Home

PPC-2000 User's Guide

Contents

1. 8A 15 78 _ _ 16 pin terminal block 14 zA for relay outputs mM 13 iB y Pp A Sn 11 9 E aiet 4A 7 3B 6 3A 5 2B 4 2A 3 1B 2 1A Loo co Common Terminals SS Ce CA C1 D j PPC 2062 PPC 2061 Figure 2 58 PPC 206x Connections bottom view 70 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Wiring PPC 2061 Relay Outputs nN WARNING The PPC 2061 has 16 normally open relay outputs Outputs 1 to 8 share one common and outputs 9 16 share the second common Either AC or DC may be switched See Figure 2 59 for an example of how to connect to the relay outputs Table 2 23 on page 72 lists the connections to the PPC 2060 and PPC 2061 modules 3 PPC 2061 Neutral or 120V Source 1 AC Neutral or 120V MM Figure 2 59 Relay Output Connections on a PPC 2061 Outputs 1 2 9 and 10 shown Do not switch AC neutral L2 Load switching must occur on the hot L1 side of the AC line Failure to do so could cause injury or death Wiring PPC 2062 Relay Outputs Doc 30002 00 Rev 2 3 The PPC 2062 has eight normally open single contact relay outputs The load may b
2. 485 Communications 232 Communications a extermiah a Shielded twisted pair cable resistor serial port ja termination eses 89869 ve oy a terminal Teen isolating block 232 to 485 i coe converter as See me no more ake iG z than 10 ft rl il EE l E flat cable FEE EE ioe a with RJs EEE k pa fol 2 i a AAA AA AAA PPC 1 PPC 2 PPC N Figure 2 70 Connecting Multiple PPCs to a Computer Using RS 485 Doc 30002 00 Rev 2 3 Watlow Anafaze Chapter 2 Hardware Installation Converter or Host TXA TDA TX TXB TDB TX RXA RDA RX RXB RDB RX DC Common PPC 2000 User s Guide The host computer uses one twisted pair to send messages to any PPC on the network All the PPCs receive all the messages The one PPC addressed by a particular message uses the other twisted pair to respond This twisted pair is shared by the transmitters of all the PPCs on the network Only one PPC transmits at a time Therefore one twisted pair connects the transmitter terminals at the host computer or converter to the receivers on each of the controllers The second twisted pair connects the computer or converter s receiver to the transmitters on all the PPCs on the network Figure 2 71 illustrates this Network wiring should
3. J Input it Connection 10 t 9 8 w 8 Common Connections er Nicene NC Cl PPC 2070 PPC 2071 PPC 2072 PPC 2073 Figure 2 62 PPC 207x Connections bottom view Input Device l PPC 2070 _ PPC 2071 2072 only Z ae Input Device o e e x DC DC l Source Source l l L TL eC ee ee Figure 2 63 Input Connections to a PPC 2070 or PPC 2072 Inputs 1 and 2 shown Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Input Device PPC 2071 i PPC 2073 PPC 2073 only Input Device z3 ize 2 Po Z ts DC DC Source Source M Bice Se p00 Input Device Input Device PPC 2073 onl P
4. i Figure 1 2 Sample PPC 2000 System PPC 2000 Modules The following sections describe the purpose and features of each type of module available with the PPC 2000 system PPC 2010 Processor Module The PPC 2010 processor module houses the system microprocessor memory and controller programs Modular communication ports support connections with a PC running AnaWin38 and LogicPro or third party interface software and connections with third party operator interface panels or other devices that communicate using Modbus protocol Communica tions ports one and two may be used simultaneously Additional modules may be connected to the processor module s expansion bus to add capabilities to the PPC system Precision analog outputs can be provided using Serial Digital to Analog Converters SDAC Each SDAC unit converts a control output from the processor module to an analog voltage or current signal For more specific information see SDAC Serial Analog to Digital Converter on page 9 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 1 Overview The PPC 2010 has 48 built in digital I O points 24 points are outputs only 22 of these outputs are user configurable for PID control alarms or logic outputs The other 2 outputs are dedicated to system status and global alarm The remaining
5. PPC 2051 Figure 7 10 PPC 2050 Bottom View Table 7 38 Model Number PPC 2050 8 Analog Out PPC 2051 4 Analog Out Table 7 39 Environmental Specifications Storage Temperature 20 to 70 C Operating Temperature 0 to 60 C C Humidity 10 to 95 non condensing Table 7 40 Physical Specifications Weight 0 6 Ib 0 27 kg Height 8 0 in 203 mm Width 1 5 in 38 mm Depth 5 25 in 133 mm 248 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 7 Specifications Table 7 41 Connections Wire Gauge 24 to 16 AWG Screw Terminal Torque 0 22 to 0 25 Nm 1 9 to 2 2 in lb Mounting DIN rail or panel mount Table 7 42 Power Specifications PPC 2050 Power Requirement 9 6 W typical Current 12Vdc 800mA typical 25 C Current 24Vdc 400mA typical 25 C Table 7 43 Power Specifications PPC 2051 Power Requirement 6 W typical Current 12Vdc 500mA typical 25 C Current 24Vdc 250mA typical 25 C Table 7 44 Output Specifications Number 8 PPC 2050 4 PPC 2051 Configuration 4 individually isolated PPC 2051 4 isolated pairs 1 amp 2 3 amp 4 5 amp 6 7 amp 8 PPC 2050 Isolation 120Vac to power common and earth ground 120Vac
6. PS PPC E TB50 Digital 1 9 Out ECX S SSR Figure 2 52 Powering Output with 12 24Vdc from PPC supply ice PPC E TB50 controller Digital 4 Out PS 5 to 24Vdc B Tri SSR Output Figure 2 53 Powering Output with Separate Power Supplies 66 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Connecting Analog Outputs to the PPC 205x Connect wires directly to the terminals on the bottom of the PPC 205x modules The PPC 2050 can source up to eight analog signals and the PPC 2051 up to four Table 2 22 lists the terminal connections for the PPC 2050 module Sess O 8 C INC au 16 pin Terminal Block ae a eg Outputs hia C6 O JNC E I6A c JNC C45 O 3B E54 E34 O O JNC O 1 44 O INC D 3 LJ eB L 4 34 2A Olle E Nc O 2A NC Ojj 1B O I
7. e Outputs 1 amp 2 _ DIN Rail Latch Figure 2 45 PPC 2030 Analog Out Terminal Block Table 2 20 Analog Output Connections on Encoder In Analog Out Module Encoder In Analog AnaWin3 Name Module I O Out Module Input Spread Number Connections i sheet Analog Out 1 J1 1 J1 1 PPC1 EIAO 11 3 1 Analog Out 2 J1 2 J1 2 PPC1 EIAO 11 3 2 Analog Out 3 J2 3 J2 3 PPC1 EIAO 11 3 3 Analog Out 4 J2 4 J2 4 PPC1 EIAO 11 3 4 1 The AnaWin3 name is shown for the Encoder In Analog Out module with address 11 on the first PPC 2000 in the system Refer to Outputs on page 135 for a full explanation of Analog output naming 60 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Figure 2 46 Analog Output Connections on a PPC 2030 Outputs 1 and 2 Shown Connecting I O to the PPC 2040 A TB50 connects to a PPC 2040 Digital I O module through the 50 pin SCSI connector Refer to Figure 2 47 on page 62 The terminal block interfaces to field wiring of the digital I O sensors actuators relays SSRs etc Connecting the TB50 to the PPC 2040 Module Refer to Figure 2 47 on page 62 Connect the SCSI connector from the PPC 2040 module to the TB50 Doc 30002 00 Rev 2 3 Watlow Anafaze 61 Chapter 2 Hardware Installatio
8. Notch _t lt JU1 i Not Terminated Position Battery t Notch Figure 2 4 PPC 2010 Jumpers PPC 2030 Dip Switch Settings A CAUTION Doc 30002 00 Rev 2 3 Switch settings in the PPC 2030 determine whether encoder inputs accept single phase or quadrature encoder signals Each of the four inputs is configured individually therefore single phase and quadrature inputs may be mixed in a module Wear a grounding strap and place components on static free grounded surfaces only Locate switch bank 1 near the center of the PPC 2030 module Refer to Figure 2 5 on page 20 Set each switch for the corresponding input to the single phase on or quadrature off position The switch is on when in the direction indicated by the arrow Be sure to take antistatic precautions Watlow Anafaze 19 Chapter 2 Hardware Installation Single Phase Quadrature Counter Input Number Improve illustration More like 2 6 and 2 7 PPC 2000 User s Guide LS Mind c ic E Analog Output Jumpers Dip Switch JU1 Output 4 I JU2 Output 3 oa co JU3 Output 2 lt lt JU4 Output 1 Voltage Current Position Position IA
9. 12 11 vuU RUANO Common c Cc PPC 2070 PPC 2072 Connections A Ce Ir PPC 2071 PPC 2073 Figure 7 14 PPC 207x Bottom Views Table 7 51 Model Number PPC 2070 PPC 2071 8 Digital In 120Vac 16 Digital In 120Vac PPC 2072 8 Digital In 24Vac dc PPC 2073 16 Digital In 24Vac dc Table 7 52 Environmental Specifications Storage Temperature Operating Temperature 20 to 70 C 0 to 60 C Humidity 10 to 95 non condensing Table 7 53 Physical Specifications Weight 0 52 lbs 0 24 kg Height 8 0 in 203 mm Width 1 5 in 38 mm Depth 5 25 in 133 mm 254 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter 7 Specifications Table 7 54 Connections Wire Gauge 24 to 12 AWG Screw Terminal Torque 0 5 to 0 6 Nm 4 4 to 5 3 in lb Mounting DIN rail or panel mount Table 7 55 Power Specifications Power Requirement 1 2 W typical Current 12V
10. 1The AnaWin3 names are shown for the first PPC 2000 in the system See Inputs on page 127 for a full explanation of analog input naming 2LogicPro Variable Type must be INT and IO Size must be WORD 3Use this address with the Soft_ nput IO Driver when addressing the Input Value of a Soft Input 4Use this address with the Database IO Driver when addressing other input parameters Re place the with the parameter number from Table 5 8 on page 168 for the parameter you want to address Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference Table 5 7 Addresses for Encoder Inputs on the PPC 2040 Digital I O Modules TEA ie Modbus Addressing AnaWin3 Name Input Spreadsheet Digital_lO 2040 Database Database Sample IO Driver IO Driver Offset Address PPC1 DIO 21 1 1 C 21 1 1 301 301 31101 PPC1 DIO 21 2 1 F 21 2 1 302 302 31102 PPC1 DIO 21 1 2 C 21 1 2 303 303 31103 PPC1 DIO 21 2 2 F 21 2 2 304 304 31104 PPC1 DIO 22 1 1 C 22 1 1 305 305 31105 PPC1 DIO 22 2 1 F 22 2 1 306 306 31106 PPC1 DIO 22 1 2 C 22 1 2 307 307 31107 PPC1 DIO 22 2 2 F 22 2 2 308 308 31108 PPC1 DIO 23 1 1 C 23 1 1 309 309 31109 PPC1 DIO 23 2 1 F 23 2 1 310 310 31110 PPC1 DIO 23 1 2 C 23 1 2 311 311 31111 PPC1 DIO 23 2 2 F 23 2 2 312 312 31112 PPC1 DIO 24 1 1 C 24 1 1 313 313 31113 PPC1 DIO 24 2 1 F 24 2 1 314 314 31114 PPC1 DIO 24 1 2 C 24 1 2
11. Listed values are maximum ranges Other ranges within these limits may be selected in software Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Analog Output Jumpers o gt gt Voltage Current Position Position JU8 2050 Output 8 Chapter 2 Hardware Installation O JUL gt A JU 06 Vigo BP vow p p gt Vioo JUS Vioo Ju4 Jl vlou JU3 pm H JU7 2050 Output 7 2051 Output 4 JU6 2050 Output 6 JU5 2050 Output 5 2051 Output 3 JU4 2050 Output 4 JU3 2050 Output 3 2051 Output 2 JU2 2050 Output 2 JU1 Output 1 Doc 30002 00 Rev 2 3 Figure 2 7 PPC 205x Jumpers Watlow Anafaze 23 Chapter 2 Hardware Installation PPC 2000 User s Guide Module Assembly Modules should be assembled prior to mounting The processor module is always the first module left side on a PPC system To connect other modules use the following procedure A CAUTION To avoid damaging your PPC system never connect or disconnect modules that are powered CAUTION PPC modules contain sensitive electronic components Be sure to observe ESD safety precautions such as wearing a ground strap 1 Make sure the red top and bottom module latches on the module to be added are in the
12. a AITB Transducer 2A input 1 with linear voltage output ss e 1B input 1 Transducer 2A input 2 with linear voltage output ______e 2B input 2 e COM Figure 2 35 Connecting Linear Voltage Signals to Differential Inputs 1 and 2 Single ended voltage sources should have the positive lead on the positive terminal of the desired input The negative lead should be connected to the COM terminal See Figure 2 36 on page 53 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation AITB Transducer e 1A input 1 with linear voltage output x Transducer lt e 2A input 2 with linear voltage output 9 e A COM Figure 2 36 Connecting Linear Voltage Signals to Single ended Inputs 1 and 2 Connecting Sensors with Linear Current Signals Differential current transducers or sensors should be connected with the positive signal lead on the A terminal and the negative signal lead to the B terminal for the selected input See Figure 2 37 power power 28V Max e 28V Max 3A Input 3 power Typical Power baa 3 wire 3 wire Supply oe current 3B put 3 current P source nput z3 SINKIN transmitter transmitter transmiter i power 1A Input 1 e 2A Input 2 ae B Input 1 Zz 2B In
13. Changed Data Queue The Changed Data Queue is a tool for hosts which need to maintain a mirror image database of the PPC 2000 database Typically these are PC based hosts Most simple operator interfaces such as operator interface terminals constantly query the PPC for only the information that needs to be displayed on the current screen These devices would not read the queue The PPC 2000 can communicate with 1 or 2 host devices with read write capability If 2 hosts are used the changed data queue alerts port 1 host that port 2 host has changed a section s of the database and vice versa Each port has a dedicated queue which must be continuously monitored by the respective host The addresses are the same for both ports but the data in each queue may differ because port 1 queue monitors port 2 activity while port 2 queue monitors port 1 activity The queue consists of a group of read only registers Register 33051 contains the quantity of parameters which have been changed by the other host Registers 33052 N form a first in first out stack of changed parameters consisting of the parameter ID numbers The queue does not report the changed status of specific elements within a parameter but only the parameter ID number that has been changed Therefore if the changed data queue notifies host 1 that host 2 has changed a parameter it is necessary for host 1 to read all elements within a parameter to update host 1 s database Usin
14. Min Set Point When the primary channel s output is 0 the 13907 secondary channel s set point is 150 F Max Set Point When the primary channel s output is 100 the 10E secondary channel s set point is 190 F Heat Prop Band Heat Integral Heat Derivative The secondary channel s PID parameter values may be determined by autotuning or manual tuning As the temperature in the middle of the tank channel 1 drops the output goes up proportionally and the set point of channel 2 goes up proportionally Thus heat is added to the system at the element even though the temperature near the element may have been at the desired temperature With proportional control when channel 1 is at set point its output is 0 and the set point of channel 2 is equal to the desired temperature 150 F Ifthe temperature of the channel 1 drops below 149 F the deviation results in a proportional output of 10 This results in an increase to the set point for channel 2 equal to 10 of the set point range The set point range is defined by Max Set Point Min Set Point In this case the range is 40 F 190 F 150 F 40 F Ten percent of 40 F is 4 F So when the temperature at channel 2 drops 1 degree channel 2 s set point increases by 4 F to 154 F For every degree channel 1 drops channel 2 s set point increases by 4 F until channel 1 s output is 100 and channel 2 s set point is 190 F At t
15. After performing the following procedure refer to Setting Programmable Modbus Addresses on page 87 if necessary to reprogram the Modbus address or baud rate Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide A CAUTION Disabling Control A CAUTION Doc 30002 00 Rev 2 3 Chapter 4 Troubleshooting Do not perform this procedure at a time during which closed loop control and logic program outputs should not be turned off 1 2 ono ou e o Remove power from the PPC 2000 system Note the setting of the rotary switch on the Processor Module Set the rotary switch to position E Power up the PPC 2000 system Wait five seconds Remove power from the PPC 2000 system Set the rotary switch back to the position noted in Step 2 Power up the PPC 2000 system If the settings in a PPC are not known it may be desirable to power up the system in a state that will not generate outputs The following procedure describes how to power up the PPC 2000 such that the closed loop control and logic program if any do not automatically begin Do not perform this procedure at a time during which closed loop control and logic program outputs should not be turned off 1 2 Remove power from the PPC 2000 system Note the setting of the rotary switch on the Processor Module Set the rotary switch to position H Power up the PPC 2000 system Set channels to the desired control modes to begin clos
16. The CRC field is appended to the message as the last field in the message When this is done the low order byte of the field is appended first followed by the high order byte The CRC high order byte is the last byte to be sent in the message When messages are transmitted on standard Modbus serial networks each character or byte is sent in this order left to right Least Significant Bit LSB Most Significant Bit MSB The bit sequence is e With Parity Checking Start 1 2 3 4 5 E 7 8 Parity Stop e Without Parity Checking Start 1 2 E 4 5 6 7 8 Stop Stop Watlow Anafaze 273 Appendix A Modbus Protocol 274 PPC 2000 User s Guide Error Checking Methods Parity Checking Modbus RTU use two kinds of error checking e Parity checking e Frame checking CRC Parity checking can be optionally applied to each character while the frame checking is applied to the entire message Both the character check and message frame check are generated in the master device and applied to the message contents before transmission The slave device checks each character and the entire message frame during receipt The master is configured by the user to wait for a predetermined time out interval before aborting the transaction This interval is set to be long enough for any slave to respond normally If the slave detects a transmission error the message will not
17. Accuracy calibrated for voltage output For voltage output 0 005V 0 05 at full scale For current output 0 1mA 0 5 at full scale Temperature coefficient 440 ppm C typical Isolation Breakdown 1000V between input power and signals Voltage Current 0 20mA 500 Ohm load max Voltage 0 10Vdc with 10mA source capability Output Response Time 1 ms typical Update Rate Once per controller A D cycle nominal Twice per second maximum for 60 Hz clock rate Output changes are step changes due to the fast time constant All SDAC loop outputs are updated at the same time Doc 30002 00 Rev 2 3 Watlow Anafaze 267 Chapter 7 Specifications PPC 2000 User s Guide 268 Watlow Anafaze Doc 30002 00 Rev 2 3 Appendix A Modbus Protocol Doc 30002 00 Rev 2 3 Watlow Anafaze offers a modbus driver DLL for use with user written Windows based software applications that communicate with the PPC 2000 Using that driver makes it unnecessary for the programmer to understand and implement the modbus protocol PPC 2000 serial communications use the Modbus RTU protocol This protocol defines the message structure for all communication packets The protocol is the same for both RS 232 and RS 485 serial interfaces Modbus ASCII is not supported Up to 32 PPCs may be connected on a network Controllers communicate using a master slave model in which only one device the mast
18. CAUTION Resetting Closed NOTE PPC 2000 User s Guide Do not perform this procedure at a time during which closed loop control and logic program outputs should not be turned off 1 Remove power from the PPC 2000 system 2 Set the rotary switch on the Processor module to position H 3 Power up the PPC 2000 system 4 Set the communications parameters used by the host device or software to the appropriate values for setting H Network address 1 Baud rate 19 2 kbaud Parity Even Data bits 8 Stop bits 1 5 Attempt to communicate If the PPC 2000 still will not communicate and all other com ponents and settings have been verified contact technical support at the number in the front of this manual Loop Control Parameters To restore all the closed loop control alarm global and I O parameters to their factory default settings perform the fol lowing procedure This procedure erases ALL user settings including I O assignments and restores all parameters to the factory defaults and all retained logic program values are reset Make a record of all settings you may wish to restore before performing this procedure A Snapshot may be made in AnaWin3 to record closed loop control parameters for future downloading This procedure resets the programmable communications parameters and restores them to the factory defaults Make a record of all settings you may wish to restore before performing this procedure
19. PPC 2062 16 15 14 13 12 11 10 ts 9 re 8 7 6 5 4 3 2 Gommon onnections a c2 2 Cl PPC 2061 Figure 7 12 PPC 206x Bottom View Table 7 45 Model Number PPC 2061 16 Digital Out Relay PPC 2062 8 Digital Out Relay Table 7 46 Environmental Specifications Storage Temperature 20 to 70 C Operating Temperature 0 to 60 C Humidity 10 to 95 non condensing Table 7 47 Connections Screw Terminal Wire Gauge 24 to 12 AWG Screw Terminal Torque 0 5 to 0 6 Nm 4 4 to 5 3 in lb Mounting DIN rail or panel mount Watlow Anafaze 251 Chapter 7 Specifications PPC 2000 User s Guide Table 7 48 Physical Specifications Weight 0 50 Ibs 0 27 kg Height 8 0 in 203 mm Width 1 5 in 38 mm Depth 5 25 in 133 mm Table 7 49 Power Specifications Power Requirement 3 W typical Current 12Vdc 250mA typical 25 C Current 24Vdc 125mA typical 25 C Modules per Processor 6 Table 7 50 Output Specifications 8 PPC 2062
20. Relay Outputs 16 PPC 2061 Relay Type Form A SPST NO Isolation 240Vac to power common or ground Contact Arrangement open in power off fault or inactive condition Maximum Load Cur 2A PPC 2062 rent 1A up to 5A per common PPC 2061 Contact Voltage Rating 240Vac 30Vdc 252 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 7 Specifications PPC 207x Digital In Specifications The PPC 207x modules provide 8 or 16 digital inputs The 2070 and 2071 accept 120Vac signals The 2072 and 2073 accept 24Vac or 24Vdc signals P Status A PEC 2070 LE ie oe 5 MODULE aa Rotary moo ie Address 5152 ad Switch Os 1002 Input 1002 300 bee LEDs 5004 500 po os 7008 Gaal ae c 30 Oto 110 O12 130 O14 150 O16 PXX XXXXX LS aaun H Figure 7 13 PPC 2070 PPC 2071 Front Views Doc 30002 00 Rev 2 3 Watlow Anafaze 253 Chapter 7 Specifications PPC 2000 User s Guide er nw sR Input 10 Connections _ 3 rh 16 15 14
21. The temperature of a tank of water is controlled by a heater near the bottom of the tank Two thermocouples measure the water temperature One is placed near the heater and is referred to as the inner TC The other is placed in the center of the tank and referred to as the outer TC The desired temperature of the water at the outer TC is 150 F The outer TC is connected to the first input on the Analog Input module Output 22 on the Processor module is used to drive a solid state relay power control Figure 3 8 on page 107 illustrates this application 106 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 3 Operating with AnaWin 3 Tank Outer TC Channel 1 Input Channel 2 Heat Output Inner TC Channel 2 Input Heater Power Control Figure 3 8 Sample Application Using Cascade Control For cascade control the Outer TC is selected as the PV Source for the primary channel and the inner TC is selected as the PV Source for the secondary channel The secondary channel s output is used to control the heater An engineer familiar with the process has determined that as the temperature of the outer primary TC drops from 150 F to 140 F the set point of the secondary channel should rise from 150 F to 190 F Table 3 9 and Table 3 10 on page 108 list the parameter settings for the primary and secondary channels The PID parameters of the primary channel must be tuned to p
22. Encoders may be connected directly to the PPC 2030 module Table 2 17 and Table 2 19 on page 60 indicate the functional pinout for HD 15 connectors connected to the Encoder In Analog Out module connectors J1 and J2 Table 2 18 HD 15 Encoder Signal Connections Connector and Pin Number 3 sare AnaWin3 Name 1 Number Phase 1 Phase 2 Input Spreadsheet Count 1 PPC1 EIAO 11 1 1 C Frequency 1 J3 1 J3 2 J3 3 J3 10 PPC1 EIAO 11 2 1 F Count 2 PPC1 EIAO 11 1 2 C Frequency 2 J3 6 J3 7 J3 8 J3 11 PPC1 EIAO 11 2 2 F Count 3 PPC1 EIAO 11 1 3 C Frequency 3 J4 1 J4 2 J43 J410 PPC1 EIAO 11 2 3 F Count 4 PPC1 EIAO 11 1 4 C Frequency 4 J4 6 J4 7 J48 J411 PPC1 EIAO 11 2 4 F 1 The AnaWin3 name is shown for the Encoder In Analog Out module with address 11 on the first PPC 2000 in the system Refer to Inputs on page 127 for a full explanation of analog input naming Both count and frequency are measured for each input Doc 30002 00 Rev 2 3 Watlow Anafaze 59 Chapter 2 Hardware Installation PPC 2000 User s Guide Table 2 19 HD 15 Power Connections Voltage Pin Number 5Vdce 12 15 COM 13 14 Analog Output Connections The connector pinouts are shown in Table 2 20 Use 16 28 AWG wire When making connections tighten to 0 5 to 0 6 Nm or 4 5 to 5 4 inch pound Outputs 3 amp 4
23. Figure 2 5 PPC 2030 Jumpers and Switches PPC 2030 Jumper Settings Each of the four analog outputs on the PPC 2030 may be configured either as a voltage output or a current output A mixture of current and voltage outputs may be used on a particular module The jumpers only determine if the output signal is current or voltage The actual span of the signal is software selectable See Output Type in Channels on page 115 for the various analog output signal settings Locate Jumpers 1 through 4 Table 2 6 on page 21 describes the analog output jumper configuration Install the jumper in the orientation shown in Figure 2 5 A CAUTION Incorrectly installing the jumper may damage the PPC 2030 module 20 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Table 2 6 PPC 2030 Analog Output Jumpers Analog i current V volt Output Jumper position position 1 JU4 0 20mA 0 10Vdc 2 JU3 0 20mA 0 10Vdc 3 Ju2 0 20mA 0 10Vdc 4 JU1 0 20mA 0 10Vdc Listed values are maximum ranges Other ranges within these limits may be selected in software PPC 2040 Jumper Settings Each of the counter inputs on the PPC 2040 can be configured for single phase or quadrature input Jumper positions determine the counter input configuration To select single phase or quadrature see Table 2 7 and Figure 2 6 to determine which jumper to set and appropriate position Tabl
24. 10V 10mA maximum Accuracy Voltage Mode 0 3 of reading 0 5 of range at 25 C Load Voltage Mode gt 1000 ohm Range Current Mode 0 to 20mA with 8V minimum compliance 400 Ohm load Accuracy Current Mode 1 5 of reading 0 2 of range at 25 C Output Update Time 0 1 sec Table 7 29 Safety and Agency Approvals UL C UL Watlow Anafaze 3121 1 Listed Category II Installation File E212113 243 Chapter 7 Specifications PPC 2000 User s Guide PPC 2040 Digital I O Specifications The PPC 2040 provides 32 digital I O points Each may be configured as an input or an output The count and frequency of changes to the state of the first two inputs are read as analog inputs as well STATUS ERRORO5 MODULE 21 5 LPPC 2040 32 DIGITAL 1 0 _ LED ie la Address Status Rotary Switch I O LEDs 50 pin SCSI Connector Figure 7 8 PPC 2040 Front View Table 7 30 Model Number PPC 2040 Digital 1 0 Table 7 31 Environmental Specifications Storage Temperature 20 to 70 C Operating Temperature 0 to 60 C Humidity 244 Watlow Anafaze 10 to 95 non condensing Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 7 Specifications Table 7 32 Physical Specifications We
25. 2 7 F 1 5 C E T C 454 to 1221 F 270 to 661 C 0 08 F 0 04 C 1 8 F 1 0 C F T C Platinel2 32 to 2250 F 0 to 1232 C 0 19 F 0 11 C 4 1 F 2 3 C GT C 32 to 4200 F 0 to 2316 C 0 02 F 0 01 C 2 7 F 1 5 C JT C 346 to 1598 F 210 to 870 C 0 07 F 0 04 C 2 1 F 1 2 C KT C 454 to 2249 F 270 to 1232 C 0 17 F 0 09 C 3 9 F 2 2 C N T C 454 to 2372 F 270 to 1300 C 0 08 F 0 04 C 2 7 F 1 5 C RTI C 58 to 3215 F 50 to 1768 C 0 02 F 0 01 C 4 6 F 2 6 C RTD 100 Ohm Plat 418 to 521 F 250 to 272 C 0 04 F 0 02 C 0 8 F 0 4 C RTD 100 Ohm Plat High 418 0 to 1562 0 F 250 0 to 850 0 C 0 14 F 0 08 C 4 2 F 2 3 C S T C TT C 58 to 3215 F 50 to 1768 C 454 to 752 F 270 to 400 C 0 31 F 0 17 C 0 07 F 0 04 C 5 6F 3 1 C 2 1 F 1 2 C Thermistor 100K Ohm 24 78 F to 327 F 31 54 to 163 89 C 0 01 F 0 006 C 0 08 F 0 04 C Doc 30002 00 Rev 2 3 Table 7 21 Sensor Reference Voltage Output Voltage 10Vdc 0 3Vdc 25 C Maximum Current 20mAdc Watlow Anafaze 239 Chapter 7 Specifications PPC 2000 User s Guide PPC 2030 Encoder In Analog Out Specifications 5Vdc is supplied at a maximum of 60mA per encoder An external terminal block is used to interface to the encoders Th
26. 30002 00 Rev 2 3 Chapter 5 LogicPro and Modbus Reference Sample Time Time in milliseconds between scans for this input as last reported by the analog input driver This is a read only parameter Input Raw Counts Actual raw counts read during the last scan for analog and counter inputs Input Value Fully linearized and filtered input reading in engineering units degrees for temperature inputs or specified engineering units for linear inputs Input values are copied to the process variable register for channels with this input chosen as the Process Variable Source Units depend on Input Type Input Status This read only register contains information about the sensor Table 5 9 lists and describes the possible values for the parameter Table 5 9 Input Status Value Input Status 0 No problems 1 Open sensor 2 Shorted RTD sensor 8 Common mode overvoltage There is too much noise on the sensor to make an accurate reading 16 Ambient temperature error Temperature is outside con troller s operating range Input Type Specify the sensor type Table 5 10 on page 170 shows the default sensor ranges for the various inputs All Input Value registers store integers In order to provide the desired precision for many Input Types the integer stored in the register may be in tenths of a degree or hundredths of a millivolt For example if an input is set to input type 6 and the Input Value r
27. 315 315 31115 PPC1 DIO 24 2 2 F 24 2 2 316 316 31116 PPC1 DIO 25 1 1 C 25 1 1 317 317 31117 PPC1 DIO 25 2 1 F 25 2 1 318 318 31118 PPC1 DIO 25 1 2 C 25 1 2 319 319 31119 PPC1 DIO 25 2 2 F 25 2 2 320 320 31120 PPC1 DIO 26 1 1 C 26 1 1 321 321 31121 PPC1 DIO 26 2 1 F 26 2 1 322 322 31122 PPC1 DIO 26 1 2 C 26 1 2 323 323 31123 PPC1 DIO 26 2 2 F 26 2 2 324 324 31124 1The AnaWin3 names are shown for the first PPC 2000 in the system See Inputs on page 127 for a full explanation of analog input naming C Counter input F Frequency input LogicPro Variable Type must be INT and IO Size must be WORD 3Use this address with the Digital_IO_2040 IO Driver when addressing the count or frequency Input Value 4Use this address with the Database IO Driver when addressing input parameters other than Input Value Replace the with the parameter number from Table 5 8 on page 168 for the parameter you want to address Doc 30002 00 Rev 2 3 Watlow Anafaze 167 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide Analog and Encoder Input Parameters Table 5 8 lists the parameter number range and first and last Modbus addresses for each analog input parameter These values are used when accessing analog input parameters with third party software operator interface terminals or LogicPro programs The range of some of the parameters depends on which input type is selected See Table 5
28. 5 075 in 4 5 570 in 6 030 in 5 6 525 in 6 985 in 6 7 480 in 7 940 in 7 8 435 in 8 895 in 8 9 390 in 9 850 in 9 10 345 in 10 805 in 10 11 300 in 11 760 in Power Specifications See Chapter 2 Power Supply Requirements on page 18 to determine the power requirements for a PPC 2000 system 230 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 7 Specifications PPC 2010 Processor Specifications Up to 32 PPCs may be connected on a network The default baud rate is 19200 and is configured via AnaWin3 The processor module s front panel has two serial communications ports Both Port 1 and Port 2 can be used with either RS 232 or RS 485 connections Each port s baud rate network address and format are configured via the rotary switch on the front panel The bottom panel includes a 50 pin SCSI connector and a 10 28Vdc power connector The processor module has 48 built in digital I O points 24 points are outputs only 22 of these are user configurable for control alarms or logic program outputs and 2 are dedicated to system status and the global alarm The remaining 24 I O points are user configurable as either inputs or outputs for control alarms or logic 7 TN Power Error A LEDs PPC 2010 PROCESSOR Serial Port 1 Rotary Address Switch STATUSO N RS 485 Connector RS 232 Connector Serial Port 2
29. 7D0 BB7 State This register stores a logical bit which together with the corresponding Logic bit determines the physical state of digital outputs and indicates the state of digital inputs When writing to these bits the controller will ignore any data being written to an I O point configured as an input Table 5 39 on page 201 lists and describes possible combinations of State and Logic values Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference Table 5 39 State and Logic State Value Logic Value Description 0 0 1 On Input signal detected or output is energized 0 1 0 On Input signal not detected or out put is de energized 1 0 1 On Input signal detected or output is energized 1 1 0 On Input signal not detected or out put is de energized Direction Select whether the flexible I O points are being used as inputs or outputs All flexible I O points default to inputs See Table 5 37 on page 200 for restrictions on particular I O points Table 5 40 Direction Value State 0 Input 1 Output Logic Specify the active true level On state for each system digital output Table 5 41 Logic Value State 0 1 0n 1 0 0n Doc 30002 00 Rev 2 3 Watlow Anafaze 201 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide Analog Output Parameters in the Database Analog Output Value is the o
30. Analog Output Connections on a PPC 2050 Configured for Voltage Outputs 1 and 2 shown 69 Figure 2 57 Analog Output Connections on a PPC 2051 Configured for Current and Voltage Outputs 1 and 2 shown 69 Figure 2 58 PPC 206x Connections bottom view 70 Figure 2 59 Relay Output Connections on a PPC 2061 Outputs 1 2 9 and 10 shown 71 Figure 2 60 Relay Output Connections on a PPC 2062 Outputs 1 and 2 Shown 72 Figure 2 61 Snubber Connections 73 Figure 2 62 PPC 207x Connections bottom view 74 Figure 2 63 Input Connections to a PPC 2070 or PPC 2072 Inputs 1 and 2 shown 74 Figure 2 64 Input Connections to a PPC 2071 or PPC 2073 Inputs 1 2 9 and 10 Shown 75 Figure 2 65 Connecting a Current Sinking Field Device to a PPC 2072 or PPC 2073 Input 1 Shown 75 Figure 2 66 Connecting a Current Sourcing Field Device to a PPC 2072 or PPC 2073 Input 1 Shown 76 Figure 2 67 PPC IPS 2 Power Connections 78 Figure 2 68 RS 232 and RS 485 RJ Type Connectors 79 Figure 2 69 Connecting One PPC to a Computer Using RS 232 81 Figure 2 70 Connecting Multiple PPCs to a Computer Using RS 485 81 Figure 2 71 RS 485 Wiring 82 Figure 2 72 Two Wire RS 485 Wiring 84 Figure 2 73 Connecting Several PPCs with Short Cable Runs 84 x Watlow Anafaze Doc 30002 00 Rev 2 3 PPC User s Guide List of Figures Operating with AnaWin3 89 Figure 3 1 Sample Screen Text 89 Figure 3 2 Process Variable Alarms 96 Figure 3 3 Linear Input Example
31. Digital In Out 32 32 PPC1 DIO 21 0 32 Com DC Common for Input Return 37 to 50 N A 1 The AnaWin3 name is shown for the first Digital I O module on the PPC 2000 system See Digital I O on page 132 for a complete explanation of digital I O names 2 Both count and frequency are measured for the pulse input See nputs on page 127 for an explanation of analog input names Doc 30002 00 Rev 2 3 Watlow Anafaze Chapter 2 Hardware Installation PPC 2000 User s Guide Connecting Digital Inputs The PPC 2040 module can accept digital inputs When the resistance of an input device is 27 kOhm or greater the input is considered off by the PPC 2000 When the resistance is 1 kOhm or less the input is considered on To install a switch as a digital input connect one lead to the DC Common input return on the TB50 Connect the other lead to the desired digital input on the TB50 Refer to Table 2 21 on page 63 for screw terminal numbering Use the Digital I O parameters to configure digital inputs Refer to Digital I O on page 132 Digital av a r Input X TB50 Device n Digital In Com Figure 2 48 Wiring Digital Inputs Connecting Counter or Frequency Inputs A PPC 2040 module accepts single phase or quadrature pulse signals from devices such as encoders Counts and frequencies of the inputs may be scaled with user selectable parameters See Setting up User Selectable Linear Inputs on page 98 for more i
32. Frame 4 Bare Shield Ground N C N C Watlow Anafaze 79 Chapter 2 Hardware Installation PPC 2000 User s Guide Table 2 28 RS 485 Connector Pin Out and Connections RJ12 PPC Converter Pin Wire Color Function Connection 1 White or Blue Common Common 2 Black RB TXB TDB TX 3 Red TB RXB RDB RX 4 Green TA RXA RDA RX 5 Yellow RA TXA TDA TX 6 Bare Shield not used N C Jumpers in RS 232 Connectors Some software programs and some operator interface terminals require a Clear to Send CTS signal in response to their Request to Send RTS signal or a Data Set Ready DSR in response to their Data Terminal Ready DTR The PPC 2000 is not configured to receive or transmit these signals To use such software with the PPC jumper RTS to CTS and DTR to DSR in the DB connector Table 2 29 lists the standard pin assignments for DB 9 and DB 25 connectors Table 2 29 RTS CTS Pins in DB 9 and DB 25 Connectors DB 9 DB 25 RTS 7 4 CTS 8 DTR 4 20 DSR 6 6 Cables manufactured by Watlow Anafaze for RS 232 communications include these jumpers AnaWin3 and LogicPro do not require these jumpers and are not affected by their presence 80 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Connecting RS 232 Communications RS 232 may be used for communications between one PPC and a host device over cables of up to 50 feet in len
33. Input Spreadsheet Processor_2010 Database Database Sample IO Driver IO Driver Offset Address PPC1 Proc 0 1 1 C 0 1 1 161 161 30961 PPC1 Proc 0 2 1 F 0 2 1 162 162 30962 The AnaWin3 names are shown for the first PPC 2000 in the system See Inputs on page 127 for a full explanation of analog input naming C Counter input F Frequency input LogicPro Variable Type must be INT and IO Size must be WORD 3Use this address with the Processor_2010 IO Driver when addressing the count or frequency Input Value 4Use this address with the Database IO Driver when addressing input parameters other than Input Value Replace the with the parameter number from Table 5 8 on page 168 for the parameter you want to address Soft inputs are used when the Process Variable Source of a channel must be a register to which a logic program can write Channel Output registers are used as the Setpoint Source for the secondary cascade channel Table 5 6 Addresses for Soft Inputs and Channel Outputs LogicPro I O Physical Address Modbus Addressing AnaWin3 Name Input Spreadsheet Soft_Input Database Database Sample IO Driver IO Driver Offset Address PPC1 Soft Input 1 1 165 165 30965 PPC1 Soft Input 2 2 166 166 30966 PPC1 Soft Input 48 48 212 212 31012 PPC1 Channel 1 Output 215 215 31015 PPC1 Channel 2 Output 216 216 31016 nia PPC1 Channel 48 Output 262 262 31062
34. Inputs Single ended PPC 2021 16 Differential PPC 2022 32 Single ended PPC 2024 8 Differential High Isolation PPC 2025 16 Differential High Isolation Doc 30002 00 Rev 2 3 Watlow Anafaze 47 Chapter 2 Hardware Installation PPC 2000 User s Guide Table 2 13 Sensor Connections to the AITB AITB Connection Terminal Numbers AnaWin3 Name Module Differential Input Me PPC 2021 Single Ended Spreadsheet Number PPC 2024 PPC 20222 PPC 2025 Input 1 1A 1B 1A Com PPC1 Al 1 1 Input 2 2A 2B 1B Com PPC1 Al 1 2 Input 3 3A 3B 2A Com PPC1 Al 1 3 Input 4 4A 4B 2B Com PPC1 Al 1 4 Input 5 5A 5B 3A Com PPC1 Al 1 5 Input 6 6A 6B 3B Com PPC1 Al 1 6 Input 7 7A 7B 4A Com PPC1 Al 1 7 Input 8 8A 8B 4B Com PPC1 Al 1 8 Input 9 9A 9B 5A Com PPC1 Al 1 9 Input 10 10A 10B 5B Com PPC1 Al 1 10 Input 11 11A 11B 6A Com PPC1 Al 1 11 Input12 12A 12B 6B Com PPC1 Al 1 12 Input 13 13A 13B 7A Com PPC1 Al 1 13 Input 14 14A 14B 7B Com PPC1 Al 1 14 Input 15 15A 15B 8A Com PPC1 Al 1 15 Input16 16A 16B 8B Com PPC1 Al 1 16 Input 17 n a n a 9A Com PPC1 Al 1 17 Input 18 n a n a 9B Com PPC1 Al 1 18 Input 19 n a n a 10A Com PPC1 Al 1 19 Input 20 n a n a 10B Com PPC1 Al 1 20 Input 21 n a n a 11A Com PPC1 Al 1 21 Input 22 n a n a 11B Com PPC1 Al 1 22 Input 23 n a n a 12A Com PPC1 Al 1 23 Input 24 n a n a 12B Com PPC1 Al 1 24 Input 25 n a n a 13A Com PPC1 Al 1
35. Insert the appropriate key in the socket provided on the AITB See Table 2 11 for a description of the various keys There are two rows of eight key sockets Each socket location is labeled IN1 to IN16 which correlate with each Analog In or High Isolation Analog input address Keys should be inserted with the component side facing the terminal blocks Figure 2 29 illustrates key installation keys component side of keys face terminal blocks Figure 2 29 Inserting Sensor Keys in AITB Table 2 11 Sensor Keys Used Key Color Sensors with TC None TC and Voltage All 2021 2 Wire or 3 Wire RTD Red 2024 Platinum 1009 RTD 2025 Diff tial 2021 rani a Blue 0 20mA 2024 2025 single Ended Black 0 20mA 2022 Current 46 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation ndicates component side Color indicates key type Figure 2 30 An Input Key AITB Connections The AITB accommodates wiring thermocouples RTDs and voltage current linear inputs for all analog input modules Table 2 12 describes each analog module and Table 2 13 on page 48 correlates the AITB labels with the sensor wire connections for the various modules When connecting sensor wires tighten to 0 5 0 6 Nm or 4 5 5 4 inch pound Table 2 12 Numbers and Types of Inputs by Module Type Number Differential or Module of Note
36. Me ee Figure A 1 Query Response Cycle The function code in the query tells the addressed slave device what kind of action to perform The data bytes contain any additional information that the slave will need to perform the function For example function code 03 will query the slave to read holding registers and respond with their contents The data field must contain the information telling the slave which register to start at and how many registers to read The error check field provides a method for the slave to validate the integrity of the message contents If the slave makes a normal response the function code in the response is an echo of the function code in the query The data bytes contain the data collected by the slave such as register values or status If an error occurs the function code is modified to indicate that the response is an error response and the data bytes contain a code that describes the error The error check field allows the master to confirm that the message contents are valid Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Appendix A Modbus Protocol Modbus ASCII and RTU Modes Modbus protocol specifies two distinct modes ASCII and RTU While the PPC 2000 only supports RTU it is important to understand the differences Typically ASCII is used for simple communication tasks or diagnostics while RTU is used where a more robust and efficient protocol is required The
37. RS 485 Network Connections Run twisted pair from the host or converter to a 485 terminal block as close to first PPC as possible and from that point to another 485 terminal block near the next PPC and so on Connect 485 terminal blocks in series using appropriate lengths of 485 cable Be sure to connect all five conductors at each junction such that the 485 terminal block at each PPC will see the same signals on each ofits pins Install the 485 terminal blocks as close to each PPC as possible To avoid unacceptable interference use less than ten cable feet from the terminal to the PPC serial port Use cables with RJ12 plugs to connect from the 485 terminal blocks to the serial ports on each PPC 2010 or use cables with bare wires on one end and RJ12 connectors on the other to connect from terminal strips to the PPCs Two Wire RS 485 Connections By placing jumpers between the pins and between the pins on the 485 terminal blocks RS 485 systems may be configured for two wire connections as well Use the same cables with RJ12 plugs as you would use for four wire connections to connect from the 485 terminal blocks to the serial ports on each PPC 2010 Connect the two wire RS 485 network to the 485 terminal block according to Figure 2 72 Doc 30002 00 Rev 2 3 Watlow Anafaze 83 Chapter 2 Hardware Installation PPC 2000 User s Guide Converter or Host Color RJ Pin PPC 1 Color RJ Pin PPC N Yellow 5 TXA TDA T
38. System Status 106 10001 10050 0 31 System Commands 04051 04100 FD2 1003 Changed Data Queue 107 33051 33150 BEA C4D Program Version 108 33151 33200 C4E C7F See Table 5 60 System Error Log 33201 33450 C80 D79 114 46151 46157 672 678 See Table 5 63 Time and Date Full Scale The values stored in the Full Scale registers are the readings from the high voltage references These readings are used in conjunction with the zero reference readings to scale the analog input readings Doc 30002 00 Rev 2 3 Watlow Anafaze 209 Chapter 5 LogicPro and Modbus Reference 210 PPC 2000 User s Guide Table 5 53 Full Scale Readings Database Module Range Reference Offset Address Voltage 1 1 1 to 10V 10V 2 1 5 to 50mV 50mV 3 2 1 to 10V 10V 4 2 5 to 50mV 50mV 5 3 1 to 10V 10V 6 3 5 to 50mV 50mV 7 4 1 to 10V 10V 8 4 5 to 50mV 50mV Zero Reference The values stores in the Zero Reference registers are the readings from the low voltage reference These readings are used in conjunction with the Full Scale reading to scale the analog input readings Table 5 54 Zero Reference Readings Database Module Range Reference Offset Address Voltage 1 1 1 to 10V OV 2 1 0 5 to 5V OV 3 1 0 1 to 1V OV 4 1 50 to 500mV OV 5 1 10 to 100mV OV 6 1 5 to 50mV OV 7 2 1 to 10V
39. Table 3 8 lists the settings used on the retransmit channel Furnace PPC Channel 1 Input Channel 2 Heat Output To Chart Recorder Channel 1 Heat Output Heater MA Power Control Figure 3 5 Sample Application Using Process Variable Retransmit Table 3 8 Retransmit Channel Parameter Settings Parameter Setting Description Control Type This disables normal closed loop control and PAS Reransmii enables the PV retransmit feature The first output on the Analog Output module with Heat Output Dest PPC1 AO 31 1 its address set to 31 will be used to retransmit channel 1 s process variable The analog input to be retransmitted is from the PV Source PPC1 Al 1 1 first sensor on the Analog Input module with its address set to 1 Heat Output Type Analog 4 20mA A 4 20mA signal is output representing the value of the analog input z When the analog input value is less than or equal Min Set Point oE to 0 F channel 2 s output will be 4mA Max Set Point 1000F When the analog input value is equal to or greater than 1000 F channel 2 s output will be 20mA Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 3 Operating with AnaWin 3 Cascade Control Cascade control is used with thermal systems with long lag times which cannot be as accurately controlled with a single control loop To accomplish this the output o
40. The State registers containing the value of the digital I O point must be interpreted in terms of the Logic in order to determine the physical state of the I O point For example if the State is 1 and the Logic is 1 On the corresponding input or output is on For a de digital input this indicates the input is connected to the power supply common For an ac input this indicates the signal is detected For a digital output or relay output this indicates the output is conducting Conversely if the State is 1 and the Logic is 0 On the corresponding input or output is off For an input this indicates the field device is an open circuit For an open collector output this indicates the output is an open circuit For a relay output this indicates the output is de energized Accessing Digital I O Parameters with Modbus For Digital I O parameters the Modbus address offsets correspond to the digital I O numbers See Table 5 33 on page 196 through Table 5 36 on page 199 for a list of the module I O numbers corresponding to the digital I O on the Processor and Digital I O modules Addresses for digital I O State Direction Logic are relative to the hardware connection to the corresponding field I O device For example the PPC 2000 processor module has 48 digital I O points with registered addresses 1 to 48 The state of the device connect to pin 1 on the TB50 is stored at address 03001 The state of the device connected to pin 2 on the TB50
41. described in Function Codes on page 276 When a message is sent from a master to a slave device the function code field tells the slave what kind of action to perform Examples are to read the On Off states of a block of digital inputs or outputs to read the data contents of a block of registers to read the diagnostic status of a controller When the slave responds to the master it uses the function code field to indicate either a normal error free response or that some kind of error occurred called an exception response For a normal response the slave simply echoes the original function code For an exception response the slave returns a code that is equivalent to the original function code with its most significant bit set to a logic 1 For example a message from the master to slave to read a block of holding registers would have the following function code 0000 0011 Hexadecimal 03 If the slave device takes the requested action without error it returns the same code in its response If an exception occurs it returns 1000 0011 Hexadecimal 83 In addition to its modification of the function code for an exception response the slave places a unique code into the data field of the response message This tells the master what kind of error occurred or the reason for the exception The master device s application program has the responsibility of handling exception responses Typical processes are to post subsequent r
42. e COM Figure 2 33 Wiring 2 Wire RTDs Input 1 and 2 Shown Three wire RTDs may only be used with differential analog input modules The single wire side of a 3 wire RTD sensor connects to the 4 terminal one of the double wire sides connects to the B terminal and the other connects to the COM terminal Both A and B terminals must be of the same desired input i e 1A and 1B See Figure 2 34 AITB 7A input 1 7B input 1 2A input 2 af 2B input 2 e COM Figure 2 34 Wiring 3 Wire RTDs Input 1 and 2 Shown Doc 30002 00 Rev 2 3 Watlow Anafaze 51 Chapter 2 Hardware Installation A CAUTION PPC 2000 User s Guide Do not connect the COM terminals on the AITB to earth ground Connecting COM to earth ground limits the input protection to 10Vac and could result in damage to the input circuit Connecting Sensors with Linear Voltage Signals 52 For sensors with single output connections connect the negative input B terminal to the sensor common terminal Differential voltage transducers or sensors such as bridges should be connected with the positive signal lead on the A terminal and the negative signal lead to the B terminal for the selected input See Figure 2 35 Check sensor power supply connections and ground connections to avoid exceeding the common mode range of the Analog Input module or creating ground loops
43. the function forces the same coil references in all attached slaves Preset Multiple Registers 16 Presets values into the sequence of holding registers 4X references When broadcast the function presets the same register references an all attached slaves The following sections detail the Diagnostics 08 subfunctions Diagnostics Subfunction Return Query Data 00 The data passed in the query data field is to be returned looped back in the response The entire response message should be identical to the query Subfunction Data Field Query Data Field Response 00 00 Any Echo Query Data Diagnostics Subfunction Restart Communications Option 01 The slave s peripheral port is to be initialized and restarted and all of its communications event counters are to be cleared If the port is currently in Listen Only Mode no response is returned This function is the only one that brings the port out of Listen Only Mode If the port is not currently in Listen Only Mode a normal response is returned This occurs before the restart is executed Subfunction Data Field Query Data Field Response 00 01 00 00 Echo Query Data 00 01 FF 00 Echo Query Data Watlow Anafaze 277 Appendix A Modbus Protocol 278 PPC 2000 User s Guide Diagnostics Subfunction Return Diagnostic Register 02 The contents of the slave s 16 bit diagnostic register are returned in the response Subfunction Data Field Query Data F
44. 0 32 80 80 00080 PPC1 DIO 22 0 1 22 0 1 81 81 00081 PPC1 DIO 22 0 2 22 0 2 82 82 00082 PPC1 DIO 22 0 32 22 0 32 112 112 00112 PPC1 DIO 23 0 1 23 0 1 113 113 00113 PPC1 DIO 23 0 2 23 0 2 114 114 00114 PPC1 DIO 23 0 32 23 0 32 144 144 00144 PPC1 DIO 24 0 1 24 0 1 145 145 00145 PPC1 DIO 24 0 2 24 0 2 146 146 00146 PPC1 DIO 24 0 32 24 0 32 176 176 00176 PPC1 DIO 25 0 1 25 0 1 177 177 00177 PPC1 DIO 25 0 2 25 0 2 178 178 00178 PPC1 DIO 25 0 32 25 0 32 208 208 00208 PPC1 DIO 26 0 1 26 0 1 209 209 00209 PPC1 DIO 26 0 2 26 0 2 210 210 00210 PPC1 DIO 26 0 32 26 0 32 240 240 00240 1The AnaWin3 names are shown for the first PPC 2000 in the system See Digital I O on page 132 for a full explanation of digital I O naming LogicPro Variable Type must be BOOL 3Use this address with the Digital _1O_2040 IO Driver when addressing State 4Use this address with the Database IO Driver when addressing digital I O parameters other than State Replace the with the parameter number from Table 5 38 on page 200 for the parameter you want to address Doc 30002 00 Rev 2 3 Watlow Anafaze 197 Chapter 5 LogicPro and Modbus Reference 198 PPC 2000 User s Guide Table 5 35 Addresses for Digital Outputs on the PPC 206x Digital Out Modules AnaWin3 Name LogicPro I O Physical Address Modbus Addressing Dig area Digital_Out_206x Database Database Sample IO Driver IO Driver
45. 00 Setpoint Offset For ratio control differential control and remote setpoint applications set the offset which is added to the product of the analog input value selected as the Setpoint Source and the Setpoint Ratio to calculate the setpoint Ratio Control on page 109 Differential Control on page 112 and Remote Set Point on page 112 This parameter may be set to any value from 32768 to 32767 The number of decimal places depends on the Input Type selected See Table 3 15 on page 130 Maximum Setpoint This parameter determines the maximum value the PPC will accept for the setpoint of the channel This parameter is also used to scale a cascade channel See Cascade Control on page 105 The range is the same as that of the input type for the channel Minimum Setpoint This parameter determines the minimum value the PPC will accept for the setpoint of the channel This parameter is also used to scale a cascade channel See Cascade Control on page 105 The range is the same as that of the input type for the channel Heat Cool Output Type This parameter specifies the type of output signal and determines whether the PID or on off control algorithm is used for the channel See Table 5 20 on page 183 For specific information on control terminology and definitions refer to Chapter 6 Control Terminology Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference Table 5 20
46. 1 2089 44 3 Input 2 2089 44 3 Input 3 2089 44 3 ee ee ol Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference The cells in the database tables are referred to as registers There are two types of registers in the database bit registers and word registers Bit registers hold a single bit and word registers hold 16 bit integers These registers may be accessed by software running on a PC or by an operator interface terminal or by a logic program running on the PPC itself Some parameters are read only but others may be read or changed Data Table Organization The datatable is organized according to the Modbus standard for PLC memory Memory is divided into four sections by size and function The Modbus specification allows for up to 9 999 registers for each section Some registers are not available in the PPC 2000 Consult the parameter tables in this chapter to determine which registers are available Also the usage of some registers in the PPC 2000 differs from standard PLC usage for instance coils are used for digital input status Coils Coils are bit registers Each have a value of 1 or 0 Software interfaces may read or write the values stored in these registers The modbus addresses for Coils range from 0001 to 9999 decimal Inputs Inputs are bit registers Each has a value of 1 or 0 Software interfaces may read but not write the values stored in these registers Th
47. 205x Analog Out Modules LogicPro I O Physical p Address Modbus Addressing AnaWin3 Name Output Spreadsheet Analog_Out_205x l ier Decimal Hex IO Driver PPC1 AO 31 1 31 1 46267 187A PPC1 AO 31 2 31 2 46268 187B PPC1 AO 31 8 31 8 46274 1881 PPC1 AO 32 1 32 1 46275 1882 PPC1 AO 32 2 32 2 46276 1883 PPC1 AO 32 8 32 8 46282 1889 PPC1 AO 33 1 33 1 46283 188A PPC1 AO 33 2 33 2 46284 188B PPC1 AO 33 8 33 8 46290 1891 PPC1 AO 34 1 34 1 46291 1892 PPC1 AO 34 2 34 2 46292 1893 PPC1 AO 34 8 34 8 46298 1899 The AnaWin3 names are shown for the first PPC 2000 in the system See Outputs on page 735 for a full explanation of analog output naming Use this address with the Analog Out_205x IO Driver when addressing Analog Output Value There are no other analog output parameters so you will not use the Database IO Driver Analog Output Value NOTE An array of addressable I O words that represent the output value for each analog output as a number between 0 and 32767 These numbers correspond to the minimum and maximum output signal levels for the selected Output Type The analog signal range is determined by the hardware jumper configuration and the setting of the Output Type for the channel with the output selected as Heat Cool Output Destination Range 0 to 32767 The resolution of the analog outputs is 12 bit The output Value is displayed as a 15 bit integer The output Value must change
48. 22 PPC1 Proc 0 0 22 Digital In Out 23 23 PPC1 Proc 0 0 23 Digital In Out 24 24 PPC1 Proc 0 0 24 Digital Out 25 25 PPC1 Proc 0 0 25 Digital Out 26 26 PPC1 Proc 0 0 26 Digital Out 27 27 PPC1 Proc 0 0 27 Digital Out 28 28 PPC1 Proc 0 0 28 Digital Out 29 29 PPC1 Proc 0 0 29 Digital Out 30 30 PPC1 Proc 0 0 30 Digital Out 31 31 PPC1 Proc 0 0 31 Digital Out 32 32 PPC1 Proc 0 0 32 Digital Out 33 33 PPC1 Proc 0 0 33 Digital Out 34 34 PPC1 Proc 0 0 34 Doc 30002 00 Rev 2 3 Watlow Anafaze Chapter 2 Hardware Installation 40 PPC 2000 User s Guide TB 50 AnaWin3 Name Module I O Number Terminal Dig I O Spreadsheet Digital Out 35 35 PPC1 Proc 0 0 35 Digital Out 36 36 PPC1 Proc 0 0 36 Digital Out 37 37 PPC1 Proc 0 0 37 Digital Out 38 38 PPC1 Proc 0 0 38 Digital Out 39 39 PPC1 Proc 0 0 39 Digital Out 40 40 PPC1 Proc 0 0 40 Digital Out 41 SDAC Out 41 41 PPC1 Proc 0 0 41 Digital Out 42 SDAC Out 42 42 PPC1 Proc 0 0 42 Digital Out 43 i SDAC Out 43 43 PPC1 Proc 0 0 43 Digital Out 44 SDAC Out 44 44 PPC1 Proc 0 0 44 Digital Out 45 SDAC Out 45 45 PPC1 Proc 0 0 45 Digital Out 46 SDAC Clock 46 PPC1 Proc 0 0 46 Global Alarm 47 PPC1 Proc 0 0 47 CPU Watchdog 48 PPC1 Proc 0 0 48 Com DC Common for 49 50 N A Input Return 1 The name is shown for the first PPC 2000 in the system See Digital I O on page 132 for a complete explanat
49. 25 Input 26 n a n a 13B Com PPC1 Al 1 26 Input 27 n a n a 14A Com PPC1 Al 1 27 Input 28 n a n a 14B Com PPC1 Al 1 28 Input 29 n a n a 15A Com PPC1 Al 1 29 Input 30 n a n a 15B Com PPC1 Al 1 30 Input 31 n a n a 16A Com PPC1 Al 1 31 Input 32 n a n a 16B Com PPC1 Al 1 32 1 The AnaWin3 name is shown for the first Analog Input module on the first PPC 2000 in the system See Inputs on page 127 for a full explanation of analog input naming 2 For the single ended module the negative sensor lead is connected to any one of the Com Analog Common terminals 48 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Table 2 14 Power Connections on AITB Voltage AITB Terminals 10 00V Ref Ref 4 PL Analog Common Com 8 PL NOTE The Ref voltage is provided for special sensor types Do not use this voltage without consulting Watlow Anafaze Connecting Thermocouples NOTE Connect thermocouple shields directly to a good frame or chassis ground Connect thermocouple shields at one end only either near the terminal board or the sensor end A thermocouple is connected in a differential configuration by wiring the positive signal lead to the A terminal of the proper input and the negative signal lead to the B terminal of the same input The designators are located on the terminal block cards near each screw terminal See Figure 2 31 AITB t e 1A input 1
50. 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Communication Cables Watlow Anafaze supplies flat oval cables with modular plug and DB 9 connectors for RS 232 RS 485 cables have RJ12 connectors and bare wire ends These cables may be used for short runs between a PPC and a host device or between a PPC and a terminal strip or other wiring interface When using other cables or connecting over longer distances select cables and connectors that meet the standards described in this section Do not use cables from sources other than Watlow Anafaze unless the shield wire is in the proper position pin 6 in the connector Table 2 27 and Table 2 28 on page 80 describe the pin outs for the two connector types Cable Connector Pin Outs Doc 30002 00 Rev 2 3 Cable connectors must have the correct pin outs Refer to Figure 2 68 on page 79 to determine the location of pin 1 in the connectors Refer to Table 2 27 on page 79 for RS 232 cable pin outs Refer to Table 2 28 on page 80 for the RS 485 pin out and connections The colors in the table are for Watlow Anafaze cables pin 1 pin 1 RS 232 Modular Plug RS 485 RJ12 4 Position 4 Conductor 6 Position 6 Conductor Handset Plug Plug Figure 2 68 RS 232 and RS 485 RJ Type Connectors Table 2 27 RS 232 Connector Pin Outs Plug PPC DB9 DB25 ping WireColor Function Pin Pin 1 Black Common 5 7 2 Red R 3 2 3 Green T 2 3
51. 3 3 1016 PPC1 EIAO 14 3 4 Table 5 26 Output Destinations for Analog Outputs on the PPC 205x Modules Value Output Name AnaWin3 Outputs Spreadsheet 1017 PPC1 AO 31 1 1018 PPC1 AO 31 2 1024 PPC1 AO 31 8 1025 PPC1 AO 32 1 1026 PPC1 AO 32 2 1032 PPC1 AO 32 8 1033 PPC1 AO 33 1 1034 PPC1 AO 33 2 1040 PPC1 AO 33 8 1041 PPC1 AO 34 1 1042 PPC1 AO 34 2 1048 PPC1 AO 34 8 Doc 30002 00 Rev 2 3 Watlow Anafaze 189 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide NOTE 190 Table 5 27 Output Destinations for Soft Boolean and Soft Integers AnaWin3 Name Value 1 Soft Bool and Soft Int Spreadsheets 3001 PPC1 Soft Bool 1 3002 PPC1 Soft Bool 2 4000 PPC1 Soft Bool 1000 2051 PPC1 Soft Int 1 2052 PPC1 Soft Int 2 2150 PPC1 Soft Int 100 Soft Integers 1 100 may be used as output destinations Extended Soft Integers 101 2100 may not be used as output destinations See Alarms on page 95 for an overview of alarm functions Alarm Status Flags Each Alarm Status register contains a 16 bit word The bits may be read to detect the status of each of a channel s alarms When an alarm occurs the controller sets the appropriate bit equal to one When the alarm condition clears the controller sets the bit back to 0 Table 5 28 summarizes these definitions See Table 5 29 on page 191 for alarm bit definitions Table 5 28 Alarm Status Value Cond
52. 30002 00 Rev 2 3 Glossary Input Process variable information that is supplied to the instrument Input Scaling The ability to scale input readings readings in percent of full scale to the engineering units of the process variable Input Type The signal type that is connected to an input such as thermocouple RTD linear or process Integer A variable with a potential range of 32 768 to 32 767 Integral Control I Control action that automatically eliminates off set or droop between setpoint and actual process temperature Jumper A removeable connector that acts as a switch between a set of pins on a circuit board used to configure electronic hardware L Linear Input A process input that represents a straight line function Low Deviation Alarm Warns that the process is below the setpoint but above the low process variable It can be used as either an alarm or control function Low Process Alarm A signal that is tied to a set minimum value that can be used as either an alarm or control function Watlow Anafaze 287 Glossary M Manual Mode A selectable mode that has no automatic control aspects The operator sets output levels Modbus Industrial communications protocol developed by AEG Schneider Automation Modbus Address Number that specifies a bit or word register within a controller s memory Modbus Database Offset A number which is combined with a parameter s first address to lo
53. 5 LogicPro and Modbus Reference High Process Limit HP Limit The high process alarm activates when the Process Variable PV goes above the high process setpoint The PV must drop to the alarm setpoint minus the alarm deadband for the alarm to clear The alarm limit is set in the engineering units of the channel Its value does not change when the process setpoint changes The default high process alarm setpoint is 0 Low Process Limit LP Limit The low process alarm activates when the process variable PV goes below the low process setpoint The PV must rise to the alarm setpoint plus the alarm deadband for the alarm to clear The alarm limit is set in the engineering units of the channel Its value does not change when the process setpoint changes The default low process alarm setpoint is 0 High Deviation Offset HD Offset This value determines the high deviation alarm limit relative to the current setpoint The high deviation alarm occurs when the process variable is greater than the current setpoint plus this value The offset is set in the engineering units of the channel but relative to the process setpoint The alarm limit changes when the process setpoint changes The default high deviation offset is 0 Low Deviation Offset LD Offset This value determines the low deviation alarm limit relative to the current setpoint The low deviation alarm occurs when the process variable is lower than the current setpoint less thi
54. Acknowledge 192 Table 5 32 Alarm Enable Disable 192 Table 5 33 Database Offsets and Sample Modbus Addresses for Digital I O 196 Table 5 37 Digital I O Uses 200 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC User s Guide List of Tables Table 5 38 Digital I O Parameters 200 Table 5 39 State and Logic 201 Table 5 40 Direction 201 Table 5 41 Logic 201 Table 5 44 Soft Bool and Soft Int Parameters 205 Table 5 45 Soft Bool Values 205 Table 5 46 Soft Bool and Soft Int Registers 206 Table 5 47 Rotary Switch Configuration 207 Table 5 48 Communications Parameters 208 Table 5 49 Database Offsets for Baud Rate 208 Table 5 50 Baud Rate 208 Table 5 51 System HW Parameters 209 Table 5 52 Miscellaneous System Parameters 209 Table 5 54 Zero Reference Readings 210 Table 5 55 Ambient Temperature Readings 211 Table 5 56 Modules Present 211 Table 5 57 Module Types 212 Table 5 59 System Status 214 Table 5 60 System Status Bits 214 Table 5 63 Real Time Clock Format 218 Tuning and Control 219 Table 6 1 Proportional Band Settings 226 Table 6 2 Integral Term and Reset Settings 227 Table 6 3 Derivative Term vs Rate 227 Table 6 4 General PID Constants 228 Specifications 229 Table 7 1 Safety and Agency Approvals 229 Table 7 2 PPC System Dimensions 230 Table 7 3 Model Number 232 Table 7 4 Environmental Specifications 232 Table 7 5 Physical Specifications 232 Table 7 7 Power Specif
55. Analog Out Module 60 Table 2 21 Digital I O Module Connections 63 Table 2 22 Analog Output Connections on Analog Out Module 67 Table 2 23 Relay Output Connections on PPC 206x Digital Output Modules 72 Table 2 24 Digital Input Connections on PPC 207x Modules 76 Table 2 25 PPC IPS 2 Voltage Input Switch Settings 77 Table 2 26 Power Supply Connections 77 Table 2 27 RS 232 Connector Pin Outs 79 Table 2 28 RS 485 Connector Pin Out and Connections 80 Table 2 29 RTS CTS Pins in DB 9 and DB 25 Connectors 80 Table 2 30 485 Terminal Block Pin Assignment 83 Table 2 31 PPC 2010 Rotary Switch Configuration 86 Doc 30002 00 Rev 2 3 Watlow Anafaze xiii List of Tables PPC User s Guide Operating with AnaWin3 89 Table 3 1 Control Types PID1 and PID2 91 Table 3 2 Alarm Types 95 Table 3 3 Range and Sensitivity of theCustom Linear Input Types 99 Table 3 4 PV Range permitted for various Decimal Places Settings 100 Table 3 5 Scaling Parameters for 0 10Vdc Linear Input Example 101 Table 3 6 Scaling Parameters for 4 20mA Linear Input Example 101 Table 3 7 Scaling Parameters for 0 1Vdc Linear Input Example 102 Table 3 8B Retransmit Channel Parameter Settings 104 Table 3 9 Primary Channel Parameter Settings 107 Table 3 10 Secondary Channel Parameter Settings 108 Table 3 11 Ratio Channel Parameter Settings 111 Table 3 12 AnaWin3 Control Types 118 Table 3 14 Module Abbreviations Seen on the Inputs Spreadsheet 12
56. CZ o a Figure 2 40 PPC EITB 1 Table 2 15 Encoder Connections to the EITB Connected to J3 on the PPC 2030 Module EITB Terminal AnaWin3 Name I O Number Phase 1 Phase 2 Input aian ga le Spreadsheet Count 1 2 3 4 5 PPC1 EIAO 11 1 1 C Frequency 1 PPC1 EIAO 11 2 1 F Count 2 8 9 FADE PPC1 EIAO 11 1 2 C Frequency 2 PPC1 EIAO 11 2 2 F Table 2 16 Encoder Connections to the EITB Connected to J4 on the PPC 2030 Module EITB Terminal AnaWin3 Name I O Number Phase 1 Phase 2 Input foil eri eal Spreadsheet Count 3 5 3 4 5 PPC1 EIAO 11 1 3 C Frequency 3 PPC1 EIAO 11 2 3 F Count 4 r Paley sey PPC1 EIAO 11 1 4 C Frequency 4 PPC1 EIAO 11 2 4 F 1 The AnaWin3 name is shown for the Encoder In Analog Out module with address 11 on the first PPC 2000 in the system See Inputs on page 127 for a full explanation of Analog input naming Both count and frequency are measured for each input Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Table 2 17 Power Connections on EITB Voltage EITB Terminals 5Vdc 1 7 COM 6 12 Encoder Wiring The EITB accommodates four configurations of frequency counter inputs Single ended single phase Single ended quadrature Differential single phase Differential quadrature Note that these are four unique inputs and
57. Field Response 00 OF 00 00 Slave No Response Count Watlow Anafaze 279 Appendix A Modbus Protocol Examples Read Examples PPC 2000 User s Guide The data read must be sequentially located When reading a coil rather than a register the address must be offset by the location of the bit to read Table A 3 shows the query and Table A 4 shows the response Table A 3 Sample Packet for Host Query Start Start Number Number Slave of of Example Address Function pees a Points Points CRC g High Low Reading PV of loop 2 controller 1 01 04 OB B9 00 01 E2 0B single point read Reading loops 4 a primary out 03 03 18 OF 00 02 F3 67 put of controller 3 multipoint read Reading digital DOO 01 01 0B BB 00 10 4F C7 controller 1 input status read Table A 4 Sample Packet for Slave Response Slave Byte Data1 Data1 Data2 Data2 Example address Function count High Low High Low CRC Reading PV of loop 2 1600 01 04 02 06 40 BB 60 controller 1 single point read Reading loops 4 amp 5 primary out put 50 60 03 03 04 01 F4 02 58 99 67 of controller 3 Reading digital input 4 t0 13 01 01 02 08 00 BE 3C controller 1 input status read 280 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Appendix A Modbus Protocol Write Examples The data written is echo
58. NOTE When panel mounting terminal boards remove the DIN rail brackets before mounting the boards o 2 O ol Standoff co co co 2 co BERI E S co cold S l os le ja si E S Elei E si ms lel las os S Wel E A cos S gt c IS ao co ND Figure 2 18 TB50 Panel Mounted Stand offs are provided for all terminal boards 1 Doc 30002 00 Rev 2 3 Remove the DIN rail mounting brackets from terminal board Select a location with enough clearance for the board and its SCSI cable Refer to Figure 2 15 on page 31 for installed clearances When a location has been determined for board mark the four mounting holes Drill and tap the four 6 32 mounting holes Place the terminal board so the standoffs are aligned with the holes insert the screws in to the standoffs and tighten them Watlow Anafaze 33 Chapter 2 Hardware Installation PPC 2000 User s Guide Mounting an SDAC Module Follow these steps to install the SDAC module 1 Select a location for installation The SDAC is designed for wall mounting It should be installed as close to the controller as possible 2 Mark and drill four holes for screw mounting Use the di agrams below for the correct locations 3 Install the unit with the four 4 screws o 0 v 3 60 in Electri
59. O O Set Point Cool Prop Band Cool Scale Hi 2 28 oO x Cool Scale Lo S ae Set Point 2 O Heat Scale Lo 8 z fam Set Point Heat Prop Band Heat Scale Hi As the process variable increases away from set point the cool output trends toward the Cool Scale Hi value As the process variable decreases away from set point the heat output trends toward the Heat Scale Hi value PPC 2000 User s Guide Alarms PPE Chapter 3 Operating with AnaWin 3 Parameters on the Alarms spreadsheet enable and set the behavior of the process and deviation alarms for each channel Channels Alarms eee Dig 170 Outputs Soft Int Soft Bool PPC1 Channel 1 PPC1 Channel 2 PPC1 Channel 3 PPC1 Channel 4 Doc 30002 00 Rev 2 3 HP Limit HP Type HP Enable HP Output De 35 00 PSI Alarm Enabled PPC1 Proc 0 0 1 150 F Alarm Enabled PPC1 Proc 0 0 2 150 F Alarm Enabled PPC1 Proc 0 0 2 150 F Alarm Enabled PPC1 Proc 0 0 4 Figure 3 14 Alarms Spreadsheet Select the Alarms button to configure or monitor PPC alarm parameters Channel names are located in the first column each channel has a row of associated alarm parameters For example PPC1 Channel 3 indicates PPC 1 and channel 3 HP Limit Enter the value at which you want the high process alarm to activate The high process alarm activates when the process variable PV goes above the high process set
60. OV 8 2 0 5 to 5V OV 9 2 0 1 to 1V OV 10 2 50 to 500mV OV 11 2 10 to 100mV OV 12 2 5 to 50mV OV 13 3 1 to 10V OV 14 3 0 5 to 5V OV 15 3 0 1 to 1V OV 16 3 50 to 500mV OV 17 3 10 to 100mV OV 18 3 5 to 50mV OV 19 4 1 to 10V OV 20 4 0 5 to 5V OV 21 4 0 1 to 1V OV 22 4 50 to 500mV OV 23 4 10 to 100mV OV 24 4 5 to 50mV OV Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter 5 LogicPro and Modbus Reference Ambient Temperatures The analog input modules measure the temperatures of each terminal block on up to 4 AITBs in tenths of a degree Fahrenheit These give the cold junction compensation temperature in degrees F for each half of the terminal block Note that the channel numbers associated with a given cold junction reference depend on whether the card is single ended or differential Table 5 55 Ambient Temperature Readings Associated gree Module Address AITB Connectors 1 1 TB1 and TB2 2 1 TB3 and TB4 3 2 TB1 and TB2 4 2 TB3 and TB4 5 3 TB1 and TB2 6 3 TB3 and TB4 7 4 TB1 and TB2 8 4 TB3 and TB4 Modules Present Eight registers are required to describe the features and capabilities of each module As many as 12 modules may be inventoried on start up totalling 96 registers After the inventory routines run the registers are updated with the current configuration Refer to Table 5 56 and Table 5 57
61. Offset Address PPC1 DO 41 1 41 1 241 241 00241 PPC1 DO 41 2 41 2 242 242 00242 PPC1 DO 41 16 41 16 256 256 00256 PPC1 DO 42 1 42 1 257 257 00257 PPC1 DO 42 2 42 2 258 258 00258 PPC1 DO 42 16 42 16 272 272 00272 PPC1 DO 43 1 43 1 273 273 00273 PPC1 DO 43 2 43 2 274 274 00274 PPC1 DO 43 16 43 16 288 288 00288 PPC1 DO 44 1 44 1 289 289 00289 PPC1 DO 44 2 44 2 290 290 00290 PPC1 DO 44 16 44 16 304 304 00304 PPC1 DO 45 1 45 1 305 305 00305 PPC1 DO 45 2 45 2 306 306 00306 PPC1 DO 45 16 45 16 320 320 00320 PPC1 DO 46 1 46 1 321 321 00321 PPC1 DO 46 2 46 2 322 322 00322 PPC1 DO 46 16 46 16 336 336 00336 1The AnaWin3 names are shown for the first PPC 2000 in the system See Digital I O on page 132 for a full explanation of digital I O naming LogicPro Variable Type must be BOOL 3Use this address with the Digital_Out_206x IO Driver when addressing State 4Use this address with the Database IO Driver when addressing digital I O parameters other than State Replace the with the parameter number from Table 5 38 on page 200 for the parameter you want to address Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference Table 5 36 Addresses for Digital Inputs on the PPC 207x Digital In Modules LogicPro I O Physical Address Modbus Addressing AnaWin3 Name g y Dig een Digital_In_207x Database Databas
62. Operating Temperature 0 to 70 C Humidity 10 to 95 non condensing Doc 30002 00 Rev 2 3 Watlow Anafaze 265 Chapter 7 Specifications PPC 2000 User s Guide Table 7 79 Physical Specifications Weight 0 76 lbs 0 34 kg Height 5 4 in 137 mm Width 3 6 in 91mm Length 1 75 in 44mm 8mm 0 4 in 10 mm Figure 7 23 SDAC Dimensions Table 7 80 Safety and Agency Approvals UL C UL UL 916 File E177240 CE EMC Directive 89 336 EEC Inputs The SDAC requires a proprietary serial data signal and the clock signal from the PPC 2010 via the TB50 Any control output can be configured to provide the data signal The SDAC also requires a 5Vdc power input 266 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 7 Specifications Table 7 81 Inputs Data Clock 4mA maximum to dc COM Open collector or HC CMOS logic levels 0 5mA max to dc COM Open collector or HC CMOS logic levels Maximum Clock Rate 10 kHz 833 updates second Table 7 82 Power Requirements Voltage 4 75 to 5 25Vdc 300mA max Current 210mA typical 20Vdc out Analog Outputs Table 7 83 Analog Output Specifications Absolute Maximum Common Mode Voltage Resolution Measured between output pins and controller common 1000V 15 bits plus polarity bit for voltage outputs 0 305mV for 10V output range 0 00061mA for 20mA output range
63. Output Types AnaWin3 fas bake Value Name Description Destinations Digital output from a Digital time PPC 2010 PPC 2040 or Time Prop proportioned PPC 206x Soft Bool internal database value 1 DZC Digital distributed Digital output from a zero crossing PPC 2010 or PPC 2040 Digital output from a Pee PPC 2010 PPC 2040 or 2 On Off Digital on off PPC 206x Soft Bool internal database value 3 14 Reserved Soft Int internal database value Stored in the data base in the PPC 2010 15 Internal Count a an No ad itional hardware software register required Cannot drive field I O device directly i Analog output type 16 Analog 0 20MA 9 soma 17 Analog 4 20ma_ Analog output type 4 20mA Analog output using a X Analog output type PPC 2030 or PPC 2050 18 Analog 0 5Vde 0 5Vdc Soft Int internal database lue i Analog output type va 19 Analog 1 5Vdc 1 5Vde z Analog output type 20 Analog 0 10Vde Vdc Serial digital to ana 21 SDAC 0 20mA log converter 0 20mA Serial digital to ana 22 SDAC 4 20mA log converter 4 Eom Analog output using a Serial digital to ana digital output from the 23 SDAC 0 5Vde log converter 0 PPC 2010 module 5Vdc connected to a peripheral Serial digital to ana SDAC module 24 SDAC 1 5Vde log converter 1 5Vdc Serial digital to ana 25 SDAC 0 10Vdc log converter 0 10Vdc Doc 30002 00 Rev 2 3 Watlow Anafaze 183 Chapte
64. PPC 2040 Jumper Settings 21 Figure 2 7 PPC 205x Jumpers 23 Figure 2 8 Assembled Modules Top View 24 Figure 2 9 Assembled Modules Bottom View 25 Figure 2 10 Modules Bottom Side View 25 Figure 2 11 DIN Rail Latches 27 Figure 2 12 Mounting Assembled PPC Modules on a DIN rail side 27 Figure 2 13 AITB Dimensions Clearances 29 Figure 2 14 EITB Dimensions Clearances 30 Figure 2 15 TB50 Dimensions Clearances 31 Figure 2 16 TB50 Mounted on DIN Rail Front 32 Figure 2 17 TB50 Mounted on DIN Rail Side 32 Figure 2 18 TB50 Panel Mounted 33 Figure 2 19 SDAC Dimensions 34 Figure 2 20 PPC 2010 Connection to TB50 38 Figure 2 21 Wiring Digital Inputs 41 Figure 2 22 Encoder with 5Vdc TTL Signal 41 Figure 2 23 Powering Output with 5Vdc from PPC Supply 42 Figure 2 24 Powering Output with 12 24Vdc from PPC supply 42 Figure 2 25 Powering Output with Separate Power Supplies 42 Figure 2 26 Recommended circuitry for CPUWatchdog 43 Figure 2 27 Wiring Single Multiple SDACs 44 Figure 2 28 PPC 2021 2025 Connection to AITB 45 Figure 2 29 Inserting Sensor Keys in AITB 46 Figure 2 30 An Input Key 47 Figure 2 31 Thermocouples Connected to Differential Inputs 1 and 2 49 Figure 2 32 Thermocouples Connected to Single ended Inputs 1 and2 50 Figure 2 33 Wiring 2 Wire RTDs Input 1 and 2 Shown 51 Figure 2 34 Wiring 3 Wire RTDs Input 1 and 2 Shown 51 Doc 30002 00 Rev 2 3 Watlow Anafaze ix List of Figures PPC
65. PPC system constantly monitors the functioning of its microprocessor The CPU watchdog output is Low on when the microprocessor is operating when it stops operating the output goes High off This sink output is available on screw terminal 48 on the TB50 attached to the PPC 2010 Processor module The figure below shows the recommended circuit for the CPU Watchdog signal output 5Vde ae PPC IPS 2 Monitoring or Interlocking SSR epi Device Watchdog pin 48 TB50 Figure 2 26 Recommended circuitry for CPU Watchdog SDAC Connections Up to 5 Serial Digital to Analog Converter SDAC modules can be connected to digital outputs on the processor module Each can provide an analog current or voltage signal Single SDAC Systems Doc 30002 00 Rev 2 3 Use the 5V output on the PPC IPS 2 to power SDACs Use stranded 18 to 22 gauge wire for most installations Refer to Figure 2 27 on page 44 for system setup e Connect SDAC Pin 1 to the 5V terminal on the power supply e Connect SDAC Pin 2 to the DC COM terminal on the power supply e Ifa separate power supply is used connect the common to the DC COM on the PPC 2000 power supply e Connect SDAC Pin 3 to the SDAC clock output on the processor s TB50 digital output 46 e Connect SDAC pin 4 to the desired control output on the TB50 digital output 41 45 e Connect SDAC pins 5 and 6 to the input of the controlled
66. PPC1 DI 51 9 Digital In 10 n a n a 10 C2 PPC1 DI 51 10 Digital In 11 n a n a 11 C2 PPC1 DI 51 11 Digital In 12 n a n a 12 C2 PPC1 DI 51 12 Digital In 13 n a n a 13 C2 PPC1 DI 51 13 Digital In 14 n a n a 14 C2 PPC1 DI 51 14 Digital In 15 n a n a 15 C2 PPC1 DI 51 15 Digital In 16 n a n a 16 C2 PPC1 DI 51 16 1 The AnaWin3 name is shown for the Digital In module with address 51 on the first PPC 2000 in the system See Digital I O on page 132 for a full explanation of digital I O output naming 76 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Connecting Power PPC IPS 2 Power Supply The PPC IPS 2 accepts two ranges of voltages Connections are made at screw terminals Table 2 25 PPC IPS 2 Voltage Input Switch Settings IPS 2 Switch Input Voltage Input Setting Range Frequency 115V 88 132Vac 47 440Hz 230V 176 264Vac A CAUTION The PPC IPS 2 accepts two ranges of voltage Be sure to set the switch to the appropriate range before applying power Processor Module The processor module accepts 10 to 28Vdc Connect the terminal labeled V on the PPC 2010 to the DC power and the terminal labeled C to the DC common See Table 2 26 for connections for the two power supplies Table 2 26 Power Supply Connections PPC 2010 IPS 2 V V2 C COM Figure 2 67 on page 78 illustrates the connections whe
67. PPC1 Proc 0 0 2 indicates PPC 1 digital I O on the processor module which has module address 0 I O type O digital and point 2 See Figure 3 21 for a breakdown of this example Alternatively the Digital Out T O name PPC1 D0 41 2 indicates PPC 1 Digital Out module with address 41 and point 2 See Figure 3 22 for a breakdown of the example See Table 3 17 on page 134 for module type abbreviations See Table 2 10 on page 39 for a list of module I O numbers corresponding to the TB50 terminals PPC1 Proc 0 0 2 module 1 0 number i pe I O type module address module type L__y controller number Figure 3 21 PPC 2010 and PPC 204X Digital I O Names PPC1 DO 41 12 p gt module I O number _ys module address module type L controller number Figure 3 22 PPC 206X and PPC 207X Digital I O Names Watlow Anafaze 133 Chapter 3 Operating with AnaWin 3 PPC 2000 User s Guide Table 3 17 Module Abbreviations Seen on the Digital I O Spreadsheet Module Type Abbreviation PPC 2010 Processor Proc PPC 204x Digital I O DIO PPC 206x Digital Out DO PPC 207x Digital In DI State This field indicates the state of the digital I O in the system I O points configured as inputs are read only Range 0 or 1 NOTE The state must be interpreted in terms of the Logic setting in order to know if the I O point is on or o
68. Refer to Table 3 21 for a description of the global settings Time and Date The PPC 2000 s clock calendar automatically updates the year month date hour minute and second Table 3 21 Global Settings Parameter Definition Determines whether closed loop control chan nels are set to Off mode when the PPC is pow ered up or reset or whether the control channels resume operation in the same control mode that was active before the PPC was powered down Loop Start State Determines whether or not the logic program if Logic Start State present runs when the PPC is powered up or reset Determines the input scan duration and DZC AC Frequency output time base Set this parameter equal to the AC line frequency Watlow Anafaze 139 Chapter 3 Operating with AnaWin 3 PPC 2000 User s Guide Time and Date The PPC 2000 s clock calendar automatically updates the year day of the week month date hour minute and second Program Version The Program Version is an embedded program version label for the firmware program This selection is read only View the program version by selecting About from the Help menu 140 Watlow Anafaze Doc 30002 00 Rev 2 3 Troubleshooting This chapter describes troubleshooting methods and fault indicators that may be useful if you experience difficulties with your PPC 2000 system Appropriate remedial procedures are detailed below General Description Th
69. Volts 1 to 10V 1Vdc 10Vdc Volts 0 5 to 5V 0 5Vdc 5Vdc Volts 0 1 to 1V 0 1Vdc 1Vdc Volts 50 to 500mV 50mVdc 500mVdc Volts 10 to 100mV 10mVdc 100mVdc Volts 5 to 50mV 5mVdc 50mVdc Linear 1 to 10 V 1 000Vdc 10 000Vdc Linear 0 1 to 1 V 100 0mVdc 1000 0mVdc Linear 10 to 100 mV 10 00mVdc 100 00mVdc Linear 2 to 20 mA 2 000mA 20 000mA Linear Counts 32768 Counts 32767 Counts Linear 0 300 Hz 32768Hz 32767Hz Linear 0 to 10K Hz 327 68Hz 327 67Hz Current 0 20mA OmA 20mA Current 4 20mA 4mA 20mA Reserved N A N A Counter 32768 Counts 32767 Counts Frequency 10000Hz 10000Hz BT C 32 F 3308 F CT C 32 F 4200 F D T C 32 F 4200 F E T C 454 F 1221 F JT C 346 F 1598 F J T C without open sensor detection 346 F 1598 F K T C 454 F 2249 F K T C without open sensor detection 454 F 2249 F N T C 454 F 2372 F R T C 58 F 3215F S T C 58 F 3215F TT C 454 F 752 F F T C Platinel2 32 F 2250 F GT C 32 F 4200 F RTD 100 Ohm Plat 418 F 521 F RTD 100 Ohm Plat High 418 F 1562 F 100K Ohm Thermistor 25 F 327 F Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 NOTE Chapter 3 Operating with AnaWin 3 The counter and frequency inputs update four times per second 4Hz except the Linear 0 300 Hz input type which updates once every 25 seconds 04Hz The update rate of all other input types depends on th
70. be acted upon The slave will not construct a response to the master Thus the time out will expire and allow the master s program to handle the error Note that a message addressed to a nonexistent slave device will also cause a time out Users can configure controllers for Even or Odd Parity checking or for No Parity checking This will determine how the parity will be set in each character If either Even or Odd Parity is specified the quantity of 1 bits will be counted in the data portion of each character 8 bits The parity bit will then be set to a 0 or 1 to result in an Even or Odd total of 1 bits For example these eight data bits are contained in an RTU character frame 1100 0101 The total quantity of 1 bits in the frame is four If Even Parity is used the frame s parity bit will be a 0 making the total quantity of 1 bits still an even number four If Odd Parity is used the parity bit will be a 1 making an odd quantity five When the message is transmitted the parity bit is calculated and applied to the frame of each character The receiving device counts the quantity of 1 bits and sets an error if they are not the same as configured for that device all devices on the Modbus network must be configured to use the same parity check method Note that parity checking can only detect an error if an odd number of bits are picked up or dropped in a character frame during transmission For example if Odd Parity
71. by more than seven to effect a measurable change in an analog output Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference Soft Bool and Soft Int Registers in the Database The database provides 1000 1 bit Boolean registers and 2100 word Integer registers that may be accessed both by a logic program and by AnaWin3 or third party software Table 5 44 lists the parameter number range and first and last Modbus addresses for each Soft Bool and Soft Int parameter Table 5 44 Soft Bool and Soft Int Parameters Modbus Address 3001 4000 46301 46400 47001 49000 Parameter GEWIS Hex Address Soft Bool Soft Int 136 Extended Soft Int 137 BB8 F9F 189C 18FF 1B58 2327 32 768 to 32 767 32 768 to 32 767 Accessing Soft Bool and Soft Int Registers with Modbus The Boolean and Integer registers are accessed by Modbus address Table 5 46 on page 206 lists first and last Modbus addresses for the Boolean and Integer registers Use these addresses when accessing Boolean and Integer registers with third party software or operator interface terminals Accessing Soft Bool and Soft Int Registers with LogicPro When a logic program variable accesses a Boolean or Integer register the database offset is used in conjunction with the LogicPro Soft_Bool or Soft_Int I O driver The LogicPro IO Physical Address is constructed from the database
72. das de voltaje variaciones y peque as interrupciones de voltaje EN 61000 3 2 1995 con A1 3 1999 Emisiones de corriente arm nica EN 61000 3 3 1995 con A1 1998 Fluctuaciones de voltaje y centelleo 73 23 EEC Directriz de bajo voltaje EN 61010 1 1993 con A1 1995 Requisitos de seguridad de equipo el ctric para medici n control y uso en laboratorio Parte 1 Requisitos generales Watsonville California USA Place of Issue Jim Boigenzahn Name of Authorized Representative February 2002 Date of Issue General Manager Title of Authorized Representative E ir s P Signature of Authorized Representative Doc 30002 00 Rev 2 3 A Alarm A signal that indicates that the process has exceeded or fallen below a certain range around the setpoint For example an alarm may indicate that a process is too hot or too cold See also Deviation Alarm Failed Sensor Alarm Global Alarm High Deviation Alarm High Process Alarm Loop Alarm Low Deviation Alarm Low Process Alarm Ambient Temperature The temperature of the air or other medium that surrounds the components of a thermal system American Wire Gauge AWG A standard of the dimensional characteristics of wire used to conduct electrical current or signals AWG is identical to the Brown and Sharpe B amp S wire gauge Analog input A continuously variable signal that is generated by a process sensor and measured by a controller It usually represents a
73. dienes I3 PPC1 EIAO 11 1 1 C 180 PPC1 EIAO 11 2 1 F 131 PPC1 EIAO 11 1 2 C 132 PPC1 EIAO 11 2 2 F ibs PPC1 EIAO 11 1 3 C 134 PPC1 EIAO 11 2 3 F Pa PPC1 EIAO 11 1 4C i56 PPC1 EIAO 11 2 4 F 137 PPC1 EIAO 12 1 1 C ro PPC1 EIAO 12 2 1 F ib PPC1 EIAO 12 1 2 C o PPC1 EIAO 12 2 2 F 141 PPC1 EIAO 12 1 3 C 142 PPC1 EIAO 12 2 3 F PA PPC1 EIAO 12 1 4 C 144 PPC1 EIAO 12 2 4 F je PPC1 EIAO 13 1 1 C ae PPC1 EIAO 13 2 1 F 147 PPC1 EIAO 13 1 2 C i s PPC1 EIAO 13 2 2 F 349 PPC1 EIAO 13 1 3 C IEO PPC1 EIAO 13 2 3 F 151 PPC1 EIAO 13 1 4 C 152 PPC1 EIAO 13 2 4 F 153 PPC1 EIAO 14 1 1 C 154 PPC1 EIAO 14 2 1 F abe PPC1 EIAO 14 1 2 C IER PPC1 EIAO 14 2 2 F 157 PPC1 EIAO 14 1 3 C 158 PPC1 EIAO 14 2 3 F 158 PPC1 EIAO 14 1 4 C ig PPC1 EIAO 14 2 4 F Doc 30002 00 Rev 2 3 Watlow Anafaze 177 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide 178 Table 5 15 Process Variable and Setpoint Source Settings for Counter Inputs on the PPC 2010 Module Input Name AnaWin3 Input Spreadsheet Value 161 PPC1 Proc 0 1 1 C 162 PPC1 Proc 0 2 1 F Table 5 16 Process Variable and Setpoint Source Settings for Soft Input and Channel Out Registers Value Input Name AnaWin3 Input Spreadsheet 165 PPC1 Soft Input 1 166 PPC1 Soft Input 2 212 PPC1 Soft Input 48 213 Reserved 214 Reserved 215 PPC1 Channel 1 Out 216 PPC1 Channel 2 Out 262 PPC1 Channel 48 Out 263 Reserved 264 Re
74. digital I O field wiring sensors actuators relays SSRs etc The TB50 has 48 input output points This terminal board is DIN rail or panel mount compatible Additional Components The following sections describe the optional SDAC module and the PPC IPS 2 power supply SDAC Serial Analog to Digital Converter PPC IPS 2 Safety A WARNING Doc 30002 00 Rev 2 3 The SDAC peripheral module can be connected to a digital output on the PPC 2010 Processor module The SDAC converts a special serial signal to an analog output One digital output is required for each SDAC module Up to 5 SDACS may be connected When using one or more SDACs the SDAC clock output from the PPC 2010 is used as well The Processor SDAC clocks are tied together the same clock line is used for each SDAC The PPC IPS 2 accepts power in two switch selectable ranges 88 to 132Vac and 176 to 264Vac at 47 to 440Hz It has overload and overvolt protection The PPC IPS 2 powers the PPC system with 24Vdc and has 5Vdc available for powering loads Watlow Anafaze has made every effort to ensure the reliability and safety of this product In addition we have provided recommendations that will allow you to safely install and maintain this controller This product should not be used in any manner not specified by Watlow Anafaze Ensure that power has been shut off to your entire process before you begin installation or servicing of the controller Watlow
75. e 1B input 1 V7 w shield frame groun if present te 2A input 2 2B input 2 ww shield frame groun if present Figure 2 31 Thermocouples Connected to Differential Inputs 1 and 2 Doc 30002 00 Rev 2 3 Watlow Anafaze 49 Chapter 2 Hardware Installation nN WARNING Connecting RTDs 50 PPC 2000 User s Guide A T C is connected to a single ended input by wiring the positive signal lead to the A or B terminal and the negative signal lead to the analog COM terminal See Figure 2 32 and refer to Table 2 13 on page 48 Thermocouples connected to single ended inputs PPC 2022 must be isolated ungrounded and should not be embedded within heater elements as some cartridge heaters are constructed AITB 1A input 1 me X shield if present lt te 2A input 2 e Analog COM shield frame ground if present Figure 2 32 Thermocouples Connected to Single ended Inputs 1 and 2 Two wire RTDs are connected between the A and B terminals of the selected input They may only be used with a differential analog input module A jumper wire must be added on the terminal board from the B terminal to the COM terminal See Figure 2 33 on page 51 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation AITB 1A input 1 1B input 1 2A input 2 2B input 2 i
76. each input has two phases Both phases are used only in quadrature mode nominally EITB f E 2 input 1 phase 1 S1 8 input 2 phase 1 S2 e12 COM Figure 2 41 EITB Single ended Single Phase Doc 30002 00 Rev 2 3 Connections Input 1 and 2 Shown Watlow Anafaze 57 Chapter 2 Hardware Installation PPC 2000 User s Guide EITB 1 2 input 1 phase 1 Q1 24 4 input 1 phase 2 S IMH COM 14 8 input 2 phase 1 10 input 2 phase 2 Q2 COM e 12 COM Figure 2 42 EITB Single ended Quadrature Connections Input 1 and 2 Shown 2 input 1 phase 1 e S1 7 3 input 1 phase 1 o 12 COM ip 8 input 2 phase 1 S2 9 input 2 phase 1 12 COM Figure 2 43 EITB Differential Single Phase Connections Input 1 and 2 Shown 58 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation EITB 14 2 input 1 phase 1 e 4 3 input 1 phase 1 Q1 24 4 mpal 1 phase 2 2 5 input 1 phase 2 e 12 COM 14 8 oper 2 phase 1 i 9 input 2 phase 1 Q2 24 10 input 2 phase 2 2 11 input 2 phase 2 12 COM Figure 2 44 EITB Differential Quadrature Connections Input 1 and 2 Shown Encoder Connections without the EITB
77. kinds of alarms failed sensor alarms the global alarm and process alarms For information on each of these alarms refer to the following sections Failed Sensor Alarms Global Alarm Process Alarms Doc 30002 00 Rev 2 3 Failed sensor alarms indicate T C breaks and failed RTDs due to open leads When a channel is in Auto or Tune mode and a failed sensor alarm occurs the controller sets the channel to Manual control at the Sensor Fail Heat or Sensor Fail Cool set in the Channels spreadsheet A failed sensor alarm is only detected for an input that is selected as the PV Source for a channel The global alarm occurs when a channel alarm set to Alarm not Control occurs or when there are any failed sensor alarms If an alarm occurs the Alarm screen displays the corresponding alarm message The global alarm output stays on until the original alarm is acknowledged Process alarms include high and low deviation and high and low process alarms Each of these alarms may be enabled or disabled If enabled each may be set to function as an alarm or a control Refer to Alarms on page 123 for descriptions of the parameters used to set up these alarms Table 3 2 describes the difference between Alarm type and Control type alarms Table 3 2 Alarm Types Alarm Type Description Standard alarm function Digital output or Soft Bool if selected activates on alarm deactivates Alarm when channel is not in alarm Global ala
78. on each module by turning the arrow to an appropriate address number See Figure 2 3 WATLOW ANAFAZE a PPC 2010 PPC 2021 PPC 2022 PPC 2025 PPC 2030 PPC 2040 PROCESSOR 16 ANALOG IN 32 ANALOG IN 16 ANALOG IN 4 ENCODER IN 32 DIGITAL 1 0 HIGH ISOLATION 4 ANALOG OUT STATUSO STATUSO STATUSO STATUSO STATUSO STATUSO ERRORO 1 ERROR O3 ERRORO3 ERROR O3 ERROR O5 O2 O4 O4 O4 P O CONFIG MODULE MODULE MODULE MODULE MODULE Rl HA B 1 3 2 12 te 2122 ieke I Os a or Os es FED 4 4 4 14 26 J5 24 RX IX aa OO u J 1 O O 2 Figure 2 3 Sample Addresses Table 2 4 on page 18 lists the maximum number allowable of each type of module per system as well as the available address settings Pay close attention when using more than one module of a particular type in a system For example one PPC system allows up to four analog input modules PPC 2021 2025 and each must have a unique address setting as shown in Figure 2 3 If address settings are changes modules added or removed after the system has been initialized modules may not function correctly To assure proper operation perform a RAM Clear after changing the number of modules or address settings in a PPC system Refer to Chapter 4 Resetting Closed Loop Control Parameters on page 156 It may
79. on page 212 These settings are read only Table 5 56 Modules Present ee Description Range 1 Type of Module 0 9 2 Module number rotary switch address 0 14 3 Number of digital inputs 0 48 4 Number of digital outputs 0 48 5 Number of analog inputs 0 32 6 Number of analog outputs 0 8 7 Number of frequency counter inputs 0 4 8 Reserved n a Watlow Anafaze 211 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide 212 For modules with configurable I O the total number of potential inputs and outputs are set in the corresponding registers For example the Processor module inventory returns 24 digital inputs and 46 digital outputs The count of analog outputs does not include outputs that can be configured for SDACs Table 5 57 Module Types Value Description No module PPC 2010 Reserved PPC 2021 2024 2025 PPC 2022 PPC 2030 PPC 2040 PPC 2050 2051 PPC 2061 2062 O DMWINIDOI ATARI O M l o PPC 2070 2071 2072 2073 System Commands System Commands force specific actions within the controller Write a 1 in the register to execute the corresponding command Some command bits are executed and reset to 0 by the controller immediately after a host writes a 1 Other command bits are latched in whatever state was last written Table 5 58 lists each type Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 Use
80. or pulse sensors set the linear scaling parameters Input Signal Lo Input Signal Hi PV Lo and PV Hi See Setting up User Selectable Linear Inputs on page 98 of the PPC 2000 User s Guide 3 On the Channels spreadsheet for each channel PPC 2000 User s Guide Watlow Anafaze 3 a Inthe PV Source field choose the input that you want to monitor or use as feedback for closed loop control b Inthe Heat Output Dest and or Cool Output Dest fields choose the outputs that you want to use for closed loop control c Choose a Heat Cool Output Type for each output d Set the Heat Cool Cycle Time for any outputs with Heat Cool Output Type set to Time Prop 4 On the Digital I O spreadsheet a Set the Direction for each I O point to be used for control to Output 5 On the Channels spreadsheet a For channels other than the adaptive ones if both heat and cool outputs are used set the Spread b For each channel that will perform adaptive control for the Control Type choose Adaptive c Set the Set Point to the desired value at least 40 engineering units typically degrees above the process variable d Set the Control Mode to Auto to begin adaptive closed loop control NOTE Only channels 1 to 8 can be selected for adaptive control Adaptive Addendum PPC 2000 User s Guide 0600 0049 0001 rev C Watlow Anafaze 4 PPC 2000 User s Guide Addendum Overview This document contains additional specifications for the PP
81. other wiring correct See Connecting Communication Ports on page 78 Is the RS 232 485 converter configured and working properly See Connecting Communication Ports on page 78 and the converter documentation Are the communications parameters set the same in both the PPC 2000 and the host device or software See Modbus Network Address on page 86 Is the host device or software configured properly See the appropriate user documentation Is the correct communications port selected See the appropriate user documentation If communications was working and has failed check these things Is the PPC 2010 Processor running The RX LED on the port lights as the controller receives signals The TX LED lights if the controller receives a valid Modbus request This indicates a response being sent by the PPC Has the rotary switch setting on the Processor Module been changed See Modbus Network Address on page 86 Is the wiring correct See Connecting Communication Ports on page 78 Have any of the communications port settings on the computer been changed See the appropriate user documentation Is the RS 232 485 converter working properly If one of the programmable communications parameters may have changed establishing communications by following these steps will demonstrate that all the components are functioning and connections are correct Doc 30002 00 Rev 2 3 Watlow Anafaze 155 Chapter 4 Troubleshooting 156 A
82. output to output PPC 2051 120Vac output pair to output pair Paired outputs share power supply PPC 2050 Voltage Range 0 to 10Vdc 10mA maximum Current Range Voltage Accuracy 0 to 20mA with 8V minimum compliance 400 Ohm load 0 5 of range at 25 C Current Accuracy 0 8 of range at 25 C Output Update Time 0 1 second Doc 30002 00 Rev 2 3 Watlow Anafaze 249 Chapter 7 Specifications PPC 2000 User s Guide PPC 206x Digital Output Specifications PPC 2061 R Status a LED el al STATUSOM sTATUSO Rotary Address _ C SE A Switch Ha an 8 16 Relay 1002 Output LEDs erat 50 Og NA 30 04 50 O6 50 O6 E 70 08 70 08 90 Oto FT 10O 0O12 130 O14 150 O16 PXX XXXXX J PXX XXXXX LJ L i Figure 7 11 PPC 206x Front View 250 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter 7 Specifications Ir
83. over the user selected fixed time DZC digital distributed zero crossing Output on off state calculated for every AC not available for mechanical relay outputs line cycle On Off digital on off Output either full ON or full OFF Internal Count Integer register Calculated output may be used by a logic program Analog 0 20mA Analog output type 0 20mA Analog 4 20mA Analog output type 4 20mA Analog output using a PPC 2030 or PPC Analog 0 5Vdc Analog output type 0 5Vdc 2050 through 2053 Analog 1 5Vdc Analog output type 1 5Vdc Analog 0 10Vdc Analog output type 0 10Vdc SDAC 0 20mA Serial digital to analog converter 0 20mA SDAC 4 20mA Serial digital to analog converter 4 20mA naib cupat Using s digital Suiput Hom SDAC 0 5Vdc Serial digital to analog converter 0 5Vdc the PPC 2010 module connected to a SDAC 1 5Vde Serial digital to analog converter 1 5Vdc pe prera SO BG Madue SDAC 0 10Vdc Serial digital to analog converter 0 10Vdc Heat Cool Cycle Time Specify the time base for time proportional outputs The output percentage is proportioned over this time period For example a 50 output with a 10 second cycle time is on for 5 seconds and off for 5 seconds Heat Cool Cycle Time only affects control when the corresponding output type is set to Time Prop digital time proportioning Range 0 to 255 seconds Heat Cool Curve Indicate which output scaling method is to be used e Str
84. point The PV must drop to the alarm set point minus the alarm deadband for the alarm to clear The default high process alarm set point is 0 Range same as the range of the input type selected See Table 3 15 on page 130 HP Type Select the function of the high process alarm See Process Alarms on page 95 for a description of the settings Range Alarm or Control HP Enable Set this field to enable or disable the high process alarm When it is Enabled the high process alarm activates if the process variable PV rises above the HP Limit The PV must drop below the HP Limit minus the alarm deadband to be reset cleared When this parameter is set to Disabled the high process alarm does not occur Range Enable or Disable Watlow Anafaze 123 Chapter 3 Operating with AnaWin 3 124 PPC 2000 User s Guide HP Output Dest Choose a digital output to toggle when the high process alarm occurs This may be any available hardware output or Soft Boolean register accessible by the logic program The default for this parameter is Not Assigned Outputs that are already assigned to control output destinations will be rejected The same output may not be used for multiple alarm output destinations Range Not Assigned or any of the digital outputs on the Digl 0 spreadsheet or any of the Soft Bool registers HD Offset Designate an offset value that determines the high deviation alarm limit relative to the current set point
85. power supply and connecting wires Refer to Figure 2 1 on page 15 Install a section of DIN rail Hook the top of the DIN rail latch over the DIN rail such that the spring is under the lip of the rail Push down on the power supply compressing the spring then rock the bottom of the latch onto the rail To panel mount the PPC IPS 2 1 Locate a space with sufficient room for the power supply and connecting wires Refer to Figure 2 2 Mark the mounting holes See Table 2 3 on page 16 Drill and tap the mounting holes Place the power supply such that the holes are aligned insert the screws and tighten them Table 2 3 Power Supply Screw Mounting PPC IPS 2 Number of Screws 3 Drill and tap size 6 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Hardware Configuration In order for multiple PPC modules to function together each needs to be addressed correctly Some of the PPC modules may require jumper or switch settings to work with field input and output devices The following sections describe the configuration options and procedures Module Addresses A CAUTION Doc 30002 00 Rev 2 3 NOTE Each module in a PPC assembly must have a unique address The PPC 2010 module is fixed as module address 0 in the firmware The other modules addresses are set with rotary switches on the face of each module Set a unique address
86. setpoint is the desired value for the process variable The setpoint may be set to any value within the range of the type of the input selected as the Process Variable Source for the channel If the setpoint set is out of the defined range the controller assigns the closest number within the range Control Mode This parameter indicates the mode of control for the channel Table 5 13 lists and describes the values to which this parameter can be set Table 5 18 Control Mode Value Mode Description Control algorithm is inactive and no output 0 Off is set Output is set by the user or a logic program 1 Manual See Heat Output and Coo Output in this section 2 Auto Output is determined by the PID or on off control algorithm The PPC determines and sets the propor tional band derivative and integral parame 3 Tune ters for the channel by setting the output and measuring the system s response See Autotuning on page 93 Heat Cool Feedback Value The raw output value in parts per thousand 0 1 calculated by the PID algorithm In a normal control loops this value is filtered with the output filter before it becomes the Heat Output or Cool Output Heat Cool Proportional Band Heat Cool Prop Band The proportional band is used to calculate PID output Larger numbers result in less proportional action for a given error or deviation from setpoint This parameter is set in engineering units to a positive
87. stop learning temporarily but retain the learned load characteristics For example in the event that maintenance will be performed it may be advantageous to pause adapting to avoid false data being introduced Select this option anytime you want the controller to stop adapting and continue to control with the parameters learned up to that point This parameter indicates the amount of delay in seconds in the load This characteristic of the load or plant has a significant impact on adaptive control A larger number indicates a longer delay between for example an increase in heater power and an increase in the temperature Choose Automatic and then set the Control Mode to Auto to have the adaptive algorithm determine the plant delay for the loop The loop must be at least 40 degrees below set point and the controller must observe a temperature change of at least 20 degrees to determine the Plant Delay If you have determined the Plant Delay with the PPC 2000 s adaptive control previously and found the performance acceptable you may choose the delay directly and the loop will use the value you choose rather than measure it This setting is not reset by the Adaptive Mode parameter s Reset option To have the controller relearn the Plant Delay set the loop s Control Mode to Manual or Off set the Plant Delay to Automatic and then set the Control Mode to Auto again PPC 2000 User s Guide Watlow Anafaze 2 Tuning Gain This param
88. the value you entered for Min Set Point 2 Set the Heat Scale Hi to a percent of the range of the selected heat output type This is the signal level that will be trans mitted when the analog input selected as PV Source is at the value you entered for Max Set Point 3 Set the Cool Scale Lo to a percent of the range of the se lected cool output type This is the signal level that will be transmitted when the analog input selected as Set Point Source is at a value you entered for Min Set Point Watlow Anafaze Chapter 3 Operating with AnaWin 3 104 PPC 2000 User s Guide 4 Set the Cool Scale Hi to a percent of the range of the selected cool output type This is the signal level that will be trans mitted when the analog input selected as Set Point Source is at the value you entered for Max Set Point 5 Set the Control Mode for the channel to Auto Process Variable Retransmit Example In this example channel 1 on the PPC measures a furnace temperature with a thermocouple connected to an Analog Input module and controls the firing of a power controller with an output from the Processor module The PPC is equipped with an Analog Out module configured for current outputs Channel 2 is used to retransmit channel 1 s process variable from one of these analog outputs to a chart recorder The chart recorder requires a 4 20mA dc signal This signal range represents 0 to 1000 F on the chart Figure 3 5 illustrates this example
89. to the value displayed when the signal is at the level set in Input Signal Low Input Signal Lo Figure 5 1 Sample Text The words Process Variable Low and Input Signal Low represent parameter names The words PV Lo and Input Signal Lo are the abbreviated terms seen in AnaWin3 These abbreviations are shown for reference in this chapter only when the AnaWin3 name differs from the listed parameter names The PPC 2000 Database The PPC stores setpoints and other control parameters along with process variable values and digital I O states in its database The database is analogous to a set of tables Parameters form the columns of the tables AnaWin3 third party HMI software operator interface terminals and LogicPro programs access these process parameters and data in the database Think of the database as a series of tables Each table holds the values of a different set of parameters analog inputs channels digital I O analog outputs soft integers soft booleans and globals In each table the columns represent parameters and the rows represent analog inputs or channels or digital I O and so on For example in the analog input table the columns represent the analog input parameters such as Input Value Input Type and Input Filter Each row holds the settings of each of these parameters for a particular analog input Table 5 2 Example Database Table Input Value Input Type Input Filter Input
90. to which this parameter may be set Figure 5 2 on page 185 illustrates the effects of the options Table 5 21 Heat Cool Curve AnaWin3 Ste Value Name Description nar Output is unaffected and is set as 0 ee in calculated by the closed loop PID calculation 1 Lag curve A Output is reduced somewhat from calculated value 2 Lag curve B Output is further reduced from calculated value Watlow Anafaze Doc 30002 00 Rev 2 3 Heat Cool Scale Lo Set this parameter in conjunction with Heat Cool Scale Hi to scale the output or to change the control action See table 3 x Enter the value as a percent of range that the output should approach as the process variable approaches the set point from below for a heat output or from above for a cool output See Figure 3 x The default and typical value is 0 For example as a heater raises the temperature of a load towards set point the output decreases toward 0 In some cases it is desirable that the output never reach 0 in that case enter a minimum value greater than 0 This parameter is set in tenths of a percent The valid range is 0 to 1000 and corresponds to 0 0 to 100 0 for example a setting of 500 corresponds to 50 0 Heat Cool Scale Hi Set this parameter in conjunction with Heat Cool Scale Lo to scale the output or to change the control action See table 3 x Enter the value as a percent of range that the output should approach as the process va
91. unlocked position pushed toward the back of the module Refer to Figure 2 8 Module top latch unlocked Module top latch locked Figure 2 8 Assembled Modules Top View 24 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 2 Chapter 2 Hardware Installation Align the 4 interconnect tabs and their related slots as well as the module expansion bus connector Front Module bottom latch locked Module bottom latch unlocked latch locked Module bottom latch unlocked Figure 2 10 Modules Bottom Side View 3 Gently press the modules together while observing the alignment of the tabs and slots as well as the pins on the expansion bus connector When the module is properly seated close the module latches on the processor by pushing the latch toward the front of the module The modules are properly locked when there is a firm connection with no rocking or shifting Repeat these steps for any additional modules When there are no additional modules install the right end cap in a similar manner Watlow Anafaze 25 Chapter 2 Hardware Installation PPC 2000 User s Guide Module Disassembly A CAUTION To separate modules reverse the procedure in Module Assembly on page 24 When separating modules gently rock and pull the modules apart To avoid damaging your PPC system never connect or disconn
92. value such as process vari able Some analog input signals are 10 to 100 mV 4 20 mA 0 5Vdc Analog Output A continuously variable signal that is generated to control a process element such as a heater or motor speed Some analog output signals are 0 20 mA and 0 10Vdc Auto Mode A feature that allows the controller to set PID control outputs in response to the Process Vari able PV and the setpoint Doc 30002 00 Rev 2 3 Glossary B Baud Rate The rate of information transfer in serial commu nications measured in bits per second Boolean A variable with a value of either 1 or 0 C Calibration The comparison of a measuring device an unknown against an equal or better standard Channel The hardware and firmware that determine the behavior of control and alarm outputs based on user set parameters and measured feedback Closed Loop A control system that uses a sensor to measure a process variable and makes decisions based on that feedback Control Action The response of a control output when the pro cess variable is changed Control Loop A system that affects controlled elements out puts either in response to process or user defined input Control Mode The type of action that a controller uses For example On Off time proportioning PID Auto matic or manual and combinations of these Cool A control method and association of parameters organized around maintaining temperature below
93. 08808800800 HHBUBREBRE EE 228 GAH GOES GG9 4 0 in W 102 mm ij DVNDANnNANUVAVnARVnPAVnRAUNY BRHBBKRBBBUREE A 5in D RN mm Figure 7 20 PPC TB50 SCSI Dimensions with Straight SCSI Cable Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 7 Specifications Table 7 71 PPC TB50 SCSI with Right Angle SCSI Height 5 4 in 137 mm Width 4 0 in 102 mm Depth 1 5 in 3 7 mm S 5 4in H 137 mm Sl co oll pe 8 co co co lol co ERIS E s si ja y si ra 8 ca co 2 co co S co Cos le co LE e es 6 co SL E ia 4 0 in W 102 mm 1 5 in D 38 mm Figure 7 21 PPC TB50 SCSI Dimensions with Right Angle SCSI Cable Doc 30002 00 Rev 2 3 Watlow Anafaze 263 264 Chapter 7 Specifications PPC 2000 User s Guide PPC IPS 2 International Power Supply Specifications Watlow Anafaze offers a dual output power supply for PPC 2000 systems The PPC IPS 2 accepts worldwide AC voltages and outputs 5 and 24Vdc pf Pd Po A NE 2 5 in min Air Flow Space V1 i gt ADI lt _ 3 1 in 2 CDM COM vi v1 Li Lo NIM lt 1 9
94. 1 0 number Figure 3 16 Analog Input Names Select the Inputs button to configure or monitor PPC input parameters Input names are located in the first column each input has a row of associated parameters The default input name identifies the PPC module and module I O number Double click on a parameter to edit it The module type is indicated in the default input name Module types are abbreviated See Table 3 14 for a description Table 3 14 Module Abbreviations Seen on the Inputs Spreadsheet Module Type Abbreviation PPC 202x Analog Input Al PPC 2030 Encoder Input Analog Output EIAO PPC 2010 Processor Proc PPC 2040 Digital I O DIO For example PPC1 Al 1 3 indicates PPC 1 the analog input module with address 1 and input 3 For a description of module addresses see Module Addresses on page 17 for a table that correlates the module I O numbers with screw terminals on the AITB see Table 2 13 on page 48 Doc 30002 00 Rev 2 3 Watlow Anafaze 127 Chapter 3 Operating with AnaWin 3 128 PPC 2000 User s Guide The Processor module Digital I O and Encoder In Analog Output modules accept pulse inputs Both the count and frequency of each pulse signal are listed as inputs Pulse input names identify the PPC module I O type and module I O number and indicate counter C or frequency F See example in Figure 3 17 PPG1 Proc 0 1 2 F Frequency Counter Lg module O numbe
95. 10 Rotary Switch Configuration Position Network Address A Fixed 1 B Fixed 2 Cc Fixed 3 D Programmable Default 4 E G N A H Fixed 1 Switch positions A D select the following settings e 19 2 kbaud programmable e Even parity fixed e 8 data bits fixed e 1 stop bit fixed Switch position H selects the following fixed settings e 19 2 kbaud e Even parity e 8 data bits e 1 stop bit Switch settings E G are reserved Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Setting Programmable Modbus Addresses A WARNING Doc 30002 00 Rev 2 3 Modbus addresses one through four may be set using the rotary switch on the face of the PPC 2010 Processor Module See Modbus Network Address on page 86 for information on setting the rotary switch The following procedure describes how to set other addresses Power is shut off to the PPC during the following procedure Power cycling will interfere with process control Do not perform this procedure if interrupting process control is not acceptable 1 Close AnaWin3 and LogicPro if either is running 2 Connect only the PPC to be configured to the computer on which AnaWin3 is installed 3 Set the rotary switch on the Processor Module to position H 4 Turn off power to the PPC system 5 Turn power on to the PPC system 6 Launch PPCComSu 7 Select the desired Baud Rate f
96. 10 on page 170 for a list of the input types and their corresponding ranges While all the input parameter values are 16 bit integers many such as Input Type are numerical representations of settings that have special meanings to the controller See the tables under the corresponding parameter descriptions for explanations of the possible settings Note that while any analog input can be assigned to any control channel the channel number that an input is assigned to has no effect on the input variable s data table address Table 5 8 Input Parameters Modbus Hex Ran N Parameter ange Address Addres otes Sample Time 74 200700 ms 31801 32200 708 897 typical Input 72 0 65535 31201 31600 4B0 63F Raw Counts 32768 to Input Value BT or 30801 31200 320 4AF Input Status 75 0 16 32201 32600 898 A27 See Table 5 9 Input Type 60 0 60 41751 42150 6D6 865 See Table 5 9 Input Filter 61 0 255 42151 42550 866 9F5 alt ica 64 0 1 42951 43350 B86 D15 See Table 5 11 l 32768 to Input Signal Low 71 432767 44551 44950 11C6 1355 See Table 5 11 f i 32768 to Input Signal High 70 432767 44151 44550 1036 11C5 See Table 5 11 Process 32768 to eh a el a77 43751 44150 EA6 1035 Process 32768 to Variable High 68rll anges 43351 43750 D16 EA5 PV Offset 32768 to E PES TE eee 44951 45350 1356 14E5 168 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc
97. 2000 User s Guide Mounting Terminal Boards 28 DIN Rail Mounting 31 DIN Rail Removal 32 Panel Mounting 33 System Wiring 34 Wiring Recommendations 35 Noise Suppression 35 Avoiding Ground Loops 37 Connecting I O to the PPC 2010 37 Connecting the TB50 to the PPC 2010 Module 37 TB50 Connections 38 Connecting Digital Inputs 40 Connecting Counter or Frequency Inputs 41 Connecting Digital Outputs 41 SDAC Connections 43 Connecting Analog Inputs to the PPC 2021 2025 45 Connecting the AITB to the PPC 202x 45 Sensor Keys 46 AITB Connections 47 Connecting Thermocouples 49 Connecting RTDs 50 Connecting Sensors with Linear Voltage Signals 52 Connecting Sensors with Linear Current Signals 53 Connecting the Encoder Input Cable to the PPC 2030 55 Encoder Wiring 57 Encoder Connections without the EITB 59 Analog Output Connections 60 Connecting I O to the PPC 2040 61 Connecting the TB50 to the PPC 2040 Module 61 TB50 Connections 62 Connecting Digital Inputs 64 Connecting Counter or Frequency Inputs 64 Connecting Digital Outputs 65 Connecting to the Relay Outputs on the PPC 206x 70 Wiring PPC 2062 Relay Outputs 71 Using Snubbers for Relay Outputs 73 Connecting Power 77 PPC IPS 2 Power Supply 77 Processor Module 77 Connecting Communication Ports 78 Communication Ports 78 Connecting RS 485 Communications 81 iv Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Table of Contents Operating with AnaWin3 89 Type Definitions 89 Cl
98. 21 16 input analog input module differential PPC 2022 32 input analog input module single ended PPC 2024 8 input high isolation analog input module PPC 2025 16 input high isolation analog input module Table 7 15 Environmental Specifications Storage Temperature 20 to 70 C Operating Temperature 0 to 60 C Humidity 10 to 95 non condensing Table 7 16 Physical Specifications Weight 0 6 Ibs 0 27 kg Height 8 0 in 203 mm Width 1 5 in 38 mm Depth 5 25 in 133 mm Mounting DIN rail or panel mount Table 7 17 Connections Connector on Module SCSI 2 female Table 7 18 Power Specifications Power Requirement 4 7 W typical Current 12Vdc 390mA typical 25 C Current 24Vdc 195mA typical 25 C Modules per Processor 4 Watlow Anafaze 237 Chapter 7 Specifications PPC 2000 User s Guide Table 7 19 Analog Input Specifications Analog Inputs Nominal Isolation 8 or 16 differential 32 single ended Input to bus 500Vdc continuous Input to frame ground 120Vac Between inputs 60Vac PPC 2021 Between inputs 240Vac PPC 2024 2025 Between inputs no isolation PPC 2022 Calibration Automatic zero and full scale Normal Mode Rejection Ratio between and inputs 60 dB dc to 1000Hz with 500 ohm input impedance Common Mode Rejection Ratio between input and frame ground 120 dB dc to 1000Hz with 500
99. 225 Proportional Band PB Settings 226 Integral Settings 226 Derivative Settings 227 General PID Constants by Application 228 Proportional Band Only P 228 Proportional with Integral Pl 228 PI with Derivative PID 228 Specifications 229 System Specifications 229 Safety and Agency Approvals 229 Physical Specifications 230 Power Specifications 230 PPC 2010 Processor Specifications 231 PPC 205x Analog Out Specifications 247 PPC 206x Digital Output Specifications 250 PPC 207x Digital In Specifications 253 PPC EITB 1 Encoder Input Terminal Block Specifications 258 PPC TB50 SCSI 50 Pin Specifications 261 SDAC Specifications 265 Inputs 266 Analog Outputs 267 Appendix A Modbus Protocol 269 Query 270 Response 270 Message Framing 271 Address Field 272 Function Field 272 Data Field 273 Error Checking Field 273 Field Format 273 Parity Checking 274 CRC Checking 275 Read Examples 280 Appendix B Declaration of Conformity 283 Glossary 285 Doc 30002 00 Rev 2 3 Watlow Anafaze vii Table of Contents PPC 2000 User s Guide viii Watlow Anafaze Doc 30002 00 Rev 2 3 List of Figures Overview 1 Figure 1 1 System Diagram 4 Figure 1 2 Sample PPC 2000 System 6 Hardware Installation 13 Figure 2 1 PPC IPS 2 DIN Mounting Dimensions 15 Figure 2 2 PPC IPS 2 Panel Mounting Dimensions 16 Figure 2 3 Sample Addresses 17 Figure 2 4 PPC 2010 Jumpers 19 Figure 2 5 PPC 2030 Jumpers and Switches 20 Figure 2 6
100. 227 Chapter 6 Tuning and Control PPC 2000 User s Guide General PID Constants by Application This section gives PID values for many applications They are useful as control values or as starting points for PID tuning Proportional Band Only P Set the Proportional Band to 7 of the Setpoint Example Setpoint 450 Proportional Band 31 Proportional with Integral Pl Set the Proportional Band to 10 of Setpoint Example Setpoint 450 Proportional Band 45 Set Integral to 60 Set Derivative to Off Set the Output Filter to 2 PI with Derivative PID Set the Proportional Band to 10 of the Setpoint Example Setpoint 450 Proportional Band 45 Set the Integral to 60 Set the Derivative to 15 of the Integral Example Integral 60 Derivative 9 Set the Output Filter to 2 Table 6 4 shows general PID constants by application Table 6 4 General PID Constants Application pope Integral Derivative Filter Ciput a Electrical heat with SSR 50 F 60 15 4 DZC Electrical heat with EM relays 50 F 60 15 6 TP 20 Cool w solenoid valve 70 500 90 4 TP 10 Cool w fans 10 F off 10 4 TP 10 Electric heat with open heat coils 30 F 20 off 4 DZC Gas heat w motorized valves 60 F 120 25 3 Analog i SP gt 1200 100 F 240 40 228 Watlow Anafaze Doc 30002 00 Rev 2 3 Specifications The following sections contain specifications for the PPC 2000
101. 24 I O points are individually configurable as either inputs or outputs The following summarizes the processor s features e 2isolated communication ports e Transmit receive indicators e Rotary switch for setting the Modbus network address e 46 user configurable digital I O e System status and digital output overload indicators e Realtime clock e Flash PROM and battery backed RAM e Connects to terminal block board via 50 pin SCSI cable PPC 2021 2022 Analog In Modules The PPC 2021 and 2022 modules plug in to the module expansion bus The analog input modules support 16 differential inputs or 32 single ended inputs and accommodate various sensors such as thermocouples TCs Resistive Temperature Sensing Devices RTDs and linear transducers using the terminal boards described later in this section e Supports TCs RTDs and linear voltage and current signals e LED status indicator e DINrail panel mount e Connects to analog input terminal board via 50 pin SCSI cable PPC 2024 2025 Analog In High Isolation Modules Doc 30002 00 Rev 2 3 The PPC 2024 and 2025 modules plug in to the module expansion bus The high isolation analog input modules accept 8 or 16 differential analog inputs and accommodate various sensors such as TCs RTDs and linear transducers using the terminal boards described later in this section e High voltage isolation capability e Supports TCs RTDs and linear voltage amp current signals e
102. 3 Digital In Modules Up to four modules of this type may be added to a PPC system Each module includes either 8 or 16 discrete inputs The PPC 2070 and 2071 modules accept 120Vac signals The PPC 2072 and 2073 modules accept either 24Vac or 24Vdc PPC 2000 Terminal Boards The following sections describe the terminal boards that support field I O connections to some modules PPC AITB 1 Analog Input Terminal Board The AITB is a compact field wiring interface for all analog input modules The AITB includes terminal blocks and removable keys used for different types of inputs such as TCs RTDs and linear signals For more information on these signals refer to PPC KEY 01 through 04 in Table 1 1 on page 5 The keys allow easy configuration of the terminal block for different types of inputs on different channels The AITB is DIN rail or panel mount compatible 8 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 1 Overview PPC EITB 1 Encoder Input Terminal Board The EITB is a DIN rail or panel mountable terminal block card which provides means to interface with motor encoders Two pulse inputs single ended or differential single or quadrature phased may be connected to the screw terminals A 5Vdc power source interconnect is provided to supply encoders PPC TB50 SCSI 50 Pin Terminal Board The TB50 connects to the Processor or Digital I O module through the SCSI connector The terminal blocks interface to
103. 3 names are shown for the first PPC 2000 in the system See Inputs on page 127 for a full explanation of analog input naming 2Use this address with the Analog_In_202x IO Driver when addressing Input Value 3Use this address with the Database IO Driver when addressing input parameters other than Input Value Replace the with the parameter number from Table 5 8 on page 168 for the parameter you want to address Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference Table 5 4 Addresses for Encoder Inputs on the PPC 2030 Encoder In Analog Out Module 1 LogicPro I O Physical Address Modbus Addressing AnaWin3 Name Input Spread Encoder_Analog_ Database Database Sample sheet 2030 IO Driver IO Driver Offset Address PPC1 EIAO 11 1 1 C 11 1 1 129 129 30929 PPC1 EIAO 11 2 1 F 11 2 1 130 130 30930 PPC1 EIAO 11 1 2 C 11 1 2 131 131 30931 PPC1 EIAO 11 2 2 F 11 2 2 132 132 30932 PPC1 EIAO 11 1 3 C 11 1 3 133 133 30933 PPC1 EIAO 11 2 3 F 11 2 3 134 134 30934 PPC1 EIAO 11 1 4 C 11 1 4 135 135 30935 PPC1 EIAO 11 2 4 F 11 2 4 136 136 30936 PPC1 EIAO 12 1 1 C 12 1 1 137 137 30937 PPC1 EIAO 12 2 1 F 12 2 1 138 138 30938 PPC1 EIAO 12 1 2 C 12 1 2 139 139 30939 PPC1 EIAO 12 2 2 F 12 2 2 140 140 30940 PPC1 EIAO 12 1 3 C 12 1 3 141 141 30941 PPC1 EIAO 12 2 3 F 12 2 3 142 142 30942 PPC1 EIAO 12 1 4 C 12 1 4 143 143 30943 PP
104. 5 Flash Memory Chip firmware PPC 2000 User s Guide Insert the new flash memory chip into the socket as shown in Figure 4 3 with the beveled edge and notched corner of the flash memory chip facing the bottom edge of the module Be careful not to bend any legs while installing Reassemble the controller When the module is properly seated close the two module latches by pushing the latches toward the front of the module The two modules should be properly locked Replace the module on the DIN rail latch or screw the unit back to the panel Reconnect cables Power the unit Download the Snapshot from AnaWin3 and reload the logic program from LogicPro if necessary Ct WJ 3 Battery Notch Notch i Jsu B B A Figure 4 3 PPC 2010 Internal View 144 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 4 Troubleshooting Battery Installation Procedures Changing the battery on the processor module involves minor mechanical disassembly and reassembly of the controller Appropriate precautions should be taken to prevent electrostatic discharge damage to the electronic components Wear a grounding strap and place components on static free grounded surfaces only A small flathead screwdriver is needed A CAUTION All control parameters and retained values in the logic program will be lost whe
105. 5 11 lists and describes the possible settings Table 5 11 Temperature Scale Conversion Value Temperature Scale 0 degrees F 1 degrees C Input Signal Low Input Signal Lo This is the input signal level that corresponds to the low process value set in Process Variable Low see below For custom linear inputs this parameter is the lowest level signal the sensor or encoder will supply Typically this corresponds to the lowest process variable to be measured The units and range for this parameter correlate to the selected Input Type See Table 5 10 on page 170 See Setting Input Signal Lo and Input Signal Hi on page 99 for detailed information Input Signal High Input Signal Hi This is the input signal level that corresponds to the high process value set in Process Variable High see below For custom linear inputs this parameter is the highest level signal the sensor or encoder will supply Typically this corresponds to the highest process variable to be measured The units and range for this parameter correlate to the selected Input Type See Table 5 9 See Setting Input Signal Lo and Input Signal Hi on page 99 for detailed information Watlow Anafaze 171 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide 172 Process Variable Low PV Lo Set this register to the value to be displayed when the signal is at the level set in Input Signal Low see above See Setting PV Lo and PV Hi on p
106. 51 Table 7 46 Environmental Specifications 251 Table 7 47 Connections 251 Table 7 48 Physical Specifications 252 Table 7 49 Power Specifications 252 Table 7 50 Output Specifications 252 Table 7 51 Model Number 254 Table 7 52 Environmental Specifications 254 Table 7 53 Physical Specifications 254 Table 7 54 Connections 255 Table 7 55 Power Specifications 255 Table 7 56 Digital Input Specifications 255 Table 7 57 Environmental Specifications 256 Table 7 58 Physical Specifications 256 Table 7 59 Connections 257 Table 7 60 PPC AITB with Straight SCSI 257 Table 7 61 Sensor Key Cards 258 Table 7 62 Environmental Specifications 259 Table 7 63 Physical Specifications 259 Table 7 64 Connections 259 Table 7 65 PPC EITB with HD Type Cable 259 Table 7 66 Safety and Agency Approvals 259 Table 7 67 Environmental Specifications 261 Table 7 68 Physical Specifications 261 Table 7 70 PPC TB50 SCSI with Straight SCSI 262 Table 7 72 Environmental Specifications 264 Table 7 73 Physical Specifications 264 Table 7 74 Dimensions with Din Rail Bracket 265 Table 7 75 Power Specifications 265 Table 7 76 Connections 265 Table 7 77 Safety and Agency Approvals 265 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC User s Guide List of Tables Table 7 78 Environmental Specifications 265 Table 7 79 Physical Specifications 266 Table 7 80 Safety and Agency Approvals 266 Table 7 81 Inputs 26
107. 518 1549 Low Process Output 0 336 Destination 84 3103 4102 45551 45600 15AE 15DF High Deviation Output 0 336 x f Destination 87 3103 4102 45701 45750 1644 1675 Low Deviation Output 0 336 Destination 90 3103 4102 45851 45900 16DA 170B 16 bit binary number NOTE Refer to Setting up Control Channels on page 92 for Doc 30002 00 Rev 2 3 the basics of setting up closed loop control channels Process Variable Source PV Source This variable determines the input used as the process variable for this channel The process variable is a hardware input converted to engineering units A value of 0 indicates a channel with no input See Table 5 13 on page 176 through Table 5 17 on page 179 for a list and explanation of input numbering Watlow Anafaze 175 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide Table 5 13 Process Variable and Setpoint Source Settings for Analog Inputs on the PPC 202x Modules Input Name Value AnaWin3 Input Spreadsheet 1 PPC1 Al 1 1 2 PPC1 Al 1 2 32 PPC1 Al 1 32 33 PPC1 Al 2 1 34 PPC1 Al 2 2 64 PPC1 Al 2 32 65 PPC1 Al 3 1 66 PPC1 Al 3 2 96 PPC1 Al 3 32 97 PPC1 Al 4 1 98 PPC1 Al 4 2 128 PPC1 Al 4 32 176 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference Table 5 14 Process Variable and Setpoint Source Settings for Encoder Inputs on the PPC 2030 Modules Values ending tase Sare
108. 60 to 15980 0 1 F 45 K T C 0 1F 4540 to 22490 0 1 F 46 N T C 0 1 F 4540 to 23720 0 1 F 47 R T C 0 1 F 580 to 32150 0 1 F 48 S T C 0 1 580 to 32150 0 1 F 49 T T C 0 1 F 4540 to 7520 0 1 F 50 F T C Platinel2 320 to 22500 0 1 F 51 G T C 1 F 32 to 4200 1F 52 57 Spare N A N A 58 J T C without open detection 3460 to 15980 0 1 F 59 K T C without open detection 4540 to 22490 0 1F 60 RTD 100 Ohm Plat 4180 to 5210 0 1F 61 RTD 100 Ohm Plat High 4180 to 15620 0 1 F Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 NOTE Chapter 5 LogicPro and Modbus Reference The counter and frequency inputs update four times per second 4Hz except the Linear 0 to 300 Hz input type which updates once every 25 seconds 04Hz The update rate of all other input types depends on the module See Chapter 7 Specifications Input Filter This parameter determines the time constant for the filter applied during the conversion of Input Raw Counts to Input Value The input value responds to a step change by going to approximately 2 3 of its final value within the number of scans set here A larger number yields a slower or more damped response to changes as measured by the sensor Temperature Scale This register sets the units used during the conversion of Input Raw Counts to Input Value This parameter applies only to temperature sensor input types Table
109. 7 Table 7 82 Power Requirements 267 Table 7 83 Analog Output Specifications 267 Appendix A Modbus Protocol 269 Table A 1 Example Message Frame 271 Table A 2 Function Codes 276 Table A 3 Sample Packet for Host Query 280 Table A 4 Sample Packet for Slave Response 280 Table A 5 Sample Packet for Host Query 281 Table A 6 Sample Packet for Slave Response 281 Doc 30002 00 Rev 2 3 Watlow Anafaze xvii List of Tables PPC User s Guide xviii Watlow Anafaze Doc 30002 00 Rev 2 3 Overview Manual Contents This manual describes how to install set up and operate a PPC 2000 controller Each chapter covers a different aspect of your control system and may apply to different users The following describes each chapter s purpose Doc 30002 00 Rev 2 3 Chapter 1 Overview Provides component list and summary of features for the PPC 2000 Chapter 2 Hardware Installation Provides detailed instructions on installing the PPC 2000 system and its peripherals Chapter 3 Software Setup Describes how to use your PPC system with AnaWin3 the Watlow Anafaze Human Machine Interface HMI software Chapter 4 Troubleshooting Includes troubleshooting upgrading and reconfiguring procedures for technical personnel Chapter 5 Custom Interfacing Provides information on setting up third party software or an operator interface terminal for operating and monitoring a PPC System Also provides information needed
110. 7 Table 3 16 Units 131 Table 3 18 Function Values 134 Table 3 19 Module Abbreviations Seen on the Outputs Spreadsheet 135 Table 3 20 System Status 139 Table 3 21 Global Settings 139 LogicPro and Modbus Reference 159 xiv Table 5 1 Parameter Names amp Abbreviations 159 Table 5 2 Example Database Table 160 Table 5 3 Addresses for Analog Inputs on the PPC 202x Modules 164 Table 5 4 Addresses for Encoder Inputs on the PPC 2030 Encoder In Analog Out Module 165 Table 5 5 Addresses for Counter Inputs on the PPC 2010 Processor Module 166 Table 5 6 Addresses for Soft Inputs and Channel Outputs 166 Table 5 7 Addresses for Encoder Inputs on the PPC 2040 Digital I O Modules 167 Table 5 8 Input Parameters 168 Table 5 9 Input Status 169 Table 5 11 Temperature Scale Conversion 171 Table 5 13 Process Variable and Setpoint Source Settings for Analog Inputs on the PPC 202x Modules 176 Table 5 16 Process Variable and Setpoint Source Settings for Soft Input and Channel Out Registers 178 Table 5 18 Control Mode 180 Table 5 19 Control Types 181 Table 5 21 Heat Cool Curve 184 Table 5 22 Output Destinations for Digital Outputs on the PPC 2010 Module 186 Table 5 26 Output Destinations for Analog Outputs on the PPC 205x Modules 189 Table 5 27 Output Destinations for Soft Boolean and Soft Integers 190 Table 5 28 Alarm Status 190 Table 5 30 Alarm and Control Functionality 192 Table 5 31 Alarm
111. 7 in Figure 7 22 PPC IPS 2 Table 7 72 Environmental Specifications Storage Temperature 20 C to 70 C Operation Temperature 0 C to 60 C Humidity Conditions 20 to 90 non condensing Table 7 73 Physical Specifications Weight 1 4 Ibs 0 64 kg Height 7 8 198 mm Width 1 9 48 mm Depth 4 3 109 mm Mounting Panel mount Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 7 Specifications Table 7 74 Dimensions with Din Rail Bracket Height 4 5 in 114mm Width 1 9 in 48 mm Depth 8 5 in 216 mm Table 7 75 Power Specifications 88 to 132Vac 115V Range Input 176 to 264Vac 230V Range V1 5Vdc 6A Output V2 24Vdc 4A Input Frequency 47 to 440 Hz 9A 5Vdc Peak Current Output 6A 24Vdc Table 7 76 Connections Connector Type Spade Output Screw Terminal Wire Gauge 24 to 12 AWG Screw Terminal Torque 0 5 to 0 6 Nm 4 4 to 5 3 in Ib Table 7 77 Safety and Agency Approvals UL eu UL 1012 UL 1950 CE EN 60950 CE EMC EN 55022 SDAC Specifications Watlow Anafaze offers a Serial DAC for precision open loop control The SDAC is jumper selectable for a 0 10Vdc or 4 20mA output Multiple SDAC modules can be used with one PPC system The SDAC carries a CE mark Table 7 78 Environmental Specifications Storage Temperature 20 to 60 C
112. 98 Figure 3 4 Linear Scaling of the Analog Input for Retransmit on the Heat or Cool Output 102 Figure 3 5 Sample Application Using Process Variable Retransmit 104 Figure 3 6 How the Secondary Channel s Set Point is Determined When the Primary Channel Has Heat and Cool Outputs 105 Figure 3 7 How the Secondary Channel s Set Point is Determined When the Primary Channel Has Only a Heat Output 106 Figure 3 8 Sample Application Using Cascade Control 107 Figure 3 9 The Secondary Channel s Set Point is Determined by the Primary Channel s Process Variable 109 Figure 3 10 Relationship between the Master Channel s Process Variable and the Ratio Channel s Set Point 110 Figure 3 11 Sample Application Using Ratio Control 111 Figure 3 12 Channels Spreadsheet 115 Figure 3 13 Output Scaling Heat Cool Curves 121 Figure 3 14 Alarms Spreadsheet 123 Figure 3 15 Inputs Spreadsheet 127 Figure 3 16 Analog Input Names 127 Figure 3 17 Pulse Input Names 128 Figure 3 18 Soft Input Names 128 Figure 3 19 Channel Output Names 129 Figure 3 20 Dig I O Spreadsheet 132 Figure 3 21 PPC 2010 and PPC 204X Digital O Names 133 Figure 3 22 PPC 206X and PPC 207X Digital I O Names 133 Figure 3 23 Outputs Spreadsheet 135 Figure 3 24 Analog Output Names 135 Figure 3 25 Soft Int Spreadsheet 136 Figure 3 26 Soft BOOL Spreadsheet 137 Figure 3 27 PPC Globals Screen 138 Troubleshooting 141 Figure 4 1 Assemb
113. A WARNING Battery Safety A CAUTION Provide a labeled switch or circuit breaker connected to the PPC 2000 power wiring as the means of disconnection for servicing Failure to do so could result in damage to equipment and or property and or injury or death to personnel The disconnect should be located so that operators and technicians can access it quickly and easily The battery used in this device may result in a fire or chemical burn hazard if mistreated Do not disassemble heat above 100 C 212 F or incinerate Dispose of used battery properly Keep away from children Product Markings and Symbols CE LISTED Doc 30002 00 Rev 2 3 This symbol indicates that the products meets the essential requirements of applicable European Union Directives This symbol indicates that the product is listed by Underwriters Laboratory and Canadian Underwriters Laboratory The terminals adjacent to this symbol should be connected to DC voltage only Watlow Anafaze 11 Chapter 1 Overview PPC 2000 User s Guide 12 Watlow Anafaze Doc 30002 00 Rev 2 3 Hardware Installation This section describes how to install your PPC system hardware It provides detailed instructions for each component and peripheral item Read this chapter before installing your PPC 2000 system Power Supply Requirements Watlow Anafaze provides the PPC IPS2 power supply for the PPC 2000 system This unit supplies sufficient current f
114. Adaptive to enable adaptive control and tuning on a channel This option is only valid for channels 1 to 8 Values PID1 0 PID2 1 Adaptive 2 and Retransmit 3 Default PID1 0 Modbus Address Channels 1 to 32 46401 to 46432 Parameter Number 19 LogicPro Driver Database LogicPro Address Channels 1 to 32 19 1 to 19 32 PPC 2000 User s Guide Watlow Anafaze 1 Adaptive Mode Plant Delay Adaptive Addendum 0600 0049 0001 rev C When Control Type is set to Adaptive this parameter can be used to pause tuning or to reset the adaptive algorithm and have it relearn the system This parameter has no effect on control if the Control Type for the loop is set to an option other than Adaptive Values Adapt 0 Reset 1 and Hold 2 Default Reset 1 Modbus Address Channels 1 to 32 49001 to 49032 Parameter Number 21 LogicPro Driver Database LogicPro Address Channels 1 to 32 21 1 to 21 32 Table 1 Adaptive Mode Settings Setting Description Adapt The normal setting for a loop with Control Type set to Adaptive The loop is adapting and tuning while controlling Reset Select this option to have the control loop start from scratch and relearn the load characteristics The Contro Mode must be set to Off or Manual to select this option for an adaptive loop This is the normal setting for a loop with Control Type set to a value other than Adaptive Hold Select this option to have the control loop
115. Anafaze 9 Chapter 1 Overview A WARNING A WARNING PPC 2000 User s Guide Power input or output circuits with hazardous voltage levels should not have any live accessible parts In any application failures can occur These failures can result in full control output 100 power or the occurrence of other output failures which can cause damage to the controller or to the equipment or process connected to the controller Therefore always follow good engineering practices electrical codes and insurance regulations when installing and operating this equipment CAUTION This product is intended for indoor use only External Safety Devices nN WARNING External safety devices should be used to prevent potentially dangerous and unsafe conditions upon equipment failure Always assume that this device can fail with outputs full on or full off by the occurrence of an unexpected external condition Always install high or low temperature protection in installations where an over temperature or under temperature fault will present a potential hazard Failure to install external protection devices where hazards exist can result in damage to equipment and property as well as loss of human life Contact Watlow Anafaze immediately if you have any questions about system safety or system operation Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 1 Overview External Switch Disconnect
116. C 2000 system Environmental Specifications Table 1 here contains specifications in addition to those found in tables 7 4 7 15 7 23 7 31 7 39 7 46 7 52 7 57 7 62 7 67 in the PPC 2000 User s Guide TABLE 1 Environmental Specifications Altitude 2000 meters max Non Condensing Humidity 10 to 95 Relative Humidity 80 max ambient temperature lt 31 C 50 max ambient temperature 40 C Pollution Category Degree 2 per IEC 664 Operating Temperature Range 0 to 60 C 82 to140 F Storage Temperature Range 20 to 70 C 4 to 158 F PPC IPS International Power Supply Specifications Table 2 here contains specifications in addition to those found in table 7 75 in the PPC 2000 User s Guide TABLE 2 Power Specifications Input Mains Supply 88 to 132 Vac 120 Vac nominal 176 to 264 Vac 240 Vac nominal Voltage Fluctuation lt 10 of nominal voltage Transient Over Voltage Category II per IEC 664 Output V1 5 Vdc 6 A V2 24 Vdc 4 A Input Frequency 47 to 440 Hz Peak Current Output 9A 5Vdc 6A 24 Vdc A mow 1241 Bundy Blvd Winona MN 55987 Phone 507 494 5656 Fax 507 452 4507 2004 Watlow Page 1 of 1 Copyright 1998 2002 Watlow Anafaze Information in this manual is subject to change without notice No part of this publication may be reproduced stored in a retrieval system or transmitted in any form without written permission from
117. C1 EIAO 12 2 4 F 12 2 4 144 144 30944 PPC1 EIAO 13 1 1 C 13 1 1 145 145 30945 PPC1 EIAO 13 2 1 F 13 2 1 146 146 30946 PPC1 EIAO 13 1 2 C 13 1 2 147 147 30947 PPC1 EIAO 13 2 2 F 13 2 2 148 148 30948 PPC1 EIAO 13 1 3 C 13 1 3 149 149 30949 PPC1 EIAO 13 2 3 F 13 2 3 150 150 30950 PPC1 EIAO 13 1 4 C 13 1 4 151 151 30951 PPC1 EIAO 13 2 4 F 13 2 4 152 152 30952 PPC1 EIAO 14 1 1 C 14 1 1 153 153 30953 PPC1 EIAO 14 2 1 F 14 2 1 154 154 30954 PPC1 EIAO 14 1 2 C 14 1 2 155 155 30955 PPC1 EIAO 14 2 2 F 14 2 2 156 156 30956 PPC1 EIAO 14 1 3 C 14 1 3 157 157 30957 PPC1 EIAO 14 2 3 F 14 2 3 158 158 30958 PPC1 EIAO 14 1 4 C 14 1 4 159 159 30959 PPC1 EIAO 14 2 4 F 14 2 4 160 160 30960 1The AnaWin3 names are shown for the first PPC 2000 in the system See Inputs on page 127 for a full explanation of analog input naming C Counter input F Frequency input 2Use this address with the Encoder_Analog_2030 IO Driver when addressing Input Value 3Use this address with the Database IO Driver when addressing input parameters other than Input Value Replace the with the parameter number from Table 5 8 on page 168 for the parameter you want to address Doc 30002 00 Rev 2 3 Watlow Anafaze 165 Chapter 5 LogicPro and Modbus Reference 166 PPC 2000 User s Guide Table 5 5 Addresses for Counter Inputs on the PPC 2010 Processor Module LogicPro I O Physical Address Modbus Addressing AnaWin3 Name
118. Control On Off control is the simplest way to control a process a controller using On Off control turns an output on or off when the process variable reaches limits around the desired setpoint This limit is adjustable Watlow Anafaze controllers use an adjustable spread For example if the set point is 1000 F and the spread is 20 F the heat output switches On when the process variable drops below 980 F and Off when the process rises above 1000 F A process using On Off control cycles around the set point Figure 6 1 illustrates this example Heat off Heat off Sanka ee 4 SP 1000 F PV SP Spread 980 F Off Be ea eat 4 ee Figure 6 1 On Off Control 220 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 6 Tuning and Control Proportional Control Doc 30002 00 Rev 2 3 Proportional control eliminates cycling by increasing or decreasing the output in proportion to the process variable s deviation from the setpoint The magnitude of proportional response is defined by the Proportional Band PB outside this band the output is either 100 or 0 Within the proportional band the output power is proportional to the PV s difference from the setpoint For example if the setpoint is 1000 F and the PB is 20 F the output is e 0 when the process variable is 1000 F or above e 50 when the process variable is 990 F e 75 when the process variable is 985 F e 100
119. DIN Deutsche Industrial Norms A set of technical scientific and dimensional standards developed in Germany Many DIN standards have worldwide recognition Dip Switch A set of compact toggle switches used to config ure electronic hardware The toggle switches are housed in a Dual In line Package 286 Watlow Anafaze PPC 2000 User s Guide Distributed Zero Crossing DZC A form of digital output control Similar to burst fire E Electromagnetic Interference EMI Electrical and magnetic noise imposed on a sys tem There are many possible causes such as switching ac power on inside the sine wave EMI can interfere with the operation of controls and other devices Engineering Units Selectable units of measure such as degrees Cel sius and Fahrenheit pounds per square inch Newtons per meter gallons per minute liters per minute cubic feet per minute or cubic meters per minute EPROM Erasable Programmable Read Only Memory inside the controller F Failed Sensor Alarm Warns that an input sensor no longer produces a valid signal For example when there are thermo couple breaks infrared problems or resistance temperature detector RTD open or short fail ures Filter Filters are used to handle various electrical noise problems Digital Filter DF A filter that allows the response of a system when inputs change unreal istically or too fast Equivalent to a standard resistor capacitor RC filter D
120. Database Offset are used in conjunction with LogicPro s Database IO Driver Watlow Anafaze 163 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide 164 The IO Physical Address is constructed from the parameter number and the database offset See the LogicPro User s Guide for specific instructions on addressing analog and encoder input parameters See Table 5 3 below through Table 5 6 on page 166 for a list of the database offsets for each analog and counter input See Table 5 8 on page 168 for analog input parameter numbers Analog Input Numbers and Address Offsets Table 5 3 below through Table 5 6 on page 166 list the LogicPro IO Physical Addresses Database Offsets and sample Modbus addresses corresponding to each analog and counter input The sample Modbus addresses are for the Input Value Table 5 3 Addresses for Analog Inputs on the PPC 202x Modules 1 LogicPro I O Physical Address Modbus Addressing AnaWin3 Name Sheen Analog_In_202x Database Database Sample IO Driver IO Driver Offset Address PPC1 Al 1 1 1 1 1 1 30801 PPC1 Al 1 2 12 2 2 30802 PPC1 Al 1 32 1 32 32 32 30832 PPC1 Al 2 1 21 33 33 30833 PPC1 Al 2 2 22 34 34 30834 PPC1 Al 2 32 2 32 64 64 30864 PPC1 Al 3 1 3 1 65 65 30865 PPC1 Al 3 2 3 2 66 66 30866 PPC1 Al 3 32 3 32 96 96 30896 PPC1 Al 4 1 4 1 97 97 30897 PPC1 Al 4 2 42 98 98 30898 PPC1 Al 4 32 4 32 128 128 30928 The AnaWin
121. Dig I O Spreadsheet Digital In Out 1 PPC1 DIO 21 0 1 Counter 1 Phase 1 1 PPC1 DIO 21 1 1 C Frequency 1 PPC1 DIO 21 2 1F Digital In Out 2 2 PPC1 DIO 21 0 2 Counter 1 Phase 2 PPC1 D1021 1 1C Digital In Out 3 PPC1 D1021 0 3 Counter 2 Phase 1 3 PPC1 D1021 1 2 C Frequency 2 PPC1 D1021 2 2 F Digital In Out 4 PPC1 DIO 21 0 4 Counter 2 Phase 2 PPC1 D1021 1 2 C Digital In Out 5 5 PPC1 DIO 21 0 5 Digital In Out 6 6 PPC1 DIO 21 0 6 7 8 Digital In Out 7 PPC1 DIO 21 0 7 Digital In Out 8 PPC1 DIO 21 0 8 Digital In Out 9 9 PPC1 DIO 21 0 9 Digital In Out 10 10 PPC1 DIO 21 0 10 Digital In Out 11 11 PPC1 DIO 21 0 11 Digital In Out 12 12 PPC1 DIO 21 0 12 Digital In Out 13 13 PPC1 DIO 21 0 13 Digital In Out 14 14 PPC1 DIO 21 0 14 Digital In Out 15 15 PPC1 DIO 21 0 15 Digital In Out 16 16 PPC1 DIO 21 0 16 Digital In Out 17 17 PPC1 DIO 21 0 17 Digital In Out 18 18 PPC1 DIO 21 0 18 Digital In Out 19 19 PPC1 DIO 21 0 19 Digital In Out 20 20 PPC1 DIO 21 0 20 Digital In Out 21 21 PPC1 DIO 21 0 21 Digital In Out 22 22 PPC1 DIO 21 0 22 Digital In Out 23 23 PPC1 DIO 21 0 23 Digital In Out 24 24 PPC1 DIO 21 0 24 Digital In Out 25 25 PPC1 DIO 21 0 25 Digital In Out 26 26 PPC1 DIO 21 0 26 Digital In Out 27 27 PPC1 DIO 21 0 27 Digital In Out 28 28 PPC1 DIO 21 0 28 Digital In Out 29 29 PPC1 DIO 21 0 29 Digital In Out 30 30 PPC1 DIO 21 0 30 Digital In Out 31 31 PPC1 DIO 21 0 31
122. Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Using Snubbers for Relay Outputs 120 240Vac Doc 30002 00 Rev 2 3 Relay contacts can arc and or generate EMI Over time arcing will shorten the life of relay contacts and EMI can disrupt system functions Use snubbers a resistor and capacitor in series to protect against EMI and lengthen relay life The capacitor should be non polarized and may be metallized polyester film or metallized polypropylene and the voltage rating must be 600Vdc 250Vac The resistor may be carbon composition or carbon film It should be 0 5 or 1 watt with 5 tolerance Use 1 watt if the contacts are used in a rapid cycling application The following values are acceptable for most applications using the PPC 2061 and PPC 2062 relay output modules e Resistor 120 Q e Capacitor 0 47 uF Install the snubber across the contacts or the load Generally it performs more reliably across the contacts R Preferred Method N Co Contacts N Alternative Method Figure 2 61 Snubber Connections Watlow Anafaze 73 Chapter 2 Hardware Installation PPC 2000 User s Guide 74 Connecting Digital Inputs to the PPC 207x Connect wires directly to the terminals on the bottom of the PPC 207x modules Up to 16 inputs are accommodated Depending on the module type DC and AC inputs are accommodated
123. EN 61000 3 3 1995 mit A1 1998 Spannungsfluktationen und Flimmern 73 23 EEC Niederspannungsrichtlinie EN 61010 1 1993 mit A1 1995 Sicherheitsanforderungen f r elektrische Ger te f r Messungen Kontrolle und Laborgebrauch Teil 1 Allgemeine Anforderungen Declara que el producto siguiente Espa ol Designaci n PPC 2000 N meros de modelo PPC 2 010 02X 040 05X 06X o 07X PPC AITB PPC TB50 X representa un n mero de 0 a 9 Equipo Para Control de Proceso de Tipo Abierto Voltaje nominal 12 a 24 V CD Consumo de energ a nominal 50 VA m ximo Clasificaci n Cumple con los requisitos esenciales de las siguientes Directrices de la Uni n Europea mediante el uso de las normas aplicables que se muestran a continuaci n para indicar su conformidad 89 336 EEC Directriz de compatibilidad electromagn tica EN 61326 1997 CON A1 1998 Equipo el ctrico para medici n control y uso en laboratorio Requisitos EMC Inmunidad industrial Emisiones Clase A Este Equipo no debe ser utilizado en Ambientes de Emisi n Clase B sin filtrado adicional EN 61000 4 2 1996 con A1 1988 Inmunidad a descarga electrost tica EN 61000 4 3 1997 Inmunidad a campo radiado EN 61000 4 4 1995 Inmunidad a incremento repentino r pidas fluctuaciones el ctricas transitorias EN 61000 4 5 1995 con A1 1996 Inmunidad a picos de voltaje o corriente EN 61000 4 6 1996 Inmunidad por conducci n EN 61000 4 11 1994 Inmunidad a ca
124. Height 5 1 in 130 mm Width 4 2 in 107 mm Depth 2 3 in 58 mm 256 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Table 7 59 Connections Chapter 7 Specifications Terminals Screw Terminal Wire Gauge 24 to 12 AWG Screw Terminal Torque 0 5 to 0 6 Nm 4 4 to 5 3 in Ib Connector on Board SCSI 2 female Captive screw cage clamp Mounting DIN rail or panel mount Table 7 60 PPC AITB with Straight SCSI Height 7 1 in 180 mm Width 4 2 in 107 mm Depth 2 3 in 58 mm 5 10 in H 130 mm 8 OS8SE8G8 8G BUDRRERURED peseougue cospar WUUTETER ATEN 2 3 in D 58 mm 4 70 in 119 mm Figure 7 16 PPC AITB Dimensions with Straight SCSI Cable Doc 30002 00 Rev 2 3 Watlow Anafaze 257 Chapter 7 Specifications PPC 2000 User s Guide Four factory configured input sensor keys plug into the AITB and accommodate various input types The following table describes usage for the various keys Table 7 61 Sensor Key Cards ice Color Key Type Key Description Code Adapts AITB for h l iff ial ingle PPC KEY 01 thermocoup es dif erentia or sing e ended None Linear voltages differential or single ended 4 wire RTDs differential PPC KEY 02 adapts AITB for 0 20mA linear current Blue differential PPC KEY 03 adapts AITB for 0 20mA linear curren
125. J12 splitter PPC 1 PPC 2 PPCN Figure 2 73 Connecting Several PPCs with Short Cable Runs 84 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Signal Common Termination Doc 30002 00 Rev 2 3 Chapter 2 Hardware Installation Each controller and the converter should be connected to the signal common to insure they can properly interpret the signals on the network Pin 1 in the RJ12 connectors connects the signal commons of all the PPCs to each other At the converter connect the signal common to the common of the converter s DC power supply The communications ports are optically isolated from the sensors and the rest of the PPC circuitry so connecting the communications commons together will not create a ground loop In some installations particularly when transmission lines are long the transmission lines must be terminated The receive lines at the converter or host device should be terminated in the converter the connector to the host device or the device itself Typically the converter documentation provides instructions for termination The PPC receive lines can be terminated by setting a jumper on the last PPC 2010 module To terminate the lines for port 1 set jumper JU1 on the last PPC 2010 module on the network to the A position This places a 120 ohm resistor across the receive lines To terminate the line for port 2 set jumper JU2 on the last PPC 2010 module on the network to the A position Thi
126. L wr 5 p Se ei S Sss 86 mm 1 04 mm o e 8 wy o jo me sm a a e ie g D 2 a o 1O t 3 98 s x 8 z g 8 5 o o MaE T0 fel v 2 6 in 66 mm 4 2 in W 102 mm Figure 2 15 TB50 Dimensions Clearances DIN Rail Mounting All factory terminal boards snap onto a DIN rail A TB50 is shown in the following figures for illustration purposes only To install a terminal board on a DIN rail place the hook side of the mounting mechanism over one of the DIN rail lips and snap the board over the other lip Doc 30002 00 Rev 2 3 Watlow Anafaze 31 Chapter 2 Hardware Installation PPC 2000 User s Guide j 900800800800 HHRRRRRHRRGE AKIITAKA BUBBRBBBRBBRR ED gD gt Hook side Figure 2 16 TB50 Mounted on DIN Rail Front DIN Rail Removal Place a flat blade screw driver through the slot in the board and hook the blade into the snap latch Pry the snap latch away from the DIN rail lip and repeat for the other side See Figure 2 17 LJ Removal H y catch for k screwdriver E l DIN Rail snap latch Hook side Figure 2 17 TB50 Mounted on DIN Rail Side 32 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Panel Mounting Chapter 2 Hardware Installation
127. L2032 3 volt only contact Watlow Anafaze Use of another battery may present a risk of fire or explosion See Battery Safety on page 11 for safety instructions 8 Dispose of used battery promptly Keep away from children 9 Install the new battery 10 Reassemble the controller 11 When the module is properly seated close the module latches on the processor by pushing the latch toward the front of the module The two modules should be properly locked 12 Replace the module on the DIN rail or panel 13 Reconnect cables 14 Power the unit 146 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide 15 16 Chapter 4 Troubleshooting Reset the controller and download the AnaWin3 Snapshot Refer to Resetting Closed Loop Control Parameters on page 156 Reload logic program stored variables Processor Module LEDs Refer to the following descriptions of LED indicators when troubleshooting the Processor module Doc 30002 00 Rev 2 3 Status Green LED On Normal condition with logic program stopped Status Green LED blinking four times per second on briefly 230 ms Off 20 ms On Normal condition with logic program running Status LED Off Indicates low power input Corrective Actions Check power connections Measure power output from power supply Disconnect I O to check for excessive draw on power supply Status Green LED blinking four times per second off briefly 50 ms Off 200 ms O
128. LED status indicator e DIN rail panel mount e Connects to analog input terminal board via 50 pin SCSI cable Watlow Anafaze 7 Chapter 1 Overview PPC 2000 User s Guide PPC 2030 Encoder In Analog Out Module The PPC 2030 is used in applications including monitoring and controlling belt speeds motor speeds positioning etc Four isolated analog outputs are jumper configurable for current or voltage These outputs may be used to provide software selectable analog output signals to field devices Four counter inputs are used for interfacing to motor encoder signals The counters interface to both single ended and differential styles of encoder signals and count quadrature signals for increased resolution accuracy and direction PPC 2040 Digital I O Module Up to four PPC 2040 modules may be added to a PPC system Each module includes 32 digital I O points which are individually configurable as inputs or outputs and two counter and frequency inputs PPC 2050 2051 Analog Out Modules Up to four PPC 2050 and PPC 2051 modules may be added to a PPC system Modules include four or eight analog outputs PPC 2061 2062 Digital Out Relays Module Up to six PPC 2060 PPC 2061 and PPC 2062 modules may be added to a PPC system The PPC 2061 features 16 electromechanical relays These relays can switch AC or DC loads Two sets of eight relays each have a common The PPC 2062 features eight electromechanical relays PPC 2070 207
129. O 22 0 32 113 PPC1 DIO 23 0 1 114 PPC1 DIO 23 0 2 144 PPC1 DIO 23 0 32 145 PPC1 DIO 24 0 1 146 PPC1 DIO 24 0 2 176 PPC1 DIO 24 0 32 177 PPC1 DIO 25 0 1 178 PPC1 DIO 25 0 2 208 PPC1 DIO 25 0 32 209 PPC1 DIO 26 0 1 210 PPC1 DIO 26 0 2 240 PPC1 DIO 26 0 32 Doc 30002 00 Rev 2 3 Watlow Anafaze Chapter 5 LogicPro and Modbus Reference 188 PPC 2000 User s Guide Table 5 24 Output Destinations for Digital Out puts on the PPC 206x Modules Value Digital I O Name AnaWin3 Dig I O Spreadsheet 241 PPC1 DO 41 1 242 PPC1 DO 41 2 256 PPC1 DO 41 16 257 PPC1 DO 42 1 258 PPC1 DO 42 2 272 PPC1 DO 42 16 273 PPC1 DO 43 1 274 PPC1 DO 43 2 288 PPC1 DO 43 16 289 PPC1 DO 44 1 290 PPC1 DO 44 2 304 PPC1 DO 44 16 305 PPC1 DO 45 1 306 PPC1 DO 45 2 320 PPC1 DO 45 16 321 PPC1 DO 46 1 322 PPC1 DO 46 2 336 PPC1 DO 46 16 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference Table 5 25 Output Destinations for Analog Outputs on the PPC 2030 Modules Value Output Name AnaWin3 Outputs Spreadsheet 1001 PPC1 EIAO 11 3 1 1002 PPC1 EIAO 11 3 2 1003 PPC1 EIAO 11 3 3 1004 PPC1 EIAO 11 3 4 1005 PPC1 EIAO 12 3 1 1006 PPC1 EIAO 12 3 2 1007 PPC1 EIAO 12 3 3 1008 PPC1 EIAO 12 3 4 1009 PPC1 EIAO 13 3 1 1010 PPC1 EIAO 13 3 2 1011 PPC1 EIAO 13 3 3 1012 PPC1 EIAO 13 3 4 1013 PPC1 EIAO 14 3 1 1014 PPC1 EIAO 14 3 2 1015 PPC1 EIAO 14
130. Oke Logic Start State Not Running Loop Checksum Ok __AC Frequency 60 Hz HAW Cig Status OK Logic Run Status E Not Running Logic Load Status Loaded RAM Batt Status K Ready Ctr 1 aS Figure 3 27 PPC Globals Screen PPC Controller Select Select the pertinent controller to display its parameters on this screen Ambient Temperatures The analog input modules measure the temperatures of each terminal block on up to four AITBs in tenths of degrees F These give the cold junction compensation temperature for each half of the terminal block Note that the channel numbers associated with a given cold junction reference depend on whether the card is single ended or differential Table 2 13 on page 48 correlates the terminals with the input number Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter 3 Operating with AnaWin 3 System Status Refer to Table 3 20 for a description of the system status parameters Table 3 20 System Status Parameter Definition Ambient Status Ambient temperature error Memory Status RAM verification error Loop Checksum Closed loop control program verified HW Cfg Status Hardware configuration error Logic Run Status Logic program is is not running Logic Load Status Logic program is is not loaded Battery Status Battery status Logic Program Controls Select Start or Stop to control the logic program Global Settings
131. Operating with AnaWin 3 LD Offset Designate an offset value that determines the low deviation alarm limit relative to the current set point The low deviation alarm occurs when the process variable is lower than the channel set point less this value The alarm limit changes when the set point changes The default low deviation alarm offset is 0 Range same as the range of the input type selected See Table 3 15 on page 130 LD Type Set the function of the low deviation alarm See Process Alarms on page 95 for a description of the settings Range Alarm or Control LD Enable Set this field to enable or disable the low deviation alarm When it is Enabled the low deviation alarm activates if the process variable PV dips below set point by more than the LD Offset The PV must rise above the low deviation limit plus the alarm deadband to be reset cleared When this parameter is set to Disabled the low deviation alarm does not occur Range Enable or Disable LD Output Dest Choose a digital output to toggle when the low deviation alarm occurs This may be any available hardware output or Soft Boolean register accessible by the logic program The default for this parameter is Not Assigned Outputs that are already assigned to control output destinations will be rejected The same output may net be used for multiple alarm output destinations Range Not Assigned or any of the digital outputs on the Digl 0 spreadsheet or an
132. PC only e 9 Input Device l e e10 5 a DC Source Source RO Eesi Lame a au Figure 2 64 Input Connections to a PPC 2071 or PPC 2073 Inputs 1 2 9 and 10 Shown PPC 2072 PPC 2073 hg C C1 V Sensor s Outpyt 4 DC Sensor Source Circuit V Current Sinking Field Device Figure 2 65 Connecting a Current Sinking Field Device to a PPC 2072 or PPC 2073 Input 1 Shown Doc 30002 00 Rev 2 3 Watlow Anafaze 75 Chapter 2 Hardware Installation PPC 2000 User s Guide PPC 2072 PPC 2073 l C C1 l l V l Sensor s Outputs 4 DC Sensor Source Circuit V l l ee a Jd Current Sourcing Field Device Figure 2 66 Connecting a Current Sourcing Field Device to a PPC 2072 or PPC 2073 Input 1 Shown Table 2 24 Digital Input Connections on PPC 207x Modules Digital In Module Connections i Module 1 O ens Dale Number PPC 2070 PPC 2071 i PPC 2072 PPC 2073 Spreadsheet Input Com Input Com Digital In 1 1 C 1 C1 PPC1 DI 51 1 Digital In 2 2 C 2 C1 PPC1 DI 51 2 Digital In 3 3 C 3 C1 PPC1 DI 51 3 Digital In 4 4 C 4 C1 PPC1 DI 51 4 Digital In 5 5 C 5 C1 PPC1 DI51 5 Digital In 6 6 C 6 C1 PPC1 DI 51 6 Digital In 7 7 C 7 C1 PPC1 DI 51 7 Digital In 8 8 C 8 C1 PPC1 DI 51 8 Digital In 9 n a n a 9 C2
133. PPC 2000 User s Guide WATLOW 1241 Bundy Boulevard Winona Minnesota USA 55987 Phone 1 507 454 5300 Fax 1 507 452 4507 Part No 0600 3000 2000 Rev 2 3d http www watlow com PPC 2000 Adaptive Control Addendum Scope Introduction This document describes the additional features and functionality found in the PPC 2010 xxB with adaptive control Refer to the PPC 2000 User s Guide regarding all other functionality which is the same as the standard version The Watlow Anafaze PPC 2000 controller offers these standard options e Forty eight loops of conventional PID control with auto tuning capability OYr e Eight loops of adaptive control plus 24 loops of conventional PID control with auto tuning for a total of 32 loops the option described in this document ANAWIN3 HMI software is available to support either option A mix of these options is not supported by ANAWIN3 ANAWINS Software Installation Follow the standard instructions to install and setup ANAWIN3 In the setup program select the Adaptive Control option Spreadsheet Overview Screen Control Type Adaptive Addendum 0600 0049 0001 rev C Several new parameters and options appear on the Spreadsheet Overview screen in support of the adaptive control option These parameters and options are applicable only for the first eight channels and are omitted or ignored for channels 9 to 32 An additional option appears for Control Type Select
134. PPC 2040 max 6 x 150mA PPC 2050 400mA PPC 2051 x 250mA max 4 PPC 206x max 6 x 125mA PPC 207x max 4 x 50mA Total Number of Bisham B Modules max 10 E required Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide A WARNING Chapter 2 Hardware Installation The PPC is designed to operate on 12 28Vdc Connection to a power source other than this will cause damage to the PPC To avoid electrical shock correctly connect the power supply s earth ground Mounting the Power Supply Doc 30002 00 Rev 2 3 Mount the hardware in an area free of moisture or corrosive chemicals Mount the power supply vertically with adequate vent space Locate the power supply for the PPC such that the AC supply and DC connections to the PPC may be made The PPC IPS 2 can be DIN rail or screw mounted Refer to Figure 2 1 for power supply mounting clearances All dimensions are measured in inches LILIN A A 2 5 in min Air Flow Space gt S fo 3 fo cs S l Figure 2 1 PPC IPS 2 DIN Mounting Dimensions Watlow Anafaze 15 Chapter 2 Hardware Installation PPC 2000 User s Guide 0 24 in 7 5 in 7 84 in t EE 0 10 11 0 93 in Figure 2 2 PPC IPS 2 Panel Mounting Dimensions To DIN rail mount the PPC IPS 2 1 Locate a space with sufficient room for the
135. RS 485 Connector RS 232 Connector Wu fe l N S Figure 7 2 PPC 2010 Front View Doc 30002 00 Rev 2 3 Watlow Anafaze 231 Chapter 7 Specifications PPC 2000 User s Guide at 50 pin SCSI Connector 12 28Vdc a Power Figure 7 3 PPC 2010 Bottom View Table 7 3 Model Number PPC 2010 Processor Table 7 4 Environmental Specifications Storage Temperature 20 to 70 C 42 to 158 F Operating Temperature Humidity 0 to 60 C 32 to 140 F 10 to 95 non condensing Table 7 5 Physical Specifications Weight 0 82 lbs 0 37 kg Height 8 0 in 203 mm Width including endcaps 3 2 in 81mm Depth 5 25 in 133 mm 232 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Table 7 6 Connections Chapter 7 Specifications Power Terminals Captive screw cage clamp Power Wire Gauge 24 to 12 AWG Power Terminal Torque 0 5 to 0 6 Nm 4 4 to 5 3 in lb Connector on Module SCSI 2 female Mounting DIN rail or panel mount Port 1 and Port 2 See Table 7 13 on page 235 Table 7 7 Pow
136. Text Conventions in the Database Sections 159 The PPC 2000 Database 160 Data Table Organization 161 How LogicPro Accesses the Database 162 Analog and Counter Input Parameters in the Database 163 Accessing Analog and Counter Input Parameters with Modbus 163 Accessing Analog and Counter Input Parameters with LogicPro 163 Analog Input Numbers and Address Offsets 164 Analog and Encoder Input Parameters 168 Channel Parameters in the Database 172 Accessing Channel Parameters with Modbus 172 Accessing Channel Parameters with LogicPro 173 Channel Parameters for Heat and Cool Outputs 173 Channel Parameters 173 State and Logic 195 Accessing Digital I O Parameters with Modbus 195 Digital I O Numbers and Address Offsets 196 Digital I O Parameters 200 Accessing Analog Outputs with Modbus 202 Accessing Analog Outputs with LogicPro 202 Analog Outputs and Modbus Addresses 202 Analog Output Value 204 Soft Bool and Soft Int Registers in the Database 205 Accessing Soft Bool and Soft Int Registers with Modbus 205 Accessing Soft Bool and Soft Int Registers with LogicPro 205 Soft Bool and Soft Int Registers 205 Global Parameters in the Database 206 Accessing Global Parameters with Modbus 206 Communications Parameters 207 Global Database Parameters 209 vi Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Table of Contents Tuning and Control 219 Introduction 219 Control Algorithms 220 On Off Control 220 Output Control Forms 224 Output Filter
137. The high deviation alarm occurs when the process variable is greater than the channel set point plus this value The alarm limit changes when the set point changes The default high deviation alarm offset is 0 Range same as the range of the input type selected See Table 3 15 on page 130 HD Type Set the high deviation alarm function See Process Alarms on page 95 for a description of the settings Range Alarm or Control HD Enable Set this field to enable or disable the high deviation alarm When it is Enabled the high deviation alarm activates if the process variable PV rises above the set point by more than the HD Offset The PV must drop below the high deviation limit minus the alarm deadband to be reset cleared When this parameter is set to Disabled the high deviation alarm does not occur Range Enable or Disable HD Output Dest Choose a digital output to toggle when the high deviation alarm occurs This may be any available hardware output or Soft Boolean register accessible by the logic program The default for this parameter is Not Assigned Outputs that are already assigned to control output destinations will be rejected The same output may net be used for multiple alarm output destinations Range Not Assigned or any of the digital outputs on the Digl 0 spreadsheet or any of the Soft Bool registers Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter 3
138. User s Guide Figure 2 35 Connecting Linear Voltage Signals to Differential Inputs 1 and 2 52 Figure 2 36 Connecting Linear Voltage Signals to Single ended Inputs 1 and 2 53 Figure 2 37 Connecting Current Inputs to a Differential Input Module Input 1 2 and 3 Shown 53 Figure 2 38 Connecting Current Inputs to a Single ended Analog Input Module Input 1 and 2 Shown 54 Figure 2 39 PPC 2030 Connections Bottom View 55 Figure 2 40 PPC EITB 1 56 Figure 2 41 EITB Single ended Single Phase Connections Input 1 and 2 Shown 57 Figure 2 42 EITB Single ended Quadrature Connections Input 1 and 2 Shown 58 Figure 2 43 EITB Differential Single Phase Connections Input 1 and 2 Shown 58 Figure 2 44 EITB Differential Quadrature Connections Input 1 and 2 Shown 59 Figure 2 45 PPC 2030 Analog Out Terminal Block 60 Figure 2 46 Analog Output Connections on a PPC 2030 Outputs 1 and 2 Shown 61 Figure 2 47 PPC 2040 Connection to TB50 62 Figure 2 48 Wiring Digital Inputs 64 Figure 2 49 Single Phase Connections Input 1 and 2 Shown 64 Figure 2 50 Quadrature Connections Inputs 1 and 2 Shown 65 Figure 2 51 Powering Output with 5Vdc from PPC Supply 65 Figure 2 52 Powering Output with 12 24Vdc from PPC supply 66 Figure 2 53 Powering Output with Separate Power Supplies 66 Figure 2 544 PPC 205x Connections Bottom View 67 Figure 2 55 Analog Output Connections on a PPC 2050 Configured for Current Outputs 1 and 2 Shown 68 Figure 2 56
139. Vde 310 kOhm Encoder Frequency Counter Input Com pe Ol Figure 2 22 Encoder with 5Vdc TTL Signal Connecting Digital Outputs Doc 30002 00 Rev 2 3 The digital outputs sink current from a load connected to the controller s power supply or another power supply referenced to the PPC 2000 power common Do not exceed 24 volts on the outputs If you must tie the external load to ground or if you cannot connect it as shown in Figure 2 28 through Figure 2 25 use a solid state relay to drive your load The outputs conduct current when they are LOW or ON The maximum current sink capability is 100mA at 24Vdc They cannot source current to a load Watlow Anafaze 41 Chapter 2 Hardware Installation PPC 2000 User s Guide 12 04 lt lt ppc 4 TB50 ES 2010 9 Digital 5 Out SSR Figure 2 23 Powering Output with 5Vdc from PPC Supply PPC PS 2010 4 o paia Out PN Ko SSR Figure 2 24 Powering Output with 12 24Vdc from PPC supply fee dc PEC TB50 controller 2010 Digital S Output SSR Figure 2 25 Powering Output with Separate Power Supplies 42 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Using the CPU Watchdog Signal The
140. Watlow Anafaze Warranty Watlow Anafaze Incorporated warrants that the products furnished under this Agreement will be free from defects in material and workmanship for a period of three years from the date of ship ment The Customer shall provide notice of any defect to Watlow Anafaze Incorporated within one week after the Customer s discovery of such defect The sole obligation and liability of Watlow Anafaze Incorporated under this warranty shall be to repair or replace at its option and without cost to the Customer the defective product or part Upon request by Watlow Anafaze Incorporated the product or part claimed to be defective shall immediately be returned at the Customer s expense to Watlow Anafaze Incorporated Replaced or repaired products or parts will be shipped to the Customer at the expense of Watlow Anafaze Incorporated There shall be no warranty or liability for any products or parts that have been subject to misuse accident negligence failure of electric power or modification by the Customer without the written approval of Watlow Anafaze Incorporated Final determination of warranty eligibility shall be made by Watlow Anafaze Incorporated If a warranty claim is considered invalid for any reason the Customer will be charged for services performed and expenses incurred by Watlow Anafaze Incorporated in handling and shipping the returned unit If replacement parts are supplied or repairs made during the original w
141. X Black 2 Termination TXB TDB TX Resistor Green 4 RXA RDA RX Red 3 RXB RDB RX White Blue 1 Signal Common DC Common Not Used Not Used Figure 2 72 Two Wire RS 485 Wiring PPCs Mounted Close Together In installations where two or more PPCs are close enough together that using terminal strips or modular jack junction boxes would result in greater lengths of flat cable than the distance between the communications ports use modular jack splitters and flat oval cables with RJ12 connectors on both ends See Figure 2 73 232 Communications 485 Communications mer 7 enal por optically shielded twisted pair cable J isolating Fi 232 to 485 converter AEN GL ii elet f lt UN HE 35 Hra z S S Se A EEEE e oom mee Er oo Fy 6 wire R
142. a Input c 202 connector gt I eee inputs 3 amp 4 HD 15 female es J3 Encoder O Input connectors E inputs 1 amp 2 2 HD 15 female J2 Analog a A Output Terminal S 44 Block al outputs 3 amp 4 z J1 Analog E2 Output Terminal ae Block 14 outputs 1 amp 2 Figure 2 39 PPC 2030 Connections Bottom View Connecting the Encoder Input Cable to the PPC 2030 NOTE Doc 30002 00 Rev 2 3 Connect the 15 pin HD cable s between J1 or J2 on the PPC 2030 shown in Figure 2 39 and the encoder input terminal block EITB Figure 2 40 on page 56 illustrates the EITB Table 2 15 on page 56 shows the EITB pinout and Table 2 18 on page 59 shows the HD D type connector pinout Analog Output Connections on page 60 discusses analog outputs from the PPC 2030 If more than one EITB has been installed it may be useful to label both ends of the HD 15 connector and each EITB with the corresponding module address and jack number Watlow Anafaze 55 Chapter 2 Hardware Installation EITB Connections Table 2 15 and Table 2 16 indicate the encoder connections to PPC 2000 User s Guide the EITB connected to the Encoder In Analog Out module Table 2 17 on page 57 lists the terminals that carry power n 6 pin 1 frn J i rp WU lo a jo ei is 40 lo RA I of Ont ES Bobs 2630 o rs lj ge
143. ads the binary contents of holding registers 4X references in the slave Broadcast is not supported Read Input Registers 04 Reads the binary contents of input registers 3X references in the slave Broadcast is not supported Force Single Coil 05 Forces a single coil 0X reference to either On or OFF When broadcast the function forces the same coil reference in all attached slaves Preset Single Register 06 Presets a value into a single holding register 4X reference When broadcast the function presets the same register reference in all attached slaves 276 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Appendix A Modbus Protocol Diagnostics 08 This function provides a series of tests for checking the communication system between the master and slave or for checking various internal error conditions within the slave Broadcast is not supported The function uses a two byte Sub function code field in the query to define the type of test to be performed The slave echoes both the function code and sub function code in a normal response Most of the diagnostic queries use a two byte data field to send diagnostic data or control information to the slave Some of the diagnostics cause data to be returned from the slave in a data field of a normal response Force Multiple Coils 15 Forces each coil OX reference in a sequence of coils to either ON or OFF When broadcast
144. age 99 for detailed information Process Variable High PV Hi Set this register to the value to be displayed when the signal is at the level set in Input Signal High see above See Setting PV Lo and PV Hi on page 99 for detailed information PV Offset Counter Reset This value is added to the scaled input before it is entered in the Input Value register for temperature sensor input types T Cs and RTDs For counter input types when this register is written to the count is set equal to the value written This can be used to reset or pre load counter values Channel Parameters in the Database Channel parameters determine the behavior of the PPC s 48 closed loop control channels Channels are not inherently associated with any particular hardware I O The user associates a channel with a particular input and output by setting the Process Variable Source and the Output Destination parameters Channel numbers are therefore selected at the users discretion Each channel does however have many parameters associated with it It is up to the user to make sure the channel parameters are appropriate for closed loop control Accessing Channel Parameters with Modbus For channel parameters the Modbus address offsets correspond to the channel numbers Note that channel numbers are not affected by the analog input selected as the Process Variable Source or the output selected as the Output Destination Heat Cool Output Dest For
145. aight Linear Output is unaffected and is set as calculated by the closed loop PID calculation e Lag Curve A Output is reduced somewhat from calculated value e Lag Curve B Output is further reduced from calculated value Straight linear is used for most applications Lag curves are usually used in plastic extruder applications 120 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter 3 Operating with AnaWin 3 100 Actual Output Applied Linear 40 20 Calculated Closed Loop Control Action as Figure 3 13 Output Scaling Heat Cool Curves With Lag Curve A or Lag Curve B selected a PID calculation results in a lower actual output level than the linear output requires This output is used when the response of the system to the output device is non linear Heat Cool Output Filter Use this menu to damp the heat or cool output s response The output responds to a step change by going to approximately 2 3 of its final value within the number of scans set here A larger number yields a slower or more damped control response to changes in the calculated output Range 0 to 100 scans 0 disables the filter Auto Heat Cool Limit Use this menu to limit the control output for a channel s heat and cool outputs This limit may be continuous or it may be in effect for a specified number of seconds see Heat Cool Limit Time b
146. al Message Count Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Appendix A Modbus Protocol Diagnostics Subfunction Return Bus Communication Error Count 12 0C Hex The response data field returns the quantity of CRC errors encountered by the slave since its last restart clear counters operation or power up Subfunction Data Field Query Data Field Response 00 0C 00 00 CRC Error Count Diagnostics Subfunction Return Bus Exception Error Count 13 OD Hex The response data field returns the quantity of Modbus exception responses returned by the slave since its last restart clear counters operation or power up Subfunction Data Field Query Data Field Response 00 0D 00 00 Exception Error Count Diagnostics Subfunction 14 OE Hex Return Slave Message Count The response data field returns the quantity of messages addressed to the slave or broadcast that the slave has processed since its last restart clear counters operation or power up Subfunction Data Field Query Data Field Response 00 0E 00 00 Slave Message Count Diagnostics Subfunction Return Slave No Response Count 15 OF Hex The response data field returns the quantity of messages addressed to the slave for which it returned a no response neither a normal response nor an exception response since its last restart clear counters operation or power up Subfunction Data Field Query Data
147. alog Terminal Board Keys Key ext Descriptions Color Code p Adapts AITB for EERE Yee Thermocouples differential or single ended none Linear voltages differential or single ended PPC KEY 30 Adapts AITB for 0 20mA linear current blue differential PPC KEY 40 Adapts AITB for 0 20mA linear current black single ended PPC KEY 50 Adapts AITB for 2 wire RTDs differential or red 3 wire RTDs differential Watlow Anafaze Chapter 1 Overview PPC 2000 User s Guide ANLO ANAFAZE PPC 2010 PPC 2021 PPC 2022 PPC 2025 PPC 2030 PPC 2040 PROCESSOR STATUSO ERRORO 1 2930 s8 ease90 1 E 16 ANALOG IN STATUSO ERRORO3 O4 MODULE OS 4 32 ANALOG IN STATUSO ERRORO3 O4 MODULE 4 16 ANALOG IN HIGH ISOLATION STATUSO ERRORO3 O4 4 ENCODER IN 4 ANALOG OUT STATUSO MODULE 32 DIGITAL 1 0 STATUSO ERRORO5 z no m N O YIN N ENB N a AZonaw 200000000 OO0000000 O OO 230 24 23500 2 700 8 20 30 30032 PXX XXXXX PXX XXXXX PXX XKXXX PXX XXXXX PXX XXXXX PXX XXXXX
148. alue set here is loaded as the Input Value when it is entered Enter 0 to reset a counter Range 32768 to 32767 Decimal placement depends on Input Type selected Watlow Anafaze 131 Chapter 3 Operating with AnaWin 3 Digital I O PPC PPC 2000 User s Guide Input Signal Lo For linear inputs see Setting up User Selectable Linear Inputs on page 98 enter the sensor signal level that corresponds to the low process value entered in PV Lo see below The input Signal Lo is entered in the units of the Input Type Range Depends on Input Type selected See Table 3 15 on page 130 Input Signal Hi For linear inputs see Setting up User Selectable Linear Inputs on page 98 enter the sensor signal level that corresponds to the high process value entered in PV Hi see below The Input Signal Hi is entered in the units of the Input Type selected Range Depends on Input Type selected See Table 3 15 on page 130 PV Lo For linear inputs see Setting up User Selectable Linear Inputs on page 98 enter a low process value Set this parameter to the value to be displayed when the signal is at the level set in Input Signal Lo see above The Input Value PV will not indicate a value less than the PV Lo regardless of how low the sensor signal dives The set point and alarm limits for an associated channel cannot be set to values less than PV Lo Range Depends on Decimal Places See Table 3 4 on page 100 PV Hi For lin
149. ambient Current The rate of flow of electricity The unit of mea sure is the ampere A 1 ampere 1 coulomb per second Watlow Anafaze 285 Glossary Custom Linear Input A user defined process input that represents a straight line function D Deadband The range through which a variation of the input produces no noticeable change in the output In the deadband specific conditions can be placed on control output actions Operators select the deadband It is usually above the heating propor tional band and below the cooling proportional band Default Parameters The programmed instructions that are perma nently stored in the microprocessor software Derivative Control D The last term in the PID algorithm Action that anticipated the rate of change of the process and compensates to minimize overshoot and under shoot Derivative control is an instantaneous change of the control output in the same direction as the proportional error This is caused by a change in the process variable PV that decreases over the time of the derivative TD The TD is in units of seconds Deviation Alarm Warns that a process has exceeded or fallen below a certain range around the setpoint Digital to Analog Converter DAC A device that converts a numerical input signal to a signal that is proportional to the input in some way Digital O T O that interfaces to 2 state field devices such limit switches or solid state relays
150. an be used for frequency or counter inputs or serial digital to analog SDAC outputs Refer to Table 5 37 on page 200 for specific information Watlow Anafaze 199 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide Table 5 37 Digital I O Uses PPC 2070 PPC 2071 Use PPC 2010 PPC 2040 PPC 2061 PPC 2062 PPC 2072 PPC 2073 Configurable I O points 1 24 1 32 n a n a n a n a Output only points 25 46 n a 1 16 1 8 n a n a Input only points n a n a n a n a 1 8 1 16 Pulse or counter inputs 1 1 2 n a n a n a n a Digital outputs that may k be used as SDACs 41 45 n a n a n a n a n a Reserved outputs Global Alarm CPU Watchdog 47 48 n a n a n a n a n a SDAC clock output 46 n a n a n a n a n a 200 Digital I O Parameters Table 5 38 lists the parameter number range and first and last Modbus addresses for each digital I O parameter These values are used when accessing digital I O parameters with third party software operator interface terminals or LogicPro programs All the digital I O parameters are 1 bit values and therefore have a range of 0 1 See the tables under the corresponding parameter descriptions for explanations of the possible settings Table 5 38 Digital I O Parameters Parameter BEUL Modbus nex Address Address State 130 0 1 00001 03560 0 DE7 Direction 132 0 1 01001 02000 3E8 7CF Logic 133 0 1 02001 03000
151. and 15 40451 40500 1C2 1F3 hig te ea Heat Integral 4 0 600 40151 40200 96 C7 Cool Integral 16 0 600 40501 40550 1F4 225 Heat Derivative 5 0 255 40201 40250 C8 F9 Cool Derivative 17 0 255 40551 40600 226 257 Spread 2 40051 40100 32 63 See explanation on p 181 Heat Manual Reset 8 0 1000 40301 40350 12C 15D Cool Manual Reset 20 0 1000 40601 40650 258 289 Control Type 19 0 4 46401 46450 1900 1931 Setpoint Source 7 0 324 40251 40300 FA 12B See explanation on p 182 Setpoint Ratio 9 30000 30000 40351 40400 15E 18F Setpoint Offset 14 32767 32767 40401 40450 190 1C1 See explanation on p 182 Maximum Setpoint 26 46451 46500 1932 1963 See explanation on p 182 Minimum Setpoint 27 46501 46550 1964 1995 See explanation on p 182 Output Parameters Heat Output Type 30 0 25 40651 40700 28A 2BB See Table 5 19 on page 183 Cool Output Type 45 0 25 41201 41250 2BCO 2BF1 See Table 5 19 on page 183 Heat Output Cycle Time 32 1 255 40751 40800 2EE 31F Cool Output Cycle Time 47 1 255 41301 41350 514 545 Heat Scale Lo 38 0 1000 41051 41100 41A 44B Cool Scale Lo 53 0 1000 41601 41650 2D50 2D81 Heat Scale Hi 39 0 1000 41101 41150 2B5C 2B8D Cool Scale Hi 54 0 1000 41651 41700 672 6A3 Heat Curve 35 0 2 40901 40950 384 3B5 See Table 5 21 on page 184 Cool Curve 50 0 2 41451 41500 5AA 5DB See Table 5 21 on page 184 Auto Heat Limit 33 0 1000 40801 40850 320 351 Auto Cool Limit 48 0 1000 41351 41400 546 577 Heat L
152. approximate a daisy chain as closely as possible Keep the distance from the point at which the wires are split to the PPC as short as possible Long spurs can cause destructive interference of the signals Color RJ Pin PPC 1 Color RJ Pin PPC N Yellow 5 Ra 7 External Termination Black 2 Resistor RB Green 4 White Blue 1 e Signal TA Red 3 8 m White Blue 1 Common Common Not Used Not Used Figure 2 71 RS 485 Wiring 485 Terminal Block 82 The 485 terminal block accepts an RJ12 cable connector and converts each line on the cable to a screw terminal Use the 485 terminal block to wire multiple PPC 2000 controllers together on the same 485 network Pins on the terminal block are designated 1 to 6 The function and number of each pin corresponds to the function and pin numbers of the 485 ports on the PPC 2010 module Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Table 2 30 485 Terminal Block Pin Assignment 485 Terminal Bok Pn pPPG2NOWS Function 1 1 Common 2 2 RB 3 3 TB 4 4 TA 5 5 RA 6 6 Not used S Not used Not used Cable Recommendations Watlow Anafaze recommends Belden 9843 or its equivalent This cable includes three 24 AWG shielded twisted pairs It should carry signals of up to 19 2 kbaud with no more than acceptable losses for up to 4000 feet
153. arranty period the warranty period for the replacement or repaired part shall terminate with the termination of the warranty period of the original product or part The foregoing warranty constitutes the sole liability of Watlow Anafaze Incorporated and the Cus tomer s sole remedy with respect to the products It is in lieu of all other warranties liabilities and remedies Except as thus provided Watlow Anafaze Inc disclaims all warranties express or implied including any warranty of merchantability or fitness for a particular purpose Please Note External safety devices must be used with this equipment Table of Contents iii List of Figures ix List of Tables xv Overview 1 Manual Contents 1 Getting Started 2 Safety symbols 2 Contacting Watlow Anafaze 2 Initial Inspection 2 Product Features 3 System Components 3 PPC 2000 Modules 6 PPC 2000 Terminal Boards 8 Additional Components 9 Safety 9 External Safety Devices 10 External Switch Disconnect 11 Battery Safety 11 Product Markings and Symbols 11 Hardware Installation 13 Power Supply Requirements 13 Mounting the Power Supply 15 Hardware Configuration 17 Module Addresses 17 PPC 2010 Jumper Settings 18 PPC 2030 Dip Switch Settings 19 PPC 2030 Jumper Settings 20 PPC 2040 Jumper Settings 21 PPC 205x Jumper Settings 22 Module Disassembly 26 Mounting Modules 26 DIN Rail Mounting 27 Doc 30002 00 Rev 2 3 Watlow Anafaze Table of Contents Table of Contents PPC
154. ary switch on the processor module Use setting D and PPCComSU to program the remaining addresses 5 32 Refer to Setting Programmable Modbus Addresses on page 87 for programming information Changed communication parameters do not take affect until the controller resets or cycles power and only with the appropriate rotary switch settings on the Processor module NOTE Do not cycle power with the rotary switch set in positions E G unless specifically directed to do so These positions are used for clearing memory and other functions Parameter settings can be lost See Chapter 4 Troubleshooting for more on these switch settings Table 5 47 Rotary Switch Configuration Position Network Address A Fixed 1 B Fixed 2 C Fixed 3 D Programmable Default 4 E G N A H Fixed 1 Doc 30002 00 Rev 2 3 Watlow Anafaze 207 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide 208 Switch settings A D have the following settings e 19 2 kbaud programmable e Even parity fixed e 8 data bits fixed e 1 stop bit fixed Switch setting H has the following fixed settings e 19 2 kbaud e Even parity e 8 data bits e 1 stop bit Switch settings E G are Reserved Table 5 48 lists the parameter number range and first and last Modbus addresses for the communications parameters Table 5 48 Communications Parameters Parameter BEULI Modbus Hex
155. asured by a thermocouple attached to the first input on an Analog In module with address 2 is accessed with the Analog_In_202x driver and the Logic Pro IO Physical Address 2 1 The LogicPro Database driver facilitates access to all database parameters Because the database is large it impractical and undesirable to list each LogicPro address Instead the parameter number and database offset range for each parameter are supplied Individual registers are addressed by coupling the parameter number and the database offset corresponding to the particular input output or channel Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference For example the parameter number for setpoint found in Table 5 12 on page 174 is 95 The database offset for channel parameters is channel number So using the Database IO Driver supplied with LogicPro the IO Physical Address for the setpoint of channel 23 is 95 23 Refer to the LogicPro User s Guide for detailed instructions on using the IO Drivers and creating logic programs Refer to this chapter of this manual for specific LogicPro IO Physical Addresses and parameter numbers Analog and Counter Input Parameters in the Database Analog input parameters determine how measurements of signals from sensors attached to modules are read and scaled into engineering units for use by closed loop control channels monitor channels and logic programs These
156. at 5 gps Separate feeder pipes for each chemical feed in to a common pipe The flow rate of each feeder pipe is measured by flow transducers providing 0 5Vdc signals to analog inputs on a PPC Motorized valves controlling the flow of each chemical are controlled by outputs from the PPC Figure 3 11 illustrates this application Channel 1 Input Channel 1 Output Channel 2 Output Channel 2 Input Mixture Out Figure 3 11 Sample Application Using Ratio Control In this application the first input on an Analog Input module is set up to convert the linear voltage signals from the flow sensors to gallons per second gps The water flow is controlled by channel 1 The KOH flow is controlled by channel 2 and is set up as the ratio channel The KOH flow set point must be half of the water flow value The process engineer doesn t want the KOH set point to exceed 15 gps regardless of the water flow Table 3 11 lists the channel parameter settings for the ratio KOH channel Table 3 11 Ratio Channel Parameter Settings Parameter Setting Description Set Point Source PPC1 Al 1 1 The PV Source of the master channel Set Point Ratio 05 KOH should flow at one half of the water flow rate When water flow is 0 gps the KOH flow Set Point Offset 0 gps should be 0 gps Min Set Point 0 gps When the water flow is 0 gps the KOH flow should be 0 gps Max Set Point 15 gps The KOH set point wil
157. be useful to label each module with the address you select Watlow Anafaze 17 Chapter 2 Hardware Installation PPC 2000 User s Guide Table 2 4 System Modules and Addressing Module Max Rotary Switch Address Range 2010 PROCESSOR 1 0 not switch selectable 2021 2022 ANALOG IN 2023 2024 2025 4 1 4 ANALOG IN HIGH ISOLATION 2030 ENCODER IN 4 11 14 ANALOG OUT 2040 DIGITAL I O 21 20 2050 2051 ANALOG OUT fe asa 2061 2062 DIGITAL OUT a haa 2070 2071 DIGITAL IN 120Vac 2072 2073 i oe DIGITAL IN 24Vac DC Maximum number of this type of module in a system PPC 2010 Jumper Settings Jumper settings in the PPC 2010 select whether the communication lines are terminated or not Each communication port is configured separately For installation information refer to Connecting RS 485 Communications on page 81 Wear a grounding strap and place components on static free grounded surfaces only Locate jumpers 1 and 2 Table 2 5 describes the PPC 2010 jumper configuration Install the jumper in the orientation shown in Figure 2 4 on page 19 Table 2 5 PPC 2010 Processor Module Jumpers Terminated Unterminated Port a Position Position 1 JU1 A B 2 JU2 A B 18 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Flash memory Chip firmware Termination Jumper Port 1 Chapter 2 Hardware Installation
158. cal 91 mm connections 3 00 in 76 mm Bi lo p p 468 in 119 mm Electrical connections 1 75 in 44 mm 5401 40 in 137 mm E Figure 2 19 SDAC Dimensions System Wiring A CAUTION 34 Successful installation and operation of the control system can depend on placement of the components and on selection of the proper cables sensors and peripheral components Routing and shielding of sensor wires and proper grounding of components can insure a robust control system This section includes wiring recommendations instructions for proper grounding and noise suppression and considerations for avoiding ground loops Never route low power circuits next to high power AC wiring Instead physically separate high power circuits from the controller If possible install high voltage AC power circuits in a separate panel Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation A CAUTION Power input or output circuits with hazardous voltage levels should not have any live accessible parts Wiring Recommendations Keep the following guidelines in mind when selecting wires and cables e Use stranded wire Solid wire can be used for fixed service but it makes intermittent connections when you move it for maintenance e Use 20 AWG TC extension wire Larger or smaller sizes may be difficult to install may break easily or may cause intermittent con
159. cate specific Modbus addresses Module A component of a PPC 2000 system which attaches and interfaces with other components Module I O Number Number designating each I O supported on a module For example a PPC 2021 has 16 analog inputs each input on the module has a unique designation from 1 to 16 O Offset The difference in temperature between the set point and the actual process temperature Offset is the error in the process variable that is typical of proportional only control Output Control signal action in response to the difference between setpoint and process variable Output Type The form of PID control output such as Time Proportioning Distributed Zero Crossing SDAC or Analog Also the description of the electrical hardware that makes up the output P Parameters The programmed instructions and readings that are stored in a microprocessor software 288 Watlow Anafaze PPC 2000 User s Guide Parity A communications error checking method in which the quantity of bits in each byte is deter mined to be odd or even If there is a discrepancy between the transmitter and receiver a communi cations error has occurred PID Proportional Integral Derivative A control mode with three functions Proportional action dampens the system response Integral corrects for droops and Derivative prevents overshoot and undershoot Pin Number Generic terminal block identification numbers which are correlat
160. ch output used for alarms as desired 5 Return to the Alarms spreadsheet Enable the alarm by setting the corresponding field LP Enable LD Enable HD Enable HP Enable to Enabled Watlow Anafaze 97 Chapter 3 Operating with AnaWin 3 PPC 2000 User s Guide 98 Setting up User Selectable Linear Inputs The Input Type and linear scaling fields Input Signal Lo Input Signal Hi PV Lo and PV Hi appear on the Inputs spreadsheet Linear input types are used with sensors whose signals are straight line linear functions of the quantity being measured For example a sensor that supplies a voltage signal proportional to the pressure it detects would use one of the linear input types and the signal would be converted to a process variable using the scaling values set on the Inputs spreadsheet To define the conversion function the user specifies two points on the line See Figure 3 3 20 PSI PV Hi Process Variable PV Lo 0 PSI l OV Input Signal Lo Input Signal Hi 10V Sensor Input Figure 3 3 Linear Input Example Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 3 Operating with AnaWin 3 Choosing a Linear Input Type To set up a linear input first choose an Input Type There are seven user selectable linear input types three input types for voltage signals one for current two for frequencies and one for counts Pick an Input Type with the appropriate signal type voltage curren
161. checking is used and two 1 bits are dropped from a character containing three 1 bits the result is still an odd count of 1 bits Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide CRC Checking Doc 30002 00 Rev 2 3 Appendix A Modbus Protocol If No Parity checking is specified no parity bit is transmitted and no parity check can be made An additional stop bit is transmitted to fill out the character frame All messages include an error checking field that is based on a Cyclical Redundancy Check CRC method The CRC field checks the contents of the entire message It is applied regardless of any parity check method used for the individual characters of the message The CRC field is two bytes containing a 16 bit binary value The CRC value is calculated by the transmitting device which appends the CRC to the message The receiving device recalculates a CRC during receipt of the message and compares the calculated value to the actual value it received in the CRC field If the two values are not equal an error results The CRC is started by first pre loading a 16 bit register to all 1 s Then a process begins of applying successive 8 bit bytes of the message to the current contents of the register Only the eight bits of data in each character are used for generating the CRC Start and stop bits and the parity bit if one is used do not apply to the CRC During generation of the CRC each 8 bit character is e
162. ct a measurable change in an analog output Soft Integer The Soft Int spreadsheet lists the values of each of the 2100 software integer registers set aside in the PPC database for exchanging data with the logic program PPC Channels Alarms Inputs Dig 1 0 Outputs Soft int Soft Bool PPC1 Soft Int 1 PPC1 Soft Int 2 PPC1 Soft Int 3 PPC1 Soft Int 4 Figure 3 25 Soft Int Spreadsheet Select the Soft Int button to monitor or edit the software integer values Double click a field to change the setting The left column in the spreadsheet lists the name of the register The name contains the PPC number the word and the register offset 1 2100 There is only one parameter on the Soft Int spreadsheet Value Value Software integer registers can be used to set or monitor values in logic program variables that have been linked to the corresponding database locations The registers are all read write but if a register is set as an output in the logic program the logic program updates its value and user entered values are disregarded Range 32768 to 32767 136 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Soft Boolean PPC Chapter 3 Operating with AnaWin 3 The Soft Bool spreadsheet lists the values of each of the 1000 software Boolean registers set aside in the PPC database for exchanging data with the logic program Channels Alarms Inputs Dig 1 0 Outputs Soft Int Sof
163. d by performing an autotune on each channel or by oth er means See Autotuning on page 93 or more infor mation on autotuning If both heat and cool outputs are used set the Spread Set the Set Point to the desired value and the Control Mode to Auto to begin closed loop control Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Autotuning Prerequisites Background Doc 30002 00 Rev 2 3 Chapter 3 Operating with AnaWin 3 Autotuning is a process by which a controller determines the correct PID parameters for optimum control Before autotuning the controller it must be installed with control and sensor circuitry and the thermal load in place It must be safe to operate the thermal system and the approximate desired operating temperature set point must be known The technician or engineer performing the autotune should know how to use HMI software interface e g AnaWin3 to perform the following e Set a channel s set point e Change a channel s control mode manual tune auto e Read and change the controller s parameters Autotuning is performed at the maximum allowed output If you have set a limit autotuning occurs at that value Otherwise the control output is set to 100 during the autotune Only the heat output of a channel may be autotuned The PID constants are calculated according to process s response to the output The channel need not reach or cross set point to successfully
164. d Cool Prop Band is the proportional band for the cool output A description for each parameter in Channels follows Doc 30002 00 Rev 2 3 Watlow Anafaze 115 Chapter 3 Operating with AnaWin 3 116 PPC 2000 User s Guide Set Point The set point is the desired value for the process variable Use this field to enter a set point for the selected channel If the set point entered is out of the defined range the controller assigns the closest number within the range Range same as the range of the input type selected See Table 3 14 on page 130 Process Variable This field shows the actual value measured by the sensor attached to the input selected in the PV Source field for the channel The process variable is used in the channel s feedback calculation This field is read only Range same as the range of the input type selected See Table 3 14 on page 130 Control Mode This parameter indicates the mode of control e Off Select this option to turn off closed loop control Any associated output will not be set by the closed loop control program and cannot be set manually or by a logic program e Manual Output is set by the user or a logic program See Heat Output and Cool Output earlier in this section e Auto Output is determined by the PID or on off control algorithm e Tune The loop determines and sets its proportional band derivative and integral parameters by setting the output and measuri
165. dc 100mA typical 25 C Current 24Vdc 50mA typical 25 C Modules per Processor 4 Table 7 56 Digital Input Specifications Number 8 PPC 2070 and 2072 16 PPC 2071 and 2073 Input Voltage Range 70 120Vac 10 PPC 2070 2071 12 24Vac de 10 PPC 2072 2073 Logic Voltage Levels 120Vac High gt 70V Low lt 20V 24Vac dc High gt 10V Low lt 3V Input Response Time 32 ms PPC 2070 2071 32 ms 12 24Vdc PPC 2072 2073 32 ms 20 24Vac PPC 2072 2073 64 ms 12 20Vac PPC 2072 2073 Input Impedance 77 kOhms PPC 2070 2071 16 9 kOhms PPC 2072 2073 Input Current 1 5mA typical 120Vac or 24Vac dc Switch Resistance to Pull Low 1 kOhms Maximum Switch Resistance for High Watlow Anafaze 27 kOhms Minimum 255 Chapter 7 Specifications PPC 2000 User s Guide PPC AITB 1 Analog Input Terminal Block Specifications 5 10 in H 130 mm 8882889882 ERRRRERHHETA 28 608 088 808f990 4 2 in W 107 mm 7 QO 35 37 6 I T HHARHHHEHE Figure 7 15 PPC AITB 1 Table 7 57 Environmental Specifications 4 70 in 119 mm Storage Temperature 20 to 70 C Operating Temperature Humidity 0 to 60 C 10 to 95 non condensing Table 7 58 Physical Specifications Weight 0 5 Ibs 0 22 kg
166. dentifies the basic steps 1 See Inputs on page 127 for descriptions of the input parameters On the Inputs spreadsheet a Choose the appropriate Input Type for the sensor con nected to each analog input you have wired Choose Units for each analog input For any linear voltage current or pulse sensors set the linear scaling parameters Input Signal Lo Input Sig nal Hi PV Lo and PV Hi See Setting up User Selectable Linear Inputs on page 98 See Channels on page 115 for descriptions of the channel parameters On the Channels spreadsheet a Choose the input in the PV Source field that you want to monitor or use as feedback for closed loop control for each channel Choose outputs in the Heat Output Dest and or Cool Out put Dest fields for each channel that you want to use for closed loop control Choose a Heat Cool Output Type for each output Set the Heat Cool Cycle Time for any outputs with Heat Cool Output Type set to Time Prop See Digital I O on page 132 for descriptions of the digital T O parameters On the Digital 1 0 spreadsheet a Set the Direction for each I O point to be used for con trol to Output On the Channels spreadsheet a Set the Heat Cool Prop Band for any outputs with Heat Cool Output Type set to On Off to 1 Set the PID parameters Heat Cool Prop Band Heat Cool Derivative and Heat Cool Integral for each output used for PID control The parameters may be determine
167. determine the PID parameters While autotuning the controller looks at the delay between when power is applied and when the system responds in order to determine the integral term Heat Cool Integral The controller also looks for the slope of the rising temperature to become constant in order to determine the proportional band Heat Cool Prop Band The derivative term Heat Cool Derivative is derived mathematically from the integral term When the controller has finished autotuning the channel s control mode switches to Auto If the process reaches 80 of the set point or the autotuning time exceeds ten minutes the controller switches to Auto and applies the PID constants it has calculated up to that point If the tune can not get good data the controller returns to its previous control state i e manual mode and leaves the PID parameters unchanged The Watlow Anafaze autotune is started at ambient temperature or at a temperature above ambient However the temperature must be stable and there must be sufficient time for the controller to determine the new PID parameters Watlow Anafaze 93 Chapter 3 Operating with AnaWin 3 Tuning Method PPC 2000 User s Guide The steps to autotune a channel are 1 SS Oe OV AR st In manual control set the set point to the value you will use for the autotune Note the value of the input filter Set the input filter to 0 scans Set the control mode to tune Wait for the chan
168. device Watlow Anafaze 43 Chapter 2 Hardware Installation PPC 2000 User s Guide Multiple SDAC Systems As many as 5 SDACs can be run from one PPC 2000 Be sure to provide sufficient current Use stranded 18 to 22 gauge wire for most installations Refer to Figure 2 27 for system setup Connect SDAC Pin 1 to the 5V terminal on the power supply Connect SDAC Pin 2 to the DC COM terminal on the power supply If a separate power supply is used connect the common to the DC COM on the PPC 2000 power supply Connect SDAC Pin 3 to the SDAC clock output on the TB50 digital output 46 Connect SDAC pin 4 to the desired control output on the TB50 digital output 41 45 Connect SDAC pins 5 and 6 to the input of the controlled device Daisy chain up to 5 SDAC PPC IPS 1 or other 5V Power Supply SDAC 5V 1 5V In DC COM 2 COMIn PPC 2010 43 CLKin Processor 4 Data ln DC COM Electrical W5 Out Isolation SCSI Po TB50 Connection 6 Out SDAC Clock 26 Control 141 to 45 Load Output Figure 2 27 Wiring Single Multiple SDACs 44 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Connecting Analog Inputs to the PPC 2021 2025 PPC 202X pe cto ggs Connector anaman an am am am a The Analog Input Terminal Board AITB connects to the analog input module through the SCSI connector bottom cente
169. dress Offsets Table 5 33 lists the LogicPro IO Physical Address Database Offsets and sample Modbus address corresponding to each digital I O point Table 5 33 Database Offsets and Sample Modbus Addresses for Digital I O i i 2 Modbus Addressin AnaWin3Name LogicPro I O Physical Address g Dig eee Processor_2010 Database Database Sample IO Driver IO Driver Offset Address PPC1 Proc 0 0 1 0 0 1 1 1 00001 PPC1 Proc 0 0 2 0 0 2 2 2 00002 PPC1 Proc 0 0 48 0 0 48 48 48 00048 The AnaWin3 names are shown for the first PPC 2000 in the system See Digital I O on page 132 for a full explanation of digital I O naming LogicPro Variable Type must be BOOL 3Use this address with the Processor_2010 IO Driver when addressing State 4Use this address with the Database IO Driver when addressing input parameters other than State Replace the with the parameter number from Table 5 38 on page 200 for the pa rameter you want to address Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference Table 5 34 Addresses for Digital I O on the PPC 2040 Digital I O Modules LogicPro I O Physical Address Modbus Addressing AnaWin3 Name g y Dig Ae a ae Digital_IO_2040 Database Database Sample IO Driver IO Driver Offset Address PPC1 DIO 21 0 1 21 0 1 49 49 00049 PPC1 DIO 21 0 2 21 0 2 50 50 00050 PPC1 DIO 21 0 32 21
170. dressing the Soft Boolean and Soft Integer Registers Global Parameters in the Database These system parameters are global and not relative to channels or I O hardware addresses Accessing Global Parameters with Modbus Some global parameters have only one Modbus address others use arange of addresses Table 5 48 on page 208 and Table 5 51 on page 209 list first and last Modbus address for the global parameters Use Modbus addresses when accessing global parameters with third party software or operator interface terminals See the parameter descriptions for addressing details Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference Accessing Global Parameters with LogicPro When a logic program variable accesses global parameters the parameter number and the offset are used in conjunction with the LogicPro Database I O driver The I O physical address is constructed from the parameter number and the database offset See the LogicPro User s Guide for specific instructions on addressing global parameters See Table 5 48 on page 208 and Table 5 51 on page 209 for the parameter number and the parameter descriptions for database offsets for each global parameter Communications Parameters For multiple PPC installations each PPC must have a unique network address As many as 32 PPC systems may communicate on a network Network addresses 1 through 4 can be set using the rot
171. e Conditions g n rales Doc 30029 00 284 Watlow Anafaze PPC 2000 User s Guide Erklart dass das folgende Produkt Deutsch Bezeichnung PPC 2000 Modell Nummern PPC 2 010 02X 040 05X 06X oder 07X PPC AITB PPC TB50 X anstelle einer Nummer 0 to 9 Klassifikation Offenes Prozessregelsystem Installationskategorie Il Verschmutzungsgrad II Nennspannung 12 bis 24 V DC Nennstromverbrauch 50 VA max Erfullt die wichtigsten Normen der folgenden Anweisung en der Europaischen Union unter Verwendung des wichtigsten Abschnitts bzw der wichtigsten Abschnitte die unten zur Befolgung aufgezeigt werden 89 336 EEC Elektromagnetische Kompatibilitatsrichtlinie EN 61326 1997 mit A1 1998 Elektrisches Ger t f r Messung Kontrolle und Laborgebrauch EMV Anforderungen Storfestigkeit Industriebereich Klasse A Emissionen Equipment ist nicht fur die Benutzung in Klasse B Emmisionsumgebung ohne zus tzliche Filter geeignet EN 61000 4 2 1996 mit A1 1998 St rfestigkeit gegen elektronische Entladung EN 61000 4 3 1997 St rfestigkeit gegen Strahlungsfelder EN 61000 4 4 1995 St rfestigkeit gegen schnelle St6Be Burst EN 61000 4 5 1995 mit A1 1996 St rfestigkeit gegen Uberspannung EN 61000 4 6 1996 Geleitete St rfestigkeit EN 61000 4 11 1994 St rfestigkeit gegen Spannungsabfall kurze Unterbrechungen und Spannungsschwankungen EN 61000 3 2 1995 mit A1 3 1999 Harmonische Stromemissionen
172. e 115 for more information on these parameters Control Output Signal Forms The output level calculated by the controller is represented by a percent 0 100 of power to be applied That value is applied on a digital or analog output according to the user selected output type See Output Control Forms on page 224 for more information on the output types available Heat and Cool Outputs The 48 control channels may each have one or two outputs Often a heater is controlled according to the feedback from a thermocouple and in that case only one output is needed In other applications it is possible that two outputs may be used for control according to one input If for example a system with a heater and proportional valve that controls cooling water flow are controlled according feedback from one thermocouple the channel has one input and two outputs In such systems provisions are made in the control algorithm to avoid switching too frequently back and forth between the heat and cool outputs The On Off algorithm uses the Spread parameter to prevent this bucking See Channels on page 115 for more information When PID control is used for one or both channel outputs both the spread and the PID parameters determine when control switches between heating and cooling Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter 3 Operating with AnaWin 3 The PPC 2000 provides two methods for co
173. e 2 7 PPC 2040 Counter Input Jumpers Counter Jumper Single Phase Quadrature Input PPC 2040 Position Position 1 JU1 A B 2 JU2 A B J LJ lt H eal Q O de N Figure 2 6 PPC 2040 Jumper Settings Doc 30002 00 Rev 2 3 Watlow Anafaze 21 Chapter 2 Hardware Installation 22 PPC 2000 User s Guide PPC 205x Jumper Settings Each of the analog outputs on the PPC 205x modules may be configured either as a voltage output or a current output A mixture of current and voltage outputs may be used on a particular module The jumpers only determine if the output signal is current or voltage The actual span of the signal is software selectable See Heat Cool Output Type in Channels section on page 119 for the various analog output signal settings To configure an output see Table 2 8 on page 22 and Figure 2 7 on page 23 to determine which jumper to set Set the jumper in the indicated position and orientation Table 2 8 PPC 205x Analog Out Jumpers Analog Jumper Jumper i current v voltage Output PPC 2050 PPC 2051 Position Position 1 JU1 JU1 0 20mA 0 10Vdc 2 JU2 JU3 0 20mA 0 10Vdc 3 JU3 JU5 0 20mA 0 10Vdc 4 JU4 JU7 0 20mA 0 10Vdc 5 JU5 n a 0 20mA 0 10Vdc 6 JU6 n a 0 20mA 0 10Vdc 7 JU7 n a 0 20mA 0 10Vdc 8 JU8 n a 0 20mA 0 10Vdc
174. e Sample IO Driver IO Driver Offset Address PPC1 DI 51 1 54 1 337 337 00337 PPC1 DI 51 2 51 2 338 338 00338 PPC1 DI 51 16 51 16 352 352 00352 PPC1 DI 52 1 52 1 353 353 00353 PPC1 DI 52 2 52 2 354 354 00354 PPC1 DI 52 16 52 16 368 368 00368 PPC1 DI 53 1 53 1 369 369 00369 PPC1 DI 53 2 53 2 370 370 00370 PPC1 DI 53 16 53 16 384 384 00384 PPC1 DI 54 1 54 1 385 385 00385 PPC1 DI 54 2 54 2 386 386 00386 PPC1 DI 54 16 54 16 400 400 00400 1The AnaWin3 names are shown for the first PPC 2000 in the system See Digital I O on page 132 for a full explanation of digital I O naming LogicPro Variable Type must be BOOL 3Use this address with the Digital_In_207x IO Driver when addressing State 4Use this address with the Database IO Driver when addressing digital I O parameters other than State Replace the with the parameter number from Table 5 38 on page 200 for the parameter you want to address Digital I O Uses Doc 30002 00 Rev 2 3 The Processor module and the Digital I O modules have 48 TO points each These modules have configurable I O Some or all of their points can be individually configured as either an input or an output by setting a bit in the Direction register 24 of the 48 I O points on the Processor module are configurable 22 I O points are fixed as outputs The remaining two I O points are reserved for the global alarm and CPU fail system OK signals Some I O points c
175. e analog output is isolated 12Vac individually from processor and bus power common In both voltage and current modes the return is to the analog common The PPC 2030 bottom panel includes two encoder input 15 pin HD connectors and two analog output connections with two 4 position plug type connectors Each signal has a dedicated return Status a LED Rotary Address Switch Figure 7 6 PPC 2030 Front View 240 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter 7 Specifications vr er 4 4 of 3 e J4 Encoder Input Connectors HD 15 female J3 Encoder Input Connectors HD 15 female J2 Analog ae Output Terminal Block Le 1 7 J1 Analog Output Terminal Block Figure 7 7 PPC 2030 Bottom View Table 7 22 Model Number PPC 2030 4 Encoder Inpu t 4 Analog Output Module Table 7 23 Environmental Specifications Storage Temperature 20 to 70 C Operating Temperature 0 to 60 C Humidity 10 to 95 non condensing Table 7 24 Physical Specifications Weight 0 62 lbs 0 28 kg Height 8 0 in 203 mm Width 1 5 in 38 mm D
176. e connected to either contact DC or AC power may be switched See Figure 2 60 on page 72 for an example of how to connect to the relay outputs Watlow Anafaze 71 Chapter 2 Hardware Installation PPC 2000 User s Guide AC or DC Source AC or DC Source Figure 2 60 Relay Output Connections on a PPC 2062 Outputs 1 and 2 Shown Table 2 23 Relay Output Connections on PPC 206x Digital Output Modules Digital Out Module Connections AnaWin3 Name 72 Module Dig I O Spread 1 0 Number PPC 2061 1 PPC 2062 sheet Out Com Digital Out 1 1 C1 1A 1B PPC1 DO 41 1 Digital Out 2 2 C1 2A 2B PPC1 DO 41 2 Digital Out 3 3 C1 3A 3B PPC1 DO 41 3 Digital Out 4 4 C1 4A 4B PPC1 DO 41 4 Digital Out 5 5 C1 5A 5B PPC1 DO 41 5 Digital Out 6 6 C1 6A 6B PPC1 DO 41 6 Digital Out 7 7 C1 7A 7B PPC1 DO 41 7 Digital Out 8 8 C1 8A 8B PPC1 DO 41 8 Digital Out 9 9 C2 n a n a PPC1 DO 41 9 Digital Out 10 10 C2 n a n a PPC1 DO 41 10 Digital Out 11 11 C2 n a n a PPC1 DO 41 11 Digital Out 12 12 C2 n a n a PPC1 DO 41 12 Digital Out 13 13 C2 n a n a PPC1 DO 41 13 Digital Out 14 14 C2 n a n a PPC1 DO 41 14 Digital Out 15 15 C2 n a n a PPC1 DO 41 15 Digital Out 16 16 C2 n a n a PPC1 DO 41 16 The AnaWin3 name is shown for the Digital Out module with address 41 on the first PPC 2000 in the system See Digital I O on page 132 for a full explanation of Digital I O naming Watlow Anafaze
177. e following LEDs light for status or diagnostic purposes e Green Function operational communications status tx e Red Fault e Yellow Communication status rx e Orange Processor reset due to low power condition or watchdog timeout PPC 2010 Processor The processor provides a System OK circuit for monitoring program and microcontroller integrity The output of the watchdog timer is available through the 50 pin I O header on the processor board This is an open collector type output up to 100mA and will sink current to common when the processor is operating properly An open circuit indicates a processor failure and remains open until proper operation is established Doc 30002 00 Rev 2 3 Watlow Anafaze 141 Chapter 4 Troubleshooting 142 PPC 2000 User s Guide Firmware Installation Procedures A CAUTION Changing the firmware on the processor module involves minor mechanical disassembly and reassembly of the controller Appropriate precautions should be taken to prevent electrostatic discharge damage to the electronic components Wear a grounding strap and place components on static free grounded surfaces only A small flathead screwdriver is needed All control parameters will revert to factory defaults when installing a new flash memory chip containing controller firmware Take a snapshot of the current configurations using AnaWin3 before removing the flash memory chip The flash memory chip also sto
178. e modbus addresses for Inputs range from 10001 to 19999 decimal Holding Registers Holding registers are 16 bit size they store values from 32 768 to 32 767 Software interfaces may read or write the values stored in these registers Some of the PPC 2000 parameters stored in holding registers have more limited ranges than the register size The modbus addresses for holding registers range from 40001 to 49999 Input Registers Input registers are 16 bit in size they store values from 32 768 to 32 767 Software interfaces may read but not write the values stored in these registers The PPC 2000 uses these registers to store analog and encoder input values The Modbus addresses for the input registers range from 30001 to 39999 Doc 30002 00 Rev 2 3 Watlow Anafaze 161 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide 162 Accessing the Database with Modbus Each register can be individually accessed using software and the Modbus communications protocol via a serial port on the processor module because each register has a unique Modbus address The Modbus address for each parameter is given in sections Analog and Counter Input Parameters in the Database on page 163 through Global Parameters in the Database on page 206 Because the database is quite large it is impractical and undesirable to list each Modbus address Instead the first and last addresses for each parameter are listed Individual registers are addr
179. e module See Chapter 7 Specifications Units For temperature sensors choose the temperature scale for the input value For custom linear and pulse type inputs choose a three character description of the input s engineering units Table 3 16 Units Input Character Sets for Units T C and RTD F or C Linear or Pulse 0 to 9 A to Z degrees space Decimal Places Set the Decimal Places parameter to determine how many decimal places are entered and displayed in the Process Variable Set Point and alarm limits for channels with the corresponding input selected as the PV Source The range for Decimal Places is limited by the range of the PV to be displayed The more decimal places to be displayed the smaller the range of PV that can be displayed The greater the difference between the PV Lo and PV Hi the fewer the decimal places that can be displayed Input Filter Set the filter value to damp changes to the process variable The process variable used to calculate the outputs responds to a step change by going to approximately 2 3 of its final value within the number of scans set here A larger number yields a slower or more damped response to changes as measured by the sensor Range 0 to 255 scans 0 disables the filter PV Offset Enter a number to adjust the reading of an Input Value For T Cs and RTDs the value entered here is added to the temperature measurement For counter inputs the v
180. ear inputs see Setting up User Selectable Linear Inputs on page 98 enter a high process value Set this parameter to the value to be displayed when the signal is at the level set in Input Signal Hi see above The Input Value PV will not indicate a value greater than the PV Hi regardless of how low the sensor signal rises The set point and alarm limits for an associated channel cannot be set to values higher than PV Hi Range Depends on Decimal Places See Table 3 4 on page 100 Parameters on the Dig I 0 spreadsheet determine the state and behavior of digital or discrete inputs and outputs found on the PPC s processor and digital I O modules Channels Alarms Inputs a se m Soft Bool State irection gic Fun Output 1 On Alarm Oul Output 1 On Alarm Oul Output 1 On Alarm Oul Output 1 On Alarm Oul 132 Figure 3 20 Dig I O Spreadsheet Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter 3 Operating with AnaWin 3 Select the Dig 1 0 button to configure or monitor PPC Digital I O parameters TO names are located in the first column The I O names identify each I O point Names for Processor PPC 2010 and Digital I O PPC 204X modules differ slightly from Digital Out PPC 206X and Digital In PPC 207X names Processor and Digital I O names include an I O type designator because those modules support digital count and frequency types For example a Processor I O name
181. ect modules that are powered Mounting Modules A WARNING A CAUTION NOTE 26 Once the modules have been assembled the PPC system may be mounted on a DIN rail or fastened directly to a vertical surface inside an electrical cabinet or other enclosure that requires a key or tool to open or that has a safety interlock system Consult Table 7 2 on page 230 and Figure 7 1 on page 230 to determine mounting hole spacing and installed clearances See Figure 1 1 on page 4 for a sample configuration of PPC system hardware Install the PPC 2000 in a controlled environment relatively free of contaminants to reduce the risk of fire or electric shock The controller may function incorrectly if the ambient temperature exceeds the operating specification Make sure the air temperature surrounding the controller does not exceed 140 F 60 C During wiring and cabinet assembly prevent debris from falling inside the PPC by removing the unit from the area or cover the ventilation holes on the PPC system Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation DIN Rail Mounting 1 Each module in the assembly has a DIN rail latch Pull all the latches to the open position See Figure 2 11 DIN Rail Latch closed DIN Rail Latch open Figure 2 11 DIN Rail Latches 2 Place the module assembly on the upper lip of the DIN rail push the lower side of the assembly ov
182. ed loop control Click the Start Logic button on the PPC Globals screen to start the logic program if desired Watlow Anafaze 157 Chapter 4 Troubleshooting PPC 2000 User s Guide 158 Watlow Anafaze Doc 30002 00 Rev 2 3 LogicPro and Modbus Reference Overview This chapter is designed for engineers and technicians tasked with setting up third party software or an operator interface terminal for operating and monitoring of a PPC System The parameter addressing described in this chapter applies to firmware versions 2 0 released 9 1 99 and later This chapter provides information needed to address parameters when writing programs using LogicPro For instructions on operating the Watlow Anafaze software AnaWin3 with your PPC system refer to Chapter 3 Software Setup Text Conventions in the Database Sections Table 5 1 shows the parameter names and abbreviations as seen in AnaWin3 Parameter names are shown as a reference only for programming purposes Table 5 1 Parameter Names amp Abbreviations Abbreviation Parameter SP Setpoint PV Process Variable HP High Process LP Low Process HD High Deviation LD Low Deviation Doc 30002 00 Rev 2 3 Watlow Anafaze 159 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide 160 A special font or typeface is used to indicate parameter names and text seen in the AnaWin3 screens Process Variable Low PV Lo Set this parameter
183. ed back to the controller The following table displays information for sample packet for host transmission Table A 5 shows the query and Table A 6 shows the response Table A 5 Sample Packet for Host Query Slave Address Address Data Data Example address Function High Low High Low CRC Writing loop 1 PB 20 controller 4 04 06 0C 1C 00 14 4B 06 single point write Writing digital output 300r 02 05 0B D5 FF o0 9F D5 controller 2 single coil write Table A 6 Sample Packet for Slave Response Slave Address Address Example Address Function High Low CRC Writing loop 1 PB 20 04 06 oC 1C 4B 06 controller 4 single point write Writing digital out put 30 0n con gt 02 05 0B D5 FF oo 9F D5 troller 2 single coil write Doc 30002 00 Rev 2 3 Watlow Anafaze 281 Appendix A Modbus Protocol PPC 2000 User s Guide 282 Watlow Anafaze Doc 30002 00 Rev 2 3 B Appendix B Declaration of Conformity Doc 30002 00 Rev 2 3 Watlow Anafaze 283 Appendix B Declaration of Conformity Declaration of Conformity Series PPC 2000 CE WATLOW Anafaze 314 Westridge Drive Watsonville California 95076 USA Declares that the following product English Designation Model Numbers PPC 2000 PPC 2 010 02X 040 05X 06X or 07X PPC AITB PPC TB50 X denotes any number 0 9 Open Type Process Control Equipment nsta
184. ed to module I O numbers in terminal block identification tables for wiring Polarity The electrical quality of having two opposite poles one positive and one negative Polarity determines the direction in which a current tends to flow Process Variable The parameter that is controlled or measured Typical examples are temperature relative humidity pressure flow fluid level events etc The high process variable is the highest value of the process range expressed in engineering units The low process variable is the lowest value of the process range Proportional P Output effort proportional to the error from set point For example if the proportional band is 20 and the process is 10 below the setpoint the heat proportioned effort is 50 The lower the PB value the higher the gain Proportional Band PB A range in which the proportioning function of the control is active Expressed in units degrees or percent of span See PID Proportional Control A control using only the P proportional value of PID control Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Protocol A set of rules and formats governing a serial or parallel communication channel Pulse Input Digital pulse signals from devices such as opti cal encoders R Range The area between two limits in which a quantity or value is measured It is usually described in terms of lower and upper limits Register A controller memory locat
185. eeds 150mA Check to make sure the I O wiring is correct See Con necting I O to the PPC 2040 on page 61 Doc 30002 00 Rev 2 3 Watlow Anafaze 151 Chapter 4 Troubleshooting 152 PPC 2000 User s Guide PPC 2050 Analog Out Refer to the following descriptions of LED indicators when troubleshooting the analog output module Green Status LED remains off on or blinks incorrectly When the module is correctly functioning the green LED blinks If the LED remains off on or blinks incorrectly the module may not be functioning correctly Corrective Actions Make sure the rotary switch is set to the proper module address Each module must have a unique address Cycle power to PPC 2000 system Check that the modules are connected properly refer to Module Assembly on page 24 Perform a RAM clear refer to Resetting Closed Loop Control Parameters on page 156 Replace the module Green Status LED is blinking but outputs are not functioning correctly Corrective Actions Check to make sure the I O wiring is correct See Con necting Analog Outputs to the PPC 205x on page 67 Check that the jumpers are set correctly See PPC 205x Jumper Settings on page 22 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 4 Troubleshooting PPC 206x Digital Out Refer to the following descriptions of LED indicators when troubleshooting the digital output module Green Status LED remains off on or bl
186. egister contains a value of 2506 the actual measure value is 25 06mV because the values in the register are in units of hundredths of a millivolt Watlow Anafaze 169 Chapter 5 LogicPro and Modbus Reference 170 Table 5 10 Input Types PPC 2000 User s Guide Value AnaWin3 Name Range Units 0 No Input N A N A 1 Volts 1 to 10Vdc 1000 to 10000 mV 2 Volts 0 5 to 5Vdc 500 to 5000 mV 3 Volts 0 1 to 1Vdc 1000 to 10000 0 1mV 4 Spare N A N A 5 Volts 50 to 500mVdc 500 to 5000 0 1mV 6 Volts 10 to 100mVdc 1000 to 10000 0 01mV 7 Volts 5 to 50mVdc 500 to 5000 0 01mV 8 9 Spare N A N A 10 Linear 1 to 10 V 1000 to 10000 mV 11 Linear 0 1 to 1 V 1000 to 10000 0 1mV 12 Linear 10 to 100 mV 1000 to 10000 0 01mV 13 Linear 2 to 20 mA 2000 to 20000 0 01mA 14 Linear Counts 32767 to 32768 Counts 15 Linear 0 to 10k Hz 32767 to 32768 Hz 16 Linear 0 to 300 Hz 32767 to 32768 0 01Hz 17 19 Spare N A N A 20 Current 0 20mA 0 to 20000 0 1mA 21 Current 4 20mA 40 to 20000 0 1mA 22 Spare N A N A 23 Counter 32767 to 32768 counts 24 Frequency 10000 to 10000 Hz 25 39 Spare N A N A 31 100K ohm Thermistor 2500 to 32760 F 0 01 F 40 B T C 1 F 32 to 3308 1 41 C T C 1 F 32 to 4200 1 F 42 D T C 1 F 32 to 4200 1 F 43 E T C 0 1 F 4540 to 12210 0 1 F 44 J T C 0 1 F 34
187. elow If you choose a timed limit the heat cool limit restarts when the controller powers up and when the channel changes from Manual to Automatic control The heat cool limit only affects channels under automatic control It does not affect channels under manual control Range 0 0 to 100 0 Watlow Anafaze 121 Chapter 3 Operating with AnaWin 3 122 PPC 2000 User s Guide Heat Cool Limit Time Set a time limit for the Auto Heat Cool Limit If set to 0 the heat cool limit is in affect whenever the channel is in automatic control Range 0 to 32767 seconds Heat Cool Scale Lo A control output may be linearly scaled by setting this parameter Enter the percent of the output range of the selected Heat Cool Output Type that should correspond to a calculated Heat Cool Output of 0 Range 0 0 to 100 0 Heat Cool Scale Hi A control output may be linearly scaled by setting this parameter Enter the percent of the output range of the selected Heat Cool Output Type that should correspond to a calculated Heat Cool Output of 100 Range 0 0 to 100 0 Sensor Fail Heat Cool When a failed sensor alarm occurs on a channel under automatic control that channel goes to manual control at the percent power output set here Enter the default percentage to which a channel s output is set if its input sensor fails Range 0 0 to 100 0 Spread Enter the offset between heat and cool modes when both heat and cool
188. epth 5 25 in 133 mm Watlow Anafaze 241 Chapter 7 Specifications PPC 2000 User s Guide Table 7 25 Connections Mounting DIN rail or panel mount Terminals Captive screw cage clamp Gohnecior High Density D sub 15 female contact Screw Terminal Wire Gauge Screw Terminal Torque 24 to 16 AWG 0 22 to 0 25 Nm 1 9 to 2 2 in lb Table 7 26 Power Specifications Power Requirement 10 8 W typical Current 12Vdc 900mA typical 25 C Current 24Vdc Modules per Processor 450mA typical 25 C 4 Table 7 27 Input Specifications Encoder Inputs 4 Maximum Input Frequency 10 kHz Max Counts Sample Rate 10 000 counts sec single phase 32 000 counts sec quadrature 250 ms to sample all 4 inputs 4 Hz Pulse Input Voltage Range Single ended 3 0 V lt V lt 5 0V 0 0 V lt V lt 2 0 V Pulse Input Voltage Range Differential 14 0 max 0 0 to 5 0V nominal Input Current Single ended 1 0mA Input Current Differential Count Range 3 0mA 16 bits Power for Encoders 5V 240mA max Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter 7 Specifications Table 7 28 Output Specifications Analog Outputs 4 Isolation 120Vac to power common or ground Resolution 12 bits Range Voltage Mode 0 to
189. er a similar interval of at least 3 5 character times marks the end of the message A new message can begin after this interval Similarly if a new message begins earlier than 3 5 character times following a previous message the receiving device will consider it a continuation of the previous message This will set an error as the value in the final CRC field will not be valid for the combined messages An example message frame is shown in Table A 1 Table A 1 Example Message Frame CRC Start Address Function Data Check End T1 T2 T3 T4 8 Bits 8 Bits n X 8 Bits 16 Bits T1 T2 T3 T4 Watlow Anafaze 271 Appendix A Modbus Protocol 272 Address Field Function Field PPC 2000 User s Guide The address field of a message frame contains eight bits Valid slave device addresses are in the range of 0 247 decimal The individual slave devices are assigned addresses in the range of 1 247 Address 0 is reserved for broadcast messages The PPC controller currently supports only 32 devices A master addresses a slave by placing the slave address in the address field of the message When the slave sends its response it places its own address in this address field of the response to let the master know which slave is responding The function code field of a message frame contains eight bits Valid codes are in the range of 1 255 decimal Not all these codes are applicable to PPC controllers Current codes are
190. er can initiate transactions called queries The other devices slaves respond by supplying the requested data to the master or by taking the action requested in the query Typical master devices include host PCs and operator panels The PPC 2000 is a slave device The master can address individual slaves or initiate a broadcast message to all slaves Slaves return a message called a response to queries that are addressed to them individually Responses are not returned to broadcast queries from the master The Modbus protocol establishes the format for the master s query by placing into it the device or broadcast address a function code defining the requested action any data to be sent and an error checking field The slave s response message is also constructed using Modbus protocol It contains fields confirming the action taken any data to be returned and an error checking field If an error occurred in receipt of the message or if the slave is unable to perform the requested action the slave will construct an error message and send it as its response Watlow Anafaze 269 Appendix A Modbus Protocol 270 Query Response PPC 2000 User s Guide Query Message from Master Device Address Function Code Device Address Function Code EightBit __ EightBit __ Data Bytes _ DataBytes _ Error Check Error Check Response Message from Slave
191. er Specifications System Power Requirement 12 to 26 2 Vdc Power 3 W typical Current 12Vdc 250mA typical 25 C Current 24Vdc 125mA typical 25 C Max Voltage between Ground and Common ae Table 7 8 Capacity and Programming Digital I O Points on Processor 46 Max Number Digital I O Points 288 Max Number of Counter Inputs 17 Max Number of Additional I O Mod ules 9 Max Number of Analog Inputs 128 Max Number of Analog Outputs not counting DACs SDACs Program Capacity 48 Requires 4 PPC 2030 and 4 PPC 2050 Logic program memory 128 kB Data memory in battery back RAM 60 kB Programming Language IEC1131 3 compliant Ladder Diagram SFC and FBD Number of Instructions 7 logic instructions 42 applied instructions Logic Program Storage Flash memory Logic Programming Software LogicPro Operating System for Programming Windows95 98 Software WindowsNT Watlow Anafaze 233 Chapter 7 Specifications PPC 2000 User s Guide Table 7 9 Control Specifications Control Modes On Off P PI or PID 48 programmable channels Chan nels may be single or dual output Number of Control Loops Time proportioning Distributed Zero Control Outputs Crossing On Off or analog all inde pendently selectable for each loop Time Proportioning 1 to 255 seconds Cycle Time Control Actio
192. er the lower lip of the DIN rail See Figure 2 12 Upper lip of DIN Rail DIN Rail Latch open Push to lock Figure 2 12 Mounting Assembled PPC Modules on a DIN rail side 3 Push the DIN rail latches up and under the lower lip of the DIN rail Doc 30002 00 Rev 2 3 Watlow Anafaze 27 Chapter 2 Hardware Installation PPC 2000 User s Guide 28 Panel Mounting The PPC modules may be panel mounted using the mounting holes located on the end plates The width of a system varies depending on the number of modules Consult Figure 7 1 on page 230 to determine installed clearances To panel mount the modules 1 Locate a space with sufficient room for the appropriate number of modules and connecting wires Refer to Figure 7 1 on page 230 for a system footprint and dimensions 2 The mounting holes are located on the end caps of the module assembly Mark each mounting hole 3 Drill and tap the four 10 mounting holes 4 Place the modules such that the holes are aligned insert the screws and tighten them Mounting Terminal Boards Terminal boards support interfacing field I O devices with the PPC modules All terminal boards may be DIN rail or panel mounted The following sections provide procedures for mounting the terminal boards There are smaller holes on each terminal board that may be used to secure wiring with tie wraps Refer to Figure 2 13 on page 29 for AITB dimensions Refer to Figure 2 14 on pa
193. er written logic programs Logic programs are stored along with the controller firmware in nonvolatile memory Consult the LogicPro User s Guide for specific instructions on how to write compile and download logic programs to the PPC 2000 NOTE If an output variable in a logic program sets a value using an IO Driver and IO Physical Address the associated register in the PPC 2000 cannot be written to by the closed loop control program an HMI or any other device 112 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 3 Operating with AnaWin 3 Setting up Analog Inputs for Use with a Logic Program The closed loop control program updates any analog input whether it is selected as the source for a channel or not A logic program can read and use the scaled Input Value from the PPC s datatable Set up the input as you would for a closed loop control channel Select an Input Type set the Units and set scaling parameters if using a Linear Input type See Setting up User Selectable Linear Inputs on page 98 Setting up Outputs for Use with a Logic Program Various types of conditioned outputs are available for logic programs These outputs include digital outputs conditioned for time proportioning DZC SDAC and analog outputs scaled in units of 0 0 to 100 0 Conditioned outputs are not accessed directly from the I O physical address but rather through channels output address See Accessing Channel Paramet
194. ers with LogicPro on page 173 In order to have the logic program write to these outputs a loop must be set up with the output destination output type and PV source An unused input may be used for the PV source The loop should be in Manual mode The logic program can then write to the Heat or Cool Output and the Heat or Cool Output Type will determine the kind of conditioning performed Using Logic to Set an Analog Input A logic program can set a process variable by outputting a value to one of the Soft Input registers The Soft Inputs show up on the Inputs Spreadsheet and the list of options for PV Source in AnaWin To use the logic calculated value select the Soft Input as the PV Source and set up the channel as usual Starting and Stopping Logic Programs Doc 30002 00 Rev 2 3 After developing and downloading a logic program with LogicPro use the PPC Globals screen in AnaWin3 to start and stop the logic program To start the logic program 1 Select the View menu 2 Select PPC Globals 3 Double click on the Start Logic Program button 4 Click on the Send button to command the PPC to start the logic program Or click Cancel Watlow Anafaze 113 Chapter 3 Operating with AnaWin 3 114 A CAUTION A CAUTION A CAUTION A CAUTION PPC 2000 User s Guide The logic program will begin executing immediately after clicking the Send button Assure that the equipment is in a safe conditi
195. essed by determining the offset from the first address corresponding to the particular input output or channel For example in a PPC 2000 system with 32 analog inputs on one module the register addresses for inputs 1 32 are 30601 to 30632 The measured value corresponding to the first analog input is stored at address 33601 The value of the second input is stored at address 33602 The value of input 26 is stored at address 30626 and so on The Database Offset for the first analog input is said to be 1 for the second input is 2 and for the 26th input is 26 In each section describing a database table the Database Offset scheme is explained How LogicPro Accesses the Database Logic programs can be written and downloaded using LogicPro Typically such programs access digital and or analog T O and may also access other values stored in the database Because the user written logic program resides in the processor module it does not use the serial port or Modbus to access the database Instead each register can be accessed by logic program variables using one of the I O drivers supplied with LogicPro Some drivers correspond to modules These drivers are used to access the digital and analog I O values corresponding to the field devices connected to each module The LogicPro IO Physical Address is used in conjunction with these module specific drivers to use a digital or analog I O value ina logic program For example the value me
196. eter has no effect on control if the Control Type for the loop is set to an option other than Adaptive Values Automatic 0 and 1 1 to 600 seconds 600 Default Automatic 0 Modbus Address Channels 1 to 32 49051 to 49082 Parameter Number 28 LogicPro Driver Database LogicPro Address Channels 1 to 32 28 1 to 28 32 This parameter indicates the amount of delay in seconds in the load This characteristic of the load or plant has a significant impact on adaptive control A larger number indicates a longer delay between for example an increase in heater power and an increase in the temperature Values Aggressive 0 Nominal 1 Damped 1 2 Damped 2 3 Damped 3 4 and Damped 4 5 Default Nominal 1 Modbus Address Channels 1 to 32 46551 to 46682 Parameter Number 29 LogicPro Driver Database LogicPro Address Channels 1 to 32 29 1 to 29 32 Figure 1 The Effect of Tuning Gain on Recovery from a Load Change Load Change Process Variable deviates from Set Point L ow Tune Gain More Conservative Process Variable Temperature Time Using Adaptive Control Adaptive Addendum 0600 0049 0001 rev C To set up adaptive control on one or more channels 1 Open the Spreadsheet Overview screen in ANAWIN3 2 On the Inputs spreadsheet for each analog input you have wired a Choose the appropriate Input Type for the sensor b Choose Units c For any linear voltage current
197. etries of the message to try diagnostic messages to the slave and to notify operators Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Data Field Appendix A Modbus Protocol The contents of the data field varies depending on whether messages originate from a master or slave Data fields in slave messages consist of hexadecimal values Data fields of master messages contain additional information which the slave must use to take the action defined by the function code This can include items like digital and register addresses the quantity of items to be handled and the count of actual data bytes in the field For example if the master requests a slave to read a group of holding registers function code 03 the data field specifies the starting register and how many registers are to be read If no error occurs the data field of a response from a slave to a master contained the data requested If an error occurs the field contains an exception code that the master application can use to determine the next action to be taken The data field can be nonexistent of zero length in certain kinds of messages where the function code alone specifies the action Error Checking Field Field Format Doc 30002 00 Rev 2 3 The error checking field contains a 16 bit value implemented as two 8 bit bytes The error check value is the result of a Cyclical Redundancy Check calculation performed on the message contents
198. event process and deviation alarms from toggling on and off when the process variable is near the alarm limit set point For high alarms the deadband is below the set point for low alarms the deadband is above the set point An alarm that occurs when the process variable crosses the alarm set point will not clear until the process returns within the alarm set point and the deadband value The default alarm deadband is 2 Range Depends on the input type selected Alarm Delay Set this parameter to delay alarm reporting Use this feature to prevent false alarms due to noise on sensors The alarm delay applies to failed sensor alarms and process and deviation alarms Only alarms that are present for longer than alarm delay time are reported Range 0 to 100 seconds Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 3 Operating with AnaWin 3 Inputs Parameters on the Inputs spreadsheet determine how measurements of signals from sensors attached to the analog input modules are read and scaled into engineering units for use by closed loop control channels monitor channels and logic programs PPC Channels Alarms Inputs Dig 1 0 Outputs Soft Int Soft Boot Soft Bool No Problem Linear 1 to 10 PSI No Problem J T C F No Problem J T C F No Problem J T C F Figure 3 15 Inputs Spreadsheet module address Waa type abbreviation controller number PPC1 sAI 1 fo Peele
199. example register addresses for Heat Proportional Band Heat Prop Band for channels 1 48 are 43101 to 48148 Channel 1 s Heat Proportional Band is stored at address 43101 Channel 2 s Heat Proportional Band is stored at address 43102 and so on Table 5 12 on page 174 lists first and last Modbus addresses for each channel parameter Use these addresses when accessing channel parameters with third party software or operator interface terminals Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference Accessing Channel Parameters with LogicPro When a logic program variable accesses a channel parameter the parameter number and the channel number database offset are used in conjunction with the LogicPro s Database IO Driver The IO Physical Address is constructed from the parameter number and the channel number See the LogicPro User s Guide for specific instructions on addressing channel parameters See Table 5 12 on page 174 for channel parameter numbers Channel Parameters for Heat and Cool Outputs Each of the PPC s closed loop control channels may have one or two outputs heat and or cool Many of the channel parameters may be independently set for the heat and cool outputs and therefore have two registers in the database For example Heat Proportional Band Heat Prop Band is the proportional band for the heat output and Cool Proportional Band Cool Prop Band is t
200. f the primary channel is used to adjust the set point of the secondary channel The secondary channel executes the actual control In some applications two zone cascade control systems are used In such systems the primary channel s output is used for heat control and the secondary channel s output is used for a heat boost Such arrangements are used in metal applications such aluminum casting The PPC s cascade control feature allows the primary channel s output to be used both to determine the secondary channel s set point and as an actual control output The secondary channel s set point is determined according to the heat and cool output values from the primary loop and the user supplied Max Set Point and Min Set Point parameters Figure 3 6 and Figure 3 7 on page 106 illustrate the relationship between the primary channel s output and the set point of the secondary channel When the primary channel has both heat and cool outputs enabled the secondary channel s set point is equal to the Min Set Point setting when the cool output is at 100 See Figure 3 6 When the primary loop has only its heat output enabled the secondary channel s set point is equal to the Min Set Point setting when the heat output is at 0 See Figure 3 7 on page 106 In either case the secondary channel s set point is equal to the Max Set Point setting when the heat output is at 100 For a cool only primary channel the secondary channel
201. ff For example if the state of an I O point is 1 and the Logic is 1 On then the I O point is On low Direction Select whether the flexible I O points are being used as inputs or outputs All flexible I O points default to inputs Range Input or Output Logic Specify the active true level ON state for each digital I O Range 1 Onor 0 On Function Indicates how an I O point is being used in the system Table 3 18 Function Values Not Assigned Output not used for control or alarm Output selected in Heat Cool Output Dest field on the Channels spreadsheet Selected in LP LD HD or HP Output Dest field on the Alarms spreadsheet Control Output Alarm Output 134 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Outputs PPC Chapter 3 Operating with AnaWin 3 The Outputs spreadsheet lists the output value for each of the analog outputs Output behavior is set by the parameters of the channel with the output set as the output destination on the Channels spreadsheet Channels Alarms Inputs Dig 1 0 outputs Soft Int Soft Bool PPC1 EIAO 11 3 1 PPC1 EIAO 11 3 2 PPC1 EIAO 11 3 3 PPC1 EIAO 11 3 4 Doc 30002 00 Rev 2 3 Figure 3 23 Outputs Spreadsheet Select the Outputs button to monitor the analog output values Analog Output names are located in the first column The Analog Output names identify the module I O type if necessary and module I O n
202. g Address Address Baud Rate 119 46171 46180 181A 1823 Address 122 1 247 46191 46200 182E 1837 Baud Rate Select the communications baud rate for the corresponding port Table 5 49 Database Offsets for Baud Rate Database Offset Description 1 Port 1 2 Port 2 Table 5 50 Baud Rate Value Baud Rate 9600 9600 19200 19200 Address This is the Modbus communications network address to which the PPC will answer on ports 1 and 2 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference Global Database Parameters Table 5 51 lists parameter number range and first and last Modbus addresses for the remaining global parameters These values are used when accessing global parameters with third party software operator interface terminals or LogicPro programs Table 5 51 System HW Parameters Parameter Range Modbus Hex g Address Address 32768 Full Scale 142 33451 33500 D7A DAB See Table 5 52 to 32767 32768 Zero Reference 143 33501 33550 DAC DDD See Table 5 54 to 32767 See Table 5 56 Modules Present 113 0 255 33551 33750 DDE EA5 and Table 5 57 Ambient Temperature 140 92768 33751 33770 EA6 EB9 See Table 5 55 P to 32767 i Table 5 52 Miscellaneous System Parameters Modbus Hex Parameter BEULI Address Addr ss Notes See Table 5 59 and Table 5 60 See Table 5 57
203. g a First In First Out FIFO stack the queue logs all changes to the database originating from another host Register 33052 contains the oldest change logged 33053 contains the second oldest and so on After the host reads the register s the data is cleared and shifted in the FIFO stack Watlow Anafaze 215 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide 216 It is necessary to begin any host read command Modbus function 04 with register 33051 Read requests that do not start at 33051 are not supported It is not necessary to continually read the entire queue at once A recommended technique is to read the first 8 registers of the queue on a periodic basis If there are more than 7 changes in the queue then subsequent changes would be shifted down so that the next time the queue is read the host will pick up the changes System Error Log The System Error log indicates how many times particular failures have occurred since the last time the error log was cleared The first register contains a total count of system errors The last register contains a number of unidentified or illegal error codes logged Refer to Table 5 62 on page 217 The counts stop incrementing at 255 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference Table 5 62 System Error Log D 7 Bee Ea eee Name Descript
204. ge 24 Perform a RAM clear refer to Resetting Closed Loop Control Parameters on page 156 Replace the module Green Status LED is blinking but inputs are not working correctly Corrective Actions Check to make sure the I O wiring is correct See Con necting Digital Inputs to the PPC 207x on page 74 Watlow Anafaze 153 Chapter 4 Troubleshooting 154 PPC 2000 User s Guide Troubleshooting and Corrective Actions If the system fails to perform as expected it may be necessary to perform one or more of the following procedures to discover the cause and restore normal operation Digital Inputs and Outputs If a digital input or output doesn t seem to be working check the following Process Variable Is the digital I O point s Direction set correctly as an input or output See Digital I O on page 132 Is the Logic set correctly Refer to Digital I O on page 132 Is the output selected as an Output Destination for more than one function e g a control output and an alarm output See Channels on page 115 and Alarms on page 123 Is the digital I O point associated with a variable set as an output in a logic program Refer to the LogicPro User s Guide Are the cable and wiring connections correct See Connecting I O to the PPC 2010 on page 37 Connecting to the Relay Outputs on the PPC 206x on page 70 and Connecting Digital Inputs to the PPC 207x on page 74 Is leakage current from one of the configurab
205. ge 30 for EITB dimensions Refer to Figure 2 15 on page 31 for TB50 dimensions Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter 2 Hardware Installation For more detailed specification information refer to Chapter 7 Specifications 3 6 91 mm 2 0 51 mm gt 4 e amam amam amam am o am am am am am am a Cea aaa aa aa a aa jam an an an an an an les ee 5 1 5 756 m Joj oj me am fe o M 128 mm 146 mm 30 O jo mz SW O jo we m jo je me sm loj jo me aml jo lo ms sm lol e De sl 9 je me m Jo Jo ime T S S rae w E e 3 al joj je De am lol jo mis sM o o Me sq lol je MEA am jo je Hk sm loj jo mz am joj jo me am jo je mie gm joj o MS 4M lo o Ms Watlow Anafaze 0 O O Pca Cy AA o d 2 6 66 mm lt 4 4 0 W 102 mm Figure 2 13 AITB Dimensions Clearances Watlow Anafaze 29 Chapter 2 Hardware Installation PPC 2000 User s Guide Figure 2 14 EITB Dimensions Clearances 30 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation A 2 3 in 58 mm v A 1A z x i be O g 3 9 L PN o x x o gt k g oO 2 am O jel me sm jo 3 4 in 4 1in
206. gth RS 232 does not support more than two devices on a network See Figure 2 69 RS 232 may be used to connect a computer through a 232 485 converter to an RS 485 communications network with up to 32 PPC controllers See Figure 2 70 RS 232 4 pin RJ type Serial Port DB 9 or DB 25 iT Figure 2 69 Connecting One PPC to a Computer Using RS 232 Connecting RS 485 Communications An RS 485 communications network can connect up to 32 PPCs directly with a host device equipped with an RS 485 port or via a converter to a host s RS 232 port See Figure 2 70 RS 485 wiring can be used over much greater distances than RS 232
207. he proportional band for the cool output Channel Parameters Doc 30002 00 Rev 2 3 Table 5 12 lists the parameter number range and first and last Modbus addresses for each channel parameter These values are used when accessing channel parameters with third party software operator interface terminals or LogicPro programs The range of some of the parameters is equal to the range of the input type selected for the channel See Table 5 10 on page 170 for a list of the input types and their corresponding ranges While all the channel parameter values are 16 bit integers many such as Control Mode are numerical representations of settings that have special meanings to the controller See the tables under the corresponding parameter descriptions for explanations of the possible settings Watlow Anafaze 173 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide Table 5 12 Channel Parameters Parameter BEULI mocbuS Hax Address Address Ai le 99 0 324 46101 46150 17D4 1805 Process Variable 96 33001 33050 BB8 BE9 Setpoint 95 46051 46100 17A2 17D3 OPR RPP Control Mode 1 0 3 40001 40050 0 31 See Table 5 18 on page 180 PID Parameters Heat Feedback Value 13 0 1000 30151 30200 96 C7 Cool Feedback Value 25 0 1000 30351 30400 15E 18F Heat Proportional Band 3 40101 40150 64 95 Cool Proportional B
208. his point further decreases to channel 1 s process variable have no additional affect on channel 2 Figure 3 9 on page 109 illustrates this relationship Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Ratio Control Doc 30002 00 Rev 2 3 Chapter 3 Operating with AnaWin 3 190 F 170 F 150 F 0 50 100 Primary Channel s Heat Output of Full Scale Set Point of the Secondary Channel Engineering Units 150 F 145 F 140 F Primary Channel s Process Variable F Figure 3 9 The Secondary Channel s Set Point is Determined by the Primary Channel s Process Variable Using ratio control the process variable of one channel or any analog input can determine the set point of another channel With ratio control the set point of the ratio channel is calculated by multiplying the process variable value of the master channel by a ratio then adding an offset Set Point Ratio and Set Point Offset are user set parameters By adjusting these parameters you can adjust the relationship between the process variable of the master channel and the set point of the ratio channel Figure 3 10 on page 110 illustrates this relationship The set point of the ratio loop is limited by the settings of Max Set Point and Min Set Point Watlow Anafaze 109 Chapter 3 Operating with AnaWin 3 PPC 2000 User s Guide Max Set Point Min Set Point Set Point of the Ratio Channel Engi
209. ications 233 Table 7 8 Capacity and Programming 233 Table 7 9 Control Specifications 234 Table 7 10 Counter Frequency Input Specifications 234 Table 7 11 Digital Input Specifications 234 Table 7 12 Digital Output Specifications 235 Table 7 13 Serial Interface 235 Table 7 14 Model Numbers 237 Table 7 15 Environmental Specifications 237 Table 7 16 Physical Specifications 237 Table 7 17 Connections 237 Table 7 18 Power Specifications 237 Table 7 21 Sensor Reference Voltage Output 239 Table 7 22 Model Number 241 Table 7 23 Environmental Specifications 241 Doc 30002 00 Rev 2 3 Watlow Anafaze Xv List of Tables PPC User s Guide xvi Table 7 24 Physical Specifications 241 Table 7 25 Connections 242 Table 7 26 Power Specifications 242 Table 7 27 Input Specifications 242 Table 7 29 Safety and Agency Approvals 243 Table 7 30 Model Number 244 Table 7 31 Environmental Specifications 244 Table 7 32 Physical Specifications 245 Table 7 33 Connections 245 Table 7 34 Power Specifications 245 Table 7 35 Counter Frequency Specifications 245 Table 7 37 Digital Output Specifications 246 Table 7 38 Model Number 248 Table 7 39 Environmental Specifications 248 Table 7 40 Physical Specifications 248 Table 7 41 Connections 249 Table 7 42 Power Specifications PPC 2050 249 Table 7 43 Power Specifications PPC 2051 249 Table 7 44 Output Specifications 249 Table 7 45 Model Number 2
210. ications equip ment for serial binary data interchange This is usually for communications over a short distance 50 feet or less and to a single device RS 485 An Electronics Industries of America EIA standard for electrical characteristics of generators and receivers for use in balanced digi tal multipoint systems This is usually used to communicate with multiple devices over a com mon cable or where distances over 50 feet are required Setpoint SP The desired value programmed into a controller For example the temperature at which a system is to be maintained Soft Bool A generic Boolean variable which is stored in the PPC 2000 database and is accessible by AnaWin or a logic program Values range from to 0 true or false Soft Int A generic integer variable which is stored in the PPC 2000 database and is accessible by AnaWin or a logic program Values are 32 768 to 32 767 Spread In heat cool applications the difference between heat and cool Also known as process deadband Switch Dip A set of compact toggle switches used to config ure electronic hardware The toggle switches are housed in a Dual In line Package Rotary A switch with multiple dial in settings used to configure electronic hardware Watlow Anafaze 289 Glossary T Thermistor A temperature sensing device made of semicon ductor material that exhibits a large change in resistance for a small change in temperature Thermistor
211. ield Response 00 02 00 00 Diag Register Contents Diagnostics Subfunction Force Listen Only Mode 04 Forces the addressed slave to its Listen Only Mode for Modbus communications This isolates it from the other devices on the network allowing them to continue communicating without interruption from the addressed slave No response is returned When the slave enters its Listen Only Mode all active communication controls are turned off The ready watchdog timer is allowed to expire locking the controls off While in this mode any Modbus messages addressed to the salve or broadcast are monitored but no actions will be taken and no responses will be sent The only function that will be processed after the mode is entered will be the Restart Communications Option function function code 8 subfunction 1 Subfunction Data Field Query Data Field Response 00 04 00 00 No Response Returned Diagnostics Subfunction Clear Counters 10 0A Hex Clears all Communication Event counters Counters are also cleared upon power up Subfunction Data Field Query Data Field Response 00 0A 00 00 Echo Query Data Diagnostics Subfunction Return Bus Message Count 11 OB Hex The response data field returns the quantity of messages that the slave has detected on the communications system since its last restart clear counters operations or power up Subfunction Data Field Query Data Field Response 00 OB 00 00 Tot
212. ight 0 82 Ibs 0 37 kg Height 8 0 in 203 mm Width 1 5 in 38 mm Depth 5 25 in 133 mm Table 7 33 Connections Connector on Module 50 pin SCSI 2 female Mounting DIN rail or panel mount Table 7 34 Power Specifications Power Requirement 3 6 W typical Current 12Vdc 300mA typical 25 C Current 24V 150mA typical 25 C Modules per Processor 6 Table 7 35 Counter Frequency Specifications Number Maximum Frequency 10 kHz Max Counts Sample Rate 10 000 counts sec single phase 32 000 counts sec quadrature 250 ms 4 Hz Pulse Input Voltage Range Single ended lt 0 6 Low 3 8V High Maximum Current 0 5mA from module with input at OV Input Resistance 6 kOhms Min Count Range 16 bits Doc 30002 00 Rev 2 3 Watlow Anafaze 245 Chapter 7 Specifications PPC 2000 User s Guide Table 7 36 Digital Input Specifications Number 32 Voltage Limiting and Protection 40Vdc Logic Voltage Levels lt 0 6 Low 3 8V High 0 5mA from processor with input at OV Switch Resistance to Pull Low 1 kOhms Maximum Maximum Current Switch Resistance for High 27 kOhms Minimum The PPC 2040 has 32 digital I O points Each can be configured as either an input or an output Table 7 37 Digital Output Specifications Number 32 Maximum Voltage 24Vdc Maxim
213. ight intensity between 0 and 500 Lumens and outputs a 0 1Vdc signal set the following parameters Table 3 7 Scaling Parameters for 0 1Vdc Linear Input Example Parameter Setting Units Input Type Linear 0 1 to 1 v Units Lumens Input Signal Lo 0 0 mV Input Signal Hi 1000 0 mV PV Lo 0 Lumens PV Hi 500 0 Lumens Decimal Places 1 Process Variable Retransmit Heat Cool Output of Full Scale This feature allows you to output signals representing the process variables of source channels or other analog inputs on the heat and cool outputs of a retransmit channel The analog input selected as the PV Source of the retransmit channel is output on the heat output The analog input selected as the Set Point Source of the retransmit channel is output on the cool output The output signals are scaled using the Min Set Point and Max Set Point and Heat Cool Scale Hi and Heat Cool Scale Lo parameters Figure 3 4 illustrates how the output signals are related to the analog inputs by these scaling parameters Heat Cool Scale Hi T Heat Cool Scale Lo Sensor Range Min Set Point Max Set Point Sensor Range Low High Analog Input Range Engineering Units Figure 3 4 Linear Scaling of the Analog Input for Retransmit on the Heat or Cool Output Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 3 Operating with AnaWin 3 A channel cannot be used for closed loop control
214. igital Adaptive Filter A filter that rejects high frequency input signal noise noise spikes Heat Cool Output Filter A filter that slows the change in the response of the heat or cool out put The output responds to a step change by going to approximately 2 3 its final value within the numbers of scans that are set Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Flags A program variable with a value of either 1 or 0 Frequency The number of cycles over a specified period of time usually measured in cycles per second Also referred to as Hertz Hz The reciprocal is called the period G Gain The amount of amplification used in an electrical circuit Gain can also refer to the Proportional P mode of PID Global Alarm Alarm associated with a global digital output that is cleared directly from a controller or through a user interface H Heat A control method and association of parameters organized around maintaining temperature above ambient Hertz Hz Frequency measured in cycles per second High Deviation Alarm Warns that the process is above setpoint but below the high process variable It can be used as either an alarm or control function High Isolation System used on some PPC 2000 analog input modules to protect electronic components from high voltage faults High Process Alarm A signal that is tied to a set maximum value that can be used as either an alarm or control function Doc
215. imensions 261 Figure 7 20 PPC TB50 SCSI Dimensions with Straight SCSI Cable 262 Figure 7 21 PPC TB50 SCSI Dimensions with Right Angle SCSI Cable 263 Figure 7 22 PPC IPS 2 264 Figure 7 23 SDAC Dimensions 266 Appendix A Modbus Protocol 269 Figure A 1 Query Response Cycle 270 xii Watlow Anafaze Doc 30002 00 Rev 2 3 List of Tables Overview 1 Table 1 4 PPC 2000 System Modules 5 Table 1 2 PPC 2000 Terminal Boards and Peripheral Modules 5 Table 1 3 Analog Terminal Board Keys 5 Hardware Installation 13 Table 2 2 Power Supply Current Requirements at 24Vdc 14 Table 2 3 Power Supply Screw Mounting 16 Table 2 4 System Modules and Addressing 18 Table 2 5 PPC 2010 Processor Module Jumpers 18 Table 2 6 PPC 2030 Analog Output Jumpers 21 Table 2 7 PPC 2040 Counter Input Jumpers 21 Table 2 8B PPC 205x Analog Out Jumpers 22 Table 2 9 Cable Recommendations 35 Table 2 10 Processor Module I O Connections 39 Table 2 11 Sensor Keys 46 Table 2 12 Numbers and Types of Inputs by Module Type 47 Table 2 13 Sensor Connections to the AITB 48 Table 2 14 Power Connections on AITB 49 Table 2 15 Encoder Connections to the EITB Connected to J3 on the PPC 2030 56 Table 2 16 Encoder Connections to the EITB Connected to J4 on the PPC 2030 56 Table 2 17 Power Connections on EITB 57 Table 2 18 HD 15 Encoder Signal Connections 59 Table 2 19 HD 15 Power Connections 60 Table 2 20 Analog Output Connections on Encoder In
216. imit Time 34 0 32767 40851 40900 352 383 174 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference Modbus Hex Parameter Ran Notes ii z aoe Address Address Cool Limit Time 49 0 32767 41401 41450 578 5A9 Sensor Fail Heat 37 0 1000 41001 41050 3E8 419 Sensor Fail Cool 52 0 1000 41551 41600 60E 63F Heat Output Filter 31 0 100 40701 40750 2BC 2ED Cool Output Filter 46 0 100 41251 41300 462 513 Heat Output 36 0 1000 40951 41000 3B6 3E7 Cool Output 51 0 1000 41501 41550 5DC 60D Heat Output Destination 40 0 4102 41151 41200 47E 4AF Cool Output Destination 55 0 4102 41701 41750 6A4 6D5 Alarm Parameters Alarm Status Flags 82 45451 45500 154A 157B See Table 5 28 on page 190 Alarm Control Flags 85 45601 45650 15E0 1611 See Table 5 30 on page 192 aad Acknowledge 88 45751 45800 1676 16A7 See Table 5 31 on page 192 Alarm Enable Flags 91 45901 45950 170C 173D See Table 5 32 on page 192 High Process Limit 80 45351 45400 14E6 1517 Low Process Limit 83 45501 45550 157C 15AD See explanation on p 193 High Deviation Offset 86 45651 45700 1612 1643 Low Deviation Offset 89 45801 45850 16A8 16D9 Alarm Deadband 92 0 255 45951 46000 173E 176F Alarm Delay 93 0 100 46001 46050 1770 17A1 High Process Output 0 336 3 f Destination 81 3103 4102 45401 45450 1
217. ing Be sure the software configuration matches the hardware setup Check that the jumpers are set correctly See PPC 2030 Jumper Settings on page 20 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 4 Troubleshooting PPC 2040 Digital I O Refer to the following descriptions of LED indicators when troubleshooting the digital I O module e Green Status LED remains off on or blinks incorrectly When the module is correctly functioning the green LED blinks If the LED remains off on or blinks incorrectly the module may not be functioning correctly Corrective Actions Make sure the rotary switch is set to the proper module ad dress Each module must have a unique address Cycle power to PPC 2000 system Check that the modules are connected properly refer to Module Assembly on page 24 Perform a RAM clear refer to Resetting Closed Loop Control Parameters on page 156 Replace the module e Green Status LED is blinking but inputs and or outputs are not reading correctly Corrective Actions Check to make sure the I O wiring is correct See Con necting I O to the PPC 2040 on page 61 e Red Error LED remains on Indicates at least one digital output is in an incorrect state The cause could be an overloaded output or a failed output driver Corrective Actions Check the output circuits for shorts and repair if nec essary Check the load on the outputs to make sure that none of them exc
218. inks incorrectly When the module is correctly functioning the green LED blinks If the LED remains off on or blinks incorrectly the module may not be functioning correctly Corrective Actions Make sure the rotary switch is set to the proper module ad dress Each module must have a unique address Cycle power to PPC 2000 system Check that the modules are connected properly refer to Module Assembly on page 24 Perform a RAM clear refer to Resetting Closed Loop Control Parameters on page 156 Replace the module Green Status LED is blinking but outputs are not functioning correctly Corrective Actions Check to make sure the I O wiring is correct See Con necting to the Relay Outputs on the PPC 206x on page 70 Check to make sure the digital outputs are correctly con figured See Digital Inputs and Outputs on page 154 PPC 207x Digital In Refer to the following descriptions of LED indicators when troubleshooting the digital input module Doc 30002 00 Rev 2 3 Green Status LED remains off on or blinks incorrectly When the module is correctly functioning the green LED blinks If the LED remains off on or blinks incorrectly the module may not be functioning correctly Corrective Actions Make sure the rotary switch is set to the proper module ad dress Each module must have a unique address Cycle power to PPC 2000 system Check that the modules are connected properly refer to Module Assembly on pa
219. ion Offset 1 33201 Error Count Total error count 255 maximum 22 33222 Logic Checksum Bad checksum in a logic program hex record 24 33224 Logic Load Pia programming of a logic program hex 42 33242 Undefined Parm Parameter number outside the range of the database 43 33243 Bad Data Sent Attempt to write data outside of a parameter s range 44 33244 Bad Offset Parameter offset beyond last element of the parameter 45 33245 Parm Size Internal error in parameter size during read or write 47 33247 Database Reg Internal error registering database entry 48 33248 Write to RO Attempt was made to write to a read only variable 49 33249 Change Q Overflow Overflow in database change queue 51 33251 Bad Flash Type Flash type was not found in table 52 33252 Flash Overflow Attempted write past end of flash 53 33253 Program Verify Failed program verify test 61 33261 Bad Interrupt Received bad interrupt 66 33266 Divide by Zero Divide by zero exception 67 33267 Illegal OpCode Illegal opcode exception 71 33271 Al Address Multiple Al boards detected at one address 73 33273 Al Cal Data Al board has invalid calibration data 74 33274 Al Timeout System unable to process Al input on time 75 33275 CMO or Open T C CMO or OTC occurred on an Al channel 92 33292 Bad Baud Rate Configured baud rate not supported 93 33293 UART Not Found A UART not detected 94 33294 Wrong Port Internal error attempt to configure unsupported port 96 33296 Closed Port Internal error attempt to acces
220. ion Registers are either bit or word values Relay A switching device Electromechanical Relay A power switching device that completes or interrupts a circuit by physically moving electrical contacts into contact with each other Not recommended for PID con trol Solid State Relay SSR A switching device with no moving parts that com pletes or interrupts a circuit electrically Reset Control action that automatically eliminates off set or droop between setpoint and actual process temperature See also Integral Automatic Reset The integral function of a PI or PID temperature controller that adjusts the process temperature to the setpoint after the sys tem stabilizes The inverse of integral RTD Resistance Temperature Detector Device A sensor that uses the resistance temperature characteristic to measure temperature There are two basic types of RTDs the wire RTD which is usually made of platinum and the thermistor which is made of a semiconductor material The wire RTD is a positive temperature coefficient sensor only while the thermistor can have either a negative or positive temperature coefficient Doc 30002 00 Rev 2 3 Glossary Serial Communications A method of transmitting information between devices by sending all bits serially over a single communication channel RS 232 An Electronics Industries of America EIA standard for interface between data termi nal equipment and data commun
221. ion of digital I O names 2 Both count and frequency are measured for the pulse input See Inputs on page 127 for an explanation of analog input names Connecting Digital Inputs The PPC 2010 module can accept digital inputs When the resistance of an input device is 27 kOhm or greater the input is considered off by the PPC 2000 When the resistance is 1 kOhm or less the input is considered on To install a switch as a digital input connect one lead to the DC Common input return on the TB50 Connect the other lead to the desired digital input on the TB50 Refer to Table 2 10 on page 39 for screw terminal numbering Use the Digital I O parameters to configure digital inputs Refer to Digital I O on page 132 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Add examples with transistor inputs on digital and pulse inputs Chapter 2 Hardware Installation Digital Sane ol Input X TB50 Device Digital In Com l l l _ g Figure 2 21 Wiring Digital Inputs Connecting Counter or Frequency Inputs PPC 2010 module accepts a single phase pulse signal from devices such as encoders Counts and frequencies of the inputs may be scaled with user selectable parameters See Setting up User Selectable Linear Inputs on page 98 for more information The PPC 2010 module can accommodate encoder signals up to 24Vdc The following figures illustrate connecting encoders TB50 PPC 2010 5
222. is stored at address 03002 and so on Table 5 38 on page 200 lists first and last Modbus addresses for each digital I O parameter Use these addresses when accessing digital I O parameters with third party software or operator interface terminals Doc 30002 00 Rev 2 3 Watlow Anafaze 195 Chapter 5 LogicPro and Modbus Reference 196 PPC 2000 User s Guide Accessing Digital I O Parameters with LogicPro When a logic program variable accesses a digital input State the LogicPro IO Physical Address is used in conjunction with the LogicPro IO Driver for the corresponding module type See Table 5 33 on page 196 to determine the LogicPro IO Physical Address The LogicPro IO Physical Addresses are listed by I O point according to the default names as seen in AnaWin3 To correlate the AnaWin3 name with the hardware connection see Table 2 10 on page 39 Table 2 23 on page 72 and Table 2 24 on page 76 When a logic program variable accesses a digital I O parameter the parameter number and the Database Offset are used in conjunction with the LogicPro s Database IO Driver The IO Physical Address is constructed from the parameter number and the database offset See the LogicPro User s Guide for specific instructions on addressing digital I O parameters See Table 5 33 on page 196 for a list of the database offsets for each digital I O point See Table 5 38 on page 200 for digital I O parameter numbers Digital I O Numbers and Ad
223. ition 0 No alarm condition exists 1 Alarm condition exists Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide A CAUTION Doc 30002 00 Rev 2 3 Chapter 5 LogicPro and Modbus Reference Table 5 29 Alarm Bit Definitions Bit Alarm Name 1 least significant Spare 2 Spare 3 Low deviation 4 High deviation 5 Low process 6 High process 7 Spare 8 Spare 9 T C break or open 10 RTD open 11 RTD short 12 Spare 13 Spare 14 Ambient Temperature 15 Spare 16 most significant Spare Failed sensor alarms are only checked on inputs associated with channels Any input that is not selected as the PV Source of a channel will not generate failed sensor alarms Alarm Control Flags Each Alarm Control register contains a 16 bit word The bits determine the behavior of the various alarms Setting an Alarm Control bit to 1 makes the corresponding alarm behave as a control Setting a bit to 0 makes it behave as a standard alarm Table 5 30 on page 192 describes the difference between standard alarms and controls See Table 5 29 for alarm bit definitions Watlow Anafaze 191 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide 192 NOTE Table 5 30 Alarm and Control Functionality Value Function Description Standard alarm function Digital output if set activates on alarm deactivates when 0 Alarm channel is not in alarm Gl
224. l This parameter is also used to scale a cascade channel See Cascade Control on page 105 Range The range is the same as that of the input type for the channel Max Set Point Enter the maximum value the PPC should accept for the set point of the channel This parameter is also used to scale a cascade channel See Cascade Control on page 105 Range The range is the same as that of the input type for the channel Set Point Ratio For ratio control differential control and remote set point applications set the ratio by which the analog input value selected as the Set Point Source is multiplied to calculate the set point See Ratio Control on page 109 Differential Control on page 112 and Remote Set Point on page 112 Range 0 01 to 300 0 Set Point Offset For ratio control differential control and remote set point applications set the offset which is added to the product of the analog input value selected as the Set Point Source and the Set Point Ratio to calculate the set point Ratio Control on page 109 Differential Control on page 112 and Remote Set Point on page 112 Range 32768 to 32767 Decimal placement depends on the Input Type selected See Table 3 15 on page 130 Watlow Anafaze 117 Chapter 3 Operating with AnaWin 3 118 PPC 2000 User s Guide Control Type Select the function of the channel Refer to Table 3 12 Refer to Heat and Cool Outputs on page 90 for more on PID1 and PID2 Tab
225. l not exceed 15 gps Doc 30002 00 Rev 2 3 Watlow Anafaze 111 Chapter 3 Operating with AnaWin 3 PPC 2000 User s Guide Differential Control Differential control is a special case of ratio control With differential control as with ratio the set point of one channel is determined by the process variable value of another channel The set point of the differential channel is calculated by adding an offset Set Point Offset to the process variable value of the master channel The Set Point Ratio parameter is set to 1 Remote Set Point Remote set point is implemented in the PPC as a special case of ratio control As with ratio control the set point of a channel is set by multiplying an analog input value by a ratio Set Point Ratio and adding an offset Set Point Offset Typically however the analog input is not used as feedback for closed loop control so there is no master channel The Max Set Point and Min Set Point parameters may be used to limit the set point value Setup remote set point according to the instructions for ratio control Logic Programs The PPC 2000 is able to run not only the closed loop control program but also a user written logic program LogicPro is a software program that runs under Windows95 98 NT This logic programming tool can be used to customize the function of the PPC 2000 controller Any of the digital and analog I O as well as all of the controller parameters can be accessed and changed by us
226. laces to the maximum allowable setting when the PV Lo or PV Hi is changed Table 3 4 PV Range permitted for various Decimal Places Settings Decimal PV Lo PV Hi Places minimum maximum 0 32768 32767 1 3276 8 3276 7 2 327 68 327 67 3 32 768 32 767 4 3 2768 3 2767 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 3 Operating with AnaWin 3 Linear 0 10Vdc Input Example For a sensor that measures pressures from 0 0 to 15 0 psia and outputs a 0 10Vdc signal set the following parameters Table 3 5 Scaling Parameters for 0 10Vdc Linear Input Example Parameter Setting Units Input Type Linear 1 to 10 v Units psia Input Signal Lo 0 000 V Input Signal Hi 10 000 V PV Lo 0 0 psia PV Hi 15 0 psia Decimal Places 1 Linear 4 20mA Input Example For a sensor that measures relative humidity with a range of 0 00 to 100 00 and outputs a 4 20mA signal set the parameters according to Table 3 6 Doc 30002 00 Rev 2 3 Watlow Anafaze Table 3 6 Scaling Parameters for 4 20mA Linear Input Example Parameter Setting Units Input Type Linear 2 to 20 mA Units Input Signal Lo 4 000 mA Input Signal Hi 20 000 mA PV Lo 0 00 PV Hi 100 00 Decimal Places 2 101 Chapter 3 Operating with AnaWin 3 102 PPC 2000 User s Guide Linear 0 1Vdc Input Example For a sensor that measures l
227. le 3 12 AnaWin3 Control Types Control Type Description Heat and Cool outputs used to control PIDI Only one output may be on at a time Heat and Cool outputs used to control pee Both outputs can be on at the same time Choose this type to use the channel to Retransmit retransmit one or two analog inputs Heat Cool Prop Band Set the proportional band Larger numbers result in less proportional action for a given error or deviation from set point This parameter is set in engineering units Range depends on the input type See Table 3 15 on page 130 Heat Cool Integral Enter the integral term value which controls the amount of influence the history of error has on the output Increasing the integral value decreases the integral contribution to the output Entering an integral value of 0 however yields no integral action This value is in seconds per repeat Range 0 to 6000 seconds repeat Heat Cool Derivative Enter the derivative term value which controls the amount of influence the rate of change of the error has on the output A greater value yields a greater derivative action The derivative constant is in units of seconds Range 0 to 255 seconds Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter 3 Operating with AnaWin 3 Heat Cool Man Reset Enter a value to add to the PID output calculation When the corresponding Integ
228. le I O points such that a device is being switched on or partly on See Connecting Digital Outputs on page 41 Is the field I O device powered Note digital outputs on the PPC 2010 and PPC 2040 sink current That current must be sourced by an external device that is referenced to the PPC s common See Connecting Digital Outputs on page 41 for the PPC 2010 and Connecting Digital Outputs on page 65 for the PPC 2040 If the Process Variable is not updating check the following Is a valid analog input selected as the PV Source See Channels on page 115 Is the input corresponding to the PV Source updating as expected If not check LEDs on the associated module See corresponding module section in this chapter Is the input wiring correct See Connecting I O to the PPC 2010 on page 37 Connecting Analog Inputs to the PPC 2021 2025 on page 45 Connecting Encoders and Analog Outputs to the PPC 2030 on page 55 or Connecting to the Relay Outputs on the PPC 206x on page 70 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Communications Chapter 4 Troubleshooting If communications has never worked check the following Is the PPC 2010 Processor running The RX LED on the port lights as the controller receives signals The TX LED lights if the controller receives a valid Modbus request This indicates a response being sent by the PPC Is the communications cable in the correct connector on the PPC 2010 Is the
229. led Modules Top View 143 Figure 4 2 Assembled Modules Bottom View 143 Figure 4 3 PPC 2010 Internal View 144 Figure 4 4 PPC Assembled Modules Top View 145 Figure 4 5 PPC Assembled Modules Bottom View 146 Doc 30002 00 Rev 2 3 Watlow Anafaze xi List of Figures PPC User s Guide LogicPro and Modbus Reference 159 Figure 5 1 Sample Text 160 Figure 5 2 Output Scaling Curves 185 Tuning and Control 219 Figure 6 1 On Off Control 220 Figure 6 2 Proportional Control 221 Figure 6 3 Proportional and Integral Control 222 Figure 6 4 Proportional Integral and Derivative Control 223 Figure 6 5 Example Time Proportioning and Distributed Zero Crossing Waveforms 224 Specifications 229 Figure 7 1 System Footprint 230 Figure 7 2 PPC 2010 Front View 231 Figure 7 3 PPC 2010 Bottom View 232 Figure 7 4 PPC 2021 Front View 236 Figure 7 5 PPC 2021 2025 Bottom View 236 Figure 7 6 PPC 2030 Front View 240 Figure 7 7 PPC 2030 Bottom View 241 Figure 7 8B PPC 2040 Front View 244 Figure 7 9 PPC 2050 Front View 247 Figure 7 10 PPC 2050 Bottom View 248 Figure 7 11 PPC 206x Front View 250 Figure 7 12 PPC 206x Bottom View 251 Figure 7 13 PPC 2070 PPC 2071 Front Views 253 Figure 7 14 PPC 207x Bottom Views 254 Figure 7 15 PPC AITB 1 256 Figure 7 16 PPC AITB Dimensions with Straight SCSI Cable 257 Figure 7 17 PPC EITB 1 258 Figure 7 18 PPC EITB Dimensions with HD Type Cable 260 Figure 7 19 PPC TB50 SCSI D
230. llation Category Il Pollution degree II 12 to 24 V dc 50 VA maximum Classification Rated Voltage Rated Power Consumption Meets the essential requirements of the following European Union Directives by using the relevant standards show below to indicate compliance 89 336 EEC Electromagnetic Compatibility Directive EN 61326 1997 With A1 1998 Electrical equipment for measurement control and laboratory use EMC requirements Industrial Immunity Class A Emissions Equipment is not for use in Class B emission environment without additional filtering EN 61000 4 2 1996 With A1 1998 Electrostatic Discharge Immunity EN 61000 4 3 1997 Radiated Field Immunity EN 61000 4 4 1995 Electrical Fast Transient Burst Immunity EN 61000 4 5 1995 With A1 1996 Surge Immunity EN 61000 4 6 1996 Conducted Immunity EN 61000 4 11 1994 Voltage Dips Short Interruptions and Voltage Variations Immunity EN 61000 3 2 1995 With A1 3 1999 Harmonic Current Emissions EN 61000 3 3 1995 With A1 1998 Voltage Fluctuations and Flicker 73 23 EEC Low Voltage Directive EN 61010 1 1993 With A1 1995 Safety Requirements of electrical equipment for measurement control and laboratory use Part 1 General requirements d clare que le produit suivant Fran ais D signation PPC 2000 Num ros de mod le PPC 2 010 02X 040 05X 06X ou 07X PPC AITB PPC TB50 X remplace tout chiffre de 0 9 Appareil de contr le de
231. lt in digital I O points 24 points are outputs only 22 of the outputs are user configurable for PID control alarms or logic outputs The other 2 outputs are dedicated to system status and global alarm The remaining 24 I O points are individual configurable as either inputs or outputs Table 7 13 Serial Interface Number of Ports 2 Type RS 232 3 wire or RS 485 5 wire Modular Jacks RS 232 4 position 4 conductor phone handset RS 485 RJ12 6 position 6 conductor Isolation 40Vdc working 200Vdc peak Baud Rate 19200 default configurable 9600 or 19200 Error Check CRC of Controllers 1 with RS 232 32 with RS 485 Protocol Modbus RTU Doc 30002 00 Rev 2 3 Watlow Anafaze 235 Chapter 7 Specifications PPC 2000 User s Guide 236 PPC 2021 2025 Analog In Analog In High Isolation Specifications Status Error EDs Rotary Address Switch PRXEKA Figure 7 4 PPC 2021 Front View 50 pin SCSI Connector Figure 7 5 PPC 2021 2025 Bottom View Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter 7 Specifications The Analog In modules addresses are configured with the rotary switch The bottom panel includes a 50 pin SCSI connection for the Analog Input Terminal Board AITB Table 7 14 Model Numbers PPC 20
232. may be used r PPC 2050 7 1A T l Source Figure 2 55 Analog Output Connections on a PPC 2050 Configured for Current Outputs 1 and 2 Shown Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation r PPC 2050 7 1A Figure 2 56 Analog Output Connections on a PPC 2050 Configured for Voltage Outputs 1 and 2 shown Figure 2 57 Analog Output Connections on a PPC 2051 Configured for Current and Voltage Outputs 1 and 2 shown NOTE The B terminal sources current and the A terminal sinks it on outputs configured for current On outputs configured for voltage the A terminal is at the greater potential Doc 30002 00 Rev 2 3 Watlow Anafaze 69 Chapter 2 Hardware Installation PPC 2000 User s Guide Connecting to the Relay Outputs on the PPC 206x The PPC 2061 and PPC 2062 provide connections located on the bottom panel for eight electromechanical relay outputs and three counter inputs Relay output field wiring is terminated at a sixteen position removable terminal block
233. mode determines how messages are framed and coded In ASCII each character in a message string is composed of a hexadecimal character which is correlated to an ASCII character So for example an ASCII message string contains the value of a process variable 5500 550 0 degrees 5500 in an ASCII string is composed of 4 bytes 35 35 30 30 35 and 30 in hexadecimal equate to the characters 5 and 0 in the ASCII table respectively In RTU mode the actual value is embedded in a message string There is no translation to ASCII characters This results in more compact message strings and efficient serial communications The value 5500 in an RTU string is composed of its hexadecimal equivalent which is only 2 bytes 15 7C Many host devices can communicate in either ASCII or RTU mode However it should be noted that some PLCs can only be an ASCII host Message Framing Doc 30002 00 Rev 2 3 Messages start with a silent interval of at least 3 5 character times This is most easily implemented as a multiple of character times at the baud rate that is being used on the network shown as T1 T2 T3 T4 in the figure below The first field then transmitted is the device address Networked controllers monitor the network bus continuously including during the silent intervals When the first field the address field is received each device decodes it to find out if it is the addressed device Following the last transmitted charact
234. module output numbers of each analog output 202 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference Table 5 42 Addresses for Analog Outputs on the PPC 2030 Encoder In Analog Out Modules ee aerate Modbus Addressing AnaWin3 Name Output Spreadsheet Encoder_Analog_2030 head Decimal Hex IO Driver PPC1 EIAO 11 3 1 11 3 1 46201 1838 PPC1 EIAO 11 3 2 11 3 2 46202 1839 PPC1 EIAO 11 3 3 11 3 3 46203 183A PPC1 EIAO 11 3 4 11 3 4 46204 183B PPC1 EIAO 12 3 1 12 3 1 46205 183C PPC1 EIAO 12 3 2 12 3 2 46206 183D PPC1 EIAO 12 3 3 12 3 3 46207 183E PPC1 EIAO 12 3 4 12 3 4 46208 183F PPC1 EIAO 13 3 1 13 3 1 46209 1840 PPC1 EIAO 13 3 2 13 3 2 46210 1841 PPC1 EIAO 13 3 3 13 3 3 46211 1842 PPC1 EIAO 13 3 4 13 3 4 46212 1843 PPC1 EIAO 14 3 1 14 3 1 46213 1844 PPC1 EIAO 14 3 2 14 3 2 46214 1845 PPC1 EIAO 14 3 3 14 3 3 46215 1846 PPC1 EIAO 14 3 4 14 3 4 46216 1847 1The AnaWin3 names are shown for the first PPC 2000 in the system See Outputs on page 135 for a full explanation of analog output naming 2Use this address with the Encoder_Analog_2030 IO Driver when addressing Analog Output Val ue There are no other analog output parameters so you will not use the Database IO Driver Doc 30002 00 Rev 2 3 Watlow Anafaze 203 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide 204 Table 5 43 Addresses for Analog Outputs on the PPC
235. n 62 50 pin SCSI Connector NOTE PPC 2000 User s Guide 19 20 21 22 23 24 TB2 TB 6 37 38 39 40 41 42 43 44 45 46 47 48 49 50 O90AOVOAQQQO SEDSXDDSO9DO9S ge SE pe ee ze Ie oe 62 82 Le 92 Se 73 4 15 16 17 18 09099909Q et ott Ob Watlow Anafaze oO PPC TB50 Q O O A IW O PPC 2040 Bottom View Figure 2 47 PPC 2040 Connection to TB50 To avoid confusing the SCSI cables during servicing label each end of each cable and each terminal board with the address of the module to which it should be connected TB50 Connections Connect digital inputs and digital outputs for control signals alarms and digital field I O to the TB50 The PPC 2040 Digital T O Module supports up to 32 digital inputs and outputs and up to two single ended counter frequency inputs Counter inputs may be single phase or quadrature Connecting one single phase counter or frequency signal uses one digital input Connecting one quadrature input requires two digital inputs Table 2 21 on page 63 shows the TB50 pinout when used with the PPC 2040 Use 14 to 22 AWG wire When making connections tighten to 0 5 to 0 6 Nm or 4 5 to 5 4 inch pound Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Table 2 21 Digital I O Module Connections TB 50 AnaWin3 Name Module I O Number Terminal
236. n Seen at the beginning of logic program download while previous logic program is being erased Error 1 Orange LED and Error 2 Red LED on Indicates watchdog timeout control program no longer running Corrective Actions Cycle power to PPC 2000 system Perform RAM clear see Resetting Closed Loop Control Parameters on page 156 Replace Processor module Error 1 Orange LED on Indicates low battery or low voltage from the power supply Corrective Actions Check to make sure the voltage on the power supply is 12 to 28Vdc Replace the battery See Battery Installation Procedures on page 145 Watlow Anafaze 147 Chapter 4 Troubleshooting PPC 2000 User s Guide PPC 2021 2025 Analog Input Refer to the following descriptions of LED indicators when troubleshooting the analog input modules 148 Error 3 Red LED blinking in sync with Green Status LED Indicates an open thermocouple Corrective Actions Verify that the correct sensor keys are installed correctly See Sensor Keys on page 46 Check for an open thermocouple alarm and repair the cor responding thermocouple If the input is not used make sure it is not selected as the PV Source for any channel Failed sensors are only re ported for an input chosen as the PV Source for a channel Error 3 Red LED on or blinking but not in syne with Green Status LED Indicates common mode overvoltage The cause could be either a transitional noise source or a
237. n Reverse heat or direct cool Independently set high low process Alarm Outputs alarms and high low deviation alarms Tuning Auto or manual Soft Input Update 1 sec Additional I O modules required Table 7 10 Counter Frequency Input Specifications Number 1 Maximum Frequency 10 kHz single phase Sample Rate 250 ms 4 Hz Voltage Levels lt 0 6 Low 3 8V High 0 5mA from processor with Max Input Current input at OV Input Resistance 6 kOhms Min Count Range 16 bits Table 7 11 Digital Input Specifications 234 Number Voltage Limiting and Protection 24 40Vdc Voltage Levels lt 0 6 Low 3 8V High Max Input Current 0 5mA from processor with input at OV Max Switch Resistance to Pull Input Low 1 kOhm Min Switch Off Resistance Watlow Anafaze 27 kOhm Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 7 Specifications Table 7 12 Digital Output Specifications Number 48 Configuration 1 global alarm 1 system status CPU watchdog timer 22 control outputs 24 configurable as inputs or control outputs Max Voltage Max Current 24Vdc 100mA sink to power common continuous Off State Leakage Cur rent Outputs 1 to 24 100A rent Outputs 25 48 Off State Leakage Cur 5A On State Maximum Voltage lt 0 7Vdc output to common The PPC 2010 has 48 bui
238. n the battery is removed Take a Snapshot of the current configurations in AnaWin3 before removing the battery Be sure to take antistatic precautions 1 Power down the controller 2 Remove the power connection to the processor module and any cables between the modules and terminal boards 3 Note and label cable locations 4 Remove the PPC 2000 system from the DIN rail or panel 5 Make sure the red top and bottom module latches on the processor module are in the unlocked position pushed toward the back of the module Back Module F TT top latch ee unlocked Ess ae NH E Module top e latch locked PESO na i e Tana TON Figure 4 4 PPC Assembled Modules Top View Doc 30002 00 Rev 2 3 Watlow Anafaze 145 Chapter 4 Troubleshooting PPC 2000 User s Guide Front Module bottom latch locked Module bottom latch unlocked Back Figure 4 5 PPC Assembled Modules Bottom View 6 Gently rock and pull the modules apart 7 Refer to Figure 4 3 on page 144 to locate the battery on the controller board Hold the controller board with the battery side facing down a few inches above a table or bench top Pull up on the battery s spring tab and allow the battery to slip out of its housing and to the table top Do not use a metal object screwdriver etc to remove the battery this can short the and terminals Replace battery with Duracell D
239. n using the PPC IPS 2 Doc 30002 00 Rev 2 3 Watlow Anafaze 77 Chapter 2 Hardware Installation PPC 2000 User s Guide ae 2 EENS gt lt Vi45Vde S amo eS SS V1 45Vde gt oi 7 O l Ge O nS cu V2 24Vde gt i B 5 Zz any E V 24 Vdc J 7 c DC Com Figure 2 67 PPC IPS 2 Power Connections Connecting Communication Ports Communications ports 1 and 2 on the PPC 2010 Processor module may be used to communicate with an operator interface terminal a computer running AnaWin3 LogicPro or third party software or any device capable of acting as a host using the Modbus RTU protocol PPC controllers always act as servers or slaves The computer or other host device must act as the client or master Communication Ports Both communication ports support RS 232 and RS 485 signals A 4 position 4 conductor telephone handset connector is provided for RS 232 communications and an RJ12 connector is provided for RS 485 communications Only one of these connectors may be used Both ports are optically isolated 78 Watlow Anafaze Doc 30002 00 Rev 2
240. nal Hi set the corresponding PV Lo and PV Hi The PV Lo is the process variable measured when the sensor signal is at the level set in the Input Signal Lo field The PV Hi is the process variable measured when Doc 30002 00 Rev 2 3 Watlow Anafaze 99 Chapter 3 Operating with AnaWin 3 PPC 2000 User s Guide the sensor signal is at the level set in the Input Signal Hi field Both parameters are entered in units for the input Setting Decimal Places 100 Set the Decimal Places parameter to determine how many decimal places are entered and displayed in the Process Variable Set Point and alarm limits LP Limit LD Offset HD Offset HP Limit for channels with the corresponding input selected as the PV Source The range for Decimal Places is limited by the range of the PV to be displayed The more decimal places to be displayed the smaller the range of PV that can be displayed therefore the greater the difference between the PV Lo and PV Hi the fewer the decimal places that can be displayed Table 3 4 shows the maximum range for the PV for each Decimal Places setting For example a sensor that measures pressure over a range of 0 1000 Torr set up with a PV Hi equal to 1000 Torr would limit the choices of Decimal Places to 0 or 1 Two decimal places would not be possible when the PV must go up to 1000 because when two decimal places are used the highest PV that can be displayed is 327 67 AnaWin83 automatically sets the Decimal P
241. nd adjusting the output appropriately For example if the process variable is rapidly approaching the set point from below derivative control reduces the output anticipating that the process variable will reach set point Use derivative control to reduce the overshoot and oscillation of the process variable common to PI control Figure 6 4 shows a process under full PID control SP Figure 6 4 Proportional Integral and Derivative Control Doc 30002 00 Rev 2 3 Watlow Anafaze 223 Chapter 6 Tuning and Control PPC 2000 User s Guide Control Outputs The controller provides open collector and analog outputs for control Open collector outputs normally control the process using solid state relays Open collector outputs can be configured to drive a Serial Digital to Analog Converter SDAC that in turn can provide 0 5Vdc 0 10Vdc or 4 20mA control signals to operate field output devices Output Control Forms The following sections explain the various control output signals available On Off When On Off control is used the output is on or off depending on the difference between the setpoint and the process variable PID algorithms are not used with On Off control The output variable is always off or on 0 or 100 Time Proportioning TP With time proportioning outputs the PID algorithm calculates an output between 0 and 100 which is represented by turning on an output for that percent of a fixed
242. nections e Use shielded wire The electrical shield protects the signals and the PPC 2000 from electrical noise Connect only one end of the shield to earth ground e Use copper wire for all connections other than thermocouple sensor inputs See Table 2 9 for cable recommendations Table 2 9 Cable Recommendations No of AWG Max Function Mfr P N Wires Gauge Length Analoa inputs Belden 9154 2 20 adn Belden 8451 2 22 Belden 8772 3 20 AL puts Belden 9770 3 22 TC Inputs TC Ext Wire 2 20 Digital PID Outputs Belden 9539 9 24 and Digital I O Belden 9542 20 24 Belden 9154 2 20 Anad Oupure Belden 8451 2 22 eter Belden 9729 4 24 4000 ft ic tesa aera Belden 9730 6 24 Belden 9842 4 24 4000 ft RS232 RS422 RS485 or 20mA Belden 9843 6 24 Belden 9184 4 22 6000 ft Noise Suppression The PPC 2000 s outputs are designed to drive resistive loads Open collector outputs can drive solid state relays These relays may in turn operate more inductive types of loads such as Doc 30002 00 Rev 2 3 Watlow Anafaze 35 Chapter 2 Hardware Installation 36 PPC 2000 User s Guide electromechanical relays alarm horns and motor starters Such devices may generate electromagnetic interference EMI or noise If the controller is placed close to sources of EMI it may not function correctly Below are some tips on how to recognize and avoid problems with EMI Sym
243. neering Units SP Offset Sensor Sensor Range Range Hig Master Channel s Process Variable Engineering Units Figure 3 10 Relationship between the Master Channel s Process Variable and the Ratio Channel s Set Point Setting up Ratio Control To set up ratio control 1 Set up the master channel as you would for a standard closed loop application See Setting up Control Channels on page 92 2 Set up the ratio channel as you would for a standard closed loop application 3 Make the following additional settings on the ratio channel a For Set Point Source select the analog input that should be used to determine the set point the PV Source of the master channel b Set the Set Point Ratio and Set Point Offset to create the desired relationship between the analog input s value and the ratio channel s set point c Set the Min Set Point to the lowest set point value the ratio channel should ever have d Set the Max Set Point to the highest set point value the ratio channel should ever have 110 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 3 Operating with AnaWin 3 Ratio Control Example Water Input KOH Input Flow Sensors Control Valves Achemical process requires a formula of two parts water to one part Potassium Hydroxide KOH to produce diluted Potassium Hydroxide The desired flow of water is 10 gallons per second gps and the KOH should flow
244. nel to autotune Restore the input filter to its original value Note the PID parameters for future reference NOTE A channel must be stable at a temperature well below the set point in order to successfully autotune The controller will not complete tuning if the temperature exceeds 75 of set point before the new parameters are found Using AnaWin3 to Tune The following procedure explains how to autotune a channel using AnaWin3 1 A Choose AnaWin3 s Channels spreadsheet screen and locate the channel to be tuned Ensure that the temperature is stable and the channel is in manual control mode typically 0 heat output level Note which input is used as the PV Source for the channel On the Inputs spreadsheet note the setting of the Input Filter for that input and then set it to 0 scans On the Channels spreadsheet increase the Set Point to a value such that the temperature will not rise from 60 to 80 of that value in less than 10 seconds when heated at 100 output Select Tune as the Control Mode When tuning is completed the control mode changes to Auto Adjust the Set Point to the desired temperature Restore the setting of the input filter to its original value CAUTION Never set the set point above the safe operating limits of your system 94 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Alarms Chapter 3 Operating with AnaWin 3 The controller has three different
245. nformation The PPC 2040 module can accommodate encoder signals up to 24Vdc The following figures illustrate connecting encoders TB50 1 input 1 phase 1 S1 3 input 2 phase 1 S2 e37 COM Figure 2 49 Single Phase Connections Input 1 and 2 Shown 64 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation TB50 1 1 input 1 phase 1 Q1 2 2 input 1 phase 2 COM 3 input 2 phase 1 1 24 4 input 2 phase 2 e Q2 a 37 COM Figure 2 50 Quadrature Connections Inputs 1 and 2 Shown Connecting Digital Outputs Doc 30002 00 Rev 2 3 The digital outputs sink current from a load connected to the controller s power supply or another power supply referenced to the PPC 2000 power common Do not exceed 24 volts If you must tie the external load to ground or if you cannot connect it as shown in Figure 2 51 through Figure 2 53 use a solid state relay to drive your load The outputs conduct current when they are LOW or ON The maximum current sink capability is 150mA at 24Vdc They cannot source current to a load 12 24 PS PPC _4 TB50 Digital _ 5 Out SSR Figure 2 51 Powering Output with 5Vdc from PPC Supply Watlow Anafaze 65 Chapter 2 Hardware Installation PPC 2000 User s Guide
246. ng the system s response See Autotuning on page 93 Heat Output Enter a heat output value in percent when the channel is in manual control mode or monitor the output in automatic control For PID output types the output is calculated based on the heat PID parameters Range 0 0 to 100 0 Cool Output Enter a cool output value in percent when the channel is in manual control mode or monitor the output in automatic control For PID output types the output is calculated based on the cool PID parameters Range 0 0 to 100 0 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter 3 Operating with AnaWin 3 PV Source Select the input used as the process variable for this channel Choose one of the displayed analog inputs Use the scroll bar in the pop up window to view the available inputs Range Not Assigned and all the analog inputs on the Inputs spreadsheet Set Point Source Select a setting to determine how the set point for the channel is set Select User for normal closed loop control applications Select a channel output Channel Out for cascade control Select an analog input for ratio control differential control remote set point or process variable retransmit Range User Channel 1 Output to Channel 48 Output and all analog inputs on the Inputs spreadsheet Min Set Point Enter the minimum value the PPC should accept for the set point of the channe
247. nly analog output parameter The analog output registers determine the levels of signals output by the analog outputs on the Encoder In Analog Out modules Accessing Analog Outputs with Modbus The Modbus address offsets for Analog Output Value correspond to the analog output See Table 5 42 on page 203 and Table 5 43 on page 204 for a list of the analog outputs and the corresponding Modbus addresses The table lists first and last Modbus addresses for each module with analog outputs Use these addresses when accessing analog output values with third party software or operator interface terminals Accessing Analog Outputs with LogicPro When a logic program variable accesses an Analog Output Value the LogicPro IO Physical Address is used in conjunction with the LogicPro IO driver for the corresponding module type The LogicPro IO Physical Addresses are listed by output according to the default output names as seen in AnaWin3 To correlate the AnaWin3 name with the hardware connection see Table 2 20 on page 60 and Table 2 22 on page 67 See the LogicPro User s Guide for specific instructions on addressing analog outputs See Table 5 42 and Table 5 43 for a list of the LogicPro IO Physical Addresses corresponding to the analog outputs Analog Outputs and Modbus Addresses Table 5 42 and Table 5 43 list the LogicPro I O physical address and Modbus address for each Analog Output Value corresponding to the modules module addresses and
248. not functioning Corrective Actions Make sure the rotary switch is set to the proper module ad dress Each module must have a unique address Cycle power to PPC 2000 system Check that the modules are connected properly refer to Module Assembly on page 24 Perform a RAM clear refer to Resetting Closed Loop Control Parameters on page 156 Replace module LED indicators are OK but inputs are not seen Some or none of the wired input data is being transferred to the system This may be an indication of a software or hardware problem Corrective Actions Check all interconnects terminal blocks and SCSI con nector Check the input configuration in the AnaWin3 software Refer to Chapter 3 Software Setup for configuration infor mation Incorrect sensor type or wrong channel setup could be seen as incorrect data retention Watlow Anafaze 149 Chapter 4 Troubleshooting 150 PPC 2000 User s Guide PPC 2030 Encoder In Analog Out Refer to the following descriptions of LED indicators when troubleshooting the encoder input analog output module Green Status LED remains off on or blinks incorrectly If counter input scanning is properly functioning the green LED blinks If the LED remains off on or blinks incorrectly the module is not functioning Corrective Actions Make sure the rotary switch is set to the proper module ad dress Each module must have a unique address Cycle power to the PPC 2000 sy
249. nsors actuators relays SSRs etc Connecting the TB50 to the PPC 2010 Module Refer to Figure 2 20 on page 38 Connect the SCSI connector from the PPC 2010 module to the TB50 Doc 30002 00 Rev 2 3 Watlow Anafaze 37 Chapter 2 Hardware Installation 38 50 pin SCSI Connector NOTE PPC 2000 User s Guide TB50 pin1 O ea 56 e jaa e m jes Me sl jo O Ms a 8 S eR B 9 BEE je ma O Ms zE o joj me m joj Je MA lt je We S e Ms S Z tae 9 e a 8 ao 82 Te 8 ey 8 j O o oj me sm jol je MA z 8 16 e 0 1O 2 O eR Oj e 3 V s j 2 8l 9 gt G Watlow Anafaze C o O PPC TB50 Q o PPC 2010 Bottom View Figure 2 20 PPC 2010 Connection to TB50 If more than one module in the PPC system is connected to a terminal board using a 50 pin SCSI connector label each end of each cable and each terminal board with the address of the module to which it should be connected TB50 Connections Connect digital inputs and digital outputs for control signals alarms and digital field T O to the TB50 When connected to the PPC 2010 Processor mod
250. obal alarm output activates and requires alarm acknowledgment to clear Digital output if set activates on alarm deactivates when channel is not in alarm Global alarm output does not activate No alarm acknowledgment required to clear 1 Control Alarm Acknowledge Flags Each Alarm Acknowledge register contains a 16 bit word When an alarm occurs and it is not a control alarm the corresponding Alarm Acknowledge bit is set equal to 1 The bit remains set even if the corresponding alarm condition is corrected Read the Alarm Acknowledge bits to determine if there are unacknowledged alarms Set bits to 0 to acknowledge the corresponding alarm Table 5 31 Alarm Acknowledge Value Description 0 Acknowledged alarm 1 Unacknowledged alarm Alarm Enable Flags Alarm Status and Alarm Acknowledge bits are set when the process variable crosses the process or deviation limit only when the corresponding alarm enable bit set to 1 Set the alarm enable bit to 1 for each alarm limit to be monitored Set the alarm enable bit to 0 to ignore the corresponding alarm Table 5 32 Alarm Enable Disable Value Description 0 Disable 1 Enable The range and precision of the process limits and deviation offsets are the same as that of the corresponding input See Table 5 10 on page 170 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter
251. offset only See the LogicPro User s Guide for specific instructions on addressing Boolean and Integer registers See Table 5 46 on page 206 for the LogicPro IO Physical Address of each register Soft Bool and Soft Int Registers Table 5 46 lists the LogicPro IO Physical Address ranges database offsets and first and last Modbus addresses for the Boolean and integer registers These values are used when accessing Boolean and Integer registers with third party software operator interface terminals or LogicPro programs Table 5 45 Soft Bool Values Doc 30002 00 Rev 2 3 Value AnaWin3 Value 0 False 1 True Watlow Anafaze 205 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide 206 These registers may be chosen as output destinations for a channel See Table 5 27 on page 190 for a list of output destinations values that includes these registers Table 5 46 Soft Bool and Soft Int Registers AnaWin3 Name LogicPro I O Physical Modbus Addressing Soft Bool and Soft Add 1 Int Spreadsheets i Decimal Hex PPC1 Soft Bool 1 1 3001 BB8 PPC1 Soft Bool 2 2 3002 BB9 PPC1 Soft Bool 1000 1000 4000 FOF PPC1 Soft Int 1 1 46301 189C PPC1 Soft Int 2 2 46302 189D PPC1 Soft Int 100 100 46400 18FF PPC1 Soft Int 101 101 47001 1B58 PPC1 Soft Int 102 102 47002 1B59 PPC1 Soft Int 2100 2100 49000 2327 1Use this address with the Soft_Bool or Soft_Int O Driver when ad
252. ohm input imped ance A D Conversion DC Voltage Input Range Integrating voltage to frequency 1 to 10Vdc ranges selectable 0 to 50mV 0 to 100mV 0 to 500mV 0 to 1V 0 to 5V 0 to 10V Current Input Range RTD Input 0 to 20mA ranges selectable 0 to 20mA or 4 to 20mMA 100 ohm Pt 3 wire T C Open Detect 2 5 kOhms or more upscale Source Impedance Measurements are within specification up to 500 ohm source resistance Resolution 0 003 greater than 15 bits Accuracy voltage 0 05 at 25 C PPC 2021 2024 2025 0 1 at 25 C PPC 2022 Accuracy current 0 1 at 25 C PPC 2021 2024 2025 0 75 at 25 C PPC 2022 Temperature Coefficient lt 50 ppm 2C 0 005 2C Sample Rate 60 Hz PPC 2021 PPC 2025 Sample Rate 60 Hz PPC 2022 380 msec to sample all 16 channels 2 6 Hz 666 msec to sample all 32 channels 1 5 Hz Sample Rate 60 Hz PPC 2024 220 msec to sample all 8 channels 4 5 Hz Not applicable to PPC 2022 238 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 7 Specifications Table 7 20 Temperature Sensor Accuracy Type Range Resolution Total Accuracy BT C 32 to 3308 F 0 to 1820 C 0 32 F 0 18 C 5 9 F 3 3 C Cire 32 to 4200F 0 to 2316 C 0 02 F 0 01 C 2 8 F 1 6C DTIC 32 to 4200 F 0 to 2316 C 0 02 F 0 01 C
253. oller depending upon their size Check the shipping invoice carefully against the contents received in all boxes Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 1 Overview Product Features The PPC 2000 PPC offers high performance closed loop PID control and the ability to manipulate process control algorithms and sequential logic in a very user friendly way It is amodular programmable process control system that utilizes plug in modules to meet different system requirements The controller can be configured for as many as 48 channels of PID control and supports up to 288 programmable digital I O points A motor interface module allows for operating up to 16 motor speed control systems Seven types of hardware modules are supported by the PPC system AnaWin3 HMI software is used for configuration operation and data acquisition LogicPro software is available as an option and can be used to write logic programs for sequential and process control The PPC controller includes the following features e Multiple channels of closed loop control and programmable logic in an integrated package e User programmable advanced control algorithms e Modular hardware e Bus expansion up to 9 additional modules e Serial communication e AnaWin3 operator interface compatible single or multiple PPC modbus network capability e Analog inputs as many as 128 per PPC system e Multiple sensor inputs multiple TC ty
254. omatic control When tuning a loop choose PID parameters that will best control the process This section gives PID values for a variety of heating and cooling applications Tuning is a slow process After adjusting a loop allow about 20 minutes for the change to take effect Proportional Band PB Settings Table 6 1 shows PB settings for various temperatures in degrees Fahrenheit Table 6 1 Proportional Band Settings Temperature PB Temperature PB Temperature PB Setpoint Setpoint Setpoint 100 to 99 20 1100 to 1199 75 2200 to 2299 135 100 to 199 20 1200 to 1299 80 2300 to 2399 140 200 to 299 30 1300 to 1399 85 2400 to 2499 145 300 to 399 35 1400 to 1499 90 2500 to 2599 150 400 to 499 40 1500 to 1599 95 2600 to 2699 155 500 to 599 45 1600 to 1699 100 2700 to 2799 160 600 to 699 50 1700 to 1799 105 2800 to 2899 165 700 to 799 55 1800 to 1899 110 2900 to 2999 170 800 to 899 60 1900 to 1999 120 3000 to 3099 175 900 to 999 65 2000 to 2099 125 3100 to 3199 180 1000 to 1099 70 2100 to 2199 130 3200 to 3299 185 Integral Settings As a general rule set the PB to 10 of the setpoint below 1000 and 5 of the setpoint above 1000 This setting is useful as a starting value The controller s Integral parameter is set in seconds per repeat Some other products use an integral term called Reset in units of repeats per minute Table 6 2 on page 227 shows Integral settings
255. on to run logic To stop the logic program 1 Select the View menu 2 Select PPC Globals 3 Double click on the Stop Logic Program button 4 Click the Send button to command the PPC to stop the logic program Or click Cancel When stopping the logic program all PPC digital outputs are turned off Outputs controlled by a closed loop control channel or a process alarm resume outputs on the next scan Ensure the logic program can be safely stopped If necessary shutdown logic should be integrated into the logic program To set whether the logic program runs on power up or not Select the View menu Select PPC Globals Double click the Logic Start State button Select Startup Running or Startup Not Running Click the Send button Cros Ce DD 3 When the logic start state is set to Startup Running the logic program begins executing immediately on power up Ensure the equipment is in a safe condition to run logic Closed loop control is disabled during logic downloads Control modes are set to Off Ensure that all loops can be safely disabled before downloading programs After the program has been successfully downloaded loops remain in the Off mode Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 3 Operating with AnaWin 3 Controller Parameters View and set the parameters that determine how the PPC interprets inputs performs closed loop control operates outputs and monitors proces
256. oose a timed limit the output limit restarts when the controller powers up and when the channel changes from Manual to Automatic control The output limit only affects channels under automatic control It does not affect channels under manual control The valid range is 0 to 1000 and corresponds to 0 0 to 100 0 for example a setting of 500 corresponds to 50 0 Heat Cool Limit Time Set a time limit for the Auto Heat Cool Limit If set to 0 the limit is in effect whenever the channel is in automatic control The Heat Cool Limit Time is set in seconds Sensor Fail Heat Cool When a failed sensor alarm occurs on a channel under automatic control that channel goes to Manual control at this percent power output The valid range is 0 to 1000 and corresponds to 0 0 to 100 0 for example a setting of 500 corresponds to 50 0 Doc 30002 00 Rev 2 3 Watlow Anafaze 185 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide Heat Cool Output Filter This parameter determines how much the heat or cool output s response is damped The Heat or Cool Output responds to a step change in Feedback Value by going to approximately 2 3 of its final value within the number of scans set A larger number yields a slower or more damped control response to changes in the calculated output A value of 0 disables the filter Heat Cool Output Set a heat or cool output value in percent when the channel is in Manual control mode or moni
257. or a processor and various combinations of I O modules For specification information on the power supply refer to Chapter 7 Specifications Any power supply connected to the PPC 2000 should meet these requirements e Transformer isolation e Reliable operation without noise or feedback e Provides specified voltage and current e UL Listed e Suitable for use in a 60 C ambient environment Regardless of which power supply you use you must provide sufficient current in the specified voltage range 10 28Vdc The current requirement depends on the type and number of modules used A separate power supply is required for each controller Use Table 2 1 on page 14 to calculate the current requirements for your system Doc 30002 00 Rev 2 3 Watlow Anafaze 13 Chapter 2 Hardware Installation PPC 2000 User s Guide Table 2 1 Power Supply Current Requirements at 12Vdc Module Number Current Current of startup modules per module PPC 2010 1 x 250mA 250mA PPC 202x si 30A max 4 PPC 2030 lt B6amA z max 4 PPC 2040 x 300mA max 6 PPC 2050 800mA PPC 2051 500mA max 4 PPC 206x x 250mA _ max 6 PPC 207x ar 7 max 4 Total Number of total Modules current max 10 required Table 2 2 Power Supply Current Requirements at 24Vdc Module Number Current Current of startup modules per module PPC 2010 1 x 125mA 125mA PPC 202x max 4 x 195mA PPC 2030 max 4 x 450mA
258. or each port 8 Select the desired Modbus address for the PPC system 9 Click the Send button 10 Close PPCComSu 11 Set the rotary switch on the Processor Module to position D 12 Turn off power to the PPC system 13 Turn on power to the PPC system Once configured with unique addresses as many as 32 PPC controllers may be connected to the PC on a 485 communications network Watlow Anafaze 87 Chapter 2 Hardware Installation PPC 2000 User s Guide 88 Watlow Anafaze Doc 30002 00 Rev 2 3 Operating with AnaWin3 This section describes how to use your PPC system with AnaWin3 the Watlow Anafaze HMI software For hardware installation and configuration information refer to Chapter 2 Hardware Installation For AnaWin3 installation and user information refer to the AnaWin3 User s Guide Type Definitions In the following sections a special font or typeface is used to indicate text seen on the AnaWin3 screens LP Enable Set this field to enable or disable the low process alarm When it is Enabled the low process alarm activates if the process variable PV dips below the LP Limit The PV must rise above the LP Limit plus the alarm deadband to be reset cleared When this parameter is set to Disabled the low process alarm Figure 3 1 Sample Screen Text The words LP Enable and LP Limit are shown as they appear in AnaWin3 Closed Loop Control Doc 30002 00 Rev 2 3 The PPC 2000 closed loop cont
259. ordinating a heat and a cool output driven by a single channel The Control Type parameter offers two choices PID1 and PID2 Table 3 1 describes these two algorithms Table 3 1 Control Types PID1 and PID2 PID1 Only the heat output or the cool output is on at any instant in time The spread parameter pro vides a minimum switching hysteresis between the two outputs The channel will not switch from heating to cooling until the heat integral sum has dropped to zero which is to say until the process variable has been above set point for some amount of time When the spread is set to zero however the channel switches from heat to cool depending on the PID calculation only regardless of whether the process variable is above the set point PID2 When a channel uses the PID2 control type the cool output will come on whenever the process variable is above the set point by more than the spread setting The cool output remains on until the process variable drops to the set point The heat output operates as it would if the cool out put were not enabled This algorithm was devel oped for plastic extruders but may be of benefit whenever a load is typically heated but occa sionally needs cooling Watlow Anafaze 91 Chapter 3 Operating with AnaWin 3 92 PPC 2000 User s Guide Setting up Control Channels Closed loop control channels can be set up in various ways in the PPC 2000 The following procedure i
260. osed Loop Control 89 Feedback 90 Control Algorithm 90 Control Output Signal Forms 90 Heat and Cool Outputs 90 Prerequisites 93 Background 93 Using AnaWin3 to Tune 94 Alarms 95 Failed Sensor Alarms 95 Global Alarm 95 Process Alarms 95 Alarm Delay 96 Setting up Process and Deviation Alarms 97 Setting Input Signal Lo and Input Signal Hi 99 Setting Engineering Units 99 Setting PV Lo and PV Hi 99 Setting Decimal Places 100 Linear 4 20mA Input Example 101 Process Variable Retransmit 102 Setting up Process Variable Retransmit 103 Process Variable Retransmit Example 104 Cascade Control 105 Setting up Cascade Control 106 Cascade Control Example 106 Ratio Control 109 Setting up Ratio Control 110 Differential Control 112 Remote Set Point 112 Logic Programs 112 Setting up Outputs for Use with a Logic Program 113 Using Logic to Set an Analog Input 113 Starting and Stopping Logic Programs 113 Controller Parameters 115 Channels 115 Digital O 132 Soft Integer 136 Soft Boolean 137 Doc 30002 00 Rev 2 3 Watlow Anafaze Table of Contents PPC 2000 User s Guide Troubleshooting 141 General Description 141 PPC 2010 Processor 141 Processor Module LEDs 147 PPC 2040 Digital I O 151 PPC 207x Digital In 153 Troubleshooting and Corrective Actions 154 Digital Inputs and Outputs 154 Process Variable 154 Communications 155 Resetting Closed Loop Control Parameters 156 Disabling Control 157 LogicPro and Modbus Reference 159 Overview 159
261. outputs for a channel are used The spread is also the switching hysteresis for on off channels with Output Type set to On Off The spread is in the channel s engineering units Range same as the range of the input type selected See Table 3 14 on page 130 Watlow Anafaze Doc 30002 00 Rev 2 3 Heat Cool Scale Lo Set this parameter in conjunction with Heat Cool Scale Hi to scale the output or to change the control action See table 3 x Enter the value as a percent of range that the output should approach as the process variable approaches the set point from below for a heat output or from above for a cool output See Figure 3 x The default and typical value is 0 For example as a heater raises the temperature of a load towards set point the output decreases toward 0 In some cases it is desirable that the output never reach 0 in that case enter a minimum value greater than 0 Range 0 0 to 100 0 Heat Cool Scale Hi Set this parameter in conjunction with Heat Cool Scale Lo to scale the output or to change the control action See table 3 x Enter the value as a percent of range that the output should approach as the process variable moves away from the set point either upward for a heat output or downward for a cool output See Figure 3 x The default and typical value is 100 For example as the temperature of a heated system drops the controller increases its output toward 100 In some cases it is desirable that the o
262. parameters can be read and set by Modbus devices and logic programs Accessing Analog and Counter Input Parameters with Modbus To access analog and counter input parameters use the database offset as the Modbus address offset See Table 5 3 on page 164 through Table 5 6 on page 166 for a list of the database offsets and Modbus addresses corresponding to the analog and counter inputs Table 5 8 on page 168 lists first and last Modbus addresses for each input parameter Use these addresses when accessing analog or counter input parameters with third party software or operator interface terminals Accessing Analog and Counter Input Parameters with LogicPro Doc 30002 00 Rev 2 3 To access counts frequencies and analog input values measured by the modules use the appropriate IO Driver in LogicPro There are separate drivers for each type of module The driver requires an IO Physical Address to determine which analog input to read on the module See Table 5 3 on page 164 through Table 5 6 on page 166 to determine LogicPro IO Physical Address The LogicPro IO Physical Addresses are listed by input according to the default Input names as seen in AnaWin3 To correlate the AnaWin3 name with the hardware connection see Table 2 10 on page 39 Table 2 12 on page 47 Table 2 15 on page 56 Table 2 16 on page 56 and Table 2 19 on page 60 When a logic program variable accesses an analog input parameter the parameter number and the
263. pes RTD voltage current e As many as 288 digital I O points e 48 closed loop control channels with autotune e Windows based logic programming software option e Third party operator interface terminal OIT support option System Components Doc 30002 00 Rev 2 3 Any system must include a power supply and a processor module PPC 2010 with built in digital I O The appropriate additional modules are added for analog inputs analog outputs and expanding the digital I O See Figure 1 1 on page 6 4 and Figure 1 2 on page 6 6 for illustrations of the PPC s system components and modules Refer to Table 1 1 on page 5 for a description of the modules and their functions The number and types of I O are determined by which modules are selected for the application Field wiring connects to DIN rail or panel mounted terminal block boards Terminal block boards connect to I O modules via 50 pin SCSI cables Watlow Anafaze 3 Chapter 1 Overview PPC 2000 User s Guide The following hardware and software interfaces are provided Hardware e Serial ports for interfacing host computers and third party operator displays e Analog input and output terminal block connections e Digital input and output terminal block connections Software Firmware e Remote third party operator interface panel software using Modbus protocol option e AnaWin3 Configurator edition Windows configuration utility e LogicPro Windows logic p
264. proc d s Cat gorie d installation II Degr de pollution II Tension nominale 12 24 V c c Consommation d alimentation nominale 50 VA maximum Classification R pond aux normes essentielles des directives suivantes de l Union europ enne en utilisant les standards normalis s ci dessous qui expliquent les normes auxquelles r pondre Directive 89 336 CEE sur la compatibilit lectromagn tique EN 61326 1997 avec A1 1998 Mat riel lectrique destin l talonnage au contr le et l utilisation en laboratoire Exigences CEM Immunit industrielle Emissions de cat gorie A Doit tre quip de filtre ext rieur pour l utilisation en classe B EN 61000 4 2 1996 Avec A1 1998 Immunit aux d charges lectrostatiques EN 61000 4 3 1997 Immunit aux champs de radiation EN 61000 4 4 1995 Immunit contre les surtensions lectriques rapides Rafale EN 61000 4 5 1995 avec A1 1996 Immunit contre les surtensions EN 61000 4 6 1996 Immunit conduite EN 61000 4 11 1994 Immunit contre les carts de tension interruptions courtes et variations de tension EN 61000 3 2 1995 avec A1 3 1999 Emissions de courant harmoniques EN 61000 3 3 1995 avec A1 1998 Fluctuations et vacillements de tension Directive 73 23 CEE sur les basses tensions EN 61010 1 1993 avec A1 1995 Normes de s curit du mat riel lectrique pour la mesure le contr le et l utilisation en laboratoire 1 re parti
265. ptoms of RFI EMI If your controller displays the following symptoms suspect EMI Measured values for analog inputs fluctuate or are incorrect Open collector outputs fail The watchdog time out LED on the Processor Module lights EMI may also damage the digital output circuit so digital outputs will not turn on If the digital output circuit is damaged return the controller to Watlow Anafaze for repair Avoiding Noise Problems To avoid RFI EMI noise problems PPC 2022 32 analog input module must be used with isolated ungrounded thermocouples only PPC 2022 32 analog input module should not be used with thermocouples that are embedded within heaters as some cartridge heaters are constructed Separate the 120 or 240Vac power leads from the low level input and output leads connected to the controller Don t run the digital I O or control output leads in bundles with 120Vac wires Where possible use solid state relays SSRs instead of electromechanical EM relays If you must use EM relays try to avoid mounting them in the same panel as the PPC 2000 series equipment When switching an inductive load such as an electromechanical relay or solenoid install a snubber across the load Use a 0 01 microfarad capacitor rated at 1000Vac or higher in series with a 47 Ohm 0 5 watt resistor across the NO contacts of the relay load See Chapter 2 Connecting to the Relay Outputs on the PPC 206x on page 70 for specific instr
266. put 2 gt Analog Com optional Figure 2 37 Connecting Current Inputs to a Differential Input Module Input 1 2 and 3 Shown Single ended current sources should be have the positive lead on the positive terminal of the desired input The negative lead should be connected to the COM terminal See Figure 2 38 on page 54 Doc 30002 00 Rev 2 3 Watlow Anafaze 53 Chapter 2 Hardware Installation 54 PPC 2000 User s Guide Redraw like other I O diagrams Power Supply power 28V Max Typical 2 wire current transmitter Typical 3 wire current source transmitter power 28 V Max 4 DAlnput 2 Com Figure 2 38 Connecting Current Inputs to a Single ended Analog Input Module Input 1 and 2 Shown Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Connecting Encoders and Analog Outputs to the PPC 2030 The PPC 2030 accepts four encoder inputs and outputs four current or voltage signals Encoder signals are connected to the module via two HD 15 cables These cables may be used in conjunction with up to two EITBs or may be connected directly from the encoders to the module Connect analog outputs via the analog output terminal block as shown in Figure 2 39 LT J4 Encoder l
267. r s Guide Chapter 5 LogicPro and Modbus Reference Table 5 58 System Commands Doc 30002 00 Rev 2 3 Reset Database Modbus After i Offset Address Name Host Ackon Write Load defaults to most run time parameters The exceptions are protocol baud parity address Reload system HW config system com 1 04051 Reset mands system status program Defaults version change data queue system error log real time clock and analog input calibration data 2 04052 Reserved N A 3 04053 Reserved N A 4 04054 RAM Clear Reset Clear RAM reset controller and Reset load defaults 5 04055 ore Reset Force watchdog timeout 6 04056 Start Logic Reset Start logic program 04057 Reserved N A 04058 Stop Logic Reset Stop logic program 0 Start control loops in off Loop mode Undo not available 04059 Startup Latched 1 Start control loops from last mode stored in memory AC 0 60Hz 10 04060 Frequency Latched 1 50Hz 0 Start logic program when 11 Gadey oae statii gidis Commences tup 1 Start logic program on star tup 12 04062 Reset PPC Reset Reset controller Watlow Anafaze 213 Chapter 5 LogicPro and Modbus Reference 214 PPC 2000 User s Guide System Status Provides information about various controller functions and errors These values are read only Some status bits are sets to 0 after being read by a host Other status bits are not affected by host reads and are la
268. r L O type L module address i e module type L_y controller number Figure 3 17 Pulse Input Names Soft inputs appear on the Inputs spreadsheets A soft input can be selected as the PV Source of a channel when that channel is to get its feedback from a logic program There are 50 soft inputs in a PPC These inputs are not associated with any physical I O A value written to a soft input by a logic program is treated as a raw input and is scaled and filtered according to its input parameter settings If a soft input is selected as a PV Source the input type will be set automatically to Linear counts Figure 3 18 illustrates how soft input names appear in the spreadsheet PPG1 Soft ae soft input number L controller number Figure 3 18 Soft Input Names Channel outputs appear on the Inputs spreadsheets A channel output can be selected as the Set Point Source of a channel for cascade control applications See Cascade Control on page 105 There are 48 channel outputs in a PPC These inputs get their value from the sum of the Heat Output and Cool Output of each channel Channel outputs are treated as raw inputs and are scaled and filtered according to the input parameter settings Figure 3 19 on page 129 illustrates how channel output names appear in the spreadsheet settings Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chap
269. r 5 LogicPro and Modbus Reference PPC 2000 User s Guide 184 Heat Cool Cycle Time Specify the time base in seconds for time proportional outputs The output percentage is proportioned over this time period For example a 50 output with a 10 second cycle time is on for 5 seconds and off for 5 seconds Output cycle time only affects control when the corresponding output type is set to Digital Time Proportioning Time Prop Heat Cool Scale Lo A control output may be linearly scaled by setting this parameter Set the percent of the output range of the selected Heat Cool Output Type that should correspond to a calculated Heat Cool Output of 0 This parameter is set in tenths of a percent The valid range is 0 to 1000 and corresponds to 0 0 to 100 0 for example a setting of 500 corresponds to 50 0 Heat Cool Scale Hi A control output may be linearly scaled by setting this parameter Set the percent of the output range of the selected Heat Cool Output Type that should correspond to a calculated Heat Cool Output of 100 This parameter is set in tenths of a percent The valid range is 0 to 1000 and corresponds to 0 0 to 100 0 for example a setting of 500 corresponds to 50 0 Heat Cool Curve Use this register to choose which output scaling method is used Straight linear is used for most applications Lag curves are usually used in plastic extruder applications Table 5 21 on page 184 lists and describes the values
270. r of the analog input module The AITB accommodates wiring thermocouples RTDs and voltage current linear inputs a a a a a a aD S68 G88 G86 aaa 660 S55 Sag oco oni ooo oo oj JE Pao INTL NSI NSL N L NOL INTIL NISL NISI KEY CARD COMPONENTS FACE ARROW DIRECTION if oco ooo ooo ooa ooo ooo ol y 4L 6 JE o o TE am J6 S Me SH O MS Sm O jo ME z o le 3 s O g jo o ms sm loj le MEA sim o je me m Jo e g m l o Siez i S Sa sm o je me m jo e e all jo je Ms al O z s o jo Me sm jo lo mA am je je Ws sl lol lol me am jo jo ME am loj je me Jm loj lol ms sm jo lol ms Watlow Anafaze O gt fe O PPC ATB o Figure 2 28 PPC 2021 2025 Connection to AITB Connecting the AITB to the PPC 202x NOTE Doc 30002 00 Rev 2 3 Refer to Figure 2 28 Connect the 50 pin SCSI connector from the analog input module s to the analog input terminal block AITB Table 2 13 on page 48 shows the AITB pinout If more than one AITB has been installed it may be useful to label both ends of the SCSI cable and the AITB with the address selected on the corresponding analog input or high isolation analog input module Watlow Anafaze 45 Chapter 2 Hardware Installation Sensor Keys PPC 2000 User s Guide Sensor keys with built in jumpers or resistors are used to customize the AITB for various sensor types
271. ral is set to zero the value substitutes for the integral sum portion of the feedback calculation In this case the output equals the heat cool manual reset value when the process variable is at set point When the integral value is set to a value other than zero the manual reset value is added to the result of the PID calculation and thereby shifts the output variable Range 0 0 to 100 0 Heat Cool Output Dest Select the output destination to specify the I O point used for the control output This is the output for the closed loop control channel Selecting Not Assigned indicates no output is to be used and is an appropriate setting for monitor only channels If both heat and cool output destinations are set the channel performs bimodal control See Heat and Cool Outputs on page 90 for more information on this type of control Range Any output found on the Dig I 0 or Outputs spreadsheet or any of the Soft Bool or Soft Int registers Heat Cool Output Type This field specifies the type of output signal and determines whether the PID or on off control algorithm is used for the channel Refer to AnaWin3 Output Types on page 120 for a description of the output type options Watlow Anafaze 119 Chapter 3 Operating with AnaWin 3 PPC 2000 User s Guide Table 3 13 AnaWin3 Output Types Output Type Description Function z o Percent output converted to a percent duty Time Prop digita mie proportioned cycle
272. rameter is set to a value greater than the corresponding Heat Cool Scale Hi the Heat Output or Cool Output values are inversely related to the actual output signal In this case when the Heat Cool Output indicates 0 the output is fully on regardless of whether the Control Mode is set to Auto Manual or Tune Always remove power from the controller before servicing any components Figure 3 x Heat and Cool Scaling Parameters a o O O Set Point Cool Prop Band Cool Scale Hi 2 28 oO x Cool Scale Lo S ae Set Point 2 O Heat Scale Lo 8 z fam Set Point Heat Prop Band Heat Scale Hi As the process variable increases away from set point the cool output trends toward the Cool Scale Hi value As the process variable decreases away from set point the heat output trends toward the Heat Scale Hi value PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference 100 20 90 80 80 79 Actual Me irf Output Linear S e Applied 60 50 A N 48 ae 4 0 40 A 36 30 oy 29 a 20 19 19 fo 4 4 13 A2 8 7 B F a pt Seay 0 Calculated Closed Loop Control Action Figure 5 2 Output Scaling Curves Auto Heat Cool Limit This parameter limits the control output for a channel s heat and cool outputs This limit may be continuous or it may be in effect for a specified number of seconds see Heat Cool Limit Time below If you ch
273. res the logic program if one has been programmed After replacing a flash memory chip the logic program should be downloaded to the controller using LogicPro Be sure to take antistatic precautions 1 Save snapshot The logic program will be erased 2 Power down the controller and system including heaters etc 3 Remove the power connection to the processor module and any cables between the modules and terminal boards 4 Note and label cable locations 5 Remove the PPC 2000 system from the DIN rail or panel 6 Make sure the red top and bottom module latches on the processor module are in the unlocked position pushed toward the back of the module Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 4 Troubleshooting Module top latch unlocked Module locked Figure 4 1 Assembled Modules Top View Front O O Module bottom latch locked o 2 Module bottom latch unlocked Back Figure 4 2 Assembled Modules Bottom View T 8 Doc 30002 00 Rev 2 3 Gently rock and pull the modules apart Refer to Figure 4 3 on page 144 to locate the flash memory chip on the controller board Use a PLCC extractor tool or insert a small flat blade screwdriver into one of the notches at the corner of the socket and gently pry the flash memory chip out of the socket Watlow Anafaze 143 Chapter 4 Troubleshooting 10 11 12 13 14 1
274. riable moves away from the set point either upward for a heat output or downward for a cool output See Figure 3 x The default and typical value is 100 For example as the temperature of a heated system drops the controller increases its output toward 100 In some cases it is desirable that the output never reach 100 in that case enter a maximum value less than 100 See also Auto Heat Cool Limit This parameter is set in tenths of a percent The valid range is 0 to 1000 and corresponds to 0 0 to 100 0 for example a setting of 500 corresponds to 50 0 Note Sometimes it is necessary for a heat output to increase as the process variable approaches the set point from below In such cases the Heat Cool Scale Lo value is set above the Heat Cool Scale Hi parameter See Direct Heat in Table 3 x For example in some systems heat is added outside the control loop and the heat output controls a cooling water flow In such a system as the temperature rises to set point the output increases to flow more water and slow the heating process Table 3 x Output Scaling Parameters Settings and Control Action Output Control Action Scale Lo Scale Hi Note Heat Reverse Default 0 100 As the process variable increases Cool Reverse 100 0 the output decreases Heat Direct 100 0 As the process variable increases Cool Direct Default 0 100 the output increases CAUTION When a Heat Cool Scale Lo pa
275. rm output activates and requires alarm acknowledgment to clear Digital output or Soft Bool if set activates on alarm deactivates when channel is not in alarm Pentel Global alarm output does not activate No alarm acknowledgment required to clear Watlow Anafaze 95 Chapter 3 Operating with AnaWin 3 PPC 2000 User s Guide High and low process and deviation alarms activate when the process variable goes outside the limits set by the user The alarm remains active until both the process variable comes within the limit and the deadband and the alarm is acknowledged Any digital output not used as a control output can be assigned to a process alarm The output activates when the alarm is active Set the Logic of outputs used with alarms to determine whether the alarm output turns on or off when an alarm occurs An alarm output remains active only as long as the process variable remains outside the alarm limit and deadband Once the process variable is within the limit and deadband the output reverts to the inactive state No alarm acknowledgment is required When the controller powers up or the set point changes deviation alarms set to alarm type do not activate until the process variable comes within the deviation alarm band preventing deviation alarms during a cold start Deviation alarms set to control type activate whenever the process variable is outside the deviation band High Process alarm on High P
276. rocess alarm off High Process alarm limit High Deviation alarm on SP HD Offset High eel alarm off Set Point Low Deviation alarm off boa Low Deviation alarm on SP LD Offset Deadband Deadband ie Pracase BX fs Process alarm off Figure 3 2 Process Variable Alarms Low Process alarm limit Alarm Delay The controller may be configured to delay alarm reporting Alarm Delay delays failed sensor alarms and process alarms for the channel Only alarms that are continuously present for longer than the alarm delay time are reported 96 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 3 Operating with AnaWin 3 Setting up Process and Deviation Alarms Doc 30002 00 Rev 2 3 To enable alarms on the process variable for a channel follow these steps See Alarms on page 123 for descriptions of the alarm parameters On the Alarms spreadsheet 1 Set the Alarm Deadband 2 Set the Alarm Delay 3 For each alarm you wish to activate a Set the alarm limits in the corresponding fields LP Limit LD Offset HD Offset HP Limit b Choose the alarm behavior by setting the correspond ing field LP Type LD Type HD Type HP Type to Alarm or Control c Choose an available digital output to activate when the alarm occurs if desired in the corresponding field LP Output Dest LD Output Dest HD Output Dest HP Output Dest 4 On the Dig 1 0 spreadsheet set the Logic of ea
277. roduce the desired effect on the secondary channel s set point The primary channel typically uses proportional only control Disabling the integral and derivative components of PID makes the secondary set point a predictable function of the primary channel s process variable The proportional band is selected so the set point of the secondary channel has the desired relationship to the process variable of the primary channel In this application the proportional band of the primary channel is set to 10 F Table 3 9 Primary Channel Parameter Settings Parameter Setting Description PV Source PPC1 Al 1 1 The outer TC is selected for the primary channel Set Point 150 F The desired temperature at the inner TC Heat Prop Band 10 As the input drops 10 F the output increases to 100 Heat Integral 0 Only proportional control is used Heat Derivative 0 Only proportional control is used Heat Output Dest PPC1 Soft Bool The primary output must be enabled but is not used to drive a load Doc 30002 00 Rev 2 3 Watlow Anafaze 107 Chapter 3 Operating with AnaWin 3 PPC 2000 User s Guide Table 3 10 Secondary Channel Parameter Settings Parameter Setting Description PV Source PPC1 Al 1 2 Theinner TC is selected for the secondary channel Set Point Source For cascade control the primary channel s output Channeli determines the secondary channels set point
278. rogramming utility option e AnaWin3 Developer edition Windows user interface data monitoring and trend logging utility option PC for AnaWin3 HMI Power PPC 2000 Encoder Input Software and or LogicPro Supply Assembly Termiti __Analog Input Terminal Board pan AITB TB50 for F z Digital I O Operator deaan Interface 3 m1 f Terminal EFR EE gt TE MeLe al Le ah hal Figure 1 1 System Diagram 4 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter 1 Overview Table 1 1 PPC 2000 System Modules Module Description PPC 2010 Processor 48 digital I O 2 serial ports PPC 2021 2022 1 counter frequency input 16 differential or 32 single ended analog inputs PPC 2024 2025 8 or 16 highly isolated analog inputs PPC 2030 4 encoder inputs and 4 analog outputs PPC 2040 cea aaa digital I O 2 counter frequency PPC 2050 8 analog outputs PPC 2051 4 analog outputs PPC 2061 16 relay outputs PPC 2062 8 relay outputs PPC 2070 2071 8 16 120Vac inputs PPC 2072 2073 8 16 24V AC DC inputs Table 1 2 PPC 2000 Terminal Boards and Peripheral Modules Terminal Board Description PPC IPS 2 International Power Supply 120W PPC AITB 1 Analog Input Terminal Board PPC TB50 SCSI Terminal board for digital I O PPC EITB 1 Encoder Input Terminal Board Table 1 3 An
279. rol program can control up to 48 channels Closed loop control refers to the control of an output based on feedback from a sensor or other signal Watlow Anafaze 89 Chapter 3 Operating with AnaWin 3 90 Feedback PPC 2000 User s Guide Electrical signals from a sensor used to determine a control output is feedback The Input parameters determine how the electrical signal is interpreted Many standard sensor types are pre programmed into the PPC 2000 and can be selected during setup The controller interprets or scales the electronic signals for these sensor types in engineering units F or C Other sensor types may require user supplied scaling information See Setting up User Selectable Linear Inputs on page 98 In some cases the feedback signal may come from a value other than a sensor input Using a Soft Input a logic program can determine the feedback to a channel Control Algorithm The PPC 2000 determines the appropriate output signal when a set point is supplied and the controller is set to automatically control a loop The controller calculates the output based on the feedback and the control algorithm Each channel may use either On Off or any combination of Proportional Integral and Derivative PID control modes See Control Algorithms on page 220 for information on these control modes The PPC 2000 also includes a manual reset term that may be used in conjunction with some of the PID modes See Channels on pag
280. s places a 120 ohm resistor across the receive lines See PPC 2010 Jumper Settings on page 18 Alternately the line may be terminated externally on the 485 terminal block by placing a termination resistor across the receive line screw terminals near the last PPC See Figure 2 70 on page 81 The value of the termination resistor should be equal to the impedance of the communications cable used Values are typically 120 to 200 ohm Watlow Anafaze 85 Chapter 2 Hardware Installation 86 PPC 2000 User s Guide Modbus Network Address NOTE For multiple PPC installations each PPC 2010 must have a unique network address As many as 32 PPC systems may communicate on a network Both port 1 and 2 have the same network address Network addresses 1 through 4 can be set using the rotary switch on the processor module Changed communication parameters do not take affect until the controller resets or cycles power and only with the appropriate rotary switch settings on the Processor module Use rotary switch setting D and PPCComSu to program the remaining addresses 5 32 See Setting Programmable Modbus Addresses on page 87 for programming information Do not cycle power with the rotary switch set in positions E G unless specifically directed to do so These positions are used for clearing memory and other functions Parameter settings can be lost See Chapter 4 Troubleshooting for more on these switch settings Table 2 31 PPC 20
281. s value The offset is set in the engineering units of the channel but relative to the process setpoint The alarm limit changes when the process setpoint changes The default low deviation offset is 0 Alarm Deadband This parameter prevents the process and deviation alarms from toggling on and off when the process variable is near the alarm limit For high alarms the deadband is below the setpoint for low alarms the deadband is above the setpoint An alarm that occurs when the process variable crosses the alarm setpoint does not clear until the process returns within the alarm setpoint and the deadband value The deadband is set in the engineering units of the channel The default alarm deadband is 2 Watlow Anafaze 193 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide NOTE 194 Alarm Delay This value delays alarm reporting to prevent the reporting of false alarms due to noise on the input The alarm delay applies to failed sensor alarms and process and deviation alarms Only alarms that are present for longer than the alarm delay time are reported The alarm delay is set in seconds Use the Database Offset number of an output for the alarm output value See Table 5 33 on page 196 through Table 5 36 on page 199 If more than one alarm is assigned to the same output number that output will be on if any of those alarms is active High Process Output Destination HP Output Dest Choose the digital outp
282. s port that isn t open 97 33297 Bad Parity Internal error attempt to configure unsupported parity 101 33301 Bad CRC Modbus message CRC did not match 102 33302 Bad Modbus Func Modbus message attempted unsupported function 103 33303 Invalid Address Invalid Modbus register address 104 33304 Pckt Ln or Func Bad Modbus packet length or diagnostic subfunction 107 33307 Packet Length Bad Modbus packet length 108 33308 Bad Address Bad Modbus register address 111 33311 Missed I O Update Internal error missed I O update deadline 129 33329 Bad Error Msg Internal error attempted to post error of 128 or greater Doc 30002 00 Rev 2 3 Watlow Anafaze 217 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide 218 Time and date The PPC 2000 s clock calendar automatically updates the year day of the week month date hour minute and second The time and date can be set initially with a PC or similar host The information located in seven registers can be used in logic programs or a host computer Table 5 63 describes the data format Table 5 63 Real Time Clock Format Database ipti Ran Offset Description ange 0 Year 0 to 99 1 Day of Week 1 to7 2 Month 1to 12 3 Date 1 to 31 4 Hours 0 to 23 5 Minutes 0 to 59 6 Seconds 0 to 59 The values for day of the week are not predefined They are in cremented with the date The user chooses what day equals a val ue of one and
283. s set point is equal to the Min Set Point when the primary channel s cool output is at 100 and equal to the Max Set Point when the primary channel s cool output is at 0 Max Set Point Min Set Point 100 d Primary Channel s Output of Full Scale Set Point of the Secondary Channel Engineering Units Figure 3 6 How the Secondary Channel s Set Point is Determined When the Primary Channel Has Heat and Cool Outputs Doc 30002 00 Rev 2 3 Watlow Anafaze 105 Chapter 3 Operating with AnaWin 3 PPC 2000 User s Guide Max Set Point Min Set Point 0 1d0 Primary Channel s Heat Output of Full Scale Set Point of the Secondary Channel Engineering Units Figure 3 7 How the Secondary Channel s Set Point is Determined When the Primary Channel Has Only a Heat Output Setting up Cascade Control To setup cascade control 1 Set up the primary loop See Cascade Control Example below 2 Set up control for the secondary loop as you would for a standard closed loop application See Setting up Control Channels on page 92 3 On the secondary channel a Select the primary channel s output Channel Out for the Set Point Source setting b Set the Min Set Point to the desired set point when the primary channel s output is at its minimum value c Set the Max Set Point to the desired set point when the primary channel s output is at its maximum value Cascade Control Example
284. s usually have negative temperature coefficients although they are also available with positive temperature coefficients Thermocouple T C A temperature sensing device made by joining two dissimilar metals This junction produces an electrical voltage in proportion to the difference in temperature between the hot junction sensing junction and the lead wire connection to the instrument cold junction Tune To set PID parameters on a closed loop control system v Volt V The unit of measure for electrical potential volt age or electromotive force EMF Voltage V The difference in electrical potential between two points in a circuit It s the push or pressure behind current flow through a circuit One volt V is the difference in potential required to move one cou lomb of charge between two points in a circuit consuming one joule of energy In other words one volt V is equal to one ampere of current I flowing through one ohm of resistance R or V IR 290 Watlow Anafaze PPC 2000 User s Guide Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Watlow Anafaze Glossary 291 Glossary PPC 2000 User s Guide 292 Watlow Anafaze Doc 30002 00 Rev 2 3
285. s variables for alarm conditions on AnaWin3 s Spreadsheet Overview screen Select the buttons on the PPC tab to configure the seven spreadsheets Channels Alarms Inputs Dig 1 0 Outputs Soft INT and Soft BOOL each detailed below Global parameters are found on the PPC Globals screen under AnaWin3 s View menu These parameters may also be accessed by a properly configured operator interface terminal or third party software Parameter definitions and ranges are defined below When using a third party interface refer to Chapter 5 Custom Interfacing for additional information Channels Select the Channels button to configure or monitor PPC channel parameters Channel names are located in the first column each channel has a row of parameters associated with it These parameters control the behavior of the closed loop control channels and determine which sensor input and control outputs are used Setpoin Process Variable Control Heat Outpu PPC1 Channel 1 PPC1 Channel 2 90 PPC1 Channel 3 0 6 PPC1 Channel 4 9 2 Figure 3 12 Channels Spreadsheet Channel names indicate the controller and the channel For example PPC1 Channel 3 indicates the third channel on the first PPC Each channel can have one input and one or two outputs heat and or cool Many of the channel parameters may be individually set for the heat and cool outputs For example Heat Prop Band is the proportional band for the heat output an
286. ser s Guide A ol S Se 2 QS aO fe NNN 8 WS Ae 2 B63 fe VRS S XAL lo X SS lo Se A BLS lo Sre e 3 4 in 86 mm Figure 7 18 PPC EITB Dimensions with HD Type Cable 260 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 7 Specifications PPC TB50 SCSI 50 Pin Specifications 4 1 in H 104 mm a HHHEHHHEHHHHEJ 229 G08 S09 228 D BRBRBBRABRBERY l 4 0 in W 102 mm Figure 7 19 PPC TB50 SCSI Dimensions Table 7 67 Environmental Specifications Storage Temperature 20 to 70 C Operating Temperature 0 to 60 C Humidity 10 to 95 non condensing Table 7 68 Physical Specifications Weight 0 32 Ibs 0 14 kg Height 4 1 in 104 mm Width 4 0 in 102 mm Depth 1 45 in 37 mm Doc 30002 00 Rev 2 3 Watlow Anafaze 261 Chapter 7 Specifications 262 Table 7 69 Connections PPC 2000 User s Guide Screw Terminal Wire Gauge 24 to 12 AWG Screw Terminal Torque 0 5 to 0 6 Nm 4 4 to 5 3 in lb Connector on Board SCSI 2 female Terminals Captive screw cage clamp Mounting DIN rail or panel mount Table 7 70 PPC TB50 SCSI with Straight SCSI Height 6 4 in 163 mm Width 4 0 in 102 mm Depth 1 45 in 37 mm IN 6 4 in H 163 mm N A 9
287. served Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 NOTE Chapter 5 LogicPro and Modbus Reference Table 5 17 Process Variable and Setpoint Source Settings for Counter Inputs on the PPC 2040 Modules Input Name Values AnaWin3 Input Spreadsheet 301 PPC1 DIO 21 1 1 C 302 PPC1 DIO 21 2 1 F 303 PPC1 DIO 21 1 2 C 304 PPC1 DIO 21 2 2 F 305 PPC1 DIO 22 1 1 C 306 PPC1 DIO 22 2 1 F 307 PPC1 DIO 22 1 2 C 308 PPC1 DIO 22 2 2 F 309 PPC1 DIO 23 1 1 C 310 PPC1 DIO 23 2 1 F 311 PPC1 DIO 23 1 2 C 312 PPC1 DIO 23 2 2 F 313 PPC1 DIO 24 1 1 C 314 PPC1 DIO 24 2 1 F 315 PPC1 DIO 24 1 2 C 316 PPC1 DIO 24 2 2 F 317 PPC1 DIO 25 1 1 C 318 PPC1 DIO 25 2 1 F 319 PPC1 DIO 25 1 2 C 320 PPC1 DIO 25 2 2 F 321 PPC1 DIO 26 1 1 C 322 PPC1 DIO 26 2 1 F 323 PPC1 DIO 26 1 2 C 324 PPC1 DIO 26 2 2 F The range of values and the precision of the Process Variable and Setpoint depend on the Input Type of the analog input selected as the Process Variable Source for the channel See Table 5 10 on page 170 Process Variable This register contains the actual value measured by the sensor attached to the input set as the Process Variable Source for the channel see above The process variable is used in the channel s feedback calculation This register is read only Watlow Anafaze 179 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide 180 Setpoint The
288. steady state signal such as an AC continuous source electrically tied into an input line Corrective Actions Locate the source of the noise and remove it Remove ground loop problems Check cabling loose cables or input wires may cause in termittent noise Error 4 Red LED on Indicates a reference voltage overload The precision 10Vdc source is being overdrawn The LED will glow and increase with intensity as more current is overdrawn Corrective Actions If an AITB is used with an analog input module check to make sure all key cards are inserted properly Reverse in sertion will cause the LED to light If the 10V reference on the AITBs are used to power an ex ternal circuit i e bridges etc make sure the total current required does not exceed the specified limit Refer to Chapter 7 Specifications for current information These conditions will not harm the voltage source Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter 4 Troubleshooting Green Status and Error 3 LEDs remains on Indicates two or more modules are set to the same address Corrective Actions Change the rotary switch settings so that each module has a unique address Refer to Module Addresses on page 17 Green Status LED remains off on or blinks incorrectly If analog input scanning is properly functioning the green LED blinks If the LED remains off on or blinks incorrectly the module is
289. stem Check that the modules are connected properly refer to Module Assembly on page 24 Perform a RAM clear refer to Resetting Closed Loop Control Parameters on page 156 Replace the module LED indicators are OK but pulse inputs are not seen or are incorrect Some or none of the wired input data is being transferred to the system This may be an indication of a software or hardware problem Corrective Actions Ensure that inputs are wired to the correct pins on the high density cable connector or EITB Check that the cable is connected to the correct port The connector closest to the back carries pulse inputs 1 and 2 The connector closer to the face of the module carries pulse inputs 3 and 4 Make sure that the module has been configured properly for quadrature vs single phase pulse inputs for each channel used A quadrature encoder connected to an input configured as a single phase will appear to operate back wards Rotation that should increase the count decreases it and vice versa Refer to Figure 2 5 on page 20 for in structions on setting switches for the encoder inputs LED indicators are OK but analog outputs are not seen or are incorrect Some or none of the wired input data is being transferred to the system This may be an indication of a software or hardware problem Corrective Actions Ensure connections to terminal blocks are correct Refer to Analog Output Connections on page 60 for analog output wir
290. system and each type of module Specifications are subject to change without notice System Specifications This section contains specifications for the PPC 2000 system as a whole Safety and Agency Approvals Table 7 1 describes safety and agency approvals for the PPC 2000 system Approvals apply to all PPC 2000 modules and peripherals except as noted in the specifications for individual modules or peripherals on the following pages Table 7 1 Safety and Agency Approvals UL C UL CE Safety EN 61010 1 CE EMC EN 61326 EN 55011 3121 1 Listed Category II Installation File E212113 Doc 30002 00 Rev 2 3 Watlow Anafaze 229 Chapter 7 Specifications PPC 2000 User s Guide Physical Specifications d 3 Inch Min Air A A Flow Space a A 0 46 in _____ po _ Width A 4 I d l 3 5 in 6 6 in 10 Screw 4Places NL 5 ain 1 4 in 4 a Sy a STL 1 1 in a i 4 8 3 to 4 in Typical La al Figure 7 1 System Footprint Table 7 2 PPC System Dimensions Number of Modules Width A Overall Width 1 2 705 in 3 165 in 2 3 660 in 4 120 in 3 4 615 in
291. t frequency or counts Also choose an Input Type with the appropriate range and sensitivity for the sensor Generally the appropriate Input Type for Soft Inputs is Linear Counts Table 3 3 Range and Sensitivity of the Custom Linear Input Types Input Type Range Input Resolution gia Linear 1 to 10 V 1 000 to 10 000V 0003V Linear 0 1 to 1 V 100 0 to 1000 0mV 03mV Linear 10 to 100 mV 10 00 to 100 0mV 003mV i Linear 2 to 20 mA 2 000 to 20 000mA 0006mA Linear Counts Bs logeree 1 count 4Hz ounts Linear 0 to 300 00 Hz 327 68 to 327 67Hz 04Hz 04Hz Linear 0 to 10k Hz 32768 to 32767Hz 4Hz 4Hz Depends on module type See Chapter 7 Specifications Setting Input Signal Lo and Input Signal Hi After choosing the Input Type set the Input Signal Lo and Input Signal Hi The Input Signal Lo is the lowest level signal the sensor will supply Typically this corresponds to the lowest process variable to be measured The Input Signal Hi is the highest level signal the sensor will supply Typically this corresponds to the highest process variable to be measured Setting Engineering Units Set the engineering units in which you will specify the PV Lo and PV Hi When used with linear inputs the Units parameter is for display only and has no effect on the process variable value calculated or displayed Setting PV Lo and PV Hi After setting the Input Signal Lo and Input Sig
292. t Black single ended adapts AITB for 2 wire RTDs differential or 3 PPC KEY 04 Wire RTDs differential iii PPC EITB 1 Encoder Input Terminal Block Specifications N 4 0 in H 102 mm g z IN S nal Se ls SYBE wy Q Vg Ii lo n z RIS fo 3 4 in 86 mm y Figure 7 17 PPC EITB 1 258 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 7 Specifications Table 7 62 Environmental Specifications Storage Temperature 20 to 70 C Operating Temperature 0 to 60 C Humidity 10 to 95 non condensing Table 7 63 Physical Specifications Weight 0 10 Ibs 0 05 kg Height 4 0 in 102 mm Width 2 0 in 51mm Depth 1 5 in 38 mm Mounting DIN rail or panel mount Table 7 64 Connections Screw Terminal Wire Gauge 24 to 12 AWG Screw Terminal Torque 0 5 to 0 6 Nm 4 4 to 5 3 in lb Connector on Board High density D sub 15 pin female connection Terminals Number of Screw Terminals Captive screw cage clamp 12 Table 7 65 PPC EITB with HD Type Cable Height 4 0 in 102 mm Width 2 0 in 51 mm Depth 2 2 in 56 mm Table 7 66 Safety and Agency Approvals UL C UL 3121 1 Listed Category II Installation File E212113 Doc 30002 00 Rev 2 3 Watlow Anafaze 259 Chapter 7 Specifications PPC 2000 U
293. t Boot PPC1 Soft Bool 1 PPC1 Soft Bool 2 PPC1 Soft Bool 3 PPC1 Soft Bool 4 Doc 30002 00 Rev 2 3 Figure 3 26 Soft BOOL Spreadsheet Select the Soft Bool button to monitor or edit the software Boolean values Double click a field to change the setting The left column in the spreadsheet lists the name of the register The name contains the PPC number the word and the register offset 1 1000 There is only one parameter on the Soft Bool spreadsheet Value Value Software Boolean registers can be used to set or monitor internal coils in logic program that have been linked to the corresponding register The registers are all read write but ifa register is set as an output in the logic program the logic program updates its value and user entered values are disregarded Range False 0 or True 1 Watlow Anafaze 137 Chapter 3 Operating with AnaWin 3 PPC 2000 User s Guide 138 PPC Globals Select PPC Globals from the View menu to display the screen in Figure 3 27 AnaWin PPC Global dex Fie System Recipe Logs TrendPlot View Developer Help Last Recipe Downloaded PPC Global Setup PEC Controller Select Ambient aoe 0 1 F Logic Program Controls TB1and2 TB3and4 Start Logic j Al RSN ent Stop Logic a er Al3 Al4 762 762 System Status Global Settings __ Ambient Status i Loop Start State Off Memory Status Rete
294. ta 1A al i PPC 2050 PPC 2051 Figure 2 54 PPC 205x Connections Bottom View Table 2 22 Analog Output Connections on Analog Out Module Analog Out Module Modulel O Connections eee age Number Voltage Current 1 Spreadsheet Source Sink Analog Out 1 1A 1B 1B 1A PPC1 AO 31 1 Analog Out 2 2A 2B 2B 2A PPC1 AO 31 2 Analog Out 3 3A 3B 3B 3A PPC1 AO 31 3 Analog Out 4 4A 4B 4B 4A PPC1 AO 31 4 Analog Out 5 5A 5B 5B 5A PPC1 AO 31 5 Analog Out 6 6A 6B 6B 6A PPC1 AO 31 6 Analog Out 7 7A 7B 7B 7A PPC1 AO 31 7 Analog Out 8 8A 8B 8B 8A PPC1 AO 31 8 1 The AnaWin3 name is shown for the Encoder In Analog Out module with address 11 on the first PPC 2000 in the system Refer to Outputs on page 135 for a full explanation of Analog output naming Doc 30002 00 Rev 2 3 Watlow Anafaze 67 Chapter 2 Hardware Installation 68 NOTE PPC 2000 User s Guide On the PPC 2050 each consecutive pair of analog outputs 1 2 3 4 5 6 and 7 8 shares an internal power supply In current mode the power supply is shared and in voltage mode the common is shared If an external power supply is tied into the internal power supply though the B pin the signal to each output may be distorted It may be necessary to use a separate external power supply for each analog output within the pair Each output on the PPC 2051 has a separate internal power supply so the same external power supply
295. tched in whatever state the controller determines See Table 5 59 Table 5 59 System Status Reset Database Modbus After Za D ription Offset Address Name Host esctiptio Read Defaults Default values have 1 10901 Loaded Rese been loaded 2 10002 Reserved N A 3 10003 Reserved N A 4 10004 Controller Reset Controller has reset has reset 5 10005 Ambient Latched Ambient Status temperature error 6 10006 HW Cig Latched Hardware Status configuration error Battery f 7 10007 Status Latched Battery voltage is low 14 10014 Logic Run Latched Logic program is run Status ning 15 10015 Logic Load L atched Logic program is loaded Status gic prog The values of the bits in the System Status Registers are interpreted according to the following table Table 5 60 System Status Bits Value Status 0 no error false 1 error true Program Version Embedded program version label for the firmware program Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter 5 LogicPro and Modbus Reference Table 5 61 Program Version Information Database Offset Description Major version first digit Major version second digit Minor version first digit Minor version second digit Release level alpha character Reserved Reserved OINIO ATR IJO mP Reserved
296. tenths of a percent The valid range is 0 to 1000 and corresponds to 0 0 to 100 0 for example a setting of 500 corresponds to 50 0 Control Type Select the function of the channel Table 5 19 Control Types Value AnaWin3 Name Description 0 PID1 Heat and Cool outputs only one on at a time 1 PID2 Heat and Cool outputs both may be on 3 Reserved n a 4 Retransmit Retransmit one or two analog inputs Watlow Anafaze 181 Chapter 5 LogicPro and Modbus Reference PPC 2000 User s Guide 182 Setpoint Source This parameter determines how the setpoint for the channel is set Select User for normal closed loop control applications Select a channel output Channel Out for cascade control Select an analog input for ratio control differential control remote setpoint or process variable retransmit A value of 0 indicates a user set setpoint See Table 5 13 on page 176 through Table 5 17 on page 179 for values to select a channel output or analog input as the source of the setpoint value Setpoint Ratio For ratio control differential control and remote setpoint applications set the ratio by which the analog input value selected as the Setpoint Source is multiplied to calculate the setpoint See Ratio Control on page 109 Differential Control on page 112 and Remote Set Point on page 112 This parameter may be set to any value from 30000 to 30000 corresponding to a range of 300 00 to 300
297. ter 3 Operating with AnaWin 3 PPC1 Channel 1 Output Lye channel number L_y controller number Figure 3 19 Channel Output Names Table 2 15 on page 56 correlates module I O numbers with screw terminals on the EITB Input Value PV This field displays the scaled and filtered value measured by the sensor attached to the corresponding input This field is read only Range Depends on input type selected See Table 3 15 Input Status This field displays information about the sensor e No Problem sensor is functioning as expected e Open Sensor T C or RTD not properly connected e CM0 Common Mode Overvoltage there is too much noise on the sensor to make an accurate reading e Shorted RTD sensor e Ambient temperature error temperature is outside controller s operating range If two or more problems occur simultaneously the Input Status lists the errors Input Type Choose the input type appropriate for the sensor connected to the corresponding input Table 3 14 lists the choices available Select No Input if no sensor is attached to the input Doc 30002 00 Rev 2 3 Watlow Anafaze 129 Chapter 3 Operating with AnaWin 3 130 Table 3 15 Input Types PPC 2000 User s Guide Sensor Sensor Input Type Range Range Low High No Input N A N A
298. the rest of the day values follow Watlow Anafaze Doc 30002 00 Rev 2 3 Tuning and Control Introduction Doc 30002 00 Rev 2 3 NOTE This chapter describes the different methods of control available with the your controller This section covers e On Off Control e Proportional Control e Proportional and Integral Control e PID Control e Control Outputs e Tuning PID Loops e PID Constants by Application This chapter explains PID control and supplies some starting PID values and tuning instructions to help appropriately set control parameters in the PPC system For more information on PID control consult the Watlow Anafaze Practical Guide to PID The control algorithm dictates how the controller responds to an input signal Do not confuse control algorithms with control output signals for example analog or pulsed DC voltage There are several control algorithms available On Off Proportional P Proportional and Integral PI Proportional with Derivative PD and Proportional with Integral and Derivative PID P PI or PID control is necessary when process variable PV cycling is unacceptable or if the process or setpoint SP is variable For any of these control modes to function the channel must be in automatic mode Watlow Anafaze 219 Chapter 6 Tuning and Control PPC 2000 User s Guide Control Algorithms The next sections explain the different methods for controlling a loop On Off
299. tion of DZC output and a solid state relay can inexpensively approach the effect of analog phase angle fired control Note however DZC switching does not limit the current or voltage applied to the heater as phase angle firing does For analog outputs the PID algorithm calculates an output between 0 and 100 This percentage of the analog output range can be applied to an output device via an analog module or a digital module in conjunction with an SDAC The output filter smooths PID control output signals It has a range of 0 255 scans which gives a time constant of 0 170 seconds for the PPC Use the output filter if you need to filter out erratic output swings due to extremely sensitive input signals like a turbine flow signal or an open air thermocouple in a dry air gas oven The output filter can also enhance PID control Some processes are very sensitive and would otherwise require a large PB making normal control methods ineffective Using the output filter allows a smaller PB to be used achieving better control Also use the digital filter to reduce the process output swings and output noise when a large derivative is necessary or to make badly tuned PID loops and poorly designed processes behave properly Watlow Anafaze 225 Chapter 6 Tuning and Control 226 NOTE PPC 2000 User s Guide Setting Up and Tuning PID Loops After installing your control system tune each control loop and then set the loop to aut
300. to address parameters when writing programs using LogicPro Chapter 6 Tuning and Control Describes available control algorithms and provides suggestions for applications Chapter 7 Specifications Lists detailed specifications of the controller and optional components Watlow Anafaze 1 Chapter 1 Overview PPC 2000 User s Guide Getting Started Safety symbols AN WARNING A CAUTION NOTE The following sections provide information regarding product features system components safety requirements and preparation for operation These symbols are used throughout this manual Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury or property damage Indicates pertinent information or an item that may be useful to document or label for later reference Contacting Watlow Anafaze Initial Inspection To contact Watlow Anafaze send correspondence to Watlow Anafaze Inc 314 Westridge Drive Watsonville CA 95076 Our technical support and customer service departments may be reached Monday Friday 8 a m to 5 p m Pacific time Telephone 1 831 724 3800 Email anafazetechsupport watlow com Be sure to specify PPC2000 when asking for technical support Accessories may or may not be shipped in the same container as the PPC 2010 contr
301. tor the output in Automatic control For PID output types the output is calculated based on the heat PID parameters The valid range is 0 to 1000 and corresponds to 0 0 to 100 0 for example a setting of 500 corresponds to 50 0 Heat Cool Output Destination Heat Cool Output Dest Select the output destination to specify the I O point used for the control output This is the output for the closed loop control channel Selecting 0 indicates no output is to be used and is an appropriate setting for monitor only channels Values are calculated for the corresponding output whenever the output destination has a non zero setting If both the heat and cool output destinations are non zero the channel performs bimodal control See Heat and Cool Outputs on page 90 Refer to Table 5 22 for a list of values and the corresponding physical or software output destinations Table 5 22 Output Destinations for Digital Outputs on the PPC 2010 Module Value Digital I O Name AnaWin3 Dig I O Spreadsheet 1 PPC1 Proc 0 0 1 2 PPC1 Proc 0 0 2 48 PPC1 Proc 0 0 48 186 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference Table 5 23 Output Destinations for Digital Outputs on the PPC 2040 Modules Value Digital I O Name AnaWin3 Dig I O Spreadsheet 49 PPC1 DIO 21 0 1 50 PPC1 DIO 21 0 2 80 PPC1 DIO 21 0 32 81 PPC1 DIO 22 0 1 82 PPC1 DIO 22 0 2 112 PPC1 DI
302. uctions on using snubbers with the PPC 206x modules Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation e You can use other voltage suppression devices but they are not usually required For instance you can place a metal oxide varistor MOV rated at 130Vac for 120Vac control circuits across the load which limits the peak AC voltage to about 180Vac You can also place a transorb back to back zener diodes across the digital output which limits the digital output voltage The above steps will eliminate most EMI RFI noise problems If you have further problems or questions please contact Watlow Anafaze Avoiding Ground Loops Ground Loops can cause instrument errors or malfunctions Do not connect any of the following pins to each other or to earth ground e DC power common terminals on the PPC power supply and PPC 2010 Processor Module e DC common terminals on TB50s e Analog common terminals on AITBs e Signal common terminals on the EITB or other devices connected to the encoder inputs on a PPC 2030 Watlow Anafaze strongly recommends that you e Isolate outputs through solid state relays where possible e Isolate RTDs or bridge type inputs from ground Connecting I O to the PPC 2010 A TB50 connects to the PPC 2010 Processor module through the 50 pin SCSI connector Refer to Figure 2 20 on page 38 The terminal block interfaces to field wiring of the digital I O se
303. ule one pulse signal input and up to five SDAC analog output modules can be connected to the TB50 Table 2 10 on page 39 shows the TB50 pinout for use with the PPC 2010 Use 14 to 22 AWG wire When making connections tighten to 0 5 to 0 6 Nm or 4 5 to 5 4 inch pound Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 2 Hardware Installation Table 2 10 Processor Module I O Connections TB 50 AnaWin3 Name Module I O Number Terminal Dig I O Spreadsheet Digital In Out 1 PPC1 Proc 0 0 1 Counter 1 1 PPC1 Proc 0 1 1C Frequency 1 PPC1 Proc0 2 1F Digital In Out 2 2 PPC1 Proc 0 0 2 Digital In Out 3 3 PPC1 Proc 0 0 3 Digital In Out 4 4 PPC1 Proc 0 0 4 Digital In Out 5 5 PPC1 Proc 0 0 5 Digital In Out 6 6 PPC1 Proc 0 0 6 Digital In Out 7 7 PPC1 Proc 0 0 7 Digital In Out 8 8 PPC1 Proc 0 0 8 Digital In Out 9 9 PPC1 Proc 0 0 9 Digital In Out 10 10 PPC1 Proc 0 0 10 Digital In Out 11 11 PPC1 Proc 0 0 11 Digital In Out 12 12 PPC1 Proc 0 0 12 Digital In Out 13 13 PPC1 Proc 0 0 13 Digital In Out 14 14 PPC1 Proc 0 0 14 Digital In Out 15 15 PPC1 Proc 0 0 15 Digital In Out 16 16 PPC1 Proc 0 0 16 Digital In Out 17 17 PPC1 Proc 0 0 17 Digital In Out 18 18 PPC1 Proc 0 0 18 Digital In Out 19 19 PPC1 Proc 0 0 19 Digital In Out 20 20 PPC1 Proc 0 0 20 Digital In Out 21 21 PPC1 Proc 0 0 21 Digital In Out 22
304. um Current 150mA sink to common Off State Leakage Current lt 0 010mA up to 30Vdc The PPC 2040 has 32 digital I O points Each can be configured as either an input or an output 246 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 7 Specifications PPC 205x Analog Out Specifications The PPC 2050 and PPC 2051 provide eight and four analog outputs respectively Each output is configurable as a voltage or current output PPC 2050 Status STATUS LED MODULE Rotar y Address 34 Switch PIX Figure 7 9 PPC 2050 Front View Doc 30002 00 Rev 2 3 Watlow Anafaze 247 Chapter 7 Specifications PPC 2000 User s Guide gt gt 16 pin Terminal Block AT for Analog Outputs gt wD Ir gt gt gt wwii Innn Nn O gt PPC 2050 N E Ir g
305. umber The module type is abbreviated in the default I O name For example PPC1 EIAO 11 3 2 indicates PPC 1 the encoder input analog output module with module address 11 I O type 3 analog out and output 2 See Figure 3 24 and Table 3 19 PPC1 EIA0 11 3 2 module I O number L O type L module address module type L controller number Figure 3 24 Analog Output Names Table 3 19 Module Abbreviations Seen on the Outputs Spreadsheet Module Type Abbreviation PPC 2030 Encoder Input Analog Output EIAO PPC 205x Analog Output AO There is only one parameter on the Outputs spreadsheet Value Watlow Anafaze 135 Chapter 3 Operating with AnaWin 3 PPC 2000 User s Guide Value This parameter displays the output value of the analog output as a number between 0 and 32767 These numbers correspond to the minimum and maximum output signal levels for the selected Output Type The analog signal range is determined by the hardware jumper configuration and the setting of the Output Type on the Channels spreadsheet for the channel with the output selected as Heat Cool Output Dest The range may also be scaled by the Output Scale Lo and Output Scale Hi settings Range 0 to 32767 NOTE The resolution of the analog outputs is 12 bits The output Value is displayed as a 15 bit integer The output Value must change by more than seven to effe
306. user selected time base or cycle time The cycle time is the time over which the output is proportioned and it can be any value from 1 to 255 seconds For example if the output is 30 and the cycle time is 10 seconds then the output will be on for 3 seconds and off for 7 seconds Figure 6 5 shows example TP and Distributed Zero Crossing DZC waveforms TP 30 DZC 33 Off 0 10 0 1 4 6 3 3 Seconds Cycle Time 10 AC Cycle Figure 6 5 Example Time Proportioning and Dis tributed Zero Crossing Waveforms 224 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 6 Tuning and Control Distributed Zero Crossing DZC Analog Outputs Output Filter Doc 30002 00 Rev 2 3 With DZC outputs the PID algorithm calculates an output between 0 and 100 but the output is switched on a variable time base For each AC line cycle the controller decides whether the power should be on or off There is no fixed cycle time since the decision is made for each line cycle When used in conjunction with a zero crossing device such as an SSR switching is done only at the zero crossing of the AC line which helps reduce electrical noise Using a DZC output should extend the life of heaters Since the time period for 60Hz power is 16 6 ms the switching interval is very short and the power is applied uniformly DZC should be used with SSRs Do not use DZC output for electromechanical relays The combina
307. ut that is toggled when the high process alarm occurs This can be any available hardware output or a Boolean register accessible to the logic program The default high process alarm output is 0 When 0 is selected there is no output Low Process Output Destination LP Output Dest Choose the digital output that is toggled when the low process alarm occurs This may be any available hardware output a Boolean register accessible to the logic program The default alarm output is 0 When 0 is selected there is no output High Deviation Output Destination HD Output Dest Choose the digital output that is toggled when the high deviation alarm occurs This may be any available hardware output or a Boolean register accessible to the logic program The default alarm output is 0 When 0 is selected there is no output Low Deviation Output Destination LD Output Dest Choose the digital output that is toggled when the low deviation alarm occurs This may be any available hardware output or a Boolean register accessible to the logic program The default alarm output is 0 When 0 is selected there is no output Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 5 LogicPro and Modbus Reference Digital I O Parameters in the Database Digital I O parameters determine the state and behavior of digital inputs and outputs found on the PPC s Processor Digital I O Digital Input and Digital Output modules State and Logic
308. utput never reach 100 in that case enter a maximum value less than 100 See also Auto Heat Cool Limit Range 0 0 to 100 0 Note Sometimes it is necessary for a heat output to increase as the process variable approaches the set point from below In such cases the Heat Cool Scale Lo value is set above the Heat Cool Scale Hi parameter See Direct Heat in Table 3 x For example in some systems heat is added outside the control loop and the heat output controls a cooling water flow In such a system as the temperature rises to set point the output increases to flow more water and slow the heating process Table 3 x Output Scaling Parameters Settings and Conirol Action Output Control Action Scale Lo Scale Hi Note Heat Reverse Default 0 100 As the process variable increases Cool Reverse 100 0 the output decreases Heat Direct 100 0 As the process variable increases Cool Direct Default 0 100 the output increases CAUTION When a Heat Cool Scale Lo parameter is set to a value greater than the corresponding Heat Cool Scale Hi the Heat Output or Cool Output values are inversely related to the actual output signal In this case when the Heat Cool Output indicates 0 the output is fully on regardless of whether the Control Mode is set to Auto Manual or Tune Always remove power from the controller before servicing any components Figure 3 x Heat and Cool Scaling Parameters a o
309. value less than the sensor range Heat Cool Integral The integral term controls the amount of influence the history of error has on the output Increasing the integral value decreases the integral contribution to the output Zero is a special case that disables integral action This value is in seconds per repeat Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Doc 30002 00 Rev 2 3 Chapter 5 LogicPro and Modbus Reference Heat Cool Derivative The derivative term controls the amount of influence the rate of change of the error has on the output A greater value yields a greater derivative action The derivative constant is in units of seconds Spread This is the offset between heat and cool modes when both heat and cool outputs for a channel are used The spread is also the switching hysteresis for on off channels The spread is set in the channel s engineering units to a positive value less than the sensor range Heat Cool Manual Reset Enter a value to add to the PID output calculation When the corresponding Integral is set to zero the value substitutes for the integral sum portion of the feedback calculation In this case the output equals the manual reset value when the process variable is at setpoint When the integral value is set to a value other than zero the manual reset value is added to the result of the PID calculation and thereby shifts the output variable This parameter is set in
310. versus Reset settings Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 6 Tuning and Control Table 6 2 Integral Term and Reset Settings Integral Reset Integral Reset sec repeat repeat min sec repeat repeat min 30 2 0 210 0 28 45 1 3 240 0 25 60 1 0 270 0 22 90 0 66 300 0 20 120 0 50 400 0 15 150 0 40 500 0 12 180 0 33 600 0 10 As a general rule use 60 120 180 or 240 as a starting value for the Integral Derivative Settings Doc 30002 00 Rev 2 3 NOTE The controller s Derivative parameter is programmed in seconds Some other products use a derivative term called Rate programmed in minutes Use the table or the formula to convert parameters from one form to the other Table 6 3 shows Derivative versus Rate Rate Derivative 60 Table 6 3 Derivative Term vs Rate Derivative Rate Derivative Rate seconds minutes seconds minutes 5 0 08 35 0 58 10 0 16 40 0 66 15 0 25 45 0 75 20 0 33 50 0 83 25 0 41 55 0 91 30 0 50 60 1 0 As a general rule set the Derivative to 15 of Integral as a starting value While the basic PID algorithm is well defined and widely recognized various controllers implement it such that parameters may not be taken from one controller and applied to another with optimum results even if the above unit conversions are performed Watlow Anafaze
311. when it is configured as a retransmit channel Setting up Process Variable Retransmit Doc 30002 00 Rev 2 3 On the Channels spreadsheet for the channel that will output the retransmit signal 1 Set the Control Type to PV Retransmit 2 Set the PV Source to the same setting as the PV Source pa rameter of the channel to be retransmitted or any other analog input you want to retransmit 3 Set the Heat Output Dest to the PPC output on which you want to retransmit the analog input 4 Set the Heat Output Type to a setting appropriate for the heat output destination you chose in step 3 5 Set the Min Set Point to the minimum value of the analog input that you want to retransmit 6 Set the Max Set Point to the maximum value of the analog input that you want to retransmit To retransmit a second analog input on the same retransmit channel with the same scaling 1 Set the Set Point Source to the second analog input to be retransmitted 2 Set the Cool Output Dest to the BPG output on which you want to retransmit 3 Set the Cool Output Type to a setting appropriate for the cool output destination you chose in step 2 If you do not wish to use the full range of the heat or cool output type signal the signal can be scaled 1 Set the Heat Scale Lo to a percent of the range of the selected heat output type This is the signal level that will be transmitted when the analog input selected as PV Source is at
312. when the process variable is 980 F or below However a process which uses only proportional control settles at a point above or below the setpoint it never reaches the setpoint by itself This behavior is known as offset or droop a SP Pee aa are offset PB A tt py Figure 6 2 Proportional Control Watlow Anafaze 221 Chapter 6 Tuning and Control PPC 2000 User s Guide Proportional and Integral Control With proportional and integral control the integral term corrects for offset by repeating the proportional band s error correction until there is no error For example if a process tends to settle about 5 F below the set point appropriate integral control brings it to the desired setting by gradually increasing the output until there is no deviation SP Figure 6 3 Proportional and Integral Control Proportional and integral action working together can bring a process to setpoint and stabilize it However with some processes the user may be faced with choosing between parameters that make the process very slow to reach setpoint and parameters that make the controller respond quickly but introduce some transient oscillations when the setpoint or load changes 222 Watlow Anafaze Doc 30002 00 Rev 2 3 PPC 2000 User s Guide Chapter 6 Tuning and Control Proportional Integral and Derivative Control Derivative control corrects for overshoot by anticipating the behavior of the process variable a
313. xclusive ORed with the register contents Then the result is shifted in the direction of the least significant bit LSB with a 0 filled into the most significant bit MSB position The LSB is extracted and examined Ifthe LSB was a 1 the register is then exclusive ORed with a preset fixed value A001 hex If the LSB was a 0 no exclusive OR takes place This process is repeated until eight shifts have been performed After the last shift the next 8 bit byte is exclusive ORed with the register s current value and the process repeats for eight more shifts as described above The final contents of the register after all the bytes of the message have been applied is the CRC value Watlow Anafaze 275 Appendix A Modbus Protocol PPC 2000 User s Guide Function Codes The listing below shows the function codes supported by the PPC controllers Codes are listed in decimal Table A 2 Function Codes 01 Read Coil Status 02 Read Input Status 03 Read Holding Registers 04 Read Input Registers 05 Force Single Coil 06 Preset Single Register 08 Diagnostics 15 Force Multiple Coils 16 Preset Multiple Registers Read Coil Status 01 Reads the On Off status of discrete outputs OX references coils in the slave Broadcast is not supported Read Input Status 02 Reads the On Off status of discrete inputs 1X references in the slave Broadcast is not supported Read Holding Registers 03 Re
314. y of the Soft Bool registers LP Limit Set the low process alarm limit An alarm occurs when the process variable is less than this value This value does not change when the set point changes The default low process alarm set point is 0 Range same as the range of the input type selected See Table 3 15 on page 130 LP Type Select the function of the low process alarm See Process Alarms on page 95 for a description of the settings Range Alarm or Control Watlow Anafaze 125 Chapter 3 Operating with AnaWin 3 126 PPC 2000 User s Guide LP Enable Set this field to enable or disable the low process alarm When it is Enabled the low process alarm activates if the process variable PV dips below the LP Limit The PV must rise above the LP Limit plus the alarm deadband to be reset cleared When this parameter is set to Disabled the low process alarm does not occur Range Enable or Disable LP Output Dest Choose a digital output to toggle when the low process alarm occurs This may be any available hardware output or Soft Boolean register accessible by the logic program The default for this parameter is None Outputs that are already assigned to control output destinations will be rejected The same output may net be used for multiple alarm output destinations Range None or any of the digital outputs on the Digl 0 spreadsheet or any of the Soft Bool registers Alarm Deadband Set this parameter to pr

Download Pdf Manuals

Related Search

Related Contents

  Tandberg Data 2U LTO User's Manual  取扱説明書 お客さまへ  | Guía de Referencia Rápida        Sección 2: Características y Especificaciones 35  Manuel d`utilisation de Visiocar 8  Final Design Report  

Copyright © All rights reserved. Failed to retrieve file