for position transmission with three-step output and external position feed-
back (F01 WE), or for feedforward control (F02 WE).
In the parameter level, you define the desired value of the reference variable (W, W2) and
its measuring range ( WINT, WINT). You can limit this measuring range via the para-
meters WRAN and WRAN. The value of the reference variable can only be chosen
to be between WRAN and WRAN, this also applies to the operating level.
Choose between:
Internal reference variable W
on W Internal reference variable W, always active
Parameters to be set
W Internal reference variable W
WINT Lower range value for W, W2, WE
WINT Upper range value for W, W2, WE
WRAN Limitation of W, W2, WE, lower limit
WRAN Limitation of W, W2, WE, upper limit

Internal reference variable W2

oFF W2 Internal reference variable W2 not active
on W2 Internal reference variable W2 active
Parameter to be set
W2 Internal reference variable W2

External reference variable WE

oFF WE External reference variable not active
on WE External reference variable active
F01 WE WE as input for external position feedback with 3-step output
F02 WE WE as input for feedforward control (in this case, WE is not displayed
in the operating level! It is only displayed in the I-O level, see chapter 3.9.3)

22 EB 6493 EN
 3.3 SETP Reference variable 3 Functions of the compact controller

3.3.2 SP.FU
This function enables you to define a set point ramp and change between the different refer-
ence variables through the binary input.
The term set point ramp means that the reference variable changes at constant rate. When the
reference variable is changed, the compact controller follows this change with a certain delay
to prevent against oscilla-
W tions. The transit time of the
WINT set point ramp is determined
by the parameter TSRW.
TSRW refers to the entire de-
W2 fined measuring range, so
this would be WINT and
W1
WINT. When the refer-
ence variable changes from
a value W1 to a new value
WINT
t1 t W2, the actual transit time of
TSRW the set point ramp is the time
WINT Upper range value W1 Previous value of ref. variable t1 as shown in Fig. 4. You
WINT Lower range value W2 New value of ref. variable can start the set point ramp
TSRW Transit time of set t1 Actual transit time of set
point ramp point ramp via the binary input and
Fig. 4 : Set point ramp
choose between two starting
values (actual value or para-
meter WIRA). The set point ramp can also be active upon each change in the reference varia-
ble.
Choose between:
Set point ramp
oFF RAMP Set point ramp deactivated
F01 RAMP Set point ramp starts with BI1 and actual value
F02 RAMP Set point ramp starts with BI1 and WIRA
F03 RAMP Set point ramp activated, no starting conditions
Parameters to be set
TSRW Transit time of set point ramp in seconds
WIRA Starting value of reference variable in absolute values
You can use the binary input to change between the internal and external reference variable:
Changeover of W via BI1
oFF CH.SP No changeover between internal reference variable W (W2) and
external WE
F01 CH.SP Changeover between active internal reference variable W (W2) and
external reference variable WE via binary input BI1

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 3 Functions of the compact controller 3.4 CNTR Controller structure and functions

F02 CH.SP Changeover between internal reference variables W and W2 via

binary input BI1. If W2 is active when setting the binary input,
no function will be performed. The function -CO- SP.VA may not
be set to "ON" for WE.
Note: The binary input can be assigned to several functions!

3.4 CNTR Controller structure and functions

This main group enables you to determine the functions for the controller algorithm. You can
define the dynamic behavior of the controller output, the operating direction of error and the
output variable, select the input variable for the D element and fix control mode changeover.
If you use the input WE for feedforward control, you may link this signal with parameters.
The binary input can also be used to influence the actual value.
Finally, you have the option of defining an operating point in manual mode, which is then
added to the calculated operating point in automatic mode.

3.4.1 C.PID Dynamic behavior of controller output

This function enables you to define the dynamic behavior to be performed by the compact
controller. Factory default is PI action. You can also define the control parameters in this
function. For the error, you can define the dead band DZXD within which the control signal
does not change. In addition, you can determine limit values for the error with the parame-
ters DZXD and DZXD. Minimum or maximum values of error are then used for output
signal calculation.
Choose between:
P P controller
PI PI controller
PD PD controller
PID PID controller
PPI P2I controller
Parameters to be set
KP Proportional-action coefficient
TN Reset time
TV Derivative-action time
TVK1 Derivative-action gain
Y.PRE Y rate action
DZXD Dead band of error
DZXD Min. limitation of error
DZXD Max. limitation of error

24 EB 6493 EN
 CNTR ALRM

Comparator Limit monitor Xd%

Fig. 5 : Main group CNTR

Dead LIM1 LIM2
W band Limiter
+

X
+ + – L1.XD L2.XD
3.4 CNTR Controller structure and functions

C.PID
Feedforward control

WE Actual

—
—
(+/–) ( WE – FC.K1 ) x FC.K2 + FC.K3
BI value*
>0

F.FOR *–1
XD
P Reversal of
AV.K1 operating
direction
AC.VA
I + +

X Y.PRE
D
XD
X
DPID CH.CA
SIGN
* Displayed in the operating level M.ADJ DIRE

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3 Functions of the compact controller

25
 3 Functions of the compact controller 3.4 CNTR Controller structure and functions

3.4.2 SIGN Inversion of error Xd

This function enables you to reverse the input operating direction. Multiplication by −1 con-
vertes increasing error into a decreasing one or, the other way round, a decreasing error
into an increasing one. This also inverts the operating direction of the output signal. Note the
adjusted operating direction in the function DIRE (see chapter 3.4.6)! There you can change
the operating direction of the output signals once more.
Choose between:
dir.d No inversion of error
in.d Inversion of error

3.4.3 D.PID Assignment of controller output D element

When dynamic behavior with D component has been selected (see chapter 3.4.1), you have
the choice of defining different input variables for the D element: error or controlled variable.
If you have selected error, the compact controller reacts to a fast change in the controlled va-
riable, the reference variable or the disturbance variable by generating a D-step response.
If you select the controlled variable, a fast change only in the controlled variable causes a D-
step response in the output variable. The D component of the compact controller does not
consider changes in the disturbance or the reference variable.
Choose between:
F01 DP.YP Assignment of controller output D element to error
F02 DP.YP Assignment of controller output D element to controlled variable

26 EB 6493 EN
 3.4 CNTR Controller structure and functions 3 Functions of the compact controller

3.4.4 CH.CA Control mode changeover P(D)/PI(D)

Control mode changeover enables the compact controller to be operated under varying ope-
rating conditions with different dynamic behaviors as to the control algorithm. Selection of
control mode changeover is
principally only useful when
control action with I compo-
nent has been selected. (see
W, XD
chapter 3.4.1).
CLI.P
P(D) The function control mode
changeover activates either
P (or PD) or PI (or PID) con-
PI(D)
trol depending on the error
CLI.M
or reference variable.
P(D)
Beyond the definable range
t of the reference variable or
error, the parameters for P
or PD control are used to
operate the controller. Wit-
hin this defineable range,
Fig. 6 : Control mode changeover
the D component is inclu-
ded. The reference variable or error or is defined by the parameters CLI.P and CLI.M.
Fig. 6 clearly illustrates this.
Choose between:
oFF CC.P No control mode changeover
F01 CC.P Control mode changeover activated by error
F02 CC.P Control mode changeover activated by reference variable
Parameters to be set
CLI.P Maximum limit for range of PI(D) control
CLI.M Minimum limit for range of PI(D) control

EB 6493 EN 27
 3 Functions of the compact controller 3.4 CNTR Controller structure and functions

3.4.5 M.ADJ Operating point adjustment in manual mode for YPID

This function enables you to activate operating point adjustment in manual mode. In factory
default, this option is not available.
Proceed as follows to activate the operating point adjustment: Go to manual mode and ad-
just the output variable using the cursor keys to the desired value. When switching to auto-
matic mode, the last received value is stored as operating point and added to the output
variable calculated by the P or PD algorithm. The stored operating point remains effective un-
til you either deactivate operating point adjustment in manual mode by selecting oFF MA.YP
or you adjust a new operating point in manual mode.
If you deactivate operating point adjustment in manual mode, the output variable specified
in manual mode will assume the calculated value within approx. 2 seconds.
Choose between:
oFF MA.YP Operating point adjustment in manual mode for YPID deactivated
on MA.YP Operating point adjustment in manual mode for YPID activated

3.4.6 DIRE Operating direction of output variable

The output variable may either act directly or inversely to the error. This operating direction
is defined with the function DIRE. Note that the operating direction can also be inverted with
the function SIGN, see chapter 3.4.2!
Choose between:
dir.d DI.AC Direct operating direction of output variable (factory default)
in.d DI.AC Inverted operating direction of output variable

3.4.7 F.FOR Feedforward control

You may use the input WE for feedforward control, see chapter 3.3.1. The disturbance si-
gnal can be multiplied and additively linked by means of parameters according to the formu-
la: ± (|WEX − FC.K1|) FC.K2 + FC.K3. Finally, the signal is connected with the controlled
variable. FC.K1, FC.K2 and FC.K3 are constants you have to define in the parameter level.
The mathematical sign of the formula stated above is determined in the function F.FOR.
Choose between:
oFF FECO Feedforward control deactivated (factory default)
POS FECO Feedforward control with positive sign
nE6 FECO Feedforward control with negative sign
Parameters to be set
FC.K1 Constant for formula stated above
FC.K2 Constant for formula stated above
FC.K3 Constant for formula stated above

28 EB 6493 EN
 3.4 CNTR Controller structure and functions 3 Functions of the compact controller

3.4.8 AC.VA Increase, decrease of actual value

This function enables you to increase or decrease the actual value.
Upon activation of the binary input, the input signal X is additively linked with the parameter
AV.K1. The new actual value is now used for control. This is also indicated on the upper dis-
play section of the controlled variable. Upon deactivation of the binary input, the input signal
X is used for control again.
The parameter AV.K1 is stated in the parameter level in percent ranging from −110 to
110 %. When you enter, for example, AV.K1 = 30 %, the current X value will be increased
from 50 to 80 %.
Choose between:
oFF IN.DE Increase, decrease of actual value deactivated
bi1 IN.DE Increase, decrease of actual value via binary input BI1
Parameter to be set
AV.K1 Constant in %
Note: The binary input can be assigned to several functions!

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 3 Functions of the compact controller 3.5 OUT Output definition

3.5 OUT Output definition

This main group enables you to define the output functions of the compact controller. You
can specify whether the compact controller operates with continuous or discontinuous output.
You can limit the output signal and define ramps. You also have the option of issuing X, WE
or XD at the continuous output and transfer them to a recorder. For the continuous output,
you can make mathematical adaptations. The discontinuous outputs can also be used as bi-
nary outputs to signalize varying operating conditions. The following functions can be assi-
gned to the binary input in this main group: locking of the output signal, manual/automatic
transfer, start of an output ramp or initialization of a 2nd output variable Y1K1.

3.5.1 SAFE Initialization of 2nd output variable Y1K1 for YPID

This function enables you to generate a predefined value for the output variable at the con-
troller output, provided that the binary input is activated. This output value is the parameter
Y1K1. It is adjusted in the parameter level in percent.
oFF SA.VA Deactivated
bi1 SA.VA Initializing Y1K1 via binary input BI1
Parameter to be set
Y1K1 2nd output variable in %
Note: The binary input can be assigned to several functions!

3.5.2 MA.AU Manual/automatic transfer

When you choose the setting bi1 in this function, the controller switches to manual mode
upon activation of the binary input and locks the manual/automatic transfer key at the same
time. When the binary input is deactivated, the controller switches back to automatic mode.
Exception: If the controller was already in manual mode upon activation of the binary input,
it remains in manual mode. Manual mode is indicated by the symbol appearing on the
display.
Choose between:
oFF CH.MA Function deactivated
bi1 CH.MA Transfer to manual mode via binary input BI1
Note: The binary input can be assigned to several functions!

30 EB 6493 EN
 OUT I–O OUT TUNE OUT ALRM

YPID**

2nd output Function LIM1 LIM2

variable Manual Limitation Ramp Locking Adaptation generation

Fig. 7 : Main group OUT

ADAP
3.5 OUT Output definition

LIM1 LIM2
SAFE MA.AU Y.LIM RAMP BLOC ADAP FUNC[FU.YP] [L1.YP] [L2.YP]

OUT I–O OUT

Y* YOUT

Output Y Adaptation of controller output Output signal range

YPID
X 0-20 mA Y

—
—
(+/–) ( Y – CA.K1 ) x CA.K2 + CA.K3
XD >0 4-20 mA
WE
Y.SRC CALC Y.VA

Two-/three-step output Configuration B01

1)
BI
2stp 2) L1
3stp int. RF 1/– PPC WE
Automatic 3)
3stp ext. RF LIM1
mode
C.OUT B.OUT[B.B01]

Configuration B02
1)
* y displayed in the operating level in automatic mode BI
** In manual mode: y displayed in the operating level 2) L2
WE
1) Assignment to two-step/three-step output Automatic 3)
LIM2

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2) Assignment to binary output BO1, BO2 mode
B.OUT[B.B02]
3 Functions of the compact controller

3) Assignment to limit relays L1, L2

31
 3 Functions of the compact controller 3.5 OUT Output definition

3.5.3 Y.LIM Output signal limitation YPID

Output signal limitation is always active. When entering the parameter level, you can only
set the parameters minimum and maximum output variable.
on LI.YP Output signal limitation YPID activated
Parameters to be set
Y Minimum output variable
Y Maximum output variable

3.5.4 RAMP Output ramp or limitation of rate of output changes YPID

This function enables you to implement an output ramp or limit the rate of output changes.
The latter is possible for an increasing and/or a decreasing output signal.
The term output ramp means that the output variable changes at constant speed. The parame-
ter TSRA determines the transit time of the output ramp and, hence, the speed. This parame-
ter refers to an output change by 100 %, see Fig. 8. The output ramp can be started by
activating the binary input
bi1. In doing this, you have
the choice of starting the
Y'PID [%]
ramp with either − 10 % or
110
the value of the parameter
100
Y1RA. Manual mode and re-
start after power failure de-
YPID Y'PID activate the output ramp.

0
-10
-10 t
TSRA

Fig. 8 : Output ramp

32 EB 6493 EN
 3.5 OUT Output definition 3 Functions of the compact controller

You can limit the rate of out-

put changes for a decrea-
Y'PID
sing and an increasing
YPID
output variable (F03 RA.YP),
but also only for an increa-
sing (F04 RA.YP), or only for
YPID Y'PID a decreasing (F05 RA.YP)
output variable. The output
variable then changes in the
limited direction(s) only as
fast as the parameter TSRA
t
allows it. If the rate of output
YPID= Input signal without limitation changes is slower than the
Y'PID= Output signal with limitation defined rate of changes, the
limitation will not be effecti-
ve. Fig. 9 shows the effect of
Fig. 9 : Limitation of rate of output changes
the described function.
The rate of changes for the output variable vy calculates as follows:
100 %
vy =
TSRA
Choose between:
oFF RA.YP Deactivated
F01 RA.YP Ramp with activated BI1; starts with −10%,
F02 RA.YP Ramp with activated BI1; starts with parameter Y1RA
F03 RA.YP Limitation for decreasing and increasing output variable
F04 RA.YP Limitation for increasing output variable
F05 RA.YP Limitation for decreasing output variable
Parameters to be set
TSRA Transit time of output ramp
Y1RA Starting value for output ramp
Note: The binary input can be assigned to several functions!

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 3 Functions of the compact controller 3.5 OUT Output definition

3.5.5 BLOC Locking of output signal YPID

This function locks the output signal upon activation of the binary input BI1. As a result, the
current value of the output variable at the controller output is not changed as long as the bi-
nary input is active. When it is deactivated again, the output signal locking will be cancelled
and the controller continues by using the last calculated output value.
Choose between:
oFF BL.YP No locking of output signal via binary input (factory default)
bi1 BL.YP Locking of output signal via binary input BI1
Note: The binary input can be assigned to several functions!

3.5.6 FUNC Function generation of output variable

You can generate functions of the output variable as well as the input variables X and WE.
We do not go into further details since function generation is thoroughly described in chap-
ter 3.2.8. However, make sure that you enter the pairs of value in percent. The parameters
MIN and MAX are preset and cannot be changed here.
Choose between:
oFF FU.YP No function generation of output variable
on FU.YP Function generation of output variable
Parameters to be set
K1.X bis K7.X Input values for points 1 to 7 in %
K1.Y bis K7.Y Output values for points 1 to 7 in %

3.5.7 Y.VA Output signal range

This function enables you to define the range of the continuous output:
oFF Y No continous output
0-20 mA 0-20 mA output
4-20 mA 4-20 mA output

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 3.5 OUT Output definition 3 Functions of the compact controller

3.5.8 Y.SRC Assignment of continous output

This function enables you to determine whether the continuous output is used as controller
output (PID output) or assigned to the inputs X or WE, or to error. Optionally, the signals can
then be transferred to a recorder.
on Y.PID Assignment to PID output
on Y.X ~ to X input
on Y.WE ~ to WE input for feedforward control
on Y.XD ~ to error Xd

3.5.9 CALC Mathematical adaptation of continuous output Y

This function enables you to mathematically modify the continuous output to adapt it, for ex-
ample, to the requirements of a recorder. The following formula applies:
y ’ = ±(|Y−CA.K1|) CA.K2+CA.K3
oFF CA.Y Mathematical adaptation deactivated (note: no output signal!)
POS CA.Y Mathematical adaptation with positive sign
nE6 CA.Y Mathematical adaptation with negative sign
on CA.Y Mathematical adaptation without conditions
Parameters to be set
CA.K1 Constant for above formula in %
CA.K2 Constant for above formula (for continuous output, adjust > 0!)
CA.K3 Constant for above formula in %

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 3 Functions of the compact controller 3.5 OUT Output definition

3.5.10 C.OUT Configuration of two-step or three-step output

This function enables you to select a two-step or three-step output. The active two-step output
is easily recognized by the symbol . For the three-step output, the symbol indicates an
active Y+ output, whereas the symbol indicates an active Y- output.
Note! The selection of one of these settings has priority over the settings in the functions
B.OUT (see chapter 3.5.11), LIM1 and LIM2 (see chapter 3.6). When you configure a three-
step output, the functions of the binary outputs or limit relays can therefore not be used!
When you configure a two-step output, you are able to use the functions of the binary output
BO2 or the limit relay L2.
Choose between:
oFF 2/3S. No two-step or three-step output
on 2.STP Two-step output
i.Fb 3.STP Three-step output with internal position feedback
E.Fb 3.STP Three-step output with external position feedback
PP 2.STP Two-step output with pulse-pause modulation (PPM)
i.PP 3.STP Three-step output with internal position feedback and PPM
E.PP 3.STP Three-step output with external position feedback and PPM
When accessing the parameter level, all the possible parameters for output definition are dis-
played. The following pages will show you which parameters are relevant for which output.

36 EB 6493 EN
 3.5 OUT Output definition 3 Functions of the compact controller

Two-step output
The two-step output can only assume two states, which is on (1) or off (0). This controller out-
put is used for applications, such as electric radiators with thermostat behavior.
The parameters dead band TZ and XSDY determine the switch-on and switch-off point of the
two-step output. The parameter XSDY represents the differential gap and is used to prevent
the two-step output from constantly switching on and off upon small system deviations.

Parameters to be set
XSDY Differential gap
TZ Dead band

XSDY

Y+

YPID Y+

TZ YPID

Fig. 10 : Two-step output

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 3 Functions of the compact controller 3.5 OUT Output definition

Three-step output with internal position feedback

The three-step output with internal position feedback determines the position of a valve by
means of the transit time of the connected actuator. This transit time can be specified by the
parameter TY.
The output variable of the three-step output can assume three values: −100 %, 0 and 100 %.
This controller output is used, e.g. for electric actuators where the three output variables cor-
respond to “counterclockwise rotation”, “motor switched off” or “clockwise rotation”. A defi-
nable dead band lies between both switching points. The dead band is the parameter TZ,
see Fig. 11. In addition, you have to specify the parameter XSDY representing the diffe-
rential gap. The differential gap applies to both switching points. Note that the differential
TZ
gap must always be smaller than .
2
A comparator produces the difference between the YPID signal and the feedback signal YR.
This difference constitutes the output value for the three-step output. The following applies:
TZ
When the difference is larger than and larger than 0, the Y+ output is active.
2
TZ
When it is larger than and smaller than 0, the Y− output is active.
2
TZ
When the difference is smaller than − XSDY, the three-step output is deactivated.
2
When the YPID value exceeds 105 % or falls below −5 %, a permanent signal is issued at the
controller output.

Parameters to be set
XSDY Differential gap
TZ Dead band for three-step output
TY Transit time of actuator

Three-step output with external position feedback

This type of three-step output feeds back the position of a connected actuator externally via
the WE input using, for example, a potentiometer.
Apart from that, this three-step output is similar to the three-step output with internal position
feedback.
When a potentiometer is used for external position feedback, you have to calibrate it as des-
cribed in chapter 3.9.5.

Parameters to be set
XSDY Differential gap of two-step/three-step output
TZ Dead band of three-step output

38 EB 6493 EN
3.5 OUT Output definition 3 Functions of the compact controller

TZ
XSDY

Y+ Y+
YPID
+

YR %
_
Y–
Y–

XSDY
YR

Internal position feedback

Fig. 11 : Three-step output with internal position feedback

TZ
XSDY

Y+ Y+

YPID

%
WE
Y–
Y–

XSDY

Fig. 12 : Three-step output with external position feedback

EB 6493 EN 39
 3 Functions of the compact controller 3.5 OUT Output definition

Two-step output with pulse-pause modulation (PPM)

The two-step output with pulse-pause modulation (PPM) converts the continuous YPID signal
into a pulse sequence whose pulse-pause ratio varies depending on the YPID value, see Fig.
13. The on-time TE of the two-step signal Y+ results from:
(Y [%] −TZ[%])⋅ KPL1
TE = ⋅ TYL1 [s].
100 [%]
The parameter TYL1 is the duty cycle and at the same time the maximum on-time. KPL1 is a
gain factor.
You also have to set the parameter TYL1. It specifies the minimum on-time in percent of
the duty cycle. The minimum on-time in seconds TE is calculated by:
min

TYL1 [s]
TE = ⋅ TYL1 [%]
min
100 %
Due to the hardware, TE lasts 0.3 s minimum.
min

When choosing the parameters TYL1, KPL1 and TYL1 suitably, the two-step output with
PPM provides a good compromise between small fluctuations in the controlled variable
(high switching frequency) and high service life of the final control element (low swit-
ching frequency).

Parameters to be set
KPL1 Gain Y+
TYL1 Duty cycle, maximum on-time in seconds
TYL1 Minimum on-time of BO1 in % of TYL1
TZ Dead band of three-step output in %

40 EB 6493 EN
3.5 OUT Output definition 3 Functions of the compact controller

E Y+
TYL1
1
1

YPID Y+
YPID = 50%
KPL1

TZ TE t
YPID
TYL1 TYL1
TYL1

Fig. 13 : Two-step output with PPM

EB 6493 EN 41
 3 Functions of the compact controller 3.5 OUT Output definition

Three-step output with internal position feedback and PPM

The three-step output with internal position feedback and pulse-pause modulation converts
the three-step signal into a pulse sequence.
The characteristic of this output is shown in Fig. 14. The position of the control valve is deter-
mined by the transit time of the connected actuator. You can specify the transit time via the
parameter TY. The difference created from the YPID signal and the feedback signal YR is con-
verted into a pulse sequence depending on the defined duty cycle. The duty cycle can be defi-
ned individually for the Y+ as well as the Y− signal. The parameter TYL1 determines the duty
cycle for the Y+ signal, and the parameter TYL2 for the Y− signal. In addition, you have to
specify the minimum on-time in percent of the duty cycle via the parameter TYL1 for
the Y+ signal, and via TYL2 for the Y− signal. The minimum on-time in seconds calcula-
tes as follows:
TYL1 [s] TYL2 [s]
TE = TYL1 [%] ⋅ for Y+ signal, or TE = TYL2 [%] ⋅ for Y− signal.
min
100 % min
100 %
You also have to define the dead band for this output using the parameter TZ. The dead
band must be specified in percent referred to the difference YPID - WE. As required you can
also change the parameters KPL1 and KPL2 which provide a certain gain. You can use them
together with the parameters TYL1 and TYL2 to adapt the connected actuator to different ope-
ning and closing times.

Parameters to be set
KPL1 Gain Y+
KPL2 Gain Y−
TYL1 Duty cycle Y+ in s
TYL2 Duty cycle Y− in s
TYL1 Minimum on-time Y+ in % referred to TYL1
TYL2 Minimum on-time Y− in % referred to TYL2
TZ Dead band of three-step output
TY Transit time of actuator

42 EB 6493 EN
3.5 OUT Output definition 3 Functions of the compact controller

Y+

1
Y+

TE TE
YPID TYL2, TYL1
TYL1 TYL1

KPL2 KPL1
YR
+Y
TZ

Y-

TYL2 TYL2
YR

TY

Fig. 14 : Three-step output with internal position feedback and PPM

EB 6493 EN 43
 3 Functions of the compact controller 3.5 OUT Output definition

Three-step output with external position feedback and PPM

This type of three-step output is similar to the three-step output with internal position feed-
back and pulse-pause modulation (PPM). The only difference is that the position of a connec-
ted actuator is fed back externally via the WE input, for example using a potentiometer. The
parameter TY is omitted. If a potentiometer is used for external position feedback, it must be
calibrated as described in chapter 3.9.5.

Parameters to be set
KPL1 Gain Y+
KPL2 Gain Y−
TYL1 Duty cycle Y+ in s
TYL2 Duty cycle Y− in s
TYL1 Minimum on-time Y+ in % referred to TYL1
TYL2 Minimum on-time Y− in % referred to TYL2
TZ Dead band of three-step output

Y+

1
Y+

TE TE
YPID TYL2, TYL1
TYL1 TYL1

KPL2 KPL1
WE
+Y
TZ

Y-

TYL2 TYL2

Fig. 15 : Three-step output with external position feedback and PPM

44 EB 6493 EN
 3.5 OUT Output definition 3 Functions of the compact controller

3.5.11 B.OUT Configuration of binary outputs BO1 and BO2

This function enables you to specify which operating conditions are to be indicated by the bi-
nary outputs BO1 and BO2. You can display the states of the binary outputs in the I-O level
with the function BIN, see chapter 3.9.4.
Note! When you have selected a three-step output (see chapter 3.5.10), you are not able to
use the functions of the binary outputs. Having selected a two-step output, you can use the
functions of the binary output BO2. All the settings of B.OUT have priority over the settings
made with the functions LIM1 and LIM2, see chapter 3.6.1.
Choose between:
Configuration of binary output BO1
oFF B.BO1 Binary output BO1 deactivated
F01 B.BO1 Active when binary input active
F02 B.BO1 Active when external reference variable selected
F03 B.BO1 Active in automatic mode
Configuration of binary output BO2
oFF B.BO2 Binary output BO1 deactivated
F01 B.BO2 Active when binary input active
F02 B.BO2 Active when external reference variable selected
F03 B.BO2 Active in automatic mode

EB 6493 EN 45
 3 Functions of the compact controller 3.6 ALRM Alarm functions

3.6 ALRM Alarm functions

This main group enables you to determine the functions of the limit relays L1 and L2.
The limit relays monitor variables as to whether they exceed or fall below a limit value. The
limit relay can assume two switching states. When the switching condition is fulfilled, the limit
relay is closed, if not, it is open.
The functions LIM1and LIM2 determine which variable will be monitored by the limit relay L1
or L2, and also whether the limit relay becomes active when limit values are exceeded or not
reached.
The limit value of the selec-
ted variable is defined in the
parameter level via LI.X,
L1 Exceeding LI.X L1 Falling below LI.X LI.WE, LI.YPID or LI.XD. In
addition, you have to set the
1 1 parameter L.HYS to define a
differential gap (hysteresis).
The differential gap is the di-
stance to be set between the
0 0 points where the limit relay
L.HYS X[%] L.HYS X[%] switches on and off. It is gi-
LI.X[%] LI.X[%]
ven in percent referred to
the measuring range.
Fig. 16 shows an example
to illustrate the function of
Fig. 16 : Function of the limit relays L1 and L2
the limit relay and the para-
meters to be set for this purpose. Here, the controlled variable X is monitored.
First case: The limit relay monitors the controlled variable for exceeding a preset limit value.
The limit relay is activated when the controlled variable X increases and reaches the preset li-
mit value LI.X. When the controlled variable decreases again to finally reach the preset limit
value minus a hysteresis L.HYS, the limit relay is deactivated.
Note that LI.X and LI.WE are stated in absolute values, however, in Fig. 16, LI.X is repre-
sented in percent!
Second case: The limit relay monitors the controlled variable X for falling below a preset
limit value. The limit relay is activated when the controlled variable decreases and reaches
the preset limit value LI.X. When the controlled variable increases again to finally reach the li-
mit value LI.X plus a hysteresis L.HYS, the limit relay is deactivated.
When the limit relay 1 is activated, the symbol appears on the display. The symbol
appears when the limit relay 2 is activated.

46 EB 6493 EN
 3.6 ALRM Alarm functions 3 Functions of the compact controller

3.6.1 LIM1 Limit relay L1

The function of the limit relays has been described in detail in the previous chapter 3.6.
Note! Functions of the two-step or three-step output C.OUT (see chapter 3.5.10) and
functions of the binary outputs B.OUT (see chapter 3.5.11) have priority over the settings of
the functions LIM1 and LIM2.
Choose between:
Limit relay L1
oFF L1 Limit relay L1 deactivated
Lo L1.X ~ L1 is activated when LI.X is not reached
Hi L1.X ~ L1 is activated when LI.X is exceeded
Lo L1.WE ~ L1 is activated when LI.WE is not reached
Hi L1.WE ~ L1 is activated when LI.WE is exceeded
Lo L1.YP ~ L1 is activated when LI.YP is not reached
Hi L1.YP ~ L1 is activated when LI.YP is exceeded
Lo L1.XD ~ L1 is activated when LI.XD is not reached
Hi L1.XD ~ L1 is activated when LI.XD is exceeded
AbS L1.XD ~ L1 is activated when the sum of LI.XD is exceeded
Parameters to be set
LI.X Limit value for X, as absolute value
LI.WE Limit value for WE, as absolute value
LI.YP Limit value for YPID in %
LI.XD Limit value for XD in %
L.HYS Differential gap in % referred to the measuring range

3.6.2 LIM2 Limit relay L2

This function enables you to define the limit relay L2 which is described in detail in chapter
3.6.
Note! Functions of the two-step or three-step output C.OUT (see chapter 3.5.10) and
functions of the binary outputs B.OUT (see chapter 3.5.11) have priority over the settings of
the functions LIM1 and LIM2.
Choose between:
Limit relay L2
oFF L2 Limit relay L2 deactivated
Lo L2.X ~ L2 is activated when X is not reached
Hi L2.X ~ L2 is activated when X is exceeded
Lo L2.WE ~ L2 is activated when WE is not reached
Hi L2.WE ~ L2 is activated when WE is exceeded
Lo L2.YP ~ L2 is activated when YPID is not reached
Hi L2.YP ~ L2 is activated when YPID is exceeded

EB 6493 EN 47
 3 Functions of the compact controller 3.7 AUX Additional functions

Lo L2.XD ~ L2 is activated when XD is not reached

Hi L2.XD ~ L2 is activated when XD is exceeded
AbS L2.XD ~ L2 is activated when the sum of XD is exceeded
Parameters to be set
LI.X Limit value for X, as absolute value
LI.WE Limit value for WE, as absolute value
LI.YP Limit value YPID in %
LI.XD Limit value for X, in %
L.HYS Differential gap in % referred to the measuring range

3.7 AUX Additional functions

This main group enables you to determine restart conditions after power failure has occur-
red. You have several options, such as resetting functions, parameters and calibrating values
to factory default and locking operator keys. Finally, you can modify the contrast setting of
the display.

3.7.1 RE.CO Restart conditions upon power failure

This function enables you to define the output variable and operating mode after power failu-
re has occurred. When selecting F03, acknowledgement is necessary to return to normal con-
trol operation. In this case, the display sections for reference variable and controlled variable
are blinking until you press the reset key.
Choose between:
F01 MODE Manual mode with 2nd output variable Y1K1
F02 MODE Automatic mode with last received value of reference variable and Y1K1,
without acknowledgement
F03 MODE Automatic mode with last received value of reference variable and Y1K1,
restart with acknowledgement via reset key

3.7.2 ST.IN Resetting to factory default

This function enables you to reset all the settings of parameters, functions and calibrating va-
lues together or each individually:
FrEE INIT Resetting deactivated/completed
All INIT Resetting of all the functions, parameters and the key number
FUnC INIT Resetting of all the functions
PArA INIT Resetting of all the parameters and the key number
AdJ INIT Basic initialization of the calibrating values for In1, In2 and Y1

48 EB 6493 EN
 3.7 AUX Additional functions 3 Functions of the compact controller

To reset to factory default, proceed as follows:

You are in the main group AUX and have selected ST.IN.
1. Press the programming key. FrEE INIT appears on the display.
2. Use the cursor keys to choose from the settings listed above (All, FUnC,PArA or AdJ).
3. Press the programming key. The selected settings are reset to factory default. When the
resetting procedure is completed, FrEE INIT appears again.

3.7.3 KEYL Operator keys

This function enables you to turn the function of the six keys via the binary input on and off,
or to disable the following keys: selector key, manual/automatic transfer key and the cursor
keys.
oFF LOCK Operator keys enabled
bi1 LOCK Enabling/disabling all the keys via the binary input BI1
on noH.W Selector, manual/automatic transfer and cursor keys disabled. The compact
controller remains in the operating mode that was in effect before you
have activated this function
Note: The binary input can be assigned to several functions!

3.7.4 VIEW Setting of display contrast

This function enables you to modify the display contrast from grade 1 to 10. This allows opti-
mum display illumination at the site of installation. 1 is especially suitable for installation on
high places, whereas 10 suits low places of installation.
Choose between:
1 VIEW Contrast setting 1
. .
. .
. .
10 VIEW Contrast setting 10

3.7.5 FREQ Power frequency

This function enables you to set the power frequency of the system to either 50 or 60 Hz.
Choose between:
on 50Hz Power frequency set to 50 Hz
on 60Hz Power frequency set to 60 Hz

EB 6493 EN 49
 3 Functions of the compact controller 3.8 TUNE Start-up adaptation

3.7.6 DP Decimal point setting

This function enables you to determine the number of decimal places for all variables which
directly apply to the analog inputs In1 and In2.
Choose between:
on DP0 No decimal place
on DP1 One decimal place (factory default)
on DP2 Two decimal places

3.8 TUNE Start-up adaptation

This main group enables you to initiate a start-up adaptation. It works according to the inflec-
tional tangent principle which means that one unit step response is used to determine the in-
flectional point, the inflectional tangent as well as different characteristics. The controller
calculates then the parameters KP, TN and TV.
For start-up adaptation, observe the following:
 The controlled system must be stable. Eliminate disturbance variables (e.g. drifting).
 The controlled system must be settled when you begin start-up adaptation.
 You can only adapt controlled systems with self-regulation.
 Adaptation must be completed after 5 hours.

3.8.1 ADAP Start-up adaptation

The start-up adaptation is initiated if you select run ADP.S. Before you start this procedure,
define the parameter Y.JMP. Its value is added to the output variable to subsequently determi-
ne the step response of the controlled system. The step response can take place in both direc-
tions. It should be as large as possible and located around the operating point, however,
without leaving the defined controlled variable range. If the latter happens during adapta-
tion, the adaptation procedure is interrupted and Err 32 appears on the display.
When the start-up adaptation is successfully completed, the determined parameters become
instantaneously effective. The compact controller is in manual mode. Now, switch to automat-
ic mode.
The function ADAP includes the following settings:
oFF ADP.S No adaptation
run ADP.S Initiating start-up adaptation
Parameter to be set
Y.JMP Value of step response in %

Carry out the following steps to initiate start-up adaptation:

The compact controller is in the operating level.

50 EB 6493 EN
 3.8 TUNE Start-up adaptation 3 Functions of the compact controller

Press! Display shows Comment

IN You have accessed the setup level.

TUNE You have reached the main group TUNE.

2x

-CO- You have reached the function for start-up

ADAP adaptation.

oFF Start-up adaptation is not yet activated.

ADP.S
PA First, enter the parameter level so that you can
ADAP (blinking) define the value for the step response.

1.0 (factory default) KP, TN, TV are the same as in C.PID.

KP
20.0 (factory default) Parameter of value for step response.
Y.JMP
---- Key number optionally prompted. If so,
KEY proceed as described on p. 8.

(blinking display) Adjust the value for the step response.

or

You have acknowledged the value for the step

response and the display stops blinking.

oFF You leave the parameter level.

ADP.S
oFF (blinking)
ADP.S
run (blinking)
ADP.S
20 Adaptation is initiated. In sequence, status
ADP.S (blinking) messages indicating the running procedure
are displayed on the upper section.

EB 6493 EN 51
 3 Functions of the compact controller 3.8 TUNE Start-up adaptation

Press! Display shows Comment

End You have successfully completed start-up

ADP.S adaptation.

Cancelling start-up adaptation

Press! Display shows Comment

StoP You can cancel the adaptation procedure at

ADP.S any time to modify the parameters.
Pressing again on the programming key
restarts adaptation.

Errors during start-up adaptation

The following errors appear in the display and, in addition, the binary output for messages
is set.

Display shows Type of error Comment

30 Timeout > 5h Termination of adaptation procedure after 5

ERR hours.

31 Parameter determination The adaptation procedure cannot determine

ERR impossible parameters.

32 X input < 0% or > 100% Modify Y.JMP.

ERR

33 Interferences too strong Increase Y.JMP and check interferences

ERR

34 Selected PID setting does not Set P, PI or PID control in the function
ERR allow adaptation. C.PID (main group CNTR) .

35 Output signal limited Modify Y.JMP.

ERR

52 EB 6493 EN
 3.9 I-O View process data 3 Functions of the compact controller

3.9 I-O View process data

This main group enables you to view different variables and information. In addition, you
can adjust zero and span for the analog inputs IN1 and IN2 as well as the analog output Y.

3.9.1 CIN Firmware

This function shows you the version of your firmware (software version).
FIR View firmware version

3.9.2 S-No Serial number

This function shows you the serial number of the controller. All controllers are given a serial
number by the manufacturer.
View serial number

3.9.3 ANA View values of analog inputs

This function enables you to view the values of analog variables. Please also note Fig. 1 on
page 15 , Fig. 3 on page 21, Fig. 5 on page 25, and Fig. 7 on page 31. There you will
find the displayed variables illustrated.
IN1 Analog input 1 (absolute value)
IN2 Analog input 2 (absolute value)
CO.VA Controlled variable before function generation has been performed
WE.VA Reference variable after function generation has been performed
FE.CO WE prior to applying feedforward control (when using WE for feedforward
control, i.e. parameter SP.VA set to F02 WE in the main
group SETP, WE is not displayed in the operating level).
SP.CO Reference variable at the comparator
YPID YPID after the limitation
YOUT Controller output after mathematical adaptation YOUT

3.9.4 BIN Status of binary input and outputs

This function enables you to view the respective status of the binary input and outputs.
BI1 Status of binary input BI1 on/oFF
BO1 Status of binary output BO1 on/oFF
BO2 Status of binary output BO2 on/oFF

EB 6493 EN 53
 3 Functions of the compact controller 3.9 I-O View process data

3.9.5 ADJ Adjusting the analog inputs and output

This function enables you to adjust zero and span for the analog inputs and the analog out-
put.
To do this, proceed as described below:
You are in the main group I-O and you have selected ADJ.
1. Press the programming key. ADJ IN1 appears on the display.
2. Choose the respective input or output using the cursor keys:
AdJ IN1 Adjusting the analog input IN1
AdJ IN2 Adjusting the analog input IN2
AdJ Y1 Adjusting the analog output Y
3. Press the programming key.
4. You are prompted to enter the key number. Enter the key number via the cursor keys!
5. Acknowledge with the programming key!
6. Adjust the desired signal to the lower range value using a high-precision meter. The dis-
play section indicating adjustment range shows ZERO and IN1 (IN2 or Y1) in turn.
7. Press the programming key! Now, zero adjustment is completed. The display shows 0.0 and
ZERO.
8. Adjust the desired signal to the upper range value using a high-precision meter. The dis-
play section indicating adjustment range shows SPAN and IN1 (IN2 or Y1) in turn.
9. Press the programming key! Span adjustment is completed. The display stops blinking
and shows 100.0 and SPAN.
10. Press the reset key once ! Continue with step 2 when you want to adjust other inputs or
the output. Now, the key number prompt is omitted (step 3 and 4).

54 EB 6493 EN
 4.1 Fixed set point control 4 Practical examples

4 Practical examples
In this chapter, we will show you how to configure your TROVIS 6493 Compact Controller
so that you can implement fixed set point control, follow-up control and follow-up control
with function generation. We assume you know how to operate this controller. If not, plea-
se read chapter 2. Note that there are two controller versions due to the different inputs In2!

4.1 Fixed set point control

For this example, we have chosen a simple temperature control loop as shown in Fig. 17.
The controlled variable X is the flow temperature which is measured at the input IN2 via a
Pt 100 sensor. The flow tem-
perature is to follow a fixed
TROVIS
reference variable value.
6493
The TROVIS 6493-01 Com-
y x
pact Controller issues a conti-
nuous 4 to 20 mA signal as
output variable Y. To perform
this control task, you just
have to define the reference
variable and the control pa-
rameters. The reference varia-
ble can be directly set in the
operating level using the cur-
sor keys. Whereas, the con-
trol parameters must be
Fig. 17 : Single temperature control loop
defined in the setup level in
the main group CNTR. All the other settings required are standard configured in the compact
controller. The table below lists the settings you require:
Setup level
Main Function Setting Parameter Value Comment
group -CO- -PA-
CNTR -CO- PI KP 0.8 Define control parameter.
C.PID (factory TN 16.0
default
-CO- DIRE dir.d - Change oper. dir., if needed.
Operating level
Use selector key to display W. Determine new value for
Use cursor keys to enter new value. reference variable.

EB 6493 EN 55
 4 Practical examples 4.2 Follow-up control

4.2 Follow-up control

A follow-up control loop is il-
lustrated in Fig. 18. In this
example, a pressure be-
tween 0 to 10 bar is control-
led and measured via a
TROVIS
6493–02 two-wire transmitter. The
WE 4...20 mA two-wire transmitter could
4...20 mA y
X Transmitter supply be, e.g. the SAMSOMATIC
4...20 mA 994-0050 Transmitter. The
external reference variable
p1 is provided by a 4 to 20 mA
signal. We also want to be
able to switch to a fixed va-
lue for the internal reference
variable. The control valve
with positioner is controlled
Fig. 18 : Pressure control
by a continuous output varia-
ble Y ranging from 4 to 20 mA. The controller version TROVIS 6493-02 with two mA inputs
is used in this example. Now, proceed as described below:
 The controlled variable X is the pressure p1 which is measured via a two-wire transmitter
and is connected to the input In2. This input is designed for 4 to 20 mA as standard, i.e.
it does not need to be changed. However, you have to set the measuring range for this in-
put to 1 to 10 bar. To do this, select for this in the main group IN the function -CO- IN2
and define the measuring range in the parameter level.
 The external reference variable WE is applied to the input In1 as 4 to 20 mA signal. The
input In1 is originally set up for 4 to 20 mA, therefore it must not be changed. However,
you must determine the measuring range for the reference variable in the parameter level
with 0 to 10 bar. To do this, open the parameter level in the main group IN in the
function -CO-IN1.
WE is principally not activated. To activate WE, enter the function -CO- SP.VA in the
main group SETP and select WE. Set WE to "on". Additionally, set the measuring range
of W (internal reference variable) to 0 to 10 bar. In the operating level, you can now
choose W or WE as reference variable. When you define WE as active reference varia-
ble, you automatically obtain follow-up control. When you define W to be active, you
have a set up fixed set point control. For this control action, you can enter the value of the
reference variable in the operating level via the cursor keys.
 Control action must be PID, not PI as specified in factory default. Go to the main group
CNTR and change the setting of the function -CO- C.PID to PId and also change KP, TN,
and TV in the parameter level.

56 EB 6493 EN
 4.2 Follow-up control 4 Practical examples

 The output variable Y is principally set up for a continuous signal ranging from 4 to
20 mA. Therefore, the output variable must not be modified in this example.

The following table lists the required settings in short together with the parameter definitions:
Setup level
Main Function Setting Parameter Value Comment
group -CO- -PA-

IN -CO- 4 -20 mA IN1 0 [bar] Define measuring range

IN1 (factory IN1 for input 1, WE assigned
10 [bar]
default) (factory default)

-CO- 4-20 mA IN2 0 [bar] Define measuring range

IN2 IN2 10 [bar] for input 2, X assigned
(factory default)

-CO- X In2 Assign the controlled

CLAS (factory variable X to input In2
default)
WE In1 Assign the external reference
(factory variable to input In1
default)

SETP -CO- WE on Activate WE and, hence,

SP.VA follow-up control
W on W 5.2 [bar] Value for internal W
(factory WINT Measuring range for W
0 [bar]
default)
WINT 10 [bar]

CNTR -CO- PId KP 0.8 Select PID action and

C.PID TN 16.0 specify control parameters
TV 6.0
TVK1 1.0
-CO- dir.d - Change oper. dir., if needed
DIRE

Operating level
Press selector key to view WE. Define WE as active
Press programming key. reference variable

EB 6493 EN 57
 4 Practical examples 4.3 Follow-up control with function generation

4.3 Follow-up control with function generation

We will show you how to
WEX use function generation by
means of a weather-sensitive
Pt 100
X flow temperature control
tA loop as illustrated in Fig. 19.
tV 4...20 mA The controlled variable is the
flow temperature. The out-
door temperature is measu-
red by a Pt 100 sensor and
subsequently converted into
M a flow temperature through
function generation. The rela-
tionship between outdoor
temperature and required
tv Flow temperature tA Outdoor temperature flow temperature is repre-
sented in the table below.
Fig. 19 : Temperature control with function generation
The resulting characteristic
serves as external reference variable. The compact controller controls the valve via a three-
step signal with internal position feedback.
Carry out the following steps:
 The controlled variable X is the flow temperature which is measured by a two-wire trans-
mitter. Two-wire transmitters can only be connected in controller version 6493-01 to the
input In1. This input is adjusted to 4 to 20 mA as factory default, i.e. it does not need to
be changed. However, you have to specify the measuring range for this input as to range
from 0 to 150 °C. Additionally, you must assign the controlled variable X to the input In1.
 The outdoor temperature is the external reference variable WE and is applied to the input
In2. This input is already set up for Pt 100 sensors. The measuring range is also fixed.
Now, you have to assign WE to the input In2. WE is principally inactive. Set the measu-
ring range for the internal reference variable W to 0 to 150 °C. In the operating level,
you can choose between W and WE. When you select WE as to be the active reference
variable, you automatically obtain follow-up control.
 Define the relationship between outdoor temperature and flow temperature in the main
group IN with the function FUNC and WE in the parameter level.
tA in °C (K1.X … K7.X) −20.0 −10.0 0.0 10.0 20.0 30.0 40.0
tV in °C (K1.Y … K7.Y) 100.0 90.0 85.0 75.0 60.0 55.0 50.0

 For the output, select a three-step signal with internal position feedback.

58 EB 6493 EN
 4.3 Follow-up control with function generation 4 Practical examples

The following table lists the required settings in short:

Setup level

Main Function Setting Parameter Value Comment

group -CO- -PA-

IN -CO- 4 -20 mA IN1 0.0 [°C] Define measuring range

IN1 (fact.def.) IN1 150.0 [°C] for input 1 (tv).

-CO- X In1 Assign the controlled

CLAS variable X (tv) to input In1.
WE In2 Assign the external reference
variable WE (tA) to input In2.
-CO- WE on MIN 0.0 [°C] Activate function
FUNC MAX 150.0 [°C] generation for WE.
K1.X -20.0 [°C] Define measuring range
K1.Y 100.0 [°C] for the output signal tv
K2.X -10.0 [°C] obtained by function
K2.Y 90.0 [°C] generation.
K3.X 0.0 [°C] Indicate 7 pairs of value
K3.Y 85.0 [°C] which determine the
K4.X 10.0 [°C] relationship
K4.Y 75.0 [°C] between outdoor and flow
K5.X 20.0 [°C] temperature.
K5.Y 60.0 [°C]
K6.X 30.0 [°C]
K6.Y 55.0 [°C]
K7.X 40.0 [°C]
K7.Y 50.0 [°C]
SETP -CO- WE on Activate WE and, hence,
SP.VA follow-up control.

W on W 25 [°C] Define value for internal

(factory WINT 0 [°C] reference variable W and
default) 150 [°C] measuring range of W.
WINT
CNTR -CO- PI KP 0.8 Specify control parameters.
C.PID (factory TN 16.0
default) TV 6.0

OUT -CO- 3.STP i.FB XSDY 0.8 [%] Define three-step output
C.OUT TZ 2.0 [%] with internal position
TY 90.0 [s] feedback and appropriate
parameters.

Operating level
Press selector key to view WE. Define WE as active
Press programming key. reference variable.
 5 Start-up 5.1 P controller

5 Start-up
When all the inputs and outputs and the power supply are connected, the compact controller
must be set up according to the desired control task. This means that you have to configure
and parmeterize the controller. Appendix C contains a checklist form where the settings can
be filled in.
The compact controller must be adapted to the dynamic behavior of the controlled system via
the parameters KP, TN and TV. So the system deviations caused by disturbances can be eli-
minated or largely suppressed. There are two ways to adjust these parameters, either via
start-up adaptation (see chapter 3.8.1) or via manual optimization. The latter will be descri-
bed in the following chapters, however, we can give you but general instructions. If appro-
priate setting values have not yet been determined for your controlled system, you should
proceed as follows:
Note: Before you start manual optimization, close the connected control valve!
1. Press the manual/automatic transfer (13) key to switch to manual mode. The symbol
appears on the display.
2. Use the cursor keys to change the output variable to a value at which the control valve
slowly opens.
3. Choose the required control action and continue as described below.

5.1 P controller
 Enter KP = 0.1.
 Adjust the reference variable in the operating level to the desired value.
 Use the cursor keys to change the output variable to a value at which the control valve
slowly opens and error Xd assumes approximately zero.
 Switch to automatic mode.
 Increase the KP value until the controlled system tends to oscillate.
 Slowly decrease the KP value until the oscillations disappear.
 You can eliminate the remaining system deviation as follows: Switch to manual mode!
Change the output variable to obtain error Xd = 0. Now, read the value produced for
the output variable and set the parameter Y.PRE (CNTR, C.PID) to this value.
Important: Each change in the reference variable also changes the operating point!

5.2 PI controller
 Enter KP = 0.1 and TN = 1999.
 Adjust the reference variable in the operating level to the desired value.
 Use the cursor keys to change the output variable to a value at which the control valve
slowly opens and error Xd approximately assumes zero.
 Switch to automatic mode.

60 EB 6493 EN
 5.3 PID controller 5 Start-up

 Increase the KP value until the controlled system tends to oscillate.

 Slightly decrease the KP value until the oscillations are eliminated.
 Decrease the TN value until the controlled system tends to oscillate.
 Slightly increase the TN value until the oscillations are eliminated.
5.3 PD controller
 Enter KP = 0.1, TV = 1 and derivative-action gain TVK1 = 1.
 Adjust the reference variable in the operating level to the desired value.
 Use the cursor keys to change the output variable to a value at which the control valve
slowly opens and error Xd approximately assumes zero.
 Switch to automatic mode.
 Increase the KP value until the controlled system tends to oscillate.
 Increase the TV value until the oscillations are eliminated.
 Increase the KP value until the oscillations appear again.
 Increase the TV value further until the oscillations are eliminated.
 Repeat this procedure several times until the oscillations can no longer be suppressed.
 Slightly decrease the KP and TV value to calm down the controlled system.
 The remaining system deviation can be eliminated as follows: Switch to manual mode!
Change the output variable until error Xd = 0. Read the value produced for the output va-
riable and set the parameter Y.PRE (CNTR, C.PID) to this value.
Important: Each change in the reference variable also changes the operating point!

5.4 PID controller

 Enter KP = 0.1, TN = 1999 and TV = 1.
 Adjust the reference variable to the desired value.
 Use the cursor keys to change the output variable to a value at which the control valve
slowly opens and error Xd approximately assumes zero.
 Switch to automatic mode.
 Increase the KP value until the controlled system tends to oscillate.
 Increase the TV, value until the oscillations are eliminated.
 Increase the KP value until the oscillations appear again.
 Increase the TV value until the oscillations are eliminated.
 Repeat this procedure several times until the oscillation can no longer be suppressed.
 Slightly decrease the KP and TV value to calm down the controlled system.
 Decrease the TN value until the controlled system tends to oscillate again and slightly in-
crease, once again, so that the oscillations disappear.

EB 6493 EN 61
 6 Installation 5.4 PID controller

6 Installation
The TROVIS 6493 Compact Controller is a panel-mounting unit with the front dimensions
48 x 96 mm. To mount the controller, carry out the following steps:
1. Make a panel cut-out with the dimensions 45+0.6 x 92+0.8 mm.
2. Push the controller into the panel cut-out so that its front panel goes through first.
3. Insert the provided mounting brackets (2) into the remaining slots between the upper and
lower edge of the controller front and the panel cut-out, see Fig. 20.
4. Screw the threaded rods towards the control panel using a screwdriver to clamp the hou-
sing against the panel cut-out.

62 EB 6493 EN
5.4 PID controller 6 Installation

1 Compact controller
2 Mounting brackets
3 Control panel

Fig. 20 : Mounting the controller

EB 6493 EN 63
 7 Electrical connections 5.4 PID controller

7 Electrical connections
The compact controller has screw terminals suitable for lines up to 1.5 mm2.
For electrical installation, you are required to observe the VDE 0100 regulation and the regu-
lations relevant in your country.
To avoid measurement errors or other faults, use screened cables for the signal lines of the
analog and binary inputs running outside the switching cabinets. Within the cabinets, these
signal lines have to be installed separately from the control and network lines with sufficient
space between them.
Ground the cable screenings on one side in the neutral point of the measuring and control sy-
stem.

Input IN1
Transmitter supply*
4(0) to 20 mA 0(2) to 10 V 4 to 20 mA
11 12 13 11 12 13 12 13 14 15

– +
– + + –

Input IN2 (controller version 6493-01)

Pt100/Pt 1000
Ni100/Ni1000 0 to 1kΩ * Note! The transmitter supply can only be
used for one two-wire transmitter (at IN1
17 19 20 17 19 20 or at IN2) or for the supply of the binary
input BI!
0%

Input IN2 (controller version 6493-02)

Transmitter supply*
4(0) to 20 mA 4 to 20 mA
19 20 14 15 19 20

+ –
+ –

Fig. 21 : Electrical connections

64 EB 6493 EN
5.4 PID controller 7 Electrical connections

Voltage output for

Binary input transmitter supply *
81 82 14 15 14 15 81 82
– +

+ – – +
24 V 20 V, max. 25 mA
BI1

* Note! The transmitter supply can only be

used for one two-wire transmitter (at IN1
or at IN2) or for the supply of binary
input BI!

Continuous output Binary output

0(4) to 20 mA for messages Power supply
31 32 83 84 N L

+ – + – N L

Switching outputs
Binary outputs Limit relays Three-step output

42 43 41 42 43 51 52 53 41 42 43 51 52 53 41 42 43 51 52 53

BO1 BO2 LIM1 LIM2

Floating contacts + –
L +

L N

Fig. 22 : Electrical connections (continued)

EB 6493 EN 65
 8 Technical data 5.4 PID controller

8 Technical data
Inputs Two analog inputs, optionally for the controlled
variable X or the reference variable W
0(4) to 20 mA or 0(2) to 10 V, or two-wire
Analog input 1
transmitter (see below)
Analog input 2 (two controller versions) Version 1 (6493-01): Temperature sensor or
potentiometer (see below)
Version 2 (6493-02): 0(4) to 20 mA or two-wire
transmitter (see below)

mA or V Measuring ranges 0(4) to 20 mA, or 0(2) to 10 V

input
Meas. range changeover Done by software
Max. perm. values Current ± 50 mA, voltage ± 25 V
Internal resistance Current Ri = 50 Ω, voltage Ri = 20 kΩ
Permissible common 0 to 5 V
mode voltage
Error Zero < 0.2 %, span < 0.2 %, linearity < 0.2 %
Temperature influence Zero < 0.1 %/10 K, span < 0.1 %/10 K
Transmitter supply According to DIN IEC 381 (NAMUR NE06) 20 V,
max. 25 mA, resistant to short-circuit
Temperature Measuring range Pt 100, Pt 1000: −100 to 500 °C
sensor Ni 100, Ni 1000: −60 to 250 °C
Line resistances Three-wire RL1 = RL2 = RL3 < 15 Ω
Error Zero < 0.2 %, gain < 0.2 %,
linearity < 0.2 %
Pt 100, Pt 1000 in the Zero < 0.1 %, gain < 0.1 %,
range −40 to 150 °C linearity < 0.1 %
Temperature influence Zero < 0.2 %/10 K, span < 0.2 %/10 K
Potentiometer Measuring range 0 to 1kΩ, three-wire
Line resistances RL < 15 Ω each
Error Zero < 0.2 %, gain < 0.2 %
Temperature influence Zero < 0.1 %/10 K, gain < 0.2 %/10 K
Binary input External switching voltage 24 V DC, ±30 %; 3 mA

66 EB 6493 EN
5.4 PID controller 8 Technical data

Outputs Continuous, two-step or three-step output

Continuous Signal range 0(4) to 20 mA, load < 740 Ω
controller
Control range 0 to 22 mA (0 to 110 %)
output
Error Zero < 0.2 %, gain < 0.1 %
Temperature influence Zero < 0.1 %/10 K, span < 0.1 %/10 K
Discontinuous 2 relays with floating contact,
output max. 250V AC, max. 250 V DC, max. 1 A AC,
max. 0.1 A DC, cos θ = 1
Spark extinguisher C= 2.2 nF and varistor U= 275 V
Binary output Electrically isolated transistor output,
max. 50 V DC and 30 mA, min. 3 V DC

General specifications
Display Four-digit liquid crystal display
Configuration Fixed-programmed function blocks for fixed set point
control and follow-up control
Power supply 230 V AC (200 to 250 V AC),
120 V AC (102 to 132 V AC),
24 V AC (21.5 to 26.5 V AC); 48 to 62 Hz
Power consumption Approx. 6 VA
Temperature range 0 to 50 °C (operation);
−20 to 70 °C (transport and storage)
Degree of protection Front panel IP 65, housing IP 30, terminals IP 00
Device safety Design and inspection acc. to EN 61010, edition 3.94
Class of protection II
Overvoltage category II
Degree of contamination 2
Noise emission EN 50081 Part 1
Noise immunity EN 50081 Part 2
Electrical connection Screw terminals 1.5 mm2
Sampling time ≤100 ms
Resolution Input: 0.1 °C, 0.1%
Weight Approx. 0.5 kg

EB 6493 EN 67
 Appendix A Appendix A

Appendix A Function and parameter table

Main Function Displayed KEY Setting Description of function Details Parameters Parameter Parameter designation Range of values Factory
1)
group -CO- setting options see page -PA- selection [unit of meas.] default

Fast setting Kp, Tn, Tv

(Press the programming key only once p. 14 KP Proportional-action coefficient 0.1…100.0 [1] 1.0
PAR to go to Kp!) TN Reset time 1…9999 [s] 120
TV Derivative-action time 1…9999 [s] 10

Input functions

IN -CO- 4 -20 mA 1) 4-20 mA Input signal range IN1 4-20 mA -PA- IN1/mA IN1 Lower range value −999… IN1 0.0
IN1 0-10 V ~ 0-10 mA -PA- IN1/mA IN1 Upper range value IN1…9999 100.0
2-10 V ~ 2-10 V -PA- IN1/V [absolute]3)
0-20 mA ~ 0-20 mA p. 16 -PA- IN1/V
-CO- 100 PT 1) 100 PT Input signal range IN2 Pt 100 (−100…500 °C) -PA- IN2/PT IN2 Lower range value −999… IN2 −100
IN2 1000 P T ~ Pt 1000 (−100…500 °C) -PA- IN2/PT IN2 Upper range value IN2…9999 500
100 NI ~ Ni 100 (−60…250 °C) -PA- IN2/NI [absolute]3)
6493-01 1000 NI ~ Ni 1000(−60…250 °C) -PA- IN2/NI
0-1 KOHM ~ 0 to 1000 Ω p. 16 -PA- IN2/KOHM
-CO- 4 -20 mA 4-20 mA Input signal range IN2 4-20 mA -PA- IN1/mA IN2 Lower range value −999… IN2 0.0
IN2 0-20 mA ~ 0-20 mA p. 17 -PA- IN1/mA IN2 Upper range value IN2…9999 100.0
[absolute]3)
6493-02

-CO- oFF ME.MO 1) oFF ME.MO Measuring range monitoring analog inputs off noPA MEAS/ME.MO No parameter
MEAS IN1 ME.MO ~ analog input 1
IN2 ME.MO ~ analog input 2
ALL ME.MO ~ analog inputs 1 and 2 p. 17
-CO- FAIL oFF 1) oFF FAIL Transfer to manual mode upon -PA- MAN/FAIL Y1K1 2nd output variable -10.0…110.0 -10.0
MAN transmitter failure off [%]
F01 FAIL ~ with 2nd output variable Y1K1
F02 FAIL ~ with last received output value p. 17
-CO- IN2 X 1) IN2 X Assignment of X to analog input IN2 noPA CLAS/X No parameter
CLAS IN1 X ~ to analog input IN1
IN1 WE 1) IN1 WE Assignment of WE to analog input IN1 noPA CLAS/WE No parameter
IN2 WE ~ to analog input IN2 p. 18

1) Functions and parameters can be read without key number. Only when changing functions or 3) Decimal place depends on the function DP (main group AUX)
parameters for the first time, you are prompted to enter the key code. 4) The parameter values in brackets are only valid for controller version 6493-02.
2) Range of values equals that of the assigned input.

68 69
 Appendix A Appendix A

Main Function Displayed KEY Setting Description of function Details Parameters Parameter Parameter designation Range of values Factory
1)
group -CO- setting options see page -PA- selection [unit of meas.] default
IN -CO- oFF X 1) oFF X Filtering of input variable X off -PA- DI.FI/X TS.X Time constant of X filter 0.1… 100.0 1.0
DI.FI on X ~ on [s]
(conti-
nued)

oFF WE 1) oFF WE Filtering of input variable WE off -PA- DI.FI/WE TS.WE Time constant of WE filter 0.1… 100.0 1.0
on WE ~ on p. 18 [s]
-CO- oFF X 1) oFF X Root extraction of input variable X off no PA SQR/X
SQR on X ~ on
oFF WE 1) oFF WE Root extraction of input variable WE off no PA SQR/WE
on WE ~ on p. 18
-CO- oFF X 1) oFF X Function generation of X off -PA- FUNC/X MIN Output signal lower range value -999… 9999 0.0
FUNC on X ~ on p. 19 MAX Output signal upper range value [absolute]3) 100.0
K1.X Input value point 1 −100.0
K1.Y Output value point 1 X values (e.g. K1.X): 0.0
K2.X Input value point 2 IN1… IN1 −100.0
K2.Y Output value point 2 or 2) 0.0
K3.X Input value point 3 IN2… IN2 −100.0
K3.Y Output value point 3 0.0
K4.X Input value point 4 Y values (e.g. K1.Y): −100.0
K4.Y Output value point 4 MIN…MAX 0.0
K5.X Input value point 5 −100.0
K5.Y Output value point 5 0.0
K6.X Input value point 6 −100.0
K6.Y Output value point 6 0.0
K7.X Input value point 7 −100.0
K7.Y Output value point 7 0.0

1) Functions and parameters can be read without key number. Only when changing functions or 3) Decimal place depends on the function DP (main group AUX)
parameters for the first time, you are prompted to enter the key code. 4) The parameter values in brackets are only valid for controller version 6493-02.
2) Range of values equals that of the assigned input.

70 71
 Appendix A Appendix A

Main Function Displayed KEY Setting Description of function Details Parameters Parameter Parameter designation Range of values Factory
1)
group -CO- setting options see page -PA- selection [unit of meas.] default
IN oFF WE 1) oFF WE Function generation of WE off -PA- FUNC/WE MIN Output signal lower range value -999… 9999 0.0
on WE ~ on p. 19 MAX Output signal upper range value [absolute]3) 100.0
(continu K1.X Input value point 1 0.0
ed) K1.Y Output value point 1 X values (e.g. K1.X): 0.0
K2.X Input value point 2 IN1… IN1 0.0
K2.Y Output value point 2 or 2) 0.0
K3.X Input value point 3 IN2… IN2 0.0
K3.Y Output value point 3 0.0
K4.X Input value point 4 Y values (e.g. K1.Y): 0.0
K4.Y Output value point 4 MIN…MAX 0.0
K5.X Input value point 5 0.0
K5.Y Output value point 5 0.0
K6.X Input value point 6 0.0
K6.Y Output value point 6 0.0
K7.X Input value point 7 0.0
K7.Y Output value point 7 0.0

1) Functions and parameters can be read without key number. Only when changing functions or 3) Decimal place depends on the function DP (main group AUX)
parameters for the first time, you are prompted to enter the key code. 4) The parameter values in brackets are only valid for controller version 6493-02.
2) Range of values equals that of the assigned input.

72 73
Appendix A Appendix A

Main Function Displayed KEY Setting Description of function Details Parameters Parameter Parameter designation Range of values Factory
group -CO- setting options see page -PA- selection [unit of meas.] default

Reference variable

SETP -CO- on W 1) Internal reference variable W (always active) -PA- SP.VA/W W Internal reference variable 1 WRAN… -100.0
SP.VA WRAN [1] (0.0)4)
WINT Lower range value for W, W2, WE −999… −100.0
WINT [1] (0.0)4)
WINT Upper range value for W, W2, WE WINT… 500.0
9999 [1] (100.0)4)
WRAN Limitation of lower range value WINT… −100.0
WRAN [%] (0.0)4)
WRAN Limitation of upper range value WRAN… 500.0
WINT (100.0)4)
[absolute]3)
oFF W2 1) oFF W2 Internal reference variable W2 off -PA- SP.VA/W2 W2 Internal reference variable W2 WRAN… −100.0
onW2 ~ on WRAN 0.0
[absolute]3)
oFF WE 1) oFF WE External reference variable WE off noPA SP.VA/WE No parameter
on WE ~ on
F01 WE ~ input for ext. pos. feedback with 3-step output
F02 WE ~ input for feedforward control p. 22
-CO- oFF RAMP 1) oFF RAMP Set point ramp off -PA- SP.FU/RAMP TSRW Time parameter 1.0… 9999 [s] 10
SP.FU F01 RAMP ~ starts with BI and meas. value WIRA Starting value for WINT… −100.0
F02 RAMP ~ starts with BI and WIRA reference variable WINT (0.0)4)
F03 RAMP ~ without starting condition [absolute]3)
oFF CH.SP 1) oFF CH.SP Changeover W(W2)/WE via BI off noPASP.VA/CH.SP No parameter
F01 CH.SP ~ W(W2)/WE via BI
F02 CH.SP ~ W/W2 via BI p.23

1) Functions and parameters can be read without key number. Only when changing functions or 3) Decimal place depends on the function DP (main group AUX)
parameters for the first time, you are prompted to enter the key code. 4) The parameter values in brackets are only valid for controller version 6493-02.
2) Range of values equals that of the assigned input.

74 75
Appendix A Appendix A

Main Function Displayed KEY Setting Description of function Details Parameters Parameter Parameter designation Range of values Factory
group -CO- setting options see page -PA- selection [unit of meas.] default

Control structure and functions

CNTR -CO- PI CP.YP 1) PI CP.YP Dynamic behavior of controller output PI -PA- C.PID/CP.YP KP Proportional-action coefficient 0.1… 100.0 [1] 1.0
C.PID Pd CP.YP ~ PD TN Reset time 1…9999 [s] 120
PId CP.YP ~ PID TV Derivative-action time 1…9999 [s] 10
PPI CP.YP ~ P2I TVK1 Derivative-action gain 0.1…10.0 [1] 1.0
P CP.YP ~P p.24 Y.PRE Y rate action -10.0… 110.0 [%] 0.0
DZXD Dead band of error XD 0.0… 110.0 [%] 0.0
DZXD Limitation of XD min. -110… DZXD [%] -110.0
DZXD Limitation of XD max. DZXD…110 [%] 110.0

-CO- dir.d XD 1) dir.d XD Inversion of error Xd no noPA SIGN/XD No parameter

SIGN in.d XD yes p.26
-CO- F01 DP.YP 1) Assignment of controller output D element noPA D.PID/DP.YP No parameter
D.PID F01 DP.YP ~ to error
F02 DP.YP ~ to controlled variable p.26
-CO- oFF CC.P/ 1) oFF CC.P/ Control mode changeover P(D)/PI(D) off -PA- CH.CA/CC.P/ CLI.P Maximum limit 0.0… 110.0 [%] 110.0
CH.CA F01 CC.P/ ~ via error CLI.M Minimum limit for -110… 0.0 [%] -110
F02 CC.P/ ~ via reference variable p.27 PI(D) control
-CO- oFF MA.YP 1) Operating point adjustment in manual mode for YPID noPA M.ADJ/MA.YP No parameter
M.ADJ oFF MA.YP ~ off
on MA.YP ~ on p.28
-CO- dir.d DI.AC 1) dir.d DI.AC Operating direction of output variable direct noPA DIRE/DI.AC No parameter
DIRE in.d DI.AC ~ inverted p. 28
-CO- oFF FECO 1) oFF FECO Feedforward control off -PA- F.FOR/FECO ± (|WEX −FC.K1|) FC.K2 +FC.K3
F.FOR P05 FECO ~ with positive sign FC.K1 Constant 0.0… 110.0 [%] 0.0
nE6 FECO ~ with negative sign p.28 FC.K2 Constant 0.0… 10.0 [1] 1.0
FC.K3 Constant -10.0 …110.0 [%] 0.0
-CO- oFF IN.DE 1) oFF IN.DE Increase, decrease of actual value off -PA- AC.VA/IN.DE AV.K1 Constant -110 …110.0 [%] 0.0
AC.VA bi1 IN.DE ~ via binary input BI p.29

1) Functions and parameters can be read without key number. Only when changing functions or 3) Decimal place depends on the function DP (main group AUX)
parameters for the first time, you are prompted to enter the key code. 4) The parameter values in brackets are only valid for controller version 6493-02.
2) Range of values equals that of the assigned input.

76 77
Appendix A Appendix A

Main Function Displayed KEY Setting Description of function Details Parameters Parameter Parameter designation Range of values Factory
group -CO- setting options see page -PA- selection [unit of meas.] default

Output functions

OUT -CO- oFF SA.VA 1) oFF SA.VA Initialization of 2nd output variable Y1K1 for YPID off -PA- SAFE/SA.VA Y1K1 2nd output variable -10.0…110 [%] -10.0
SAFE bi1 SA.VA ~ via binary input BI p.30
-CO- oFF CH.MA 1) oFF CH.MA Manual/automatic transfer off noPA MA.AU/CH.MA No parameter
MA.AU bi1 CH.MA ~ via binary input BI p.30
-CO- on LI.YP 1) on LI.YP Output signal limitation YPID on p.32 -PA- Y.LIM/ LI.YP Y Min. output variable -10.0…110 [%] -10.0
Y.LIM Y Max. output variable 110.0

-CO- oFF RA.YP 1) oFF RA.YP Output ramp or limitation of -PA- RAMP/RA.YP TSRA Transit time of ramp 1.0… 9999 [s] 1.0
RAMP rate of output changes YPID off Y1RA Starting value for ramp -10.0… 110.0 [%] -10.0
F01 RA.YP Increasing ramp, starts with -10% via BI
F02 RA.YP Decreasing ramp, starts with Y1RA via BI
F03 RA.YP Limitation for decreasing and increasing
output variable
F04 RA.YP Limitation for increasing output variable
F05 RA.YP Limitation for decreasing output variable p.32
-CO- oFF BL.YP 1) oFF BL.YP Locking of output signal YPID off noPA BLOC/BL.YP No parameter
BLOC bi1 BL.YP ~ via binary input BI
-CO- oFF FU.YP 1) oFF FU.YP Function generation of controller output off -PA- FUNC/FU.YP K1.X Input value point 1 X values ( K1.X…): 0.0
FUNC on FU.YP ~ on p.34 K1.Y Output value point 1 -10.0… 110.0 [%] 0.0
K2.X Input value point 2 0.0
K2.Y Output value point 2 Y values (K1.Y…): 0.0
K3.X Input value point 3 -10.0… 110.0 [%] 0.0
K3.Y Output value point 3 0.0
K4.X Input value point 4 0.0
K4.Y Output value point 4 0.0
K5.X Input value point 5 0.0
K5.Y Output value point 5 0.0
K6.X Input value point 6 0.0
K6.Y Outpout value point 6 0.0
K7.X Input value point 7 0.0
K7.Y Output value point 7 0.0
-CO- 4-20 mA 1) 0-20 mA Output signal range 0 to 20 mA no PA Y.VA/Y No parameter
Y.VA 4-20 mA ~ 4 to 20 mA no PA Y.VA/mA
oFF Y No continuous output p.34 no PA Y.VA/mA

1) Functions and parameters can be read without key number. Only when changing functions or 3) Decimal place depends on the function DP (main group AUX)
parameters for the first time, you are prompted to enter the key code. 4) The parameter values in brackets are only valid for controller version 6493-02.
2) Range of values equals that of the assigned input.

78 79
 Appendix A Appendix A

Main Function Displayed KEY Setting Description of function Details Parameters Parameter Parameter designation Range of values Factory
group -CO- setting options see page -PA- selection [unit of meas.] default
OUT -CO- on Y.PID 1) Assignment of continuous output no PA Y.SRC/Y.PID No parameter
Y.SRC on Y.PID ~ to PID output no PA Y.SRC/Y.X
(continue on Y.X ~ to X input no PA Y.SRC/ Y.WE
d) on Y.WE ~ to WE input (feedforward control) no PA Y.SRC/ Y.XD
on Y.XD ~ to error Xd p.35
-CO- on CA.Y 1) Mathematical adaptation of controller output Y -PA- CALC/CA.Y Y2 = ± (|Y1 − CA.K1|) CA.K2 + CA.K3
CALC on CA.Y ~ without condition CA.K1 Constant 0.0… 100.0 [%] 0.0
oFF CA.Y ~ off (no output signal!) CA.K2 Constant 0.0… 10.0 [1] 1.0
POS CA.Y ~ with positive sign CA.K3 Constant −10.0…110.0 [%] 0.0
nE6 CA.Y ~ with negative sign p.35
-CO- oFF 2/3.S 1) oFF 2/3.S Configuration of two-step or three-step output off -PA- C.OUT/2/3.S KPL1 Gain for BO1 0.1… 100.0 [1] 1.0
C.OUT on 2.STP Two-step output -PA- C.OUT/2.STP KPL2 Gain for BO2 0.1… 100.0 [1] 1.0
i.Fb 3.STP Three-step output with internal position feedback -PA- C.OUT/3.STP TYL1 Duty cycle of BO1 0.1… 9999 [s] 10.0
E.Fb 3.STP Three-step output with external position feedback -PA- C.OUT/3.STP TYL2 Duty cycle of BO2 0.1… 9999 [s] 10.0
PP 2.STP Two-step output with pulse-pause modulation (PPM) -PA- C.OUT/2.STP TYL1 Min. on-time of BO1 0.1… TYL1[%] 1.0
i.PP 3.STP Three-step output with internal position feedback + PPM -PA- C.OUT/3.STP TYL2 Min. on-time of BO2 0.1… TYL2 [%] 1.0
E.PP 3.STP Three-step output with external position feedback + PPM -PA- C.OUT/3.STP XSDY Diff. gap of 2-stp/3-stp output 0.10… TZ [%] 0.50
p.36 TZ Dead band of 3-step output XSDY… 100.0 [%] 2.00
TY Transit time 1… 9999 [s] 60

-CO- oFF B.BO1 1) oFF B.BO1 Configuration of binary output BO1 off noPA OUT1/B.BO1 No parameter
B.OUT F01 B.BO1 Active when binary input active
F02 B.BO1 Active when WE activated
F03 B.BO1 Active in automatic mode
oFF B.BO2 1) oFF B.BO2 Configuration of binary output BO2 off noPA OUT1/B.BO2 No parameter
F01 B.BO2 Active when binary input active
F02 B.BO2 Active when WE activated
F03 B.BO2 Active in automatic mode p.45

1) Functions and parameters can be read without key number. Only when changing functions or 3) Decimal place depends on the function DP (main group AUX)
parameters for the first time, you are prompted to enter the key code. 4) The parameter values in brackets are only valid for controller version 6493-02.
2) Range of values equals that of the assigned input.

80 81
Appendix A Appendix A

Main Function Displayed KEY Setting Description of function Details Parameters Parameter Parameter designation Range of values Factory
group -CO- setting options see page -PA- selection [unit of meas.] default

Alarm functions

ALRM -CO- oFF L1 1) oFF L1 Limit relay L1 off

LIM1 Lo L1.X L1 is activated when X is not reached -PA- LIM1/L1.X LI.X Limit value for X IN1… IN1 500.0
Hi L1.X L1 is activated when X is exceeded or IN2… IN2 2),3) (100.0)4)
Lo L1.WE L1 is activated when WE is not reached -PA- LIM1/L1.WE LI.WE Limit value for WE IN1… IN1 100.0
Hi L1.WE L1 is activated when WE is exceeded or IN2… IN2 2),3)
Lo L1.YP L1 is activated when YPID is not reached -PA- LIM1/L1.YP LI.YP Limit value for YPID Y… Y [%] 110.0
Hi L1.YP L1 is activated when YPID is exceeded
Lo L1.XD L1 is activated when + XD is not reached -PA- LIM1/L1.XD LI.XD Limit value for XD -110… 110.0 [%] 0.0
Hi L1.XD L1 is activated when − XD is exceeded
Ab S L1.XD L1is activated when the sum of XD is exceeded p.47 L.HYS Differential gap 0.10…100.0 [%] 0.50

-CO- oFF L2 1) oFF L2 Limit relay L2 off

LIM2 Lo L2.X L2 is activated when X is not reached -PA- LIM2/L2.X LI.X Limit value for X IN1… IN1 500.0
Hi L2.X L2 is activated when X is exceeded or IN2… IN2 2),3) (100.0)4)
Lo L2.WE L2 is activated when WE is not reached -PA- LIM2/L2.WE LI.WE Limit value for WE IN1… IN1 100.0
Hi L2.WE L2 is activated when WE is exceeded or IN2… IN2 ,2) 3)
Lo L2.YP L2 is activated when YPID is not reached -PA- LIM2/L2.YP LI.YP Limit value for YPID Y… Y [%] 110.0
Hi L2.YP L2 is activated when YPID is exceeded
Lo L2.XD L2 is activated when + XD is not reached -PA- LIM2/L2.XD LI.XD Limit value for XD -110… 110.0 [%] 0.0
Hi L2.XD L2 is activated when − XD is exceeded
Ab S L2.XD L2 is activated when the sum of XD is exceeded p.47 L.HYS Differential gap 0.1…100.0 [%] 0.50

1) Functions and parameters can be read without key number. Only when changing functions or 3) Decimal place depends on the function DP (main group AUX)
parameters for the first time, you are prompted to enter the key code. 4) The parameter values in brackets are only valid for controller version 6493-02.
2) Range of values equals that of the assigned input.

82 83
Appendix A Appendix A

Main Function Displayed KEY Setting Description of function Details Parameters Parameter Parameter designation Range of values Factory
group -CO- setting options see page -PA- selection [unit of meas.] default

Additional functions

AUX -CO- F01 MODE 1) Restart conditions upon power failure -PA- RE.CO/MODE Y1K1 2nd output variable -10.0…110 [%] -10.0
RE.CO F01 MODE Manual mode with 2nd output variable Y1K1
F02 MODE Automatic mode with last received value of reference
variable and Y1K1, no acknowledgement
F03 MODE Automatic mode with last received value of reference
variable and Y1K1, acknowledgement needed p.48
-CO- FrEE INIT 1) FrEE INIT Resetting to factory default off/completed noPA ST.IN/INIT No parameter
ST.IN All INIT ~ of all the functions, parameters and the key number
FUnC INIT ~ of all the functions
PArA INIT ~ of all the parameters
AdJ INIT Basic initialization of calibrating values for
IN1, IN2, Y p.48
-CO- oFF LOCK 1) oFF LOCK Operator keys enabled noPA KEYL/LOCK No parameter
KEYL bi1 LOCK ~ enabling /disabling via BI
on noH.W Selector, manual/automatic transfer and
cursor keys disabled p.49
-CO- 04 VIEW 1) 04 VIEW Display contrast grade 4 noPA No parameter
VIEW 05 VIEW Grade 5
06 VIEW Grade 6
07 VIEW Grade 7
08 VIEW Grade 8
09 VIEW Grade 9
10 VIEW Grade 10
01 VIEW Grade 1
02 VIEW Grade 2
03 VIEW Grade 3 p.49
-CO- on 50HZ 1) on 50Hz Power frequency 50 Hz noPA FREQ/50Hz No parameter
FREQ on 60Hz 60 Hz p. 49
-CO- on DP1 1) on DP1 One decimal place noPA DP1 No parameter
DP on DP2 Two decimal places
on DP0 No decimal place p. 50

1) Functions and parameters can be read without key number. Only when changing functions or 3) Decimal place depends on the function DP (main group AUX)
parameters for the first time, you are prompted to enter the key code. 4) The parameter values in brackets are only valid for controller version 6493-02.
2) Range of values equals that of the assigned input.

84 85
Appendix A Appendix A

Main Function Displayed KEY Setting Description of function Details Parameters Parameter Parameter designation Range of values Factory
group -CO- setting options see page -PA- selection [unit of meas.] default

Start-up adaptation

TUNE -CO- oFF ADP.S 1) oFF ADP.S Adaptation on -PA- ADAP/ADP.S KP Proportional-action coefficient 0.1…100.0 [1] 1.0
ADAP run ADP.S Initiate adaptation p.50 TN Reset time 1.0…9999 [s] 120.0
TV Derivative-action time 1.0…9999 [s] 1.0
Y.JMP Value of step response -100…100.0 [%] 20.0

View process data

I-O CIN FIR 1) View software version p.53

S-No 1) View serial number p. 53
ANA IN1 3) View values of analog input 1 -999…9999 [1]
IN2 3) View values of analog input 2
CO.VA 3) View value of controlled variable after root extraction
WE.VA 3) View value of reference variable after root extraction
FE.CO 3) View value of WE before applying feedforward control
SP.CO 3) View value of reference variable at the comparator
YPID View value of YPID after limitation −10.0…110.0 [%]
YOUT View value of controller output after mathematical
adaptation YOUT p.53
BIN BI1 1) Status of binary input BI1
BO1 Status of binary output BO1
BO2 Status of binary output BO2 p.53
ADJ AdJ IN1 1) Adjusting analog input IN1 −10.0…110.0 [%]
AdJ IN2 Adjusting analog input IN2
AdJ YOUT Adjusting analog output Y p.54

1) Functions and parameters can be read without key number. Only when changing functions or 3) Decimal place depends on the function DP (main group AUX)
parameters for the first time, you are prompted to enter the key code. 4) The parameter values in brackets are only valid for controller version 6493-02.
2) Range of values equals that of the assigned input.

86 87
 Appendix B

Appendix B Error messages

Display is blinking What does it mean? What you need to do

1 No access to EEPROM Ship the device to the

ERR manufacturer!

2 EEPROM cannot be programmed Ship the device to the

ERR manufacturer!

3 Factory default is lost Ship the device to the

ERR manufacturer!
4 Functions are changed without Check the setting of the functions!
ERR user intervention

5 Parameters are changed without Check the setting of the

ERR user intervention parameters!
6 Unknown whether internal or Specify either internal or external
ERR external reference variable is to be reference variable!
used

7 Data of adjustment procedure are Re-adjust the analog inputs and

ERR changed without user intervention /or the analog output!
31 Error during adaptation procedure More details are given on p. 52.
ERR

to

35
ERR
The binary output for messages (fault indication output) is set when any error message
occurs, likewise when the CPU fails.

88 EB 6493 EN
 Appendix C Checklist

Appendix C Checklist
TROVIS 6493 Compact Controller

Controller no.: Firmware version:

Date of configuration: Signature:

Main Function -CO- Setting Parameters

group

IN IN1 IN1
IN1
IN2 IN2
IN2
MEAS
MAN Y1K1
CLAS X
WE
DI.FI X TS.X
WE TS.WE
SQR X
WE
FUNC X MIN
MAX

1 2 3 4 5 6 7
K .X
K .Y

EB 6493 EN 89
Appendix C Checklist

Main Function -CO- Setting Parameters

group
WE MIN
MAX

1 2 3 4 5 6 7
K .X
K .Y

SETP SP.VA W W
WINT
WINT
WRAN
WRAN
W2 W2
WE
SP.FU RAMP TSRW
WIRA
CH.SP
CNTR C.PID KP
TN
TV
TVK1
Y.PRE
DZXD
DZXD
DZXD
SIGN
D.PID
CH.CA CLI.P
CLI.M
M.ADJ
DIRE
F.FOR FC.K1
FC.K2
FC.K3

90 EB 6493 EN
 Appendix C Checklist

Main Function -CO- Setting Parameters

group
AC.VA AV.K1
OUT SAFE Y1K1
MA.AU
Y.LIM Y
Y
RAMP TSRA
Y1RA
BLOC
FUNC MIN
MAX

1 2 3 4 5 6 7
K .X
K .Y

Y.VA
Y.SRC
CALC CA.K1
CA.K2
CA.K3
C.OUT KPL1
KPL2
TYL1
TYL2
MinTYL1
MinTYL2
XSDY
TZ
TY
B.OUT

EB 6493 EN 91
Appendix C Checklist

Main Function -CO- Setting Parameters

group
ALRM LIM1 LI.X
LI.WE
LI.YP
LI.XD
L.HYS
LIM2 LI.X
LI.WE
LI.YP
LI.XD
L.HYS
AUX RE.CO Y1K1
KEYL
VIEW
FREQ

92 EB 6493 EN
 Index

Index
A Continuous output
assignment........................................35
Actual value mathematical adaptation....................35
increase, decrease ............................ 29 signal range......................................34
Adaptation Control mode...................................20 - 23
See start-up adaptation Control mode changeover........................27
Alarm messages ..................................... 17 Cursor keys ..............................................5
Analog inputs
adjustment........................................ 54 D
assignment ....................................... 18
view................................................. 53 D element ...............................................26
Analog output Decimal point setting ...............................50
assignment ....................................... 35 Derivative-action gain TVK1 ....................24
mathematical adaptation ................... 35 Derivative-action time TV .........................24
signal range ..................................... 34 Dynamic behavior of controller output ......24

B E

Binary input Error messages .......................................88

changeover to manual mode.............. 30 Error Xd
enabling/disabling operator keys ...... 49 inversion ...........................................26
increase, decrease of actual value ...... 29 view ...................................................4
initialization of 2nd output variable .... 30 Errors
locking of output signal ..................... 34 displayed during adaptation ..............52
reference variable changeover ........... 23
start of output ramp........................... 32 F
start of set point ramp ....................... 23
Factory default
status of ~......................................... 53
view status via binary input................ 45 See parameter table
Binary output resetting to ~ .....................................48
for messages ........................ 17, 52, 88 Feedforward control ................................28
Filtering..................................................18
Binary outputs ........................................ 45
Firmware................................................53
status of ~......................................... 53
view operating status......................... 45 Fixed set point control ......................20 - 23
practical example ..............................55
C Follow-up control .............................20 - 23
practical example .......................56 - 57
Configuration of outputs................... 30 - 45 practical example with function
Configuration table................................. 62 generation .................................58 - 59

EB 6493 EN 93
 Index

Function Manual/automatic transfer ........................6

indication on display......................... 10 via binary input .................................30
Function generation Manual/automatic transfer key ..................5
of input variables .............................. 19 Measuring range monitoring ...................17
of output variable.............................. 34
Functions of the compact controller ... 14 - 54 N

I Ni 100...................................................16
Ni 1000.................................................16
Input functions ................................. 14 - 19
Input signal range
In1................................................... 16 O
In2................................................... 16
Input variables Operating direction
assignment ....................................... 18 of error Xd ........................................26
filtering ............................................ 18 of output variable ..............................28
function generation of ~ .................... 19 Operating level....................................5 - 6
monitoring via limit relay............ 46 - 47 Operating point adjustment in man. mode 28
root extraction .................................. 18 Operation .........................................4 - 13
Operator keys
K disabling ..........................................49
Output ramp...........................................32
Key number ........................................ 8 - 9 Output signal limitation ...........................32
KP ....................................................... 24 Output signal range ................................34
fast setting ............................ 10, 12, 14
P

L P controller .............................................24
P2I controller...........................................24
Limit relay L1.......................................... 47 Parameter table ......................................62
Limit relay L2.......................................... 47 PD controller...........................................24
Limit relays PI controller ............................................24
differential gap (hysteresis) ......... 46 - 47 PID controller ..........................................24
Limitation Power failure
of rate of output changes ................... 32 restart conditions ...............................48
Locking of output signal .......................... 34 Power frequency .....................................49
Programming key......................................5
M Proportional-action coefficient KP .............24
Pt 100....................................................16
Manual mode Pt 1000..................................................16
upon transmitter failure ..................... 17

94 EB 6493 EN
 Index

R T

Reference variable Technical data .................................66 - 68

activation ......................................... 22 Three-step output
change............................................... 6 configuration.....................................36
changeover .................................. 6, 23 with external position feedback...........38
external..................................... 20 - 23 with internal position feedback ...........38
internal ..................................... 20 - 23 with pulse-pause modulation ..............42
Reset key.................................................. 5TN ........................................................24
Reset time TN ......................................... 24 fast setting.........................................14
Root extraction ....................................... 18 Transmitter failure
changeover to manual mode ..............17
S TV ........................................................24
fast setting.........................................14
Second output variable Two-step output.......................................37
after power failure ............................ 48 configuration.....................................36
initialization via binary input ............. 30 with pulse-pause modulation ..............40
upon transmitter failure...................... 17
Selector key ............................................. 5 V
Set point ramp ....................................... 23
Setup level .......................................... 5 - 7 View process data............................53 - 54
Start-up adaptation.......................... 50 - 52
Y

Y rate action Y-PRE .................................24

Service key number 1732

EB 6493 EN 95
1 Controlled variable X 8 Hand symbol 12 Selector key
2 Value assumed by W, W2, 9 When pressing the selector 13 Manual/automatic transfer
WE, Y or Xd key, W, W2, WE, Y or Xd key
3 Limit relay L2 active appear with their associa- 14 Cursor key
4 Three-step output − ted values in 2 (increase, forward)
5 Limit relay L1 active 10 Bar graph display of Xd 15 Cursor key
in % (decrease, back)
6 Three-step output +
11 Programming key 16 Reset key
7 Alarm message
17 Exchangeable label
 S 03/2001

SAMSON AG ⋅ MESS- UND REGELTECHNIK

Weismüllerstraße 3 ⋅ D-60314 Frankfurt am Main
Phone (0 69) 4 00 90 ⋅ Fax (0 69) 4 00 95 07
Internet: http://www.samson.de EB 6493 EN