CAL Controls CALogix Programming and Installation Manual 33087
Contents
1. 0 To set a count value enter the required number in counts A counter requires two inputs to operate a count input and a control input As pulses are received at the count input the counter will increment an output is given when the set number of counts is received The counts received will reset to 0 when the control input goes to a high state 1 the block output is also reset to a low state 0 if the count value had been previously reached The operation of each of the input 1 and 2 can be selected in the properties window shown above It is also possible to select whether the counter will increment on a rising edge low to high state or level triggered i e when input reaches and is stable at a high state This is set within the trigger parameter within the properties window Comparator Comparator blocks take a voltage level from a logic 1 0 module and compare the value with either a constant or the value of another logic I O module input Page 34 of 44 Comparators convert the input level to a percentage of full scale e g a logic I O module input with range of 0 24V an input voltage of 2 4V will be considered to have a value of 10 0 in a comparator block The compare function allows a greater or a less than comparison with the input If the comparison is true the block will have a high state output 1 The block will require one input for comparing with a constant or two when comparing inputs The output mu2. 2 3 Mouse over properties select programmer and set points Expand programmer menu Module 1 Piagam Number Module 1 Run Mode Module 1 Paogam Loop Count Module I Program Segmeri Time Module 2 Program Number Module 2 gt Progam Run Mode Module 2 Progen Loop Count Scroll to required module Set program run mode of required module to off Apply settings to controller The program will now stop Page 30 of 44 Logic I O Module and Logic Programming OVERVIEW CALogix has integrated logic function capability that can be used for controlling a system by linking associated inputs and outputs using logic timer counter and comparator functions A logic programming utility is included within CALogix sw that can be used to create logic function block diagrams when a CALogix system has logic I O modules fitted The logic programming memory will allow programs up to 40 Boolean blocks or up to 16 timers counters depending on the complexity of the blocks used i e some function blocks e g timers have been developed by using several other function blocks and will therefore require more memory LOGIC I O MODULE SETTINGS To access logic I O settings right mouse click on the controller image mouse over properties then click on the module number module slot number must have logic I O module fitted The settings window will now open A user defined label name for the module can be entered
3. Input settings A Output settings Setpoint1 control Autotune setting Setpoint2 control Setpoint3 control Programmer For details of parameters in each of the sub menus see section on PID Module settings To expand a sub menu double click on next to the menu title Scroll to find required parameter To close sub menu click on CHANGING A SETTING VALUE UE Double click on value box of parameter Enter value for parameter Some parameters will have a drop down list select required option from list in these cases Click on parameter name to accept setting Repeat for all other required setting changes Once complete click on apply The setting changes will now be written to controller INITIAL SETTINGS There are a number of key settings required before initial operation of a CALogix PID module 1 Input sensor type Input settings menu Select input sensor type from drop down list Default J When changing the sensor type ensure that the setpoint 1 upper and lower limits are set to values that will allow the setpoints you wish to enter If selecting linear refer to section on linear inputs Select operating unit Module settings Select process units from drop down list Allocate outputs 1 2 amp 3 Output settings Allocate physical outputs 1 2 and 3 to SP1 SP2 SP3 Any physical output can be assigned as any setpoint but each output can only
4. Programmer 25 a Function overview 25 b Accessing the programmer interface 25 c Programmer interface 25 d Creating a program 25 e Program segment types 26 f Program properties 28 g Reading program data from a controller 28 h Creating an additional program 29 i Selecting a program 29 j Insert segments to a program 29 Deleting segments 29 I Modifying a program 29 m Running Programs 29 n Stopping a program 30 Logic module and Logic Programming 31 a Overview 31 b Logic I O module settings 31 C Accessing logic programming 31 d The logic toolbar 31 e Placing a function block on desktop 33 f Arranging function blocks 33 g Linking function blocks 33 h Function blocks selecting operation 33 Logic 33 Boolean 33 Timer 34 Counter 34 Comparator 34 Input 35 Output 35 Physical Output 39 Changing setpoint 35 Manual power 35 Autotune 36 Event input 36 Program 36 i Inverting Inputs 36 j Validating a logic program 37 k Writing a logic program to a controller 37 Running and stopping a logic program 37 m Trace mode 38 Appendix Function Block Operation 39 a Boolean tables 39 b Timer charts 40 Technical Specification 43 Safety and Warranty Information 44 Page 3 of 44 CALogix Installation Instructions System Overview CALogix is a modular multi loop PID controller with logic function capability The controller consists of a DIN rail mount base unit that
5. at the connection to the PC in addition to the last instrument in the chain See example below CALogix 1 CALogix 2 CALogix 3 E PC or HMI pie 13 gm When transmission lines are not transmitting they remain in an intermediate state which can allow receivers to receive invalid data bits due to electrical noise on the cable To prevent this bias resistors may be required to force the lines into a known state Some RS485 interface cards and converters may have bias resistors fitted please check manufacturer s specification and recommendations for use of bias resistors Note The default Modbus address for each base unit is 1 for a network with a number of CALogix units power up each unit individually and configure them with a unique Modbus address using CALogix sw configuration tool See section on base unit set up in manual CALOGIX SW MINIMUM PC SYSTEM REQUIREMENTS As a general requirement we would recommend a minimum of Pentium 450MHz with 256MB RAM Windows 2000 XP and screen resolution 1024 x 768 INSTALLING CALOGIX SW 1 Insert CALogix sw disk into CD drive 2 CALogix sw install program should auto run If this does not happen manually run setup exe on CALogix sw cd 3 Follow on screen instructions to complete installation RUNNING CALOGIX SW 1 Click start on Windows toolbar 2 Mouse over all programs 3 Mouse over CALogix folder in menu Page 12 of 44 4 Click on CALog
6. Click on LE to add a new instrument 2 Click on browse 3 Select communications port baud rate and Modbus address default 1 Once settings are entered click on browse 4 CALogix unit is then shown in device list when detected Click on OK THE CALOGIX SW TOOLBAR New meter visible when no controller open Search for a CALogix system on a network New device visible when controller open Access a different CALogix base unit Page 14 of 44 Open File Open controller application settings or logic program file Note when a saved application or logic file is loaded to a CALogix unit the logic program will not be running Save Save controller application settings or logic programs Export Application Creates rich text file rtf with application settings data iJ Export device Creates rich text file rtf with current device settings data Export program only available when programmer interface is open Creates rich text file rtf with device program data Export logic only available when logic desktop is open Creates rich text file rtf with logic program data Properties Select security settings see section on security settings Edit programs Open programmer interface for profile creation see section on programmer TE Edit logic Open logic desktop see section on logic programming 8 About BASE UNIT SETUP To access settings for a base unit 1 Right click on con
7. across the input range 0 to 50 mV using a divider of 100 Where a transducer provides a smaller output the input maximum and minimum values can be similarly calculated 0 10V Models with 0 to 10V input use an internal resistor to spread the signal across the input range 0 to 50 mV using a divider of 200 Where a transducer provides a smaller output the input maximum and minimum values can be similarly calculated Decide what scale minimum and maximum will be required and whether the scale needs inverting Example The example below gives an example of how a 4 20mA input could be configured for an application The input to the controller is linear where 4mA 80 units and 20mA 300 units Action Parameter Menu Parameter Value Select input sensor type Input settings linear Select unit Module settings select from list if unit not available select Set Allocate SP1 output Output settings Select output 1 2 or 3 Enter Linear high Input settings Enter 50 represents 20mA i e multiplier 2 5 Enter Linear low Input settings Enter 10 represents 4mA i e multipler 2 5 Enter Linear low scale Input settings Enter 80 i e units at 4mA Enter Linear high scale Input settings Enter 300 i e units at 20mA Enter display resolution Input settings Set as 0 01 0 1 1 Note changing the display resolution will affect set point value and other operating parameters Ensure that display resolution settings are selected before adjusting set point
8. autotune cycle time parameter to yes If the autotune cycle time is not required set parameter as no and cycle time parameter value in setpoint settings will be used default value 10S Page 17 of 44 Cycle time recommendations It is recommended that relay outputs should not have a cycle time of less than 10S If a cycle time of less than 10s is required solid state drive outputs are advised SECOND AND THIRD SETPOINTS SP2 and SP3 Primary Alarm Modes Configure SP2 and SP3 outputs to operate as an alarm from setpoint 2 and 3 control sections in the module settings menu The alarms will be individually triggered when the process value changes according to the options listed below DVHI Rises above the main setpoint by the value inserted at setpoint 2 or 3 DVLO Falls below the main setpoint by the value inserted at setpoint 2 or 3 Band Rises above or falls below the main setpoint by the value inserted at setpoint 2 or 3 FSHI Rises above the full scale setting of setpoint 2 or 3 FSLO Falls below the full scale setting of setpoint 2 or 3 COOL Heat cool operation see section on heat cool EOP Event Output See Programmer section Subsidiary SP2 SP3 modes The following additional subsidiary alarm functions can be added to any primary alarm configurations Latch Once activated the alarms will latch and can be manually reset via CALogix sw or an operator panel when the alarm condition has been removed Hold This fea
9. be set as 0 01 0 1 or 1 This resolution is also the format used for the corresponding data register with CALogix unit to be read by an operator panel or for data acquisition It is recommended that display setting of 0 01 is NOT used when a thermocouple or PT100 sensor is used as the displayed value will fluctuate Setpoint 1 upper limit Sensor Max 9999 to 9999 step 0 01 Sets a maximum permissible value for Setpoint 1 Setpoint 1 Lower limit Sensor Min 9999 to 9999 step 0 01 Seets a minimum permissible value for Setpoint 1 Span Offset 0 0 9999 to 9999 step 0 01 Realigns readings to match another instrument e g calibration source or meter see note on recalibration Zero offset 0 0 9999 to 9999 step 0 01 Zero sensor error ve zero offset increases measured PV ve zero offset reduces measured PV see note on recalibration Linear High 50 0 0 0 to 50 0 step 0 1 Configures maximum linear input see Linear inputs Linear Low 10 0 0 0 to 50 0 step 0 1 Configures minimum linear input see Linear inputs Linear high scale 1000 9999 to 9999 step 0 01 Scale controller to display value at Linear high value Linear low scale 0 9999 to 9999 step 0 01 Scale controller to display value at Linear low value Module Output settings Default Options Setpoint 1 output None Output 1 Output 2 Output 3 Select physical output to be assigned as Setpoint 1 Setpoint 2 output None Output 1 Output 2 Output 3 Select physical output to be assigned a
10. high noise immunity and multi drop capability It enables a PC to communicate with up to 31 CALogix base units over distances up to 1200 metres and requires the addition of an RS485 interface card or a separate RS232 485 converter connected to the RS232 port of the PC RS485 converters that derive power from the RS232 port must have all 9 pins RS232 connected for full operation of the converter RS485 cards and converters can differ greatly in their requirements and therefore the installation instructions supplied with the interface should be read carefully 2m CALogix PC cable part number CAB RJ45 2M 01 and a RS232 485 converter part number 3C 25 000 K 3X that fits directly on to the RS232 serial port on a PC are available from your nearest CAL Controls distributor If wiring your own cable the RS485 connections are as follows RJ45 PIN 2 gt 3 gt 4 5 _ GND 6 _ TX 7 TX As CALogix is designed for an industrial environment CAL recommends using a 4 wire shielded RS485 cable such as Belden 8132 Ensure that connectors are suitable for use with shielded cable and are correctly bonded Auto baud rate function On power up CALogix detects the network speed and automatically adjusts its baud rate accordingly If the network baud rate is later modified remove the power and reapply so that CALogix can resynchronise to the new baud rate MULTIPLE CALOGIX NET
11. in the module name field once a label is entered click on the apply button to write the label to the controller This label will be visible on the controller image in CALogix sw and will be included when the application is exported to rtf files The label can have a maximum of 10 characters Input 1 2 3 range The voltage range of inputs 1 2 and 3 can be user defined as one of three voltage ranges i e 0 24V 0 10V and 0 5V These voltages are used to determine high and low states for logic functions and also for comparator switching levels Voltages above 66 of the input range will be considered as high state and below 33 as low state e g for a 0 10V input range lt 3 3V low logic state 0 and gt 6 6V high logic state 1 Comparators will convert the input level to a percentage of full scale and will be compared against other inputs or a constant e g With an input range of 0 24V an input voltage of 2 4V will be considered to have a value of 10 0 in a comparator block Each of the inputs can be independently set for a different voltage level input Once each input has been set write the settings to the controller by clicking the apply button LOGIC PROGRAMMING CREATING LOGIC PROGRAMS ACCESSING LOGIC PROGRAMMING 104 1 Click d icon on main toolbar 2 Logic programming desktop should now open THE LOGIC TOOL BAR Create Boolean function block AND OR LATCH NAND NOR XNOR boolean function block can be c
12. incorporates the power supply RS485 communications ports and slots for up to 4 control modules The control modules are available as PID or Logic I O and can be selected then mounted into the base unit as required for the application Variations in PID control modules include temperature sensor and linear 0 50mV 4 20mA 0 5V amp 0 10V inputs with options for relay ssd or analog 4 20mA 0 5V amp 0 10V outputs Logic I O modules have user defined 0 5 0 10 0 24Vdc inputs with relay or ssd outputs All wiring connectors to the base unit and control modules are plug in to reduce installation and maintenance times CALogix is configured using the Windows based CALogix sw configuration tool which is provided with each base unit PID setup input amp output parameter settings profile creation and writing logic function block diagrams can all be performed within the software utility These settings can be read modified and written to and from the controller and also saved on the PC as a file to be recalled at a later date when required The program also provides information on current process value set points and output status which can be useful when commissioning the system Mechanical Installation The controller is designed as two main components BASE UNIT DIN rail mount device containing main CPU and connections for up to 4 control modules CONTROL MODULE PID or Logic control modules can be mixed as required for the applica
13. to clear a latched alarm output on SP3 once the alarm condition has cleared Set value to yes to clear Module Programmer Default Options Program number 0 1 to 31 Select programmer profile to run See section on programmer Run mode Off Hold Run Off Program run mode See section on programmer Page 24 of 44 PROGRAMMER FUNCTION OVERVIEW The Programmer function enables CALogix to control applications that require setpoint changes over time Examples of this are ramp changes where setpoint is gradually increased at a specified rate until a target level is reached or step changes which are instantaneous These can be separated by soak periods during which the process is held at a constant value Each individual time interval of the program or segment together with it s associated moving setpoint value can be stored as a unique program An example is shown below Setpoint l 1 l 1 1 Time segments In addition to those settings that determine the segment profile it is also necessary to set program start values together with the preferred ramp rate time units for each individual program At the end of a sequence a program can be arranged to repeat loop either a specified number of cycles or continuously Only one loop can be included in a program When the program is running CALogix sw indicates progress through the sequence of segments and can additionally be interrogated for further segmen
14. 0 01 SP3 proportional band or Hysteresis 100 sensor maximum proportional control eliminates the cycling of on off control Output power is varied by proportioning action across the proportional band Cycle time 10 0 1 to 9 9 step 0 1 10 to 81 step 1 SP3 proportional cycle time Determines the cycle rate of the output device for proportional control The choice of cycle time is influenced by the external switching device or load eg contactor SSR valve A setting that is too long for the process will cause oscillation and a setting that is too short will cause unnecessary wear to an electro mechanical switching device Maximum power 100 0 to 100 step 1 Maximum proportional output of SP3 When using proportional control the output of SP3 will not exceed maximum power setting Minimum Power 0 0 to 100 step 1 Minimum proportional output of SP3 When proportional control is used the output of SP3 will not reduce below the minimum power setting Output Power Read Only 0 to 100 step 1 Page 23 of 44 The current proportional output of SP3 shown as Manual Power Off Off 0 to 100 step 1 Manual power overrides PID calculated power output The proportional output for SP3 will remain constant at the entered value To return to PID control set manual power to 0 Display Alarm No No Yes When set to yes alarm symbol is shown on controller image within CALogix sw when an alarm output is switched Reset Latched Alarm No No Yes Used
15. AK Soak time 60 EOP Status 2D Click soak time parameter value box and time is displayed as hh mm ss Soak time 00 01 00 Enter soak time required then click parameter the soak time displayed is then displayed as total number seconds At the end of the soak period an event output can be triggered see notes on Event outputs below Step A step is an instantaneous change in setpoint Please note that it can take a process value some time to reach target setpoint after a step function If a soak function is preceded by a step function the soak period commences immediately after the setpoint has changed and not when the process value reaches setpoint this can result in the soak period appearing to be shorter than expected Segment 3 STEP Segment type STEF Target Setpoint 200 _EOP Status 2D At the end of the soak period an event output can be triggered see notes on Event outputs below Event outputs SP2 and SP3 output state can be changed at various points of the program using event outputs Page 26 of 44 Event outputs be selected as an individual segment or after other segment types have completed such as ramps soaks steps and loop Segment 8 EOP Segment type EOP EOP Status 2D Outputs must be assigned as event outputs in setpoint 2 and or setpoint 3 control settings menu before EOP s can be used See section on PID Module settings Once outputs are configured select the correct EOP status f
16. ALL Segment type CALL __Called program 1 This will be shown on the profile chart as a shaded section Called LT program Loop The loop function will run the same profile a specified number of times recycle count E g If a program has a recycle count of 5 the profile will run 6 times in total Only one loop can be used in a program ElSegment5 LO00F Segment type LOOP Recycle count 5 Status 2E Once the number of loops are completed an event output can be triggered see notes on Event outputs Page 27 of 44 PROGRAM PROPERTIES Program properties allows you to set parameters for a program displayed on the profile chart area When a program is displayed on the user interface click on properties in the programmer menu The program properties box should now open Current program tab Program Number Displays the number of the currently open program Description A user defined label name can be set as a program name Power Fail After a power failure one of three options can be chosen Continue Resume program from last point before failure Hold Hold program at current point until manually restarted Reset Restart program from beginning Ramp rate units Set ramp rate units as minutes or hours Program start point Start program from process value or set point Colours Tab The grid main program profile sub program profile background loop marker EOP marker and EIP marker colours can be se
17. CALogix Programming and Installation s 4 CAL Controls DMOO00M22 Page 1 of 44 Introduction Installation Mechanical Installation a XD P Q gt Base unit Control module Mounting Removing a module Removing the base unit from DIN rail Cleaning Dimensions Electrical Installation Nr SNr N NS ee 50 50 O amp o Output devices Supply Voltage Wiring a connector Replacing modules Inductive loads EN61010 EMC guidelines Supply and RS485 communications connections Input options module Output options module Example circuit Input sensor selection Configuring CALogix vagga CALogix network Multiple CALogix network CALogix sw minimum PC requirements Installing CALogix sw Running CALogix sw Using CALogix sw Diagnostics CALogix sw configuration software Starting CALogix sw Connecting to a controller CALogix sw toolbar Base unit setup Configuring a PID module uu Nl O TOS OM x Settings menu Viewing Parameter settings Changing a setting value Initial settings Park Mode Setpoint adjustment Autotune Proportional cycle time Second and third setpoints Heat Cool Recalibration Linear inputs OO Ooan n r AAA O O 14 14 14 14 Page 2 of 44 Error messages 20 n PID module settings 20
18. PARK P Pl PID PD PARK On Off Primary control type for setpoint 2 Proportional PI Proportional Integral PID Proportional Integral Derivative PD Proportional Derivative Park Holds controller operation disables output On Off On Off Control PI PID and PD can only be selected when operating mode is set as Cool Subsidiary mode None LTCH HOLD LTHO NLIN Setpoint 2 0 9999 to 9999 step 0 01 Page 22 of 44 Change setpoint 2 value Band 2 9999 to 9999 step 0 01 SP2 proportional band or Hysteresis 100 sensor maximum proportional control eliminates the cycling of on off control Output power is varied by proportioning action across the proportional band Integral time 5 mins 0 to 1000 step 0 1 SP2 integral time reset Auto corrects proportional control offset error Derivative time 25 secs 0 to 200 step 1 SP2 derivative time rate Suppresses overshoot and speeds response to disturbances DAC 2 0 to 5 step 0 5 SP2 derivative approach control dAC Tunes warm up characteristics independent of normal operating conditions by adjusting when derivative action starts during start up smaller dAC value nearer setpoint Derivative sensitivity 0 5 0 1 to 1 step 0 1 Cycle time 10 secs 0 1 to 9 9 step 0 1 10 to 81 step 1 SP2 proportional cycle time Determines the cycle rate of the output device for proportional control The choice of cycle time is influenced by the external switching device or load eg contactor SSR valv
19. WORKS Each CALogix unit has an RS485 in and RS485 out RJ45 socket To connect a number of CALogix units on a network wire as shown below The cables should be wired so that the corresponding pins of RS485 out are connected to the same pin number on RS485 in of the next controller i e Pin 2 out to Pin 2 in Pin 3 out to Pin 3 in Pin 5 out to Pin 5 in Pin 6 out to Pin 6 in and Pin 7 out to Pin 7 in Page 11 of 44 8 30Vvac 18 30Vde ky a 18 30Vde mi 21 C _ 209 RS485 IN R5465 QUT RJA5 RJ45 Rs485 IN RJ45 R5485 IN RJ45 R5485 IN ru45 m Roe a ee ee GR GR Dr mmm eS m omm ee PORRO RA RR GG Gm amin LIRE IUE IOY oe RD Y rfe mmo ums eee em SS ES SS e e e X i c ee Red Gene ee Connection i Connect to b from PC or HMI other CALogix units For multiple instrument networks each transmission line must be properly terminated to prevent reflections 1200 termination resistors should be fitted between TX4 amp TX and RX amp RX
20. a control module follow the instructions above for removing and installing control modules If a control module is being replaced with another that has the same part number all parameter settings will be automatically transferred from the base unit to the new module on re powering the system no reconfiguration will be required N If a module is being replaced with a module that has a different part number ensure that the system is re wired accordingly and the module settings are modified to reflect the changes made before running your system Failure to do so may result in dangerous operation or damage to the system If you are replacing logic modules with PID modules it is important to turn off or delete any associated logic CLEANING Wipe down with damp cloth water only Page 5 of 44 DIMENSIONS C C3 es 76mm 2 95 Note Ensure adequate clearance for connectors and wiring Page 6 of 44 Electrical Installation The system is designed to be installed in an enclosure which provides adequate protection against electrical shock The enclosure should also be of a sufficient IP NEMA rating for protection against water and dust CALogix should be mounted in an enclosure with minimum internal dimensions of 160 wide x 125 high x 85 mm deep OUTPUT DEVICES Three types of output are available on an output module relay solid state relay drive ssd and analog Output 1 may be any one of the three options output 2 can be rel
21. and tuning the controller to the application ERROR MESSAGES CALogix sw error messages are shown below Tune Fail Will be displayed if an autotune cycle fails 1 Check setpoint is not set at O 2 The characteristics of the load exceed the algorithm limits i Change conditions e g raise setpoint li Try tune at setpoint atsp iii lf error persists call local CAL representative Input Fail Sensor is open short circuit or linear input is over range Check sensor wiring connections Error On Off Error On Off will be displayed if autotune when in On Off control PID MODULE SETTINGS module position number Module settings Default Options Module name Module User defined A user defined label name up to 10 characters can be set for each module Operating units None C F Bar PSI PH RH Set None Process value operating units can be defined as C F Bar PSI Ph RH or Set Important note If switching from C to F or vice versa ensure that set point and other temperature value based parameter settings are adjusted accordingly to reflect the change made Failure do so may result in dangerous operation or damage to the system Module input settings Default Options Sensor Type J E J K L N R S RTD 2 wire RTD 3 wire linear custom sensor custom sensor with consult factory Display Resolution 1 0 01 0 1 1 Page 20 of 44 Resolution of PV and Setpoint on CALogix sw
22. ay or ssd and output 3 is always relay Any of these outputs can be assigned as SP1 SP2 and SP3 using the CALogix sw software Check the model number and output configuration before wiring the instrument and applying power See section on output options for more details 1 Solid state relay drive 12Vdc 10 15 nominal 20mA To switch remote SSR 2 Miniature power relay 2A 250Vac resistive Form A SPST contacts 3 Analog Output Isolated NOT AVAILABLE WITH LOGIC I O MODULE Specify 4 20mA 5000 max 0 1 fs typical 0 5Vdc 10mA 5000 min 0 1 fs typical 0 10Vdc 10mA 1 min 0 1 fs typical SUPPLY VOLTAGE 18 30Vdc 8 watts 10 fluctuation permitted WIRING A CONNECTOR Prepare the cable carefully remove between 6 and 8mm insulation and ideally tin or terminate to avoid bridging Prevent excessive cable strain Maximum recommended wire size 32 0 2mm 1 0mm 18 AWG REPLACING MODULES Hot plugging of modules should not be carried out To change a module always depower the base unit Once power is re applied the carrier will reload the settings for that module and continue with the original module settings Hotplugging can cause the carrier to fail and is potentially dangerous INDUCTIVE LOADS To prolong relay contact life and suppress interference it is recommended engineering practice to fit a snubber 0 1uF 100Q between relay output terminals CAUTION Snubber leakage current can cause some electro mechanical devic
23. be assigned once Note If the outputs have been previously allocated to a set point and you wish to change assignment then the outputs need to be set to none and this setting applied before you can re allocate a new output to a setpoint Please consider any wiring changes that may be required Page 16 of 44 4 Once these settings have been made click on apply to write to the controller PARK MODE Once initial settings are written to the controller it will still be in park mode i e outputs to the controller are disabled To take the controller out of park change mode setpoint 1 settings to control type required i e P proportional PI proportional integral PID proportional integral derivative PD proportional derivative or ON OFF control SETPOINT ADJUSTMENT Before carrying out an autotune or run with the default settings ensure the system is safe to operate at the setpoint value To enter or adjust a setpoint 1 1 Right click on controller image 2 Mouse over properties and select programmer and set points 3 Expand setpoints menu Settings shortlist setpoints Module 1 Setpoint Module 2 Setpointl Module 3 Setpointl Module 4 Setpoint Programmer Apply Cancel 4 Enter Setpoint 1 value for the required module click out of value box once setting entered to ensure value is accepted 5 Apply setting and click OK 6 New setpoint is now written to the controller and should be visible
24. cking on the time required and entering the data in HHH MM SS S format Once entered click on OK to accept the settings change All timers require a single input from either an input block or another function block The block output must be connected to another function block or an output block Time settings for standard timer types are set via CALogix software To adjust timer settings remotely via an operator panel SCADA or field device ensure that the remote box is ticked in the function block properties This feature is only available for on and off delay timers other timer types can be created from these basic timer blocks contact CAL for more information The data register in which the timer can be accessed remotely is shown outlined in the function block when the logic program has been downloaded to CALogix see below Timer value is stored in register 2824 dec Counters select timer block Counters blocks will give an output after the input has received a user specified number of input pulses Two types of counter blocks can be selected counter reset and high speed counter The high speed counter can count pulses up to 1kHz and counter reset to a frequency of 10Hz Otherwise both counters function in a similar Way If using a high speed counter the physical input for the counter must be from input 1 on the logic I O module Cort E input Curt Lm p
25. e A setting that is too long for the process will cause oscillation and a setting that is too short will cause unnecessary wear to an electro mechanical switching device Maximum power 100 0 to 100 step 1 Maximum proportional output of SP2 When using proportional control the output of SP3 will not exceed maximum power setting Minimum Power 0 0 to 100 step 1 Minimum proportional output of SP2 When proportional control is used the output of SP3 will not reduce below the minimum power setting Output power Read Only 0 to 100 step 1 The current proportional output of SP2 shown as 96 Manual power Off Off O to 100 step 1 Manual power overrides PID calculated power output The proportional output for SP1 will remain constant at the entered value To return to PID control set manual power to O Display alarm No No Yes When set to yes alarm symbol is shown on controller image within CALogix sw when an alarm output is switched Reset latched alarm No No Yes Used to clear a latched alarm output on SP2 once the alarm condition has cleared Set value to yes to clear Module Setpoint 3 control Default Options Operating mode None DVHI DVLO BAND FSHI FSLO EOP None Mode PARK P PARK On Off Primary control type for setpoint 3 Proportional Park Holds controller operation On Off On Off Control Subsidiary mode None LTCH HOLD LTHO Setpoint 3 0 9999 to 9999 step 0 01 Change setpoint 3 value Band 2 9999 to 9999 step
26. e process hunts between heating and cooling a deadband setting may be needed Enter a small value e g 1 for Setpoint 2 setpoint 2 settings Water cooled applications Water cooled applications at temperatures greater than 100 C may suffer from the non linear effect caused by water turning to steam This can be countered by setting subsidiary mode setpoint 2 settings to NLIN Multi zone applications When tuning multi zone applications like extruders distortions due to thermal interaction between adjacent zones can be minimised by running autotune on all controllers at the same time RECALIBRATION If the controller and instrument readings are different the zero and span input settings will require adjustment Adjust zero to make an equal adjustment across the full scale of the controller and or span to make a correction where the error increases or decreases across the scale 1 To adjust the zero function substitute the measured values in the expression Instrument reading controller reading zero Example Instrument reading 245 Controller reading 250 245 250 5 Adjust zero to 5 to correct the error 2 Adjusting the span function i e to make a correction when errors are different across the scale a Choose a temperature near the bottom and another near the top of the scale b Run the process at the lower temperature T1 Note the error E1 between the controller and the instrument readings C Check value of setpo
27. ecified module Manual Power PID control can be suspended and replaced by a constant proportional output by using a manual power function block The value is entered as a 96 of full power i e 10096 output fully on Page 35 of 44 IV Vee Manual power can be selected to apply to SP1 SP2 or SP3 of a specified module and will operate when input to the block switches from low 0 to high 1 logic state To return to PID control from manual power an additional block can be created within the logic program to set manual power value to 0 Autotune A PID module can be tuned using an output logic block Autotune 75 SP 75 setpoint or Autotune ATSP at setpoint can be selected for the required PID module PARK can also be selected to disable the controller outputs In a situation where PARK is activated using a logic function the controller can only be taken out of PARK by changing the mode settings in CALogix sw or via an operator panel Event Input Event inputs are set within the programmer functions of CALogix If required within a program a profile will be held in its current position until an event input is received Select the module number and give the event a numerical tag that corresponds to the required event input For easy identification it is recommended that you give an event input the same number as he segment in the program For instance if the EIP segment is 4 then set the event
28. es to be held ON Check with manufacturers specification EN61010 1 UL61010C 1 CSA22 2 No 1010 Compliance shall not be impaired when fitted to the final installation Designed to offer a minimum of basic insulation only The body responsible for the installation is to ensure suitable for measurement category II or III To avoid possible hazards accessible conductive parts of the installation should be protectively earthed in accordance with EN61010 for Class 1 equipment Output wiring should be within a protectively earthed cabinet Sensor sheaths should be bonded to protective earth or not be accessible Live parts should not be accessible without the use of a tool Page 7 of 44 EMC GUIDELINES We make a number of general recommendations that can reduce the possibility of EMC problems 1 It is important to suppress CALogix relay contacts this will reduce switching interference and also prolongs life of the contacts RC Networks fitted across the relay contacts are recommended for resistive and larger inductive loads values such as 0 1uF capacitor in series with a 100 resistor Relay Contact For small inductive loads a suitable rated VDR is recommended Relay Contact Varistor For small inductive dc loads relays etc a suitably rated diode fitted in parallel with the load is recommended Relay Contact Diode CALogix should be mounted into a metal cabinet which is properly earthed good all r
29. esses overshoot and speeds response to disturbances DAC 2 0 5 to 8 step 0 5 SP1 derivative approach control dAC Tunes warm up characteristics independent of normal operating conditions by adjusting when derivative action starts during start up smaller dAC value nearer setpoint Page 21 of 44 Derivative Sensitivity 0 5 0 1 5 step 0 1 Cycle time 10 secs 0 1 to 9 9 step 0 1 10 to 81 step 1 SP1 proportional cycle time Determines the cycle rate of the output device for proportional control The choice of cycle time is influenced by the external switching device or load eg contactor SSR valve A setting that is too long for the process will cause oscillation and a setting that is too short will cause unnecessary wear to an electro mechanical switching device Control offset 0 9999 to 9999 step 0 01 SP1 offset manual reset 50 band Applicable in proportional and ON OFF mode with integral disable Integral time OFF Maximum power 100 0 to 100 step 1 Maximum proportional output of SP1 When using proportional control the output of SP1 will not exceed maximum power setting Minimum power 0 0 to 100 step 1 Minimum proportional output of SP1 When proportional control is used the output of SP1 will not reduce below the minimum power setting Output power Read Only 0 to 100 Step 196 The current proportional output of SP1 shown as 96 Manual Power Off Off O to 100 step 196 Manual power overrides PID calculated p
30. figured sWitcned outputs e g Alamis OUTPUTS OUTPUTS PID MODULE LOGIC I O MODULE 7P1110A000 7L1110EO00 INPUTS INPUTS For communications connections refer to section on CALogix Network FS1 Fuse 1A time lag type to IEC127 CSA UL rating 250V 51 FS2 Fuse 2A time lag type to IEC127 CSA UL rating 250V 24vDC FS3 Fuse High rupture capacity HRC Suitable for maximum rated load current Moins Supply _ eee 1 switch IEC CSA UL approved disconnection device must be used It is strongly recommended that the power supply zero volts and all logic module zero volts are common to prevent ground loops INPUT SENSOR SELECTION B 130 16 E Chromel Con L Fe Konst __ R P13 RH PH S 10 0 to 1600 C 32 to 2192 F T Copper Con 200 to 250 C 273 to 482 F pel oru ou Resistance Thermometer Pt100 RTD 2 3 200 to 800 C 273 to 1472 rtd 2 3 wire Note Type B accuracy not specified below 100 C 212 F Page 10 of 44 Configuring CALogix CALogix is configured using Windows based CALogix sw software Before using CALogix sw connect CALogix to a PC as shown below CALOGIX NETWORK DD Rolelndmda md To other CALogix controllers RS485 from PC 1200m 15m gt CALogix uses RS485 full duplex serial communications link which is the standard most commonly used for industrial applications due to
31. heat cool Enter a setpoint then allow the process to reach the setpoint using factory settings for heating only Ensure that procedure for initial settings has been carried out before heating the application When application process value has stabilised at setpoint change the following parameters Parameter Menu Value DAC Setpoint 1 control 1 Cycle time Setpoint 1 control 10 Operating mode Setpoint 2 control COOL Cycle time Setpoint 2 control 10 Use cycle time Autotune settings No Apply these settings then set Mode Autotune settings ATSP When the setting is applied there will be a temporary disturbance in temperature as autotune is running ATSP is displayed on the module within CALogix sw controller image Once ATSP is no longer displayed the controller is tuned Further settings If regular oscillations occur change Use cycle time to Yes See section on proportional cycle time Note minimum recommended cycle time using relay outputs is 10s Page 18 of 44 Autotune sets PID terms for Heat and Cool with the same setting values Band integral time derivative time DAC and derivative sensitivity settings can all be modified independently for both heat setpoint 1 settings and cool setpoint 2 settings In some processes oscillations occur during cooling If this occurs double the value of band setpoint 2 settings If no improvement return band SP2 to its original value and half the cycle time setpoint 2 settings If th
32. imers counters Boolean comparators can have multiple outputs Inputs can connect to multiple timers counters Boolean and comparators simultaneously You cannot link physical outputs to inputs use Output In blocks FUNCTION BLOCKS SELECTING OPERATION Each type of function block has a number of variations in operation Once a block has been dropped on the logic desktop right click on the block and select properties By clicking on the drop down menu for operation type or mode in some blocks the operation type can be selected The various function block options and how they are configured is shown below LOGIC BLOCKS I Boolean Operation mode for a Boolean function block ban be selected as AND NAND OR NOR XOR XNOR or LATCH see selecting operation above Truth table for Boolean functions are given in truth tables in the appendix Each Boolean function block requires a two inputs from either an input block or other function blocks The output of the block must be connected to another function block or an output block Page 33 of 44 Il IV Timers A number of timer functions are available with CALogix these are on delay off delay on off delay on pulse off pulse on off pulse delayed pulse symmetrical recycler pause symmetrical recycler pulse asymmetrical recycler pause and asymmetrical recycler pulse Timer charts showing the operation of these are shown in appendix The time settings are entered by cli
33. input to number 4 in the logic This will mean that when the EIP segment is displayed it will appear as EIP4 Program A program output can be used to run stop or hold a program profile Select the module and the program number along with the control mode Page 36 of 44 When the input to the block is high 1 the chosen programmer function will be activated INVERTING INPUTS Function block inputs can be inverted in the following way 1 Right click on function block 2 Click on inputs 3 Click on invert boxes for the inputs that require inverting 4 Click on OK to accept setting VALIDATING A PROGRAM Once a logic program is complete click on icon the logic toolbar A check is then carried out for program validity and any errors are displayed see example below WRITING A PROGRAM TO CONTROLLER Programs are written to the controller by clicking on the logic toolbar Any changes made to the program before writing to the controller are only stored on the logic desktop As the program is being written to the controller a progress bar is visible RUNNING AND STOPPING A LOGIC PROGRAM Page 37 of 44 Click a on the logic toolbar to start a program that is written to the controller the a running LED on the base unit should be ON when a logic program is running To stop a logic program running click logic running LED should switch off on the logic toolbar and the TRACE MODE Trace mode allow
34. int 1 upper limit SP1UL in input settings menu d Repeat at the upper temperature T2 and note error E2 e Substitute the values for T1 T2 E1 E2 in the expression below 2 1 X SP1UL span T2 T1 Example T1 T2 Instrument reading 58 385 Controller reading 60 400 Error E1 2 E2 15 Substituting values in the formula 15 2 x 450 13 x 450 17 9 385 58 327 Therefore adjust span to 18 to correct error Notes 1 After making the adjustment the reading will immediately change Allow time for the temperature to stabalise at T2 before making any further adjustment At this point zero adjustment may be needed refer to step 1 above 2 Check that the temperature correctly stabalises at T2 and then adjust setpoints to T1 If an error is present at T1 repeat from step 2 LINEAR INPUT Modules can be ordered with analog inputs for use with other field devices and instruments Check the specification of the device providing the input to ensure it is compatible Set up Procedure 4 20mA The 4 20mA input model converts current into voltage using an internal resistor which spreads the signal across the input range 10 to 50 mV using a multiplier of 2 5 When using a transducer with an output less than 4 20mA the input maximum and minimum mV values can be calculated using the same multiplication factor Page 19 of 44 0 5V Models with 0 to 5V input use an internal resistor to spread the signal
35. ix icon 5 CALogix program should now run USING CALOGIX SW 1 Refer to on screen help or CALogix programming manual contained on CALogix sw CD Diagnostics Each control module has LEDs to indicate when each of the outputs are on or relay closed If an analogue output option is fitted the LED dims proportionately with the output level e g a PID module with a 4 20mA output the LED will be dim at 4mA and bright at 20mA Note The output and the LED indicator are physically linked and always represent the true state of the output CALogix base unit has three status LED s to assist with diagnosing problems LED 1 Communications Off No communications On Pulsing Communications active LED 2 CALogix healthy Heartbeat Slow pulse Unit operating correctly Fast Pulse Base unit emergency comms still running On Base unit lock up When base unit emergency lock up conditions exist recycle power to clear If the problem does not clear on power recycle contact CAL controls for technical support LED Logic Off Logic not active On Logic active To start logic program running refer to section on running logic programs Page 13 of 44 CALogix sw Configuration Software STARTING CALOGIX SW Click start on Windows toolbar Mouse over all programs Mouse over CALogix folder in menu Click on CALogix icon CALogix program should now run CONNECTING TO A CONTROLLER 1
36. j Segment 1 RAMP Module Segment dope RAMP Ramp rate Target Sapori m bond EOP Shahz Hans El Segment 2 5 Segnen ppt SOAK Tet Shihe Alone 10 Adjust values for any parameters that require modification see section on segment parameters 11 If you require to add additional segments ramp soak step call programs event inputs event outputs or loops see notes below 12 Once the profile is created click on programmer menu then click on write program data 13 The program is now written to the controller PROGRAM SEGMENT TYPES Ramps During a ramp segment the setpoint will change at a user defined rate until a target setpoint is reached Ef Segment 1 RAMP Segment type RAMP Ramp rate 50 Target Setpoint 100 Holdback band 10 EOP Status None The ramp rate entered is set as process units per hour or minute refer to section on program properties to configure If the ramp rate is set too high setpoint may become much higher or lower if cooling than process value In this case the holdback band function will hold the moving setpoint when the process value falls out with the number of units set in the holdback band Once the process value increases to fall within the band value the moving setpoint will resume ramping at the specified rate Soaks During a soak cycle the setpoint will be held constant for a user defined period of time El Segment 2 SOAK Segment type SO
37. ng a message will be displayed giving details of the error Logic program trace mode Trace mode allows monitoring of a logic program that is running in a controller Green lines show the active part of the program Counter and timer values can also be read Note Windows is not a real time operating system therefore there may be a delay before changes in the controller are visible on PC screen If other applications are running in addition to CALogix sw the delay may be greater Note When in trace mode the logic desktop will be in read only mode Stop logic program The logic program running within the controller are stopped Note The logic program running LED on the CALogix base unit will switch OFF Run logic program The logic program within the controller memory will run The logic program running LED on the CALogix base unit will switch ON Align function blocks to left Align all highlighted function blocks with the blocks to the left Align function blocks to right Align all highlighted function blocks with the blocks to the right Align function blocks to top Align all highlighted function blocks to the top Align function blocks to bottom Align all highlighted function blocks to the bottom Resize function blocks to same width Resize all highlighted function blocks to the same width Resize function blocks to same height Resize all highlighted function blocks to the same height Page 32 of 44 Resize functi
38. ols Inc Bury Mead Road Hitchin Herts SG5 1RT UK 1117 S Milwaukee Av Libertyville 1 60048 USA Tel 44 0 1462 436161 Tel 847 680 7080 Fax 44 0 1462 451801 Fax 847 816 6852 e mail sales cal controls co uk e mail sales cal controls com CAL Controls www cal controls com www cal controls com
39. on blocks to same height and same width Resize all function blocks to the height and width of the blocks to that of the widest and highest blocks Apply grid to desktop Apply grid to the logic desktop to assist with aligning and creating programs PLACING A FUNCTION BLOCK ON THE LOGIC DESKTOP 1 Left Click on the icon for the logic function block type you require 2 Continuing to hold the mouse button drag the mouse pointer into the logic desktop area 3 mouse pointer is in position that you want to place function block release the mouse button 4 The function block should now be visible ARRANGING FUNCTION BLOCKS 1 Click n drag an area encapsulating function blocks 2 Function blocks that require rearranging should now be highlighted pe O OE 3 Click on 2 left ES right 8 down icons to arrange function blocks in the required direction 4 function blocks will now align LINKING FUNCTION BLOCKS 1 Create required function blocks on logic desktop Click on function block linking tool icon Click and hold left mouse button in the centre of first block Drag mouse pointer to the centre of second function block Release left mouse button The two function blocks should now be linked Repeat from step 2 to link additional function blocks Sis Sd Rage Maes Note All timers have one input but counters Boolean and comparators have two Output blocks have one input All t
40. on controller image Changes in setpoint 2 and 3 are made in the settings menu see PID module settings AUTOTUNE This is a single shot procedure to match the PID module to the process Select either tune or tune at setpoint in the mode parameter of autotune settings for a specified module The criteria for choosing the best autotune mode for an application is given below The tune at setpoint program is recommended when The process is already at setpoint and control is poor The setpoint is less than 100 C in a temperature application Re tuning after a large setpoint change Tuning multi zone and or heat cool applications Notes DAC is not re adjusted by tune at setpoint Before running autotune select whether autotune calculated proportional cycle time is to be used see below The tune program should be used for applications other than those listed for tune at setpoint shown above As autotune is running tune or atsp is displayed on the CALogix module image within CALogix sw Once tuning is complete the message will no longer be visible PROPORTIONAL CYCLE TIME The choice of cycle time is influenced by the external switching device or load eg contactor SSR valve A setting that is too long for the process will cause oscillation and a setting that is too short will cause unnecessary wear to an electro mechanical switching device To select AUTOTUNE calculated CYCLE TIME n autotune settings menu for chosen module change
41. on only Suitable for measurement within category II and III and pollution degree 2 See Electrical installation It is the responsibility of the installing engineer to ensure this equipment is installed as specified in this manual and is in compliance with appropriate wiring regulations Configuration The controller can only be configured using CALogix sw or CALgrafix software It is the responsibility of the installing engineer to ensure that the configuration is safe Ultimate Safety Alarms Do not use SP2 SP3 or logic module outputs as the sole alarm where personal injury or damage may be caused by equipment failure Warranty CAL Controls warrant this product free from defect in workmanship and materials for three 3 years from data of purchase 1 Should the unit malfunction return it to the factory If defective it will be repaired or replaced at no charge 2 There are no user serviceable parts in this unit The warranty is void if the unit shows evidence of being tampered with or subjected to excessive heat moisture corrosion or other misuse 3 Components which wear or damage with misuse are excluded e g relays 4 CAL Controls shall not be responsible for any damage or losses however caused which may be experienced as a result of the installation or use of this product CAL Controls liability for any breach of this agreement shall not exceed the purchase price paid E amp O E 33087 03 0504 CAL Controls Ltd CAL Contr
42. or program segment None No event output 2D SP2 output de energised to mark event 2E SP2 output energised to mark event 3D SP3 output de energised to mark event 2E SP3 output energised to mark event 2D 3D Both SP2 and SP3 outputs de energised to mark event 2E3D SP2 output energised and SP3 output de energised to mark the event 2E Both SP2 and SP3 outputs energised to mark event 2D 3E SP2 output de energised and SP3 output energised to mark the event Note Only valid options will be displayed on the menu for selection If required option is not shown ensure that SP2 and SP3 outputs are configured correctly Event outputs are a change of state of SP2 or and SP3 This state will remain until another event output is used to reverse it or the program is stopped Event inputs When an event input is used a program is held at that point until a signal to proceed is received via a logic program When the program is held awaiting an event input the temperature or other process value is held constant until the input is received The event input number should be selected to match the event input in the logic program Ef Segment 4 EIF Segment type EIP Event Input 2 Call If the same profile is required as part of a number of programs it can be saved as a program and called into another program when required By inserting a call segment and choosing the required program the profile section will be added Ef Segment C
43. ound metal shielding is important It should be borne in mind that the wiring of the installation can significantly reduce the efficiency of the instrumentation immunity This is due to the ease with which high frequency RF can enter via unprotected incoming and outgoing cables Earthed thermocouples or sensors with screened cable should be earthed at the cabinet entry point Any long cables entering the control cabinet should be protected at the point where they enter the cabinet large diameter ferrite sleeves are an economical and effective method of reducing high frequency RF looping the cables through ferrite sleeves a number of times will improve the efficiency of the filtering Alternatively for mains cables the fitting of a suitable mains filter can provide good results Data or communications cables should be screened If using Belden 8132 connect drain wire to PIN 5 of a shielded RJ45 connector Ideally data and sensor cables should be routed separately from power cables and away from inverters or other high power frequency devices Page 8 of 44 SUPPLY AND RS485 COMMUNICATIONS CONNECTIONS BASE UNIT Thermocouple Linear Input Logic Inputs Linear Iransdiucer 0 24vcc input OUTPUT OPTIONS MODULE Page 9 of 44 EXAMPLE CIRCUIT The circuit below shows an example applicaion which includes a base unit that has one PID module and one logic module fitted Logic Switched Outputs User con
44. ower output The proportional output for SP1 will remain constant at the entered value To return to PID control set manual power to O Module Autotune Settings Default Options Mode Off Off tune atsp Off Run current PID or On Off settings Tune Tune controller at 75 of set point ATSP Tune controller at setpoint Use cycle time No No Yes No Use manually entered cycle time Yes Automatically apply autotune calculated cycle time Band Read Only Autotune calculated proportional band Integral time Read Only Autotune calculated Integral time DAC Read Only Autotune calculated derivative approach control Cycle time Read Only Autotune calculated cycle time CtA CtB Ct1 Ct2 Ct3 Ct4 Os1 Os2 Us Read Only Autotune data Module Setpoint 2 Control Default Options Operating mode None DVHI DVLO BAND FSHI FSLO COOL EOP None DVHI Deviation high alarm output if process value rises above the main setpoint by the value inserted at setpoint2 DVLO Deviation low alarm output if process value falls below the main setpoint by the value inserted at setpoint 2 Band Band alarm output if process value rises above or falls below main setpoint by value inserted at setpoint2 FSHI Full scale high alarm output if process value rises above the value inserted at setpoint2 FSLO Full scale low alarm output if process value falls below the value inserted at setpoint2 Cool See section on heat cool EOP See event outputs in programmer section Mode
45. reated See section on Boolean function blocks lt Create comparator function block Compare two I O module inputs or compare an I O block input with a constant greater than or less than comparator options See section on comparator blocks Create timer counter function block Select one of eleven timer types or two counter types See timers counters overview section Page 31 of 44 4 amp Create input function block I O module inputs power or output status can be used as logic input function blocks Create output function block Function blocks for a switching a physical output changing setpoint selecting manual power starting autotune event input and running a program can be created Function block linking tool Creates a link between two function blocks in a logic program Read logic data from controller Existing logic data in desktop is overwritten by logic program read from controller Write logic data to controller Logic program is written from desktop to the controller Logic data is also validated at this time Clear logic data Clears logic data on the desktop Logic programs within the controller are NOT cleared unless a blank desktop is written to controller Validate logic data Logic validation ensures that a logic program is created as a functional program If function blocks are not used in the correct way or links to inputs or outputs are missi
46. s Setpoint 2 Setpoint 3 output None Output 1 Output 2 Output 3 Select physical output to be assigned as Setpoint 3 Output 1 2 amp 3 burnout state De energised De energised Energised Configure state of outputs on sensor burnout break Output 1 2 amp 3 inversion False False True Reverse operation of outputs Output 1 inhibit None None Output 2 Output 3 Prevents other outputs energising at the same time as Output1 Output 1 2 amp 3 cycle count Count value Read only Each module internally stores a read only value of the number of cycles for each output this can be used to check the estimated remaining life of a mechanical relay if fitted Module Setpoint 1 control Default Options Setpoint 1 0 9999 to 9999 step 0 01 Change setpoint 1 value Mode Park P PID PD Park On Off Primary control type for setpoint 1 Proportional PI Proportional Integral PID Proportional Integral Derivative PD Proportional Derivative Park Holds controller operation disables output On Off On Off Control Band 10 0 to 9999 step 0 01 SP1 proportional band or Hysteresis 100 sensor maximum proportional control eliminates the cycling of on off control Output power is varied by proportioning action across the proportional band Integral Time 5 mins 0 to 9999 step 0 1 SP1 integral time reset Auto corrects proportional control offset error Derivative time 25 secs 0 to 200 step 1 SP1 derivative time rate Suppr
47. s a user to monitor a logic program as it is running After a logic program is started click 2 on the logic tool bar Any active parts of the circuit are highlighted in green As the output of a function block becomes active 1 a green triangle is shown on the top left corner of the block Current timer and counter values are also shown within the logic block and will show changes as they occur While trace mode is on the logic desktop will be in read only mode no changes to the function block can be made To exit trace mode click on 955 1 Note As windows is not a real time operating system there may be a delay from when an action occurs at the controller to when it is displayed within CALogix sw This delay may be reduced by closing down other applications whilst CALogix sw is running Page 38 of 44 APPENDIX Boolean Functions INP1 INP2 OUT O 0 9 0 i 0 Lo 1 0 P O _ 1 NAND pNP 1 INP2 qq 0 0 i CO C mu NN RU el XNOR 1 INP2 po batched __ 0 _ 1 P O Page 39 of 44 Timer Functions On Delay Timer On Pulse Timer Off Pulse Timer Page 40 of 44 On Off Pulse Delayed Pulse T1 Delay T2 Pulse Symmetrical Recycler Pause Asymmetrical Recycler Pause T1 Pause T2 Pulse Page 41 of 44 Asymmetrical Recycler Pulse T1 Pulse T2 Pause Page 42 of 44 Specifica
48. st be connected to an output or another function block Inputs Inputs blocks provide a link from physical inputs to control logic functions There a three types of output block meon Physical Input The input block status mirrors the current state of a physical input on a logic I O module Power Up The input status is high 1 when the CALogix unit is powered up Output In The input block status mirrors the output state of a PID or a Logic I O block Soft I P Soft inputs allow logic to be triggered remotely from an operator panel SCADA or field device There are 8 soft inputs 0 7 available within a CALogix base unit and are stored in a single register 1910dec bits 0 7 Outputs Output blocks require a single input from other function blocks or an input block Do not connect the output of an output block to other function blocks I Il IIl Physical output To control output on a logic I O module a physical output block is used To configure an output block select the module number and the output When connected to logic function blocks the specified physical output will switch as the logic driving the output changes state Changing set point Setpoint of a PID module can be changed using an output function block By entering the required value the setpoint will be changed when switching from low 0 to high 1 logic state The setpoint change can be selected to apply to SP1 SP2 or SP3 of a sp
49. t for the profile chart area Scales Tab Scale maximum and Scale minimum settings can be set for profile chart area By selecting full screen on scale display mode the profile scales are resized to fit on screen READING PROGRAM DATA FROM A CONTROLLER Note that program data is read from the controller when opening the programmer interface The read program data function is used to recover program data that has been modified in the programmer interface but not written to the controller 1 When the programmer interface is open click on required module tab Page 28 of 44 2 3 Click on read program data in the programmer menu Information from the controller is read and program 1 is displayed on the programmer interface CREATING AN ADDITIONAL PROGRAM 1 Follow instructions in section on creating a program SELECTING A PROGRAM 1 2 3 When the programmer interface is open click on the required module tab Click on select program in the programmer menu Select required program 4 The selected program will now be displayed on the program interface INSERT SEGMENTS TO A PROGRAM eee ee ms When the programmer interface is open click on required module tab Select program required in the programmer menu In the profile chart click to highlight segment point where the additional segments are to be inserted Right click the mouse in profile chart area Mouse over insert segment then click on ramp soak s
50. t information It is also possible to Call an already existing program as a sub program that can be inserted as a segment of another program The programmer functions can be fully configured using the programmer interface in CALogix sw ACCESSING THE PROGRAMMER INTERFACE 1 Click on the icon in the main toolbar 2 Programmer interface should now be open THE PROGRAMMER INTERFACE The programmer interface is shown below m i r an El i ue LE d d i abs ssn ee 1 Y 1 1 CREATING A PROGRAM Note If a program is running in any module on the carrier the programmer interface will only be available in view mode only All programs have to be in an OFF state to enable editing of a profile see stopping a program Open the programmer interface Select module tab corresponding to required PID module On toolbar click on programmer menu select new program When pointer is in profile chart area right click mouse Mouse over add segment and the following menu should be shown ge c Page 25 of 44 6 add segments click on ramp soak step 7 Enter quantity of segments required then press OK 8 Click and drag segment points on the profile chart area to draw the required profile 9 Click to open data for each segment in segment property menu Module a Property 1 0 0 ve E
51. tep Select the number of segments to insert Adjust segments to create profile as required see creating a program Write program data in programmer menu DELETING SEGMENTS 1 prece In the profile chart click to highlight the segment node that requires deletion Right click in the profile chart area Click on delete segment Click OK to accept segment delete The segment is now deleted from the program MODIFYING A PROGRAM 1 2 3 4 Open the programmer interface and select the tab for required module Select the program to be modified see Selecting a program Click and drag chart points to create required profile Write program data in programmer menu RUNNING PROGRAMS 1 2 E IE Ensure that programs are written to the controller and programmer interface is closed Right click on controller image Mouse over properties and select programmer and set points Expand programmer menu Property 1 Pangea Humber 1 Pangem Run Kinda Module 1 Pangea Loon Cound Module I Psogesm Segment Tine Module 2 Program Humber Module 2 Program A un horde Module 2 Piman Loop Cound 9 twee Scroll to required module Enter program number to be run i e Module Program Number Set program run mode to on Apply settings to controller The selected program will now run Page 29 of 44 STOPPING A PROGRAM 1 Right click on controller image
52. tion PID MODULE THERMOCOUPLE 9 Types B J KL NR 5 CJC rejection 30 1 typical RESISTANCE THERMOMETER 2 or 3 Wire Standards IEC 751 1000 0 138 50 100 C Pt Bulb Current LINEAR PROCESS INPUTS Linear Input 0 50mV 0 1 0 00 99 99 100 00 499 95 500 999 9 1000 9999 4 20mA 0 10V APPLICABLE TO ALL INPUTS SM Sensor maximum FS Full scale 40 1 FS typical 1 C OUTPUT DEVICES Analogue Output 4 20mA 5000 max 0 1 FS typical 0 5Vdc 10mA 5000 min 0 1 FS typical 0 10Vdc 10mA 1 min 0 1 FS typical LOGIC I O MODULE Input Range 0 5 0 10 0 24 Vdc s w select Outputs SSd1 and SSd2 12Vdc 10 15 20mA Hly1 Rly2 Rly3 2A 250ac resistive load form A SPST Maximum counter input frequency 1 fast 1KHz Other 10Hz Accuracy oo O Accuracy 1 ENVIRONMENTAL Safety EN61010 UL and CSA approvals pending Weight Base unit 170g 60z including connectors Control module 90g 3 2 oz Ambient 0 to 55 C Humidity 90 max non condensing Altitude Up to 2000m SUPPLY Supply voltage 18 30Vdc 8 watts 10 fluctuation permitted Note As with all electronic devices product life is reduced at high ambient temperatures Ensure that your control panel sufficiently cooled to maximise product life Page 43 of 44 Safety and Warranty Information Installation EN61010 1 UL61010C 1 CSA 22 2 No 1010 To offer a minimum of basic insulati
53. tion and plugged in to base unit 1 base unit and 1 4 control modules must be used for operation of product A CALogix system can only be configured using CALogix sw pc based software MOUNTING To mount a base unit with control modules proceed as follows 1 Affix 35mm type DIN rail securely to mounting surface minimum length 140mm The unit should be mounted vertically as shown 2 Attach carrier unit to DIN rail ensuring the spring release is at the bottom facing downward Page 4 of 44 3 Ensuring the input terminals are facing downwards add the control modules to base unit Press the top and bottom tabs on the module lightly and ensuring module is kept straight push to locate in base unit see diagram below 4 Pre wire connectors and plug into the appropriate modules we suggest wire markers for identification REMOVING A MODULE 1 Isolate supply to CALogix and all module input and output connectors 2 Unplug connectors to module requiring removal 3 Press tabs as shown above to release module 4 Carefully pull the module away from base unit ensuring tabs are free to remove REMOVING BASE UNIT FROM DIN RAIL 1 Isolate supply to CALogix and all module input and output connectors 2 Unplug connectors to base unit and all modules 3 Insert screwdriver into DIN rail release block and apply pressure away from the controller the base unit can then be removed REPLACING A CONTROL MODULE When replacing
54. troller image 2 Mouse over properties then left click on base unit see diagram above 3 Double click on to expand menus 4 Base unit settings are shown as below Base unit Configuration Default Options Baud rate 9600 2400 4800 9600 19200 38400 57600 115200 read only The network baud rate can be read CALogix baud rate is automatically set on power up to match the baud rate used by the Modbus master Modbus address 1 1 to 255 step 1 The base unit Modbus address can be set to a value of 1 to 255 A maximum of 31 base units can be connected in a network Base unit diagnostics Default Serial number Preset read only The CALogix serial number is factory set before shipment Firmware version Preset read only Note If the Modbus address is changed CALogix sw will loose communications with the base unit as it is still communicating using the original address If the address is changed exit CALogix sw and browse for the controller using the new address Page 15 of 44 CONFIGURING A PID MODULE SETTINGS MENU To access settings for a PID module sp 6 f Right click on controller image Mouse over properties then left click on the required PID module number see diagram above The settings menu will now open VIEWING PARAMETER SETTINGS 1 Or CALogix PID module settings are split into various sub menus to simplify finding the correct parameter These are Module settings
55. ture inhibits alarm operations on power up and is automatically disabled once the process reaches the alarm setting Lt ho Combines the effects of both Latch and Hold and can be applied to any primary alarm configuration If you configure SP2 or SP3 as an alarm in on off mode please be aware the output and LED indicator to the alarm will be energised when the alarm is not active and de energised when alarm is active By setting display alarm setpoint 2 and 3 settings to on the alarm display indicator bell will replace the output LED in CALogix sw when an alarm condition exists Note Changing SP2 or 3 operating mode will default the setpoint back to zero when applied to the base unit this will not be updated in the property sheet until closed and read back HEAT COOL Heat cool strategy is a feature that improves control of processes that need heating and cooling for example Environmental test chambers used in rooms where ambient temperature can vary above and below test temperature Plastics extruders where the material initially needs heating then cooling when it begins to heat itself exothermically due to pressure and friction applied by the process The purpose of cool strategy is to maintain accurate control of the process with a smooth transition between heating to cooling This is achieved by using PID control for both heating and cooling with the proportioning bands linked by an adjustable deadband Tuning CALogix for
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