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IDEC PIC Control Module User`s Manual

1. Dimensions 38 p mi 19 70 0 q A B BB 7 d o S d _Y Dom da 9 HR x o Ut All dimensions in mm 8 5mm when the clamp is pulled out 2 6 FC5A MicroSmart PID Module User s Manual FC9Y B1283 INSTALLATION AND WIRING 3 INSTALLATION AND WIRING This chapter describes how to install and wire the PID modules For general methods and precautions for installation and wiring of the PID modules see chapter 3 in the FC5A MicroSmart user s manual FC9Y B1 268 Be sure to use the PID modules properly after understanding installation and wiring thoroughly A Caution e Assemble the CPU module and PID modules before installing them on a DIN rail Otherwise they may break Do not lay out or wire the modules while power is supplied to them Otherwise they may be damaged When installing modules follow the instructions described in the FC5A MicroSmart user s manual If there are flaws in the installation it may cause disattachment failure or malfunction Mounting Hole Layout for Direct Mounting on Panel Surface To mount the PID module on a panel surface 39 1 Direct mounting strip 6 3 pas FC4A PSP1P use the direct mounting strip and two M4 screws 1 6 or 8 mm long For details about the direct mounting strip see the FC5A MicroSmart user s manual FC9Y B1268 o o9 o S 3 2 m O Y 3 0 All
2. Alarm Type Valid Range Upper Limit Alarm Full scale to full scale 1 Lower Limit Alarm Full scale to full scale 1 Upper Lower Limits Alarm 0 to full scale 1 Upper Lower Limit Range Alarm 0 to full scale 1 Process High Alarm Input range lower limit to input range upper limit 2 Process Low Alarm Input range lower limit to input range upper limit 2 Upper Limit Alarm with Standby Full scale to full scale 1 Lower Limit Alarm with Standby Full scale to full scale 1 Upper Lower Limits Alarm with Standby 0 to full scale 1 1 When input is voltage current full scale is the linear conversion span 2 When input is voltage current the valid range is the linear conversion minimum value to linear conversion maximum value FC5A MicroSmart PID Module User s Manual FC9Y B1283 DEVICE ALLOCATION OF PID MODULE Data Register Allocation Blocks 4 5 Initial Setting Parameters SHOT Action Block 4 CHO and block 5 CH1 parameters are shown in the table below Before changing the parameters of block 4 or 5 it is recommended that the control of the PID module be disabled Offset from the SE Parameter Description R W CHO CH1 0 Reverse control action Heating T89 190 GonirolAction 1 Direct control action Cooling SU Heating Cooling Control 0 Disable 54 eal only i 1
3. 777777 Represents cooling control action FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPENDIX Output Action of Heating Cooling Control with Dead Band Heating Proportional Band Dead Band Cooling Proportional Band ON j j Control Heating i i Cooling Action Control Action i i i Control Action OFF 3 Cycle Action is Performed ccording to Deviation Cycle Action is Performed ccording to Deviation CHO a Non contact DC i 12 0V DC Voltage i Cycle Action is Performed ccording to Deviation 042VDC i 12VDC Voltage d Output C icle Action is Performed ccording to Deviation CHO dom PE a Current 20mADCi 20to4mADC Output d Changes Continuously According to Deviation oH pr P om ee Current 4mA DC i 4 to 20mA DC 20mA DC i i i Output i p Changes Continuously According to Deviation CH1 OUT Green Turns ON or OFF Represents heating control action Represents cooling control action 9 8 FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPENDIX Factory Default Settings of the PID Module The factory default settings of the parameters of each block are described Values indicated in parentheses are stored in the data registers allocated to each block Block 1 Write Only Parameters Offset from Ge es Parameter Default Value CHO CH1 2
4. While external input 15 is on auto tuning AT is performed in each step of the program control as follows Step 0 When the remaining time is 5 minutes Step 1 When step 1 is started Step 2 When the remaining time is 5 minutes Step 3 When step 3 is started D1014 5 10005 D1025 01 I W l SOTU LC W H D1014 5 When CH1 program control is completed Q3 is turned on I D1019 06 Notes The ladder program should be customized depending on actual applications Perform the auto tuning AT near the set point SP If auto tuning AT is performed near the ambient temperature temperature fluctuation cannot be given to the process In such case the auto tuning AT may not finish normally Once auto tuning AT is performed it is unnecessary to perform auto tuning AT again as long as the process is unchanged FC5A MicroSmart PID Module User s Manual FC9Y B1283 7 13 APPLICATION EXAMPLES 9 User Program Download From the WindLDR menu bar select Online gt Transfer gt Download to open Download dialog box Click the check box on the left of Write PID Module parameters after download and click OK button The user program will be downloaded to the CPU module After downloading the user program the PID module parameters will be written to the data registers in the CPU module and the PID module connected to the CPU module Tra nsfer Mode e Binary 5
5. Install the MicroSmart according to the instructions described in this user s manual Improper installation will result in disattachment failure or malfunction of the MicroSmart s Caution notices are used where inattention might cause personal injury Caution or damage to equipment e The MicroSmart is designed for installation in a cabinet Do not install the MicroSmart outside a cabinet Install the MicroSmart in environments described in this user s manual If the MicroSmart is used in places where the MicroSmart is subjected to high temperature high humidity condensation corrosive gases excessive vibrations and excessive shocks then electrical shocks fire hazard or malfunction will result The environment for using the MicroSmart is Pollution degree 2 Use the MicroSmart in environments of pollution degree 2 according to IEC 60664 1 Prevent the MicroSmart from being dropped while moving or transporting the MicroSmart otherwise damage or malfunction of the MicroSmart will result Prevent metal fragments and pieces of wire from dropping inside the MicroSmart housing Put a cover on the MicroSmart modules during installation and wiring Ingress of such fragments and chips may cause fire hazard damage or malfunction Use a power supply matching the rated value Use of an incorrect power supply may cause fire hazard Use an IEC 60127 approved fuse on the power line outside the MicroSmart This is requir
6. 1 For detail about the output ON OFF hysteresis see page 6 38 Hunting phenomenon is occurring while in PID PI PD or P control action Hunting phenomenon is occurring while in PID PI PD or P control action Is the control period setting 1 too short Set the control period to a suitable value Call IDEC for assistance 1 For detail about the control period see page 6 46 FC5A MicroSmart PID Module User s Manual FC9Y B1283 8 3 TROUBLESHOOTING The PID Module input does not operate normally Input does not operate normally NO Is the input wiring correct Correct the input wiring YES Does the sensor YES Replace the sensor malfunction NO Is the sensor or external NO device connected to the PID module securely Connect them securely YES YES Replace the sensor if it is burnt out or disconnected Make sure of input status Is the sensor burnt out or the input signal source abnormal NO Are sensor specifications suitable with the PID module NO Use a sensor with suitable specifications YES Does AC leak into the NO setsorclle it Use an ungrounded type sensor YES NO S there equipment tha interferes with or makes noise near the PID module Take countermeasures against inductive interference or
7. Difference CHO CH1 Difference CH1 CHO Addition CH0 CH1 OJOJOO O OIOIO OJOJOO OJOJOO x gt lt gt lt O xXx gt lt O 3 Control Register 57 Output CHO Function The one of the following output functions can be selected as the Output CHO Function Output CHO The output of the CHO control is outputted from output CHO Input Parameters Control Parameters Output Parameters a nput CHO m Ven 5 output cro el Was Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Control Parameters Output Parameters CHI input CHL Den CH Par D output CHI E CHI Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Output CH1 The output of the CHO control is outputted from output CH1 When Output CH1 is selected CH1 parameters are used for the control period and the output manipulated variable MV upper and lower limits CHO parameters are used for all other parameters such as the output manipulated variable rate of change output on off hysteresis and manual mode output manipulated variable Input Parameters Control Parameters CHO gt Input cHo gt CHO o output CHL Type K thermocouple Celsius Reverse Control Action Heating Input Parameters Output Parameters cH input CHL Ht Type J thermocouple Celsius Voltage Output When Output CH1
8. WindLDR gt Flow of the user program when executing the user program download gt Flow of the user program when executing the user program upload PID Module RAM Data Register 1 When Write PID Module parameters after download is checked in the Download dialog writing the PID module parameters will be executed after the user program is downloaded to the CPU module The PID module parameters are written to the data registers in the CPU module and all PID modules configured in the Expansion Modules Configuration dialog box For details see the following page FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 3 CONFIGURING PID MODULE USING WINDLDR User Program Download The user program contains the user program and the PID module parameters initial values configured in the PID Module Configuration dialog box After the user program is downloaded to the CPU module the CPU module can communicate with the PID Modules through the allocated data registers After the user program download the following actions will be taken depending on whether Write PID Module parameters after download in the Download dialog box is checked or not When Write PID Module parameters after download is checked After the user program is downloaded to the CPU module the PID module parameters configured in the PID Module Configuration dialog box are written to the CPU
9. Cascade Control b CHI Type K thermocouple Celsius Reverse Control Action Heating Input CHO Control CHO Output CHO Input CH1 Control CH1 Monitor Control Mode Fixed Value Control Mode Control Action Reverse Control Action Heating Loop Break Alarm LA Time DI 0to 200 min Set Point SP 0 S 200 to 1370 C Loop Break Alarm LA Span 9 Z 0to 150 c Proportional Term Proportional Band Proportional Band 10 Z oto 10000 c Integral Time 200 ZI 0 to 10000 sec 1 Cascade Control Settings External SP Input Min amp Max Values Derivative Time 50 k 0 to 10000 sec Linear Conversion Maximum Value 1370 200 to 1370 C ARW Anti Reset Windup 50 Z 0 to 100 2 Conversion Minimum Value 200 IZ 200 to 1370 c AT Bias 20 Z Dto 50 c Reset 0 0 7 100 0 to 100 0 c Set Point SP Rise Rate o Z 0 to 10000 C min E Set Point SP Fall Rate 0 Z 0 to 10000 C min Output MV Rate of Change 0 Z oto 100 sec Output ON OFF Hysteresis 1 0 7 0 1to 100 0 c TA EE ERE Manual Mode Qutput MV 0 0 I 0 0 to 100 0 eg Write all parameters pand al parameters Monitor ek Leal 1 Control Register 178 External SP Input Linear Conversion Maximum Value Configure the external SP input linear conversion maximum value for the cascade control The output manipulated variable MV 0 to 100 of the master CH1 corresponds to the set point SP of the slave CHO The
10. 87 164 Alarm 7 Delay Time R W 88 165 Alarm 8 Delay Time R W When input range unit is Celsius 0 to 50 C 0 0 to 50 0 C for input with decimal point TOS 109 I pias When input range unit is Fahrenheit SC 0 to 100 F 0 0 to 100 0 F for input with decimal point 0 Fixed value control mode 90 167 Control Mode 1 Program control mode R W 0 PV start 491 4168 G ai Control Mode Start 1 PVR start RW yp 2 SP start 492 169 Step Time Unit E RW 0 Terminate program control 93 170 Program End Action 1 Continue program control Repeat R W 2 Hold program control 94 171 Proportional Term H GE vas RAN 0 Air cooling 95 172 La 1 Oil cooling R W only 2 Water cooling When input is thermocouple or resistance thermometer 496 4173 Set Point SP when Program Set point SP lower limit to set point SP upper limit R W Control Starts When input is voltage or current input Linear conversion min to linear conversion max 97 174 Number of Repeats 0 to 10000 times R W When input range unit is Celsius d 0 1 to 100 0 C Cooling Output ON OFF When input range unit is Fahrenheit 98 175 Hysteresis 0 1 to 100 0 F R W CHO only When input is voltage or current input 1 to 1000 Output Type 0 Non contact voltage output for SSR drive 198 FB FC5A F2M2 only 1 Current output PUW 100 177 NE Input Biss 20 of the external SP input linear conversion span R W External SP Input Linear c 4101 178
11. If the proportional band or proportional gain of the PID module parameter is set to 0 the control action becomes ON OFF control Overshoot Undershoot As the temperature of the control target rises as shown in the figure on the right the process variable PV sometimes Set Point SP gt ts exceeds the set point SP greatly This is called overshoot If the process variable PV drops below the set point SP this is called undershoot Overshoot Hunting Temperature Undershoot Hunting The control result oscillates as shown ON i Time in the figure on the right This is the the hunting Control Output OFF P Control Action Proportional Action P control action outputs the manipulated variable MV in proportion to the deviation between the process variable PV and the set point SP within the proportional band The control output is ON until the process variable PV reaches the point A that is determined by the proportional band If the process variable PV exceeds the point A enters the proportional band the control output starts turn on off according to the control period and the manipulated variable MV If the process variable PV exceeds the set point SP the control output is completely turned off While the process variable PV rises from the point A to the set point SP the control output ON time decreases and the control output OFF time increases Compared to ON OFF control action
12. Input CHL Es CHI e output cn CHD Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Difference CHO CH1 The difference between input CHO and input CH1 is used as the process variable PV for CHO control Process variable PV of CHO control Input CHO input value Input CH1 input value Input Parameters ference Tann S Genee Output CHO m Output Parameters Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Control Parameters T Output Parameters cH gt input CH B cut cb Output CHI E cat Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Difference CH1 CHO The difference between input CH1 and input CHO is used as the process variable PV for CHO control Process variable PV of CHO control Input CH1 input value Input CHO input value Input Parameters d Control Parameters Output Parameters CHO M LDifference cH1 CHO Lg CHO 9 output CHO lt k cro Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters S Control Parameters S Output Parameters cHi T Input cnt zg CH o output CHL eg CH Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Addition CHO CH1 The addition of input CHO and input CH1 is used as the process variable PV for CHO control Process variable PV of CHO c
13. O 200 to 1370 C Loop Break Alarm LA Span Proportional Term Proportional Band E Proportional Band 10 7 0to 10000 c Integral Time 00 7 Oto 10000 sec Derivative Time Dto 10000 sec ARW Anti Reset Windup Oto 100 ATBias 20 7 Dto50 C E iia S rogram Contr ings G SE IST con Control Mode Start Type Set Point SP Rise Rate 0 to 10000 C min 2 Ak E Set Point SP Fall Rate 0 to 10000 C min Output MV Rate of Change 0 E 0to 100 sec lee Mass Output ON OFF Hysteresis 1 0 FE 0 1 to 100 0 c 26 m S Manual Mode Output MV 0 0 0 0 to 100 0 EE See Write all parameters Read all parameters Monitor EZ Voltage Output 0 0 to 200 min o 0to 150 c Air Cooling lt 1 0 E 0 0 to 10 0 Minute 0 Z 0 to 200 min o I to 150 c PV Start C200to 1370 c minute cl Terminate Program Control B 0 Oto 10000 Control parameters of CHO control are described here When the program control mode is selected as the control mode parameters for the fixed value control mode such as the set point SP proportional band proportional gain or integral time are disabled The parameters for the program control mode 23 to 27 are enabled Control parameters for CH1 control are the same as those of CHO control except cascade control parameters However the position from the control register fo
14. Reverse Control Action Heating Disable Proportional Band 10 0 to 10000 c 50 0 to 10000 sec 0 0 2 0 0 to 100 0 Read all parameters 200 200 to 1370 c 0 to 10000 sec E oto 100 0 Ez 0to 50 c DE to 100 sec o 0 1to 100 0 c Loop Break Alarm LA Time Loop Break Alarm LA Span 100 0 to 100 0 c 0 to 10000 C min 0 to 10000 C min Monitor o Z 0 to 200 min 0 ES 0 to 1501 c ok Cancel Item Seiting 1 Set Point SP 200 C 2 AT Bias 20 C 5 Input CH1 Parameters Configure the Input CH1 parameters in the PID Module Configuration dialog box To open Input CH1 Parameters in the PID Module Configuration dialog box click on Input Parameters CH1 button or Input CH1 tab PID Module Configuration Dialog Box Input CH1 Parameters PID Module Configuration Slot 1 Module Type No FCSA F2M2 InputParameters CHO Type K thermocouple Celsius Input Parameters CHI Type K thermocouple Celsius Input CHO Control CHO Output CHO Input CH1 gt input cHo gt Input cH emen g Control Parameters CH0 Output CHO Reverse Control Action Heating Control Parameters CH1 e Output CHI Reverse Control Action Heating Control CH1 Output CH1 Monitor 2 x n Output Parame
15. Set point SP lower limit to set point SP upper limit 20 pet Point SF When the input is voltage or current input ZE Linear conversion min to linear conversion max When heating cooling control is disabled CHO Output manipulated variable lower limit to output manipulated 421 Manual Mode Output variable upper limit W Manipulated Variable When heating cooling control is enabled Cooling output manipulated variable upper limit to heating output manipulated variable upper limit 22 Operation Parameter Refer to the table below for the operation parameters W When the input is thermocouple or resistance thermometer Set point SP lower limit to set point SP upper limit 28 Set Point SP When the input is voltage or current input wW CH1 Linear conversion min to linear conversion max Manual Mode Output Output manipulated variable lower limit to output manipulated 24 ee W Manipulated Variable variable upper limit 25 Operation Parameter Refer to the table below for the operation parameters W Note When the power to the PID module is turned off Block 1 parameters are cleared to zero O ab 2 3 4 5 10 peration Parameters Bit Operation Parameters 1 word Item Status Description 0 Control disable Bito Control Enable Bit 1 Control enable d NET v 0 Auto tuning AT Auto reset canc
16. 209 230 251 272 Alarm 1 value 189 210 231 252 273 Alarm 2 value 190 211 232 253 274 Alarm 3 value 191 212 233 254 275 Alarm 4 value 192 213 234 255 276 Alarm 5 value 193 214 235 256 4277 _ Alarm 6 value 194 215 236 257 278 Alarm 7 value 195 216 237 258 279 Alarm 8 value 196 217 238 259 280 Reserved 197 218 239 260 281 Output manipulated variable upper limit 198 219 240 261 282 Output manipulated variable lower limit 199 220 241 262 283 Cooling proportional band 200 221 242 263 284 Overlap Dead band Parameter Offset from the Control Register Step5 Step6 Step7 Step8 Step 9 285 306 327 348 369 Set point SP 286 307 328 349 370 1 Step time 287 308 329 350 371 Wait value 288 309 330 351 372 __ Proportional term 289 310 331 352 373 Integral time 290 311 332 353 374 Derivative time 291 312 333 354 375 ARW Anti Reset Windup 292 313 334 355 376 Output manipulated variable rate of change 293 314 335 356 377 Alarm 1 value 294 315 336 357 378 Alarm 2 value 295 316 337 358 379 Alarm 3 value 296 317 338 359 380 Alarm 4 value 297 318 339 360 381 Alarm 5 value 298 319 340 361 382 Alarm 6 value 299 320 341 362 383 Alarm 7 value 300 321 342 363 384 Alarm 8 value 301 322
17. ASCII Download Options Z Automatic start after download E Keep output during download E Suspend 1 0 force before download Automatic device clear after download L i Write PID module parameters after download E Write device datafile to the PLC after download Setting E Download comment data Setting ad systemprogra Detail Program Information Program Size 1142 bytes Comment Size 0 bytes Total 1142 bytes Communication Settings When program download is successfully completed the following message will appear Click OK button to close the message LD Program Download Succeeded 10 Starting Program Control 1 Turn on external input IO and I3 to enable CHO and CH1 controls 2 Turn on external input I2 and 15 to allow auto tuning AT to be performed 3 Turn on external input 11 and I4 to start the program control for CHO and CH1 controls 4 Turn on the load circuit power The PID module starts the configured program control from step 0 Auto tuning AT will be performed in each step When the program control for CHO or CH1 is completed Q1 or Q3 will be turned on respectively 7 14 FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPLICATION EXAMPLES Application Example 3 This application example demonstrates the heating cooling control for a system using an electric furnace The set point SP of CHO control is 200 0 C PID control is performed based on the proce
18. CESCHIPTION dE EEN power LED PWR sese power supply teret retener eden quantity oio ee Re e a a ZT dR specifications nee eee eaae Ie Eed Standby mr i TO RT ATO DUET REESE a temperature control type numbers PID module cofiguration dialog box process variable DV program Control advance E advance previous ee eee auto tuning AT Spia a aat Ell EE number of repeats parameters power failure program end action program end OULtDUL sees eee eee program pattern example eee eee eee remaining time repeat number s t point SP T Standby ecce id reete e daa ena Pene riae dea De ee STEP Bal Dal TEE step time EE step time Ulteriori tet to re eate io program end action continue repeat eee eee program CEET proportional band proportional term PV correction PV filter time constant R read only parameters eee eee eee 5 7 reset setting TTT 6 38 reverse control action eee eee 6 36 S lower limit ramp function rise rate del EE when program control starte 6 45 specifications terminal El E CONNECTION DEE type of protection U user program download and upload 6 3 V valid devices S teas 5 2 Ww WIEIDE cse TTT ere iets 3 6 write only parameterS eee eee 5 11 9 9 ii FC5A MicroSmart
19. CHO Input CH1 Output CH1 Monitor Output Type Voltage Output 1 2 Control Period 3 to 120 sec 3 2 3 4 Output MV Upper Limit 100 EI 0to 100 Output MV Lower Limit o Z Oto 100 3 Write all parameters Read all parameters Monitor ok Cancel Output Parameters when Heating Cooling Control is Enabled ER Module Type No FC5A F2m2 Input T TU CHO S Sal Eng Quos Gees selem A Type K thermocouple Celsius Reverse Control Action Heating Voltage Output v Heating Cooling Control QU Input faa input OH J ETT Parameters Type K thermocouple Celsius Voltage Output Input CHO Control CH0 Output CHO Input CH1 Output CHI Monitor Output Type Voltage Output x Control Period 3 5 ito 120 sec Output MV Upper Limit 00 7 Oto 100 Output MV Lower Limit 0 2 to 100 Cooling Control Period ES j 1 to 120 sec Br Cooling Output MV Upper Limit 100 0 to 100 6 Cooling Output MV Lower Limit o FS Oto 100 7 Write all parameters Read all parameters Monitor ok Cancel Output parameters of CHO control are described here When the heating cooling control is enabled the control period and the output manipulated variable MV upper and lower limits of CH1 are disabled The parameters 5 to 7 are enabled Output parameters for CH1 control are the same as those of CHO control except the cooling control parameters However the position
20. CHO CH1 Input Type K thermocouple 200 to 1370 C Type K thermocouple 200 to 1370 C Output Relay output Relay output Alarm 1 Type Upper limit alarm Upper limit alarm Program Pattern Settings are common between CHO and CH1 Step 0 Step 1 Step 2 Siep 3 Set Point SP 100 C 100 C 800 C 800 C Step Time 60 minutes 60 minutes 300 minutes 30 minutes Wait Value 10 C 0 C 10 C 0 C Alarm 1 Value 0 C 10 C 0 C 10 C FC5A MicroSmart PID Module User s Manual FC9Y B1283 7 9 APPLICATION EXAMPLES Parameter Configuration Procedure 1 Expansion Modules Configuration Select Configuration gt Expansion Modules from the WindLDR menu bar to open the Expansion Modules Configuration dialog box In the Expansion Modules Configuration dialog configure the quantity of modules slot number module type number control register data register and control relay internal relay Click on Configure Parameters button to open the PID Module Configuration dialog box Expansion Modules Configuration Dialog Box Expansion Modules Configuration 2 x 1 SESE Quantity of modules a E CPU module Slot 1 Slot 2 Slot 3 Slot 4 c ME FCSA C24R2X Other modules Other modules Other modules 01000 to D1189 M1000 to M1007 o BE 4 Module Type No FC5A F2M2 Data Register D1000 D1000 to D1189 ES Internal Relay m1000 M1000 to M1007 Copy Parameters To OK Can
21. Configure CH1 Parameters in the same way as CHO 7 Saving Parameters Click OK button to save the configured parameters 7 12 FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPLICATION EXAMPLES 8 Ladder Programming Create a ladder program to control the PID module Ladder Program Example While external input IO is on CHO control is enabled When QO CHO control upper limit alarm output is on CHO control is disabled 10000 Qoo00 D1022 00 When external input l1 is turned on CHO program control is started When l1 is tuned off the program control is stopped D1022 03 When CHO alarm 1 is triggered QO is turned on While external input I2 is on auto tuning AT is performed in each step of the program control as follows Step 0 When the remaining time is 5 minutes Step 1 When step 1 is started Step 2 When the remaining time is 5 minutes Step 3 When step 3 is started LC W SOTU D1005 5 10002 D1022 01 LC W j D1005 5 When CHO program control is completed Q1 is turned on While external input I3 is on CH1 control is enabled When Q2 CH1 control upper limit alarm output is on CH1 control is disabled D1025 00 When external input I4 is turned on CH1 program control is started When 14 is turned off D1025 03 the program control is stopped When CH1 alarm 1 is triggered Q2 is turned on D1019 07
22. F min Range with a decimal point 0 0 to 1000 0 F min When input is voltage or current 0 to 10000 min R W FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR Offset from Sr Parameter Setting Range R W CHO CH1 Output Manipulated 6 14 32 109 Variable Rate of Change 0 to 100 sec R W When input range unit is Celsius 0 1 to 100 0 C Output ON OFF When input range unit is Fahrenheit 15 61 138 Hysteresis 0 1 to 100 0 FUN When input is voltage or current 1 to 1000 When heating cooling control is disabled Output manipulated variable lower limit to output Manual Mode Output manipulated variable upper limit 16 gel id Manipulated Variable When heating cooling control is enabled R W Cooling output manipulated variable upper limit to heating output manipulated variable upper limit 17 35 112 7002 Break Alarm LA 9 to 200 minutes RW When input range unit is Celsius 0 to 150 C Range with a decimal point 0 0 to 150 0 C Loop Break Alarm LA When input range unit is Fahrenheit 18 36 113 Span 0 to 150 F R W Range with a decimal point 0 0 to 150 0 F When input is voltage or current 0 to 1500 0 Air cooling 19 95 Cooling Method 1 Oil cooling R W 2 Water cooling 0 0 to 10 0 times 20 48 SR RIS Cooling proportional band is the product of this value R W and the heating pr
23. If any parameters in the data registers of the CPU module have been changed but have not been written to the PID module those parameters will be overwritten with the parameters read from the PID module when auto turning AT is finished FC5A MicroSmart PID Module User s Manual FC9Y B1283 4 7 PID MODULE MAIN FUNCTIONS 4 8 Cancel Auto tuning AT To cancel auto tuning AT while it is performed turn off Auto tuning AT Auto reset bit Bit1 of the operation parameter When the operation parameter Bit1 is turned off auto tuning AT is canceled and the Auto tuning AT Auto reset LED AT0 AT1 will go off When auto tuning AT is cancelled P I D and ARW values are reverted to the original values at the time that auto tuning AT was started Perform Auto reset To perform auto reset turn on Auto tuning AT Auto reset bit Bit1 of the operation parameter The reset value will automatically be configured and the offset is corrected During auto reset is performed the Auto tuning AT Auto reset LED ATO AT1 flashes Auto reset cannot be cancelled Auto tuning AT Auto reset Program Example The ladder program and the timing chart below describe an example of performing and canceling auto tuning AT auto reset of CHO In this example D1000 is allocated to the control register and M1000 is allocated to control relay Ladder Program When external input 10 is turned on CHO operation parameter Bit1 is set and 10000 D10
24. Input CH1 is used as the set point SP for CHO control Input fane Tout CHO Ge Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Paramet eG External SP Input Output Paramet M output CHO Jj UID en SS Type K thermocouple Celsius When the external SP input bias is configured the external SP input bias is added to the input CH1 value and then the input CH1 value is used as the set point SP for CHO control One of the analog input types shown in the table blow can be selected for the external SP input Current Voltage Input Type 4 to 20mA DC or 0 to 20mA DC 1 to 5V DC or 0 to 1V DC 0 to 1V DC 5V DC maximum Allowable Input 50mA DC maximum 1 to SV DC 10V DC maximum Input Impedance 500 100kQ Cascade Control The cascade control is an advanced control that uses 2 inputs CH1 as a master primary control and CHO as a slave secondary control to control a single process a Input Geesen egen SI ES prin E gs Geen Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Control Parameters ent Cascade Control BE cH Type J thermocouple Celsius Reverse Control Action Heating Master CH1 calculates the output manipulated variable MV according to the process variable PV and the set point SP The output manipulated variable MV of the master CH1 is used as the set point SP of
25. Quantity of Modules 1 unit Slot Number Module Type No Data Register Internal Relay Slot 1 FC5A F2M2 D1000 M1000 I O Function Used as a 2 channel PID module CHO CH1 Input Type K thermocouple 200 to 1370 C Type K thermocouple 200 to 1370 C Output Non contact voltage output for SSR drive Non contact voltage output for SSR drive Alarm 1 Type Upper limit alarm Upper limit alarm Alarm 1 Value 5 C 5 C Set Point SP 200 C 210 C Control Action PID control action IP D and ARW are automatically calculated using auto tuning AT PID control action P D and ARW are automatically calculated using auto tuning AT AT Bias 20 C 20 C Parameter Configuration Procedure 1 Expansion Modules Configuration Select Configuration gt Expansion Modules from the WindLDR menu bar to open the Expansion Modules Configuration dialog box In the Expansion Modules Configuration dialog configure the quantity of modules slot number module type number control register data register and control relay internal relay Click on Configure Parameters button to open the PID Module Configuration dialog box Expansion Modules Configuration Dialog Box Expansion Modules Configuration E Expansion Modules 1 bw of modules 4E 2 4 5 internal Relay m1000 Module Type No 3 RM Em Data Register D1000 CPU module Slot 1 Slot 2 Slot 3 S
26. Type K thermocouple Celsius Input Parameters CHI Type K thermocouple Celsius Input CHO Control CHO Output CHD Input CH1 Control CH1 Output CH1 Monitor Input Range PV Correction PV Filter Time Constant Set Point SP Upper Limit Set Point SP Lower Limit gt Input cro gt Input crt lt Control Parameters Output Parameters xij x CHO CHO Output CHO Reverse Control Action Heating Voltage Output Control Parameters BE CH1 Output CH1 el o ss Reverse Control Action Heating Voltage Output Type K thermocouple lt T celsius C200 to 1370 c 0 EE 100 0 to 100 0 c 0 0 to 10 0 sec 200 to 1370 C 200 EJ 200 to 1370 C Alarms Alarm Type Alarm Value Hysteresis 0 1 to 100 0 C Delay Time 0 to 10000 sec Alarm 1 No Alarm Action 0 1 0 Alarm 2 No Alarm Action oO 1 0 Alarm 3 No Alarm Action 0 1 0 Alarm 4 No Alarm Action 0 1 0 Alarms No Alarm Action 0 1 0 Alarm 6 No Alarm Action 0 1 0 Alarm 7 No Alarm Action 0 1 0 1 3 4 5 a d Write all parameters Read all parameters Monitor o j Cancel Buttons Button Description All parameters are saved and the dialog is closed All changes made to the parameters are discarded and the dialog is closed Current parameters configured in the PID Module Configuration dialog box are written to th
27. When thermocouple input or resistance thermometer input is burnt out the over Burnout range bit of the operating status is turned on and control output is turned off when Over Range output type is current the output manipulated variable lower limit value is outputted Control Range When input is thermocouple Input range lower limit 50 C 100 F to Input range 50 C 100 F Range with a decimal point Full scale x 1 C F to Input range 50 C 100 F When input is resistance thermometer Full scale x 1 C F to Input range 50 C 100 F When input is voltage current Linear conversion minimum value 1 of linear conversion span to Linear conversion maximum value 10 of linear conversion span PID Module Standby When the power is turned on the PID module starts with the standby status During the standby the control and alarm assessment are not conducted The control and alarm assessment are enabled when the control enable bit of the operation parameters is turned on When the control mode is the program control and the power is restored the PID module resumes with the status at the time of the power failure FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPENDIX Output Action CHO CH1 Output Action of PID PI PD and P Control Action a Heating Reverse Control Action Cooling Direct Control Action Proportional Band Proportional Band Control Action
28. range upper limit of CHO R W 179 External SP Input Linear Conversion Minimum Value Input range lower limit of CHO to external SP Input linear conversion max value R W 6 16 FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR PID Module Configuration Output Parameters List CHO and CH1 The output parameters for CHO and CH1 are described here PID Module Configuration Slot 1 2x Module Type No FCSA F2M2 Input Ges Input CHO gaia Berea Ee Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Heating Cooling Control EE Input Parameters FT Output Parte Type K thermocouple Celsius Voltage Output 1 e CHO Control CH0 Output CHO Input CH1 Output CH1 Monitor 2 Output Type Voltage Output le O Period 3 1to 120 sec Output MV Upper Limit 100 0 to 100 Output MV Lower Limit o E to 100 Write all parameters Read all parameters Monitor ak Cancel Output Parameters when Heating Cooling Control is Enabled Input CHO Control CHO Output CHO Input CH1 Output CHI Monitor Output Type Voltage Output Control Period 1 to 120 sec Output MV Upper Limit 00 0 to 100 Output MV Lower Limit 0 to 100 Cooling Control Period 3 1 to 120 sec 6r Cooling Output MV Upper Limit 100 m 0 to 100 Cooling Output
29. there is no overshoot in P control action and hunting becomes less frequent however the offset is generated The P control action is suitable for processes such as gas pressure control or level control in which there is no dead time If the integral time and derivative time of the PID module parameter are set to 0 the control action becomes the P control action Temperature Proportional Band Offset Set Point SP PointA Time FC5A MicroSmart PID Module User s Manual FC9Y B1283 4 3 PID MODULE MAIN FUNCTIONS If the proportional band is narrowed Proportional gain is made larger Because the control output starts turning on off at around the set point SP the time until the process variable PV reaches the set point SP is shortened and the offset is small however hunting is frequent If the proportional band is greatly narrowed the control action becomes similar to the ON OFF control action f the proportional band is broadened Proportional gain is made smaller Because the control output starts turning on off at the significantly low temperature from the set point SP overshoot or hunting is reduced however it takes time for the process variable PV to reach to the set point SP and the offset between the process variable PV and the set point SP becomes broadened The offset caused by the P control action can be corrected by configuring the reset value If the reset value is configured the
30. 0 0 0 U 97 Alarm 8 Value 1570to 1570 c 0 o 0 o 0 o 0 o 0 o 16 Output MV Upper Limit 0 to 100 100 100 100 100 100 100 100 100 100 100 1 7 1L Output MY Lower Limit 0 to 100 0 0 0 0 0 0 0 0 0 0 1 8 Cl cxi ProporionalBand 0 0 to 10 0 times 1 1 1 1 1 1 1 1 1 1 1 or L Overlap Dead Band 200 0to 200 0 c o 0 0 0 0 0 0 H 0 0 Write all parameters Control Registers Read all parameters Monitor ok Offset from the control register CHO CH1 Parameter Description R W 180 390 Set Point SP When input is thermocouple resistance thermometer Set point SP lower limit to set point SP upper limit When input is voltage or current Linear conversion min to linear con version max R W 181 391 Step Time When step time unit is Minute 0 to 6000 minutes When step time unit is Second 0 to 6000 seconds R W 182 392 Wait Value When input range unit is Celsius 0 to 100 C Range with a decimal point 0 0 to 100 0 C When input range unit is Fahrenheit 0 to 100 F Range with a decimal point 0 0 to 100 0 F When input is voltage or current 0 to 1000 R W Proportional Band a Proportional Gain 393 184 394 Integral Time Proportional band When input range unit is Celsius 0 to 10000 C Range with a decimal point 0 0 to 1000 0 C When input range unit is Fahrenheit 0 to 10000 F Ran
31. 0 0 to 1000 0 Proportional gain 0 00 to 100 00 Integral Time 0 to 10000 sec RW Derivative Time 0 to 10000 sec R W ARW Anti Reset Windup 0 to 100 R W Output Manipulated Variable Rate of Change 0 to 100 sec R W Alarm 1 Value R W Alarm 2 Value R W Alarm 3 Value R W Alarm 4 Value RW Alarm 5 Value See 5 18 for the valid range of alarm 1 to alarm 8 values RW Alarm 6 Value R W Alarm 7 Value R W Alarm 8 Value R W Reserved R W When output type is relay or voltage Output Manipulated Variable Output manipulated variable lower limit to 100 RW Upper Limit When output type is current Output manipulated variable lower limit to 105 When output type is relay or voltage Output Manipulated Variable 0 to output manipulated variable upper limit RW Lower Limit When output type is current 5 to output manipulated variable upper limit Cooling Proportional Band 0 0 to 10 0 times R W CHO only Cooling proportional band is the multiplication of heating proportional band When input range unit is Celsius 200 0 to 200 0 C Overlap Dead Band When input range unit is Fahrenheit RW CHO only 200 0 to 200 0 F When input is voltage or current input 2000 to 2000 FC5A MicroSmart PID Module User s Manual FC9Y B1283 5 23 DEVICE ALLOCATION OF PID MODULE Data Register Allocation Blocks 30 39 CH1 Program Parameters SHOT Action When CH1 control is in program control mode block 30 to 39 should be configured A maximum of ten steps from
32. 0 to 10 0 sec R W 64 141 Reserved R W 65 142 Alarm 1 Type 0 No alarm action R W 66 143 Alarm 2 Type 1 Upper limit alarm R W 67 144 Alarm 3 Type 2 Lower limit alarm R W 68 145 Alarm 4 Type 3 Upper Lower limits alarm R W 469 146 Alarm 5 Type 4 Upper Lower limit range alarm R W 70 147 Alarm 6 Type 5 Process high alarm RW 71 148 Alarm 7 Type 6 Process low alarm RW 7 Upper limit alarm with standby 72 149 Alarm 8 Type 8 Lower limit alarm with standby R W 9 Upper Lower limits alarm with standby FC5A MicroSmart PID Module User s Manual FC9Y B1283 5 19 DEVICE ALLOCATION OF PID MODULE 73 150 Alarm 1 Hysteresis R W 74 151 Alarm 2 Hysteresis When input range unit is Celsius R W 75 152 Alarm 3 Hysteresis 0 1 to 100 0 C R W 76 153 Alarm 4 Hysteresis When input range unit is Fahrenheit R W 77 154 Alarm 5 Hysteresis 0 1 to 100 0 F R W 78 155 Alarm 6 Hysteresis When input is voltage or current input R W 79 156 Alarm 7 Hysteresis 1 to 1000 R W 80 157 Alarm 8 Hysteresis R W 81 158 Alarm 1 Delay Time R W 82 159 Alarm 2 Delay Time R W 83 160 Alarm 3 Delay Time R W 84 161 Alarm 4 Delay Time R W 85 162 Alarm 5 Delay Time pao teeters RW 86 163 Alarm 6 Delay Time R W
33. 100 sec 1 0 0 1 to 100 0 C 0 0 El 0 0 to 100 0 Read all parameters Loop Break Alarm LA Time Loop Break Alarm LA Span Program Control Mode Settings Program Control Mode Start Type SP when Program Control Starts Step Time Unit Program End Action Number of Repeats Monitor DE 0 to 200 min o Z oto 150 c PV Start 200 to 1370 c Minute Terminate Program Control lt J Oto 10000 OK Cancel Item Seiting Control Mode Program control mode FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPLICATION EXAMPLES 5 Program CHO Parameters Configure the Program CHO parameters in the PID Module Configuration dialog box To open Input CH1 Parameters in the PID Module Configuration dialog box click on Program CHO tab PID Module Configuration Dialog Box Program CHO Parameters Ax PID Module Configuration Slot 1 Module Type No FCSA F2M2 H L 1 Input CHO Control CHO Program CHO Output CHO Input CH1 Control CHI Output CHI Monitor 2 Range Step 0 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 9 Step 9 MEX Point SP 200 to 1370 C 100 100 800 800 800 800 800 800 800 800 3 Step Time 0 to 6000 min 60 60 300 30 0 0 0 0 0 0 Wait Value Oto 100 C 10 0 10 0 0 0 0 0 0 0 Proportional Band 0 to 10000 C 10 10 10 10 10 10 10 10 10 10 Integral Time 0 t
34. 4 1 Temperature Control Using the PID Module 4 1 Fixed Value erle iere ipe op abad iio ar Ede ud e Bees beo pee 4 3 Auto Tuning AT Auto R6S6t 5 em ete ERR e ORE RR ER e o e re ME ERE 4 6 Program Gontroll cohorte Pec t Pete tee eget oni Tun t a uere ue ten 4 9 Heating Cooling Control 4 14 Difference Input Control 4 14 Cascade Control m 4 15 CHAPTER 5 DEVICE ALLOCATION OF PID MODULE lt s sss sssssss sese cenen 5 1 Device Allocation of PID Module apan SE 21 there here ele EEN EC eo E Pe n DN ova 5 1 Programi Sizo EE eebe 5 2 lI Blu c EE 5 2 Control Register ee urn teet nee n n ierat ir rrt Meet eec ste te ete neve bred Sra Pete udo 5 2 Gontrol Delays coeant T 5 3 Data Register Allocation Block 0 Read Only Parameters sse 5 7 Data Register Allocation Block 1 Write Only Parameterg eee eee eee eee eee 5 10 Data Register Allocation Blocks 2 3 Basic Parameters SHOT Action eee eee eee 5 17 Data Register Allocation Blocks 4 5 Initial Setting Parameters SHOT Action see ee eee e 5 19 Data Register Allocation Blocks 10 19 CHO Program Parameters SHOT AcHon 5 22 Data Register Allocation Blocks 30 39 CH1 Program Parameters SHOT Action see eee 5 24 FC5A MicroSmart PID Module User s Manual FC9Y B1283 vii CHAPTER 6 CONFIGURING PID MODULE USING WINDL DR een 6 1 Procedure to configure the PID module sese s esse es sese essere neee 6 1 Expansion Modules Configuration Dialog Box 6 6 PID Module Configuration Dialog Bos 6 7 P
35. 5 17 DEVICE ALLOCATION OF PID MODULE Output Manipulated Variable When output type is relay or voltage Output manipulated variable lower limit to 100 i 123 Upper Limit When output type is current PUN Output manipulated variable lower limit to 105 When output type is relay or voltage Output Manipulated Variable 0 to output manipulated variable upper limit TM 124 Lower Limit When output type is current SA 5 to output manipulated variable upper limit Cooling Proportional Band Go Oe umes 48 125 Cooling proportional band is the multiplication of heating R W CHO only proportional band Cooling Control Period 49 126 CHO only 1 to 120 sec R W When input range unit is Celsius 200 0 to 200 0 C Overlap Dead Band When input range unit is Fahrenheit 50 127 Ho only 200 0 to 200 0 F ME When input is voltage or current input 2000 to 2000 e When output type is relay or voltage 451 4128 See Me Cooling output manipulated variable lower limit to 100 R W CHO onl 9 When output type is current y Cooling output manipulated variable lower limit to 105 e When output type is relay or voltage Cooling Output Manipulated SC 452 129 variable Lower Limit 0 to cooling output manipulated variable upper limit RW CHO only When output type is current 5 to cooling output manipulated variable upper limit 5 18 Valid Range for Alarm 1 to Alarm 8 Settings
36. 543 562 Step Time 0 minutes 0 487 506 525 544 563 Wait Value 0 C 0 4488 4507 526 4545 564 Proportional Term Sg G d 489 508 527 546 565 Integral Time 200 sec 200 490 509 528 547 4566 Derivative Time 50 sec 50 491 510 529 548 567 ARW Anti Reset Windup 50 50 4492 4511 4530 549 4568 Be Chae Variable oe second 0 493 512 531 550 569 Alarm 1 Value 494 513 532 551 570 Alarm 2 Value 495 514 533 552 571 Alarm 3 Value 496 515 534 553 572 Alarm 4 Value 0 C 0 497 516 535 554 573 Alarm 5 Value 498 517 536 555 574 Alarm 6 Value 499 518 537 556 575 Alarm 7 Value 500 519 538 557 576 Alarm 8 Value 501 520 539 558 577 Reserved 0 502 4521 4540 559 4578 OUS a Variable 400 100 4503 4522 4541 4560 4579 Output Manipulated Variable 0 0 9 12 FC5A MicroSmart PID Module User s Manual FC9Y B1283 INDEX delay ad lu ie siete acetates liysteresis ee oe re ee Reed upper limit alarm upper lower limits alarm with standby 7 18 valid range CI GE auto tuning AT TTT 5 9 7 6 elle 4 8 PEro coit ve et Tere tote eden Tapes 4 7 5 11 auto tuning AT auto reset esee 4 6 B basic parameters eee eee 5 3 5 18 9 9 block 0 block 1 blocks 10 19 eier edet ions 5 1 5 24 9 11 blocks 3 E EN 5 1 5 18 9 9 blocks 20 209 5 1 5 26 9 12 lore E O 5 1 5 20 9 10 DUN OUT ER
37. 8A Guanghua Road Chaoyang District Beijing 100026 PRC TEL 86 10 6581 6131 FAX 86 10 6581 5119 IDEC SHENZHEN CORPORATION Unit AB 3B2 Tian Xiang Building Tian an Cyber Park Fu Tian District Shenzhen Guang Dong 518040 PRC Tel 86 755 8356 2977 Fax 86 755 8356 2944 HONG KONG IDEC IZUMI H K CO LTD Units 11 15 Level 27 F Tower 1 Millennium City 1 388 Kwun Tong Road Kwun Tong Kowloon Hong Kong Tel 852 2803 8989 Fax 852 2565 0171 E mail info hk idec com TAIWAN IDEC TAIWAN CORPORATION 8F 1 No 79 Hsin Tai Wu Road Sec 1 Hsi Chih NewTaipei County Taiwan Tel 886 2 2698 3929 Fax 886 2 2698 3931 E mail service tw idec com SINGAPORE IDEC IZUMI ASIA PTE LTD No 31 Tannery Lane 05 01 HB Centre 2 Singapore 347788 Tel 65 6746 1155 Fax 65 6844 5995 E mail info sg idec com 2009 2011 IDEC Corporation All rights reserved http www idec com Manual No FC9Y B1283
38. Band Action FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 51 CONFIGURING PID MODULE USING WINDLDR Monitoring PID Module The PID Module status can be monitored on the monitoring screen Click on Monitor tab in the PID Module Configuration dialog box to open the monitoring screen Monitoring Screen To start monitoring the PID module click on Monitor button in the PID Module Configuration dialog box dule Type No FCSA F2M2 E 1 ISL CHI d oe o v 0 0 amma 8 v Ee 3 Bia f OUT o 50 100 3 QUT o 50 100 4 S i t Status Error E Status Error 4 Repeat oj Control PARAM Loop Repeat L 2 Control PARAM LOOP pm Him 00 00 AT Program OVER UNDER Time H M 00 00 AT Program OVER UNDER 5 Manual HOLD Al A2 A3 44 Manual HOLD A1 A2 A3 LA Send Command wan as as a as Sendcommand WAIT AS A6 A7 A 9 6 Input CHO Control CH0 Program CHO Ou 6 Input CH1 Control CH1 Program CH1 OuN HI orp 7 E i a oh EE SS ee 8 8 320 i i i i i i i i L i i i 5 9 val T 160 80 al i j 0 50 100 150 200 250 300 350 400 450 500 550 600 seon 10 Monitor Settings 1 1 Write all parameters Read all parameters Monitor ok Cancel 1 CHO CH1 SP Set Point The set point SP of CHO or CH1 is indicated During the m
39. CHO and CH1 are in fixed value control mode 8 internal relays are occupied When either CHO or CH1 is in program control mode 32 internal relays are occupied Internal Relay Allocation When both CHO and CH1 are in fixed value control mode the following 8 internal relays are allocated Se Si Description R W 0 Reading all parameters PID module CPU module data registers R W 1 Loading initial values CPU module ROM data registers R W 2 Writing all parameters CPU module data registers PID module R W 3 Block 2 CHO basic parameters writing R W 4 Block 3 CH1 basic parameters writing R W 5 Block 4 CHO initial setting parameters writing R W 6 Block 5 CH1 initial setting parameters writing R W 7 Reserved R W When either CHO or CH1 is in program control mode the following 32 internal relays are allocated o s Description R W 0 Reading all parameters PID module CPU module data register R W 1 Loading initial values CPU module ROM Data register R W 2 Writing all parameters CPU module data register PID module R W 3 Block 2 CHO basic parameters writing R W 4 Block 3 CH1 basic parameters writing R W 5 Block 4 CHO initial setting parameters writing R W 6 Block 5 CH1 initial setting parameters writing R W 7 Reserved R W 8 Block 10 CHO Step 0 writing R W 9 Block 11 CHO Step 1 writ
40. Constant 0 0 HH 0 0 to 10 0 sec Set Point SP Upper Limit 1370 200 to 1370 c Set Point SP Lower Limit 200 H 200 to 1370 c Alarms Alarm Type Alarm Value Hysteresis 0 1 to 100 0 C Delay Time 0 to 10000 sec Alarm 1 No Alarm Action 9 1 0 Alarm 2 No Alarm Action 0 1 0 Alarm 3 No Alarm Action 9 1 0 Alarm 4 No Alarm Action 0 d 0 Alarm 5 No Alarm Action o 1 0 Alarm 6 No Alarm Action 0 1 o Alarm No Alarm Action o 1 o Write all parameters Read all parameters Monitor Cancel All parameters for the PID module can be configured in this dialog box Configure the desired parameters and click on OK button to close the dialog FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 1 CONFIGURING PID MODULE USING WINDLDR 3 Download Dialog Box From the WindLDR menu bar select Online gt Download The Download dialog box will be opened Transfer Mode Binary D ASCII Download Options Z Automatic start after download Keep output during download Suspend I O force before download Automatic device clear after download Write PID module parameters after download SiG OD E Write device datafile to the PLC after download Setting E Download comment data Setting emprogra Detail Program Information Program Size 1142 bytes Comment Size 0 bytes Total 1142 bytes Cancel Communication Settings Click the check box on the left of Write PID Module parameters af
41. Control Action Heating Voltage Output FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 23 CONFIGURING PID MODULE USING WINDLDR PID Module Configuration Input Parameters Details PID Module Configuration Slot 1 2x Module TypeNo FC5A F2m2 Input Parameters Control Parameters lt Output Parameters CHO Input cHo B CHO e output cHo CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters d Control Parameters Output Parameters fan 9 Input on J Wes cb output ct el W s Type K thermocouple Celsius Reverse Control Action Heating Voltage Output 1 Input CHO Control CHO Output CHO Input CH1 Control CH1 Output CH1 Monitor a Input Range ype K thermocouple tL Celsius l C200to 1370 c 2 __ PV Correction 0 0 100 0 to 100 0 c PV Filter Time Constant 0 0 E 0 0 to 10 0 sec 3 E Set Point SP Upper Limit 1370 E 200 to 1370 C 4 Set Point SP Lower Limit 200 E 200 to 1370 C d Alarms cd Uh Pd Alarm Type Alarm Value Hysteresis 0 116 100 0 C Delay Time 0 to 16000 sec fa Alarm Action 70 10 0 6 Alarm 2 No Alarm Action 0 10 0 Alarm 3 No Alarm Action 0 10 0 Alarm 4 No Alarm Action 0 10 0 Alarms No Alarm Action 0 10 0 Alarm 6 No Alarm Action 0 10 0 Alarm 7 No Alarm Action 0 10 0 Alarm amp No Alarm Action 0 10 0 Write all parameters Read all parameters M
42. Control period 1 to 120 seconds ARW 0 to 100 Reset When input range unit is Celsius 100 0 to 100 0 C When input range unit is Fahrenheit 100 0 to 100 0 F Control Action When input is voltage current 1000 to 1000 Output ON OFF When input range unit is Celsius hysteresis 0 1 to 100 0 C When input range unit is Fahrenheit 0 1 to 100 0 F When input is voltage current 1 to 1000 Output When output type is relay or voltage manipulated Upper limit variable MV Output manipulated variable lower limit value to 100 upper limit Lower limit lower limit 0 to output manipulated variable upper limit value When output type is current Upper limit Output manipulated variable lower limit value to 105 Lower limit 5 to output manipulated variable upper limit value Output 0 to 100 sec manipulated variable rate of change The alarm range can be configured with the alarm value When the process variable PV goes outside of the range the alarm output turns on or off Alarm type can be selected from upper limit alarm lower limit alarm upper lower limits alarm upper lower limit range alarm process low alarm process high alarm upper limit alarm with standby lower limit alarm with standby upper lower limits alarm with standby and no alarm action For details about the alarm see pages 6 26 to 6 28 Setting accuracy Same with input error See page 2 4 Alarm Action ON OFF action Hysteresis When in
43. FC9Y B1283 4 13 PID MODULE MAIN FUNCTIONS Heating Cooling Control When it is difficult to control the target process with heating control only cooling control can be added to perform the heating cooling control Control results derived from the set point SP and process variable PV are outputted to 2 outputs heating output CHO and cooling output CH1 If the process variable PV is higher than the set point SP cooling output will be turned on If the process variable PV is lower than the set point SP heating output will be turned on The area in which both heating and cooling outputs are turned on can be configured as overlap The area in which neither heating output nor cooling output is output can be configured as dead band Example Heating Cooling control uses both heating and cooling outputs and is suitable for the heat producing processes such as extruders or for temperature control at near ambient temperature such as environment testers Heating Module Target Cooling Difference Input Control Difference input control is the control to keep the input difference between input CHO and input CH1 at the same level When the difference input control is selected input CHO and input CH1 are independently measured and the difference between those inputs is used as process variable PV PID module controls output so that the difference between those inputs is matched to the set point SP Example 1 Controlling the liq
44. Filter Time Constant The PV filter function is a software filter to stabilize the process variable PV affected by fluctuating processes such as pressure or flow rate by calculating first order lag of the process variable PV Even if the process variable PV changes as shown in the Figure 1 when the PV filter time constant is configured the process variable PV changes as shown in the Figure 2 After the PV filtering process the process variable PV reaches 63 of the process variable PV in T seconds If the PV filter time constant is too large it adversely affects the control results due to the delay of response Example If the least significant digit of the process variable PV is fluctuating the fluctuation can be suppressed by using the PV filter time constant Process Process d Variable Variable i PV PV a Time Second lt T Time Second Figure 1 Process variable PV Figure 2 Process variable PV before PV filtering process after PV filtering process 6 30 FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR 4 Control Register 178 External SP Input Linear Conversion Maximum Value Configure the linear conversion maximum value for the external SP input When input type is current 4 to 20mA DC or 0 to 20mA DC configure the value corresponding to 20mA for input CH1 When input type is voltage 0 to 1V DC or 1 to 5V DC configure the value corresponding to 1V or 5V fo
45. MV Lower Limit 1 0to 100 56 sj S 7 Write all parameters Read all parameters Monitor ok Cancel Control Registers Offset from Meis Parameter Description R W CHO CH1 0 Non contact voltage output for SSR drive 1 99 176 Output Type 1 Current output R W 2 30 107 Control Period 1 to 120 sec R W When output type is voltage Output Manipulated Output manipulated variable lower limit to 100 3 Tig dies Variable Upper Limit When output type is current RW Output manipulated variable lower limit to 105 When output type is voltage Output Manipulated 0 to output manipulated variable upper limit 4 G Variable Lower Limit When output type is current RUN 5 to output manipulated variable upper limit ooling Control Perio 0 sec 5 49 Cooling Control Period 1 to 120 HAN FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 17 CONFIGURING PID MODULE USING WINDLDR 6 18 Offset from GE Parameter Description R W CHO CH1 c When output type is voltage Cooling Output A 6 451 Manipulated Variable reas output manipulated variable lower limit to 100 R W Upper Limit en output type is current l Cooling output manipulated variable lower limit to 105 When output type is voltage Cooling Output f s 7 452 E Manipulated Variable Ni to cooling output manipulated variable upper limit R W Uwer Limit en output type is current l ER 5 to cooling output manipulated
46. Mode 5 Input cHo DE 9 Cascade Control lt _ Control Parameters Output CHO Reverse Control Action Heating Control Parameters CH1 Reverse Control Action Heating Control CH1 Monitor Control Action Reverse Control Action Heating Set Point SP 0 Z C200 to 1370 C Proportional Term Proportional Band lt Proportional Band 10 Z 0 to 10000 c Integral Time 200 5 0 to 10000 sec Derivative Time 0 to 10000 sec ARW Anti Reset Windup AT Bias Reset C100 0 to 100 0 Set Point SP Rise Rate Set Point SP Fall Rate Output MV Rate of Change 0 to 100 sec Output ON OFF Hysteresis 0 1 to 100 0 c Manual Mode Output MV 0 0 to 100 0 Write all parameters Read all parameters ole Loop Break Alarm LA Time Loop Break Alarm LA Span Cascade Control Settings External SP Input Min amp Max Values Linear Conversion Maximum Value ks Linear Conversion Minimum Value SC 0 to 10000 C min 0 to 10000 c min Monitor A xl ti Output CT Voltage Output 0 E 0 to 200 min o IZ oto 150 c 1370 24 200 to 1370 c 200 200to 1370 c art 0 ok Cancel Offset from the control register Parameter Setting Range R W 178 External SP Input Linear Conversion Maximum Value External SP Input linear conversion min value to input
47. OF l I l I l Advance previous step bit ON l D1022 7 i Ol E n l i l MEE SE Program end output ON i l D1010 6 S EE l l The program control is held and the fixed value control is performed with the parameters of step 9 The program control is started from the start of step 0 If the program hold advance next step and advance previous step are executed simultaneously they are executed as The program hold is canceled and the follows program control is started from 40 minutes 1 Program Hold l NL of remaining time The program control is held at 20 minutes of remaining time 2 Advance Next Step The program hold is canceled and the program control is proceeded to the start of step 2 3 Advance Previous Step The program control is moved back to the start of step 1 The control is enabled and the program control is started As a result only the execution of the advance previous step is The program control is held and the resulted in fixed value control is performed with the parameters of step 9 If the program hold and advance previous step are executed simultaneously they are executed as follows 1 Program Hold The program control is held at 30 minutes Note of remaining time 2 Advance Previous Step The program control is proceeded to the start of step 1 while the program hold is maintained Note If minute is selected as the step time unit the re
48. SP to 500 C in 30 minutes If the PV Start or PVR Start is selected as the program control mode start type when the program control is started the time is advanced until the set point SP becomes equal to the process variable PV Then the program control starts and the set point is gradually increased to 500 C at the end of the step If the SP Start is selected as the program control mode start type the set point SP is increased from the set point SP specified with Set Point SP when Program Control Starts to the set point SP of step 0 in 30 minutes See page 6 41 and 6 42 for details about the program control mode start type FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 47 CONFIGURING PID MODULE USING WINDLDR 3 Control Register 182 Wait Value During the program control running when a step is finished the PID module checks whether the deviation between the process variable PV and set point SP is less than or equal to the wait value The program control is not proceeded to the next step until the deviation becomes less than or equal to the wait value The wait function does not work and the program control is proceeded to the next step if the process variable PV satisfies the following condition Set Point SP Wait Value lt Process Variable PV Get Point SP Wait Value Example 1 Wait function when the temperature is rising Wait value 10 C Set point SP T T Set point SP
49. Slot 1 21x Module Type No FCSA F2M2 H Input een input CHO E m Poss output cro H BIL Gegen Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Peas DIST ed sss Err ET es Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input CHO Control CHO Output CHO Input CH1 Control CH1 Output CH1 Monitor Control Mode Fixed Value Control Mode E Control Action Reverse Control Action Heating D 1 Loop Break Alarm LA Time 0 Z oto 200 min Point SP 210 E 200 to 1370 C Loop Break Alarm LA Span 0 0to 150 c Proportional Term Proportional Band IS Proportional Band 10 Z oto 10000 c Integral Time 200 7 0 to 10000 sec Derivative Time EI to 10000 sec 2 ARW Anti Reset Windup 50 i 0 to 100 ATBias 20 0to 50 c Reset 0 0 7 100 0 to 100 0 C Set Point SP Rise Rate of 0 to 10000 C min eae Set Point SP Fall Rate 9 FE o to 10006 C min Output MV Rate of Change 0 Z 0 to 100 sec Output ON OFF Hysteresis 10 7 0 1 to 100 0 C Manual Mode Output MV 0 0 Z 0 0 to 100 0 Write all parameters Read all parameters Monitor ge Cancel Item Setting 1 Set Point SP 210 C 2 AT Bias 20 C FC5A MicroSmart
50. To write the PID module parameters without downloading the user program to the CPU module take the following steps 1 Connect the PID module to the CPU module 2 Open the PID Module Configuration dialog box for the slot 3 Click on Write All Parameters button All the configured parameters will be written to the data registers in the CPU module and the PID module FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR User Program Upload When the user program containing the initial parameters of the PID modules is uploaded from the CPU module the initial values will be restored The parameters saved in the PID module will not be read How to restore data register values when a keep data error has occurred If more than 30 days pass since the power to the CPU module is turned off values stored in the data registers will be lost When the data register values are lost after the power is turned on restore the PID module parameters in the data registers of the CPU module using either of the following methods and then enable the control of the PID module Method 1 Use the parameters stored in the PID module The parameters stored in the PID module can be read out and stored in the data registers of the CPU module with one of the following procedures Procedure 1 Using WindLDR 1 Open Expansion Modules Configuration dialog box in WindLDR 2 Select the slot number of the connected PID module and ope
51. Type E Thermocouple 328 to 1472 F 16h Type T Thermocouple Fahrenheit 328 0 to 752 0 F 17h Type N Thermocouple 328 to 2372F 18h PL II 32 to 2534 F 19h C W Re5 26 32 to 4199 F 1Ah Pt100 with Decimal Point 328 0 to 1562 0 F 1Bh JPt100 with Decimal Point 328 0 to 932 0 F 1Ch Pt100 328 to 1562F 1Dh JPt100 328 to 932 F 1Eh 4to 20mA DC 2000 to 10000 IER 0to 20mA DC 2000 to 10000 20h Oto 1V DC 2000 to 10000 21h Oto 5V DC 2000 to 10000 22h 1to BV DC 2000 to 10000 23h Oto 10V DC 2000 to 10000 FC5A MicroSmart PID Module User s Manual FC9Y B1283 DEVICE ALLOCATION OF PID MODULE Data Register Allocation Blocks 10 19 CHO Program Parameters SHOT Action When CHO control is in program control mode block 10 to 19 should be configured A maximum of ten steps from step 0 to step 9 can be configured All parameters of block 10 to 19 are shown in the following tables For detail about each parameter see page 5 23 Offset from the Control Register StepO Step 1 Step2 Step3 Step4 180 201 222 243 264 Set point SP 181 202 223 244 265 Step time 182 203 224 245 266 Wait value 183 204 225 246 267 Proportional term 184 205 226 247 268 __ Integral time 185 206 227 248 269 Derivative time 186 207 228 249 270 ARW Anti Reset Windup 187 208 229 250 271 Output manipulated variable rate of change 188
52. Type Upper Lower limits alarm with standby Alarm 1 Value 5 5 C Set Point SP 200 0 C PID control action P I D and ARW are Control Action automatically calculated using auto tuning AT AT Bias 20 0 C B Parameter Configuration Procedure 1 Expansion Modules Configuration Select Configuration gt Expansion Modules from the WindLDR menu bar to open the Expansion Modules Configuration dialog box In the Expansion Modules Configuration dialog configure the quantity of modules slot number module type No control register data register and control relay internal relay Click on Configure Parameters button to open the PID Module Configuration dialog box Expansion Modules Configuration Dialog Box Expansion Modules Configuration 2 x Expansion Modules 1 LT Quantity of modules gs CPU module Slot 1 Slot 2 Slot 3 Slot 4 2 a FCSA F2M2 FCSA C24R2X Other modules Other modules Other modules D1000 to D1189 M1000 to M1007 3 Module Settings Module Type No FCSA F2M2 4 Data Register D1000 D1000 to D1189 BL Internal Relay M1000 M1000 to M1007 Copy Parameters To OK Cancel Item Setting 1 Quantity of Modules 1 2 Slot No Slot 1 3 Module Type No FC5A F2M2 4 Data Register D1000 5 Internal Relay M1000 7 16 FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPLICATION EXAM
53. User s Manual FC9Y B1283 5 5 DEVICE ALLOCATION OF PID MODULE Example 3 Changing Block 4 Parameter The PV filter time constant D1063 of CHO is changed to 1 5 seconds In this example D1000 is allocated to the control register and M500 is allocated to control relay The parameter can be changed with the following procedure 1 Turn on M500 Reading all parameters All PID module parameters are read out from the PID module and stored in the data registers of the CPU module 1 2 Turn off D1022 0 Control enable bit of CH0 CHO control of the PID module will be disabled 3 Store 15 in D1063 PV filter time constant of CHO 4 Turn on M505 Block 4 writing 5 Turn on D1022 0 Control enable bit of CHO CHO of the PID module will be enabled Ladder Program Example 3rd Scan At the rising edge of M102 D1022 0 is turned on to enable CHO control M102 is turned off 2nd Scan At the falling edge of M101 M500 is turned off i MON neo video RER 15 is stored in D1063 PV filter time constant of CHO CS M505 Block 4 writing is turned on to write block 4 m0505 parameters stored in D1053 to D1102 to the PID module 5 M102 is turned on 1st Scan At the rising edge of M101 D1022 0 is turned off to disable CHO control M500 is turned on to read all parameters from the PID module M101 is turned off 1 Ifthe reading all parameters M500 is turned on all PID module parameters are read out from t
54. When input type is voltage current configure the maximum value of input CHO as the linear conversion maximum value Any value within the valid input range can be configured Set Point SP Lower Limit Linear Conversion Minimum Value When input type is thermocouple or resistance thermometer the linear conversion is disabled The linear conversion minimum value is used as the lower limit of the set point SP When input type is voltage current configure the minimum value of input CHO as the linear conversion minimum value Any value within the valid range can be configured FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 25 CONFIGURING PID MODULE USING WINDLDR 6 Control Register 65 Conirol Register 66 Control Register 67 Conirol Register 68 Conirol Register 69 Control Register 70 Control Register 71 Control Register 72 Alarm 1 Type Alarm 2 Type Alarm 3 Type Alarm 4 Type Alarm 5 Type Alarm 6 Type Alarm 7 Type Alarm 8 Type Select one of the alarm types from upper limit alarm lower limit alarm upper lower limits alarm upper lower limit range alarm process high alarm process low alarm upper limit alarm with standby lower limit alarm with standby upper lower limits alarm with standby and no alarm action The same alarm type can be selected in multiple alarms Alarm Actions Upper Limit Alarm Lower Limit Alarm Alarm Hysteresis Alarm Hysteresis OFF Alarm Value SP Setting Example Set Poin
55. alarm on off action 10 Control Register 81 Alarm 1 Action Delay Time Control Register 82 Alarm 2 Action Delay Time Control Register 83 Alarm 3 Action Delay Time Control Register 84 Alarm 4 Action Delay Time Control Register 85 Alarm 5 Action Delay Time Control Register 86 Alarm 6 Action Delay Time Control Register 87 Alarm 7 Action Delay Time Control Register 88 Alarm 8 Action Delay Time The alarm is not triggered until the configured time elapses after the process variable PV enters the alarm output range The input fluctuation due to noise may result in alarm output turning on This can be prevented by configuring the alarm delay time When an alarm output is changed from on to off status the alarm output turns off and the alarm action delay time is reset When the alarm output is changed from off to on status the time counting starts FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 33 CONFIGURING PID MODULE USING WINDLDR wo R C E Se LL L J _ Derivative Time ARW Anti Reset Windup o gt I was a et o Q E WwW M BASSE PID Module Configuration Control Parameters Details PID Module Configuration Slot 1 Module Type No FC5A F2M2 ly Input Parameters Control Parameters Output Parameters bai n 4 CHO Input cm gl CHO s Type K thermocouple Celsius Reverse Control Action Heating Voltage Output EC Heating Cooling Control
56. are loaded into the data registers RAM The control relay 2 Writing all parameters When this bit is turned off to on all parameters stored in the data registers are written to the ROM of the PID module The control relay 3 through 27 Writing blocks 2 to 5 10 to 19 and 30 to 39 When the writing bit is turned off to on the corresponding block parameters stored in the data registers are written to the ROM of the PID module Data Flow of the PID module parameters CPU Module PID Module RAM Data Registers 1 All parameters are read out from the PID module and stored in the data registers in the CPU module when the reading all parameters bit is turned off to on 2 Initial values stored in the ROM of the CPU module are loaded to the data registers when the loading initial values bit is turned off to on 3 All parameters stored in the data registers are written to the PID module when the writing all parameters bit is turned off to on 4 The block parameters stored in the data registers are written to the PID module when the block writing bit is turned off to on Note The communication status between the CPU module and the PID module can be confirmed with the following data register e When both CHO and CH1 are in fixed value control mode First data register 189 When CHO or CH1 is in program control mode First data register 589 doped Description 0 Normal operation 1 Bus error Turn off the MicroSmar
57. ccording to Deviation T UV DC T 0 12V DC Cycle Action is Performed ccording to Deviation i 1 1 20mADC i 20to4mA DC LJ i 3 H 4 4mA DC Changes Continuously According to Deviation 4mA DC 4 to 20mA DC zl j 20mA DC Changes Continuously According to Deviation Turns ON or OFF Represents heating control action Represents cooling control action FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPENDIX Output Action of Heating Cooling Control with Overlap Heating Proportional Band Cooling Proportional Band Control ON i i Action Heating i j i Cooling Control Action l i Control Action Cycle Action is Performed ccording to Deviation 4 Cycle Action is Performed ccording to Deviation CHO 12VDC i 12 0VDC Non contact i Voltage IN t Cycle Action is Performed ccording to Deviation OVDC ON2vDC 12V DC zo Pl LLLJ i ro Y Cycle Action is Performed ccording to Deviation 20mADC 20to4mA DC 4mA DC Current Zeta i Output i E Changes Continuously According to Deviation EE wn E C 4mADC 4to020mADCi 20mA DC urrent Lj iM PS okey Output Changes Continuously According to Deviation LED Indicato CHO OUT Green LED Indicato CH1 OUT Green Turns ON or OFF _ Represents heating control action
58. e a a aa 9 6 overlap ossi ei Cam UP i re dg 9 7 hunting phenomenon eee esse eee eee eee 8 3 I I O function eelst Ven EE TEE 6 23 INPUt le den WEE 6 21 output FUNCTION sss eee eee 6 23 initial setting parameters 5 3 5 20 9 10 input Operat La inire e tete ener eee CIE Status da TTT input parameters T details ineo UE TE UR ain input range installation and wiring integral time TT L linear conversion esses 6 25 linear conversion SPAN eee eee eee eee eee 5 19 loop break aarm 5 10 8 6 9 2 SPAN prec Em 5 18 6 40 ln EE 5 18 6 40 FC5A MicroSmart PID Module User s Manual FC9Y B1283 i M output manipulated variable 5 11 6 39 mounting hole layout for direct mounting 3 1 0 operating status OVERTAN Be uut nt eate odi acq nder ranges eate ei eed cete ee operation parameters eee eee eee 5 11 monitor eni etta tee aient ees 5 9 output ACTION MT 9 5 lower Tl reete eterne egeo eee haeres 6 48 manipulated variable MN 5 7 ON OFF hysteresis eee 6 39 eise rate of change OVEN LTE overlap dead band 5 19 6 41 P parameter range ertor 5 9 PID moduleren nee cete trade dE gedet 1 1 applicable CPU and WindLDR version 1 2 control OUT DUE e names re Rei ex ER Eb dad device allocation M elt ET ET enable Control MONITO eer ET t El Darts
59. including the first data register designated Precautions when Connecting Four PID Modules to All in One Type CPU Module 2000 data registers DO to D1999 are allocated to the all in one type CPU module When four PID modules are connected to the all in one type CPU module a maximum of six program controls can be conducted with three PID modules among the four PID modules The configurations shown in the examples 1 and 2 are not possible because the total number of occupied data registers exceeds 2000 Example 1 Program control mode is selected in all four PID modules Control Mode Occupied Module Type Type No Data Register CHO CH1 Word FC5A F2MR2 FC5A F2M2 Program control mode Program control mode 590 PID Module FC5A F2MR2 FC5A F2M2 Program control mode Program control mode 590 FC5A F2MR2 FC5A F2M2 Program control mode Program control mode 590 FC5A F2MR2 FC5A F2M2 Fixed value control mode Program control mode 590 Total 2360 Example 2 Program control mode is selected in all four PID modules Control Mode Occupied Module Type Type No Data Register CHO CH1 Word FC5A F2MR2 FC5A F2M2 Fixed value control mode Program control mode 590 PID Module FC5A F2MR2 FC5A F2M2 Fixed value control mode Program control mode 590 FC5A F2MR2 FC5A F2M2 Program control mode Fixed value control mode 590 FC5A F2MR2 FC5A F2M2 Program control mode Fixed value control mode 5
60. is selected output CHO is unused When output type is relay the output CHO is turned off When output type is voltage current output CHO is 0V AmA Both Outputs CHO CH1 The output of the CHO control is outputted from both outputs CHO and CH1 The control period and output manipulated variable MV upper and lower limits of CHO and CH1 are used for the corresponding output CHO parameters are used for all other parameters such as the output manipulated variable rate of change output on off hysteresis and manual mode output manipulated variable Input Parameters Control Parameters Output Parameters CHO CHO CHO CHO Input CH 4 CHO Both outputs CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Output Parameters CHI e Input CHL CH Type J thermocouple Celsius Voltage Output 4 Control Register 134 Output CH1 Function Output CH1 is always selected as Output CH1 Function The output of the CH1 control is outputted from output CH1 Output CHO Function has priority Input Parameters Control Parameters Output Parameters faa 5 input cHo V output cto eas Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Control Parameters Output Parameters cH Input CHL lt l p CH gt output cH CH Type K thermocouple Celsius Reverse
61. noise YES NO Are the input type and unit selected correctly Select Hom correcuy YES NO Is the PV correction value Suitable Set it to a suitable value YES Call IDEC for assistance 1 Refer to Input Status Checking on page 8 5 8 4 FC5A MicroSmart PID Module Users Manual FC9Y B1283 TROUBLESHOOTING Input Status Checking Sensor may be burnt out if any of the following problems occur 1 Operating status over range flag remains ON 2 Operating status under range flag remains ON 3 Input value constantly shows OmA or OV Please make sure these conditions are checked thoroughly and take the appropriate action 1 Operating status over range flag remains ON Checking Items Action Is thermocouple or resistance thermometer burnt out Is voltage input 0 to 1V DC disconnected Replace sensor How to check sensor burn out or voltage disconnection Thermocouple Short the input terminals of the PID module If a value around room temperature is indicated the PID module is operating normally and the sensor may be burnt out Resistance thermometer Connect approx 1000 resistor between the input terminals A and B and short the input terminals B and B of the PID module If a value around 0 C 32 F is indicated the PID module is operating normally and the sensor may be burnt out Voltage 0 to 1V DC Short the input
62. on as shown in the diagram below Normal Output By configuring the output manipulated variable rate of change the maximum change of the output manipulated variable MV in 1 minute can be changed as shown in the diagram below Output When Output Manipulated Variable Rate of Change is Configured This function can be used for a high temperature heater used at approximately 1500 to 1800 C which has to be heated gradually as the heater can be burnt out if the power is supplied rapidly Normal Output Output When Output Manipulated Variable Rate of Change is Configured 100 sec 20 sec 10 sec OFF 1 second 5 seconds 10 seconds 9 Control Register 188 Alarm 1 Value 10 Control Register 189 Alarm 2 Value 11 Control Register 190 Alarm 3 Value 12 Control Register 191 Alarm 4 Value 13 Control Register 192 Alarm 5 Value 14 Control Register 193 Alarm 6 Value 15 Control Register 194 Alarm 7 Value 16 Control Register 195 Alarm 8 Value There are two types of alarms Deviation alarm and process alarm Alarm Type Alarm Value Alarm Action The alarm output turns off if Upper Lower limit range alarm the process variable PV exceeds the range Upper limit alarm Deviation Lower limit alarm Deviation irom the set point SP is the alarm Alarm Upper Lower limits alarm value The alarm output turns on if Upper limit alarm with standby the process variable PV Lower limit alarm with standby ex
63. process time of each step Program Pattern Set Point SP 4 eo eo A eo Cooling Proportional Band Overlap Dead Band 100 100 800 800 60 60 300 30 10 0 10 0 Proportional Term 10 10 10 10 B Integral Time 200 200 200 200 Derivative Time 50 50 50 50 ARW 50 50 50 50 Output MV Rate of Change 0 0 0 0 Alarm 1 Value 0 10 0 10 b Alarm 2 Value 0 0 0 0 i Alarm 3 Value 0 0 0 0 Alarm 4 Value 0 0 0 0 Alarm 5 Value 0 0 0 0 0 0 0 0 Alarm 7 Value 0 0 0 0 Alarm 8 Value 0 0 0 0 i Output MV Upper Limit 100 100 100 100 Output MV Lower Limit 0 0 0 0 i Cl sch ojo S e eo e eo e When the program pattern is configured as shown in the above table the following control is performed at each step Step 0 The set point SP is gradually risen to 100 C in 60 minutes When the step 0 ends the wait function works so that the program control does not proceed to the step 1 until the process variable PV reaches 90 C Step 1 The fixed value control is performed at 100 C of the set point SP for 60 minutes Step 2 The set point SP is gradually risen to 800 C in 5 hours When the step ends the wait function works so that the program control does not proceed to the step 3 until the process variable PV reaches 790 C Step 3 The fixed value control is performed at 800 C of the set point SP for 30 minutes FC5A MicroSmart PID Module User s Manual
64. step bit have no effect The program control is held at the 30 minutes The program hold is canceled by executing advance next step and the program control is started from the start of step 0 After all steps are executed the program control is held and the fixed value control is performed with the parameters of step 9 The program control is started from the start of step 2 of remaining time and the fixed value control is performed with the current parameters The program hold is canceled and the program control is started from 30 minutes of remaining time Note The PID module executes all steps 0 to 9 even if the step times of steps are zero When the program control is terminated nine is stored in the current step number of block 0 5 14 FC5A MicroSmart PID Module User s Manual FC9Y B1283 DEVICE ALLOCATION OF PID MODULE Example 5 Hold Program Control when Program Ends The following diagram shows an example of the program control when hold program control is selected as the program end action Time of steps Step 0 and 1 60 minutes Step 2 30 minutes Steps 3 to 9 0 minute In this example D1000 is allocated to the control register and M500 is allocated to control relay Current step number D1006 Control enable bit D1022 0 Program control bit D1022 3 Program control bit Monitor D1009 3 Program hold bit D1022 4 I E rut m ON Advance next step bit D1022 6 E
65. the slave CHO With the obtained set point SP the slave CHO calculates the output manipulated variable MV and controls the output CHO 6 22 FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR When the cascade control is used the output CH1 is unused When the output type is current the output CH1 is 4 mA When the output type is voltage the output CH1 is 0 V When the output type is relay Output CH1 is turned off When heating cooling control is enabled output CH1 is used as the cooling output Output manipulated variable MV 0 to 100 of the master CH1 is converted using the external SP input linear conversion minimum and maximum values and is used as the set point SP of the slave CHO Example When the external SP input linear conversion minimum value is 0 C and the external SP input linear conversion maximum value is 1000 C the set point SP of the slave CHO is decided as follows When master CH1 output manipulated variable MV is 0 0 C When master CH1 output manipulated variable MV is 50 500 C When master CH1 output manipulated variable MV is 100 1000 C Combination of Input CHO and Input CH1 Functions The possible combinations of Input CHO and CH1 Functions are shown below O Possible X Impossible Input CH1 Input CH1 Difference Difference Addition External Cascade Input CHO CHO CH1 CH1 CHO CHO CH1 SP Input Control Input CHO
66. the Expansion Modules Configuration dialog box in WindLDR is used The following table shows the PID module type numbers PID Module Type Numbers Module Type UO Points UO Signal Type No Relay Output 2 inputs Thermocouple K J R S B E T N PL IT C W Re5 26 FC5A F2MR2 Resistance thermometer Pt100 JPt100 Voltage 0 to 1V DC 0 to 5V DC 1 to 5V DC 0 to 10V DC Current 0 to 20mA DC 4 to 20mA DC 2 outputs Relay contact Non Contact Voltage 2 inputs Thermocouple K J R S B E T N PL II C W Re5 26 FC5A F2M2 for SSR drive Resistance thermometer Pt100 JPt100 Current Output Voltage 0 to 1V DC 0 to 5V DC 1 to 5V DC 0 to 10V DC Current 0 to 20mA DC 4 to 20mA DC 2 outputs Non contact voltage for SSR drive Current Quantity of Applicable PID modules The maximum number of PID modules that can be connected to the MicroSmart CPU differs depending on the CPU type The following table shows the maximum number of the PID modules FC5A C10R2D FC5A C24R2D Type All in One Type Slim Type FC5A D16RK1 FC5A C16R2 FC5A C10R2 M E FC5A C24R2 FC5A D16RS1 3 FC5A D32K3 FC5A MicroSmart CPU FC5A C10R2C FC5A C24R2C FC5A C16R2D FC5A D32S3 FC5A D12K1E FC5A D12S1E Number of PID Modules 4 7 FC5A MicroSmart PID Module User s Manual FC9Y B1283 GENERAL INFORMATION Applicable CPU and WindLDR version PID modules can be used with the following F
67. the auto tuning AT function 7 Control Register 186 ARW Anti Reset Windup When the control is started there is a large deviation between the set point SP and the process variable PV The integral action continues its action in a given direction until the process variable PV reaches the set point SP As a result an overshoot is caused by the excessive integral action ARW suppresses the overshoot by limiting the integral action area When ARW is 0 the integral action area becomes the minimum and the suppression of the overshoot is maximized When ARW is 50 the integral action area becomes the intermediate and the suppression of the overshoot is intermediate When ARW is 10095 the integral action area becomes the maximum and the suppression of the overshoot is minimized An appropriate ARW for the control target can be automatically calculated using auto tuning AT function It is unnecessary to configure the ARW in the WindLDR when using the auto tuning AT function FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 49 CONFIGURING PID MODULE USING WINDLDR 8 Control Register 187 Output Manipulated Variable Rate of Change The maximum change of the output manipulated variable in 1 minute can be configured This function is disabled when the value is O In the case of heating control when there is a large deviation between the process variable PV and the set point SP the output immediately changes from off to
68. to 1370 C Alarms Item Setting Input CHO Function Input CHO Input CH1 Function Input CH1 Output CHO 1 2 3 Output CHO Function 4 Output CH1 Function Output CH1 4 3 Input CHO Parameters Configure the Input CHO parameters in the PID Module Configuration dialog box To open Input CHO Parameters in the PID Module Configuration dialog box click on Input Parameters CHO button or Input CHO tab PID Module Configuration Dialog Box Input CHO Parameters PID Module Configuration Slot 1 KAES Module Type No FCSA F2M2 Input Parameters uno v Control Parameters vran Output Parameters CHO gt Input cro Den CHO output cho D Km CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters d Control Parameters Output Parameters CHI s Input CH1 J CHI output CH1 lt k CHD Type K thermocouple Celsius Reverse Control Action Heating Voltage Output 1 Input CHO Control CHO Output CHD Input CH1 Control CH1 Output CH1 Monitor Input Range Type K thermocouple Celsius C200 to 1370 c PV Correction 0 0 El 100 0 to 100 0 C PV Filter Time Constant 0 0 E 0 0 to 10 0 sec 1370 El 200 to 1370 c Set Point SP Upper Limit Set Point SP Lower Limit 200 Z 200 to 1370 c Alarms Alarm Type Alarm Value Hysteresis
69. to 20mA DC 4 to 20mA DC Input impedance 500 Input Maximum permanent allowed overload No damage 50mA maximum Voltage 0to 1V DC Input impedance 1MO minimum Maximum permanent allowed overload No damage 5V DC maximum Allowable output impedance 2KO maximum 0 to 5V DC 1 to 5V DC 0 to 10V DC Input impedance 100kO minimum Maximum permanent allowed overload No damage 15V DC maximum Allowable output impedance 1000 maximum Power Supply Voltage 24V DC External power 5V DC Internal power Allowable Voltage Range 20 4 to 28 8V DC FC5A MicroSmart PID Module User s Manual FC9Y B1283 MODULE SPECIFICATIONS General Specifications Type No FC5A F2MR2 FC5A F2M2 Connector on Input F6018 17P Fujicon Mother Board Output F6018 11P Fujicon Connector Connector Insertion Removal Durability Input Specifications Type No FC5A F2MR2 FC5A F2M2 Maximum Error at 25 C Thermocouple 0 2 of full scale or 2 C 4 F whichever is greater However R S inputs 0 to 200 C 0 to 400 F 6 C 12 F B input 0 to 300 C 0 to 600 F Accuracy is not guaranteed K J E T N inputs Less than 0 C 32 F 0 4 of full scale Resistance Thermometer 0 1 of full scale or 1 C 2 F whichever is greater Voltage Current 0 2 of full scale Input Accuracy at 0 to 55 C Thermocouple 0 7 of full scale However R S input 0 to 200
70. to control the temperature to correspond with the set point SP regardless of any disturbances There should be no overshoot or response delay of time until the temperature reaches the set point SP Temperature Temperature Set point SP B zum Set point SP Set point SP A Time Time Figure 1 Ideal Temperature Control Figure 2 Optimal Temperature Control FC5A MicroSmart PID Module User s Manual FC9Y B1283 4 1 PID MODULE MAIN FUNCTIONS In reality the ideal temperature control shown in Figure 1 on the previous page is almost impossible to achieve due to a number of complicated factors such as thermal capacity static characteristics dynamic characteristics and disturbances Figure 2 is regarded as an optimal temperature control result Depending on the usage and objective for some temperature control applications suppression of overshoot is required even if the temperature rises very slowly as shown in Figure 3 For some temperature control applications it is necessary to stabilize the temperature as quickly as possible by raising the temperature rapidly even if overshoot is generated as shown in Figure 4 In general however Figure 2 is regarded as an optimal temperature control The PID module is designed to raise the process variable PV to the set point SP as quickly as possible in order to stabilize the process variable PV at the set point SP so as to perform the optimal temperature control If the temperature
71. valid range BIMO Reset Setting Range Err r Bit 1 Reset setting is out of the valid range Cooling Proportional Band Cooling 0 Cooling proportional band or cooling control period is within the valid range Bit11 Control Period Range Error Bit g z Cooling proportional band or cooling control CHO only 1 G period is out of the valid range Bit12 Overlap Dead Band Range Error 0 Overlap dead band is within the valid range Bit CHO only 1 Overlap dead band is out of the valid range 0 Alarm 1 to Alarm 8 values are within the valid Bit13 Alarm 1 to Alarm 8 Value Range range Error Bit 1 Alarm 1 to Alarm 8 values are out of the valid range Bit14 PV Filter PV Correction Range 0 PV Filter PV Correction is within the valid range Error Bit 1 PV Filter PV Correction is out of the valid range 0 Program control set point SP is within the valid Bit 5 Program Control Set Point SP range Program control set point SP is out of the valid range Note The parameter range error bit is turned on when any parameter of the PID module is out of the valid range While the parameter range error is occurring the control output is turned off 5 8 FC5A MicroSmart PID Module User s Manual FC9Y B1283 DEVICE ALLOCATION OF PID MODULE Operating Status Bit Operating Status 1 word Parameter Status Description Bito Hea
72. x27000 Interval x 27000 Trace end time Example If the interval time is 1sec the trace end time will be 27000 sec The trace will be finished in 450 minutes 6 54 FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR Monitoring Screen Example PID Module Configuration Slot 7 21x Module Type No FCSA F2M2 H CHO CHI EV ER 000 OE soo mv 337 gg bL 550 sP 550 mv W ll OUT o 50 100 OUT o 50 100 Status Error Status Error PARAM LOOP Control PARAM LOOP AT OVER UNDER AT OVER UNDER ee Manual TASTA Taal Manual A1 A2 A3 44 Send Command as ae az as Send Command AS A6 A7 AB Input CHO Control CHO Output CHO Input CH1 Control CH1 Output CH1 y Monitor N 1000 i i i i i i i 0 50 100 150 i i i r i 200 250 300 350 400 450 500 550 600 Second Monitor Settings Write all parameters Read all parameters Monitor o Gen FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 55 CONFIGURING PID MODULE USING WINDLDR 6 56 FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPLICATION EXAMPLES 7 APPLICATION EXAMPLES This chapter describes the PID modules application examples Application Example 1 This application example
73. 0 23 Set Point SP 0 C 0 21 24 Manual Mode Output Manipulated Variable 096 0 22 25 Operation Parameter 1 0 1 For details about the operation parameter see page 5 10 Blocks 2 3 Basic Parameters Offset from js Giele Parameter Default Value CHO CH1 26 103 Proportional Term Proportional band 10 C 10 27 104 Integral Time 200 sec 200 28 105 Derivative Time 50 sec 50 29 106 ARW Anti Reset Windup 50 50 FC5A F2MR2 Relay output 30 sec 30 30 107 Control Period FC5A F2M2 Non contact voltage output 3 sec 3 31 108 Reset 0 0 C 0 32 109 Output Manipulated Variable Rate of Change 0 second 0 33 110 Set Point SP Rise Rate 0 C minute 0 34 111 Set Point SP Fall Rate 0 C minute 0 35 112 Loop Break Alarm LA Time 0 minutes 0 36 113 Loop Break Alarm LA Span 0 C 0 37 114 Alarm 1 Value 38 115 Alarm 2 Value 39 116 Alarm 3 Value 40 117 Alarm 4 Value 41 118 Alarm 5 Value om 42 119 Alarm 6 Value 43 120 Alarm 7 Value 44 121 Alarm 8 Value 45 122 Reserved 0 46 123 Output Manipulated Variable Upper Limit 100 100 47 124 Output Manipulated Variable Lower Limit 0 0 48 125 Cooling Proportional Band CHO only cai e times 10 CHO FC5A F2MR2 Rela
74. 0 the value is used as overlap band When the overlap band is configured the area in which both heating and cooling control outputs are turned on is generated and the energy loss is caused However the overlap helps enhance the control accuracy and accelerate the response When the dead band is configured the area in which neither heating nor cooling control outputs are turned on is generated In the dead band the control accuracy and responsiveness is lowered however the energy loss can be suppressed Output manipulated variable MV 100 Heating Output Cooling Output j A Set Point amp SP Temperature Overlap Band Overlap Band Action Output manipulated variable MV 100 Heating Cooling Output Output 0 Temperature Set Point A SP amp Dead Band Dead Band Action FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR 23 Control Register 91 Program Control Mode Start Type Select the program control mode start type from the following PV Start When the program control is started the time is advanced until the set point SP becomes equal to the process variable PV and then the program control starts When Continue program control Repeat is selected as the program end action the time is PVR Start advanced until the set point SP becomes equal to the process variable PV at which program control is terminated and the
75. 0 1 to 100 0 C Delay Time 0 to 10000 sec EE Upper Limit Alarm JB 1 0 4 Alarm 2 No Alarm Action 1 o l farm Action M 1 0 5 Alarm 4 No Alarm Action 0 1 0 Alarm S No Alarm Action M E 1 0 Alarm6 No Alarm Action M oO Y 0 Alarm 7 No Alarm Action ER 1 a Write all parameters Read all parameters Monitor ok Cancel Item Setting Input Range Type K thermocouple Celsius Set Point SP Upper Limit 1370 C 3 Set Point SP Lower Limit 200 C 4 Alarm 1 Type Upper limit alarm 5 Alarm 1 Value 5 C alse TA oa FC5A MicroSmart PID Module User s Manual FC9Y B1283 7 3 APPLICATION EXAMPLES 4 Control CHO Parameters Configure the Control CHO parameters in the PID Module Configuration dialog box To open Control CHO Parameters in the PID Module Configuration dialog box click on Control Parameters CHO button or Control CHO tab PID Module Configuration Dialog Box Control CHO Parameters Input CHO Control CHO Output CHO Input CH1 Control CH1 Output CH1 Monitor Control Mode Control Action 1 NS Heating Cooling Control Set Point SP 2 Proportional Term Proportional Band Integral Time Derivative Time ARW Anti Reset Windup AT Bias Reset Set Point SP Rise Rate Set Point SP Fall Rate Output MV Rate of Change Output ON OFF Hysteresis Manual Mode Output MV Write all parameters Fixed Value Control Mode
76. 05 5 C Once the process variable PV enters the alarm output OFF range the standby is cancelled and the alarm is activated The ladder program should be customized depending on actual applications 7 18 FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPLICATION EXAMPLES 7 User Program Download From the WindLDR menu bar select Online gt Transfer gt Download to open Download dialog box Click the check box on the left of Write PID Module parameters after download and click OK button The user program will be downloaded to the CPU module After downloading the user program the PID module parameters will be written to the data registers in the CPU module and the PID module connected to the CPU module Transfer Mode Binary ASCII Download Options Z Automatic start after download E Keep output during download E Suspend 1 0 force before download Automatic device clear after download 7 Write PID module parameters after download E Write device data file to the PLC after download Setting 7 Download comment data Setting Fa Detail Program Information Program Size 1142 bytes Comment Size 0 bytes Total 1142 bytes Cancel Communication Settings When program download is successfully completed the following message will appear Click OK button to close the message Program Download aixi i Program Download Succeeded 8 Starting Heating Cooling Contro
77. 115 Alarm 2 Value 39 116 Alarm 3 Value 11 lt T aan vae See page 6 10 for the detail about alarm value range R W 42 119 Alarm 6 Value 43 120 Alarm 7 Value 44 121 Alarm 8 Value 73 150 Alarm 1 Hysteresis 74 151 Alarm 2 Hysteresis When the unit is Celsius 75 152 Alarm 3 Hysteresis 0 1 to 100 0 C 12 76 153 Alarm 4 Hysteresis When the unit is Fahrenheit RW 77 154 Alarm 5 Hysteresis 0 1 to 100 0 F 78 155 Alarm 6 Hysteresis When input is voltage current 79 156 Alarm 7 Hysteresis 1 to 1000 80 157 Alarm 8 Hysteresis 81 158 Alarm 1 Delay Time 82 159 Alarm 2 Delay Time 83 160 Alarm 3 Delay Time 84 161 Alarm 4 Delay Time 13 785 162 Alarm 5 Delay Time RER RAY 86 163 Alarm 6 Delay Time 87 164 Alarm 7 Delay Time 88 165 Alarm 8 Delay Time FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 9 CONFIGURING PID MODULE USING WINDLDR 6 10 Input Range Each input setting range is described Input Type and Range Unit Range 00h Type K Thermocouple 200 to 1370 C 01h Type K Thermocouple with Decimal Point 200 0 to 400 0 C 02h Type J Thermocouple 200 to 1000 C 03h Type R Thermocouple 0 to 1760 C 04h Type S Thermocouple 0 to 1760 C 05h Type B Thermocouple 0 to 1820 C 06h Type E Thermocouple 200 to 800 C 07h Type T Thermocouple with Decimal Point Celsius
78. 2 0 is turned off CHO control is disabled D1025 0 is turned off CH1 control is disabled M1000 reading all parameters is turned on All parameters are read from the PID module MO is turned off FC5A MicroSmart PID Module User s Manual FC9Y B1283 4 17 PID MODULE MAIN FUNCTIONS 4 18 FC5A MicroSmart PID Module User s Manual FC9Y B1283 DEVICE ALLOCATION OF PID MODULE 5 DEVICE ALLOCATION OF PID MODULE This chapter describes the valid devices control registers control relays and data register allocation for the PID module Device Allocation of PID Module The PID module is used by connecting to the MicroSmart CPU module To use the PID module allocate the data register and internal relay to the PID module configure the initial parameters using WindLDR and down load the user program and the parameters to the CPU module and the PID module The initial parameters are downloaded to the CPU module along with the user program The CPU module reads writes data from to the PID module according to the parameters configured in WindLDR CPU Module PID Module Block data are read from written to the PID module according to the settings configured in WindLDR The PID module parameters consist of 26 data blocks divided according to the function and frequency of use of each parameter as shown in the table below All blocks to be used are allocated to the data registers in the CPU module The parame
79. 200 0 to 400 0 C 08h Type N Thermocouple 200 to 1300 C 09h PL II 0 to 1390 C OAh C W Re5 26 0 to 2315 C OBh Pt100 with Decimal Point 200 0 to 850 0 C OCh JPt100 with Decimal Point 200 0 to 500 0 C ODh Pt100 200 to 850 C OEh JPt100 200 to 500 C OFh Type K Thermocouple 328 to 2498 F 10h Type K Thermocouple with Decimal Point 328 0 to 752 0 F 1ih Type J Thermocouple 328 to 1832 F 12h Type R Thermocouple 32 to 2200 F 13h Type S Thermocouple 32 to 3200 F 14h Type B Thermocouple 32 to 3308 F 15h Type E Thermocouple 328 to 1472 F 16h Type T Thermocouple with Decimal Point Fahrenheit 328 0 to 752 0 F 17h Type N Thermocouple 328 to 2372 F 18h PL II 32 to 2534 F 19h C W Re5 26 32 to 4199 F 1Ah Pt100 with Decimal Point 328 0 to 1562 0 F 1Bh JPt100 with Decimal Point 328 0 to 932 0 F 1Ch Pt100 328 to 1562 F 1Dh JPt100 328 to 932 F 1Eh 4to 20mA DC 2000 to 10000 IER 0 to 20mA DC 2000 to 10000 20h Oto1V DC 2000 to 10000 21h O0to5V DC 2000 to 10000 22h_ 1to5V DC 2000 to 10000 23h Oto 10V DC 2000 to 10000 Valid Range for Alarm 1 to Alarm 8 Value The valid range of each alarm type is described in the following table Alar
80. 22 01 Auto tuning AT Auto reset will be started When external input I1 is turned on CHO lt R gt _ operation parameter BI is reset and 10001 D1022 01 Auto tuning AT will be cancelled Timing Chart Control Enable Disable Bit ON D1022 0 E A y Auto tuning AT Auto reset o I d Perform Cancel Bit D1022 1 Bg U U I Auto tuning AT Auto reset 1 1 l I Perform Cancel Bit Monitor St D1009 1 OFF Auto tuning is started when Auto tuning Auto tuning AT AT Auto reset Perform Cancel bit cannot perform D1022 1 is turned off to on while Control is disable If auto tuning AT is cancelled while When auto tuning AT is completed it is performed the P D and ARW The P I D and ARW values values will be reverted to the original will be updated values at the time that auto tuning Auto tuning AT Auto reset AT was started Perform Cancel bit D1022 1 will be automatically turned off Notes Auto tuning AT Auto reset bit is automatically turned off when Auto tuning AT Auto reset is completed If Auto tuning AT Auto reset bit is kept on Auto tuning AT Auto reset will be performed continuously Use SOTU and SET instructions to turn on Auto tuning AT Auto reset bit so that auto tuning AT auto reset is performed only once If auto tuning AT is cancelled while it is performed P D and ARW values will be reverted to the original values
81. 343 364 385 Reserved 302 323 344 365 386 Output manipulated variable upper limit 303 324 345 366 387 Output manipulated variable lower limit 304 325 346 367 388 Cooling proportional band 305 326 347 368 389 Overlap Dead band Parameter 5 22 FC5A MicroSmart PID Module User s Manual FC9Y B1283 DEVICE ALLOCATION OF PID MODULE Program Parameters Parameter Description R W When input is thermocouple or resistance thermometer Set point SP lower limit to set point SP upper limit Set Point SP When input is voltage or current input dd Linear conversion min to linear conversion max When step time unit is Minute 0 to 6000 minutes Step Time When step time unit is Second iiid 0 to 6000 seconds When input range unit is Celsius 0 to 100 C Range with a decimal point 0 0 to 100 0 C When input range unit is Fahrenheit Wait Value 0 to ee 9 R W Range with a decimal point 0 0 to 100 0 F When input is voltage or current input 0 to 1000 Proportional band When input range unit is Celsius 0 to 10000 C Range with a decimal point 0 0 to 1000 0 C When input range unit is Fahrenheit Proportional Term 0 to 10000 F R W Range with a decimal point 0 0 to 1000 0 F When input is voltage or current input
82. 4 11 PID MODULE MAIN FUNCTIONS 4 12 Action after Power Is Restored When the power is restored every bit of the operation parameter excluding the program hold bit stored in the data register is maintained If the power is failed and restored while the PID module performs the program control the PID module starts its operation in accordance with the original PID module status before the power failure as shown in the table below PID Module Status before the Power Failure Program End Program E S Action Standby Control is Program Control is Program Control is Z Status 1 Performing suspended Hold Terminated Terminate Cam KOH The program control is PrearamiCohtrol started from the Step O Goes Standb The program The program hold is p Situs A control is canceled and the The oioaramhoidis i continued program control is 8 prog maintained ko o va maintained Fixed value 2 3 continued 2 3 f Hold Program control is performed with Control the set point SP at the time that the power is turned off 1 The PID module is in standby status when the control enable bit is on but the program control bit is off While in standby status the PID module performs no control 2 While the program control is running the PID module saves the program control status every 6 minutes after the program control is started after the program control bit is turned on The program control stat
83. 500 490 Step Wait value is set Moves to the next step when process variable PV reaches 490 Example 2 Wait function when the temperature is falling Set point SP Step Wait value is set Wait value 10 C Time Moves to the next step when process variable PV reaches 510T Program pattern Process variable PV eeeee T Program pattern delayed by T due to the wait function How to Cancel Wait Function The wait function can be cancelled for the program control to proceed to the next step by turning on the advance next step bit which is the bit 6 of the operation parameter 6 48 FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR 4 Control Register 183 Proportional Term The output of the proportional action varies in proportion to the deviation between the set point SP and the process variable PV When the heating cooling control is enabled this parameter becomes the heating proportional band The control action will be ON OFF control when the proportional band proportional gain is 0 If the proportional band is broadened proportional gain is made smaller the control output starts turning on or off at the significantly low temperatures from the set point SP overshoot or hunting is reduced however it takes time for the process variable PV to reach the set point SP and offset between the process variable PV and the set point SP
84. 70 C 1370 102 4179 External SP Input Linear Conversion CHO 0 Minimum Value CH1 only CH1 200 C 200 9 10 FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPENDIX Blocks 10 19 CHO Program Parameters Offset from the Control Register Step0 Step1 Step2 Step3 Step4 Parameter Default Value 4180 4201 222 243 264 Set Point SP 0 C 0 181 202 223 244 265 Step Time 0 minutes 0 182 203 224 245 266 Wait Value 0 C 0 4183 4204 4225 4246 267 Proportional Term B 0 184 205 226 247 268 _ Integral Time 200 sec 200 185 206 227 248 269 Derivative Time 50 sec 50 186 207 228 249 270 ARW Anti Reset Windup 50 50 4187 208 229 4250 4271 S Variable ge econd 0 188 209 230 251 272 Alarm1 Value 189 210 231 252 273 Alarm 2 Value 190 211 232 253 274 Alarm 3 Value 191 212 233 254 275 Alarm 4 Value 0 C 0 192 213 234 255 276 Alarm 5 Value 193 214 235 256 277 Alarm 6 Value 194 215 236 257 278 Alarm 7 Value 195 216 237 258 279 Alarm 8 Value 196 217 238 259 280 Reserved 0 197 4218 239 260 281 GC Manipulated Variable 400 100 pper Limit Output Manipulated Variable 198 219 240 261 282 lower Limit 0 0 199 220 241 262 283 Cooling Proportional Band 1 0 times 10 200 221 242 263 284 O
85. 9 4 C ON OFF control action sse eT de eTel PD controlaction ett co aiid a ads PI control action 2 0 0 ee eeeeeeeesteceseteeeeeeseeeeeeeeeeeeeteeeeees PID control action control parameters eee eee eee E UE CONTOl e Te EE control ran E eei aee N EE ENA aain ESNE over range under range control r gister Lettera edu RE loading initial values sees eee reading all parameters eee eee writing all parameters eee ee eee WHITING DIOCK T T cooling control period output manipulated variable MV output manipulated variable lower limit 6 48 output manipulated variable upper limit 6 48 output ON OFF bwsteresis 6 41 proportional band 5 19 D decimal Doll i e ee tete reae derivative time difference input control A direct control action sese E expansion modules configuration dialog box 6 1 external SP 5 11 5 20 6 11 6 22 6 31 9 2 enable disable LED 2 2 INPUT EE 5 21 6 32 linear conversion maximum value 5 21 6 32 linear conversion minimum value 5 22 6 32 F factory default settings sese eee 9 9 fixed value control UI EE H heating cooling control 4 14 5 20 6 37 7 15 cooling method eee eee ee eee 6 40 cooling proportional band sss sse eee eee eee 6 41 dead bandas crece deni dN cide teen edes 9 8 OUtp tactiON eneee e
86. 90 Total 2360 The configurations shown in the example 3 and 4 are possible because the total number of occupied data registers is less than 2000 Example 3 Program control mode is selected in three PID modules Control Mode Occupied Module Type Type No Data Register CHO CH1 Word FC5A F2MR2 FC5A F2M2 Program control mode Program control mode 590 PID Module FC5A F2MR2 FC5A F2M2 Fixed value control mode Program control mode 590 FC5A F2MR2 FC5A F2M2 Program control mode Program control mode 590 FC5A F2MR2 FC5A F2M2 Fixed value control mode Fixed value control mode 190 Total 1960 FC5A MicroSmart PID Module User s Manual FC9Y B1283 DEVICE ALLOCATION OF PID MODULE Example 4 Program control mode is selected in two PID modules Control Mode Occupied Module Type Type No Data Register CHO CH1 Word FC5A F2MR2 FC5A F2M2 Program control mode Fixed value control mode 590 PID Module FC5A F2MR2 FC5A F2M2_ Program control mode Program control mode 590 FC5A F2MR2 FC5A F2M2 Fixed value control mode_ Fixed value control mode 190 FC5A F2MR2 FC5A F2M2 Fixed value control mode Fixed value control mode 190 Total 1560 Control Relay The PID module occupies a maximum of 32 internal relays minimum 8 internal relays per module The occupied number of internal relays varies between the fixed value control mode and program control mode When both
87. 9Y B1283 APPLICATION EXAMPLES 3 Input CHO Parameters Configure the Input CHO parameters in the PID Module Configuration dialog box To open Input CHO Parameters in the PID Module Configuration dialog box click on Input Parameters CHO button or Input CHO tab PID Module Configuration Dialog Box Input CHO Parameters PID Module Configuration Slot 1 Module Type No FCSA F2M2 Input Gees Input CHO S Type K thermocouple Celsius Input uns Input CHI Type K thermocouple Celsius Input CHO Control CHO Output CHO 1 8 Input Range PV Correction PV Filter Time Constant 2 LL Set Point SP Upper Limit n Set Point SP Lower Limit 3 Alarms Type K thermocouple E Control Parameters CHO Reverse Control Action Heating Control Parameters CH1 Reverse Control Action Heating Input CH1 Control CH1 Output CH1 Monitor lt T celsius 0 0 Z 100 0 to 100 0 C 0 0 Z o o to 10 0 sec 1370 E 200 to 1370 c 200 Z 200 to 1370 sC i 200 to 1370 Output CHO Output CH1 c 2x Output Parameters CHO Voltage Output Voltage Output Alarm Type Alarm Value Hysteresis 0 1 to 100 0 C Delay Time 0 to 10000 sec E Ipper Limit Alarm 0 1 0 4 _ eae Alarm Action cb 1 0 Alarm 3 No Alarm Action M 1 D Alarm 4 No Alarm Action B 1 D Alarm S No Alarm Action E 1 D
88. Alarm 6 No Alarm Action WM 1 D Alarm 7 No Alarm Action M D Write all parameters Read all parameters Monitor OK Cancel Output Parameters CH1 Item Seiting Input Range Type K thermocouple Celsius Set Point SP Upper Limit 1370 C Set Point SP Lower Limit 200 C Alarm 1 Type Upper limit alarm 4 Control CHO Parameters Configure the Control CHO parameters in the PID Module Configuration dialog box To open Control CHO Parameters in the PID Module Configuration dialog box click on Control Parameters CHO button or Control CHO tab PID Module Configuration Dialog Box Control CHO Parameters 1 Input CHO Control CHO Program CHO Output CHO Input CH1 Control CH1 Output CH1 Monitor Control Mode Control Action Heating Cooling Control Set Point SP Proportional Term Proportional Band Integral Time Derivative Time ARW Anti Reset Windup AT Bias Reset Set Point SP Rise Rate Set Point SP Fall Rate Output MV Rate of Change Output ON OFF Hysteresis Manual Mode Output MV Write all parameters Program Control Mode Reverse Control Action Heating Disable lt 0 7 200 to 1370 c Proportional Band i 7 7 Oto 10000 c 0 to 10000 sec 50 7 Oto 10000 sec 0 to 100 Dto 50 c 0 0 2 C100 0 to 100 0 c to 10000 C min 0 Oto 10000 C min o 2 oto
89. Alarm Type Alarm Value Hysteresis 0 1 to 100 0 C Delay Time 0 to 10000 sec Alarm 1 ction d 1 0 Wa 9 L Alarm 4 No Alarm Action s E 1 0 Alarms No Ala M 1 D Alarm 6 No Alar o 1 0 Alarm 7 No Alarm Action M 1 0 Control Registers Offset from SE Parameter Description R W CHO CH1 0 Input CHO 1 Difference input Input CHO Input CH1 1 36 Input Cmo Funcion 2 Difference input Input CH1 Input CHO RAY 3 Addition input Input CHO Input CH1 0 Input CH1 1 Difference input Input CHO Input CH1 B 133 Input GHT Function 2 Difference input Input CH1 Input CHO FAY 3 Addition input Input CHO Input CH1 0 Disabled 1 External SP input 4 to 20mA DC Note 2 External SP input 0 to 20mA DC 2 3 External SP input 1 to 5V DC 4 External SP input 0 to 1V DC 55 External SP Input 5 Cascade control Note R W Note When External SP input is selected in Input E Function 1 External SP input 4 to 20mA DC selected as the default When Cascade Control i selected in Input CH1 Function 5 Cascade control is selected 0 Output CHO 3 57 Output CHO Function 1 Output CH1 R W 2 Both outputs Output CHO Output CH1 L 0 Output CH1 4 F134 J Output SAt Function The selection of Output CHO Function has priority BAK 5 58 135 Input Range See page 6 10 for the detail about the input range R W Set Point SP Upper Limit When input is thermocouple resistance thermometer 6 459 4136 Lin
90. C 0 to 400 F 6 C 12 F B input 0 to 300 C 0 to 600 F Accuracy is not guaranteed K J E T N inputs Less than 0 C 32 F 0 9 of full scale Resistance Thermometer 0 6 of full scale Voltage Current 0 7 of full scale Data Accuracy Maximum error at 25 C Minimum digital resolution of each input range Cold Junction Temperature 1 C at 0 to 55 C Compensation Accuracy Sampling Period 125 ms Output Specifications Type No FC5A F2MR2 FC5A F2M2 Control Output Relay output 1a Rated load 5A 250V AC resistive load 5A 30V DC resistive load 3A 250V AC inductive load cos 0 4 Non contact voltage for SSR drive 12V DC 15 Current 4 to 20mA DC Program Control Specifications Type No FC5A F2MR2 FC5A F2M2 Time Setting Accuracy 10 596 of setting time Progressing Time Error After Power is Restored Maximum 6 minutes Non volatile Memory Write Limit 1 000 000 times 2 4 FC5A MicroSmart PID Module User s Manual FC9Y B1283 MODULE SPECIFICATIONS Insulation Dielectric Strength Insulation Dielectric Stren th Type No FC5A F2MR2 FC5A F2M2 Isolation Photocoupler isolated between input and internal circuit Photocoupler isolated between input and power circuit Photocoupler isolated between input and internal circuit Photocoupler isolated between output and internal c
91. C5A CPU module system program version and WindLDR version as listed below Type All in One Type Slim Type FC5A D16RK1 Fosa ciop2 C OA CT R2 FC5A D16RS1 FC5A C16R2C FC5A C24R2 FC5A D32K3 FC5A MicroSmart CPU FC5A C10R2C FC5A C16R2D FC5A C24R2C FC5A D32S3 FC5A C10R2D FC5A D12K1E FC5A C24R2D FC5A D12S1E CPU System Program Version 230 or higher 1 WindLDR Version 6 40 or higher 1 The PID module can be used with FC5A D12K1E S1E with the system program version 100 or higher Confirming System Program Version The system program version can be confirmed using WindLDR 1 Connect a PC to port 1 or 2 of the FC5A CPU using serial computer link cable I F FC2A KC4C or USB cable HG9Z XCM2A for FC5A D12x1E CPU 2 From the WindLDR menu bar select Online gt Monitor 3 From the WindLDR menu bar select PLC gt Status The PLC Status dialog box appears and system program version is shown System Information PLC Type FCSA D16RX1 System Program Version 230 Operation Status Run Stop Status Running Scan Time Current 8 ms Maximum 9 ms TIM CNT Change Status Unchanged Gear Calendar 2011 03 18 09 49 02 Change Write Protection Unprotected Read Protection Unprotected Error Status C Details OK 1 2 FC5A MicroSmart PID Module User s Manual FC9Y B1283 MODULE SPECIFICATIONS 2 MODULE SPECIFICATIONS This chapter describes parts na
92. Conversion Maximum Value SEN input Linear conversion min to input range RW CH1 only PP External SP Input Linear ae 1 102 179 Conversion Minimum Value Aai range lower limit to external SP input linear conversion R W CH1 only 5 20 FC5A MicroSmart PID Module User s Manual FC9Y B1283 DEVICE ALLOCATION OF PID MODULE Input Range Input Type and Range Unit Range 00h Type K Thermocouple 200 to 1370 C Oih Type K Thermocouple with Decimal Point 200 0 to 400 0 C 02h Type J Thermocouple 200 to 1000 C OSh Type R Thermocouple 0 to 1760 C 04h Type S Thermocouple 0 to 1760 C 05h Type B Thermocouple 0 to 1820 C 06h Type E Thermocouple 200 to 800 C 07h Type T Thermocouple Celsius 200 0 to 400 0 C 08h Type N Thermocouple 200 to 1300 C 09h PL II 0 to 1390 C OAh C W Re5 26 0 to 2315 C OBh Pt100 with Decimal Point 200 0 to 850 0 C OCh JPt100 with Decimal Point 200 0 to 500 0 C ODh Pt100 200 to 850 C OEh JPt100 200 to 500 C OFh Type K Thermocouple 328 to 2498 F 10h Type K Thermocouple with Decimal Point 328 0 to 752 0 F 1ih Type J Thermocouple 328 to 1832 F 12h Type R Thermocouple 32 to 3200F 13h Type S Thermocouple 32 to 3200 F 14h Type B Thermocouple 32 to 3308 F 15h
93. E gt x 9 000 C Output Manipulated Variable MV x 27 000 1 CHO Trace Color Selection Select the color for the three parameters to be traced 2 CHO Trace Selection Select the parameter to be traced If none of the three parameters are selected CHO parameters are not traced and only parameters are monitored 3 CH1 Trace Color Selection Select the color for the three parameters to be traced 4 CH1 Trace Selection Select the parameter to be traced If none of the three parameters are selected CH1 parameters are not traced and only parameters are monitored 5 Auto Scaling If the auto scaling is enabled the range of the vertical axis is automatically updated in accordance with the process variable PV set point SP and output manipulated variable MV 6 Upper Limit The upper limit of the vertical axis for the trace can be specified 7 Lower Limit The lower limit of the vertical axis for the trace can be specified 8 Trace Time Settings Interval Configure the interval time for the tracing between 1 to 60 seconds x600 Interval x 600 Trace range Example If the interval time is 1 sec the trace range will be 600 sec When the traced data reaches the right edge the first half of the traced data is cleared and the trace continues x9000 Interval x 9000 Trace end time Example If the interval time is 1 sec the trace end time will be 9000 sec The trace will be finished in 150 minutes
94. Enable dii 0 Disabled 1 External SP input 4 to 20mA DC External SP Input 2 External SP input 0 to 20mA DC 99 aise CHO only d 3 External SP e i to 5V DC PW 4 External SP input 0 to 1V DC 5 Cascade control 0 Input CHO CH1 1 Difference input CHO CH1 SE EEN 2 Difference oe ra Se SC 3 Addition input CHO CH1 0 Output CHO 57 Output Function CHO 1 Output CH1 R W 2 Both outputs CHO CH1 0 Output CH1 i 134 Output Function CH1 S aon CHO has priority dd 58 135 Input Type See 5 21 for the input types and range R W m When input is thermocouple or resistance thermometer 459 4136 RUN UE AERA PARAR Set point SP lower limit to input range upper limit RW Value When input is voltage or current input T Linear conversion minimum to input range upper limit e Di When input is thermocouple or resistance thermometer 60 4137 a aan ne Input range lower limit to set point SP upper limit RW Value When input is voltage or current input l l Input range lower limit to linear conversion maximum When input range unit is Celsius 0 1 to 100 0 C 61 138 Output ON OFF Hysteresis Vhen inpet range unit is Fahrenheit RW When input is voltage or current input 1 to 1000 When input range unit is Celsius 100 0 to 100 0 C When input range unit is Fahrenheit 462 139 PV Correction 100 0 to 100 0 F RAN When input is voltage or current input 1000 to 1000 63 140 PV Filter Time Constant 0
95. FC5A series MicroSmart are available Refer to them in conjunction with this manual Type No Manual Name Description FC5A Series FC9Y B1283 ode Describes PID Module specifications and functions User s Manual this manual FC5A Series Describes module specifications installation instructions wiring instructions MicroSmart Pentra basic operation special function device addresses instruction list basic FC9Y B1268 c d Me User s Manual instructions analog modules user communication data link communication Basic Volume Modbus ASCII RTU communication and troubleshooting Describes instruction list move instructions data comparison instructions binary arithmetic instructions boolean computation instructions shift rotate instructions data conversion instructions week programmer instructions FC5A Series interface instructions program branching instructions refresh instructions MicroSmart Pentra interrupt control instructions coordinate conversion instructions average FC9Y B1273 User s Manual instructions pulse output instructions PID instructions dual teaching timer instructions intelligent module access instructions trigonometric function Advanced Volume l e h c ode i instructions logarithm power instructions file data processing instructions clock instructions computer link communication modem communication Modbus TCP communication expansion RS232C RS485 communication modules and AS Interf
96. FC9Y B1283 Si DE C FC5A SERIES microoSmeart_ pen tra PID Module User s Manual Kam Automation Organizer WindLDR IDEC CORPORATION SAFETY PRECAUTIONS Read this user s manual to make sure of correct operation before starting installation wiring operation maintenance and inspection of the FC5A series MicroSmart PID modules All MicroSmart modules are manufactured under IDEC s rigorous quality control system but users must add a backup or failsafe provision to the control system using the MicroSmart in applications where heavy damage or personal injury may be caused in case the MicroSmart should fail In this user s manual safety precautions are categorized in order of importance from Warning to Caution Warning notices are used to emphasize that improper operation may N Warning cause severe personal injury or death Turn off the power to the MicroSmart before starting installation removal wiring maintenance and inspection of the MicroSmart Failure to turn power off may cause electrical shocks or fire hazard Special expertise is required to install wire program and operate the MicroSmart People without such expertise must not use the MicroSmart Emergency stop and interlocking circuits must be configured outside the MicroSmart If such a circuit is configured inside the MicroSmart failure of the MicroSmart may cause a malfunction of the control system damage or accidents
97. ID Module Configuration Input Parameters List CHO and CH 6 8 PID Module Configuration Control Parameters List CHO and CH 6 13 PID Module Configuration Output Parameters List CHO and CH 6 17 PID Module Configuration Program Parameters List CHO and CH 6 19 PID Module Configuration I O Function Gelectons sss sese eee eee eee eee eee 6 21 PID Module Configuration Input Parameters Details sss sese eee eee eee eee 6 24 PID Module Configuration Control Parameters Detalls sss sees sese eee essen 6 34 PID Module Configuration Output Parameters Details eee eee 6 45 PID Module Configuration Program Parameters Details sse 6 47 Monitoring sde UE 6 52 CHAPTER 7 APPLICATION EXAMPLES ssssscccsssccsnnnosnssnsccsreecannnosnssnssssseenannnoaassnnssennecennnnoasss 7 1 Application Example dsac ic win eat E m eta edam a 7 1 Application Example 2 5 5 Ie E es 7 8 Applicaton Example 3 E 7 15 CHAPTER 8 TROUBLESHOOTING E 8 1 The PID Module Power LED PWR is OFF or Flashing sse ee eee eee eee ee ee eee eee 8 1 The PID Module output does not operate normal 8 2 Hunting phenomenon is occurring while in ON OFF control action sees sees eee cee eee eee ee eee 8 3 Hunting phenomenon is occurring while in PID PI PD or P control action sse esse eee eee eee eee eee 8 3 The PID Module input does not operate normally sese eee eee eee eee 8 4 Loop break alarm turns on even t
98. Input CHO Parameters PID Module Configuration Slot 1 3 Module Type No Fcsa F2m2 k Input eyes Input CHO Te Control Parameters CHO Output cHo Type K thermocouple with decimal point Celsius Reverse Control Action Heating PTS Gegen el N Cen ees 5 output cii Type K thermocouple Celsius Reverse Control Action Heating Input CHO Control CHO Output CHO Input CH1 Control CH1 Output CH1 Monitor peut Range Type K thermocouple with decimal point lt T Celsius 200 0 to 400 0 2c PV Correction 0 0 100 0 to 100 0 c PV Filter Time Constant i Point SP Upper Limit 2 Set Point SP Lower Limit 0 0 0 0 to 10 0 sec 400 0 0 0 to 400 0 C 0 0 E 200 0 to 400 0 C 2x Output Parameters CHO Voltage Output Output Parameters CH Voltage Output Alarms Alarm Type Alarm Value Hysteresis 0 1 to 100 0 C Alar Bl Upper Lower Limits Alarm with Standby I 5 5 1 0 4 aen No Alarm Action 1 0 0 1 0 No Alarm Action o 1 0 5 No Alarm Action zB 1 0 Alarm 6 No Alarm Action 0 1 0 Alarm 7 No Alarm Action 0 1 o Delay Time 0 to 10000 sec Write all parameters Read all parameters Monitor ok Cancel Item Setting Input Range Type K thermocouple with decimal point Celsius Set Point SP Upper Limit 400 0 C Set Point SP Lower Limit 0 0 C Alarm 1 Type Upper Lower limits alarm with st
99. P Fall Rate When the set point SP is widely changed this function makes the set point SP change gradually The rising falling span of the set point SP in 1 minute can be configured When the set point SP is changed the set point SP is gradually changed from the original set point SP to the new set point SP with the configured ratio C minute F minute When the control is started the set point SP is gradually changed from the process variable PV to the set point SP with the configured ratio C minute F minute In the fixed value control mode this function is used to configure the desired temperature gradient until the process variable PV reaches the set point SP This function is disabled when the set point SP rise fall rate is 0 14 Control Register 32 Output Manipulated Variable Rate of Change The maximum change of the output manipulated variable in one second can be configured This function is disabled when the value is 0 In the case of heating control when there is a large deviation between the process variable PV and the set point SP the output immediately changes from off to on as shown in the diagram below Normal Output By configuring the output manipulated variable rate of change the maximum change of the output manipulated variable MV in one second can be changed as shown in the diagram below Output When Output Manipulated Variable Rate of Change is Configured This function can be
100. PID Module User s Manual FC9Y B1283 EipEC UNITED STATES IDEC CORPORATION 1175 Elko Drive Sunnyvale CA 94089 2209 USA Tel 1 408 747 0550 Toll Free 800 262 IDEC Fax 1 408 744 9055 Toll Free Fax 800 635 6246 E mail opencontact idec com CANADA IDEC CANADA LIMITED 3155 Pepper Mill Court Unit 4 Mississauga Ontario L5L 4X7 Canada Tel 1 905 890 8561 Toll Free 888 317 4332 Fax 1 905 890 8562 E mail sales ca idec com AUSTRALIA IDEC AUSTRALIA PTY LTD 17 04 Ferntree Gully Road Oakleigh Victoria 3166 Australia Tel 61 3 8523 5900 Toll Free 1800 68 4332 Fax 61 3 8523 5999 E mail sales au idec com UNITED KINGDOM IDEC ELECTRONICS LIMITED Unit 2 Beechwood Chineham Business Park Basingstoke Hampshire RG24 8WA UK Tel 44 1256 321000 Fax 44 1256 327755 E mail sales uk idec com GERMANY IDEC ELEKTROTECHNIK GmbH Wendenstrasse 331 20537 Hamburg Germany Tel 49 40 25 30 54 0 Fax 49 40 25 30 54 24 E mail service idec de B 1283 0 JAPAN IDEC CORPORATION 7 31 Nishi Miyahara 1 Chome Yodogawa ku Osaka 532 8550 Japan Tel 81 6 6398 2571 Fax 81 6 6392 9731 E mail marketing idec co jp CHINA IDEC SHANGHAI CORPORATION Room 608 609 6F Gangtai Plaza No 700 Yan an East Road Shanghai 200001 PRC Tel 86 21 5353 1000 Fax 86 21 5353 1263 E mail idec cn idec com IDEC BEIJING CORPORATION Room 211B Tower B The Grand Pacific Building
101. PID Module User s Manual FC9Y B1283 7 5 APPLICATION EXAMPLES 7 Saving Parameters Click OK button to save the configured parameters PID Module Configuration Slot 1 B 2 x Module Type No FCSA F2M2 e Input Parameters maco E Control Parameters oo Output Parameters CHO gt rout cro lt k CHO 9 Output cHo Zei CHO Type K thermocouple Celsius Input Parameters CHI Type K thermocouple Celsius Input CH1 lt Control Parameters CH1 Reverse Control Action Heating Voltage Output gt Output CHL gnr Rr ete Reverse Control Action Heating Voltage Output Input CHO Control CHO Output CHO Input CH1 Control CH1 Output CH1 Monitor Output Type Voltage Output E Control Period 3 1to 120 sec Output MV Upper Limit 100 0to 100 Output MV Lower Limit o 2 oto 100 Cooling ControlPeriod 1to 120 sec Cooling Output MV Upper Limit 100 gt Oto 100 Cooling Output MV Lower Limit 0 Oto 100 Write all parameters Read all parameters Monitor 8 Ladder Programming Cancel Create a ladder program to control the PID module Ladder Program Example 10000 Qooo00 Q0001 D1022 00 D1025 00 D1010 07 D1019 07 10001 D1022 01 D1009 01 Notes While external input IO is on the control of the PID module is enabled When QO CHO control upper limit alarm out
102. PLES 2 I O Function Selection Select I O function for each channel in the PID Module Configuration dialog box PID Module Configuration Dialog Box I O Function Selection PID Module Configuration Slot 1 Module Type No FCSA F2M2 lt E E l E Input Ge Input CHO el tara res TTT 2 Type K thermocouple Celsius Reverse Control Action Heating Input Parameters ai Control Parameters CH Input CHI BI en gt output on Type K thermocouple Celsius Reverse Control Action Heating Input CHO Control CHO Output CHO Input CH1 Control CH1 Output CH1 Monitor Input Range Type K thermocouple lt T Celsius 200 to 1370 sC PV Correction oo E 100 0 to 100 0 C PV Filter Time Constant 0 0 7 0 0 to 10 0 sec Set Point SP Upper Limit 1370 E 200 to 1370 C Set Point SP Lower Limit 200 2 200 to 1370 c Alarms Ai xl Output Parameters CHO Voltage Output 4 KEL Parameters Si CH1 Voltage Output Item Setting Input CHO Function Input CHO Input CH1 Function Input CH1 Output CHO Function Output CHO Output CH1 Function Output CH1 3 Input CHO Parameters Configure the Input CHO parameters in the PID Module Configuration dialog box To open Input CHO Parameters in the PID Module Configuration dialog box click on Input Parameters CHO button or Input CHO tab PID Module Configuration Dialog Box
103. Relay Output E E Cycle Action is Performed C cle Action is Performed ccording to Deviation ccording to Deviation Non contact T Voltage Cj 12 0VDC 0VDC C omavpo ebe Output cle Action is Performed Cycle Action is Perfomed ccording to Deviation ccording to Deviation Current DC i20 to 4mA DC 4mA DC i4to 20mA DG 20mA Output ed Esc Gba i Changes Continuously Chahges Continuously According to Deviation According to Deviation LED Indicator CHO OUT NENNEN Green Turns ON or OFF CHO CH1 Output Action of ON OFF Control Action PF Heating Reverse Control Action Cooling Direct Control Action Hysteresis Hysteresis Control Action Relay Output Non contact Voltage Output Current Output LED Indicator CHO OUT Green Turns ON or OFF FC5A MicroSmart PID Module User s Manual FC9Y B1283 9 5 APPENDIX Output Action of Heating Cooling Control Control Action CHO Non contact Voltage Current Output CH1 Current Output LED Indicator CHO OUT 9 6 Heatin Coolin Proportional Band Proportional Band ON Heating i Cooling Control Action i i Control Action OFF Cycle Action is Performed ccording to Deviation Cycle Action is Performed ccording to Deviation 12V DC 12 0V DC Cycle Action is Performed
104. able MV Example When the output manipulated variable MV upper limit is 80 the control output will be 80 even when the output manipulated variable MV reaches 100 4 Control Register 47 Output Manipulated Variable Lower Limit This value specifies the lower limit of the output manipulated variable MV Example When the output manipulated variable MV lower limit is 2096 the control output will be 2096 even when the output manipulated variable MV is 096 5 Control Register 49 Cooling Control Period When the heating cooling control is enabled the cooling control period determines the duration of the ON OFF cycle of the cooling control output that is turned on and off according to the cooling output manipulated variable MV calculated by the PID control action 6 Control Register 51 Cooling Output Manipulated Variable Upper Limit This value specifies the upper limit of the cooling output manipulated variable MV The cooling output manipulated variable upper limit is used to suppress the cooling output manipulated variable MV Example When the cooling output manipulated variable MV upper limit is 8096 the cooling control output will be 8096 even when the cooling output manipulated variable MV reaches 100 7 Control Register 52 Cooling Output Manipulated Variable Lower Limit This value specifies the lower limit of the cooling output manipulated variable MV Example When the cooling output manipulat
105. ace 2 with CH1 control using program control PID control is performed based on the temperature input to the PID module and the program pattern below The control output is turned on or off in accordance with the output manipulated variable MV The program pattern for the program control consists of the following 4 steps Step 0 Preheat process Step 0 is the process to gradually raise the set point SP to the preheat temperature 100 C in 60 minutes to evaporate water in the specimen and electric furnace interior When the elapsed time in step 0 is 60 minutes if the process variable PV is less than 90 C the PID module waits until the temperature reaches 90 C When the temperature reaches 90 C the PID module proceeds to the next step Step 1 Preheat process Step 1 is the process to keep the preheat temperature 100 C constant for 60 minutes Step 2 Firing process Step 2 is the process to gradually raise the set point SP to the firing temperature 800 C in 5 hours to prevent the specimen from being damaged by a rapid temperature rise When the elapsed time in step 2 is 5 hours if the process variable is less than 790 C the PID module waits until the temperature reaches 790 C When the temperature reaches 790 C the PID module proceeds to the next step Step 3 Firing process Step 3 is the process to keep the firing temperature 800 C constant for 30 minutes PID parameters proportional band proportional gain i
106. ace master modules FC5A Series MicroSmart Pentra FC9Y B1278 User s Manual Web Server CPU Module Volume Describes FC5A Slim Type Web Server CPU Module specifications and functions FC5A MicroSmart PID Module User s Manual FC9Y B1283 vi FC5A MicroSmart PID Module User s Manual FC9Y B1283 TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION 1ssssccccccccssnssssssscssnsceeeannnsesssnsesseeeaannaussssssssseneasanaasaaes 1 1 About the KR el 1 1 Quantity of Applicable PID modules sss sese eee eee 1 1 Applicable CPU and WindLDR version 1 2 Confirming System Program Version eene nennen nnns nnn en rennen nsns nennen ns 1 2 CHAPTER 2 MODULE SPECIFICATIONS eee irre e eaa u une nnne e anas saa aRRRn n aane ARR RARE RRR nOn aaa 2 1 ID Modules diit mr d tari ER ro dad aaa edi ere REED Podio aeria 2 1 Te rcc EE 2 3 Al 2 6 CHAPTER 3 INSTALLATION AND WIRING eene nennen nnn e eee neee 3 1 Mounting Hole Layout for Direct Mounting on Panel Surface sse sese ee eee ee e e ee 3 1 Terminal Connection ode eal ee ede doe er De Vae Rupe veste de de epe en de deoa 3 3 Terminal Arrangement tat eae e eate e edat ee t eta 3 4 Type of Protectlonas iie e ot te D e abe eed ee s 3 5 Power Supply for PID Modul s roce rece a da eee gae e e Ed Lea dee eb diee do 3 6 CHAPTER 4 PID MODULE MAIN FUNCTIONS nennen enun nnne nana nana uuu u unn nana a assu saa aaa nna aaa aA
107. al FC9Y B1283 3 3 INSTALLATION AND WIRING Terminal Arrangement A Caution Connect an IEC 60127 approved fuse appropriate for the applied voltage and current draw at the position shown in the diagram This is required when equipment containing the MicroSmart is destined for Europe Do not connect a thermocouple to hazardous voltage 60V DC 42 4V DC peak or higher Be sure to check the wiring before the power is turned on Faulty wiring may result in damage to the PID module Applicable electric cables are listed below Cable size AWG16 Single cable Cable size AWG18 AWG22 Single cable Twisted cable IDEC Pip em el m OUTO C3 a EVTO C3 E molol jo ze lg eme DC Voltage Current EVT1 C3 rs AE Fuse 50V 1 2A RTD Resistance thermometer ch Ale Terminai arazer TC Thermocouple L4 H No anne Load Loa e H t Analog current input instrument S i SE avoc D I F 9 H FG Fuse Pee EE NC ei d seCh NGT e Sa si EaD NC Terminal Channel d Sa p p NC si si EB 0 to 5V 7 H n Se 1 to 5V Oto 20mA A 4 A INO NC f S SC Oto 10V 4t 20mA
108. al time 490 509 528 547 566 __ Derivative time 491 510 529 548 567 ARW Anti Reset Windup 492 511 530 549 568 Output manipulated variable rate of change 493 512 531 550 4569 Alarm 1 value 494 513 532 551 570 Alarm 2 value 495 514 533 552 571 Alarm 3 value 496 515 534 553 572 Alarm 4 value 497 516 535 554 573 Alarm 5 value 498 517 536 555 574 Alarm 6 value 499 518 537 556 575 Alarm 7 value 500 519 538 557 576 Alarm 8 value 501 520 539 558 4577 _ Reserved 502 521 540 559 578 Output manipulated variable upper limit 503 522 541 560 579 Output manipulated variable lower limit Parameter 5 24 FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR 6 CONFIGURING PID MopuLE Uewe WINDLDR This chapter describes configuration procedure of the PID modules using WindLDR PID module configuration dialogs and monitoring Procedure to configure the PID module 1 Expansion Modules Configuration Dialog Box To open the Expansion Modules Configuration dialog box follow one of the procedures below Procedure 1 1 From the WindLDR menu bar select View gt Project Window to open the Project Window 2 Double click on Expansion Modules Configuration in the Project Window Procedure 2 1 From the WindLDR menu
109. alue 1570 to 1570 C 0 0 0 0 0 0 0 0 0 0 16 Alarm 8 Value 1570to1570 C 0 0 0 0 0 0 0 0 0 0 17 LC CPt MY Upper Limit 0 to 100 100 100 100 100 100 100 100 100 100 100 o Output MY Lower Limit 0 to 100 0 0 0 0 0 0 0 0 0 0 18 1 1 1 1 1 1 1 1 1 1 19 0 o 0 0 0 0 0 0 20 T Cooling Proportional Band 0 0 to 10 0 times i Overlap Dead Band 200 0 to 200 0 0 0 Write all parameters Read all parameters Monitor ok Cancel The program parameters of step 0 of CHO control are described here The parameters of steps 1 to 9 of CHO and parameters of steps 0 to 9 of CH1 control are the same as those of step 0 of CHO control However the positions from the control register for each parameter differs For details about the positions from the control register for each program parameter see 5 22 to 5 24 1 Control Register 180 Set Point SP Configure the set point SP at the end of the step Any value within the following range can be configured When input is thermocouple or resistance thermometer Set point SP lower limit Set point SP x Set point SP upper limit When input is voltage or current Linear conversion minimum value s Set point SP lt Linear conversion maximum value 2 Control Register 181 Step Time The process time of each step can be configured as the step time When the set point SP is 500 C and the step time is 30 minutes the PID module gradually increases the set point
110. andby TJA Oo Po We ER Fe Alarm 1 Value 5 5 C FC5A MicroSmart PID Module User s Manual FC9Y B1283 7 17 APPLICATION EXAMPLES 4 Control CHO Parameters Configure the Control CHO parameters in the PID Module Configuration dialog box To open Control CHO Parameters in the PID Module Configuration dialog box click on Control Parameters CHO button or Control CHO tab PID Module Configuration Dialog Box Control CHO Parameters Input CHO Control CHO Output CHO Input CH1 Output CH1 Monitor Control Mode Fixed Value Control Mode 1 Packed helices Reverse Control Action Heating 2 leating Cooling Control Enable Loop Break Alarm LA Time 0 0to 200 min _ Point SP 200 0 Z 0 0 to 400 0 c Loop Break Alarm LA Span 0 0 0 0 to 150 0 c Proportional Term Proportional Band Cooling Control Settings Proportional Band 10 0 0 0 to 1000 0 c Cooling Method Air Cooling Integral Time 200 Z 0 to 10000 sec Cooling Proportional Band 1 0 Z 0 0 to 10 0 Derivative Time _50 S Oto 10000 sec Cooling Output ON OFF Hysteresis to 100 c 3 ARW Anti Reset Windup 50 Z to 100 Overlap Dead Band 00 200 0 to 200 0 2c eis 20 0 7 0 0 to 50 0 c Reset 0 0 100 0 to 100 0 c Set Point SP Rise Rate 0 0 Z 0 0 to 1000 0 C min Set Point SP Fall Rate RH 0 0 to 1000 0 min Output MV Rate of C
111. ariable lower variable MV limit to 10096 upper limit Lower limit 096 to cooling output manipulated variable lower limit upper limit When output type is current Upper limit Cooling output manipulated variable lower limit to 10596 Lower limit 596 to cooling output manipulated variable upper limit Air cooling Linear characteristic Oil cooling 1 5th power of the linear characteristic or Water cooling 2nd power of the linear characteristic CH1 output Cooling method Cooling output The input value of input CH1 is used as the set point SP of CHO control When the external SP input bias is configured it is added to the set point SP of CHO control The input types that can be selected are shown in the following table Input type Current 4 to 20mA or 0 to 20mA Voltage 1 to 5V or 0 to 1V Current 50mA DC maximum Voltage 0 to 1V 5V DC maximum Voltage 1 to 5V 10V DC maximum Current 500 Voltage 100kQ External SP Input Allowable input Input impedance 9 2 FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPENDIX During the program control running when a step is finished the program control Wait Function does not proceed to the next step until the deviation between the process variable PV and set point SP becomes less than the wait value During the program control running when the program control is held the Program Hold progression of th
112. arm 1 Type 0 No alarm action 143 Alarm 2 Type 1 No alarm action 144 Alarm 3 Type 2 No alarm action 4145 Alarm 4 Type 3 No alarm action 7 4146 Alarm 5 Type 4 No alarm action RW 147 Alarm 6 Type 5 Process high alarm 148 Alarm 7 Type 6 Process low alarm 149 Alarm 8 Type 7 No alarm action 8 No alarm action 9 No alarm action 114 Alarm 1 Value 4115 Alarm 2 Value 116 Alarm 3 Value 8 T Nal ane See page 6 10 for the detail about alarm value range R W 119 Alarm 6 Value 120 Alarm 7 Value 121 Alarm 8 Value FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 11 CONFIGURING PID MODULE USING WINDLDR 6 12 150 Alarm 1 Hysteresis 151 Alarm 2 Hysteresis When input range unit is Celsius 152 Alarm 3 Hysteresis 0 1 to 100 0 C 9 153 Alarm 4 Hysteresis When input range unit is Fahrenheit R W 154 Alarm 5 Hysteresis 0 1 to 100 0 F 155 Alarm 6 Hysteresis When input is voltage or current 156 Alarm 7 Hysteresis 1 to 1000 157 Alarm 8 Hysteresis 158 Alarm 1 Delay Time 159 Alarm 2 Delay Time 160 Alarm 3 Delay Time 161 Alarm 4 Delay Time 10 162 Alarm 5 Delay Time EE te 163 Alarm 6 Delay Time 164 Alarm 7 Delay Time 165 Alarm 8 Delay Time FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR PID Module Configuration Control Parameters List CHO and CH1 The control param
113. at the time that auto tuning AT was started Auto reset cannot be cancelled FC5A MicroSmart PID Module User s Manual FC9Y B1283 PID MODULE MAIN FUNCTIONS Program Control The program control allows you to define the set point SP that changes as the time progresses so that the process variable PV can be controlled to match the set point SP changing as the time progresses The set point SP and time can be configured for each step A maximum of 10 steps can be configured and performed The set point SP can be configured as shown in the following diagram The program control is suitable for applications such as electric furnaces for ceramic industries or food machineries Temperature Time Main functions of the program control are described as follows Program Pattern and Steps 1 program pattern consisting of 10 steps can be performed per channel Program Hold Function Suspends the progression of the program control while the program control is running and performs the fixed value control with the set point SP at the time that the program control is held Advance Next Function Terminates the current step while the program control is running and proceeds to the start of the next step Advance Previous Function Moves back the progression of the program control while the program control is running Wait Function When a step ends during program control if the deviation between the process variable PV and se
114. bar select Configuration gt Expansion Modules Expansion Modules Configuration Dialog Box 2x Expansion Modules Quantity of modules HS CPU module Slot 1 Slot 2 Slot 3 Slot 4 FCSA F2M2 FCSA D16RX1 D1000 to D1189 Other modules Other modules Other modules M0000 to M0007 Module Settings Module Type No FCSA F2M2 Data Register D1000 D1000 to D1189 Internal Relay m1000 M1000 to M1007 Configure Parameters Copy Parameters To Ok Cancel After specifying the quantity of modules and selecting the slot number to which the PID module is connected designate the module type number control register data register and control relay internal relay After designating those parameters click on Configure Parameters button to open the PID Module Configuration dialog 2 PID Module Configuration Dialog Box PID Module Configuration Slot 1 2x Module Type No FCSA F2M2 IE Input Parameters Control Parameters Output Parameters CHO Eg nto M CHO Eoo x i CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters d Control Parameters Output Parameters En EE nao lp m cutput CHI j aay Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input CHO Control CH Output CHO Input CH1 Control CHi Output CH1 Monitor Input Range Type K thermocouple Celsius 200 to 1370 c PV Correction 0 0 100 0 to 100 0 C PV Filter Time
115. can be specified with the AT bias When Process variable PV lt Set point SP AT bias AT starting point Set point SP AT bias When Process variable PV 2 Set point SP AT bias AT starting point Set point SP AT bias When Set point SP AT bias Process variable PV Set point SP AT bias AT starting point 2 Set point SP For details about the AT bias see page 4 6 11 Control Register 31 Reset The reset corrects the offset between the set point SP and the process variable PV generated in P or PD control action Reset can be configured only in P integral time and derivative time are 0 or PD integral time is 0 control action P or PD control action is used for the control target in which overshoot caused by the integral action is hard to be suppressed When the reverse control action is selected the manipulated variable is calculated with the ratio of the reset to the proportional band and the calculated manipulated variable is added to the output manipulated variable MV When the direct control action is selected the manipulated variable is calculated with the ratio of the reset to the proportional band and the calculated manipulated variable is subtracted from the output manipulated variable MV FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 37 CONFIGURING PID MODULE USING WINDLDR 12 Control Register 33 Set Point SP Rise Rate 13 Control Register 34 Set Point S
116. ceeds the range Upper Lower limits alarm with standby Process Process high alarm The alarm action point is To alarn output turns on i the process variable PV Alarm Process low alarm the alarm value exceeds the alarm value When the alarm value is 0 the alarm action is disabled except process high alarm and process low alarm 17 Control Register 197 Output Manipulated Variable Upper Limit This value specifies the upper limit of the output manipulated variable MV The output manipulated variable upper limit is used to suppress the output manipulated variable MV Example When the output manipulated variable MV upper limit is 80 the control output will be 80 even when the output manipulated variable MV reaches 100 18 Control Register 19 Output Manipulated Variable Lower Limit This value specifies the lower limit of the output manipulated variable MV Example When the output manipulated variable MV lower limit is 2096 the control output will be 2096 even when the output manipulated variable MV is 0 6 50 FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR 19 Control Register 199 Cooling Proportional Band The cooling proportional band can be configured when the heating cooling control is enabled The cooling proportional band is the multiplication of the heating proportional band Example When the heating proportional band is 10 C and the c
117. cel Item Setting 1 Quantity of Modules 1 2 Slot No Slot 1 3 Module Type No FC5A F2MR2 4 Data Register D1000 5 Internal Relay M1000 2 I O Function Selection Select I O function for each channel in the PID Module Configuration dialog box PID Module Configuration Dialog Box I O Function Selection PID Module Configuration Slot 1 21xl 1 Module Type No FCSA F2M2 3 Input Parameters 7 r Control Parameters Output Parameters cH Input CHO lt k CHO output CHO w CHO 2 Type K thermocouple Celsius Reverse Control Action Heating Voltage Output 4 Input Parameters 1 Control Parameters 0 MIB CHI et nt y lt gt CHI oweren H1 Type K thermocouple Celsius Reverse Control Action Heating Input CHO Control CHO Output CHO Input CH1 Control CH1 Output CH1 Monitor Input Range Type K thermocouple lt T Celsius 200 to 1370 c Voltage Output PV Correction PV Filter Time Constant Set Point SP Upper Limit Set Point SP Lower Limit 0 0 Z 100 0 to 100 0 c 0 0 to 10 0 sec 1370 E 200 to 1370 c 200 EJ 200 to 1370 c Alarms Item Setting 1 Input CHO Function Input CHO 2 Input CH1 Function Input CH1 8 Output CHO Function Output CHO 4 Output CH1 Function Output CH1 7 10 FC5A MicroSmart PID Module User s Manual FC
118. ck 1 are retained so the control action starts with the previous mode at the time of power off Auto Manual Mode Switching The cascade control is an advanced control that uses 2 inputs CH1 as a master primary control and CHO as a slave secondary control to control one process The output manipulated variable MV calculated according to the process variable PV and the set point SP of the master CH1 is used as the set point SP of the slave CHO for control The control results will be outputted from the output CHO Cascade Control When it is difficult to control the target process with heating control only cooling control can be added to perform the heating cooling control Cooling 0 0 to 10 0 times Cooling proportional band is the proportional band product of this value and the heating proportional band The cooling control becomes ON OFF control when the cooling proportional band is 0 Integral time l 0 to 10000 seconds Derivative time D 0 to 10000 seconds Cooling control 1 to 120 sec period Overlap Dead When input is thermocouple RTD 200 0 to 200 0 C F band When input is voltage current 2000 to 2000 Cooling output When input is thermocouple RTD 0 1 to 100 0 C F ON OFF hysteresis When input is voltage current input 1 to 1000 Heating Cooling Control Cooling output When output type is voltage Output CHO only manipulated Upper limit Cooling output manipulated v
119. control is not executed the program controlis moved back to step 2 even if repeated from the step 0 the advance previous step is executed in step 0 While the program hold is executed If the control is disabled after the program end output is turned when step 2 is terminated on the program hold bit has no effect the program end output does not turn on 5 12 FC5A MicroSmart PID Module User s Manual FC9Y B1283 DEVICE ALLOCATION OF PID MODULE Example 3 Continue Program Control Repeat when Program Ends The following diagram shows an example of the program control when continue program control repeat is selected as the program end action Time of steps Step 0 and 1 60 minutes Step 2 30 minutes Steps 3 to 9 0 minute Number of repeats 1 In this example D1000 is allocated to the control register and M500 is allocated to control relay Current step number D1006 le ss k gt Jo R Number of repeats remaining Am l D1007 I FN ON l Control enable bit l D1022 0 BENE i IN i l Program control bit ON l CR D1022 3 d OFF d pes A Ka SS Program control bit ON Monitor 1 de ul D1009 3 OFF Ed C1 l 1 Fog l l Fog l 1 l l l l Program hold bit B E D1022 4 OEF l WA ON i E Advance next step bit l D1022 6 EE l ra 1 It 3 ON I Ge Advance previous step bit l i Ke D1022 7 pod OFF 1 l I En l U l Program end ou
120. corrects the offset and D action corrects rapid temperature change due to disturbance in shorter time Thus using PID control action optimal temperature control can be performed The proportional band integral time derivative time and ARW can be automatically calculated by the auto tuning AT Temperature Set Point SP A Disturbance Time FC5A MicroSmart PID Module User s Manual FC9Y B1283 4 5 PID MODULE MAIN FUNCTIONS Auto Tuning AT Auto Reset The optimal temperature control parameters differ depending on the characteristics of the process to control For PID control action the proportional band integral time derivative time and ARW are automatically configured by performing auto tuning AT For P control or PD control action the reset value is automatically configured by performing auto reset A Caution Perform auto tuning AT auto reset during the trial run f the auto tuning AT is performed near the ambient temperature sufficient fluctuations cannot be given to the process and auto tuning AT may fail In such case configure the P I D and ARW values manually Perform auto reset when the process variable PV is stabilized within the proportional band Once auto tuning AT auto reset is performed it is unnecessary to perform auto tuning AT auto reset again as long as the process is unchanged When voltage or current input is selected and the auto tuning AT is performed fl
121. demonstrates the temperature control for a system using two electric furnaces The set point SP of CHO control is 200 C The set point SP of CH1 control is 210 C PID control is performed based on the temperature input to the PID module The control output is turned on or off in accordance with the output manipulated variable MV PID parameters proportional band proportional gain integral time derivative time and ARW are automatically calculated using auto tuning AT lf the process variable PV of CHO control becomes 205 C or higher the upper limit alarm output QO is turned on and the control is disabled lf the process variable PV of CH1 control becomes 215 C or higher the upper limit alarm output Q1 is turned on and the control is disabled System Configuration and Wiring Wiring Example of the FC5A F2M2 Non contact voltage output for SSR drive current output type 3 phase Power Supply Terminal No Terminal No Channel Electric Electric Furnace 2 Furnace 1 CH1 Thermocouple PID Module FC5A F2M2 FC5A MicroSmart PID Module User s Manual FC9Y B1283 7 1 APPLICATION EXAMPLES PID Module Parameter Configuration The parameters of the PID module can be configured in the Expansion Modules Configuration and PID Module Configuration dialog boxes The procedure to configure the PID module is described below Parameter Configuration Example
122. dimensions in mm FC5A MicroSmart PID Module User s Manual FC9Y B1283 3 1 INSTALLATION AND WIRING Example Mounting hole layout for FC5A C24R2 and four PID modules 103 0 All dimensions in mm FC5A MicroSmart PID Module User s Manual FC9Y B1283 113 0 02 INSTALLATION AND WIRING Terminal Connection A Caution Make sure that the operating conditions and environments are within the specified values Be sure to connect the grounding wire to a proper ground otherwise electrical shocks may be caused Do not touch live terminals otherwise electrical shocks may be caused Do not touch terminals immediately after power is turned off otherwise electrical shocks may be caused When using ferrules insert a wire to the bottom of the ferrule and crimp the ferrule When connecting a stranded wire or two solid wires to single pole terminal block be sure to use a ferrule Otherwise the wire may slip off the terminal block Ferrule for Terminal block To cramp the following ferrules use the specified crimping tool CRIMPFOX ZA 3 For 1 cable connection For 2 cable connection 6 0mm 8 0mm 7 0mm 8 0mm L mie For 1 cable connection For 2 cable connection Note The above ferrules crimping tool and screwdriver are made by Phoenix Contact and are available from Phoenix Contact FC5A MicroSmart PID Module User s Manu
123. e PV after the PV correction is within the control range the PID module controls the temperature based on the process variable PV after the PV correction When the process variable PV after the PV correction is out of the control range the under or over range error occurs and the control output is turned off The process variable PV after the PV correction can be calculated using the following formula Process variable PV after the PV correction Process variable PV PV correction value Example 1 When process variable PV is 198 C If the PV correction value is 2 0 C the process variable PV will be 200 0 C 198 C 2 0 C If the PV correction value is 2 0 C the Process variable PV will be 196 0 C 198 C 2 0 C 6 24 FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR Example 2 By setting the PV correction value for the PID module to 10 0 C the process variable PV of the PID module is adjusted from 190 C to 200 C PID Module 4 Variable PV 200 C WONEN Nee PV correction value 10 0 C 3 Control Register 63 PV Filter Time Constant The PV filter function is a software filter to stabilize the process variable PV affected by fluctuating processes such as the pressure or flow rate by calculating first order lag of the process variable PV Even if the process variable PV changes as shown in the Figure 1 when the PV filter time constant is c
124. e becomes faster Because the action to suppress the rapid temperature rise becomes strong the time for the process variable PV to reach the set point SP is extended however overshoot can be decreased An appropriate derivative time for the control target can be automatically calculated using auto tuning AT function It is unnecessary to configure the derivative time in the WindLDR when using the auto tuning AT function 9 Control Register 29 ARW Anti Reset Windup When the control is started there is a large deviation between the set point SP and the process variable PV The integral action continues its action in a given direction until the process variable PV reaches the set point SP As a result an overshoot is caused by the excessive integral action ARW suppresses the overshoot by limiting the integral action area When ARW is 0 the integral action area becomes the minimum and the suppression of the overshoot is maximized When ARW is 50 the integral action area becomes the intermediate and the suppression of the overshoot is intermediate When ARW is 10096 the integral action area becomes the maximum and the suppression of the overshoot is minimized An appropriate ARW for the control target can be automatically calculated using auto tuning AT function It is unnecessary to configure the ARW in the WindLDR when using the auto tuning AT function 10 Control Register 89 AT Bias Auto tuning AT starting point
125. e data registers RAM in the CPU module and the PID module All parameters stored in the PID module mounted on the slot selected in the Expansion Modules Configuration dialog box are read and all parameters in the dialog box are updated The PID module mounted on the slot selected in the Expansion Modules Configuration dialog box can be monitored 1 OK 2 Cancel 3 Write All Parameters 4 Upload All Parameters 5 Monitor FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 7 CONFIGURING PID MODULE USING WINDLDR PID Module Configuration Input Parameters List CHO and CH1 The input parameters for CHO and CH1 controls are described here PID Module Configuration Slot 1 zs 1 Module Type No FCSA F2M2 LANE 3 un eanes Gergen G ou CHO im a 2 Type K thermocouple Celsius Reverse Control Action Heating Voltage Output 4 e d i Ge EE S ii E oan SEN em Type K thermocouj mn Celsius Reverse Control Action Heating Voltage Output 5 Input t CHO Control CHO Output CHO Input CH1 Control CH1 Output CH1 Monitor Input Range Type K thermocouple Celsius 200 to 1370 c e rection 0 0 Z 100 9 to 100 0 c 7 PV Filter Time Constant 0 0 0 to 10 0 sec Set Point SP Upper Limit 200 to 1370 C 8 Set Point SP Lower Limit 200 El 200 to 1370 C ay 11 12 13
126. e input type is thermocouple or resistance thermometer Set point SP lower limit lt Set point SP lt Set point SP upper limit The valid range of set point SP when the input type is voltage or current Linear conversion minimum value lt Set point SP lt Linear conversion maximum value If the input type or input unit type is changed confirm the valid range of set point SP and configure an appropriate value 5 Control Register 94 Proportional Term Either proportional band or proportional gain can be selected to use The proportional band which is expressed in percentage form is the span of the input necessary for the output manipulated variable MV to change from 0 to 100 The proportional gain is the coefficient to calculate the output manipulated variable MV of the proportional action The proportional gain can be obtained as the quotient of 100 and the proportional band Example When the proportional band is 50 the corresponding proportional gain will be 2 100 50 6 Control Register 26 Proportional Band Proportional Gain The output of the proportional action varies in proportion to the deviation between the set point SP and the process variable PV When the heating cooling control is enabled this parameter becomes the heating proportional band The control action will be ON OFF control when the proportional band proportional gain is 0 If the proportional band is broadened proportional gain is made s
127. e loop break alarm span to 65 C which is about 1 25 times bigger than 50 C Program control is terminated earlier than the configured time 9 6 Program control is terminated earlier than the configured time Is PV start 1 or PVR start 1 selected as prograi control mode start type YES Select SP start 1 as program control mode start type Set each step time to a suitable Is each step time suitable value YES Call IDEC for assistance END 1 For program control mode start type see page 6 41 FC5A MicroSmart PID Module Users Manual FC9Y B1283 APPENDIX 9 APPENDIX This chapter describes the function references output actions and factory default settings of the PID module PID Module Function References PID control with auto tuning AT PI control PD control with auto reset P control with auto reset ON OFF control Proportional term Proportional band P When input range unit is Celsius 0 to 10000 C Range with a decimal point 0 0 to 1000 0 C When input range unit is Fahrenheit 0 to 10000 F Range with a decimal point 0 0 to 1000 0 F When input is voltage current 0 0 to 1000 0 Proportional gain 0 00 to 100 0096 Note The control action will be ON OFF control when proportional term is 0 Integral time l 0 to 10000 seconds Derivative time D 0 to 10000 seconds
128. e program control is suspended While the program control is held the fixed value control is performed with the set point SP at the hold point During the program control running when the advance next step bit is turned on Advance Next Step the current step is terminated and the program control is proceeded to the next step During the program control running when the advance previous step bit is turned on the progression of the program control is moved back If the elapsed time in the current step is less than 1 minute the program control Advance Previous goes back to the start of the previous step If the elapsed time in the current step is Step more than or equal to 1 minute the program control goes back to the start of the current step Even when the advance previous function is executed at Step 0 the program control does not move back to Step 9 regardless of the program end action When the program control is terminated the program control can be repeated from Repeat Function step 0 as many times as the number of repeats configured The action to be taken when the program control is terminated can be selected Terminate When the program control is terminated the program end program output bit is turned on and maintained and the PID module control will be in standby status The program control can be executed again by turning off to on the program control bit operation parameter bit3 During the progra
129. ear GE Set point SP lower limit to input range upper limit RW Maximum Value When input is voltage current Linear conversion minimum to input range upper limit 6 8 FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR Offset from the control register Parameter Description R W CHO CH1 Set Point SP Lower Limit When input is thermocouple resistance thermometer 7 60 137 Linear Conversion Input range lower limit to set point SP upper limit RW Minimum Value When input is voltage current l Input range lower limit to linear conversion maximum When input range unit is Celsius 100 0 to 100 0 C 8 62 139 PV Correction ee RA GR R W When input is voltage current 1000 to 1000 9 63 140 PV Filter Time Constant 0 0 to 10 0 sec R W 65 142 Alarm 1 Type 0 No alarm action 66 143 Alarm 2 Type 1 Upper limit alarm 67 144 Alarm 3 Type 2 Lower limit alarm 68 145 Alarm 4 Type 3 Upper Lower limits alarm 10 69 146 Alarm 5 Type 4 Upper Lower limit range alarm RW 70 147 Alarm 6 Type 5 Process high alarm 471 148 Alarm 7 Type 6 Process low alarm 472 149 Alarm 8 Type 7 Upper limit alarm with standby 8 Lower limit alarm with standby 9 Upper Lower limits alarm with standby 37 114 Alarm 1 Value 38
130. econds and the derivative time D1028 is changed to 45 seconds for CHO control In this example D1000 is allocated to the control register and M500 is allocated to control relay Those parameters can be changed with the following procedure 1 Turn on M500 Reading all parameters All PID module parameters are read out from the PID module and stored in the data registers 2 Store 150 in D1027 integral time of CHO and 45 in D1028 derivative time of CHO 3 Turn on M503 Block 2 writing The integral time 150 sec and derivative time 45 sec will be written to the PID module Ladder Program Example 2nd Scan MD100 At the falling edge of M100 M500 is turned off MOV I S1 Di REP 150 is stored in D1027 integral time of CHO 150 D1027 Mou S1 Di 45 is stored in D1028 derivative time of CHO 45 D1028 M503 Block 2 writing is turned on to write block 2 parameters stored in D1026 to D1052 to the PID module S 1st Scan mosoo At the rising edge of M100 M500 is turned on to read all parameters from the PID module M100 is turned off CR MO100 1 If the reading all parameters bit M500 is turned on all PID module parameters are read out from the PID module and stored in the data registers Block 2 parameters are stored in D1026 to D1052 2 Block 2 parameters stored in D1026 to D1052 are written to the PID module The parameters of the other blocks are not written FC5A MicroSmart PID Module
131. ed variable MV lower limit is 2096 the cooling control output will be 2096 even when the cooling output manipulated variable MV is 096 6 46 FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR PID Module Configuration Program Parameters Details PID Module Configuration Slot 1 B 21 5 Module Type No FCSA F2M2 Input CHO Control CH0 Program CHO Output CHO Input CH1 Output CH1 Monitor 1 2 IN Range Step 0 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 3 D Set Point SP 200 to 1370 C 0 0 0 0 0 0 0 0 0 0 4 _ Step Time 0 to 6000 min 0 0 0 0 0 0 0 0 0 0 IJ Wait Value 0 to 100 c 0 0 0 0 0 0 0 0 0 0 5 We Band 0 to 10000 C 10 10 10 10 10 10 10 10 10 10 6 Integral Time 0 to 10000 sec 200 200 200 200 200 200 200 200 200 200 7 ICM Derivative Time 0 to 10000 sec 50 50 50 50 50 50 50 50 50 50 8 fe ARW Anti Reset windup Oto 100 50 50 50 50 50 50 50 50 50 50 9 Output MY Rate of Change 9 to 100 sec 0 0 0 0 0 0 0 0 0 0 10 N Aam value 1570to 1570 C 0 0 0 0 0 0 0 0 0 0 Ta Alarm 2 Value 1570to 1570 C 0 0 0 o 0 0 0 0 0 0 1 1 oT Alarm 3 value 1570 to 1570 C 0 0 0 0 0 0 0 0 0 0 12 Alarm 4 Value 1570to 1570 C 0 0 0 0 0 0 0 0 0 0 13 Alarms value 1570to 1570 C 0 0 0 0 0 0 0 0 0 0 1 4 t Alarm 6 Value 1570 to 1570 C 0 0 0 0 0 0 0 0 0 0 1 5 L Alarm 7 V
132. ed when equipment containing the MicroSmart is destined for Europe Use an IEC 60127 approved fuse on the output circuit This is required when equipment containing the MicroSmart is destined for Europe FC5A MicroSmart PID Module User s Manual FC9Y B1283 i Use an EU approved circuit breaker This is required when equipment containing the MicroSmart is destined for Europe Make sure of safety before starting and stopping the MicroSmart or when operating the MicroSmart to force outputs on or off Incorrect operation on the MicroSmart may cause machine damage or accidents If relays or transistors in the MicroSmart output modules should fail outputs may remain on or off For output signals which may cause serious accidents provide a monitor circuit outside the MicroSmart Do not connect the ground wire directly to the MicroSmart Connect a protective ground to the cabinet containing the MicroSmart using an M4 or larger screw This is required when equipment containing the MicroSmart is destined for Europe Do not disassemble repair or modify the MicroSmart modules When disposing of the MicroSmart do so as an industrial waste ii FC5A MicroSmart PID Module User s Manual FC9Y B1283 ABouT Tute MANUAL Thank you for purchasing FC5A series MicroSmart PID Module This user s manual primarily describes system configuration specifications installation programming application examples and trouble shooting of the PID mod
133. el Bit Auto tuning AT Auto Reset Bit 1 1 Auto tuning AT Auto reset perform l 0 Auto mode Bit2 Auto Manual Mode Bit 1 Manual meade Bit3 Program Control Bit 0 Programcontrot stop 1 Program control run m 0 Program control run Bit4 Program Hold Bit 2 1 Program control hold 0 External SP input disable Bit5 External SP Input Enable Bit 1 External SP input enable Bit6 Advance Next Step Bit 3 a No action 1 Program control advance next step 3 d 0 No action PIDE Advance Previous Step Bit 4 1 Program control advance previous step Bit8 to Bit15 Reserved 0 Fixed value 0 Once auto reset is performed it cannot be cancelled during its performance The program control is suspended while the program hold bit is on During the program control the current step is terminated and the program control is proceeded to the start of the next step when the advance next step bit is turned off to on During the program control the progression of the program control is moved back when the advance previous step bit is turned off to on If the elapsed time in the current step is less than 1 minute the program control goes back to the start of the previous step If the elapsed time in the current step is more than or equal to 1 minute the program control goes back to the start of the current step Even when the advance previous step is executed at Step 0 the program control does not move back to Step 9 regardless of the program end ac
134. elay Time Alarm 4 Delay Time Alarm 5 Delay Time Alarm 6 Delay Time Alarm 7 Delay Time Alarm 8 Delay Time The alarm is not triggered until the configured time elapses after the process variable PV enters the alarm output range The input fluctuation due to noise may result in alarm output turning on This can be prevented by configuring the alarm delay time When an alarm output is changed from on to off status the alarm output turns off and the alarm action delay time is reset When the alarm output is changed from off to on status the time counting starts FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 29 CONFIGURING PID MODULE USING WINDLDR Input Parameters when External SP Input is Selected The input CH1 parameters when External SP input is selected as the Input CH1 Function are described here PID Module Configuration Slot 1 2 x Module Type No FCSA F2M2 Input Parameters CHO input CHO e a Output CHO H Ge Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Paramete x ca S External SP Input 2 Type K thermocouple Celsius 1 Input CHO Control CHO Output CH0 Input CH1 Monitor Input Range 4 to 20 mA lt 2000 to 10000 2 1 PV Correction ofe nng to 1000 PV Filter Time Constant 0 0 I 0 0to 10 0 sec Linear Conversion Maximum Value 1370 E 200 to 1370 sC ep Linear Conversion Minimu
135. en external input IO is turned on CHO control is enabled When QO loop break alarm output of CHO control is turned on CHO loogo SG Gaa control is disabled When loop break alarm is triggered D1010 2 loop break alarm D1010 02 QUDO0 output is turned on and QO is turned on 18 Control Register 36 Loop Break Alarm Span Configure the loop break alarm span to detect the loop break alarm The loop break alarm is disabled when the loop break alarm span is 0 19 Control Register 95 Cooling Method When the heating cooling control is enabled select the cooling method from air cooling oil cooling or water cooling The output characteristics for the cooling output manipulated variable MV are shown below Air cooling linear characteristic Oil cooling 1 5th power of the linear characteristic Water cooling 2nd power of the linear characteristic Manipulated Cooling proportional band Variable MV 10096 1 Air Cooling Oil Cooling Water Cooling 096 Process Variable PV Set Point SP Output Characteristics of Cooling Method FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 39 CONFIGURING PID MODULE USING WINDLDR 6 40 20 Control Register 48 Cooling Proportional Band The cooling proportional band can be configured when the heating cooling control is enabled The cooling proportional band is the multiplication of the heating proportional band Example When the heating proportio
136. enabled M1006 Block 5 writing is turned off 2nd Scan after the completion of CHO auto tuning AT At the falling edge of M1 the following are executed in order D1025 0 is turned on CH1 control is enabled D1025 1 is turned on AT for CH1 control is performed M1006 Block 5 writing is turned off 1st Scan after the completion of CHO auto tuning AT At the falling edge of D1009 1 CHO auto tuning monitor bit the following are executed in order D1025 0 is turned off CH1 control is disabled DO and D1 are moved to D1178 and D1179 respectively The original values are moved to the external SP input linear conversion max and min values M1006 Block 5 writing is turned on Values in D1178 and D1179 are written to the PID module M1 is turned off 2nd Scan At the falling edge of MO the following are executed in order M1000 reading all parameters is turned off D1178 external SP input linear conversion max value and D1179 external SP input linear conversion min value are moved to DO and D1 respectively D1023 is stored in D1020 CH1 set point SP is copied to CHO set point SP D1023 is stored in D1178 and D1179 CH1 set point SP is copied to the external SP input linear conversion max and min values M1006 Block 5 Writing is turned on Values in D1178 and D1179 are written to the PID module M1 is turned on 1st Scan At the rising edge of MO the following are executed in order D102
137. eriod 1 to 120 sec R W When input range unit is Celsius 100 0 to 100 0 C 431 108 Reset We E g is Fahrenheit RW When input is voltage or current input 1000 to 1000 32 109 Ge Variable Toto 100 sec RW When input range unit is Celsius 0 to 10000 C min Range with a decimal point 0 0 to 1000 0 C min e When input range unit is Fahrenheit 33 110 Set Point SP Rise Rate 0 to 10000 F min R W Range with a decimal point 0 0 to 1000 0 F min When input is voltage or current input 0 to 10000 min When input range unit is Celsius 0 to 10000 C min Range with a decimal point 0 0 to 1000 0 C min e When input range unit is Fahrenheit 34 111 Set Point SP Fall Rate 0 to 10000 F min R W Range with a decimal point 0 0 to 1000 0 F min When input is voltage or current input 0 to 10000 min 35 112 Loop Break Alarm LA Time 0 to 200 minutes R W When input range unit is Celsius 0 to 150 C Range with a decimal point 0 0 to 150 0 C 36 113 Loop Break Alarm LA Span Vie d BEER R W Range with a decimal point 0 0 to 150 0 F When input is voltage or current input 0 to 1500 37 114 Alarm 1 Value R W 38 115 Alarm 2 Value R W 39 116 Alarm 3 Value R W E Ga 2 eue See 5 18 for the valid range of alarm 1 to alarm 8 values S 42 119 Alarm 6 Value R W 43 120 Alarm 7 Value R W 44 121 Alarm 8 Value R W 45 122 Reserved R W FC5A MicroSmart PID Module User s Manual FC9Y B1283
138. ers CH1 Voltage Output 0 0 to 200 min 0 0to 150 c Air Cooling E 1 0 E 0 0 to 10 0 10 2 Cito 100 0 C 0 0 200 0 to 200 0 c Minute OK Cancel DEI Gro 200 min o Z 0to 150 c PY Start m t 200 to 1370 C Minute lt Terminate Program Control 0 to 10000 ok Cancel Offset from the control gt Parameter register aramee CHO CH1 Description R W 90 167 Control Mode 1 Program control mode selected for CHO control 0 Fixed value control mode When the cascade control is selected as Input CH1 Function only the fixed value control mode can be R W If program control is selected external SP input will not work 53 130 Control Action 0 Reverse control action Heating 1 Direct control action Cooling R W 3 54 Heating Cooling Control 0 Disable FC5A MicroSmart PID Module User s Manual FC9Y B1283 R W 6 13 CONFIGURING PID MODULE USING WINDLDR 6 14 1 Enable 20 23 Set Point SP When input is thermocouple resistance thermometer Set point SP lower limit to set point SP upper limit When input is voltage current Linear conversion min to linear conversion max R W 94 171 Proportional Term 0 Proportional band 1 Proportional gain R W 26 103 Proportional Band Proportional Gain Prop
139. ersion Maximum Value 13 200 to 1370 C a Linear Conversion Minimum Value E 200 to 1370 C a External SP Input Bias 0 Z 314to 314 c 8 9 1 0 5 Alarms n nut 6 Alarm Type Alarm Value Hysteresis 0 1 to 100 0 C Delay Time 0 to 10000 sec Alar Tio Alarm Action 10 Alarm Z No Alarm Action 10 7 Alarm 3 No Alarm Action 10 10 10 10 10 10 Alarm 4 No Alarm Action Alarm 5 No Alarm Action Alarm 6 No Alarm Action Alarm 7 No Alarm Action EI cr pes Eee Fos po uz Fez n G G I R Alarm 8 No Alarm Action Write all parameters Read all parameters Monitor OK Cancel Control Registers Offset from the control Parameter Description R W register 0 Disabled Note 1 4 to 20mA DC 2 0 to 20mA DC Input Range 3 1to 5V DC 1 Yom External SP input 4 0 to 1V DC dd 5 Cascade control Note Note Disabled and Cascade control cannot be selected in the input range 2 139 PV Correction 1000 to 1000 R W 3 140 PV Filter Time Constant 0 0 to 10 0 sec RW External SP Input Linear Ext SP Input li i ince input 4 4178 Gonverstoniaxim l xternal SP Input linear conversion min to input range pyw Value upper limit of CHO External SP Input Cingar Input range lower limit of CHO to external SP input linear 5 179 ee Minimum conversion maxi R W 6 177 External SP Input Bias 20 of the external SP input linear conversion span R W 142 Al
140. etails about the program control mode start type see page 6 41 In the following example the set point SP is 100 C the step time is 60 minutes and the process variable PV when program control starts is 25 C SP Start PV PVR Start Set Point SP Set Point SP 100 C 100 C 1 1 1 25 C 1 Time Time 45 minutes Starts program control Set point SP when program control starts PV Starting Point When program control is started the control starts from the PV starting point 25 C of the process variable Program End Action Program end action can be selected from 3 types Terminate program control Continue program control Repeat and Hold program control When the all steps from 0 to 9 are executed and completed the program control is finished When Terminate program control is selected the PID module will enter standby status after the program control is finished While in standby status no control is performed and the control output is in OFF status If Continue program control Repeat is selected the program control is repeated from step 0 as many times as the repeat number configured When Hold program control is selected the program control is held suspended after the program control is finished and the fixed value control is performed with the set point SP of Step 9 For details about the program end action see page 6 43 FC5A MicroSmart PID Module User s Manual FC9Y B1283
141. eters for CHO and CH1 are described here PID Module Configuration Slot 1 Module Type No FCSA F2M2 Input Parameters CHO Type K thermocouple Celsius Input Parameters CH1 Type K thermocouple Celsius Control CHO Output CHO N R e 1 8 Control Action Heating Cooling Control Enable Set Point SP Proportional Term Proportional Band AT Bias 20 Set Point SP Rise Rate Set Point SP Fall Rate gt res cro Input ent lt Reverse Control Action Heating 1 Proportional Band lt 10 Z 0to 10000 c Vn e Output MV Rate of Change 0 Output ON OFF Hysteresis 1 0 1 A Manual Mode Output MV 0 0 0 0 to 100 0 1 A Write all parameters Read all parameters Control Parameters CHO Reverse Control Action Heating Heating Cooling Control Input CH1 Output CH1 Monitor Fixed Value Control Mode lt l D Break Alarm LA Time DEI C200 to 1370 c 1 8 Break Alarm LA Span 19 Cooling Control Settings n SUN Method 7 integral Time 200 0to 10000 sec 20 Proportional Band 8 Derivative Time 50 Oto 10000 sec 21 Cooling Output ON OFF Hysteresis 9 ARW Anti Reset Windup 50 2 0 to 100 22 vvertap oeed Band Oto 50 c 100 0 to 100 0 c o o Ero Ero Er 0 to 10000 C min 0 to 10000 C min 0 to 100 sec 0 1 to 100 0 C Monitor Contr
142. f the output manipulated variable in one second can be configured PV Correction If the sensor cannot be installed to the location of the control target the temperature measured by the sensor may deviate from the actual temperature of the control target When a target is controlled with multiple PID modules the measured temperatures may not match due to the differences in sensor accuracy or dispersion of load capacities even though the set points SP of those PID modules are the same In such cases the process variable PV of the PID module can be adjusted to the desired temperature by using the PV Correction The process variable PV after PV correction is added should be within the control range The process variable PV after PV correction can be calculated using the following formula Process variable PV after PV correction Process variable PV PV correction value PV Correction Range When input is thermocouple or resistance thermometer 0 1 to 100 0 C F When input is voltage current 1 to 1000 The PV filter function is a software filter to stabilize the process variable PV lee Rds affected by fluctuating processes such as pressure or flow rate by calculating first order lag of the process variable PV Automatic The PID module measures the temperature at the input terminal and maintains the Cold Junction reference junction as if the reference junction was at 0 C or 32 F Temperature Compensation
143. fluctuates due to sudden disturbances the PID module responds to the fluctuation with speedy response in the shortest possible time and performs quick control to stabilize the temperature Temperature Set point SP on Time Figure 3 Stable but slow temperature rise control Temperature Set point SP Time Figure 4 The temperature rises rapidly however the control stabilizes after overshoot and undershoot Characteristics of the Control Target To perform optimal temperature control it is necessary to have a good knowledge of the thermal characteristics of the PID module sensors actuators as well as control targets For example the PID module controls a constant temperature oven and its temperature can rise up to 100 C Even if the set point SP of the PID modules is configured as 200 C the temperature of the constant temperature oven rise only up to 100 C due to its static characteristic The characteristic of the control target is determined by the combination of the following 4 factors 1 Thermal capacity This represents how the target is easily heated and has a relation with the volume size of the control target 2 Static characteristic This represents the capability of heating and is determined by the size of the heater capacity 3 Dynamic characteristic This represents the rising characteristic transitional response during initial heating This is a complicated process involving heater capacity furnace ca
144. form program wait While the program wait is functioning the program wait bit Bit5 of the operating status is turned on If the condition below is satisfied the wait function is cancelled the program control proceeds to the next step and the program wait bit Bit5 is turned off Set point SP Wait value lt Process variable PV x Set point SP Wait value If the advance next function Bit6 is turned from off to on or if the program control bit Bit3 is turned off the wait function is canceled Program End Output Program Termination When the program control is finished the program end output bit Bit6 of the operating status is turned on If the program control bit Bit3 of the operation parameter is turned off the program end output bit Bit6 is turned off To start program control again turn off to on the program control bit Bit3 of the operation parameter 4 10 FC5A MicroSmart PID Module User s Manual FC9Y B1283 PID MODULE MAIN FUNCTIONS Action when Program Control Starts The program control mode start type can be selected from 3 types PV start PVR start and SP start When SP start is selected the program control starts from the set point SP configured with Set point SP when program control starts When PV start or PVR start is selected and the program control starts the step time is advanced until the set point SP matches to the process variable PV and then the program control starts For d
145. ge with a decimal point 0 0 to 1000 0 F When input is voltage or current 0 0 to 1000 0 Proportional gain 0 00 to 100 00 0 to 10000 sec R W R W 6 185 395 Derivative Time 0 to 10000 sec FC5A MicroSmart PID Module User s Manual FC9Y B1283 R W 6 19 CONFIGURING PID MODULE USING WINDLDR Offset from the control register Parameter Description R W CHO CH1 7 4186 396 ARW Anti Reset Windup 0 to 10096 R W 8 187 397 EE 0 to 100 sec RW 9 188 398 Alarm 1 Value 10 189 399 Alarm 2 Value 11 190 400 Alarm 3 Value 12 191 401 Alarm 4 Value Refer to the valid range for alarm 1 to alarm 8 values R W 13 192 402 Alarm 5 Value shown in the following table 14 193 403 Alarm 6 Value 15 194 404 Alarm 7 Value 16 195 405 Alarm 8 Value When output type is voltage Output Manipulated Output manipulated variable lower limit to 100 LIS JEETS GEES Variable tipper Limit Wain hue is current SES Output manipulated variable lower limit to 105 When output type is voltage Output Manipulated 0 to output manipulated variable upper limit UBL 198 sate Variable Lower Limit When SECH type is Gre SE PUN 5 to output manipulated variable upper limit E 0 0 to 10 0 times 19 199 a Proportional Cooling proportional band is the multiplication of R W heating propo
146. hange o to 100 sec Output ON OFF Hysteresis 1 0 0 1 to 100 0 c Manual Mode Output MV 0 0 Z 0 0 to 100 0 Write all parameters Read all parameters Monitor OK Cancel Item Setting 1 Heating Cooling Control Enable 2 Set Point SP 200 0 C 3 AT Bias 20 0 C 5 Saving Parameters Click OK button to save the configured parameters 6 Ladder Programming Create a ladder program for heating cooling control of the PID module Ladder Program Example While external input IO is on CHO control is enabled 10000 10001 L SOTU Qono D1022 00 When QO CHO control upper lower limits alarm output is on CHO control is disabled When external input I1 is turned on D1022 1 auto tuning D1022 01 AT perform bit is turned on When the process variable PV reaches 180 0 C auto tuning AT is performed When the process variable PV is out of the range D1010 07 Notes C2 Q 0000 between 194 5 C and 205 5 C D1010 7 Alarm 1 output is turned on which turns QO on The temperature at which Auto tuning AT is performed is determined by the set point SP and AT bias In the above example auto tuning AT will be performed when the process variable PV reaches 180 0 C When upper lower limits alarm with standby is selected as the alarm type the alarm is not activated until the process variable PV enters the alarm output OFF range 194 5 C to 2
147. he PID module and stored in the data registers Block 4 parameters are stored in D1053 to D1102 2 For a value with a decimal point store the value multiplied by 10 in the data register 3 Block 4 parameters stored in D1053 to D1102 are written to the PID module The parameters of the other blocks are not written Note If parameters of block 4 or 5 are changed while CHO or CH1 control is enabled in the PID module an unexpected operation of the PID module may be caused It is recommended that the control channel of the PID module be disabled before changing the parameters of block 4 or 5 5 6 FC5A MicroSmart PID Module User s Manual FC9Y B1283 DEVICE ALLOCATION OF PID MODULE Data Register Allocation Block 0 Read Only Parameters The CPU module reads the following parameters from the PID module and store them in the data registers every scan Offset from the Control Parameter Description R W Register 0000h Initialization 0 Common PID Module Operating Status 0001h Normal operation R 0002h External power supply error When input is normal 1 Current Process Variable PV Value within the control range see 9 4 R When input is invalid Unknown value 42 Current Heating Output Output manipulated variable lower limit to upper R Manipulated Variable MV limit 43 Current Cooling Output Cooling output manipu
148. he linear conversion maximum value is 1000 C the linear conversion minimum value is 0 C and the external SP input bias is 50 C the set point SP of CHO control corresponding to 12mA of external SP input will be 550 C When the input type is voltage 0 to 1V DC the linear conversion maximum value is 1000 C the linear conversion minimum value is 0 C and the external SP input bias is 50 C the set point SP of CHO control corresponding to 0 5V of external SP input will be 550 C FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 31 CONFIGURING PID MODULE USING WINDLDR 7 Control Register 65 Conirol Register 66 Control Register 67 Conirol Register 68 Conirol Register 69 Control Register 70 Control Register 71 Control Register 72 Alarm 1 Type Alarm 2 Type Alarm 3 Type Alarm 4 Type Alarm 5 Type Alarm 6 Type Alarm 7 Type Alarm 8 Type Select one of the alarm types from process high alarm process low alarm and no alarm action The same alarm type can be selected in multiple alarms Alarm Actions Process High Alarm Process Low Alarm Alarm Hysteresis ON OFF Alarm Value Setting Example Alarm 1 Value 205 Alarm 1 Hysteresis 2 0 Alarm Action 205 amp Process Variable PV Alarm Output ON Process Variable PV S 203 Alarm Output OFF 8 Control Register 37 Control Register 38 Control Register 39 Control Register 40 Control Register 41 Control Register 42 Control Reg
149. hough the actuator operates normally sene 8 6 Program control is terminated earlier than the configured time sss sees sees eee eee cee eee ae eee aeeeeeeeeee 8 6 CHAPTER 9 APPENDIX dem T 9 1 PID Module Function References tete evt ita eerte ro el kp v t ER ex REY cane HERE FEDERER uu 9 1 Output ACORN us ee Anns rine ill ete tid ie ette rfe tete Dive edenda dabo e Ahead E 9 5 Factory Default Settings of the PID Module 9 9 viii FC5A MicroSmart PID Module User s Manual FC9Y B1283 GENERAL INFORMATION 1 GENERAL INFORMATION This chapter describes general information and specifications of the FC5A series PID modules Make effective use of the PID modules after reading and understanding thoroughly functions and characteristics About the PID Modules The PID module performs control actions to eliminate the deviation between the set point SP and process variable PV The PID module which is an expansion module is required to connect to the FC5A series CPU for use Depending on the difference of output specifications the PID modules are categorized into two types and can be used by connecting to a FC5A slim type CPU or 24 I O all in one type CPU except 12V DC CPU The input channel can accept voltage current thermocouple or resistance thermometer signals The output channel generates relay output non contact voltage for SSR drive or current signals To configure the PID modules
150. ing R W 10 Block 12 CHO Step 2 writing R W 11 Block 13 CHO Step 3 writing R W 12 Block 14 CHO Step 4 writing R W 13 Block 15 CHO Step 5 writing R W 14 Block 16 CHO Step 6 writing R W 15 Block 17 CHO Step 7 writing R W 16 Block 18 CHO Step 8 writing R W 17 Block 19 CHO Step 9 writing R W 18 Block 30 CH1 Step 0 writing R W 19 Block 31 CH1 Step 1 writing R W 20 Block 32 CH1 Step 2 writing R W 21 Block 33 CH1 Step 3 writing R W 22 Block 34 CH1 Step 4 writing R W 23 Block 35 CH1 Step 5 writing R W 24 Block 36 CH1 Step 6 writing R W 25 Block 37 CH1 Step 7 writing R W 26 Block 38 CH1 Step 8 writing R W FC5A MicroSmart PID Module User s Manual FC9Y B1283 DEVICE ALLOCATION OF PID MODULE 27 Block 39 CH1 Step 9 writing R W 28 Reserved R W 29 Reserved R W 30 Reserved R W 31 Reserved R W For details about blocks see page 5 7 to 5 24 Notes about the control relays The control relay 0 Reading all parameters When this bit is turned off to on all parameters stored in the ROM of the PID module are read out and stored in the data registers in the CPU module The control relay 1 Loading initial values When the user program is downloaded to the CPU module the initial values of all parameters for the PID module are also downloaded and stored in the ROM of the CPU module When this bit is turned off to on the initial values stored in the ROM
151. ion It is unnecessary to configure the integral time in the WindLDR when using the auto tuning AT function 6 Control Register 185 Derivative Time When the set point SP is changed or when the deviation between the set point SP and the process variable PV is increased due to a disturbance the derivative action increases the output manipulated variable MV to rapidly correct the deviation between the process variable PV and the set point SP The derivative time is a coefficient to determine the output manipulated variable MV of the derivative action The derivative action is disabled when the derivative time is 0 If the derivative time is shortened the derivative action becomes weak The response to the rapid temperature change becomes slower Because the action to suppress the rapid temperature rise becomes weaker the time for the process variable PV to reach the set point SP is shortened however overshoot can occur If the derivative time is extended the derivative action becomes strong The response to the rapid temperature change becomes faster Because the action to suppress the rapid temperature rise becomes strong the time for the process variable PV to reach the set point SP is extended however overshoot can be decreased An appropriate derivative time for the control target can be automatically calculated using auto tuning AT function It is unnecessary to configure the derivative time in the WindLDR when using
152. ircuit Dielectric Strength Output terminal External power 1500kV AC 5mA for 1 minute Output terminal Internal power 1500kV AC 5mA for 1 minute Input power Output power 1500kV AC 5mA for 1 minute FG External power 548V AC 5mA for 1 minute Input terminal External power 548V AC 5mA for 1 minute Input terminal Internal power 548V AC 5mA for 1 minute Output terminal External power 2500V AC 5mA for 1 minute Output terminal Internal power 2500V AC 5mA for 1 minute External power Internal power 548V AC 5mA for 1 minute Input terminal Output terminal 548V AC 5mA for 1 minute FG External power 548V AC 5mA for 1 minute UO terminal External power 548V AC 5mA for 1 minute UO terminal Internal power 548V AC 5mA for 1 minute External power Internal power 548V AC 5mA for 1 minute Input terminal Output terminal 548V AC 5mA for 1 minute Other Type No FC5A F2MR2 FC5A F2M2 Power Consumption Approx 3 5W maximum Module Power BV DC 65mA Consumption Interior 24V DG Om Ambient Temperature 0 to 55 C No icing Ambient Humidity 10 to 95 RH Non condensing Weight Approx 140g Environmenial Specifications Conforms to RoHS directive Recommended Cable Twisted pair cable FC5A MicroSmart PID Module User s Manual FC9Y B1283 2 5 MODULE SPECIFICATIONS
153. ired to perform auto reset when the process variable PV is stabilized within the proportional band When the auto reset is completed the CPU module automatically reads all parameters including the calculated reset value from the PID module and stores those parameters in the data registers It is unnecessary to perform the auto reset again as long as the process is unchanged When the proportional band P is set to 0 or 0 0 the reset value is cleared Temperature T T e be E E E S Offset Span Auto reset is Performed Offset is Corrected Auto tuning AT Auto reset Perform Cancel The Auto tuning AT Auto reset function can be performed or cancelled by turning on off the operation parameter bits allocated to each channel For the operation parameter bits see page 5 10 Perform Auto tuning AT To perform auto tuning AT turn on the control enable disable bit BO and auto tuning AT auto reset bit Bit1 of the operation parameter P D and ARW values will automatically be configured When auto tuning AT is performed during the program control P D and ARW values of the current step are configured While auto tuning AT is performed the Auto tuning AT Auto reset LED ATO AT1 flashes When auto tuning AT is completed the operation parameter Bit1 is automatically turned off and the CPU module reads all parameters of the AT performed channel from the PID module and store those parameters in the data registers
154. is 2 0 C Alarm Action Alarm Action 205 C lt Process Variable PV Alarm Output ON Process Variable PV amp 195 C Alarm Output ON Process Variable PV 203 C Alarm Output OFF 197 C Process Variable PV Alarm Output OFF 2 0 C 2 0 C 203 C 205 C 195 C 197 C Upper Limit Alarm with Standby Lower Limit Alarm with Standby Alarm Hysteresis Alarm Hysteresis OFF T 7N A a Alarm Value SP Alarm Value Alarm Value SP Alarm Value Setting Example Setting Example Set Point SP 200 C Set Point SP 200 C Alarm 1 Value 25 C Alarm 1 Value 5 C Alarm 1 Hysteresis 2 0 C Alarm 1 Hysteresis 2 0 C Alarm Action Alarm Action 205 C lt Process Variable PV Alarm Output ON Process Variable PV S 195 C Alarm Output ON Process Variable PV 203 C Alarm Output OFF 197 C S Process Variable PV Alarm Output OFF 5 C A OFF Ze 200 C 203 C 205 C 195 C 197 C 200 C Standby functions Note When the set point SP is changed the standby function is enabled Once the process variable PV enters the alarm output off range the standby function is canceled FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 27 CONFIGURING PID MODULE USING WINDLDR Upper Lower Limits Alarm with Standby Alarm Hysteresis LN Alarm Value SP Alarm Value Setting Example Set Point SP 200 C Alarm 1 Value 59C Alarm 1 Hysteresis 2 09C Alarm Action 205 C l
155. is broadened If the proportional band is narrowed proportional gain is made larger the control output starts turning on or off at around the set point SP the time until the process variable PV reaches the set point SP is shortened and the offset is small however the hunting phenomenon is frequent If the proportional band is greatly narrowed the control action becomes similar to the ON OFF control action An appropriate proportional band proportional gain for the control target can be automatically calculated using auto tuning AT function It is unnecessary to configure the proportional band proportional gain in the WindLDR when using the auto tuning AT function 5 Control Register 184 Integral Time In the proportional control action the offset is generated even when the control is stabilized The integral action corrects the offset The integral action is disabled when the integral time is 0 The integral time is a coefficient to determine the output manipulated variable MV of the integral action If the integral time is shortened too much the integral action becomes strong The offset can be corrected in a shorter time however the hunting phenomenon may be caused over a long cycle On the contrary if the integral time is extended too much the integral action becomes weak and it takes time to correct the offset An appropriate integral time for the control target can be automatically calculated using auto tuning AT funct
156. ister 43 Control Register 44 2 0 Alarm 1 Value Alarm 2 Value Alarm 3 Value Alarm 4 Value Alarm 5 Value Alarm 6 Value Alarm 7 Value Alarm 8 Value Alarm Hysteresis ON OFF Alarm Value Setting Example Alarm 1 Value 2195 Alarm 1 Hysteresis 2 0 Alarm Action Process Variable PV 195 Alarm Output ON 197 lt Process Variable PV Alarm Output OFF 2 0 Alarm Value Alarm Action Alarm Type Process Process high alarm Alarm Process low alarm The alarm output turns on if the process variable PV exceeds the alarm value The alarm action point is the alarm value FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR 9 Control Register 73 Control Register 74 Control Register 75 Control Register 76 Control Register 77 Control Register 78 Control Register 79 Conirol Register 80 Alarm 1 Hysteresis Alarm 2 Hysteresis Alarm 3 Hysteresis Alarm 4 Hysteresis Alarm 5 Hysteresis Alarm 6 Hysteresis Alarm 7 Hysteresis Alarm 8 Hysteresis When an alarm turns from on to off and vice versa the span between on and off is called alarm hysteresis If the alarm hysteresis is narrowed the alarm output switches to on or off even by a slight variation of temperature at around the alarm action point This frequent on off of an alarm may negatively affect the connected equipment To prevent that harmful effect configure the alarm hysteresis for
157. ith P action the response to rapid temperature change due to disturbance is faster the temperature control can be stabilized in a shorter time and transitional response characteristic can be improved in PD control action PD control action is suitable for the processes in which the temperature rapidly changes If the integral time of the PID module parameter is set to 0 the control action becomes the PD control action Temperature Proportional Band Set Point SP dac cC QS Disturbance Time If the derivative time is shortened the derivative action becomes weak The response to the rapid temperature change becomes slower Because the action to suppress the rapid temperature rises becomes weaker the time for the process variable PV to reach the set point SP is shortened however overshoot can occur If the derivative time is extended the derivative action becomes strong The response to the rapid temperature change becomes faster Because the action to suppress the rapid temperature rises becomes strong the time for the process variable PV to reach the set point SP is extended however overshoot can be decreased The offset caused by the PD control action can be corrected by configuring the reset value The reset value can be automatically calculated by the auto reset function PID Control Action Proportional Integral Derivative Action P action suppresses the overshoot and the hunting action
158. l 1 Confirm that 2000 is stored in D1020 of CPU module 2 Turn on the external input IO to enable CHO control 3 Turn on the load circuit power The PID module starts the heating cooling control action to keep the temperature of the control target at the set point SP Turn on I1 to perform the auto tuning AT for CHO control whenever necessary see pages 4 6 to 4 8 FC5A MicroSmart PID Module User s Manual FC9Y B1283 7 19 APPLICATION EXAMPLES 7 20 FC5A MicroSmart PID Module User s Manual FC9Y B1283 TROUBLESHOOTING 8 TROUBLESHOOTING This chapter describes the countermeasures when any errors or problems occur while operating the PID module If any problem occurs take actions described in the flowchart corresponding to the problem The PID Module Power LED PWR is OFF or Flashing The Power LED PWR does not go on is flashing Is the power supplied Supply the external power s the Power LED PWR on Is the power voltage correct Supply the rated voltage 24V DC s the Power LED PWR on Is the PID module NO connected to the FC5A CPU module securely Connect the PID module to the FC5A CPU module securely s the Power LED PWR on Call IDEC for assistance END FC5A MicroSmart PID Module User s Manual FC9Y B1283 8 1 TROUBLESHOOTING The PID Module output does not operate normally Out
159. lated variable lower limit R Manipulated Variable MV to upper limit When input is thermocouple or resistance thermometer Set point SP lower limit to set point SP 4 CHO Current Set Point SP upper limit R When input is voltage or current input Linear conversion min to linear conversion max 5 Current Step Remaining Time 0 to 6000 minutes seconds R 6 Current Step Number 0to9 R 7 Remaining Repeat Number 0 to 10000 R 8 Reserved 0 Fixed value R 49 Operation Parameter Monitor See 5 8 for detail about the operation parameter R monitor 10 Operating Status See 5 9 for detail about the operating status R When input is normal 11 Current Process Variable PV Value within the control range see 9 4 R When input is invalid Unknown value Current Output Manipulated Output manipulated variable lower limit to 412 E R Variable MV upper limit When input is thermocouple or resistance ther mometer Set point SP lower limit to set point SP 13 Current Set Point SP upper limit R CH1 When input is voltage or current input Linear conversion min to linear conversion max 14 Current Step Remaining Time 0 to 6000 minutes seconds R 15 Current Step Number 0to 9 R 16 Remaining Repeat Number 0 to 10000 R 17 Reserved 0 Fixed value R 18 Operation Parameter Monitor Sere Ol Jerall aaa OBSIRITSR H parameter monitor 19 Operating Status See 5 9 for detail about the operating status R FC5A MicroSmart PID Module User s Ma
160. le FC5A MicroSmart PID Module User s Manual FC9Y B1283 4 15 PID MODULE MAIN FUNCTIONS How to perform auto tuning AT in cascade control Auto tuning AT can be performed for the cascade control with the following procedure Auto tuning AT for the slave CHO 1 Turn off the CHO and CH1 control enable bits of the operation parameter to disable the CHO and CH1 controls 2 Copy the set point SP of the master CH1 to the set point SP of the slave CHO the external SP input linear conversion maximum value and the external SP input linear conversion minimum value in order to fix the set point SP of the slave CHO 3 Turn on the CHO and CH1 control enable bits of the operation parameter to enable the CHO and CH1 controls Turn on the CHO auto tuning AT auto reset bit of the operation parameter to start the auto tuning AT for the slave CHO When auto tuning AT is completed P D and ARW values of the slave CHO will be automatically configured Auto tuning AT for the master CH1 4 Turn off the CH1 control enable bit of the operation parameter to disable the CH1 control 5 Store the original values in the external SP input linear conversion maximum and minimum values 6 Turn on the CH1 control enable bit and CH1 auto tuning AT auto reset bit of the operation parame ter to enable the CH1 control and start the auto tuning AT for the master CH1 When auto tuning AT is completed P I D and ARW
161. lot 4 FCSA F2M2 FC5A C24R2X Other modules Other modules Other modules D1000 to D1189 M1000 to M1007 FCSA F2M2 D1000 to D1189 M1000 to M1007 21 5 Copy Parameters To OK Cancel Item Setting 1 Quantity of Modules 1 2 Slot No Slot 1 3 Module Type No FC5A F2M2 4 Data Register D1000 5 Internal Relay M1000 FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPLICATION EXAMPLES 2 I O Function Selection Select I O function for each channel in the PID Module Configuration dialog box PID Module Configuration Dialog Box I O Function Selection PID Module Configuration Slot 1 2x 1 Module Type No FCSA F2M2 3 Input Parameters Control Parameters EN SH CHO mwc x CHO gt output cHo Ga Type K thermocouple Celsius 2 repartee t CHI CH1 B Type K thermocouple Celsius Reverse Control Action Heating Voltage Output out Parameters CH Control Parameters cH Ra H cht Reverse Control Action Heating Voltage Output Output CH1 Monitor 1 Celsius C200to 1370 c Input CHO Control CHO Output CHO Input CH1 Control CH1 Input Range Type K thermocouple PV Correction 0 0 2 100 0 to 1000 C PV Filter Time Constant 0 0 to 10 0 sec Set Point SP Upper Limit 200 to 1370 c Set Point SP Lower Limit 200 ij 200
162. lot number to configure the PID module Number Select the type number of the PID module to configure Module Settings Module Type No Module Other modules 3 Type Data Register FCSA F2MR2 s MINE ICL 13a RR MM SHINKO TECHNOS ICL 13A AA MM SHINKO TECHNOS ICL 13A RR MM W SHINKO TECHNOS ICL 13A AA MM W SHINKO TECHNOS Data Designate the control register for the PID module Data register can be designated A 4 Reoi maximum of 590 data registers minimum 190 data registers are occupied including the first egister data register designated gister designated Designate the control relay for the PID module Internal relay can be designated A maximum nternal i G DIE ege 5 Relay of 32 internal relays minimum 8 internal relays are occupied including the first internal relay designated Buttons Button Description 6 Configure Parameters The PID Module Configuration dialog box is opened 7 Copy Parameters To The PID module parameters of the current slot can be copied to another slot 8 OK All parameters are saved and the dialog is closed 9 Cancel All changes made are discarded and the dialog is closed 6 6 FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR PID Module Configuration Dialog Box The buttons in the PID module configuration dialog box are described PID Module Configuration Slot 1 EZ Fcsa r2mz Module Type No Input Parameters cuo
163. m Type Valid Range Upper Limit Alarm Full scale to full scale 1 Lower Limit Alarm Full scale to full scale 1 Upper Lower Limits Alarm 0 to full scale 1 Upper Lower Limit Range Alarm 0 to full scale 1 Process High Alarm Input range lower limit to input range upper limit 2 Process Low Alarm Input range lower limit to input range upper limit 2 Upper Limit Alarm with Standby Full scale to full scale 1 Lower Limit Alarm with Standby Full scale to full scale 1 Upper Lower Limits Alarm with Standby 0 to full scale 1 1 When input is voltage current full scale is the linear conversion span 2 When input is voltage current the valid range is the linear conversion minimum value to linear conversion maximum value FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR Input Parameters List when External SP Input is Selected PID Module Configuration Slot 1 E 21 5 Module Type No FCSA F2M2 M Input Gamer input cho Conte Gegen Output CHO j Ger Gemeen Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Type K thermocouple Celsius 1 Input CHO Control CHO Output CHO Input CH1 Monitor Input Range 4 to 20 m 2000 to 10000 2 PV Correction 0 1000 to 1000 D PV Filter Time Constant 0 0 to 10 0 sec Linear Conv
164. m Value EE EJ 200 to 1370 c 4 Alarm Type Alarm Valffe steresis 0 1 0 100 0 C Delay Time 0 to 10000 sec External SP Input Bias ofe Lara 314 c 8 9 1 0 5 Alarms A di prod Hy ma No Alarm Action 7 Alarm 3 No Alarm Action Alarm 4 No Alarm Action Alarm S No Alarm Action Alarm 6 No Alarm Action e FS B ess Bese ne s eaaeo ea o Alarm 7 No Alarm Action Alarm 9 No Alarm Action Write all parameters Read all parameters Monitor ok Cancel 1 Control Register 55 Input Range Select input type for the external SP input Current 4 to 20mA DC or 0 to 20mA DC or voltage 0 to 1V DC or 1 to 5V DC can be selected 2 Control Register 62 PV Correction If the sensor cannot be installed to the location of the control target the temperature measured by the sensor may deviate from the actual temperature of the control target When a target is controlled with multiple PID modules the measured temperatures may not match due to the differences in sensor accuracy or dispersion of load capacities even though the set points SP of those PID modules are the same In such cases the process variable PV of the PID module can be adjusted to the desired temperature by using the PV Correction The process variable PV after PV correction can be calculated using the following formula Process variable PV after PV correction Process variable PV PV correction value 3 Control Register 63 PV
165. m action point is Mhea arm e BU gna s Alarm Process low alarm the alarm value process Vallapie thoy exceeds the alarm value When the alarm value is 0 the alarm action is disabled except process high alarm and process low alarm If the input type or input unit type is changed confirm the valid range of the alarm value and configure appropriate values 6 28 FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR 8 Control Register 73 Control Register 74 Control Register 75 Control Register 76 Control Register 77 Control Register 78 Control Register 79 Conirol Register 80 Alarm 1 Hysteresis Alarm 2 Hysteresis Alarm 3 Hysteresis Alarm 4 Hysteresis Alarm 5 Hysteresis Alarm 6 Hysteresis Alarm 7 Hysteresis Alarm 8 Hysteresis When an alarm turns from on to off and vice versa the span between on and off is called alarm hysteresis If the alarm hysteresis is narrowed the alarm output switches to on or off even by a slight variation of temperature at around the alarm action point This frequent on off of an alarm may negatively affect the connected equipment To prevent that harmful effect configure the alarm hysteresis for alarm on off action 9 Control Register 81 Alarm 1 Delay Time Control Register 82 Conirol Register 83 Control Register 84 Conirol Register 85 Conirol Register 86 Control Register 87 Conirol Register 88 Alarm 2 Delay Time Alarm 3 D
166. m control standby waiting for program control run status the control output is turned off and the operating status is not updated except the over range the under range and the program end output Continue When the program control is terminated the program program control is repeated from step 0 as many times as the control configured number of repeats When the step 9 of the last Repeat program control cycle is performed and finished the Program End Action program end output bit is turned on and maintained Hold When the program control is terminated the program control program is held at the last status of step 9 The program end output control and program hold bit are turned on and maintained While the program control is held the fixed value control is performed with the set point SP of step 9 If advance next function operation parameter Bit6 is turned off to on is executed while the program control is held the program control is started again from step 0 The program end output and program hold bit are turned off While the program control is being held the parameters of Blocks 10 to 19 and 30 to 39 can be changed The program control can be executed again after changing the program parameters such as the set point SP or step time of each step FC5A MicroSmart PID Module User s Manual FC9Y B1283 9 3 APPENDIX 9 4 Output Manipulated Variable MV Rate of Change The maximum change o
167. maining time is handled with the unit of minute If the remaining time is between 29 minutes 1 second and 30 minutes 0 second the remaining time will be 30 minutes FC5A MicroSmart PID Module User s Manual FC9Y B1283 5 15 DEVICE ALLOCATION OF PID MODULE Example 6 Hold Program Control when Program Ends The following diagram shows an example of the program control when hold program control is selected as the program end action Time of steps Step 0 and 1 60 minutes Step 2 30 minutes Steps 3 to 9 0 minute In this example D1000 is allocated to the control register and M500 is allocated to control relay Current step number D1006 Control enable bit D1022 0 Program control bit D1022 3 Program control bit Monitor D1009 3 Program hold bit D1022 4 l E 1 Advance next step bit ON l D1022 6 I I OFF i I I Advance previous step bit ON i D1022 7 l l I Program end output en D1010 6 m L l The program control is held at the ten minutes of remaining time and the fixed value control is performed with the current parameters The program control is proceeded to the start of step 3 and the fixed value control is performed with the parameters of step 3 After all steps are executed the program control is held and the fixed value control The fixed value control is performed is performed with the parameters of step 9 with the parameters of ste
168. maller the control output starts turning on or off at the significantly low temperatures from the set point SP overshoot or hunting is reduced however it takes time for the process variable PV to reach the set point SP and the offset between the process variable PV and the set point SP is broadened If the proportional band is narrowed proportional gain is made larger the control output starts turning on or off at around the set point SP the time until the process variable PV reaches the set point SP is shortened and the offset is small however the hunting phenomenon is frequent If the proportional band is greatly narrowed the control action becomes similar to the ON OFF control action An appropriate proportional band proportional gain for the control target can be automatically calculated using auto tuning AT function It is unnecessary to configure the proportional band proportional gain in the WindLDR when using the auto tuning AT function 7 Control Register 27 Integral Time In the proportional control action the offset is generated even when the control is stabilized The integral action corrects the offset The integral action is disabled when the integral time is 0 The integral time is a coefficient to determine the output manipulated variable MV of the integral action If the integral time is shortened too much the integral action becomes strong The offset can be corrected in a shorter time however
169. mes functions specifications and dimensions of the PID modules PID Module Parts Description 12 Expansion Connector 1 Module Label 2 Power LED PWR 3 Control Output LED OUTO OUT1 4 Event Output LED EVTO EVT1 5 Auto tuning AT Auto reset LED ATO AT1 6 Manual Mode LED MTO MT1 7 Fixed Value Control Mode Program Control Mode LED F PO F P1 8 Program Control RUN HOLD LED R HO R H1 9 External SP Enable Disable LED R L 10 Terminal No 11 Cable Terminal LED Details 2 PWR 3 OUTO 4 EVTO 5 ATO 6 MTO 7 F PO 8 R HO 9 R L 3 OUT1 4 EVT1 5 AT1 6 MT1 7 F P1 8 R H1 LE Co E L1 Lj L3 LE E L3 el CJ C L3 L1 LI C E 1 Module Label Indicates the PID module type No and specifications 2 Power LED PWR ON Power is normally supplied Flashes External power supply 24V DC error OFF Power is not supplied FC5A MicroSmart PID Module User s Manual FC9Y B1283 2 1 MODULE SPECIFICATIONS 2 2 3 Control Output LED OUTO OUT1 ON Control output is turned on OFF Control output is turned off Flashes When current output is used the LED flashes in a cycle of 125 ms according to the duty ratio of the output manipulated variable MV When output manipulated variable MV is 2096 the LED turns on for 25 ms and off for 100 ms continuously 4 Eve
170. module connected to the CPU module Z Write PID module parameters after download PE Transfer Mode Binary ASCII Download Options Z Automatic start after download Keep output during download E Suspend I O force before download E Automatic device clear after download E Write device data file to the PLC after download Setting E Download comment data Setting ER Program Information Program Size 1142 bytes Comment Size 0 bytes Total 1142 bytes Communication Settings Cancel When program download is successfully completed the following message will appear Click OK button to close the message Program Download J 21x Program Dovinload Succeeded 10 Starting Control 1 Confirm that 200 is stored in D1020 and 210 in D1023 of the CPU module 2 Turn on the external input I0 to enable CHO and CH1 controls 3 Turn on the load circuit power The PID module starts the control action to keep the temperature of the control target at the set point SP Turn on I1 to perform the auto tuning AT for CHO control whenever necessary see pages 4 6 to 4 8 FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPLICATION EXAMPLES Application Example 2 This application example demonstrates the program control for a system using two electric furnaces for ceramic industries The PID module controls electric furnace 1 with CHO control and electric furn
171. module and the connected PID modules When Write PID Module parameters after download is not checked After the user program is downloaded to the CPU module the PID module parameters are not written to the PID module Transfer Mode Binary D ASCII Download Options Z Automatic start after download E Keep output during download E Suspend 1 0 force before download Automatic device clear after download E Write device data file to the PLC after download E Download comment data Program Information Program Size 1142 bytes Comment Size 0 bytes Total 1142 bytes Communication Settings Cancel When Write PID Module parameters after download is checked after the user program is downloaded to the CPU module the PID module parameters configured in the PID Module Configuration dialog box will be written to the data registers in the CPU module and all PID modules configured in the Expansion Modules Configuration dialog box However if a PID module is not connected to the configured slot writing parameters to the PID module will fail Even after writing parameters to one PID module failed WindLDR continues to write the parameters to all PID modules configured in the Expansion Modules Configuration dialog box If writing parameters fails connect the PID module to the CPU module and write parameters to the PID module again
172. n the PID Module Configuration dialog box 3 Click on Read All Parameters button to read all parameters from the PID module 4 Configure the set point SP and the manual mode output manipulated variable in the PID Module Configuration dialog box 1 5 Click on Write All Parameters button When the control of the PID module is enabled the PID module will start operating with the downloaded parameters Procedure 2 Using the user program 1 Turn off to on the reading all parameters relay control relay 0 2 Configure the set point SP and the manual mode output manipulated variable if necessary 1 When the control of the PID module is enabled the PID module will start operating with the configured parameters 1 Because the block 1 parameters are not saved in the PID module it is required to configure those parameters Method 2 Use the default parameters stored in the ROM of the CPU module When the PID module parameters are configured in the PID Module Configuration dialog box and the user program is downloaded to the CPU module the PID module parameters initial values will be saved in ROM of the CPU module Those initial values can be loaded to the data registers in the CPU module and the PID module can be operated with those initial values with the following procedure 1 Turn off to on the loading initial values relay control relay 1 2 Turn off to on the writing all parameters relay control relay 2 When the co
173. n the next program control starts When the program control is started the program control starts from the set point SP that is configured as Set Point SP when Program Control Starts SP Start Examples for the PV start PVR start and SP start actions are described using the following program pattern StepNumber 0 1 2 3 4 Set Point SP 150 C 100 C 50 C Time min min PV Start Action Process variable PV is 25 C StepNumber 0 1 2 3 4 Set Point SP 150 C 100 C 50 C 25 C L Time 15 min 30 min 60 min min When the program control is started the time will be advanced shown in dotted line until the set point SP becomes equal to 25 C of the process variable PV and then the program control will start from this point Program Control Run FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 41 CONFIGURING PID MODULE USING WINDLDR PV Start Action Process variable PV is 170 C Step Number Set Point SP Time LE 180 60 min mn p ERN When the program control is started the time will be advanced shown in dotted line to the start of step 4 falling gradient step and then the program control starts from this point 1 Program Control Run 1 In the above program pattern if the set point SP of step 4 is 0 C and the step time of step 4 is 0 minutes falling gradient step does not exist the time
174. nal band is 10 C and the cooling proportional band is 2 0 the cooling proportional band will be 20 C If cooling proportional band value is 0 5 the cooling proportional band will be 5 C If the cooling proportional band is 0 the cooling side control will be ON OFF control action If the heating proportional band is 0 both heating and cooling side controls will be ON OFF control action 21 Control Register 98 Cooling Output ON OFF Hysteresis Output on off hysteresis for cooling output can be configured When cooling control action turns from on to off and vice versa the span between on and off positions of the cooling output is called cooling output on off hysteresis If the cooling output on off hysteresis is narrowed the cooling control output switches to on or off even by a slight variation of temperature at around the set point SP This frequent on off shortens the output relay life and may negatively affect the connected equipment To prevent that harmful effect the hysteresis is provided for on off control action Cooling output on off hysteresis can be configured only when cooling control action is in ON OFF control when cooling proportional band is 0 22 Control Register 50 Overlap Dead Band The overlap dead band of the heating and cooling outputs can be configured when heating cooling control is enabled When the configured value is bigger than 0 the value is used as the dead band When the configured value is less than
175. ndLDR Communication Expansion Modules Optional Modules n Use this product after thoroughly understanding the specifications of the FC5A series CPU module The PID modules is used by connecting to the FC5A series CPU module d l Cautio IMPORTANT INFORMATION Under no circumstances shall IDEC Corporation be held liable or responsible for indirect or consequential damages resulting from the use of or the application of IDEC PLC components individually or in combination with other equipment All persons using these components must be willing to accept responsibility for choosing the correct component to suit their application and for choosing an application appropriate for the component individually or in combination with other equipment All diagrams and examples in this user s manual are for illustrative purposes only In no way does including these diagrams and examples in this manual constitute a guarantee as to their suitability for any specific application To test and approve all programs prior to installation is the responsibility of the end user FC5A MicroSmart PID Module User s Manual FC9Y B1283 iil REVISION HISTORY Revision history of this user s manual is described here Date Manual No Description March 2011 FC9Y B1283 0 First print iv FC5A MicroSmart PID Module User s Manual FC9Y B1283 RELATED MANUALS The following manuals related to the
176. nt Output LED EVTO EVT1 ON Any alarm out of alarm 1 to alarm 8 loop break alarm is triggered OFF None of the alarms is triggered 5 Auto tuning AT Auto reset LED ATO AT1 Flashes Auto tuning AT or auto reset is performing OFF Auto tuning AT or auto reset is stopped 6 Manual Mode LED MTO MT1 ON Manual mode OFF Auto mode 7 Fixed Value Control Mode Program Control Mode LED F PO F P1 ON Program control mode OFF Fixed value control mode 8 Program Control RUN HOLD LED R HO R H1 ON Program control is performing or while in fixed value control enabled Flashes Program control is held or power is restored OFF Program control is stopped or while in fixed value control disabled 9 External SP Enable Disable LED R L ON External SP input is enabled OFF External SP input is disabled 10 Terminal No Indicates terminal numbers 11 Cable Terminal Spring clamp type terminal for connecting a cable 12 Expansion Connector Connects to the CPU module and other expansion modules FC5A MicroSmart PID Module User s Manual FC9Y B1283 MODULE SPECIFICATIONS Specifications PID Module Specifications Rating Type No FC5A F2MR2 FC5A F2M2 Thermocouple Type Measurement Range eee el ISCH 3o8102498F TETE K with decimal p
177. ntegral time derivative time and ARW of each step are automatically calculated using auto tuning AT In CHO control if the process variable PV in step 1 becomes 110 C or higher or if the process variable PV in step 3 becomes 810 C or higher the upper limit alarm output QO is turned on and the control is disabled In CH1 control if the process variable PV in step 1 becomes 110 C or higher or if the process variable PV in step 3 becomes 810 C or higher the upper limit alarm output Q1 is turned on and the control is disabled System Configuration and Wiring Wiring Example of the FC5A F2MR2 Relay output type 3 phase Power Supply Surge Absorber Surge Absorber Terminal E Electromagnetic Switch tara N Channel Channel 24V DC CHO Thermocouple Electric Electric Furnace 2 Furnace 1 CH1 Thermocouple PID Module FC5A F2MR2 7 8 FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPLICATION EXAMPLES PID Module Parameter Configuration The parameters of the PID module can be configured in the Expansion Modules Configuration and PID Module Configuration dialog boxes The procedure to configure the PID module is described below Parameter Configuration Example Quantity of Modules 1 unit Slot No Slot 1 Module Type No FC5A F2MR2 Data Register D1000 Internal Relay M1000 I O Function Used as a 2 channel PID module
178. ntrol of the PID module is enabled the PID module will start operating with the default values FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 5 CONFIGURING PID MODULE USING WINDLDR Expansion Modules Configuration Dialog Box Expansion Modules Configuration 215 1 L EN Modules Quantity of modules 3 E CPU module Slot 1 Slot 2 Slot 3 Slot 4 FCSA F2M2 FCSA C24R2X 999 to D1189 Other modules Othermodules Other modules M0000 to M0007 3 EE Module Type No FCSA F2M2 Data Register D1000 D1000 to D1189 Internal Relay 1000 M1000 to M1007 Configure Parameters Copy Parameters To ok Cancel Expansion Modules Configuration E 21 5 Expansion Modules Quantity of modules 3 E CPU module Slot 1 Slot 2 Slot 3 Slot 4 FCSA F2M2 FC5A C24R2X 999 a D1189 Other modules Othermodules Other modules M0000 to M0007 O i 6 4 Module TypeNo FCSA F2M2 SI 7 5 9 Data Register D1000 D1000 to D1189 8 fe MA R m1000 M1000 to M1007 9 Configure Parameters Copy Parameters To ok Cancel Settings Item Description Quantity Configure the quantity of modules to be expanded The quantity of PID modules can be 1 of connected varies with the CPU module type A maximum of four PID modules can be Modules connected to the all in one type CPU modules A maximum of seven PID modules can be connected to the slim type CPU modules 2 Slot Select a s
179. nual FC9Y B1283 5 7 DEVICE ALLOCATION OF PID MODULE Operation Parameter Monitor Operation Parameter Monitor 1 word Range Error Bit ell Parameter Status Description 0 Control is disabled Bito Control Enable Bit 1 Control is enabled S 0 Normal operation an Autotuning LAT Auto Reset Bit 1 Auto tuning AT Auto reset is being performed Bit2 Auto Manual Mode Bit 9 SE 1 Manual mode Bit3 Program Control Bit 3 PIOS SOON is stopped 1 Program control is running c f 0 Normal operation Bit4 Program Hola Bit 1 Program control is held Bits External SP Input Enable Bit 0 External SP input is disabled CHO only 1 External SP input is enabled d 0 All parameters are within the valid range Bit ee 1 All parameters are out of the valid range e 0 Set point SP is within the valid range iud PLPN VOR Pange Emor Bit 1 Set point SP is within the valid range 0 Manual mode output manipulated variable is Bits Manual Mode Output Manipulated within the valid range Variable Range Error Bit 1 Manual mode output manipulated variable is out of the valid range Proportional band integral Time derivative time SL Band Integral S ARW or control period is within the valid range SS Jine ELIE MN Proportional band integral Time derivative time EH f ARW or control period is out of the valid range s e 0 Reset setting is within the
180. o 10000 sec 200 200 200 200 200 200 200 200 200 200 Derivative Time 0 to 10000 sec 50 50 50 50 50 50 50 50 50 50 ARW Anti Reset windup Oto 100 50 50 50 50 50 50 50 50 50 50 Output MY Rate of Change Dto 100 sec 0 0 0 0 0 0 0 0 Alarm 1 Value 1570to1570 C 0 10 0 ji 10 10 10 10 10 p Alarm 2 Value 0 0 0 0 0 0 0 0 0 4 Alarm 3 Value 0 0 0 0 0 0 0 0 0 0 Alarm 4 Value 0 0 0 0 0 0 0 0 0 0 Alarm 5 Value 0 0 0 0 0 0 0 0 0 0 Alarm 6 Value 0 0 0 0 0 0 0 0 0 0 Alarm 7 Value 0 0 0 0 0 0 0 0 0 0 Alarm 8 Value 0 0 0 0 0 0 0 0 0 0 Output MY Upper Limit 0 to 100 100 100 100 100 100 100 100 100 100 100 Output MY Lower Limit 0 to 100 0 0 0 0 0 0 0 0 0 0 Cooling Proportional Band 0 0 to 10 0 times 1 1 1 1 jt 1 T 1 1 OverlapiDead Band 200 0t0200 0 C 0 0 0 0 0 0 0 0 0 0 Write all parameters Read all parameters Monitor Seiting ten Step 0 Step 1 Step 2 Step 3 1 Set Point SP 100 C 100 C 800 C 800 C 2 Step Time 60 minutes 60 minutes 300 minutes 30 minutes 3 Wait Value 10 C 0 C 10 C 0 C 4 Alarm 1 Value 0 C 10 C 0 C 10 C Notes When the wait value is 0 C the wait function is disabled When the alarm value is 0 C the alarm function is disabled When a parameter for the program control except step time is changed in WindLDR the parameter is automatically copied to the following steps 6 CH1 Parameters Setting
181. oSmart PID Module Users Manual FC9Y B1283 PID MODULE MAIN FUNCTIONS 4 PID MobuLeE MAIN FUNCTIONS This chapter describes the temperature control fixed value control auto tuning AT program control heating cooling control difference input control and cascade control of the PID module Temperature Control Using the PID Module Temperature Control Configuration Example Using the PID Module B PID Module C Actuator 200V AC Control Target such as Electric Furnace or Constant Temperature Oven A Thermocouple Heap A Sensor Measures temperature of the control target Thermocouple resistance thermometer voltage input or current input can be used as the sensor B PID module Receives the temperature measured by the sensor as the process variable PV and calculates the output manipulated variable MV so that temperature difference deviation between the process variable PV and the set point SP can be eliminated The output manipulated variable MV is outputted to the actuator as a control signal Relay output non contact voltage output or current output can be used as the control signal C Actuator Receives a control signal from the PID module and turns on the load power supply to the heater Electromagnetic switches SSR or power controllers can be used as the actuator Optimal Temperature Control The ideal temperature control as shown in Figure 1 is
182. ofo1V O e B NG S d if SC e DC DC pc LP 68 2 B S NC Lig NC OUTO d sl SI RTD 7 T_T N 3 e EICH t 2 Ti o a 0 to 5V E pu NC z i S G RO oto20mA A m i Esp 010 10V 4 to 20mA o fo 1V X LR Q NGC OUT U DC DC DC S TC B 1 Jav RTD 1 OUTO is a connection example of relay output OUT is a connection example of non contact voltage current output The PID module having both outputs is non existent 3 4 FC5A MicroSmart PID Module User s Manual FC9Y B1283 INSTALLATION AND WIRING Type of Protection Input Circuits FC5A F2MR2 FC5A F2M2 p Input Selection Signal 20MQ 15K 15kQ 160kK2 BV Z e mA QO e YO e e 2 Input p am BO 1002 B O 40kQ 509 LLL 1 Output Circuits FC5A F2MR2 K O Output Circuit FC5A F2M2 Non contact Voltage Output for SSR drive FC5A F2M2 Current Output Short Circuit Current Protected 1 Detection Ort m e P O pe Output Circuit Output Circuit FC5A MicroSmart PID Module User s Manual FC9Y B1283 3 5 INSTALLATION AND WIRING Power Supply for PID Modules When supplying power to the PID modules take the following into consideration Using the same power supply for
183. ogram control is held While program is held the Program Control RUN HOLD LED R HO or R H1 of the PID module flashes To resume the program control turn off the program hold bit Bit4 Advance Next Function Proceed to the next step Turn off to on the advance next step Bit6 of the operation parameter The current step is terminated and the program control is proceeded to the start of the next step The advance next function is also effective while the program control is in wait action Advance Previous Function Move back the program control Turn off to on the advance previous step Bit7 of the operation parameter The progression of the current step is stopped and the program control is moved back If the elapsed time in the current step is less than 1 minute the program control goes back to the start of the previous step If the elapsed time in the current step is longer than 1 minute the program control goes back to the start of the current step Even when the advance previous function is executed at Step 0 the program control does not move back to Step 9 regardless of the program end action Current Step Remaining Time The remaining time of the current step is stored in the Current Step Remaining Time of Block 0 The remaining time is stored in seconds or minutes according to the Step time unit setting Current Step Number The current step number 0 to 9 is stored in the Current Step Number of Block 0 Program Wait Per
184. oint 200 0 to 400 0 C 328 0 to 752 0 F 0 1 C F J 200 to 1000 C 328 to 1832 F 1 C F R 0 to 1760 C 32 to 3200 F 1 C F S 0 to 1760 C 32 to 3200 F 1 C F B 0 to 1820 C 32 to 3308 F 1 C F E 200 to 800 C 328 to 1472 F 1 C F T 200 0 to 400 0 C 328 0 to 752 0 F 0 1 C F N 200 to 1300 C _ 328 to 2372 F 1 C F PL II 0 to 1390 C 32 to 2534 F 1 C F C W Re5 26 0 to 2315 C 32 to 4199 F 1 C F Resistance Thermometer Input Value Rated Scale Type Measurement Range r LSB Pio 200 to geng 328101562F e Pt100 with decimal point 200 0 to 850 0 C 328 0 to 1562 0 F 0 1 C F JPt00 Lame 500 C 328 to 932 ci JPt1 OO with decimal point 200 0 to 500 0 C 328 0 to 932 0 F 0 1 C F Current Voltage Type Measurement Range ENSE 4 to 20mA DC 2000 to 10000 12000 increments 1 1 333p 0to20mA C 2000 to 10000 12000 increments 1 1 6660A 0 to 1V DC 2000 to 10000 12000 increments 1 0 083mA 0 to 5V DC 2000 to 10000 12000 increments 1 0 416mA 110 5V DC A to 100 0 12000 increments 0 333mA 0 to 10V DC 2000 to 10000 12000 increments 1 0 833mA 1 Linear conversion possible Input type Thermocouple K J R S B E T N PL II C W Re5 26 External resistance 1000 maximum However B input External resistance 400 maximum Resistance Pt100 JPt100 3 wire type Thermometer Allowable conductor resistance per wire 100 maximum Sensor detection current 0 2A Current 0
185. ol Parameters when Program Control Mode is Selected When the program control mode is selected parameters 23 to 27 are enabled Parameters for the fixed value control mode such as the set point SP proportional band proportional gain or integral time are disabled Input CHO Control CHO Program CHO Output CHD Input CH1 Control CH1 Output CH1 Monitor Control Mode Program Contral Mode lt Control Action Reverse Control Action Heating lt Heating Cooling Control Disable E Loop Break Alarm LA Time Set Point SP t 200 to 1370 c Loop Break Alarm LA Span Proportional Term Proportional Band S Proportional Band 10 7 Oto 10000 c Integral Time 200 7 Oto 10000 sec Derivative Time 50 7 Oto 10000 sec ARW Anti Reset Windup 0 Oto 100 AT Bias 2 0 to 50 c es 23 Program Control Mode Settings Reset 0 0 Z 100 0 to 100 0 c rogram Control Mode Start Type Set Point SP Rise Rate 0 0to 10000 C min 24 P when Program Control Starts Set Point SP Fall Rate 7 0to 10000 C min 25 Step Time Unit Output MV Rate of Change DE 0 to 100 sec 26 End Action Output ON OFF Hysteresis 1 0 Z 0 1 to 100 0 c 27 umber of Repeats Manual Mode Output MV 0 0 7 0 0 to 100 0 Write all parameters Control Registers Read all parameters Monitor Em d iu com 2x Output Parameters CHO Voltage Output Output Paramet
186. ollowing conditions is met the PID module considers that heater burnout sensor burnout or actuator trouble is detected and triggers the loop break alarm When the reverse control action is selected The loop break alarm is triggered when the process variable PV does not rise as much as the loop break alarm span within the loop break alarm time while the output manipulated variable MV is 100 or the output manipulated variable upper limit The loop break alarm is also triggered when the process variable PV does not fall as much as the loop break alarm span within the loop break alarm time while the output manipulated variable MV is 096 or the output manipulated variable lower limit When the direct control action is selected The loop break alarm is triggered when the process variable PV does not fall as much as the loop break alarm span within the loop break alarm time while the output manipulated variable MV is 100 or the output manipulated variable upper limit The loop break alarm is also triggered when the process variable PV does not rise as much as the loop break alarm span within the loop break alarm time while the output manipulated variable MV is 096 or the output manipulated variable lower limit value Even when the loop break alarm is triggered the PID module continues its control To stop the control ladder programming is needed Ladder Program Example The control register is D1000 in this example Wh
187. onfigured the process variable PV changes as shown in the Figure 2 After the PV filtering process the process variable PV reaches 63 of the process variable PV in T seconds If the PV filter time constant is too large it adversely affects the control results due to the delay of response Example If the least significant digit of the process variable PV is fluctuating the fluctuation can be suppressed by using the PV filter time constant Process Process Variable Variable PV PV Time Second es Time Second Figure 1 Process variable PV Figure 2 Process variable PV before PV filtering process after PV filtering process 4 Control Register 59 Set Point SP Upper Limit Linear Conversion Maximum Value 5 Control Register 60 Set Point SP Lower Limit Linear Conversion Minimum Value Linear Conversion Function The diagram below shows an example of the linear conversion When the linear conversion maximum value is 5000 and the linear conversion minimum value is 0 the current input 4 to 20mA DOC is linearly converted as shown in the diagram Input range 10000 5000 5 Linear conversion is conducted within this range 0 1 2000 L 4mA 20mA Current Set Point SP Upper Limit Linear Conversion Maximum Value When input type is thermocouple or resistance thermometer the linear conversion is disabled The linear conversion maximum value is used as the upper limit of the set point SP
188. onitor ok Cancel Input parameters for CHO control are described here Input parameters for CH1 control are the same as those of CHO control However the position from the control register for each parameter differs For details about the positions from the control register for CH1 control see 5 17 to 5 20 1 Control Register 58 Input Range Select input type and input range unit Celsius or Fahrenheit For details about the input range see 6 10 2 Control Register 62 PV Correction If the sensor cannot be installed to the location of the control target the temperature measured by the sensor may deviate from the actual temperature of the control target When a target is controlled with multiple PID modules the measured temperatures may not match due to the differences in sensor accuracy or dispersion of load capacities even though the set points SP of those PID modules are the same In such cases the process variable PV of the PID module can be adjusted to the desired temperature by using the PV Correction The process variable PV after the PV correction should be within the control range See 9 4 For example when type K thermocouple 200 to 1370 C is selected as input type configure an appropriate PV correction value so that the process variable PV after the PV correction does not exceed the control range 250 to 1420 C Input range lower limit 50 C to Input range upper limit 50 C When the process variabl
189. onitoring set point SP of CHO or CH1 can be changed 2 CHO CH1 PV Process Variable The process variable PV of CHO or CH1 is indicated 3 CHO CH1 MV Output Manipulated Variable The output manipulated variable MV of CHO or CH1 is indicated The bar graph on the right is also updated according to the output manipulated variable MV While the output is on the OUT indicator turns green While CHO or CH1 is in manual mode output manipulated variable can be changed 4 CHO CH1 Step The current step number 0 to 9 is indicated when CHO or CH1 is in program control mode 5 CHO CH1 Repeat The remaining repeat number is indicated when CHO or CH1 is in program control mode 6 CHO CH1 Time The remaining time in the current step is indicated when CHO or CH1 is in program control mode 6 52 FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR 7 CHO CH1 Send Command When a menu is selected a command to control the PID module is sent Control Enable Disable the control to the PID module AT Auto reset Perform auto tuning AT auto reset or cancel auto tuning AT Manual Mode Enable manual auto mode External SP Input CHO only Enable Disable the external SP input Program Control Run Stop the program control advance next previous step or hold run the program control 8 CHO CH1 Status Indicators Control Turns green while the control of CHO CH1 is enabled AT Tu
190. ontrol Input CHO input value Input CH1 input value Input Parameters Control Parameters T rd Output Parameters CHO gt d tion cHo cH Lel gt CHO e output cro ls CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters et Control Parameters Output Parameters gt Input cHt CHI o output cH lt l p CH Type K thermocouple Celsius Reverse Control Action Heating Voltage Output FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 21 CONFIGURING PID MODULE USING WINDLDR 2 Control Register 133 Input CH1 Function Control Register 55 External SP Input The one of the following input functions can be selected as the Input CH1 Function Input CH1 Input CH1 is used as the process variable PV for CH1 control Input Parameters o Control Parameters Output Parameters ey C5 input cro el e 5 output Ho we Was Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input pou ina CH ET Gegen rrn E Output Parameters Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Difference CHO CH1 The difference between input CHO and input CH1 is used as the process variable PV for CH1 control Process variable PV of CH1 control Input CHO input value Input CH1 input value Input Parameters Control Parameters t Output Parameters CHO E In
191. ooling proportional band is 2 0 the cooling proportional band will be 20 C If cooling proportional band value is 0 5 the cooling proportional band will be 5 C If the cooling proportional band is 0 the cooling side control will be ON OFF control action If the heating proportional band is 0 both heating and cooling side controls will be ON OFF control action 20 Control Register 200 Overlap Dead Band The overlap dead band of the heating and cooling outputs can be configured when heating cooling control is enabled When the configured value is bigger than 0 the value is used as the dead band When the configured value is less than 0 the value is used as overlap band When the overlap band is configured the area in which both heating and cooling control outputs are turned on is generated and the energy loss is caused However the overlap helps enhance the control accuracy and accelerate the response When the dead band is configured the area in which neither heating nor cooling control outputs are turned on is generated In the dead band the control accuracy and responsiveness is lowered however the energy loss can be suppressed Output manipulated variable MV 100 Heating Output Cooling Output Temperature A Set Point uo SP Overlap Band Overlap Band Action Output manipulated variable MV 100 Cooling Output Heating Output 0 Temperature Set Point A SP ky Dead Band Dead
192. oportional band When input range unit is Celsius 0 1 to 100 0 C Cooling Output ON OFF When input range unit is Fahrenheit 21 98 Hysteresis 0 1 to 100 0 F BS When input is voltage or current 1 to 1000 When input range unit is Celsius 200 0 to 200 0 C When input range unit is Fahrenheit 22 50 Overlap Dead Band 200 0 to 200 0 F R W When input is voltage or current 2000 to 2000 0 PV start 23 91 168 ae Moos 1 PVR start R W yp 2 SP start When input is thermocouple resistance thermometer Set Point SP when Set point SP lower limit to set point SP upper limit 24 20 Tis Program Control Starts When input is voltage or current PUN Linear conversion min to linear conversion max 0 Minute 25 92 169 Step Time Unit 1 Second R W 0 Terminate program control 26 93 170 Program End Action 1 Continue program control Repeat R W 2 Hold program control 27 97 174 Number of Repeats 0 to 10000 times R W p FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 15 CONFIGURING PID MODULE USING WINDLDR Control Parameters when Cascade Control is Enabled Control Registers PID Module Configuration Slot 1 Module Type No FCSA amp F2M2 Input Parameters Type K thermocouple Celsius Input Parameters CHI Type K thermocouple Celsius Input CHO Control CHO Output CHO Input CH1 Control Mode Fixed Value Control
193. ormed and finished the program end output bit is turned on and maintained When the program control is terminated the program control is held at the last status of step 9 The program end output and program hold bit are turned on and maintained While the program control is held the fixed value control is performed with the set point SP of step 9 If advance next function operation parameter Bit6 is turned off to on is executed while the program control is held the program control is started again from step 0 The program end output and program hold bit are turned off While the program control is being held the parameters of Blocks 10 to 19 and 30 to 39 can be changed The program control can be executed again after changing the program parameters such as the set point SP or step time of each step Hold program control 27 Control Register 97 Number of Repeats The number of repeats for the program control can be configured FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 43 CONFIGURING PID MODULE USING WINDLDR Control Parameters when Cascade Control is Selected PID Module Configuration Slot 1 3 21 5 Module Type No FCSA F2M2 J Input Parameters T Control Parameters Output Parameters CHO Input CH Den CHO gt output cro B CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters T Control Parameters CH1
194. ortional band When input range unit is Celsius 0 to 10000 C Range with a decimal point 0 0 to 1000 0 C When input range unit is Fahrenheit 0 to 10000 F Range with a decimal point 0 0 to 1000 0 F When input is voltage current 0 0 to 1000 0 Proportional gain 0 00 to 100 00 R W 27 104 Integral Time 0 to 10000 sec R W 28 105 Derivative Time O to 10000 sec 29 106 ARW Anti Reset Windup 0 to 100 R W 89 166 AT Bias When input range unit is Celsius 0 to 50 C Range with a decimal point 0 0 to 50 0 C When input range unit is Fahrenheit 0 to 100 F Range with a decimal point 0 0 to 100 0 F R W 11 31 108 Reset When input range unit is Celsius 100 0 to 100 0 C When input range unit is Fahrenheit 100 0 to 100 0 F When input is voltage or current 1000 to 1000 R W 12 33 110 Set Point SP Rise Rate When input range unit is Celsius 0 to 10000 C min Range with a decimal point 0 0 to 1000 0 C min When input range unit is Fahrenheit 0 to 10000 F min Range with a decimal point 0 0 to 1000 0 F min When input is voltage or current 0 to 10000 min R W 13 34 111 Set Point SP Fall Rate When input range unit is Celsius 0 to 10000 C min Range with a decimal point 0 0 to 1000 0 C min When input range unit is Fahrenheit 0 to 10000
195. osse input Parameters utput Parameters CHI Input CH M CH1 Type K thermocouple Celsius Input CHO Control CHO Output CHO Input CH1 Output CH1 Monitor Fixed Value Control Mode Reverse Control Action Heating U IL Enable gt 1 8 op Break Alarm LA Time e Break Alarm LA Span Cooling Control Settings 1 9 Cooling Method 20 Cooling Proportional Band Control Mode Control Action Heating Cooling Control Set Point SP DEI C200 to 1370 c Proportional Term Proportional Band D Proportional Band 10 Ei 0 to 10000 c Integral Time 200 Z 0 to 10000 sec Cooling Output ON OFF Hysteresis 21 22 VUE T Band 50 0to 10000 sec 50 Oto 100 ATBias 20 to 50 C Reset 0 0 7 100 0 to 100 0 Set Point SP Rise Rate 0 0 to 10000 C min Set Point SP Fall Rate 0 to 10000 min E kl Wiel Re Output MV Rate of Change 0 0 to 100 sec Output ON OFF Hysteresis 1 0 0 1 to 100 0 C ag Manual Mode Output MV 0 0 0 0 to 100 0 Write all parameters Read all parameters l Monitor Control Parameters when Program Control Mode Is Selected Input CHO Control CHO Program CHO Output CHO Input CH1 Control CH1 Output CHI Monitor Control Mode Program Control Mode EI Control Action Reverse Control Action Heating IS Heating Cooling Control Disable El Laan Beek Alene LA Times Set Point SP
196. p 9 The program hold is canceled and the program control is started from the start of Step 0 Notes The PID module executes all steps 0 to 9 even if the times of steps are zero When the program control is terminated nine is stored in the current step number of block 0 When hold program control is selected as the program end action the program control is held and the fixed value control is performed with the parameters of step 9 after all steps are executed 5 16 FC5A MicroSmart PID Module User s Manual FC9Y B1283 DEVICE ALLOCATION OF PID MODULE Data Register Allocation Blocks 2 3 Basic Parameters SHOT Action Block 2 CHO and block 3 CH1 parameters are shown in the table below The parameters of block 2 and 3 can be changed while the control of the PID module is enabled Offset from the T Parameter Description R W CHO CH1 Proportional band When input range unit is Celsius 0 to 10000 C Range with a decimal point 0 0 to 1000 0 C When input range unit is Fahrenheit 26 103 Proportional Term 0 to 10000 F R W Range with a decimal point 0 0 to 1000 0 F When input is voltage or current input 0 0 to 1000 0 Proportional gain 0 00 to 100 00 27 104 Integral Time 0 to 10000 sec R W 28 105 Derivative Time 0 to 10000 sec R W 29 106 ARW Anti Reset Windup 0 to 100 R W 30 107 Control P
197. pacity size and sensor location 4 Disturbance Any change in control temperature causes disturbance For example the change of ambient temperature or supply voltage can cause disturbance putt Characteristics of Control Target dS Je a M Static NUN VXThermalCapacily Characteristic Geh lt Dynamic We Disturbance Characteristic 7 Es a m 4 2 FC5A MicroSmart PID Module User s Manual FC9Y B1283 PID MODULE MAIN FUNCTIONS Fixed Value Control The PID module provides 2 control modes one is the fixed value control and the other is the program control The fixed value control is a standard temperature control which performs to eliminate the deviation between the single set point SP and process variable PV The program control allows you to define the set point SP that changes as the time progresses so that the process variable PV can be controlled to match the set point SP changing as the time progresses For detail about the program control see 4 9 Control actions that can be used for fixed value control and program control are described below ON OFF Control Action In the ON OFF control action when the process variable PV is lower than the set point SP the control output is turned on and when the process variable PV exceeds the set point SP the control output is turned off Overshoot undershoot and hunting are generated ON OFF control is suitable for processes which do not require accuracy
198. program control starts with this set point SP when the SP start is selected as the program control mode start type 25 Control Register 92 Step Time Unit Minute or second can be selected as the unit of program control progressing time 26 Control Register 93 Program End Action The action to be taken when the program control is terminated can be selected The program control is terminated when all steps 0 to 9 are performed and finished Each step is performed with the parameters configured for each step Steps to which step time 0 is configured are also performed For example if the program control of 4 steps is required configure parameters of steps 0 to 3 and set the step time of the remaining steps 4 to 9 to zero When the program control is terminated the program end output bit is turned on and maintained and the PID module will be in standby status The program control can be executed again by turning off to on the Terminate program program control bit operation parameter bit3 control During the program control standby waiting for program control run status the control output is turned off and the operating status is not updated except the over range the under range and the program end output When the program control is terminated the program control is repeated Continue program from step 0 as many times as the configured number of repeats When the control Repeat step 9 of the last program control cycle is perf
199. proportional band range can be shifted as shown in the figure below The reset value can be automatically calculated by the auto reset function Output Manipulated Variable 100 Output Manipulated Variable A 100 B 50 20 C 0 A gt Proportional band area that can be configured with reset function Offset can be corrected within proportional band from the set point SP PI Control Action Proportional Integral Action Integral action automatically corrects the offset caused by P control action and temperature control is performed at the set point SP However it takes time for the process variable PV to be stable if the process variable PV is changed rapidly due to disturbance PI control action is suitable for the processes in which the temperature slowly changes If the derivative time of the PID module parameter is set to 0 the control action becomes the PI control action Temperature Proportional Band Set Point SP A Disturbance Time If the integral time is shortened too much the integral action becomes strong The offset can be corrected in a shorter time however hunting with a long cycle may be caused If the integral time is extended too much the integral action becomes weak and it takes time to correct the offset FC5A MicroSmart PID Module User s Manual FC9Y B1283 PID MODULE MAIN FUNCTIONS PD Control Action Proportional Derivative Action Compared w
200. put is on or when Q1 CH1 control upper limit alarm output is on the control of the PID module is disabled When the process variable PV of CHO control exceeds 205 C D1010 7 Alarm 1 output is turned on which turns QO on When the process variable PV of CH1 control exceeds 215 C D1019 7 Alarm 1 output is turned on which turns Q1 on When external input 11 is turned on D1022 1 Auto tuning AT Auto reset bit is turned on While D1022 1 is on the PID module performs auto tuning AT for CHO control When the PID module completes auto tuning AT for CHO D1009 1 Auto tuning AT Auto reset monitor bit is turned off When D1009 1 is turned off Q3 is turned on The temperature at which Auto tuning AT is performed is determined by the set point SP and AT bias In the above example auto tuning AT will be performed when the process variable PV reaches 180 C The ladder program should be customized depending on actual applications 7 6 FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPLICATION EXAMPLES 9 User Program Download From the WindLDR menu bar select Online gt Transfer gt Download to open Download dialog box Click the check box on the left of Write PID Module parameters after download and click OK button The user program will be downloaded to the CPU module After downloading the user program the PID module parameters will be written to the data registers in the CPU module and the PID
201. put does not operate normally Is the RUN LED of the CPU module ON Click Online gt Start button to run the CPU module YES S Control Enable bi NO ON in the operation parameter Turn on Control Enable bit YES Is the parameter error YES occurring A value outside the range is set for the parameter in a channel Make sure of the setting range of the parameter and set it to a suitable value NO NO Is the control output OFF s the output manipulated variable lower limit value higher than 10096 NO YES S the output manipulated variable upper limit value less than 096 Lem p Set it to a suitable value NO the output signal type suitable for the FC5A F2M2 used Y Select a correct output signal type s the allocated data register used for other functions Allocate a data register which is not used for other functions Call IDEC for assistance YES Set it to a suitable value 8 2 FC5A MicroSmart PID Module User s Manual FC9Y B1283 END TROUBLESHOOTING Hunting phenomenon is occurring while in ON OFF control action Hunting phenomenon is occurring while in ON OFF control action Is the output ON OFF hysteresis 1 too narrow Set the output ON OFF hysteresis to a suitable value END Call IDEC for assistance
202. put is thermocouple or resistance thermometer 0 1 to 100 0 C F When input is voltage current 1 to 1000 Output Operating status See page 5 9 Alarm Delay time 0 to 10000 seconds FC5A MicroSmart PID Module User s Manual FC9Y B1283 9 1 APPENDIX Loop Break Alarm A trouble of the actuator such as heater break or heater adhesion can be detected as the loop break alarm For details about the loop break alarm see page 6 39 Loop break alarm time 0 to 200 minutes Loop break alarm span When input is thermocouple or resistance thermometer 0 to 150 C F or 0 0 to 150 0 C F When input is voltage current 0 to 1500 Bit 2 of the operating status Output When the set point SP is changed the set point SP is gradually increased from the original set point SP to the new set point SP according to the configured rate of change C minute F minute When the control is started the set point SP is increased from the current process variable PV to the configured set point SP according to the configured rate of change C minute F minute Set Point SP Ramp Function Auto or manual mode can be switched When the control mode is switched from auto to manual mode and vice versa the balanceless bumpless function works to prevent a sudden change in output manipulated variable MV When the power is turned on the operation parameters in Blo
203. r each parameter differs For details about the positions from the control register for CH1 control see pages 5 17 to 5 20 1 Control Register 90 Control Mode Either fixed value control mode or program control mode can be selected When the external SP input or the cascade control is selected in Input CH1 Function the program control mode cannot be used for CHO control Select fixed value control mode for control mode of CHO control If the program control mode is selected the external SP input does not function 6 34 FC5A MicroSmart PID Module Users Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR The fixed value control is a normal temperature control that the PID module controls the output to eliminate the deviation between a single set point SP and the process variable PV The following diagram shows an example of the fixed value control Temperature Set point SP gt Time The program control allows you to define the set point SP that changes as the time progresses so that the process variable PV can be controlled to match the set point SP changing as the time progresses The set point SP and time can be configured for each step A maximum of 10 steps can be configured and performed The set point SP can be configured as shown in the following diagram Temperature Sep 1 2131456 2 Control Register 53 Control Action Selects either direct control action or reverse control action In di
204. r input CH1 Example When input type is current 4 to 20mA DC if the external SP input linear conversion maximum value is 1000 C external SP input 20mA corresponds to the set point SP 1000 C for CHO control When input type is voltage 0 to 1V DC if external SP input linear conversion maximum value is 1200 C external SP input 1V corresponds to the set point SP 1200 C for CHO control 5 Control Register 179 External SP Input Linear Conversion Minimum Value Configure the linear conversion minimum value for the external SP input When input type is current 4 to 20mA DC or 0 to 20mA DC configure the value corresponding to 4mA or OmA for input CH1 When input type is voltage 0 to 1V DC or 1 to 5V DC configure the value corresponding to OV or 1V for input CH1 Example When input type is current 4 to 20mA DC if external SP input linear conversion minimum value is 0 C external SP input 4mA corresponds to the set point SP 0 C for CHO control When input type is voltage 0 to 1V DC if external SP input linear conversion maximum value is set to 20 C external SP input OV corresponds to the set point SP 20 C for CHO control 6 Control Register 177 External SP Input Bias The external SP input bias is added to the set point SP obtained after the linear conversion for the external SP input The set point SP is then used as the set point SP for CHO control Examples When the input type is current 4 to 20mA DC t
205. range of the set point SP of the slave CHO is the external SP input linear conversion minimum value to the external SP input linear conversion maximum value Configure the external SP input linear conversion maximum value for when the output manipulated variable MV of the master CH1 is 100 2 Control Register 179 External SP Input Linear Conversion Minimum Value Configure the external SP input linear conversion minimum value for the cascade control The output manipulated variable MV 0 to 100 of the master CH1 corresponds to the set point SP of the slave CHO The range of the set point SP of the slave CHO is the external SP input linear conversion minimum value to the external SP input linear conversion maximum value Configure the external SP input linear conversion minimum value for when the output manipulated variable MV of the master CH1 is 0 6 44 FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR PID Module Configuration Output Parameters Details PID Module Configuration Slot 1 21x Module Type No FCSA F2M2 p Input Parameters Control Parameters Output Parameters eS iw ann e EL CHO Input CHO CHO CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Heating Cooling Control los com Input Gees near CHE d ST Geen Type K thermocouple Celsius Voltage Output NN Control CHO Output
206. rect control action the output manipulated variable MV increases when the process variable PV is higher than the set point SP positive deviation For example freezers perform the direct control cooling action Output Manipulated Variable MV 0 0 Process Variable PV Low lt A gt High Set Point SP In reverse control action the output manipulated variable MV increases when the process variable PV is lower than the set point SP negative deviation For example electric furnaces perform the reverse control heating action Output Manipulated Variable MV 00 0 Process Variable PV Low lt A High ey Set Point SP FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 35 CONFIGURING PID MODULE USING WINDLDR 3 Control Register 54 Heating Cooling Control The heating cooling control can be enabled When it is difficult to control a target process with heating control only cooling control can be added to perform the heating cooling control Example Heating Cooling control uses both heating and cooling outputs and is suitable for the heat producing processes such as extruders or for temperature control at near the ambient temperature such as environment testers Heating Tie Module Target Cooling 4 Control Register 20 Set point SP Any value within the following valid range can be configured as the set point SP The valid range of set point SP when th
207. red Blocks 10 to 19 and 30 to 39 include parameters of each step of the program control By turning the control relay from off to on parameters can be read from written to the PID module FC5A MicroSmart PID Module User s Manual FC9Y B1283 5 1 DEVICE ALLOCATION OF PID MODULE Program Size The user program size that the PID module uses depends on CPU module type The table below shows the program size required to use a PID module Program Size Both CHO and CH1 are in fixed value control mode CHO or CH1 is in program control mode All in one Type 1 300 bytes 4 400 bytes Slim Type 1 200 bytes 3 900 bytes Valid Devices The following devices can be allocated as the control register and relay for the PID module Control register and relay should be configured for each PID module Duplicated device cannot be configured l Q M R T C D Constant Control Register X Control Relay Ge X Control Register The PID module occupies a maximum of 590 data registers minimum 190 data registers per PID module The occupied number of data registers varies between the fixed value control mode and program control mode When both CHO and CH1 are in fixed value control mode 190 data registers are occupied including the first data register designated When either CHO or CH1 is in program control mode 590 data registers are occupied
208. rm 3 Type 68 145 Alarm 4 Type 4 69 146 Alarm 5 Type 0 No alarm action 70 147 Alarm 6 Type 71 148 Alarm 7 Type 72 149 Alarm 8 Type 73 150 Alarm 1 Hysteresis 74 151 Alarm 2 Hysteresis 75 152 Alarm 3 Hysteresis 76 153 Alarm 4 Hysteresis 77 154 Alarm 5 Hysteresis Mee CO 78 155 Alarm 6 Hysteresis 79 156 Alarm 7 Hysteresis 80 157 Alarm 8 Hysteresis 81 158 Alarm 1 Delay Time 82 159 Alarm 2 Delay Time 83 160 Alarm 3 Delay Time 84 161 Alarm 4 Delay Time 185 162 Alarm 5 SEES Time EE 86 163 Alarm 6 Delay Time 87 164 Alarm 7 Delay Time 88 165 Alarm 8 Delay Time 89 4166 AT Bias 20 C 20 90 167 Control Mode 0 Fixed value control 91 168 Program Control Mode Start Type 0 PV start 92 169 Step Time Unit 0 Minute 93 170 Program End Action 0 Terminate program control 94 171 Proportional Term 0 Proportional band 495 172 Cooling Method CHO only S ttis 96 173 Set Point SP when Program Control Starts 0 0 C 0 4 97 174 Number of Repeats 0 times 0 Cooling Output ON OFF Hysteresis CHO 1 0 C 10 98 175 CHO only CH1 0 499 4176 Output Specifications 0 Non contact voltage output for SSR FC5A F2M2 only drive External SP Input Bias CHO 0 100 177 Gut only Gu 0 0 0 101 178 External SP Input Linear Conversion CHO 0 Maximum Value CH1 only CH1 13
209. rns green while auto tuning AT is performed for CHO CH1 Manual Turns green while CHO CH1 is in the manual control External CHO only Turns green while the external SP input is enabled Program Program control only Turns green while CHO CH1 is in program control mode HOLD Program control only Turns green while the program control of CHO CH1 is held WAIT Program control only Turns green while the program wait is functioning for CHO CH1 9 CHO CH1 Error Indicators PARAM Turns red while parameter range error is occurring LOOP Turns red while loop break alarm is turned on UP Turns red while the input is over range DOWN Turns red while the input is under range A1 to A8 Turns red while the corresponding alarm is turned on 10 Monitor Settings Click on Monitor Settings button to open the PID Module Monitor Settings dialog box 11 Monitor Click on Monitor button to start monitoring and tracing the PID module FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 53 CONFIGURING PID MODULE USING WINDLDR PID Module Monitor Settings dialog box PID Module Monitor Settings 1 gg Scaling Settings 5 z P Variable PV X 1 1 Auti li 2 NE rocess Variable PV m C Auto scaling 6 iz Set Point SP E Upper Limit 3 Output Manipulated Variable MV Lower Limit 0 3 Trace Selection CH1 Trace Time Settings Z Process Variable PV B Interval sec 1 Z Set Point SP
210. rresponding to 1V DC is indicated the PID module is operating normally and the signal wire may be disconnected Current 0 to 20mA Input 4mA to the input terminals of the PID module If a converted value calculated with the linear conversion minimum and maximum values corresponding to 4mA is indicated the PID module is operating normally and the signal wire may be disconnected FC5A MicroSmart PID Module User s Manual FC9Y B1283 8 5 TROUBLESHOOTING Loop break alarm turns on even though the actuator operates normally Loop break alarm turns on even though the actuator is operating normally Is the loop break alarm time too short 1 Set the loop break alarm time to a suitable value YES Is the loop break alarm span too great 2 Set the loop break alarm span to a suitable value NO Call IDEC for assistance END 1 Loop break alarm time may be too short compared to the loop break alarm span 2 Loop break alarm span may be too great compared to the loop break alarm time Note Loop break alarm time and loop break alarm span Set the loop break alarm span to a value around 1 25 times bigger than the operation span in normal operation Example Heater in which temperature rises 150 C in 30 minutes When the loop break alarm time is 10 minutes the operation span in normal operation is 50 C 150 C 30 minutes x 10 minutes Set th
211. rtional band When input range unit is Celsius 200 0 to 200 0 C When input range unit is Fahrenheit 200 0 to 200 0 F When input is voltage or current 2000 to 2000 20 200 Overlap Dead Band R W Valid Range for Alarm 1 to Alarm 8 Value Alarm Type Valid Range Upper Limit Alarm Full scale to full scale 1 Lower Limit Alarm Full scale to full scale 1 Upper Lower Limits Alarm 0 to full scale 1 Upper Lower Limit Range Alarm 0 to full scale 1 Process High Alarm Input range lower limit to input range upper limit 2 Process Low Alarm Input range lower limit to input range upper limit 2 Upper Limit Alarm with Standby Full scale to full scale 1 Lower Limit Alarm with Standby Full scale to full scale 1 Upper Lower Limits Alarm with Standby 0 to full scale 1 1 When input is voltage current full scale is the linear conversion span 2 When input is voltage current the valid range is the linear conversion minimum value to linear conversion maximum value 6 20 FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR PID Module Configuration UO Function Selections PID Module Configuration Slot 1 2 x 1 Module Type No FCSA F2M2 E Input Parameters Control Parameters Output Parameters CHO InputCHO Je E CHO output cHo GC 2 Type K
212. s from the control register for each parameter differs For details about the positions from the control register of CH1 control see 5 17 to 5 20 1 Control Register 99 Output Type Select the output type for the FC5A F2M2 Voltage or current output can be selected Voltage output 12V DC 15 Current output 4 to 20mA DC FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 45 CONFIGURING PID MODULE USING WINDLDR 2 Control Register 30 Control Period The control period determines the duration of the ON OFF cycle of the control output that is turned on and off according to the output manipulated variable MV calculated by the PID control action The ON pulse duration of the control output is determined by the product of the control period and the output manipulated variable MV When the heating cooling control is enabled the control period will be the heating control period When the output type is current the control period is disabled Example When the control period is 5 sec Output Manipulated Output Manipulated Output Manipulated Variable MV 8096 Variable MV 6096 Variable MV 5096 Control Output OFF ON 4sec OFF ON 3 sec OFF ON 2 5sec OFF ON ES OO gt 5 sec 5 sec 5 sec 3 Control Register 46 Output Manipulated Variable Upper Limit This value specifies the upper limit of the output manipulated variable MV The output manipulated variable upper limit is used to suppress the output manipulated vari
213. ss variable PV of CHO control The heating output and cooling output is turned on or off in accordance with heating output manipulated variable MV and cooling output manipulated variable MV PID parameters proportional band proportional gain integral time derivative time and ARW are automatically calculated using auto tuning AT If the process variable PV of CHO control becomes out of the range between 194 5 C and 205 5 the upper lower limits alarm output QO is turned on and the control is disabled System Configuration and Wiring Wiring Example of the FC5A F2M2 Non contact voltage output for SSR drive current output type 3 phase Power Supply Electric Furnace PID Module FC5A F2M2 FC5A MicroSmart PID Module User s Manual FC9Y B1283 7 15 APPLICATION EXAMPLES PID Module Parameter Configuration The parameters of the PID module can be configured in the Expansion Modules Configuration and PID Module Configuration dialog boxes The procedure to configure the PID module is described below Parameter Configuration Example Quantity of Modules 1 unit Slot No Slot 1 Module Type No FC5A F2M2 Data Register D1000 Internal Relay M1000 I O Function Used as a heating cooling control PID module CHO CH1 Input Type K thermocouple with a decimal point 0 0 to 400 0 C Output Non contact voltage output for SSR drive Non contact voltage output for SSR drive Alarm 1
214. step 0 to step 9 can be configured All parameters of block 30 to 39 are shown in the following tables For detail about each parameter see page 5 23 Offset from the Control Register StepO Step 1 Step2 Step3 Step 4 390 409 428 447 466 Set point SP 391 410 429 448 467 Step time 392 411 430 449 468 Wait value 393 412 431 450 469 Proportional term 394 413 432 451 470 Integral time 395 414 433 452 471 Derivative time 396 415 434 453 472 ARW Anti Reset Windup 397 416 435 454 473 Output manipulated variable rate of change 398 417 436 455 474 Alarm 1 value 399 418 437 456 475 Alarm 2 value 400 419 438 457 476 Alarm 3 value 401 420 439 458 477 Alarm 4 value 402 421 440 459 478 Alarm 5 value 403 422 441 460 479 Alarm 6 value 404 423 442 461 480 Alarm 7 value 405 424 443 462 481 Alarm 8 value 406 425 444 463 4482 Reserved 407 426 445 464 483 Output manipulated variable upper limit 408 427 446 465 484 Output manipulated variable lower limit Parameter Offset from the Control Register Siep5 Step6 Step7 Step8 Step 9 485 504 523 542 561 Set point SP 486 505 524 543 562 Step time 487 506 525 544 563 Wait value 488 507 526 545 564 Proportional term 489 508 527 546 565 __ Integr
215. ster Step0 Step1 Step2 Step3 Step4 Parameter Default Value 390 409 428 447 466 Set Point SP 0 C 0 391 410 429 448 467 Step Time 0 minutes 0 1392 411 1430 449 468 WaitValue 0 C 0 4393 412 431 4450 469 Proportional Term ad ET 0 1394 413 432 4451 470 Integral Time 200 sec 200 395 414 433 452 471 Derivative Time 50 sec 50 4396 415 434 4453 472 ARW Anti Reset Windup 50 50 4397 4416 4435 4454 4473 Rae Oan Variable oe I eecond 0 1398 417 436 455 474 Alarm 1 Value 399 418 437 456 475 Alarm 2 Value 3400 419 438 457 476 Alarm 3 Value 3401 1420 4439 4458 477 Alarm4 Value 0C 0 1402 421 1440 4459 478 Alarm5 Value 403 422 441 460 479 Alarm 6 Value 404 423 442 461 4480 T Alarm 7 Value 405 424 443 4462 481 Alarm 8 Value 406 425 444 463 482 Reserved 0 407 4426 445 4464 483 Ge Manipulated Variable 400 100 pper Limit 408 4427 4446 465 4484 Mu Manipulated Variable o 0 ower Limit Offset from the Control Register Lower Limit Step5 Step6 Step7 Step8 Step 9 Parameter Default Value 485 504 523 542 561 Set Point SP 0 C 0 486 505 524
216. t Process Variable PV or Process Variable PV 195 C Alarm Output ON 197 C Process Variable PV S 203 C Alarm Output OFF ee 5 C SC gt d 195 C 197 C200 C 203 C 205 C ZO Standby functions Notes When the set point SP is changed the standby function is enabled Once the process variable PV enters the alarm output off range the standby function is canceled Even when an alarm output is triggered the PID module continues its control To stop the control when an alarm is triggered ladder programming is needed For a ladder program example see 7 6 7 Control Register 37 Alarm 1 Value Conirol Register 38 Alarm 2 Value Conirol Register 39 Alarm 3 Value Conirol Register 40 Alarm 4 Value Conirol Register 41 Alarm 5 Value Conirol Register 42 Alarm 6 Value Conirol Register 43 Alarm 7 Value Conirol Register 44 Alarm 8 Value There are two types of alarms Deviation alarm and process alarm Alarm Type Alarm Value Alarm Action The alarm output turns off if the Upper Lower limit range alarm process variable PV exceeds the range Upper limit alarm Deviation Lower limit alarm Deviation TO e set point SP is the alarm Alarm Upper Lower limits alarm value The alarm output turns on if the Upper limit alarm with standby i process variable PV exceeds Lower limit alarm with standby the range Upper Lower limits alarm with standby Process Process high alarm The alar
217. t SP 200 C Alarm 1 Value 55 C Alarm 1 Hysteresis 2 0 C Alarm Action 205 C lt Process Variable PV Alarm Output ON Process Variable PV 195 C Alarm Output ON Process Variable PV 203 C Alarm Output OFF 197 C amp Process Variable PV Alarm Output OFF Alarm Value Alarm Value SP Alarm Value Setting Example Set Point SP 200 C Alarm 1 Value 5 C Alarm 1 Hysteresis 2 0 C Alarm Action Alarm Value SP Setting Example Set Point SP 200 C Alarm 1 Value 25 C Alarm 1 Hysteresis 2 0 C Alarm Action 205 C S Process Variable PV or 195 C lt Process Variable PV lt 205 C Alarm Process Variable PV 195 C Alarm Output ON Output ON 197 C lt Process Variable PV 203 C Alarm 6 26 Alarm Value Alarm Value SP Alarm Value Setting Example Set Point SP 200 C Alarm 1 Value 5 C Alarm 1 Hysteresis 2 0 C Alarm Action 207 C Process Variable PV or Output OFF Process Variable PV S 193 C Alarm Output OFF 195 C 197 C 200 C 203 C 205 C 193 C 195 C 200 C 205 C 207 C FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR Process High Alarm Process Low Alarm Alarm Hysteresis Alarm Hysteresis ON _ ON OFF OFF Alarm Value Alarm Value Setting Example Alarm 1 Value 195 C Alarm 1 Hysteresis 2 0 C Setting Example Alarm 1 Value 205 C Alarm 1 Hysteres
218. t CHO as CHO gt output cHo Lg Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Pi Pe a Pi Input Saas Difference CHO CHI E ae En Cup HE e gs basis Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Difference CH1 CHO The difference between input CH1 and input CHO is used as the process variable PV for CH1 control Process variable PV of CH1 control Input CH1 input value Input CHO input value Input Parameters Control Parameters Output Parameters CHO T Input CHO CHO gt Output CHO Den CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Control Parameters Output Parameters CH ference CH1 CHO gt CH 9 Output CH1 j CH Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Addition CH0 CH1 The addition of input CHO and input CH1 is used as the process variable PV for CH1 control Process variable PV of CH1 control Input CHO input value Input CH1 input value Input Parameters Control Parameters Output Parameters cH gt Input cHo CHO gt output CHo Den CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input us ier CHO CHI m tah Ente Seen Bm aes Type K thermocouple Celsius Reverse Control Action Heating Voltage Output External SP Input
219. t and connect the PID module again GE The PID module is not connected to the configured slot number Turn off 3 Fi the Ce and connect the PID module to the appropriate slot number 5 4 FC5A MicroSmart PID Module User s Manual FC9Y B1283 DEVICE ALLOCATION OF PID MODULE Examples of changing the PID module parameters using the control relay All parameters of block 1 to 5 10 to 19 and 30 to 39 can be changed using a ladder program The following examples demonstrate how the parameters of the PID module can be changed See pages 5 7 to 5 24 for detail about each block parameter Example 1 Changing Block 1 Parameter The set point SP of CHO control D1020 is changed to 250 5 C In this example D1000 is allocated to the control register and M500 is allocated to control relay When the new set point 2505 is stored in D1020 it is automatically written to the PID module Ladder Program Example When external input IO is turned on the set point SP of CHO will be changed to 250 5 C When l0 is turned on the new set i MOV St Dt D I point 2505 is stored in D1020 set point SP of CHO 1 When the input range has a decimal point store the value multiplied by 10 in the data register 2 When the control register is D1000 Block 1 parameters are stored in D1020 to D1025 These values are written to the PID module every scan Example 2 Changing Block 2 Parameters The integral time D1027 is changed to 150 s
220. t point SP is bigger than the wait value the program control does not move to the next step The program control proceeds to the next step once the deviation between the process variable PV and set point SP becomes smaller than the wait value Repeat Function When the all steps are executed and the program control is terminated the program control can be repeated from Step 0 as many times as the repeat number configured FC5A MicroSmart PID Module User s Manual FC9Y B1283 4 9 PID MODULE MAIN FUNCTIONS Program Control Operation Bits and Status Monitoring By turning on off the operation parameter bit program control progression can be operated By monitoring program run status the current status of program control can be monitored For the allocation of operation parameter program run status operating status see pages 5 7 to 5 10 Program Control Start Start the program control Turn on the program control bit Bit3 of the operation parameter Program control starts Program Control Stop Terminate the program control Turn off the program control bit Bit3 of the operation parameter Program control stops and enters standby status Program Hold Suspend the program control Turn on the program hold bit Bit4 of the operation parameter Program control is held Suspended While the program control is held time progression is suspended and fixed value control is performed with the set point SP at the time that the pr
221. ter download and click OK button The user program will be downloaded After downloading the user program the PID module parameters will be automatically written to the data registers in the CPU module and the PID module connected to the CPU module Note The CPU module and the connected PID module exchange data through the allocated data registers in the CPU module In order for the CPU module to communicate with the PID Module it is required that the user program be downloaded to the CPU module after configuring the PID Module in the Expansion Modules Configuration dialog box In order for the PID module to operate it is required that the parameters be written to the data registers in the CPU module and the PID module 6 2 FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR Writing and Reading Parameters When Write All Parameters or Read All Parameters is executed in the PID Module Configuration dialog box all parameters will be written to read from the PID module as follows WindLDR gt Flow of the parameters when executing Write All Parameters gt Flow of the parameter when executing Read All Parameters CPU Module PID Module RAM Data Register Downloading and Uploading User Program When the user program download or upload is executed the user program is downloaded to uploaded from the CPU module as follows
222. terminals of the PID module If a linear conversion minimum value is indicated the PID module is operating normally and the signal wire may be disconnected 2 Operating status under range flag remains ON Checking Items Action Does the input signal source for voltage 1 to 5V DO or current 4 to 20mA operate normally Check the input signal source for voltage 1 to 5V DC or current 4 to 20mA How to check whether the input signal wire is disconnected Voltage 1 to 5V DC Input 1V DC to the input terminals of the PID module If a linear conversion minimum value is indicated the PID module is operating normally and the signal wire may be disconnected Current 4 to 20mA Input 4mA to the input terminals of the PID module If a linear conversion minimum value is indicated the PID module is operating normally and the signal wire may be disconnected 3 The process variable PV constantly shows the linear conversion minimum value Checking Items Action Does the input signal source for voltage 0 to 5V DC 0 to 10V DO or current 0 to 20mA operate normally Check input signal source for voltage 0 to 5V DC or 0 to 10V DC or current 0 to 20mA How to check whether the input signal wire is disconnected Voltage 0 to 5V DC or 0 to 10V DC Input 1V DC to the input terminals of the PID module If a converted value calculated with the linear conversion minimum and maximum values co
223. ters ad CHO Voltage Output Scl Output Parameters CH1 Voltage Output Input Range Type K thermocouple Celsius 200 to 1370 c PV Correction 0 0 E 100 0 to 100 0 c PV Filter Time Constant 0 0 Z 0 0 to 10 0 sec ze Set Point SP Upper Limit 1370 200to 1370 c Set Point SP Lower Limit 200 E 200 to 1370 C Alarms Alarm Type Alarm Value Hysteresis 0 1 to 100 0 C Delay Time 0 to 10000 sec Upper Limit Alarm Kb 1 0 No Alarm Action D I 1 0 Alarm 3 No Alarm Mi 1 0 Alan o Alarm Action 0 1 0 Alarm 5 No Alarm Action Q 1 0 Alarm 6 No Alarm Action 0 1 0 Alarm 7 No Alarm Action 0 1 0 Alarm 8 No Alarm Action 0 1 0 Write all parameters Read all parameters Monitor ok Cancel Item Setting L Input Range Type K thermocouple Celsius Set Point SP Upper Limit 1370 C alse Alarm 1 Type Upper limit alarm 3 Set Point SP Lower Limit 200 C CS Alarm 1 Value 5 C 7 4 FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPLICATION EXAMPLES 6 Control CH1 Parameters Setting Configure the Control CH1 parameters in the PID Module Configuration dialog box To open Control CH1 Parameters in the PID Module Configuration dialog box click on Control Parameters CH1 button or the Control CH1 tab PID Module Configuration Dialog Box Control CH1 Parameters PID Module Configuration
224. ters of each block can be read from written to the PID module using the allocated control relays Block ee Description Block 0 20 Read only parameters CHO CH1 Block 1 6 Write only parameters CHO CH1 Block 2 27 Basic parameters CHO Block 3 27 Basic parameters CH1 Block 4 50 Initial setting parameters CHO Block 5 50 Initial setting parameters CH1 Blocks 10 to 19 21 block Program parameters CHO Blocks 30 to 39 19 block Program parameters CH1 Block 0 includes parameters such as operating status current process variable PV set point SP and output manipulated variable MV of the PID module The CPU module reads those parameters from the PID module every scan The control status and alarm status of the PID module can be monitored with Block 0 parameters Block 1 includes the set point SP manual mode output manipulated variable MV and operation parameters of the PID module Those parameters are written to the PID module every scan Operations such as changing the set point SP for the fixed value control enabling disabling the control or performing auto tuning AT can be carried out Blocks 2 and 3 include basic parameters of the PID module By turning the control relay from off to on parameters can be read from written to the PID module Blocks 4 and 5 include initial setting parameters of the PID module Parameters that are usually not changed during the operation are sto
225. the MicroSmart CPU and the PID module is recommended to suppress the influence of noise If the same power source is used for the PID module and MicroSmart CPU module after the MicroSmart CPU is started to run the PID module performs initialization for a maximum of 5 seconds During this period each parameter has an indefinite value Design the user program to make sure that each parameter is referred in the CPU module after the PID module operating status is changed to 0001h Normal operation Wiring of Power Line and I O Lines for the PID Module Separate the I O lines particularly resistance thermometers from the power line as much as possible to suppress the influence of noise Fuse 50V 1 2A Separate the UO lines from the power line as much as possible 0 to 5V 1t05V 0 to 20mA 0 to 10V 4 to 20mA 0 to 1V A m DC DC oo H Ts RTD 0 to 5V E A 1t05V 0 to 20mA 0 to 10V 4to 20mA 0 to 1V DC DC pe EB TCi DC RTD Terminal Channel 24V DC Gi Voltage Current Resistance thermometer Thermocouple Load Analog current input instrument Fuse Terminal Channel NC NC NC NC NC OUTO IN1 NC NC OUT1 FC5A Micr
226. the hunting phenomenon may be caused over a long cycle On the contrary if the integral time is extended too much the integral action becomes weak and it takes time to correct the offset An appropriate integral time for the control target can be automatically calculated using auto tuning AT function It is unnecessary to configure the integral time in the WindLDR when using the auto tuning AT function 6 36 FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR 8 Control Register 28 Derivative Time When the set point SP is changed or when the deviation between the set point SP and the process variable PV is increased due to a disturbance the derivative action increases the output manipulated variable MV to rapidly correct the deviation between the process variable PV and the set point SP The derivative time is a coefficient to determine the output manipulated variable MV of the derivative action The derivative action is disabled when the derivative time is O If the derivative time is shortened the derivative action becomes weak The response to the rapid temperature change becomes slower Because the action to suppress the rapid temperature rise becomes weaker the time for the process variable PV to reach the set point SP is shortened however overshoot can occur If the derivative time is extended the derivative action becomes strong The response to the rapid temperature chang
227. the start of step 1 while the program hold is maintained The program control is proceeded to the start of step 2 while the program hold is maintained The program hold is canceled and the program control is started from the start of step 2 Note The PID module executes all steps 0 to 9 even if the step times of steps are zero When the program control is terminated nine is stored in the current step number of block 0 FC5A MicroSmart PID Module User s Manual FC9Y B1283 5 11 DEVICE ALLOCATION OF PID MODULE Example 2 Continue Program Control Repeat when Program Ends The following diagram shows an example of the program control when continue program control repeat is selected as the program end action Time of steps Step 0 and 1 60 minutes Step 2 30 minutes Steps 3 to 9 0 minute Number of repeats 1 In this example D1000 is allocated to the control register and M500 is allocated to control relay Current step number 1 ME D1006 l l I I I i Number of repeats remaining i D1007 l I I l l I l l l Control enable bit on D1022 0 pd L l I l l l ON Program control bit I D1022 3 atp i l I l I Program control bit ON i Monitor l I l ON i i Program hold bit D1022 4 OFF Advance next step bit oN i D1022 6 OFF l l l Advance previous step bit ON D1022 7 7 I I OFF T ON Program end output i D1010 6 E 1 After the steps 0 to 2 are The program
228. thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Control Parameters Output Parameters E ETT S oem pmp m Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input CHO Control CHO Output CHO Input CHl Control CH1 Output CH1 Monitor Input Range Type K thermocouple Celsius 200to 1370 C PV Correction 0 0 100 0 to 100 0 c PV Filter Time Constant 0 0 0 0 to 10 0 sec Set Point SP Upper Limit 1370 EI 200 to 1370 c Set Point SP Lower Limit 200 EI 200 to 1370 c Alarms el Alarm Type Alarm Value Hysteresis 0 1 to 100 0 C Delay Time 0 to 10000 sec Alar 1 Upper Limit Alarm NO 1 0 Alar Upper Limit Alarm o 1 0 Alarm 3 Upper Limit Alarm zo 1 0 Alarm 4 Upper Limit Alarm o 1 0 Alarm 5 Upper Limit Alarm zo 1 0 Alarm 6 Upper Limit Alarm 0 1 0 Alarm 7 Upper Limit Alarm 70 1 H Write all parameters Read all parameters Monitor ok Cancel 1 Control Register 56 Input CHO Function The one of the following input functions can be selected as the Input CHO Function Input CHO Input CHO is used as the process variable PV for CHO control Control Parameters CH0 Input Parameters ET 2 Output Cio Output Parameters CHO ig el e S CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters ee Control Parameters a Output Parameters CH gt
229. ting Control Output 0 OFF 9 P 1 ON Unknown for current output Biti Cooling Control Output 0 OFF CHO only 1 ON Unknown for current output Bit2 Loop Break Alarm E E S 1 Loop break alarm is occurring 0 Normal operation Input value is exceeding the upper limit of the control range See page 9 4 Bit3 Over Range 1 Thermocouple or resistance thermometer may be burnt out Voltage input 0 to 1V DC may be disconnected 0 Normal operation Input value is below the lower limit of the control range See page 9 4 iu Ringer Range 1 Voltage input 0 to 5V DC may be disconnected Current input 4 to 20mA DC may be discon nected i 0 Normal operation Bip e 1 Program wait is functioning 0 OFF Bit6 Program End Output 1 ON 0 OFF Bit7 Alarm 1 Output 1 ON 0 OFF Bit8 Alarm 2 Output 1 ON 0 OFF Bit9 Alarm 3 Output 1 ON f 0 OFF Bit10 Alarm 4 Output 1 ON 0 OFF Bit11 Alarm 5 Output 1 ON 0 OFF Bit12 Alarm 6 Output 1 ON 0 OFF Bit13 Alarm 7 Output 1 ON 0 OFF Bit14 Alarm 8 Output 1 ON Bit15 Reserved 0 0 Fixed value FC5A MicroSmart PID Module User s Manual FC9Y B1283 DEVICE ALLOCATION OF PID MODULE Data Register Allocation Block 1 Write Only Parameters The CPU module writes the following parameters stored in the data registers to the PID module every scan Offset from the Control Parameter Description R W Register When the input is thermocouple or resistance thermometer
230. tion FC5A MicroSmart PID Module User s Manual FC9Y B1283 DEVICE ALLOCATION OF PID MODULE Examples of Program Control Progress Example 1 Terminate Program Control when Program Ends The following diagram shows an example of the program control when terminate program control is selected as the program end action Time of steps Step 0 and 1 60 minutes Step 2 30 minutes Steps 3 to 9 0 minute In this example D1000 is allocated to the control register and M500 is allocated to control relay Current step number D1006 30 min 5 min Control enable bit D1022 0 Program control bit l l I l D1022 3 Program hold bit D1022 4 Program end output D1010 6 The program control is started from the start of Step 1 30sec 15sec I I l I 45 min l l l l l ON L i l l l l l l OFF I l I l ON i OFF LL 2 d cor xt l PR U I I I d i i 1 I I l l l 1 i i I E xp qs 2 Program control bit ON l I m Monitor l l 1 II D1009 3 OFF dl Ing EE M l IER l 1 pg Pg Fo q B np i eae AO us d dg I Advance next step bit ON l i i T Ini D1022 6 i E usc fi OFF sL I rd I I l i E I i i Advance previous step bit ON 1 D1022 7 l 1 OFF i I I 1 The program control is held at the 40 minutes of remaining time The program control is proceeded to
231. tput En NE 7 D1010 6 a l t I l l The program control is proceeded to the start of step 2 while the program hold is maintained The program control is held at 1 minute of the remaining time The program hold works when the remaining time is not zero The program control is proceeded to the start of step 2 while the program hold is maintained The program hold is canceled and the program control is started from the start of step 2 FC5A MicroSmart PID Module User s Manual FC9Y B1283 5 13 DEVICE ALLOCATION OF PID MODULE Example 4 Hold Program Control when Program Ends The following diagram shows an example of the program control when hold program control is selected as the program end action Time of steps Step 0 and 1 60 minutes Step 2 30 minutes Steps 3 to 9 0 minute In this example D1000 is allocated to the control register and M500 is allocated to control relay Current step number D1006 Control enable bit RN D1022 0 ore Program control bit oN D1022 3 OFF Program control bit ON Monitor D1009 3 OFF Program hold bit D1022 4 Advance next step bit D1022 6 Advance previous step bit D1022 7 Program end output D1010 6 OFF After all steps are executed the program While the program hold is maintained at the control is held and the fixed value control end of the program control the program hold bit is performed with the parameters of step 9 and advance previous
232. uctuations are given to the process at the set point SP regardless of AT bias During program control fluctuations are given to the process as soon as auto tuning AT is started Auto tuning AT In order to configure P proportional band integral time D derivative time and ARW Anti Reset Windup automatically with optimal values the auto tuning AT can be performed The auto tuning AT gives temperature fluctuation to the process to calculate those parameters To perform an optimal auto tuning AT temperature fluctuation is given to the process when the process variable PV reaches near the set point SP By setting the AT bias the temperature to start giving fluctuation can be configured The relation between the set point SP AT bias auto tuning AT starting point and fluctuation starting point are shown below Process variable PV lt Set point SP AT bias value When AT bias is set to 20 C the PID module starts giving the temperature fluctuation to the process at the temperature 20 C lower from the set point SP Temperature 1 Fluctuation period PID parameters are Sin ME E measured SP 20 C 4 2 PID parameters are calculated and auto tuning AT is finished 3 Temperature is controlled with the PID parameters configured with auto tuning AT 4 AT bias value 20 C a A AT Auto tuning AT perform bit is turned on Set point SP AT bias value lt Process
233. uid level difference of 2 tanks The PID module measures the liquid levels of 2 tanks and controls output to keep liquid level difference between Tank A and Tank constant Input CH1 Input CHO Example 2 Cabinet Interior Dew Condensation Prevention The PID module measures interior and external temperatures of the cabinet and controls output to keep the temperature difference between interior and external cabinet constant so that dew condensation inside the cabinet can be prevented PID Module Output CHO Input CH1 Temperature Cabinet 4 14 FC5A MicroSmart PID Module User s Manual FC9Y B1283 PID MODULE MAIN FUNCTIONS Cascade Control The cascade control combines two PID controls to form one feedback loop to control a single target The cascade control is effective for applications in which the delay time or dead time is considerably large When delay time is large it takes a long time for the process variable PV to change after the output manipulated variable MV is changed By using the cascade control highly stable control can be realized for such applications though it takes time for the process variable PV to reach the set point SP CH1 control is used as the master and CHO control as the slave of the cascade control The output manipulated variable MV of the master CH1 control becomes the set point SP of the slave CHO control and the control result of CHO is outputted from the CHO output The o
234. ule Read this user s manual to ensure the correct understanding of the entire functions of the PID module NOTICE 1 This publication is not to be nor any parts of it photocopied reprinted sold transferred or rented out without the specific written permission and consent of IDEC 2 The contents of this user s manual are subject to change without notice 3 Care has been taken to ensure that the contents of this user s manual are correct but if there are any doubts mistakes or questions please inquire our sales department MicroSmart Modules Category Modules MicroSmart FC5A series MicroSmart pentra FC5A Series MicroSmart All in One Type FC5A C10R2 FC5A C10R2C FC5A C16R2 FC5A C16R2C FC5 Series FC5A C24R2 FC5A C24R2C CPU Modules Slim Type FC5A D16RK1 FC5A D16RS1 FC5A D32K3 FC5A D32S3 FC5A D12K1E FC5A D12S1E PID Modules FC5A F2MR2 FC5A F2M2 Expansion Communication Modules FC5A SIF2 FC5A SIF4 Memory Cartridge FC4A PM32 FC4A PM64 FC4A PM128 Expansion Modules Expansion I O module Function module Expansion I O Modules Input modules Output modules Mixed I O modules Function Modules Analog modules AS Interface master module PID module HMI base module expansion RS232C communication module expansion RS485 communication module HMI module Memory cartridge Clock cartridge RS232C communication adapter RS485 communication adapter WindLDR Application software Wi
235. us is also saved at the start of each step If the power to the PID module is turned off while the program control is running the PID module resumes the program control from the latest saved point 99 6 min Step Time a Program Control Status M gt Saved Point i l y 5d p i 1 1 E j pou a e 1 1 1 Elapsed Time pel NE from Program e y pj a a p o Control Start l 0 min 6 min 2 min 18 min e e 30min 34min 10 min 24min 28min For example if the power to the PID module is turned off in 7 minutes after the program control is started at step 0 the PID module resumes the program control at the status 1 when the power is restored If the power to the PID module is turned off in 4 minutes after the program control enters step 1 the PID module resumes the program control at the status 2 when the power is restored If the power to the PID module is turned off in 2 minutes after the program control enters step 2 the PID module resumes the program control at the status 3 which is the start of step 2 when the power is restored 3 To restart the program control from the start of step 0 turn off and on the program control bit operation parameter Bit3 FC5A MicroSmart PID Module User s Manual FC9Y B1283 PID MODULE MAIN FUNCTIONS Program Pattern Example The set point SP configured for each step is handled as the set point SP at the end of the step The time configured for each step is the
236. used for a high temperature heater used at approximately 1500 to 1800 C which has to be heated gradually as the heater can be burnt out if the power is supplied rapidly Normal Output Output When Output Manipulated Variable Rate of Change is Configured 100 sec 20 sec 10 sec 1 second 5 seconds 10 seconds 15 Control Register 61 Output ON OFF Hysteresis Output on off hysteresis can be configured When the control action turns from on to off and vice versa the span between on and off positions is called output on off hysteresis If the output on off hysteresis is narrowed the control output switches to on or off even by a slight variation of temperature at around the set point SP This frequent on off shortens the output relay life and may negatively affect the connected equipment To prevent that harmful effect the hysteresis is provided for on off control action Output on off hysteresis can be configured only for the ON OFF control action when the proportional band or proportional gain is 0 16 Control Register 21 Manual Mode Output Manipulated Variable The output manipulated variable MV for the manual mode can be configured FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR 17 Control Register 35 Loop Break Alarm Time Configure the loop break alarm time to detect the loop break alarm The loop break alarm is disabled when the loop break alarm time is 0 When one of the f
237. utput manipulated variable MV 0 to 10096 of the master CH1 control is corresponded to the set point SP of the slave CHO according to the external SP input linear conversion minimum and maximum values For example when the external SP input linear conversion minimum value is 100 C and the maximum value is 400 C the output manipulated variable MV 0 to 100 of the master CH1 control is converted as follows 0 is converted to 100 C 50 is converted to 250 C and 100 is converted to 400 C When a system using the cascade control is designed it is required that the slave CHO control have smaller delay time and faster response comparing to the master CH1 control Example The cascade control is used for an application in which the heat quantity of a heater is controlled using a power controller in order to control the temperature of the control target as shown in the figure below It is also possible to utilize the heating cooling control to prevent a rapid temperature rise of the control target by using a fan as the cooling output PID Module with Cascade Control Master Primary Control CH1 Input Control Target Slave Secondary Control SES SEET CH1 Output System Configuration and Wiring Wiring Example of the FC5A F2M2 Current Output Type Single Phase 200V SP S Channel 24V DC SUR o Control Power GE Target Heater CHO Thermocoup
238. values of the master CH1 will be automati cally configured Notes When using the cascade control store the same set point of the master CH1 to the set point SP of the slave CHO The output manipulated variable MV 0 to 10095 of the master CH1 corresponds to the set point SP of the slave CHO The range of the set point is the external SP input linear conversion minimum value to the external SP input linear conversion maximum value Depending on each control target optimum values of P D and ARW may not be calculated with the auto tuning AT In such case configure those parameters manually based on the P D and ARW values calculated with the auto tuning AT Program Example of Auto tuning AT for Cascade Control A sample ladder program to execute the auto tuning AT for the master CH1 and slave CHO in the cascade control is described in the following page 4 16 FC5A MicroSmart PID Module User s Manual FC9Y B1283 PID MODULE MAIN FUNCTIONS D1009 01 MOV W SIR D0000 MOV W SIR D1178 D1023 DIR D1178 DIR boo000 D1178 REF RER 1st Scan after the completion of CH1 auto tuning AT At the falling edge of D1018 1 CH1 auto tuning monitor bit QO is turned on 3rd Scan At the rising edge of M1 the following are executed in order D1022 0 is turned on CHO control is enabled D1022 1 is turned on AT for CHO control is performed D1025 0 is turned on CH1 control is
239. variable PV lt Set point SP AT bias value The PID module starts giving the temperature fluctuation to the process when the process variable PV reaches the set point SP Temperature 1 Fluctuation period PID parameters are SP420 C measured 2 PID parameters are calculated and auto tuning AT is finished 3 Temperature is controlled with the PID parameters configured with auto tuning AT 4 AT bias value 20 C SP LL SP 20 C A AT Auto tuning AT perform bit is turned on FC5A MicroSmart PID Module User s Manual FC9Y B1283 PID MODULE MAIN FUNCTIONS Process variable PV 2 Set point SP AT bias value When AT bias is set to 20 C the PID module starts giving the temperature fluctuation to the process at the temperature 20 C higher from the set point SP Temperature fi 1 Fluctuation period PID parameters are measured R 2 PID parameters are calculated and auto SP 20 C tuning AT is finished Ee 3 Temperature is controlled with the PID parameters configured with auto tuning AT 4 AT bias value 20 C A AT Auto tuning AT perform bit is turned on Auto reset During the P control or PD control action the deviation offset between the process variable PV and the set point SP is generated when the process variable PV is stabilized By performing auto reset the reset value can automatically be calculated to correct the offset It is requ
240. variable upper limit FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR PID Module Configuration Program Parameters List CHO and CH1 Program parameters for CHO and CH1 are described here PID Module Configuration Slot 1 Module Type No FCSA F2M2 H Ax Input CHO Control CH0 Program CHO 1 Output CHO Input CH1 Output CH1 Monitor IRL Range Step 0 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Set Point SP 200 to 1370 C 0 0 0 0 0 o 0 o 0 o D Step Time 0 to 6000 min 0 0 0 0 0 0 0 0 0 0 4 Wait Value Oto 100 C 0 o 0 o 0 0 0 o 0 o e Proportional Band 0 to 10000 C 10 10 10 10 10 10 10 10 10 10 6 Integral Time 0 to 10000 sec 200 200 200 200 200 200 200 200 200 200 GE Derivative Time 0 to 10000 sec 50 50 50 50 50 50 50 50 50 50 8 ARW Anti Reset Windup Dto 100 50 50 50 50 50 50 50 50 50 50 Output Mv Rate of change 0 to 100 sec 0 0 0 o 0 0 0 0 0 0 9 nnn Alarm 1 Value 1570 to 1570 C 0 0 0 0 0 0 0 0 0 0 10 L alarm 2 value 1570to 1570 C o o 0 o 0 o 0 0 0 o 11 Alarm 3 Value 1570 to 1570 c 0 o 0 o D 0 D 0 n 0 1 2 Alarm 4 Value 1570 to 1570 C 0 0 0 0 0 0 0 0 0 0 IE Alarm S Value 1570to 1570 C o o 0 o 0 o 0 o 0 0 14 Alarm 6 Value 1570 to 1570 C o H 0 0 0 0 0 0 0 o Alarm 7 Value 1570to 1570 C o 0 0 0 0 0 0
241. verlap Dead Band 0 0 C 0 Offset from the Control Register Step5 Step6 Step7 Step8 Step9 Parameter Default Value 285 306 327 348 369 Set Point SP 0 C 0 286 307 328 349 370 Step Time 0 minutes 0 287 308 329 350 371 Wat Value 0 C 0 4288 309 330 351 372 Proportional Term de 3 289 310 331 352 373 _ Integral Time 200 sec 200 290 311 332 353 374 Derivative Time 50 sec 50 291 312 333 354 375 ARW Anti Reset Windup 50 50 4292 4313 4384 4355 4376 uat Variable ge econd 0 293 314 335 356 377 Alarm 1 Value 294 315 336 357 378 Alarm 2 Value 295 316 337 358 379 Alarm 3 Value 296 317 338 359 380 Alarm 4 Value 0 C 0 297 318 339 360 381 Alarm 5 Value 298 319 340 361 382 Alarm 6 Value 299 320 341 362 383 Alarm 7 Value 300 321 342 363 384 Alarm 8 Value 301 322 343 364 385 Reserved 0 302 323 344 4365 4386 mE Variable 400 100 Output Manipulated Variable 5 303 324 345 366 387 Lower Limit 0 0 304 325 346 367 388 Cooling Proportional Band 1 0 times 10 305 326 347 368 389 Overlap Dead Band 0 0 C 0 FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPENDIX Blocks 30 39 CH1 Program Parameters Offset from the Control Regi
242. will be advanced to the end of Step 3 and the program control will be terminated PVR Start Action Process variable PV is 25 C sepNumber 9 3 Jef 0 1 Set Point SP 25 C 16090 beets du eo n eA E i i 100 C ym EE 4 7 NC p 1 1 1 1 B ISE che ue T T TT SE e Nee wae l BOC T EE Time When the program control is repeated the time will be advanced until the set point SP becomes equal to 60 C of the process variable PV and then the program control starts from this point When the program control is started the time will be advanced shown in dotted line until the set point SP becomes equal to 25 C of the process variable and then the program control starts from this point Program Control Run Program control is repeated The process variable is 60 C SP Start Action Set point SP when Program Control Starts is 0 C stepNumber 8 Je 3 1 4 Set Point SP 150 C 100 C 50 C Time When the program control is started the program control will start from 0 C of the set point SP configured with Set Point SP when Program Control Starts regardless of the current process variable PV 6 42 FC5A MicroSmart PID Module User s Manual FC9Y B1283 CONFIGURING PID MODULE USING WINDLDR 24 Control Register 96 Set Point SP when Program Control Starts The set point SP when program control starts can be configured The
243. y output 30 sec 30 49 126 Cooling Control Period CHO only FC5A F2M2 Non contact voltage output 3 sec 3 CH1 0 450 127 Overlap Dead Band CHO only tm E 451 4128 Cooling Output Manipulated Variable Upper CHO 100 100 Limit CHO only CH1 0 452 4129 Cooling Output Manipulated Variable Lower CHO 0 0 Limit CHO only CH1 0 FC5A MicroSmart PID Module User s Manual FC9Y B1283 APPENDIX Blocks 4 5 Initial Setting Parameters Offset from ge ae Parameter Default Value CHO CH1 453 4130 Control Action 0 Reverse action Heating 454 4131 Heating Cooling Control CHO only G S RA 55 132 External SP Input CHO only at N Disable 56 133 Input Function CHO CH1 0 Input CHO CH1 57 Output Function CHO CHO 0 Output CHO 134 Output Function CH1 CH1 0 Output CH1 58 135 Input Type 00h Type K thermocouple 200 to 1370 C 459 4136 ME ine Limit Linear Conversion 1370 C 1370 Set Point SP Lower Limit Linear Conversion 460 4137 Minimum Value 200 C 200 61 138 Output ON OFF Hysteresis 1 0 C 10 62 139 PV Correction 0 0 C 0 63 140 PV Filter Time Constant 0 0 seconds 0 64 141 Reserved 0 65 142 Alarm 1 Type 66 143 Alarm 2 Type 67 144 Ala

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