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IDEC MicroSmart Pentra PID Module User`s Manual

1. Input Range Type K thermocouple wei Celsius sl 200 to 1370 C PV Correction 0 0 100 0 to 100 0 C PV Filter Time Constant 0 0 0 0 to 10 0 sec Set Point SP Upper Limit 1370 200 to 1370 C Set Point SP Lower Limit 200 200 to 1370 C Alarms Alarm Type Alarm Yalue Hysteresis 0 1 to 100 0 C Delay Time 0 to 10000 sec No Alarm Action No Alarm Action No Alarm Action No Alarm Action No Alarm Action No Alarm Action No Alarm Action 3 4 5 A A Write all parameters Read all parameters Monitor l et OK Cancel Buttons Button Deseripteon All parameters are saved and the dialog is closed All changes made to the parameters are discarded and the dialog is closed Current parameters configured in the PID Module Configuration dialog box 3 Write All Parameters are written to the data registers RAM in the CPU module and the PID module All parameters stored in the PID module mounted on the slot selected in the 4 Upload All Parameters Expansion Modules Configuration dialog box are read and all parameters in the dialog box are updated 5 Monitor The PID module mounted on the slot selected in the Expansion Modules Configuration dialog box can be monitored FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www
2. Expansion Modules Quantity of modules 4 CPU module Slot 1 Slot 2 Slot 3 Slot 4 FCSA F2M2 FC5A D16RX1 D1000 to D1189 Other modules Other modules Other modules M0000 to M0007 Module Settings Module Type No FC5A F2M2 Data Register D1000 D1000 to D1189 Internal Relay m1000 M1000 to M1007 Configure Parameters Copy Parameters To OK Cancel After specifying the quantity of modules and selecting the slot number to which the PID module is connected designate the module type number control register data register and control relay internal relay After designating those parameters click on Configure Parameters button to open the PID Module Configuration dialog 2 PID Module Configuration Dialog Box PID Module Configuration Slot 1 EIES Module Type No FC5A F2M2 X Input Parameters Control Parameters Output Parameters CHO Input CHO Leg CHO output CHO Lelleg CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Control Parameters emt Output Parameters CHI cb Input CH1 _ CH1 Output CH CHI Type K thermocouple Celsius Reverse Control Action Heating Voltage Output
3. gt Flow of the parameter when executing Read All Parameters CPU Module PID Module ROM RAM Data Register Downloading and Uploading User Program When the user program download Tor upload is executed the user program is downloaded to uploaded from the CPU module as follows WindLDR O gt Flowof the user program when executing the user program download l A gt Flow of the user program when executing the user program upload CPU Module PID Module RAM Data Register 1 When Write PID Module parameters after download is checked in the Download dialog writing the PID module parameters will be executed after the user program is downloaded to the CPU module The PID module parameters are written to the data registers in the CPU module and all PID modules configured in the Expansion Modules Configuration dialog box For details see the following page FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 3 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR User Program Download The user program contains the user program and the PID module parameters initial values configured in the PID Module Configuration dialog box After the user program is downloaded to the CPU module the CPU module can communicate w
4. 4 Process Variable PV E Interval sec E x 600 Set Point SP ig S oint SP E x9 000 C Output Manipulated Variable MV x 27 000 1 CHO Trace Color Selection Select the color for the three parameters to be traced 2 CHO Trace Selection Select the parameter to be traced If none of the three parameters are selected CHO parameters are not traced and only parameters are monitored 3 CH1 Trace Color Selection Select the color for the three parameters to be traced 4 CH1 Trace Selection Select the parameter to be traced If none of the three parameters are selected CH1 parameters are not traced and only parameters are monitored 5 Auto Scaling If the auto scaling is enabled the range of the vertical axis is automatically updated in accordance with the process variable PV set point SP and output manipulated variable MV 6 Upper Limit The upper limit of the vertical axis for the trace can be specified 7 Lower Limit The lower limit of the vertical axis for the trace can be specified 8 Trace Time Settings Interval Configure the interval time for the tracing between 1 to 60 seconds x600 Interval x 600 Trace range Example If the interval time is 1 sec the trace range will be 600 sec When the traced data reaches the right edge the first half of the traced data is cleared and the trace continues x9000 Interval x 9000 Trace end time Example If the interval time
5. 168 Sin Mode 4 PVR start YP 2 SP start When input is thermocouple resistance thermometer 24 96 173 Set Point SP when Set point SP lower limit to set point SP upper limit Program Control Starts When input is voltage or current Linear conversion min to linear conversion max l 0 Minute 25 Step Time Unit DEE 0 Terminate program control 26 93 170 Program End Action 1 Continue program control Repeat 2 Hold program control 27 Number of Repeats 0 to 10000 times FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 15 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR Control Parameters when Cascade Control is Enabled PID Module Configuration Slot 1 FCSA F2M2 EN Input CHO wd Output CHO E Cascade Control CAL pen Fixed Value Control Mode Reverse Control Action Heating Proportional Band EI a gege Control Registers Extieinal or Input ee External SP Input linear conversion min value to input Conversion Maximum Ga R W range upper limit of CHO EI External SP Input Linear Conversion Minimum Value Input range lower limit of CHO to external SP Input linear conversion max value 6 16 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR PID Module
6. module parameters will be written to the data registers in the CPU module and the PID module connected to the CPU module Transfer Mode Binary ASCII Download Options Automatic start after download Keep output during download Suspend 1 0 force before download Automatic device clear after download i W Write PID module parameters after download Write device datafile to the PLC after download Setting Download comment data Setting Download systemprogram Detail Program Information Program Size 1142 bytes Comment Size 0 bytes Total 1142 bytes Communication Settings When program download is successfully completed the following message will appear Click OK button to close the message Program Download KIE l i Program Download Succeeded 10 Starting Program Control 1 Turn on external input I0 and I3 to enable CHO and CH1 controls 2 Turn on external input I2 and 15 to allow auto tuning AT to be performed 3 Turn on external input 11 and 14 to start the program control for CHO and CH1 controls 4 Turn on the load circuit power The PID module starts the configured program control from step 0 Auto tuning AT will be performed in each step When the program control for CHO or CH1 is completed Q1 or Q3 will be turned on respectively 7 14 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com A
7. Alarm 1 Hysteresis Alarm 2 Hysteresis When input range unit is Celsius Alarm 3 Hysteresis 0 1 to 100 0 C Alarm 4 Hysteresis When input range unit is Fahrenheit Alarm 5 Hysteresis 0 1 to 100 0 F Alarm 6 Hysteresis When input is voltage or current input Alarm 7 Hysteresis 1 to 1000 Alarm 8 Hysteresis Alarm 1 Delay Time Alarm 2 Delay Time Alarm 3 Delay Time Alarm 4 Delay Time Ste 40000 Alarm 5 Delay Time j ii Alarm 6 Delay Time Alarm 7 Delay Time Alarm 8 Delay Time When input range unit is Celsius 89 166 AT Bias 0 to 50 C 0 0 to 50 0 C for input with decimal point When input range unit is Fahrenheit O to 100 F 0 0 to 100 0 F for input with decimal point 90 167 Control Mode de Fixed value control mode 1 Program control mode 0 PV start 91 168 SEH Control Mode Start 1 PVR start yP 2 SP start Step Time Unit E Gei d R W 0 Terminate program control 93 170 Program End Action 1 Continue program control Repeat 2 Hold program control 94 171 Proportional Term d EE pane 1 Proportional gain i 0 Air cooling 95 172 oa 1 Oil cooling y 2 Water cooling When input is thermocouple or resistance thermometer Set Point SP when Program Set point SP lower limit to set point SP upper limit 96 173 i l Control Starts When input is voltage or current input A ll cl R W Linear conversion min to linear conversion max Number of Repeats 0 to 10000 times When input range unit i
8. D1178 external SP input linear conversion max value and MOVIN S1 Rk DIR REP D1179 external SP input linear conversion min value are moved to DO and D1 respectively D1172 Coooo z Movi S1 Er e REP HIER Di0z0 MOV Si Di Rk REP Did2s D1172 z D1023 is stored in D1020 CH1 set point SP is copied to CHO set point SP D1023 is stored in D1178 and D1179 CH1 set point SP is copied to the external SP input linear conversion max and min values M1006 Block 5 Writing is turned on Values in D1178 and D1179 are written to the PID module M1 is turned on 1st Scan At the rising edge of MO the following are executed in order D1022 0 is turned off CHO control is disabled SOTU FE KC D1025 0 is turned off CH1 control is disabled b1025 00 za M1000 reading all parameters is turned on migon All parameters are read from the PID module EI MO is turned off Moon FC5A MicroSmart PID Module User s Manual FC9Y B1283 4 17 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com PID MODULE MAIN FUNCTIONS 4 18 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE D DEVICE ALLOCATION OF PID MODULE This chapter describes the valid devices control registers control relays and data register allocation for the PID module
9. Web www clrwtr com Email info clrwtr com 2 5 MODULE SPECIFICATIONS Dimensions All dimensions in mm 8 5mm when the clamp is pulled out 2 6 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INSTALLATION AND WIRING 3 INSTALLATION AND WIRING This chapter describes how to install and wire the PID modules For general methods and precautions for installation and wiring of the PID modules see chapter 3 in the FC5A MicroSmart user s manual FC9Y B1268 Be sure to use the PID modules properly after understanding installation and wiring thoroughly A Caution e Assemble the CPU module and PID modules before installing them on a DIN rail Otherwise they may break e Do not lay out or wire the modules while power is supplied to them Otherwise they may be damaged e When installing modules follow the instructions described in the FC5A MicroSmart user s manual If there are flaws in the installation it may cause disattachment failure or malfunction Mounting Hole Layout for Direct Mounting on Panel Surface To mount the PID module on a panel surface 39 1 Direct mounting strip l 6 3 FC4A PSP1P use the direct mounting strip and two M4 screws 6 or 8 mm long oo For details about the direct mounting strip see the FC5A MicroSmart user s manual FC9Y B1268 3 0 All dimensions in mm FC5A Mic
10. are Time Second T Time Second Figure 1 Process variable PV Figure 2 Process variable PV before PV filtering process after PV filtering process 6 30 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 4 Control Register 178 External SP Input Linear Conversion Maximum Value Configure the linear conversion maximum value for the external SP input When input type is current 4 to 20mA DC or 0 to 20mA DC configure the value corresponding to 20mA for input CH1 When input type is voltage 0 to 1V DC or 1 to 5V DC configure the value corresponding to 1V or 5V for input CH1 Example When input type is current 4 to 20mA DC if the external SP input linear conversion maximum value is 1000 C external SP input 20mA corresponds to the set point SP 1000 C for CHO control When input type is voltage 0 to 1V DC if external SP input linear conversion maximum value is 1200 C external SP input 1V corresponds to the set point SP 1200 C for CHO control 5 Control Register 179 External SP Input Linear Conversion Minimum Value Configure the linear conversion minimum value for the external SP input When input type is current 4 to 20mA DC or 0 to 20mA DC configure the value corresponding to 4mA or OmA for input CH1 When input type is voltage 0 to 1V DC or 1 to 5V DC configure the value correspondin
11. 6 35 7 1 EE 5 19 H heating cooling contra 4 14 5 20 6 37 7 15 cooling method WE 6 40 cooling proportional band s ssssssesseesesseessrressssress 6 41 dead Dand RE 9 8 OUTPUT ACON WEE 9 6 Overlap E 9 7 hunting phenomenon sesssssssessseeessrresserresseesseeressrresseee 8 3 l I O function eise O sereine 6 23 MOUE FOC OU EE 6 21 OUUTE TUNCUON soyaciireiossieein dn rin T i 6 23 initial setting parameters cceccceeeeeeeees 5 3 5 20 9 10 input EE 8 4 el TE 5 23 status ei e A E 8 5 input parameters E 6 8 GEET 6 24 VOR eae a cect setonsinsatetanedcrseteectionstansnaseantoaecerccce 6 10 6 24 installation and wiring 3 1 integral TIMING E 5 5 5 18 6 37 L linear Conversion EE 6 25 linear conversion SPAN sssessessssersssrerssrrressressserssserene 5 19 loop break aarm 5 10 8 6 9 2 E ETE A A E A TE A A te neecenecest 5 18 6 40 gen E E 5 18 6 40 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com M remaining UME secesie E rs 5 7 manual e 9 2 repeat MUM BE asistana insipiens aS UII EE E EA E E atten 5 11 DEE ege 2 2 set point SP 6 49 RE EE erect tec cesses 5 11 6 39 DUONG SE EE tie koe aie EES 31 NADY coc tecarccasnssoncemavosancenevagaustisasmetaccseedoocanwerssconcese 4 12 e y SES CHE E 4 10 O SET 5 21 6 43 step NUMDET rrsan aa EEaeeg 5 7 operating status s ssnsesssssererresssssrsssrressrosessssesrsse 5 10 me step TIME oooi 5 25 6 49 7 9 8 6
12. A maximum of 10 steps can be configured and performed The set point SP can be configured as shown in the following diagram The program control is suitable for applications such as electric furnaces for ceramic industries or food machineries Temperature Time Main functions of the program control are described as follows Program Pattern and Steps 1 program pattern consisting of 10 steps can be performed per channel Program Hold Function Suspends the progression of the program control while the program control is running and performs the fixed value control with the set point SP at the time that the program control is held Advance Next Function Terminates the current step while the program control is running and proceeds to the start of the next step Advance Previous Function Moves back the progression of the program control while the program control is running Wait Function When a step ends during program control if the deviation between the process variable PV and set point SP is bigger than the wait value the program control does not move to the next step The program control proceeds to the next step once the deviation between the process variable PV and set point SP becomes smaller than the wait value Repeat Function When the all steps are executed and the program control is terminated the program control can be repeated from Step 0 as many times as the repeat number configured FC5A MicroSmart PID
13. Button Description Configure Parameters The PID Module Configuration dialog box is opened Copy Parameters To The PID module parameters of the current slot can be copied to another slot Ok OK All parameters are saved and the dialog is closed All parameters are saved andthe dialog is closed O O O 9 All changes made are discarded and the dialog is closed 6 6 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR PID Module Configuration Dialog Box The buttons in the PID module configuration dialog box are described PID Module Configuration Slot 1 2 xl Module Type No FCSA F2M2 M Input Parameters Control Parameters Output Parameters CHO gt Input CHO ell CHO gt Output CHO Lg CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Control Parameters Output Parameters CH1 Input CHI elef CH1 Output CHI CHI Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input CHO N Control CH0 Output CHO Input CH1 Control CH1 Output CHL Monitor Zeg
14. C W Re5 26 External resistance 100Q maximum However B input External resistance 40Q maximum Resistance Pt100 JPt100 3 wire type Thermometer Allowable conductor resistance per wire 10Q maximum Sensor detection current 0 2A Current 0 to 20mA DC 4 to 20mA DC Input impedance 50Q Maximum permanent allowed overload No damage 50mA maximum Voltage 0 to 1V DC Input impedance 1MQ minimum Maximum permanent allowed overload No damage 5V DC maximum Allowable output impedance 2kQ maximum 0 to 5V DC 1 to 5V DC 0 to 10V DC Input impedance 100kKQ minimum Maximum permanent allowed overload No damage 15V DC maximum Allowable output impedance 1000 maximum 24V DC External power 5V DC Internal power 20 4 to 28 8V DC FC5A MicroSmart PID Module User s Manual FC9Y B1283 2 3 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com MODULE SPECIFICATIONS General Specifications FC5A F2MR2 FC5A F2M2 Connector on Input F6018 17P Fujicon Mother Board Output F6018 11P Fujicon Connector Connector Insertion Removal Durability Input Specifications FC5A F2MR2 FC5A F2M2 Thermocouple 0 2 of full scale or 2 C 4 F whichever is greater However R S inputs 0 to 200 C 0 to 400 F 6 C 12 F B input 0 to 300 C 0 to 600 F Accuracy is not guaranteed K J E T N inputs Less than 0 C 32 F 0 4 of full scale Resistance 0 1 of full
15. Device Allocation of PID Module The PID module is used by connecting to the MicroSmart CPU module To use the PID module allocate the data register and internal relay to the PID module configure the initial parameters using WindLDR and down load the user program and the parameters to the CPU module and the PID module The initial parameters are downloaded to the CPU module along with the user program The CPU module reads writes data from to the PID module according to the parameters configured in WindLDR CPU Module PID Module o gt Block data are read from written to the PID module according to the settings configured in WindLDR The PID module parameters consist of 26 data blocks divided according to the function and frequency of use of each parameter as shown in the table below All blocks to be used are allocated to the data registers in the CPU module The parameters of each block can be read from written to the PID module using the allocated control relays Number of Data Gr Description Registers Block4 6 JL Write only parameters CHO CH1 _ Blocks 30 to 39 19 block Program parameters CH1 Block 0 includes parameters such as operating status current process variable PV set point SP and output manipulated variable MV of the PID module The CPU module reads those parameters from the PID module every scan The control status and alarm status of the PID module can be monitored with Block 0 parameters
16. OK Cancel pf tem Setting Input Range Type K thermocouple Celsius 1370 C o O 1370 C 4 FC5A MicroSmart PID Module User s Manual FC9Y B1283 7 3 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPLICATION EXAMPLES 7 4 4 Control CHO Parameters Configure the Control CHO parameters in the PID Module Configuration dialog box To open Control CHO Parameters in the PID Module Configuration dialog box click on Control Parameters CHO button or Control CHO tab PID Module Configuration Dialog Box Control CHO Parameters Fixed Value Control Mode Reverse Control Action Heating el 1 Proportional a tem Setting Set Point SP 200 C 5 Input CH1 Parameters Configure the Input CH1 parameters in the PID Module Configuration dialog box To open Input CH1 Parameters in the PID Module Configuration dialog box click on Input Parameters CH1 button or Input CH1 tab PID Module Configuration Dialog Box Input CH1 Parameters PID Module Configuration Slot 1 Type K thermocouple Z 2 RE og 3 S Alarm Type Alam Value Hysteresis 0 1 to 100 0 C Deler Time 0 to 10000sec E 1 0 No Alarm Action 4 No Alarm Achjo o Alarm Action 5 44 wt LE LA 1 Input Range Type K thermocouple Celsius Set Point SP Upper Limit 1370 C Item Set Point SP Lower Limit 200 C Alarm 1 Type Upper
17. The program control is held at the 30 minutes start of step 2 of remaining time and the fixed value control is performed with the current parameters The program hold is canceled and the program control is started from 30 minutes of remaining time Note The PID module executes all steps 0 to 9 even if the step times of steps are zero When the program control is terminated nine is stored in the current step number of block 0 5 14 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Example 5 Hold Program Control when Program Ends The following diagram shows an example of the program control when hold program control is selected as the program end action Time of steps Step 0 and 1 60 minutes Step 2 30 minutes Steps 3 to 9 0 minute In this example D1000 is allocated to the control register and M500 is allocated to control relay Current step number D1006 Control enable bit D1022 0 Program control bit D1022 3 Program control bit Monitor D1009 3 Program hold bit D1022 4 Advance next step bit D1022 6 Advance previous step bit D1022 7 Program end output D1010 6 1 o The program control is started from the start of step 0 The program control is held and the fixed value control is performed with the parameters of step 9 If the program hold advance next step and adva
18. failure of the MicroSmart may cause a malfunction of the control system damage or accidents e Install the MicroSmart according to the instructions described in this user s manual Improper installation will result in disattachment failure or malfunction of the MicroSmart or damage to equipment n Caution notices are used where inattention might cause personal injur AN Caution 3 d ES e The MicroSmart is designed for installation in a cabinet Do not install the MicroSmart outside a cabinet e Install the MicroSmart in environments described in this user s manual If the MicroSmart is used in places where the MicroSmart is subjected to high temperature high humidity condensation corrosive gases excessive vibrations and excessive shocks then electrical shocks fire hazard or malfunction will result e The environment for using the MicroSmart is Pollution degree 2 Use the MicroSmart in environments of pollution degree 2 according to IEC 60664 1 e Prevent the MicroSmart from being dropped while moving or transporting the MicroSmart otherwise damage or malfunction of the MicroSmart will result e Prevent metal fragments and pieces of wire from dropping inside the MicroSmart housing Put a cover on the MicroSmart modules during installation and wiring Ingress of such fragments and chips may cause fire hazard damage or malfunction e Use a power supply matching the rated value Use of an incorrect power supply may ca
19. the control Parameter Description register ARW Anti Reset Windup 0 to 100 Output Manipulated p nmn Variable Rate of Change 0 to 100 sec RW Alarm 1 Value 10 Alarm 2 Value 11 Alarm 3 Value 12 Alarm 4 Value Refer to the valid range for alarm 1 to alarm 8 values RAY 13 Alarm 5 Value shown in the following table 14 Alarm 6 Value 15 Alarm 7 Value 16 Alarm 8 Value Output Manipulated Variable Upper Limit When output type is voltage Output manipulated variable lower limit to 100 When output type is current Output manipulated variable lower limit to 105 When output type is voltage Output Manipulated 0 to output manipulated variable upper limit KE Stee ER Variable Lower Limit When output type is current 5 to output manipulated variable upper limit Cooling Proportional peo ae mee 19 199 Band Cooling proportional band is the multiplication of R W heating proportional band When input range unit is Celsius 200 0 to 200 0 C When input range unit is Fahrenheit 20 200 Overlap Dead Band 200 0 to 200 Det R W When input is voltage or current 2000 to 2000 Valid Range for Alarm 1 to Alarm 8 Value Alarm Type Upper Limit Alarm 0 to full scale 1 Full scale to full scale 1 Full scale to full scale 1 4 When input is voltage current full scale is the linear conversion span 2 When input is voltage current the valid range is the linear
20. 0 to 1V DC 5V DC maximum Allowable Input 50mA DC maximum 1 to 5V DC 10V DC maximum Input Impedance 100k Cascade Control The cascade control is an advanced control that uses 2 inputs CH1 as a master primary control and CHO as a slave secondary control to control a single process Input Parameters Control Parameters Output Parameters CHO Input CHO Lelleg CHO Output CHO CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Se Control Parameters CH1 Cascade Control CH1 Type J thermocouple Celsius Reverse Control Action Heating Master CH1 calculates the output manipulated variable MV according to the process variable PV and the set point SP The output manipulated variable MV of the master CH1 is used as the set point SP of the slave CHO With the obtained set point SP the slave CHO calculates the output manipulated variable MV and controls the output CHO FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR When the cascade control is used the output CH1 is unused When the output type is current the output CH1 is 4 mA When the output type is voltage the output CH1 is 0 V When t
21. 1570 to 1570 C Alarm 7 Value 1570 to 1570 C Alarm 8 Value 1570 to 1570 C Output MY Upper Limit 0 to 100 Output MY Lower Limit 0 to 100 Cooling Proportional Band 0 0 to 10 0 times 1 Overlap Dead Band 200 0 to 200 0 C O N sch A sch a ch a sch ech zb OOONDNIBRWNHAOOCONDIRWN Write all parameters Read all parameters Monitor OK In Di 2 A D The program parameters of step 0 of CHO control are described here The parameters of steps 1 to 9 of CHO and parameters of steps 0 to 9 of CH1 control are the same as those of step 0 of CHO control However the positions from the control register for each parameter differs For details about the positions from the control register for each program parameter see 5 22 to 5 24 1 Control Register 180 Set Point SP Configure the set point SP at the end of the step Any value within the following range can be configured When input is thermocouple or resistance thermometer Set point SP lower limit lt Set point SP lt Set point SP upper limit When input is voltage or current Linear conversion minimum value lt Set point SP lt Linear conversion maximum value 2 Control Register 181 Step Time The process time of each step can be configured as the step time When the set point SP is 500 C and the step time is 30 minutes the PID module gradually increases the set point SP to 500 C in 30 minutes If the PV Start
22. 23 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Data Register Allocation Blocks 30 39 CH1 Program Parameters SHOT Action When CH1 control is in program control mode block 30 to 39 should be configured A maximum of ten steps from step O0 to step 9 can be configured All parameters of block 30 to 39 are shown in the following tables For detail about each parameter see page 5 23 Offset from the Control Register Parameter Step0 Step1 Step2 Step3 Step4 Sr Sep Step6 Step7 Steps Ser 5 24 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 6 CONFIGURING PID MobuLE USING WINDLDR This chapter describes configuration procedure of the PID modules using WindLDR PID module configuration dialogs and monitoring Procedure to configure the PID module 1 Expansion Modules Configuration Dialog Box To open the Expansion Modules Configuration dialog box follow one of the procedures below Procedure 1 1 From the WindLDR menu bar select View gt Project Window to open the Project Window 2 Double click on Expansion Modules Configuration in the Project Window Procedure 2 1 From the WindLDR menu bar select Configuration gt Expansion Modules Expansion Modules Configuration Dialog Box
23. 3 Block 4 parameters stored in D1053 to D1102 are written to the PID module The parameters of the other blocks are not written Note If parameters of block 4 or 5 are changed while CHO or CH1 control is enabled in the PID module an unexpected operation of the PID module may be caused It is recommended that the control channel of the PID module be disabled before changing the parameters of block 4 or 5 5 6 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Data Register Allocation Block 0 Read Only Parameters The CPU module reads the following parameters from the PID module and store them in the data registers every scan Offset from the Control Parameter Description PID Module Operating Status When input is normal Current Process Variable PV Value within the control range see 9 4 When input is invalid Unknown value Manipulated Variable MV limit 0000h Initialization 0001h Normal operation 0002h External power supply error Current Cooling Output Cooling output manipulated variable lower limit Manipulated Variable MV to upper limit When input is thermocouple or resistance thermometer Set point SP lower limit to set point SP upper limit When input is voltage or current input Linear conversion min to linear conversion Current Set Point SP Current Step Numbe
24. 4 Value 8 Alarm 5 Value See page 6 10 for the detail about alarm value range R Alarm 6 Value Alarm 7 Value Alarm 8 Value FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 11 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR When input range unit is Celsius 0 1 to 100 0 C 9 When input range unit is Fahrenheit 0 1 to 100 0 F When input is voltage or current 1 to 1000 We deiten WW 6 12 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR PID Module Configuration Control Parameters List CHO and CH1 The control parameters for CHO and CH1 are described here PID Module Configuration Slot 1 arameters ep rid FCSAa F2M2 9 10 11 12 13 14 15 16 Control Parameters when Program When the program control mode is se e CHO Control CHO Pro Control Registers 90 Control Mode 1 2 TOO Control Action FC5A MicroSmart PID Module User s Manual FC9Y B1283 Input CHO Input CH1 d H EN Fixed Value Control Mode Reverse Control Action Heating F amp D r E Proportional Band Control Mode is Selected lected parameters 23 to 27 are enabled Parameters for the fixed value control mode such as the
25. Action Heating Voltage Output Input Parameters Control Parameters Output Parameters CH1 Input CH1 CH1 Output CH1 wel Sch CH1 Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Difference CH1 CH0 The difference between input CH1 and input CHO is used as the process variable PV for CHO control Process variable PV of CHO control Input CH1 input value Input CHO input value Input Parameters S Control Parameters Output Parameters CHO Difference CH1 CHO CHO Output CHO CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Control Parameters Output Parameters CH1 zc Input CH1 welch CH1 Output CHL EI EH CH1 Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Addition CH0 CH1 The addition of input CHO and input CH1 is used as the process variable PV for CHO control Process variable PV of CHO control Input CHO input value Input CH1 input value Input Parameters ep Control Parameters Output Parameters CHO e Addition CHO CH1 Leick CHO Output CHO
26. Alarm 0 to full scale 4 When input is voltage current full scale is the linear conversion span 2 When input is voltage current the valid range is the linear conversion minimum value to linear conversion maximum value 6 10 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR Input Parameters List when External SP Input is Selected PID Module Configuration Slot 1 2 x Module Type No FCSA F2M2 X Input cri Input CHO oiled aa Output CHO e eee alan Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters CH1 gt External SP Input Type K thermocouple Celsius 1 nA Input CHO Control CHO Output CHO Input CHL Monitor ll Input Range 4 to 20 m 2000 to 10000 2 Li PV Correction 0 1000 to 1000 3 i PV Filter Time Constant 0 0 0 0 to 10 0 sec Linear Conversion Maximum Value 1370 200 to 1370 c 4 Linear Conversion Minimum Value 200 200 to 1370 C J External SP Input Bias OF 314 to 314 C 8 9 1 0 5 Alarms 6 Alarm Value Hysteresis 0 1 to 100 0 C Delay Time 0 to 10000 sec j No
27. B1283 2 1 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com MODULE SPECIFICATIONS 3 Control Output LED OUTO OUT1 ON Control output is turned on OFF Control output is turned off Flashes When current output is used the LED flashes in a cycle of 125 ms according to the duty ratio of the output manipulated variable MV When output manipulated variable MV is 20 the LED turns on for 25 ms and off for 100 ms continuously 4 Event Output LED EVT0 EVT1 ON Any alarm out of alarm 1 to alarm 8 loop break alarm is triggered OFF None of the alarms is triggered 5 Auto tuning AT Auto reset LED ATO AT1 Flashes Auto tuning AT or auto reset is performing OFF Auto tuning AT or auto reset is stopped 6 Manual Mode LED MIO MII ON Manual mode OFF Auto mode 7 Fixed Value Control Mode Program Control Mode LED F P0 F P1 ON Program control mode OFF Fixed value control mode 8 Program Control RUN HOLD LED R H0 R H1 ON Program control is performing or while in fixed value control enabled Flashes Program control is held or power is restored OFF Program control is stopped or while in fixed value control disabled 9 External SP Enable Disable LED R L ON External SP input is enabled OFF External SP input is disabled 10 Terminal No Indicates terminal numbers 11 Cable Terminal Spring clamp type terminal for connecting a cab
28. Block 1 includes the set point SP manual mode output manipulated variable MV and operation parameters of the PID module Those parameters are written to the PID module every scan Operations such as changing the set point SP for the fixed value control enabling disabling the control or performing auto tuning AT can be carried out Blocks 2 and 3 include basic parameters of the PID module By turning the control relay from off to on parameters can be read from written to the PID module Blocks 4 and 5 include initial setting parameters of the PID module Parameters that are usually not changed during the operation are stored Blocks 10 to 19 and 30 to 39 include parameters of each step of the program control By turning the control relay from off to on parameters can be read from written to the PID module FC5A MicroSmart PID Module User s Manual FC9Y B1283 5 1 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Program Size The user program size that the PID module uses depends on CPU module type The table below shows the program size required to use a PID module Program Size Both CHO and GHN are in fixed value 1 Cig or CH is in program control mode control mode All in one Type 1 300 bytes 4 400 bytes Slim Type 1 200 bytes 3 900 bytes Valid Devices The following devices can be allocated as the control register and relay for the PID module
29. C Set point SP T hb Set point SP 500 Step Wait value is set Moves to the next step when process variable PV reaches 490T Example 2 Wait function when the temperature is falling Set point SP Step Wait value is set 510 Set point SP 500 See Wait value 10 C Time Moves to the next step when process variable PV reaches 510 Program pattern Process variable PV Ee Program pattern delayed by T due to the wait function How to Cancel Wait Function The wait function can be cancelled for the program control to proceed to the next step by turning on the advance next step bit which is the bit 6 of the operation parameter 6 48 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 4 Control Register 183 Proportional Term The output of the proportional action varies in proportion to the deviation between the set point SP and the process variable PV When the heating cooling control is enabled this parameter becomes the heating proportional band The control action will be ON OFF control when the proportional band proportional gain is 0 If the proportional band is broadened proportional gain is made smaller the control output starts turning on or off at the significantly low temperatures from the set point SP overshoot or hunting is reduced
30. CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Control Parameters Output Parameters CH1 gt Input CH CH1 gt Output CH Deen CHI Type K thermocouple Celsius Reverse Control Action Heating Voltage Output FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 21 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 6 22 2 Control Register 133 Input CH1 Function Control Register 55 External SP Input The one of the following input functions can be selected as the Input CH1 Function Input CH1 Input CH1 is used as the process variable PV for CH1 control Input Parameters Control Parameters Output Parameters CHO gt Input cHo Leg CHO Output CHO Leg CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Control Parameters Output Parameters CH1 Input CH1 gt CH1 output CH1 CH1 Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Difference CH0 CH1 The difference between input CHO and input CH1 is used as the process variable PV for CH1 control Process variable PV of CH1 control Input CHO input value Input
31. Delay Time FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 9 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR Input Range Each input setting range is described Input Type and Range Unit Range OOh Type K Thermocouple 200 to 1370 C 01h Type K Thermocouple with Decimal Point 200 0 to 400 0 C 02h Type J Thermocouple 200 to 1000 C i Celsius l l 03h 04h 05h 06h O7h Type T Thermocouple with Decimal Point 08h 09h OAh 0 to 2315 C OBh Pt100 with Decimal Point 200 0 to 850 0 C OCh JPt100 with Decimal Point 200 0 to 500 0 C ODh_ Pt100 OEh JPt100 OFh 10h 12h 13h 14h 15h 16h Fahrenheit 17h 18h 19h 1Ah 1Bh JPt100 with Decimal Point 1Ch 1Dh IER 4to20mADC LL 2000to10000 IEN Oto20mADC LL 2000 to 10000 20h Oto1VDC LL 2000 to 10000 a O O n 200 to 1300 C 11h Type J Thermocouple 328 to 1832 F 21h Oto5VDC 2000 to 10000 22h 1to5V DC 2000 to 10000 23h Oto 10V DC 2000 to 10000 Valid Range for Alarm 1 to Alarm 8 Value The valid range of each alarm type is described in the following table Alarm Type Upper Limit Alarm Lower Limit Alarm Upper Lower Limits Alarm 1 1 1 Process High Alarm Process Low Alarm Upper Limit Alarm with Standby Lower Limit Alarm with Standby Upper Lower Limits Alarm with Standby 0 to full scale 1 Upper Lower Limit Range
32. E NC 0 to 5V z NC 1to 5V 0 to20mA NC 0 to 10V 4to 20mMA otov O lt Iesel A NC DC DC DC Di C A NC ouTo 3 oo 0 to 5V NC r a Oto20mA _ A lt A NI E H 4 o 4 to 20mA 0 to 1V Se eis GI O NC out DC DC pc 5 GP 3 ees RTD ee FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com PID MODULE MAIN FUNCTIONS 4 PID MODULE MAIN FUNCTIONS This chapter describes the temperature control fixed value control auto tuning AT program control heating cooling control difference input control and cascade control of the PID module Temperature Control Using the PID Module Temperature Control Configuration Example Using the PID Module B PID Module C Actuator in 200V AC Control Target such as Electric Furnace or Constant Temperature Oven H A Thermocouple SS A Sensor Measures temperature of the control target Thermocouple resistance thermometer voltage input or current input can be used as the sensor B PID module Receives the temperature measured by the sensor as the process variable PV and calculates the output manipulated variable MV so that temperature difference deviation between the process variable PV and the set point SP can be eliminated The output manipulated variable MV is outputted to the actuator as a control signal Relay output non contact volt
33. EE 8 5 sun LC LING EE 5 21 6 45 under range s ssssessseresseersseressrrressrrsserressrrrsseeesseress 8 5 i STOD e E EEE cess 4 10 Operation parainmeterS scacieiccecansstatincgeanieautaninniecneessaiiaass 5 11 monitor 5 9 KEES egener ee 5 12 Seen DEE GEET 6 50 7 8 7 12 pee rogram control mode EE 9 5 H SR T lower limit EE 6 48 Se WEEK GEET EE manipulated variable MV 5 7 prog ti t 513 5 14 ON OFF hysteresis svcccpescaxaieciseicactsasernctrsesienteaacies 6 39 Or ge E See ME 5 17 OCA O I ee 8 2 PTI eege 5 12 rate of change cseeccccssscccessceceesceceeecesseseeeseuess 6 39 program parameters sssssssssssesssesesrsereeeeee 5 3 5 26 9 11 EE eege 5 21 6 47 E E E EE T A E A N 6 49 Aaa Or IG EH 6 48 E TE T A E E E A E A A E A 6 19 alt deift de et serieresirssrirrrrrsibtrre Par PErx sN kti ATER 6 17 leede IEN 5 2 EECH 6 47 proportional band exacacdiceoncsscncsdunetonksestindeeantateeceisetiecess 6 37 EE 9 4 REGER 5 18 6 37 overlap dead band 5 19 6 41 pe eee bee p PY CONC C IO E 5 20 6 24 P PV filter time Constant 5 6 5 20 6 25 parameter range effOf ssssssseesrerrssssrssrerrerrsresresresresee 5 9 R PID MOUIE seas sacterse ss cinmes den veceastuesaasieseea eater gieasencasanosseasaaee 1 1 sadn ancien 5 7 DT cpu and WmnaL OR ver oieee 1 2 ead o y pa AITICTONS sss ctaedsdencciporeranctuntiaeaagraeecsuaenotieacens RESET SCULING eeben ebe ebe Seeerei 6 38 COTE Ol OURO UE ic fot xe cceccesncetcase
34. Expansion Modules Configuration dialog box However if a PID module is not connected to the configured slot writing parameters to the PID module will fail Even after writing parameters to one PID module failed WindLDR continues to write the parameters to all PID modules configured in the Expansion Modules Configuration dialog box If writing parameters fails connect the PID module to the CPU module and write parameters to the PID module again To write the PID module parameters without downloading the user program to the CPU module take the following steps 1 Connect the PID module to the CPU module 2 Open the PID Module Configuration dialog box for the slot 3 Click on Write All Parameters button All the configured parameters will be written to the data registers in the CPU module and the PID module 6 4 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR User Program Upload When the user program containing the initial parameters of the PID modules is uploaded from the CPU module the initial values will be restored The parameters saved in the PID module will not be read How to restore data register values when a keep data error has occurred If more than 30 days pass since the power to the CPU module is turned off values stored in the data registers will be lost When the data register values are
35. Input range lower limit 50 C 100 F to Input range 50 C 100 F Range with a decimal point Full scale x 1 C F to Input range 50 C 100 F When input is resistance thermometer Full scale x 1 C F to Input range 50 C 100 F When input is voltage current Linear conversion minimum value 1 of linear conversion span to Linear conversion maximum value 10 of linear conversion span When the power is turned on the PID module starts with the standby status During the standby the control and alarm assessment are not conducted The control and alarm assessment are enabled when the control enable bit of the operation parameters is turned on When the control mode is the program control and the power is restored the PID module resumes with the status at the time of the power failure FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Output Action APPENDIX CHO CH1 Output Action of PID PI PD and P Control Action pe Heating Reverse Control Action Cooling Direct Control Action Proportional Band Control Action af al Cycle Action is Performed ccording to Deviation Relay Output 12VDC 12 0V DC Sot oe We Cycle Action is Performed ccording to Deviation Non contact Voltage Output OV DC a SS i m 4mA DC Current 20mA DC 20 to 4mA DC ee eee Output z C
36. Module Configuration Input Parameters Details PID Module Configuration Slot 1 2 xi Module Type No 1 FCSA F2M2 Input Parameters Control Parameters Output Parameters CHO Input CHO wel ec CHO Output CHO wel ec CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Control Parameters Output Parameters CH1 Input CH Leg CH1 Output CH1 len CH1 Type K thermocouple Celsius Reverse Control Action Heating Voltage Output 1 Input CHO Control CHO Output CHO Input CH1 N Control CH1 Output CH1 Monitor Input Range Type K thermocouple ll Celsius 1 200 to 1370 c 2 LS PV Correction 0 0 E 100 0 to 100 0 c 3 PV Filter Time Constant 0 0 0 0 to 10 0 sec E Set Point SP Upper Limit 1370 200 to 1370 C 4 dg Set Point SP Lower Limit 200 LG 200 to 1370 C 5 Glatz To Alarm Action 6 No Alarm Action No Alarm Action No Alarm Action No Alarm Action No Alarm Action No Alarm Action No Alarm Action Hysteresis 0 1 fo 100 0 C Delay Time 0 to 10000 sec o c 2o oO E Oo Co E oc oo coo CO Write all parameters Read all parameters Monitor OK Cancel Input parame
37. Output CHO 1 Output CH1 2 Both outputs CHO CH1 0 Output CH1 Output Function CHO has priority See 5 21 for the input types and range When input is thermocouple or resistance thermometer Set point SP lower limit to input range upper limit When input is voltage or current input Linear conversion minimum to input range upper limit When input is thermocouple or resistance thermometer Input range lower limit to set point SP upper limit When input is voltage or current input Input range lower limit to linear conversion maximum When input range unit is Celsius 0 1 to 100 0 C When input range unit is Fahrenheit 0 1 to 100 0 F When input is voltage or current input 1 to 1000 When input range unit is Celsius 100 0 to 100 0 C When input range unit is Fahrenheit 100 0 to 100 0 F When input is voltage or current input 1000 to 1000 0 0 to 10 0 sec No alarm action Upper limit alarm Lower limit alarm Upper Lower limits alarm Upper Lower limit range alarm Process high alarm Process low alarm Upper limit alarm with standby Lower limit alarm with standby Upper Lower limits alarm with standby OONDOBRWN CH FC5A MicroSmart PID Module User s Manual FC9Y B1283 IW IW IW IW IW WW IW IW IW IW R R R R R R R R R R R R 5 19 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE
38. This represents how the target is easily heated and has a relation with the volume size of the control target 2 Static characteristic This represents the capability of heating and is determined by the size of the heater capacity 3 Dynamic characteristic This represents the rising characteristic transitional response during initial heating This is a complicated process involving heater capacity furnace capacity size and sensor location 4 Disturbance Any change in control temperature causes disturbance For example the change of ambient temperature or supply voltage can cause disturbance Characteristics of Control Target Static Thermal Capacity Characteristic Disturb Dynamic isturbance Characteristic 4 2 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com PID MODULE MAIN FUNCTIONS Fixed Value Control The PID module provides 2 control modes one is the fixed value control and the other is the program control The fixed value control is a standard temperature control which performs to eliminate the deviation between the single set point SP and process variable PV The program control allows you to define the set point SP that changes as the time progresses so that the process variable PV can be controlled to match the set point SP changing as the time progresses For detail about the program control see 4 9 Contro
39. automatically calculated using auto tuning AT e If the process variable PV of CHO control becomes 205 C or higher the upper limit alarm output QO is turned on and the control is disabled e If the process variable PV of CH1 control becomes 215 C or higher the upper limit alarm output Q1 is turned on and the control is disabled System Configuration and Wiring Wiring Example of the FC5A F2M2 Non contact voltage output for SSR drive current output type 3 phase Power Supply erminal Channel No GER TS Electric Electric Furnace 2 Furnace 1 CH1 Thermocouple PID Module FC5A F2M2 FC5A MicroSmart PID Module User s Manual FC9Y B1283 7 1 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPLICATION EXAMPLES PID Module Parameter Configuration The parameters of the PID module can be configured in the Expansion Modules Configuration and PID Module Configuration dialog boxes The procedure to configure the PID module is described below Parameter Configuration Example Quantity of Modules 1 unit Slot Number Slot 1 Module Type No FCSA F2M2 Data Register D1000 Internal Relay M1000 I O Function Used as a 2 channel PID module CHO CH1 SSS Oo EHI f E Upper limit alarm 5 C Set Point SP 200 C PID control action IR D and ARW are Control Action automatically calculated using auto tuning AT AT Bias Upper limit alarm 5 C 210 C
40. derivative time is shortened the derivative action becomes weak The response to the rapid temperature change becomes slower Because the action to suppress the rapid temperature rise becomes weaker the time for the process variable PV to reach the set point SP is shortened however overshoot can occur If the derivative time is extended the derivative action becomes strong The response to the rapid temperature change becomes faster Because the action to suppress the rapid temperature rise becomes strong the time for the process variable PV to reach the set point SP is extended however overshoot can be decreased An appropriate derivative time for the control target can be automatically calculated using auto tuning AT function It is unnecessary to configure the derivative time in the WindLDR when using the auto tuning AT function 9 Control Register 29 ARW Anti Reset Windup When the control is started there is a large deviation between the set point SP and the process variable PV The integral action continues its action in a given direction until the process variable PV reaches the set point SP As a result an overshoot is caused by the excessive integral action ARW suppresses the overshoot by limiting the integral action area When ARW is 0 the integral action area becomes the minimum and the suppression of the overshoot is maximized When ARW is 50 the integral action area becomes the intermediate and the suppr
41. flag remains ON Checking Items Does the input signal source for voltage 1 Check the input signal source for voltage 1 to 5V DC or current to 5V DC or current 4 to 20mA operate 4 to 20mA normally How to check whether the input signal wire is disconnected Voltage 1 to 5V DCH Input 1V DC to the input terminals of the PID module If a linear conversion minimum value is indicated the PID module is operating normally and the signal wire may be disconnected Current 4 to 20mA Input 4mA to the input terminals of the PID module If a linear conversion minimum value is indicated the PID module is operating normally and the signal wire may be disconnected 3 The process variable PV constantly shows the linear conversion minimum value Checking Items Does the input signal source for voltage 0 Check input signal source for voltage 0 to 5V DC or 0 to 10V DC to 5V DC 0 to 10V DC or current 0 to or current 0 to 20mA 20mA operate normally How to check whether the input signal wire is disconnected Voltage 0 to 5V DC or 0 to 10V DCH Input 1V DC to the input terminals of the PID module If a converted value calculated with the linear conversion minimum and maximum values corresponding to 1V DC is indicated the PID module is operating normally and the signal wire may be disconnected Current 0 to 20mA Input 4mA to the input terminals of the PID module If a converted value calculated with the linear conv
42. however it takes time for the process variable PV to reach the set point SP and offset between the process variable PV and the set point SP is broadened If the proportional band is narrowed proportional gain is made larger the control output starts turning on or off at around the set point SP the time until the process variable PV reaches the set point SP is shortened and the offset is small however the hunting phenomenon is frequent If the proportional band is greatly narrowed the control action becomes similar to the ON OFF control action An appropriate proportional band proportional gain for the control target can be automatically calculated using auto tuning AT function It is unnecessary to configure the proportional band proportional gain in the WindLDR when using the auto tuning AT function 5 Control Register 184 Integral Time In the proportional control action the offset is generated even when the control is stabilized The integral action corrects the offset The integral action is disabled when the integral time is 0 The integral time is a coefficient to determine the output manipulated variable MV of the integral action If the integral time is shortened too much the integral action becomes strong The offset can be corrected in a shorter time however the hunting phenomenon may be caused over a long cycle On the contrary if the integral time is extended too much the integral action becomes weak an
43. is terminated earlier than the configured time Is PV start 1 or PVR start 1 selected as program control mode start type YES Select SP start 1 as program control mode start type Set each step time to a suitable Is each step time suitable value YES Call IDEC for assistance END 1 For program control mode start type see page 6 41 8 6 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPENDIX 9 APPENDIX This chapter describes the function references output actions and factory default settings of the PID module PID Module Function References PID control with auto tuning AT PI control PD control with auto reset P control with auto reset ON OFF control Proportional term Proportional band P When input range unit is Celsius 0 to 10000 C Range with a decimal point 0 0 to 1000 0 C When input range unit is Fahrenheit 0 to 10000 F Range with a decimal point 0 0 to 1000 0 F When input is voltage current 0 0 to 1000 0 Proportional gain 0 00 to 100 00 Note The control action will be ON OFF control when proportional term is 0 Integral time I Derivative time D Control period ARW Reset When input range unit is Celsius 100 0 to 100 0 C When input range unit is Fahrenheit 100 0 to 100 0 F Control Action Wh
44. is the alarm value The alarm output turns on if the Upper limit alarm with standby process variable PV exceeds Lower limit alarm with standby the range Upper Lower limits alarm with standby l The alarm output turns on if the Process Process high alarm The alarm action point is rocess variable PV exceeds Alarm Process low alarm the alarm value 8 the alarm value When the alarm value is 0 the alarm action is disabled except process high alarm and process low alarm If the input type or input unit type is changed confirm the valid range of the alarm value and configure appropriate values 6 28 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 8 Control Register 73 Control Register 74 Control Register 75 Control Register 76 Control Register 77 Control Register 78 Control Register 79 Control Register 80 Alarm 1 Hysteresis Alarm 2 Hysteresis Alarm 3 Hysteresis Alarm 4 Hysteresis Alarm 5 Hysteresis Alarm 6 Hysteresis Alarm 7 Hysteresis Alarm 8 Hysteresis CONFIGURING PID MODULE USING WINDLDR When an alarm turns from on to off and vice versa the span between on and off is called alarm hysteresis If the alarm hysteresis is narrowed the alarm output switches to on or off even by a slight variation of temperature at around the alarm action point This frequent on off of an alarm may negatively affect the
45. limit alarm Alarm 1 Value FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPLICATION EXAMPLES 6 Control CH1 Parameters Setting Configure the Control CH1 parameters in the PID Module Configuration dialog box To open Control CH1 Parameters in the PID Module Configuration dialog box click on Control Parameters CH1 button or the Control CH1 tab PID Module Configuration Dialog Box Control CH1 Parameters PID Module Configuration Slot 1 1 2 4 H d A 1 7 A A Input CHO Input CH1 sage LC Output CH1 E gt s Fixed Value Control Mode Reverse Control Action Heating Proportional Band i Set Point SP 210 C FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 7 5 APPLICATION EXAMPLES 7 Saving Parameters Click OK button to save the configured parameters PID Module Configuration Slot 1 a 2 xi Module Type No FCSA F2M2 sx Input Parameters Control Parameters Output Parameters gt Input CHO Den gt Output CHO Dee CHO CHO CHO Type K thermocouple Celsius Reverse Control Action H
46. lost after the power is turned on restore the PID module parameters in the data registers of the CPU module using either of the following methods and then enable the control of the PID module Method 1 Use the parameters stored in the PID module The parameters stored in the PID module can be read out and stored in the data registers of the CPU module with one of the following procedures Procedure 1 Using WindLDR 1 Open Expansion Modules Configuration dialog box in WindLDR 2 Select the slot number of the connected PID module and open the PID Module Configuration dialog box 3 Click on Read All Parameters button to read all parameters from the PID module 4 Configure the set point SP and the manual mode output manipulated variable in the PID Module Configuration dialog box 1 5 Click on Write All Parameters button When the control of the PID module is enabled the PID module will start operating with the downloaded parameters Procedure 2 Using the user program 1 Turn off to on the reading all parameters relay control relay 0 2 Configure the set point SP and the manual mode output manipulated variable if necessary 1 When the control of the PID module is enabled the PID module will start operating with the configured parameters 1 Because the block 1 parameters are not saved in the PID module it is required to configure those parameters Method 2 Use the default parameters stored in the ROM of the CPU modul
47. manipulated variable upper limit When the input is thermocouple or resistance thermometer 23 Set Point SP WE point SP lower limit to set point SP upper limit en the input is voltage or current input CH1 Linear conversion min to linear conversion max Manual Mode Output Output manipulated variable lower limit to output manipulated W Manipulated Variable variable upper limit 20 Set Point SP Operation Parameter Refer to the table below for the operation parameters Note When the power to the PID module is turned off Block 1 parameters are cleared to zero Operation Parameters Operation Parameters 1 word Item Status Description BitO Control Enable Bit Control disable Control enable Auto tuning AT Auto reset cancel Auto tuning AT Auto reset perform Auto mode 0 _ 0 Kies 0 Programcontrolstop _ pie NENSEN Le H H H Bit1 Auto tuning AT Auto Reset Bit 1 Bit2 Auto Manual Mode Bit Se Program control run Bit4 Program Hold Bit 2 Program control hold External SP input disable External SP input enable No action Program control advance next step No action Program control advance previous step Reserved Fixed value 0 BitS External SP Input Enable Bit Bit6 Advance Next Step Bit 3 Bit7 Advance Previous Step Bit 4 Bit8 to Bit15 1 Once auto reset is performed it cannot be cancelled during its performance 2 The program control is s
48. oe ee Changes Continuously According to Deviation 4mADC 4to20mADC i 20mADC Changes Continuously According to Deviation __ Turns ON or OFF Represents heating control action gt Represents cooling control action 9 6 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPENDIX Output Action of Heating Cooling Control with Overlap Heating Proportional Band Cooling Proportional Band Control ON Action Heating Cooling Control Action Control Action Cycle Action is Performed ccording to Deviation Cycle Action is Performed ccording to Deviation des es 123VDC 12 0VDC Non contact l 3 i E Voltage Cycle Action is Performed ccording to Deviation Sc 3 L 3 gt j OVDC TI O M2VDC 12V DC SC feed ees Cycle Action is Performed ccording to Deviation F 3 kr 20mADC 20to4mA DC 4mA DC Current J E GE Output o Changes Continuously According to Deviation 4mADC 4to20mADC 20mADC CH1 Current Output Changes Continuously According to Deviation LED Indicato CHO OUT Green LED Indicato CH1 OUT Green Turns ON or OFF Represents heating control action 2 Represents cooling control action FC5A MicroSmart PID Module User s Manual FC9
49. or PVR Start is selected as the program control mode start type when the program control is started the time is advanced until the set point SP becomes equal to the process variable PV Then the program control starts and the set point is gradually increased to 500 C at the end of the step If the SP Start is selected as the program control mode start type the set point SP is increased from the set point SP specified with Set Point SP when Program Control Starts to the set point SP of step 0 in 30 minutes See page 6 41 and 6 42 for details about the program control mode start type FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 47 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 3 Control Register 182 Wait Value During the program control running when a step is finished the PID module checks whether the deviation between the process variable PV and set point SP is less than or equal to the wait value The program control is not proceeded to the next step until the deviation becomes less than or equal to the wait value The wait function does not work and the program control is proceeded to the next step if the process variable PV satisfies the following condition Set Point SP Wait Value lt Process Variable PV lt Set Point SP Wait Value Example 1 Wait function when the temperature is rising Wait value 10
50. or if the process variable PV in step 3 becomes 810 C or higher the upper limit alarm output QO is turned on and the control is disabled e In CH1 control if the process variable PV in step 1 becomes 110 C or higher or if the process variable PV in step 3 becomes 810 C or higher the upper limit alarm output Q1 is turned on and the control is disabled System Configuration and Wiring Wiring Example of the FC5A F2MR2 Relay output type 3 phase Power Supply Surge Absorber Surge Absorber Electromagnetic Switch SST ae oe E Electric Electric Furnace 2 Furnace 1 CH1 Thermocouple PID Module FC5A F2MR2 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPLICATION EXAMPLES PID Module Parameter Configuration The parameters of the PID module can be configured in the Expansion Modules Configuration and PID Module Configuration dialog boxes The procedure to configure the PID module is described below Parameter Configuration Example Quantity of Modules 1 unit Slot No Slot 1 Module Type No FCSA F2MR2 Data Register D1000 Internal Relay M1000 I O Function Used as a 2 channel PID module CHO CH1 CHO a Type K thermocouple 200 to 1370 C Type K thermocouple 200 to 1370 C Relay output S Output Relay output Relay output Alarm 1 Type Upper l
51. parameters in the PID Module Configuration dialog box To open Input CHO Parameters in the PID Module Configuration dialog box click on Input Parameters CHO button or Input CHO tab PID Module Configuration Dialog Box Input CHO Parameters PID Module Configuration Slot 1 Input CHO Control C 0 Output CHO Input CH1 Control Cc 1 Outi e 1 op 1 REENEN 2 3 4 No Alarm Action No Alarm Action Item 1 Input Range Range Type K thermocouple Celsius 370e S Set Point SP Upper Limit 1370 C Set Point SP Lower Limit 200 C Alarm 1 Type Upper limit alarm 4 Control CHO Parameters Configure the Control CHO parameters in the PID Module Configuration dialog box To open Control CHO Parameters in the PID Module Configuration dialog box click on Control Parameters CHO button or Control CHO tab PID Module Configuration Dialog Box Control CHO Parameters Tami Zet r Contr ol CHO De zeap ap Zeit eat deu A Zei Tera ik SOL PETE SLY FTE PET SATIS Program Control Mode Reverse Control Action Heatin Disable am 1 Control Mode Program control mode FC5A MicroSmart PID Module User s Manual FC9Y B1283 7 11 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPLICATION EXAMPLES 5 Program CHO Parameters Configure the Program CHO parameters in the PID Module Configuration dialog box To open Input CH1 Par
52. proceeded to the start of the next step The advance next function is also effective while the program control is in wait action Advance Previous Function Move back the program control Turn off to on the advance previous step Bit7 of the operation parameter The progression of the current step is stopped and the program control is moved back If the elapsed time in the current step is less than 1 minute the program control goes back to the start of the previous step If the elapsed time in the current step is longer than 1 minute the program control goes back to the start of the current step Even when the advance previous function is executed at Step 0 the program control does not move back to Step 9 regardless of the program end action Current Step Remaining Time The remaining time of the current step is stored in the Current Step Remaining Time of Block 0 The remaining time is stored in seconds or minutes according to the Step time unit setting Current Step Number The current step number 0 to 9 is stored in the Current Step Number of Block 0 Program Wait Perform program wait While the program wait is functioning the program wait bit Bit5 of the operating status is turned on If the condition below is satisfied the wait function is cancelled the program control proceeds to the next step and the program wait bit Bit5 is turned off Set point SP Wait value lt Process variable PV lt Set point
53. processes such as extruders or for temperature control at near the ambient temperature such as environment testers Heating PID aaa Control Module Target Cooling 4 Control Register 20 Set point SP Any value within the following valid range can be configured as the set point SP The valid range of set point SP when the input type is thermocouple or resistance thermometer Set point SP lower limit lt Set point SP lt Set point SP upper limit The valid range of set point SP when the input type is voltage or current Linear conversion minimum value lt Set point SP lt Linear conversion maximum value If the input type or input unit type is changed confirm the valid range of set point SP and configure an appropriate value 5 Control Register 94 Proportional Term Either proportional band or proportional gain can be selected to use The proportional band which is expressed in percentage form is the span of the input necessary for the output manipulated variable MV to change from 0 to 100 The proportional gain is the coefficient to calculate the output manipulated variable MV of the proportional action The proportional gain can be obtained as the quotient of 100 and the proportional band Example When the proportional band is 50 the corresponding proportional gain will be 2 100 50 6 Control Register 26 Proportional Band Proportional Gain The output of the proportional action varies in p
54. the actual temperature of the control target When a target is controlled with multiple PID modules the measured temperatures may not match due to the differences in sensor accuracy or dispersion of load capacities even though the set points SP of those PID modules are the same In such cases the process variable PV of the PID module can be adjusted to the desired temperature by using the PV Correction The process variable PV after PV correction is added should be within the control range The process variable PV after PV correction can be calculated using the following formula Process variable PV after PV correction Process variable PV PV correction value PV Correction Range When input is thermocouple or resistance thermometer 0 1 to 100 0 C F When input is voltage current 1 to 1000 The PV filter function is a software filter to stabilize the process variable PV affected by fluctuating processes such as pressure or flow rate by calculating first order lag of the process variable PV The PID module measures the temperature at the input terminal and maintains the reference junction as if the reference junction was at 0 C or 32 F When thermocouple input or resistance thermometer input is burnt out the over range bit of the operating status is turned on and control output is turned off when output type is current the output manipulated variable lower limit value is outputted When input is thermocouple
55. the output manipulated variable MV e The program pattern for the program control consists of the following 4 steps Step 0 Step 1 Step 2 Step 3 Preheat process Step 0 is the process to gradually raise the set point SP to the preheat temperature 100 C in 60 minutes to evaporate water in the specimen and electric furnace interior When the elapsed time in step 0 is 60 minutes if the process variable PV is less than 90 C the PID module waits until the temperature reaches 90 C When the temperature reaches 90 C the PID module proceeds to the next step Preheat process Step 1 is the process to keep the preheat temperature 100 C constant for 60 minutes Firing process Step 2 is the process to gradually raise the set point SP to the firing temperature 800 C in 5 hours to prevent the specimen from being damaged by a rapid temperature rise When the elapsed time in step 2 is 5 hours if the process variable is less than 790 C the PID module waits until the temperature reaches 790 C When the temperature reaches 790 C the PID module proceeds to the next step Firing process Step 3 is the process to keep the firing temperature 800 C constant for 30 minutes e PID parameters proportional band proportional gain integral time derivative time and ARW of each step are automatically calculated using auto tuning AT e In CHO control if the process variable PV in step 1 becomes 110 C or higher
56. variable MV Example When the cooling output manipulated variable MV upper limit is 80 the cooling control output will be 80 even when the cooling output manipulated variable MV reaches 100 7 Control Register 52 Cooling Output Manipulated Variable Lower Limit This value specifies the lower limit of the cooling output manipulated variable MV Example When the cooling output manipulated variable MV lower limit is 20 the cooling control output will be 20 even when the cooling output manipulated variable MV is 0 6 46 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR PID Module Configuration Program Parameters Details PID Module Configuration Slot 1 i 21x Module Type No FCSA F2M2 Input CHO Control CHO Output CHO Input CH1 Output CH1 Monitor Range e Step 3 Step 4 Step 5 Step 6 Step 7 Set Point SP 200 to 1370 C Step Time 0 to 6000 min Wait Yalue Oto 100 C Proportional Band 0 to 10000 c Integral Time 0 to 10000 sec Derivative Time 0 to 10000 sec ARW Anti Reset Windup Oto 100 Output MV Rate of Change 0 to 100 sec Alarm 1 Value 1570 to 1570 C Alarm 2 Value 1570 to 1570 C Slarm 3 Value 1570 to 1570 C Alarm 4 Value 1570 to 1570 C Alarm 5 Value 1570 to 1570 C Alarm 6 Value
57. 0 0 0 0 0 0 0 100 0 1 200 0 to 200 0 C O Write all parameters Read all parameters Monitor OK Cancel Control Registers Offset from the control register 393 Parameter Set Point SP 2 Step Time 3 Wait Value Proportional Band ERSS Proportional Gain 4 Integral Time n Derivative Time FC5A MicroSmart PID Module User s Manual FC9Y B1283 Description When input is thermocouple resistance thermometer Set point SP lower limit to set point SP upper limit When input is voltage or current Linear conversion min to linear con version max When step time unit is Minute 0 to 6000 minutes When step time unit is Second O to 6000 seconds When input range unit is Celsius O to 100 C Range with a decimal point 0 0 to 100 0 C When input range unit is Fahrenheit R W O to 100 F Range with a decimal point 0 0 to 100 0 F When input is voltage or current O to 1000 Proportional band When input range unit is Celsius O to 10000 C Range with a decimal point 0 0 to 1000 0 C When input range unit is Fahrenheit O to 10000 F Range with a decimal point 0 0 to 1000 0 F When input is voltage or current 0 0 to 1000 0 w Proportional gain 0 00 to 100 00 O to 10000 sec 0 to 10000 sec Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR Offset from
58. 0 Input CHO CH1 57 Output Function CHO CHO 0 Output CHO 134 Output Function CH1 CH1 0 Output CH1 Input Type 00h Type K thermocouple 200 to 1370 C 59 136 Set Point SP Upper Limit Linear Conversion 1370 C 1370 Maximum Value 60 137 Set Point SP Lower Limit Linear Conversion 200 C 200 Minimum Value Output ON OFF Hysteresis 1 0 C 10 PV Correction 0 0 C 0 PV Filter Time Constant 0 0 seconds 0 64 141 Reserved H 68 145 a onmenes 1 Cooling Method CHO only Sc S Air cooling Set Point SP when Program Control Starts 0 0 C 0 Number of Repeats 0 times 0 Cooling Output ON OFF Hysteresis CHO 1 0 C 10 179 CHO only CH1 0 99 176 Output Specifications 0 Non contact voltage output for SSR FC5SA F2M2 only drive External SP Input Bias CHO 0 CH1 only CH1 0 0 C 0 External SP Input Linear Conversion CHO 0 Maximum Value CH1 only CH1 1370 C 1370 External SP Input Linear Conversion CHO 0 Minimum Value CH1 only CH1 200 C 200 N N CUO SES 0 0 ds 0 SNE 9 10 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPENDIX Blocks 10 19 CHO Program Parameters Offset from the Control Register DEET Step0 Step1 Step2 Step 3 Step4 Proportional Integral Time 200 sec 200 50 sec 50 ARW Anti Reset
59. 00 sec 200 50 sec 50 ARW Anti Reset Windup 50 50 492 511 530 549 508 Output Manipulated Variable ostieecond 0 Rate of Change Fei S Reserved en Upper Limit 503 529 541 560 579 Output Manipulated Variable 0 0 Lower Limit 9 12 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INDEX A PAI NN A E E 9 1 delay A ai EE 5 21 6 30 KEE 5 21 6 30 EEN 5 10 EILE E LEPPE N PE A N E E E AATE 6 29 KEE EII TENE T E A NT 5 20 6 27 upper limit Ed DEE 7 1 7 9 upper lower limits alarm with standby 00 7 18 CH Ren 5 19 eege 5 18 6 38 AT DS reirnos 4 6 5 21 6 38 7 6 le E EE 4 7 5 9 5 11 auto tuning AT sewssiesicincadantiislespeiiubacrinetiecarsasciecsvens 5 9 7 6 AN CS EE 4 8 ES eege 4 7 5 11 auto tuning AT auto reset cccecccccceeeeseseeeeeeeeeeeeeees 4 6 Be KEE 2 2 program example ccccesececcseceeeeeceeaeeeeeeaeeeeesseasees 4 8 B basic parameters essesesssrrsrressrererrrerererrrses 5 3 5 18 9 9 DOCE Oasan ia snasamawseaamaeseceesantcesacseseaee 5 1 5 7 aisen E 5 1 5 11 9 9 blocks 10 19 WEE 5 1 5 24 9 11 ONS E 5 1 5 18 9 9 blocks 30 39 ncceccacessvcctesniicdsvuctesaveseenancndies 5 1 5 26 9 12 aile Te E 5 1 5 20 9 10 PO OI spe eeiecens sete oe sects canton E T E 9 4 C cascade CONT e EE 4 15 5 20 6 22 9 2 linear conversion MAXIMUM v lue ees 6 46 l
60. 1 Parameters Setting Configure CH1 Parameters in the same way as CHO 7 Saving Parameters Click OK button to save the configured parameters 7 12 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPLICATION EXAMPLES 8 Ladder Programming Create a ladder program to control the PID module Ladder Program Example While external input I0 is on CHO control is enabled When QO CHO control upper limit 10000 Qo0000 D1022 00 alarm output is on CHO control is disabled When external input 11 is turned on CHO 10001 Dins2o3 Program control is started When 11 is tuned off the program control is stopped s When CHO alarm 1 is triggered QO is turned on D1010 07 Qo000 While external input I2 is on auto tuning AT is deeg SE performed in each step of the program control as follows e Step 0 When the remaining time is 5 minutes e Step 1 When step 1 is started e Step 2 When the remaining time is 5 minutes e Step 3 When step 3 is started DC D1006H Lc lt W 2 D1005 5 When CHO program control is completed Q1 is D1010 06 qooo1 turned on While external input I3 is on CH1 control is enabled When Q2 CH1 control upper limit 10003 O0O007 p1025 00 alarm output is on CH1 control is disabled When external input 14 is turned on CH1 program control is started When 14 is turned off 10004 D1025 03 the program c
61. 10000 IEN Oto20mADC IL 2000to10000 20h Oto1VDC LL 2000to10000 21h Oto5VDC LL 2000to10000 22h 1t05VDC IL C2000 t0 10000 23h 0to10VDC LL 2000to10000 FC5A MicroSmart PID Module User s Manual FC9Y B1283 5 21 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Data Register Allocation Blocks 10 19 CHO Program Parameters SHOT Action When CHO control is in program control mode block 10 to 19 should be configured A maximum of ten steps from step 0 to step 9 can be configured All parameters of block 10 to 19 are shown in the following tables For detail about each parameter see page 5 23 Offset from the Control Register Parameter Step0 Step Step2 Step3 Step4 Sen Sep Step6 Step7 Steps Ser Cooling proportional band 5 22 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Program Parameters When input is thermocouple or resistance thermometer Set point SP lower limit to set point SP upper limit SEET OELSE When input is voltage or current input Linear conversion min to linear conversion max When step time unit is Minute When step time unit is Second O to 6000 seconds When input range unit is Celsius O to 100 C Range with a decimal point 0 0 to 100 0 C When input r
62. 10000 sec 105 Derivative Time 0 to 10000 sec 106 ARW Anti Reset Windup 0 to 100 When input range unit is Celsius 0 to 50 C Range with a decimal point 0 0 to 50 0 C When input range unit is Fahrenheit O to 100 F Range with a decimal point 0 0 to 100 0 F When input range unit is Celsius 100 0 to 100 0 C When input range unit is Fahrenheit 100 0 to 100 0 F When input is voltage or current 1000 to 1000 When input range unit is Celsius 0 to 10000 C min Range with a decimal point 0 0 to 1000 0 C min R W 10 89 166 AT Bias 11 31 108 Reset When input range unit is Fahrenheit O to 10000 F min Range with a decimal point 0 0 to 1000 0 F min When input is voltage or current O to 10000 min When input range unit is Celsius O to 10000 C min Range with a decimal point 0 0 to 1000 0 C min When input range unit is Fahrenheit O to 10000 F min Range with a decimal point 0 0 to 1000 0 F min When input is voltage or current O to 10000 min 12 33 110 Set Point SP Rise Rate 13 34 111 Set Point SP Fall Rate as oss ke eS Tra 6 14 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR Offset from the control register Parameter Setting Range CHO CH1 Output Manipulated S RW KEN Variable Rat
63. 3 FCSA C24R2D FCS5A D12K1E FC5A D12S1E FC5A C10R2 FC5A MicroSmart CPU FC5A C10R2C FC5A C10R2D Number of PID Modules FC5A MicroSmart PID Module User s Manual FC9Y B1283 1 1 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com GENERAL INFORMATION Applicable CPU and WindLDR version PID modules can be used with the following FC5A CPU module system program version and WindLDR version as listed below All in One Type Slim Type FC5A D16RK1 FC5A C16R2 FC5A D16RS1 FC5A C10R2 FC5A C16R2C FC5A C24R2 FC5A D32K3 FC5A MicroSmart CPU FC5A C10R2C FC5A C16R2D FC5A C24R2C FC5A D32S3 FOON NORAD iFeSA C24R2D FC5A D12K1E FC5A D12S1E CPU System Program Version 230 or higher 1 WindLDR Version 6 40 or higher 1 The PID module can be used with FC5A D12K1E S1E with the system program version 100 or higher Confirming System Program Version The system program version can be confirmed using WindLDR 1 Connect a PC to port 1 or 2 of the FC5A CPU using serial computer link cable I F FC2A KC4C or USB cable HG9Z XCM2A for FC5A D12x1E CPU 2 From the WindLDR menu bar select Online gt Monitor 3 From the WindLDR menu bar select PLC gt Status The PLC Status dialog box appears and system program version is shown System Information PLC Type FCSA D 16RX1 E System Program Version Operation Status Run Stop Status Running Scan Time Current Maxim
64. 3 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPLICATION EXAMPLES 2 I O Function Selection Select I O function for each channel in the PID Module Configuration dialog box PID Module Configuration Dialog Box I O Function Selection PID Module Configuration Slot 1 2 xi 1 Module Type No FCSA F2M2 3 Output CHO anai i 2 Type K thermocouple Celsius Reverse Control Action Heating Voltage Output 4 Input erie Input CH1 Melen Output CHI T a i Input Parameters Control Parameters CHO Input CHO nd CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input CHO X Control CHO Output CH0 Input CH1 Control CH1 Output CH1 Monitor Soa E Input Range Type K thermocouple Celsius sl 200 to 1370 C PV Correction 0 0 H 100 0 to 100 0 C PV Filter Time Constant 0 0 H 0 0 to 10 0 sec Set Point SP Upper Limit 1370 E 200 to 1370 C Set Point SP Lower Limit 200 200 to 1370 C Alarms Input CHO Function Input CHO Input CH1 Function Input CH1 Output CHO Function Output CHO Output CH1 Function Output CH1 3 Input CHO Parameters Configure the Input CHO parameters
65. 55 57 58 59 6 6 8 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR Offset from the control SE register Parameter Description R W Set Point SP Lower Limit Ke input is thermocouple resistance thermometer 7 60 EE AER nput range lower limit to set point SP upper limit Mini When input is voltage current inimum Value as l l Input range lower limit to linear conversion maximum When input range unit is Celsius 100 0 to 100 0 C When input range unit is Fahrenheit 8 62 139 PV Correction 100 0 to 100 0 F When input is voltage current 1000 to 1000 65 Alarm 1 Type No alarm action Upper limit alarm Lower limit alarm Upper Lower limits alarm Upper Lower limit range alarm RW Process high alarm Process low alarm Upper limit alarm with standby Lower limit alarm with standby Upper Lower limits alarm with standby 11 66 Alarm 2 Type Alan 5 Valle See page 6 10 for the detail about alarm value range OO JO Om P GO A CH 37 Alarm 1 Value 38 Alarm 2 Value 67 Alarm 3 Type 68 Alarm 4 Type 10 _ 69 Alarm 5 Type 70 Alarm 6 Type 71 Alarm 7 Type 72 Alarm 8 Type When the unit is Celsius 0 1 to 100 0 C 12 When the unit is Fahrenheit RAN 0 1 to 100 0 F When input is voltage current 1 to 1000 84 161 e EE SH 88 165 Alarm 8
66. 8 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Data Register Allocation Blocks 4 5 Initial Setting Parameters SHOT Action Block 4 CHO and block 5 CH1 parameters are shown in the table below Before changing the parameters of block 4 or 5 it is recommended that the control of the PID module be disabled Offset from the Control an Register Parameter Description 53 Control Action Heating Cooling Control 0 Disable 0 Disabled 1 External SP input 4 to 20mA DC 55 132 External SP Input 2 External SP input 0 to 20mA DC CHO only 3 External SP input 1 to 5V DC 4 External SP input 0 to 1V DC 5 Cascade control 56 133 Input Function 57 Output Function CHO 134 Output Function CH1 135 58 Input Type Set Point SP Upper Limit Linear Conversion Maximum Value 59 136 Set Point SP Lower Limit Linear Conversion Minimum Value 60 137 61 138 Output ON OFF Hysteresis 62 139 PV Correction 63 PV Filter Time Constant Reserved Alarm 1 Type Alarm 2 Type Alarm 3 Type Alarm 4 Type Alarm 5 Type Alarm 6 Type Alarm 7 Type 72 149 Alarm 8 Type 0 Reverse control action Heating RIW 1 Direct control action Cooling 0 Input CHO CH1 1 Difference input CHO CH1 2 Difference input CH1 CHO 3 Addition input CHO CH1 0
67. 88 723 4773 Web www clrwtr com Email info clrwtr com
68. 888 723 4773 Web www clrwtr com Email info clrwtr com PID MODULE MAIN FUNCTIONS 1st Scan after the completion of CH1 auto tuning AT C At the falling edge of D1018 1 CH1 auto tuning monitor bit eee JH QO is turned on 3rd Scan At the rising edge of M1 the following are executed in order D1022 0 is turned on CHO control is enabled D1022 1 is turned on AT for CHO control is performed D1025 0 is turned on CH1 control is enabled M1006 Block 5 writing is turned off 2nd Scan after the completion of CHO auto tuning AT At the falling edge of M1 the following are executed in order D1025 0 is turned on CH1 control is enabled eS D1025 1 is turned on AT for CH1 control is performed CR M1006 Block 5 writing is turned off 1st Scan after the completion of CHO auto tuning AT At the falling edge of D1009 1 CHO auto tuning monitor bit SOTD C 1003 01 bio2s ag the following are executed in order D1025 0 is turned off CH1 control is disabled racy SIR ESCH T DO and D1 are moved to D1178 and D1179 respectively E Gopn0n Dii78 2 The original values are moved to the external SP input linear conversion max and min values M1006 Block 5 writing is turned on Le Values in D1178 and D1179 are written to the PID module CR M1 is turned off MOO 2nd Scan SOTD LE At the falling edge of MO the following are executed in order ERR M1000 M1000 reading all parameters is turned off
69. ALS The following manuals related to the FC5A series MicroSmart are available Refer to them in conjunction with this manual FC9Y B1283 FC9Y B1268 FC9Y B1273 FC9Y B1278 Manual Name FC5A Series PID Module User s Manual this manual FC5A Series MicroSmart Pentra User s Manual Basic Volume FC5A Series MicroSmart Pentra User s Manual Advanced Volume FC5A Series MicroSmart Pentra User s Manual Web Server CPU Module Volume FC5A MicroSmart PID Module User s Manual FC9Y B1283 Description Describes PID Module specifications and functions Describes module specifications installation instructions wiring instructions basic operation special function device addresses instruction list basic instructions analog modules user communication data link communication Modbus ASCII RTU communication and troubleshooting Describes instruction list move instructions data comparison instructions binary arithmetic instructions boolean computation instructions shift rotate instructions data conversion instructions week programmer instructions interface instructions program branching instructions refresh instructions interrupt control instructions coordinate conversion instructions average instructions pulse output instructions PID instructions dual teaching timer instructions intelligent module access instructions trigonometric function instructions logarithm power instructions file data
70. AT 20 C Parameter Configuration Procedure 1 Expansion Modules Configuration Select Configuration gt Expansion Modules from the WindLDR menu bar to open the Expansion Modules Configuration dialog box PID control action P D and ARW are automatically calculated using auto tuning In the Expansion Modules Configuration dialog configure the quantity of modules slot number module type number control register data register and control relay internal relay Click on Configure Parameters button to open the PID Module Configuration dialog box Expansion Modules Configuration Dialog Box Expansion Modules Configuration 1 Expansion Modules ew Quantity of modules e CPU module Slot 1 2 FCSA F2M2 FCSA C24R2X D1000 to D1189 M1000 to M1007 Slot 2 Slot 3 Slot 4 Other modules Other modules Other modules 3 Module Settings 4 Module Type No FCSA F2M2 Data Register D1000 5 Internal Relay mio000 D1000 to D1189 M1000 to M1007 nigue Parameters wm 21x OK Cancel em Setting O Quantity of Modules Slot No Slot 1 Data Register D1000 Internal Relay M1000 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPLICATION EXAMPLES 2 I O Function Selection Select I O function for each channel
71. Alarm Action 7 No Alarm Action No Alarm Action No Alarm Action No Alarm Action No Alarm Action No Alarm Action 4 4 4 4 4 4 4 4 oo OO OO OO GO GO CO Oo Oo DE EA GE EC GE E No Alarm Action Write all parameters Read all parameters Monitor OK Cancel Control Registers Offset from the control Parameter Description register 0 Disabled Note 1 4 to 20mA DC 2 0 to 20mA DC 1 55 Input Range 3 1 to 5V DC External SP input 4 0to1V DC 5 Cascade control Note Note Disabled and Cascade control cannot be selected in the input range PV Correction 1000 to 1000 PV Filter Time Constant 0 0 to 10 0 sec EE External SP Input linear conversion min to input range 4 178 Conversion Maximum ae p p 9 R W Valie upper limit of CHO External SP Input Linear SL l 5 179 Conversion Minimin Input range lower limit of CHO to external SP input linear R W vage conversion max 177 External SP Input Bias 20 of the external SP input linear conversion span 142 Alarm 1 Type 143 Alarm 2 Type 144 Alarm 3 Type 145 Alarm 4 Type 7 146 Alarm 5 Type 147 Alarm 6 Type 148 Alarm 7 Type 149 Alarm 8 Type OONDORWN CH No alarm action No alarm action No alarm action No alarm action No alarm action R W Process high alarm Process low alarm No alarm action No alarm action No alarm action IW 114 Alarm 1 Value 115 Alarm 2 Value 116 Alarm 3 Value Alarm
72. By setting the AT bias the temperature to start giving fluctuation can be configured The relation between the set point SP AT bias auto tuning AT starting point and fluctuation starting point are shown below Process variable PV lt Set point SP AT bias value When AT bias is set to 20 C the PID module starts giving the temperature fluctuation to the process at the temperature 20 C lower from the set point SP Temperature 1 Fluctuation period PID parameters are Se ee measured SP 20 C 2 PID parameters are calculated and auto tuning AT is finished 3 Temperature is controlled with the PID parameters configured with auto tuning AT 4 AT bias value 20 C A AT Auto tuning AT perform bit is turned on 1 2 3 VII Set point SP AT bias value lt Process variable PV lt Set point SP AT bias value The PID module starts giving the temperature fluctuation to the process when the process variable PV reaches the set point SP Temperature 1 Fluctuation period PID parameters are SP 20 C measured 2 PID parameters are calculated and auto SP ope NON tuning AT is finished SP 20 C 3 Temperature is controlled with the PID parameters configured with auto tuning AT 4 AT bias value 20 C A AT Auto tuning AT perform bit is turned on FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info
73. CH1 input value Input Parameters Control Parameters Output Parameters CHO zech Input CHD _ CHO ch Output CHO Deen CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters ge FI Control Parameters FI Output Parameters CH1 Difference CHO CH1 CHD gt output CHI D cH Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Difference CH1 CHO The difference between input CH1 and input CHO is used as the process variable PV for CH1 control Process variable PV of CH1 control Input CH1 input value Input CHO input value Input Parameters Control Parameters Output Parameters CHO SSE oe Input CHO i ee CHO Output CHO EEN CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Control Parameters Output Parameters CH1 _ Difference CH1 CHO Lei mc CH1 Output CH1 D _ gt CH1 Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Addition CH0 CH1 The addition of input CHO and input CH1 is used as the process variable PV for CH1 control Process variable PV of CH1 control
74. CHO Control CH0 Output CH0 Input CH1 Control CH1 Monitor Control Mode Fixed Yalue Control Mode D Control Action Reverse Control Action Heating D Loop Break Alarm LA Time 0 to 200 min Set Point SP 0 H 200 to 1370 C Loop Break Alarm LA Span 0 0 to 150 C Proportional Term Proportional Band Proportional Band 10 0 to 10000 C Integral Time 200 4 0 to 10000 sec 4 Cascade Control Settings External SP Input Min amp Max Values Derivative Time 50 gt 0 to 10000 sec 2 Linear Conversion Maximum Value 1370 200 to 1370 C ARW Anti Reset Windup 50 Oto 100 iner Conversion Minimum Value 200 200 to 1370 C AT Bias 20 0 to 50 C Program Control Mode Settings Reset 0 0 100 0 to 100 0 c Program Control Mode Start Type PY Start Set Point SP Rise Rate 0 ES 0 to 10000 C min SP when Program Control Starts 0 ks Set Point SP Fall Rate 0 ES 0 to 10000 C min Step Time Unit Minute X Output MV Rate of Change 0 5 0 to 100 sec Program End Action Terminate Program Control E Output ON OFF Hysteresis 1 0 0 1 to 100 0 C Number of Repeats D roum Manual Mode Output MV 0 0 0 0 to 100 0 Write all parameters Read all parameters Monitor OK Cancel 1 Control Register 178 External SP Input Linear Conversion Maximum Value Configure the external SP input linear conversion maximum value for the cascade contro
75. CHO De CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input CH1 F aaa lt i ta Output Parameters gt output CH1 Leg CHI CH1 Input Parameters Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Output CH1 The output of the CHO control is outputted from output CH1 When Output CH1 is selected CH1 parameters are used for the control period and the output manipulated variable MV upper and lower limits CHO parameters are used for all other parameters such as the output manipulated variable rate of change output on off hysteresis and manual mode output manipulated variable Input Parameters Control Parameters CHO e Input CHO Eilen CHO Output CH1 S Type K thermocouple Celsius Reverse Control Action Heating Input Parameters Output Parameters Vo CH1 Input CH1 CH1 Type J thermocouple Celsius Voltage Output E When Output CH1 is selected output CHO is unused When output type is relay the output CHO is turned off When output type is voltage current output CHO is OV 4mA Both Outputs CH0 CH1 The output of the CHO control is outputted from both outputs CHO and CH1 The control period and output manipulated variable MV upper and lower limits of CHO a
76. Configuration Output Parameters List CHO and CH1 The output parameters for CHO and CH1 are described here PID Module Configuration Slot 1 FCSA F2M2 mwem A Output Parameters when Heating Cooling Control is Enabled 5 CS 6 7 Control Registers 0 Non contact voltage output for SSR drive 1 PLEO AUR DUE Type 1 Current output When output type is voltage Output Manipulated Output manipulated variable lower limit to 100 Variable Upper Limit When output type is current Output manipulated variable lower limit to 105 When output type is voltage Output Manipulated 0 to output manipulated variable upper limit Variable Lower Limit When output type is current 5 to output manipulated variable upper limit 5 49 Cooling Control Period 1 to 120 sec FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 17 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR Offset from the control register When output type is voltage 51 Ge Cooling output manipulated variable lower limit to 100 U A Limit When output type is current PP Cooling output manipulated variable lower limit to 105 When output type is voltage TOL Parameter Description Cooling Output Manipulated Variable Lower Limit 0 to cooling output manipulated variable upper limit When output type is current 5 to cooling output manipu
77. Control register and relay should be configured for each PID module Duplicated device cannot be configured LL TM RUT C D Constant Control Register X Control Relay a S Ss Te EE NC Control Register The PID module occupies a maximum of 590 data registers minimum 190 data registers per PID module The occupied number of data registers varies between the fixed value control mode and program control mode When both CHO and CH1 are in fixed value control mode 190 data registers are occupied including the first data register designated When either CHO or CH1 is in program control mode 590 data registers are occupied including the first data register designated Precautions when Connecting Four PID Modules to All in One Type CPU Module 2000 data registers DO to D1999 are allocated to the all in one type CPU module When four PID modules are connected to the all in one type CPU module a maximum of six program controls can be conducted with three PID modules among the four PID modules The configurations shown in the examples 1 and 2 are not possible because the total number of occupied data registers exceeds 2000 Example 1 Program control mode is selected in all four PID modules Control Mode Occupied Module Type Type No Data Register mem Ge SH Word FC5A F2MR2 FC5A F2M2 Program control mode Program control mode PID Module Total Example 2 Program control mode is selected i
78. D 1 Refer to Input Status Checking on page 8 5 8 4 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com TROUBLESHOOTING Input Status Checking Sensor may be burnt out if any of the following problems occur 1 Operating status over range flag remains ON 2 Operating status under range flag remains ON 3 Input value constantly shows OmA or OV Please make sure these conditions are checked thoroughly and take the appropriate action 1 Operating status over range flag remains ON Checking Items Is thermocouple or resistance Replace sensor thermometer burnt out Is voltage How to check sensor burn out or voltage disconnection input 0 to 1V DC disconnected Thermocouple Short the input terminals of the PID module If a value around room temperature is indicated the PID module is operating normally and the sensor may be burnt out Resistance thermometer Connect approx 1000 resistor between the input terminals A and B and short the input terminals B and B of the PID module If a value around 0 C 32 F is indicated the PID module is operating normally and the sensor may be burnt out Voltage 0 to 1V DC Short the input terminals of the PID module If a linear conversion minimum value is indicated the PID module is operating normally and the signal wire may be disconnected 2 Operating status under range
79. EE EE EE CEET ee2esee Set Point SP C 30 10 200 50 50 Output MV Rate ofChange 0 Alarm iValue 0 Aam 2Value 0 Alarm 3Vale 0 Alarm 4value 0 Alarm 5Value 0 ae 6Value 0o Alarm 7Value 0 Alarm 8Value 0 100 S 0 WE 100 1 0 ech CO CO CO CO CO CO Output MV Lower Limit Cooling Proportional Band Overlap DeadBand 00 00 00 O e e ele e ee be e e ka ee ka mm em ka e e ele e e e beem ke eem e ba em em em e em em e ka em em le em em ale em em ele em em len e em alem eem sl em e ad mem em d mem e d eme eme When the program pattern is configured as shown in the above table the following control is performed at each step Step 0 The set point SP is gradually risen to 100 C in 60 minutes When the step 0 ends the wait function works so that the program control does not proceed to the step 1 until the process variable PV reaches 90 C Step 1 The fixed value control is performed at 100 C of the set point SP for 60 minutes Step 2 The set point SP is gradually risen to 800 C in 5 hours When the step ends the wait function works so that the program control does not proceed to the step 3 until the process variable PV reaches 790 C Step 3 The fixed value control is performed at 800 C of the set point SP for 30 minutes FC5A MicroSmart PID Module User s Manual FC9Y B1283 4 13 Phone 800 894 0412 F
80. Email info clrwtr com APPENDIX 9 2 Loop Break Alarm Set Point SP Ramp Function Auto Manual Mode Switching Cascade Control Heating Cooling Control Output CHO only External SP Input A trouble of the actuator such as heater break or heater adhesion can be detected as the loop break alarm For details about the loop break alarm see page 6 39 Loop break alarm O to 200 minutes time Loop break alarm When input is thermocouple or resistance thermometer span O to 150 C F or 0 0 to 150 0 C F When input is voltage current O to 1500 Output Bit 2 of the operating status When the set point SP is changed the set point SP is gradually increased from the original set point SP to the new set point SP according to the configured rate of change C minute F minute When the control is started the set point SP is increased from the current process variable PV to the configured set point SP according to the configured rate of change C minute F minute Auto or manual mode can be switched When the control mode is switched from auto to manual mode and vice versa the balanceless bumpless function works to prevent a sudden change in output manipulated variable MV When the power is turned on the operation parameters in Block 1 are retained so the control action starts with the previous mode at the time of power off The cascade control is an advanced control that uses 2 inputs CH1 a
81. F2M2 FCS5A C24R2X Other modules Other modules Other modules D1000 to D1189 M0000 to M0007 FC5A F2M2 3 Module Settings 4 Module No Gs D1000 D1000 to D1189 m1000 M1000 to M1007 Configure Parameters Copy Parameters To Settings Quantity of Modules connected to the slim type CPU modules Slot Select a slot number to configure the PID module Number Select the type number of the PID module to configure Module Settings Module Type No Module Typ item TI Deserip ion O O o o SS O No PS Configure the quantity of modules to be expanded The quantity of PID modules can be 1 Data connected varies with the CPU module type A maximum of four PID modules can be Internal connected to the all in one type CPU modules A maximum of seven PID modules can be Buttons Ober modules Data Register ECRA EZMDZ BEES ICL 134 RR MM SHINO TECHNOS ICL 134 G4 MM SHINKO TECHNOS ICL 134 RR MM WW SHINKO TECHNOS ICL 134 44 MM W SHINKO TECHNOS Designate the control register for the PID module Data register can be designated A maximum of 590 data registers minimum 190 data registers are occupied including the first data register designated Designate the control relay for the PID module Internal relay can be designated A maximum of 32 internal relays minimum 8 internal relays are occupied including the first internal relay designated
82. FC9Y B1283 FC5A series MicroSmMmMart _ pen tra PID Module User s Manual Automation Organizer WindLDR IDEC CORPORATION Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clirwtr com SAFETY PRECAUTIONS e Read this user s manual to make sure of correct operation before starting installation wiring operation maintenance and inspection of the FC5A series MicroSmart PID modules e All MicroSmart modules are manufactured under IDEC s rigorous quality control system but users must add a backup or failsafe provision to the control system using the MicroSmart in applications where heavy damage or personal injury may be caused in case the MicroSmart should fail eIn this user s manual safety precautions are categorized in order of importance from Warning to Caution n Warning notices are used to emphasize that improper operation ma N Warning 9 p PODET Bp cause severe personal injury or death e Turn off the power to the MicroSmart before starting installation removal wiring maintenance and inspection of the MicroSmart Failure to turn power off may cause electrical shocks or fire hazard e Special expertise is required to install wire program and operate the MicroSmart People without such expertise must not use the MicroSmart e Emergency stop and interlocking circuits must be configured outside the MicroSmart If such a circuit is configured inside the MicroSmart
83. Input CHO N Control CH0 Output CHO Input CH1 Control CH1 Output CH1 Monitor Input Range Type K thermocouple Celsius sl 200 to 1370 C PV Correction 0 0 100 0 to 100 0 c PV Filter Time Constant 0 0 0 0 to 10 0 sec Set Point SP Upper Limit 1370 200 to 1370 C Set Point SP Lower Limit 200 200 to 1370 C Alarm Type Alarm value Hysteresis 0 1 to 100 0 C Delay Time 0 to 10000 sec No Alarm Action No Alarm Action No Alarm Action No Alarm Action No Alarm Action No Alarm Action No Alarm Action Write all parameters Read all parameters Monitor Cancel All parameters for the PID module can be configured in this dialog box Configure the desired parameters and click on OK button to close the dialog FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 1 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 6 2 3 Download Dialog Box From the WindLDR menu bar select Online gt Download The Download dialog box will be opened Transfer Mode Binary ASCII Download Options Automatic start after download Keep output during download Suspend 1 0 force before download Automatic device clear after download L i Write PID module parameters after download Write device datafile to the PLC after download Setting Download comment data Setting Download system
84. Input CHO input value Input CH1 input value Input Parameters Control Parameters Output Parameters CHO Input CHO wel Sch CHO Output CHO CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters ee Control Parameters Output Parameters CH1 Addition CH0 CH1 x i CH1 gt Output CH1 wel ec CH1 Type K thermocouple Celsius Reverse Control Action Heating Voltage Output External SP Input Input CH1 is used as the set point SP for CHO control Input Parameters Control Parameters CHO CHO Output Parameters CHO e Input CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters H CH1 ch External SP Input Type K thermocouple Celsius gt Output CHO BE When the external SP input bias is configured the external SP input bias is added to the input CH1 value and then the input CH1 value is used as the set point SP for CHO control One of the analog input types shown in the table blow can be selected for the external SP input Crete VOLE Input Type 4 to 20mA DC or 0 to 20mA DC 1 to 5V DC or 0 to 1V DC
85. MV When the direct control action is selected the manipulated variable is calculated with the ratio of the reset to the proportional band and the calculated manipulated variable is subtracted from the output manipulated variable MV FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 37 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 12 Control Register 33 Set Point SP Rise Rate 13 Control Register 34 Set Point SP Fall Rate When the set point SP is widely changed this function makes the set point SP change gradually The rising falling span of the set point SP in 1 minute can be configured When the set point SP is changed the set point SP is gradually changed from the original set point SP to the new set point SP with the configured ratio C minute F minute When the control is started the set point SP is gradually changed from the process variable PV to the set point SP with the configured ratio C minute F minute In the fixed value control mode this function is used to configure the desired temperature gradient until the process variable PV reaches the set point SP This function is disabled when the set point SP rise fall rate is O 14 Control Register 32 Output Manipulated Variable Rate of Change The maximum change of the output manipulated variable in one second can be configured This function is
86. Module User s Manual FC9Y B1283 4 9 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com PID MODULE MAIN FUNCTIONS Program Control Operation Bits and Status Monitoring By turning on off the operation parameter bit program control progression can be operated By monitoring program run status the current status of program control can be monitored For the allocation of operation parameter program run status operating status see pages 5 7 to 5 10 Program Control Start Start the program control Turn on the program control bit Bit3 of the operation parameter Program control starts Program Control Stop Terminate the program control Turn off the program control bit Bit3 of the operation parameter Program control stops and enters standby status Program Hold Suspend the program control Turn on the program hold bit Bit4 of the operation parameter Program control is held Suspended While the program control is held time progression is suspended and fixed value control is performed with the set point SP at the time that the program control is held While program is held the Program Control RUN HOLD LED R HO or R H1 of the PID module flashes To resume the program control turn off the program hold bit Bit4 Advance Next Function Proceed to the next step Turn off to on the advance next step Bit6 of the operation parameter The current step is terminated and the program control is
87. N OFF Control Action A 8 3 Hunting phenomenon is occurring while in PID PI PD or P Control ACTION cece ceecceeeeeeeeeeeeeeeaeeeaees 8 3 The PID Module input does not operate normally ccccccesecesecceeceeeecseceeceeeceueecueesueeceeesaueeaueeseeesaeeseeees 8 4 Loop break alarm turns on even though the actuator operates normal 8 6 Program control is terminated earlier than the configured me 8 6 CHAPTER 9 APPENDIX E 9 1 PID Module Function References cccccccceeccceeeceeneeeaeeeeceeeeseeeeceeeeseeeecaeeesaeeeseeeesaueesaueeseeeseeeeseueesseeesseeees 9 1 OUTA Occ E E E eeerm eee en te eeet eats 9 5 Factory Default Settings Of the PID Module ivcsicscneisscensatwedahacds Zeg Eege See ebe enee 9 9 viii FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com GENERAL INFORMATION 1 GENERAL INFORMATION This chapter describes general information and specifications of the FC5A series PID modules Make effective use of the PID modules after reading and understanding thoroughly functions and characteristics About the PID Modules The PID module performs control actions to eliminate the deviation between the set point SP and process variable PV The PID module which is an expansion module is required to connect to the FCSA series CPU for use Depending on the difference of output specifications the PID modules are c
88. O Call IDEC for assistance Click Online gt Start button to run the CPU module Turn on Control Enable bit A value outside the range is set for the parameter in a channel Make sure of the setting range of the parameter and set it to a suitable value Is the output manipulated variable lower limit value higher than 100 NO Set it to a suitable value Select a correct output signal type Allocate a data register which is not used for other functions YES Set it to a suitable value FC5A MicroSmart PID Module User s Manual FC9Y B1283 END Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Hunting phenomenon is occurring while in ON OFF control action Is the output ON OFF hysteresis 1 too narrow Call IDEC for assistance TROUBLESHOOTING Hunting phenomenon is occurring while in ON OFF control action Set the output ON OFF hysteresis to a suitable value END 4 For detail about the output ON OFF hysteresis see page 6 38 Hunting phenomenon is occurring while in PID PI PD or P control action Is the control period setting 1 too short Call IDEC for assistance Hunting phenomenon is occurring while in PID PI PD or P control action Set the control p
89. Output Output 0 Temperature Set Point A 3 SP Dead Band Dead Band Action FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 23 Control Register 91 Program Control Mode Start Type Select the program control mode start type from the following PV Start When the program control is started the time is advanced until the set point SP becomes equal to the process variable PV and then the program control starts When Continue program control Repeat is selected as the program end action the time is PVR Start advanced until the set point SP becomes equal to the process variable PV at which program control is terminated and then the next program control starts SP Start When the program control is started the program control starts from the set point SP that is configured as Set Point SP when Program Control Starts Examples for the PV start PVR start and SP start actions are described using the following program pattern ence ECO De eee ee EC et Foin 150 C 100 C 50 C Time Step Number Set Point SP 150 C 100 C 50 C 25 C 15 min Time min min When the program control is started the time will be advanced shown in dotted line until the set point SP becomes equal to 25 C of the process variable PV P Control R SE EH and the
90. PID Module Configuration Dialog Box Input CHO Parameters PID Module Configuration Slot 1 2 x Module Type No FCSA F2M2 e Input Parameters Control Parameters Output Parameters CHO gt input CHO Dien CHO gt Output CHO CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Control Parameters Output Parameters CH1 Input CH1 wel Sc CH1 Output CH1 CH1 Type K thermocouple Celsius Reverse Control Action Heating Voltage Output 1 Input CHO N Control CHO Output CHO Input CHL Control CH1 Output CHL Monitor Input Range Type K thermocouple weil Celsius 200 to 1370 C PV Correction 0 0 100 0 to 100 0 c PV Filter Time Constant 0 0 0 0 to 10 0 sec 2 Set Point SP Upper Limit 1370 Eil 200 to 1370 c Set Point SP Lower Limit 200 200 to 1370 C Alarm Type Alarm Yalue Hysteresis 0 1 to 100 0 C Delay Time 0 to 10000 sec pper Limit Alarm 4 No Alarm Action To Alarm Action OT D 5 No Alarm Action No Alarm Action No Alarm Action No Alarm Action Write all parameters Read all parameters Monitor
91. PID module parameters using the control relay All parameters of block 1 to 5 10 to 19 and 30 to 39 can be changed using a ladder program The following examples demonstrate how the parameters of the PID module can be changed See pages 5 7 to 5 24 for detail about each block parameter Example 1 Changing Block 1 Parameter The set point SP of CHO control D1020 is changed to 250 5 C In this example D1000 is allocated to the control register and M500 is allocated to control relay When the new set point 2505 is stored in D1020 it is automatically written to the PID module be Ladder Program Example When external input I0 is turned on the set point SP of CHO will be changed to 250 5 C SOT radd 4 When the input range has a decimal point store the value multiplied by 10 in the data register 2 When the control register is D1000 Block 1 parameters are stored in D1020 to D1025 These values are written to the PID module every scan When IO is turned on the new set point 2505 is stored in D1020 set point SP of CHO MOWI S1 2505 D1 REP Dio2z0 Example 2 Changing Block 2 Parameters The integral time D1027 is changed to 150 seconds and the derivative time D1028 is changed to 45 seconds for CHO control In this example D1000 is allocated to the control register and M500 is allocated to control relay Those parameters can be changed with the following procedure 1 Turn on M500 Reading all para
92. PPLICATION EXAMPLES Application Example 3 This application example demonstrates the heating cooling control for a system using an electric furnace The set point SP of CHO control is 200 0 C e PID control is performed based on the process variable PV of CHO control The heating output and cooling output is turned on or off in accordance with heating output manipulated variable MV and cooling output manipulated variable MV e PID parameters proportional band proportional gain integral time derivative time and ARW are automatically calculated using auto tuning AT e If the process variable PV of CHO control becomes out of the range between 194 5 C and 205 5 C the upper lower limits alarm output QO is turned on and the control is disabled System Configuration and Wiring Wiring Example of the FC5A F2M2 Non contact voltage output for SSR drive current output type 3 phase Power Supply PM nay DC LBI BEES s 3 CRT Electric Furnace FC5A MicroSmart PID Module User s Manual FC9Y B1283 7 15 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPLICATION EXAMPLES PID Module Parameter Configuration The parameters of the PID module can be configured in the Expansion Modules Configuration and PID Module Configuration dialog boxes The procedure to configure the PID module is described below Parameter Configuration Example Quantity of Mo
93. Point SP 100 C 100 C eege 25 C Time Time 45 minutes Starts program control Set point SP when program control starts PV Starting Point When program control is started the control starts from the PV starting point 25 C of the process variable Program End Action Program end action can be selected from 3 types Terminate program control Continue program control Repeat and Hold program control When the all steps from O to 9 are executed and completed the program control is finished When Terminate program control is selected the PID module will enter standby status after the program control is finished While in standby status no control is performed and the control output is in OFF status If Continue program control Repeat is selected the program control is repeated from step 0 as many times as the repeat number configured When Hold program control is selected the program control is held suspended after the program control is finished and the fixed value control is performed with the set point SP of Step 9 For details about the program end action see page 6 43 FC5A MicroSmart PID Module User s Manual FC9Y B1283 4 11 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com PID MODULE MAIN FUNCTIONS Action after Power Is Restored When the power is restored every bit of the operation parameter excluding the program hold bit stored in the data regi
94. Program Control Repeat when Program Ends The following diagram shows an example of the program control when continue program control repeat is selected as the program end action Time of steps Step 0 and 1 60 minutes Step 2 30 minutes Steps 3 to 9 0 minute Number of repeats 1 In this example D1000 is allocated to the control register and M500 is allocated to control relay Current step number D1006 gt gt Number of repeats remaining D1007 l l E E i ly ON Control enable bit Mi D1022 0 pd ee OFF E i 7 l Program control bit SP EEE ra 4 D1022 3 i d l OFF l l l l d Program control bit ON l l Monitor i i LEO D1009 3 OFF Lao l oo l l l l l l l l l l Program hold bit SR D1022 4 ee 1 l l 1 oi Advance next step bit SS l E D1022 6 1 OFF 1 1 ol e ON l Advance previous step bit D1022 7 _ OFF l i l l Program end output SS lo D1010 6 l OFF WR The program control is proceeded to the start of step 2 while the program hold is maintained The program control is held at 1 minute of the remaining time The program hold works when the remaining time is not zero The program control is proceeded to the start of step 2 while the program hold is maintained The program hold is canceled and the program control is started from the start of step 2 FC5A MicroSmart PID Module Use
95. SP Wait value If the advance next function Bit6 is turned from off to on or if the program control bit Bit3 is turned off the wait function is canceled Program End Output Program Termination When the program control is finished the program end output bit Bit6 of the operating status is turned on If the program control bit Bit3 of the operation parameter is turned off the program end output bit Bit6 is turned off To start program control again turn off to on the program control bit Bit3 of the operation parameter 4 10 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com PID MODULE MAIN FUNCTIONS Action when Program Control Starts The program control mode start type can be selected from 3 types PV start PVR start and SP start When SP start is selected the program control starts from the set point SP configured with Set point SP when program control starts When PV start or PVR start is selected and the program control starts the step time is advanced until the set point SP matches to the process variable PV and then the program control starts For details about the program control mode start type see page 6 41 In the following example the set point SP is 100 C the step time is 60 minutes and the process variable PV when program control starts is 25 C SP Start PV PVR Start Set Point SP Set
96. T Auto reset bit is turned on While D1022 1 is on the PID module performs auto tuning AT for CHO control When the PID module completes auto tuning AT for CHO D1009 1 Auto tuning AT Auto reset monitor bit is turned off When D1009 1 is turned off Q3 is turned on e The temperature at which Auto tuning AT is performed is determined by the set point SP and AT bias In the above example auto tuning AT will be performed when the process variable PV reaches 180 C e The ladder program should be customized depending on actual applications 7 6 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPLICATION EXAMPLES 9 User Program Download From the WindLDR menu bar select Online gt Transfer gt Download to open Download dialog box Click the check box on the left of Write PID Module parameters after download and click OK button The user program will be downloaded to the CPU module After downloading the user program the PID module parameters will be written to the data registers in the CPU module and the PID module connected to the CPU module Transfer Mode Binary ASCII Download Options Automatic start after download CT Keep output during download Suspend I O force before download Automatic device clear after download L i Write PID module parameters after download S D
97. V 100 Heating Output Cooling Output 0 Temperature 3 A Set Point lt gt SP Overlap Band Overlap Band Action Output manipulated variable MV 100 Cooling Output Heating Output 0 Temperature Set Point A SP amp Dead Band Dead Band Action FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 51 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR Monitoring PID Module The PID Module status can be monitored on the monitoring screen Click on Monitor tab in the PID Module Configuration dialog box to open the monitoring screen Monitoring Screen To start monitoring the PID module click on Monitor button in the PID Module Configuration dialog box axl 2 1 CH1 Pv 0 sp 0 50 100 i 4 eg DEE f pime H M Program Time H M 5 Manuali HOLD araz A3 At Send Command As AG A7 Tag Send Command Menuai HOLD _ ee Lessee bee eet DEE EE EE DEE EE EE EE EE EE 0 50 100 150 200 250 300 350 400 450 500 550 600 Second 1 0 Monitor Settings 1 1 r Write all parameters Read all parameters Monitor OK Cancel 1 CHO CH1 SP Set Point The set point SP of CHO or CH1 is indicated During the monitoring set point SP of CHO or CH1 can be chan
98. Windup 50 ora 187 208 229 250 271 Output Manipulated Variable gu jsecond 0 lsecond 0 Rate of Change 0 C 0 S Reserved _ _ oper Limit Lower Limit Cooling Proportional Band 1 0 times 10 Overlap Dead Band 0 0 C 0 Step5 Step6 Step7 Step8 Step9 c0 GE Integral Time 200 sec 200 50 sec 50 ARW Anti Reset Windup 50 50 292 313 334 355 376 OUtput Manipulated Variable go second 0 Rate of Change Rien S 201 322 343 364 385 Reserved In i 302 323 344 365 386 OUtput Manipulated Variable 4 99 490 Upper Limit 303 324 345 366 387 Output Manipulated Variable 0 0 Lower Limit Cooling Proportional Band 1 0 times 10 Overlap Dead Band 0 0 C 0 FC5A MicroSmart PID Module User s Manual FC9Y B1283 9 11 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPENDIX Blocks 30 39 CH1 Program Parameters Offset from the Control Register Parameter Default Value Step0 Step1 Step2 Step3 Step4 Proportional Integral Time 200 sec 200 50 sec 50 ARW Anti Reset Windup 50 ra 307 416 435 454 473 Output Manipulated Variable 1 gop isecond 0 lsecond 0 Rate of Change 0 C 0 S Reserved Upper Limit 408 427 446 465 484 Output Manipulated Variable 0 CC Lower Limit E EE Ser Sept Step7 Steps ger Proportional Integral Time 2
99. Write device datafile to the PLC after download Setting D Download comment data Setting ownload systemprogram Detail Program Information Program Size 1142 bytes Comment Size 0 bytes Total 1142 bytes Communication Settings When program download is successfully completed the following message will appear Click OK button to close the message Program Download 2 x LL Program Download Succeeded 10 Starting Control 1 Confirm that 200 is stored in D1020 and 210 in D1023 of the CPU module 2 Turn on the external input I0 to enable CHO and CH1 controls 3 Turn on the load circuit power The PID module starts the control action to keep the temperature of the control target at the set point SP Turn on 11 to perform the auto tuning AT for CHO control whenever necessary see pages 4 6 to 4 8 FC5A MicroSmart PID Module User s Manual FC9Y B1283 1 7 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPLICATION EXAMPLES Application Example 2 This application example demonstrates the program control for a system using two electric furnaces for ceramic industries 7 8 e The PID module controls electric furnace 1 with CHO control and electric furnace 2 with CH1 control using program control e PID control is performed based on the temperature input to the PID module and the program pattern below The control output is turned on or off in accordance with
100. Y B1283 9 7 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPENDIX Output Action of Heating Cooling Control with Dead Band Heating Proportional Band Dead Band Cooling Proportional Band ON i 3 Control Heating Action Control Action i Control Action OFF 3 Cycle Action is Performed ccording to Deviation Cycle Action is Performed ccording to Deviation CHO Non contact 12V DC 12 0V DC Voltage EE Output Cycle Action is Performed ccording to Deviation CH1 Non contact O12VDC TI 12VDC Voltage Output Cycle Action is Performed ccording to Deviation CHO Lem SC eg Current 20mADC 20to4mADC Output a Changes Continuously According to Deviation oH les dame D Curent 4mA DC 4 to 20mA DC 7 20mA DC Sc m Output S Changes Continuously According to Deviation CH1 OUT Green cl lt Turns ON or OFF Represents heating control action e eg e e e Represents cooling control action 9 8 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPENDIX Factory Default Settings of the PID Module The factory default settings of the parameters of each block are described Values indicated in parentheses are stored in the data registers allocated to each block Block 1 Write Only Pa
101. age output or current output can be used as the control signal C Actuator Receives a control signal from the PID module and turns on the load power supply to the heater Electromagnetic switches SSR or power controllers can be used as the actuator Optimal Temperature Control The ideal temperature control as shown in Figure 1 is to control the temperature to correspond with the set point SP regardless of any disturbances There should be no overshoot or response delay of time until the temperature reaches the set point SP Temperature Temperature Set point SP B Set point SP Set point SP A Time Time Figure 1 Ideal Temperature Control Figure 2 Optimal Temperature Control FC5A MicroSmart PID Module User s Manual FC9Y B1283 4 1 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com PID MODULE MAIN FUNCTIONS In reality the ideal temperature control shown in Figure 1 on the previous page is almost impossible to achieve due to a number of complicated factors such as thermal capacity static characteristics dynamic characteristics and disturbances Figure 2 is regarded as an optimal temperature control result Depending on the usage and objective for some temperature control applications suppression of overshoot is required even if the temperature rises very slowly as shown in Figure 3 For some temperature control applications it is necessary to stabilize the temperature as quic
102. ameter Bit1 is turned off auto tuning AT is canceled and the Auto tuning AT Auto reset LED ATO AT1 will go off When auto tuning AT is cancelled P D and ARW values are reverted to the original values at the time that auto tuning AT was started Perform Auto reset To perform auto reset turn on Auto tuning AT Auto reset bit Bit1 of the operation parameter The reset value will automatically be configured and the offset is corrected During auto reset is performed the Auto tuning AT Auto reset LED ATO AT1 flashes Auto reset cannot be cancelled Auto tuning AT Auto reset Program Example The ladder program and the timing chart below describe an example of performing and canceling auto tuning AT auto reset of CHO In this example D1000 is allocated to the control register and M1000 is allocated to control relay Ladder Program When external input I0 is turned on CHO operation parameter Bit1 is set and 01022 01 Auto tuning AT Auto reset will be started When external input 11 is turned on CHO operation parameter Bit1 is reset and D1022 01 Auto tuning AT will be cancelled Timing Chart Control Enable Disable Bit ON D1022 0 TL ee OFF Auto tuning AT Auto reset N l Perform Cancel Bit fF tL TTT D1022 1 Ge Auto tuning AT Auto reset ON Perform Cancel Bit Monitor D1009 1 Bee l Auto tuning is started when Auto tuning Auto tuning AT AT Auto re
103. ameters in the PID Module Configuration dialog box click on Program CHO tab PID Module Configuration Dialog Box Program CHO Parameters PID Module Configuration Slot 1 21 xi Module Type No FCS4 F2M2 D 1 2 Range Step 0 Step 1 Step2 saa Step4 Step 5 Step 6 Step 7 Step 8 Step 9 Set Point SP 200 to 1370 C 100 800 800 800 800 800 3 Step Time 0 to 6000 min 60 30 Wait Yalue 0 to 100 C Proportional Band 0 to 10000 C Integral Time 0 to 10000 sec Derivative Time 0 to 10000 sec ARW Anti Reset Windup Oto 100 Output MV Rate of Change Oto 100 sec Alarm 1 Value 1570 to 1570 C Alarm 2 Value 4 Alarm 3 Value Alarm 4 Value Alarm 5 Value Alarm 6 value Alarm 7 Value Alarm 8 Value Output MY Upper Limit Output MY Lower Limit Cooling Proportional Band Overlap Dead Band Oto 100 Oto 100 0 0 to 10 0 times 200 0 to 200 0 C 0 CIEE So 5 Ee o o CH Write all parameters Read all parameters Monitor OK StepO Step1 Step2 Step3_ Set Point SP 100 C 100 C 800 C 800 C Step Time 300 minutes Wait Value Alarm 1 Value Notes e When the wait value is 0 C the wait function is disabled e When the alarm value is 0 C the alarm function is disabled e When a parameter for the program control except step time is changed in WindLDR the parameter is automatically copied to the following steps 6 CH
104. ange unit is Fahrenheit Wait Value 0 to 100 F Range with a decimal point 0 0 to 100 0 F When input is voltage or current input O to 1000 Proportional band When input range unit is Celsius O to 10000 C Range with a decimal point 0 0 to 1000 0 C When input range unit is Fahrenheit Proportional Term O to 10000 F Range with a decimal point 0 0 to 1000 0 F When input is voltage or current input 0 0 to 1000 0 Proportional gain 0 00 to 100 00 Integral Time O to 10000 sec O to 10000 sec ARW Anti Reset Windup 0 to 100 been See 5 18 for the valid range of alarm 1 to alarm 8 values Reserved LI When output type is relay or voltage Output Manipulated Variable Output manipulated variable lower limit to 100 Upper Limit When output type is current Output manipulated variable lower limit to 105 When output type is relay or voltage Output Manipulated Variable 0 to output manipulated variable upper limit Lower Limit When output type is current 5 to output manipulated variable upper limit Cooling Proportional Band 0 0 to 10 0 times CHO only Cooling proportional band is the multiplication of heating proportional band When input range unit is Celsius 200 0 to 200 0 C When input range unit is Fahrenheit A A cl Overlap Dead Band CHO only 200 0 to 200 0 F When input is voltage or current input 2000 to 2000 FC5A MicroSmart PID Module User s Manual FC9Y B1283 5
105. ate from the actual temperature of the control target When a target is controlled with multiple PID modules the measured temperatures may not match due to the differences in sensor accuracy or dispersion of load capacities even though the set points SP of those PID modules are the same In such cases the process variable PV of the PID module can be adjusted to the desired temperature by using the PV Correction The process variable PV after PV correction can be calculated using the following formula Process variable PV after PV correction Process variable PV PV correction value 3 Control Register 63 PV Filter Time Constant The PV filter function is a software filter to stabilize the process variable PV affected by fluctuating processes such as pressure or flow rate by calculating first order lag of the process variable PV Even if the process variable PV changes as shown in the Figure 1 when the PV filter time constant is configured the process variable PV changes as shown in the Figure 2 After the PV filtering process the process variable PV reaches 63 of the process variable PV in T seconds If the PV filter time constant is too large it adversely affects the control results due to the delay of response Example If the least significant digit of the process variable PV is fluctuating the fluctuation can be suppressed by using the PV filter time constant Process Process Variable Variable PV PV
106. ategorized into two types and can be used by connecting to a FC5A slim type CPU or 24 O all in one type CPU except 12V DC CPU The input channel can accept voltage current thermocouple or resistance thermometer signals The output channel generates relay output non contact voltage for SSR drive or current signals To configure the PID modules the Expansion Modules Configuration dialog box in WindLDR is used The following table shows the PID module type numbers PID Module Type Numbers Module Type UO Points UO Signal Type No Relay Output 2 inputs Thermocouple K J R S B E T N PL II C W Re5 26 FC5A F2MR2 Resistance thermometer Pt100 JPt100 Voltage 0 to 1V DC 0 to 5V DC 1 to 5V DC 0 to 10V DC Current 0 to 20mA DC 4 to 20mA DC 2 outputs Relay contact Non Contact Voltage 2 inputs Thermocouple K J R S B E T N PL II C W Re5 26 FOSA F2M2 for SSR drive Resistance thermometer Pt100 JPt100 Current Output Voltage 0 to 1V DC 0 to 5V DC 1 to 5V DC 0 to 10V DC Current 0 to 20mA DC 4 to 20mA DC 2 outputs Non contact voltage for SSR drive Current Quantity of Applicable PID modules The maximum number of PID modules that can be connected to the MicroSmart CPU differs depending on the CPU type The following table shows the maximum number of the PID modules All in One Type Slim Type FC5A D16RK1 FC5A C16R2 FC5A D16RS1 FC5A C16R2C FOSA E24R2 FC5A D32K3 FC5A C16R2D ee FC5A D32S
107. ature Ambient Humidity Environmental Specifications Recommended Cable MODULE SPECIFICATIONS Photocoupler isolated between input and internal circuit Photocoupler isolated between input and power circuit Photocoupler isolated between input and internal circuit Photocoupler isolated between output and internal circuit Output terminal External power 1500kV AC 5mA for 1 minute Output terminal Internal power 1500kV AC 5mA for 1 minute Input power Output power 1500kV AC 5mA for 1 minute FG External power 548V AC 5mA for 1 minute Input terminal External power 548V AC 5mA for 1 minute Input terminal Internal power 548V AC 5mA for 1 minute Output terminal External power 2500V AC 5mA for 1 minute Output terminal Internal power 2500V AC 5mA for 1 minute External power Internal power 548V AC 5mA for 1 minute Input terminal Output terminal 548V AC 5mA for 1 minute Approx 3 5W maximum 65mA OmA 0 to 55 C No icing 10 to 95 RH Non condensing Approx 140g Conforms to ROHS directive Twisted pair cable FG External power 548V AC 5mA for 1 minute I O terminal External power 548V AC 5mA for 1 minute I O terminal Internal power 548V AC 5mA for 1 minute External power Internal power 548V AC 5mA for 1 minute Input terminal Output terminal 548V AC 5mA for 1 minute FC5A F2M2 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773
108. ax 888 723 4773 Web www clrwtr com Email info clrwtr com PID MODULE MAIN FUNCTIONS Heating Cooling Control When it is difficult to control the target process with heating control only cooling control can be added to perform the heating cooling control Control results derived from the set point SP and process variable PV are outputted to 2 outputs heating output CHO and cooling output CH1 If the process variable PV is higher than the set point SP cooling output will be turned on If the process variable PV is lower than the set point SP heating output will be turned on The area in which both heating and cooling outputs are turned on can be configured as overlap The area in which neither heating output nor cooling output is output can be configured as dead band Example Heating Cooling control uses both heating and cooling outputs and is suitable for the heat producing processes such as extruders or for temperature control at near ambient temperature such as environment testers Heating PID Lg Control Module Target Cooling Difference Input Control Difference input control is the control to keep the input difference between input CHO and input CH1 at the same level When the difference input control is selected input CHO and input CH1 are independently measured and the difference between those inputs is used as process variable PV PID module controls output so that the difference between those inputs is ma
109. b www clrwtr com Email info clrwtr com ABOUT THIS MANUAL Thank you for purchasing FC5A series MicroSmart PID Module This user s manual primarily describes system configuration specifications installation programming application examples and trouble shooting of the PID module Read this user s manual to ensure the correct understanding of the entire functions of the PID module NOTICE 1 This publication is not to be nor any parts of it photocopied reprinted sold transferred or rented out without the specific written permission and consent of IDEC 2 The contents of this user s manual are subject to change without notice 3 Care has been taken to ensure that the contents of this user s manual are correct but if there are any doubts mistakes or questions please inquire our sales department MicroSmart Modules Modes SO MicroSmart FC5A series MicroSmart pentra FC5A Series MicroSmart FC5A C10R2 FC5A C10R2C FC5A C16R2 FC5A C16R2C FC5 Series FC5A C24R2 FC5A C24R2C CPU Modules Siim Type FC5A D16RK1 FC5A D16RS1 FC5A D32K3 FC5A D32S3 FC5A D12K1E FC5A D12S1E PID Modules SC HMI base module expansion RS232C communication module Communication Expansion Modules l ON expansion RS485 communication module l HMI module Memory cartridge Clock cartridge RS232C communication Optional Modules ae adapter RS485 communication adapter WindLDR Application software WindLDR All in One Type U B The PID mo
110. ble PV changes as shown in the Figure 1 when the PV filter time constant is configured the process variable PV changes as shown in the Figure 2 After the PV filtering process the process variable PV reaches 63 of the process variable PV in T seconds If the PV filter time constant is too large it adversely affects the control results due to the delay of response Example If the least significant digit of the process variable PV is fluctuating the fluctuation can be suppressed by using the PV filter time constant Process Process Variable Variable PV PV Time Second lt 7 Time Second Figure 1 Process variable PV Figure 2 Process variable PV before PV filtering process after PV filtering process 4 Control Register 59 Set Point SP Upper Limit Linear Conversion Maximum Value 5 Control Register 60 Set Point SP Lower Limit Linear Conversion Minimum Value Linear Conversion Function The diagram below shows an example of the linear conversion When the linear conversion maximum value is 5000 and the linear conversion minimum value is 0 the current input 4 to 20mA DC is linearly converted as shown in the diagram Input range 10000 5000 Linear conversion is conducted within this range 0 2000 4mA 20mA Current Set Point SP Upper Limit Linear Conversion Maximum Value When input type is thermocouple or resistance thermometer the linear conversion is disabled The linear conversion maxi
111. clrwtr com PID MODULE MAIN FUNCTIONS Process variable PV 2 Set point SP AT bias value When AT bias is set to 20 C the PID module starts giving the temperature fluctuation to the process at the temperature 20 C higher from the set point SP 1 Fluctuation period PID parameters are measured S 2 PID parameters are calculated and auto SP 20 C tuning AT is finished api eee E e 3 Temperature is controlled with the PID parameters configured with auto tuning AT 4 AT bias value 20 C Temperature A AT Auto tuning AT perform bit is turned on Auto reset During the P control or PD control action the deviation offset between the process variable PV and the set point SP is generated when the process variable PV is stabilized By performing auto reset the reset value can automatically be calculated to correct the offset It is required to perform auto reset when the process variable PV is stabilized within the proportional band When the auto reset is completed the CPU module automatically reads all parameters including the calculated reset value from the PID module and stores those parameters in the data registers It is unnecessary to perform the auto reset again as long as the process is unchanged When the proportional band P is set to O or 0 0 the reset value is cleared Temperature Auto reset is Performed G r E E Offset is Corrected Auto tuning AT Auto reset Per
112. clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR PID Module Configuration Input Parameters List CHO and CH1 The input parameters for CHO and CH1 controls are described here PID Module Configuration Slot 1 E 21x 1 Module Type No FCSA F2M2 3 Input Parameters Control Parameters Output Parameters 2 CHO 7 input CHO zb CHO gt Output cHo Leg CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output 4 Input Parameters Control Parameters Output Parameters CH1 F bet CH Ski CH1 gt output OH E cHt Type K thermocouple Celsius Reverse Control Action Heating Voltage Output 5 Input CHO Control CH0 Output CHO Input CH1 Control CH1 Output CHL Monitor 6 Input Range Type K thermocouple Celsius X 200 to 1370 C S PV Correction 0 0 100 0 to 100 0 c 7 i PV Filter Time Constant 0 0 0 0 to 10 0 sec Set Point SP Upper Limit 1370 200 to 1370 C 8 Lo Set Point SP Lower Limit 200 200 to 1370 c 9 Alarms Alarm Yalue Hysteresis 0 1 to 100 0 C Delay Time 0 to 10000 sec bestar Action 1 0 No Alarm Action No Alarm Action No Alarm Action No Alarm Action No Alarm Action No A
113. configured for each step Steps to which step time 0 is configured are also performed For example if the program control of 4 steps is required configure parameters of steps O to 3 and set the step time of the remaining steps 4 to 9 to zero When the program control is terminated the program end output bit is turned on and maintained and the PID module will be in standby status The program control can be executed again by turning off to on the Terminate program program control bit operation parameter bit3 control During the program control standby waiting for program control run status the control output is turned off and the operating status is not updated except the over range the under range and the program end output When the program control is terminated the program control is repeated Continue program from step 0 as many times as the configured number of repeats When the control Repeat step 9 of the last program control cycle is performed and finished the program end output bit is turned on and maintained When the program control is terminated the program control is held at the last status of step 9 The program end output and program hold bit are turned on and maintained While the program control is held the fixed value control is performed with the set point SP of step 9 If advance next function operation parameter Bit6 is turned off to on is executed while the program control is held the program control is started a
114. connected equipment To prevent that harmful effect configure the alarm hysteresis for alarm on off action 9 Control Register 81 Alarm 1 Delay Time Control Register 82 Control Register 83 Control Register 84 Control Register 85 Control Register 86 Control Register 87 Control Register 88 Alarm 2 Delay Time Alarm 3 Delay Time Alarm 4 Delay Time Alarm 5 Delay Time Alarm 6 Delay Time Alarm 7 Delay Time Alarm 8 Delay Time The alarm is not triggered until the configured time elapses after the process variable PV enters the alarm output range The input fluctuation due to noise may result in alarm output turning on This can be prevented by configuring the alarm delay time When an alarm output is changed from on to off status the alarm output turns off and the alarm action delay time is reset When the alarm output is changed from off to on status the time counting starts FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 29 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR Input Parameters when External SP Input is Selected The input CH1 parameters when External SP input is selected as the Input CH1 Function are described here PID Module Configuration Slot 1 g 2 x Module Type No FCSA F2M2 Input Parameters Control Parameters CHO Input CHO D gd CHO Type K thermocouple Ce
115. control of CHO CH1 is enabled AT Turns green while auto tuning AT is performed for CHO CH1 Manual Turns green while CHO CH1 is in the manual control External CHO only Turns green while the external SP input is enabled Program Program control only Turns green while CHO CH1 is in program control mode HOLD Program control only Turns green while the program control of CHO CH71 is held WAIT Program control only Turns green while the program wait is functioning for CHO CH1 9 CHO CH1 Error Indicators PARAM Turns red while parameter range error is occurring LOOP Turns red while loop break alarm is turned on UP Turns red while the input is over range DOWN Turns red while the input is under range A1 to A8 Turns red while the corresponding alarm is turned on 10 Monitor Settings Click on Monitor Settings button to open the PID Module Monitor Settings dialog box 11 Monitor Click on Monitor button to start monitoring and tracing the PID module FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 53 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR PID Module Monitor Settings dialog box 1 gg Scaling Settings 2 Process Variable PV IT C Auto scaling Set Point SP EB Upper Limit C Output Manipulated Variable Mv _ Lower Limit 3 Trace Selection CH1 Trace Time Settings
116. conversion minimum value to linear conversion maximum value 6 20 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR PID Module Configuration I O Function Selections PID Module Configuration Slot 1 i ixi 1 Module Type No FC5A F2M2 x Input Parameters Control Parameters Output Parameters CHO Input CHO _ CHO output CHO r CHO 2 Type K thermocouple Celsius Reverse Control Action Heating Voltage Output 4 Input Parameters Control Parameters Output Parameters CHI Input CH CH1 output cH CHI Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input CHO Control CHO Output CHO Input CHL Control CH1 Output CHL Monitor Input Range Type K thermocouple Celsius sl 200 to 1370 C PV Correction 0 0 100 0 to 100 0 C PV Filter Time Constant 0 0 0 0 to 10 0 sec d Set Point SP Upper Limit 1370 200 to 1370 C VH Set Point SP Lower Limit 200 200 to 1370 C Alarm Type Alarm value Hysteresis 0 1 to 100 0 C Delay Time 0 to 10000 sec d Upper Limit Alarm Upper Limit Alarm Upper Limi
117. d it takes time to correct the offset An appropriate integral time for the control target can be automatically calculated using auto tuning AT function It is unnecessary to configure the integral time in the WindLDR when using the auto tuning AT function 6 Control Register 185 Derivative Time When the set point SP is changed or when the deviation between the set point SP and the process variable PV is increased due to a disturbance the derivative action increases the output manipulated variable MV to rapidly correct the deviation between the process variable PV and the set point SP The derivative time is a coefficient to determine the output manipulated variable MV of the derivative action The derivative action is disabled when the derivative time is 0 If the derivative time is shortened the derivative action becomes weak The response to the rapid temperature change becomes slower Because the action to suppress the rapid temperature rise becomes weaker the time for the process variable PV to reach the set point SP is shortened however overshoot can occur If the derivative time is extended the derivative action becomes strong The response to the rapid temperature change becomes faster Because the action to suppress the rapid temperature rise becomes strong the time for the process variable PV to reach the set point SP is extended however overshoot can be decreased An appropriate derivative time for the cont
118. disabled when the value is 0 In the case of heating control when there is a large deviation between the process variable PV and the set point SP the output immediately changes from off to on as shown in the diagram below Normal Output By configuring the output manipulated variable rate of change the maximum change of the output manipulated variable MV in one second can be changed as shown in the diagram below Output When Output Manipulated Variable Rate of Change is Configured This function can be used for a high temperature heater used at approximately 1500 to 1800 C which has to be heated gradually as the heater can be burnt out if the power is supplied rapidly Normal Output Output When Output Manipulated Variable Rate of Change is Configured 100 sec 20 sec 10 sec OFF 1 second 5 seconds 10 seconds 15 Control Register 61 Output ON OFF Hysteresis Output on off hysteresis can be configured When the control action turns from on to off and vice versa the span between on and off positions is called output on off hysteresis If the output on off hysteresis is narrowed the control output switches to on or off even by a slight variation of temperature at around the set point SP This frequent on off shortens the output relay life and may negatively affect the connected equipment To prevent that harmful effect the hysteresis is provided for on off control action Output on off hysteresis can be configured only for t
119. dules 1 unit Slot No Slot 1 Module Type No FCSA F2M2 Data Register D1000 Internal Relay M1000 UO Function Used as a heating cooling control PID module CHO CH1 0 0 to 400 0 C Uppert ouer limits alarm with standby S PID control action IR LD and ARW are Control Action automatically calculated using auto tuning ATM 20 0 C a Parameter Configuration Procedure 1 Expansion Modules Configuration Select Configuration gt Expansion Modules from the WindLDR menu bar to open the Expansion Modules Configuration dialog box In the Expansion Modules Configuration dialog configure the quantity of modules slot number module type No control register data register and control relay internal relay Click on Configure Parameters button to open the PID Module Configuration dialog box Expansion Modules Configuration Dialog Box Expansion Modules Configuration Ei xi Expansion Modules 1 Lie Quantity of modules 4 CPU module Slot 1 Slot 2 Slot 3 Slot 4 2 Le FCSA F2M2 FC5A C24R2X D1000 to D1189 Other modules Other modules Other modules M1000 to M1007 3 Module Settings Module Type No FC5A F2M2 4 Data Register D1000 D1000 to D1189 5 Internal Relay m1000 M1000 to M1007 Configure Parameters Copy Parameters To OK Cancel Quantity of Modules 1 5 7 16 FC5A MicroSmart PID Module User s Manual FC9Y B128
120. dules is used by connecting to the FC5A series CPU module Caution Use this product after thoroughly understanding the specifications of the FC5A series CPU module IMPORTANT INFORMATION Under no circumstances shall IDEC Corporation be held liable or responsible for indirect or consequential damages resulting from the use of or the application of IDEC PLC components individually or in combination with other equipment All persons using these components must be willing to accept responsibility for choosing the correct component to suit their application and for choosing an application appropriate for the component individually or in combination with other equipment All diagrams and examples in this user s manual are for illustrative purposes only In no way does including these diagrams and examples in this manual constitute a guarantee as to their suitability for any specific application To test and approve all programs prior to installation is the responsibility of the end user FC5A MicroSmart PID Module User s Manual FC9Y B1283 lil Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com REVISION HISTORY Revision history of this user s manual is described here Date Manual No Description March 2011 FC9Y B1283 0 First print FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com RELATED MANU
121. e Single Phase 200V Slave Secondary Control aHa o D 3 H No Channel O 9 Power Supply 24V DC CH1 Thermocouple Lem CRT i he GK NC WF INO CNC gt SE eee RI Power Controller Taraet 1 Sea arge TNG J m OUTO DE CRT IN d s B om OUT1 T Heater CHO Thermocouple PID Module FC5A F2M2 FC5A MicroSmart PID Module User s Manual FC9Y B1283 4 15 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com PID MODULE MAIN FUNCTIONS How to perform auto tuning AT in cascade control Auto tuning AT can be performed for the cascade control with the following procedure Auto tuning AT for the slave CHO 1 Turn off the CHO and CH1 control enable bits of the operation parameter to disable the CHO and CH1 controls 2 Copy the set point SP of the master CH1 to the set point SP of the slave CHO the external SP input linear conversion maximum value and the external SP input linear conversion minimum value in order to fix the set point SP of the slave CHO 3 Turn onthe CHO and CH1 control enable bits of the operation parameter to enable the CHO and CH1 controls Turn on the CHO auto tuning AT auto reset bit of the operation parameter to start the auto tuning AT for the slave CHO When auto tuning AT is completed P D and ARW values of the slave CHO will be automatically configured Aut
122. e When the PID module parameters are configured in the PID Module Configuration dialog box and the user program is downloaded to the CPU module the PID module parameters initial values will be saved in ROM of the CPU module Those initial values can be loaded to the data registers in the CPU module and the PID module can be operated with those initial values with the following procedure 1 Turn off to on the loading initial values relay control relay 1 2 Turn off to on the writing all parameters relay control relay 2 When the control of the PID module is enabled the PID module will start operating with the default values FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 5 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR Expansion Modules Configuration Dialog Box xi Expansion Modules Configuration 1 Modules Quantity of modules 2 se Slot 1 Slot 3 Slot 4 Slot 2 FCSA F2M2 FCSA C24R2X Other modules Other modules Other modules D1000 to D1189 M0000 to M0007 3 Module Type No FCSA F2M2 7 Diop Data Register D1000 to D1189 Internal Relay m1000 M1000 to M1007 Configure Parameters Copy Parameters To Cancel Expansion Modules Configuration Expansion Modules Quantity of modules 4 H CPU module Slot 1 Slot 2 Slot 3 Slot 4 FCSA
123. e Configuration Output Parameters List CHO and CH 6 17 PID Module Configuration Program Parameters List CHO and HI 6 19 PID Module Configuration I O Function Gelechons cece cceccceeeececeeeeeeceeeeesaeeeeeaeeeesseeeeeaeeeesseeeesaaaeeesees 6 21 PID Module Configuration Input Parameters Details cccccsecccceseecceeeeceeseeeceuseeseeeeseuseeseneeessueensseas 6 24 PID Module Configuration Control Parameters Details 6 34 PID Module Configuration Output Parameters Details 6 45 PID Module Configuration Program Parameters Details 0 ccccccccecceceeeeeeeeeeeseeeeeseeeeesaeeeesseeeeeaaeeeenaes 6 47 leie erg are PID Ba ie EE 6 52 FC5A MicroSmart PID Module User s Manual FC9Y B1283 vii Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CHAPTER 7 APPLICATION EXAMPLES eagegeeee dese e gege Eege EE Ee 7 1 Applicaton EXAMP ege 1 1 Applicaton ne 1 8 Application Example 3 ae ose oa tetse node dereee aancedan secon aanee vesedaradu de dando neudaseerendunesdeaosdesevendesteestesecsdersTiceewtooiet soesiacdemes 7 15 CHAPTER 8 TROUBLESHOOTING uaccssecoucncnscnnnncnnnncnncccncuccncuenscessecnsnecanecencoeeucosaecasnecnsnecanecanenens 8 1 The PID Module Power LED PWR is OFF or Flasbung 8 1 The PID Module output does not operate normally c cece cece eeccceeeceeeeeeeeeeeceeeeeeeeseeeseeeeeeesseeeseeeseeesaeeeaeees 8 2 Hunting phenomenon is occurring while in O
124. e linear characteristic Manipulated Cooling proportional band Variable MV 100 1 Air Cooling Oil Cooling Water Cooling 0 A Process Variable PV Set Point SP Output Characteristics of Cooling Method FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 39 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 6 40 20 Control Register 48 Cooling Proportional Band The cooling proportional band can be configured when the heating cooling control is enabled The cooling proportional band is the multiplication of the heating proportional band Example When the heating proportional band is 10 C and the cooling proportional band is 2 0 the cooling proportional band will be 20 C If cooling proportional band value is 0 5 the cooling proportional band will be 5 C If the cooling proportional band is 0 the cooling side control will be ON OFF control action If the heating proportional band is 0 both heating and cooling side controls will be ON OFF control action 21 Control Register 98 Cooling Output ON OFF Hysteresis Output on off hysteresis for cooling output can be configured When cooling control action turns from on to off and vice versa the span between on and off positions of the cooling output is called cooling output on off hysteresis If the cooling output on off hysteresis is narrowed the cooling control output s
125. e of Change Bie eee RAN When input range unit is Celsius 0 1 to 100 0 C Output ON OFF When input range unit is Fahrenheit Ae ES Ee Hysteresis 0 1 to 100 0 F K When input is voltage or current 1 to 1000 When heating cooling control is disabled Output manipulated variable lower limit to output Manual Mode Output manipulated variable upper limit A Kai Ref Manipulated Variable When heating cooling control is enabled RAN Cooling output manipulated variable upper limit to heating output manipulated variable upper limit 17 SE LA Tote 200 minutes When input range unit is Celsius O to 150 C Range with a decimal point 0 0 to 150 0 C Loop Break Alarm LA When input range unit is Fahrenheit 18 36 113 Span 0 to 150 F R W Range with a decimal point 0 0 to 150 0 F When input is voltage or current O to 1500 95 0 Air cooling 19 Cooling Method 1 Oil cooling R W 2 Water cooling l l 0 0 to 10 0 times ORTE Geer SEKR Cooling proportional band is the product of this value and the heating proportional band When input range unit is Celsius 0 1 to 100 0 C Cooling Output ON OFF When input range unit is Fahrenheit 21 oe Hysteresis 0 1 to 100 0 F RES When input is voltage or current 1 to 1000 When input range unit is Celsius 200 0 to 200 0 C When input range unit is Fahrenheit 22 50 Overlap Dead Band 200 0 to 200 0 F When input is voltage or current 2000 to 2000 0 PV start 23 91
126. e valid range PV Filter PV Correction is within the valid range PV Filter PV Correction is out of the valid range Program control set point SP is within the valid range Program control set point SP is out of the valid range Manual Mode Output Manipulated ell Variable Range Error Bit Proportional Band Integral Bit9 Time Derivative Time ARW Control Period Range Error Bit Bit10 Reset Setting Range Error Bit Cooling Proportional Band Cooling Bit11 Control Period Range Error Bit CHO only Bit12 Overlap Dead Band Range Error Bit CHO only Bit13 Alarm 1 to Alarm 8 Value Range Error Bit PV Filter PV Correction Range Error Bit Bit14 Program Control Set Point SP elie Range Error Bit Note The parameter range error bit is turned on when any parameter of the PID module is out of the valid range While the parameter range error is occurring the control output is turned off 5 8 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Operating Status 1 word Parameter Status Desertpteon OFF D JORF EE Bit4 Cooling Control Output D JORF CHO only D Normal operation Ge D Normal operation Input value is exceeding the upper limit of the control range See page 9 4 Thermocouple or resistance thermometer may be burnt out Voltage input 0 to 1V DC ma
127. eating Voltage Output Input Gem Input CH1 canal Baramati Output CH1 eset ene Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input CHO Control CH0 Output CHO Input CHL Control CH1 Output CH1 Monitor Output Type Voltage Output m Control Period 3 E 1 to 120 sec Output MV Upper Limit 100 0 to 100 Output MV Lower Limit 0 to 100 Cooling Control Period 3 1 to 120 sec Cooling Output MV Upper Limit 100 Oto 100 Cooling Output MV Lower Limit 0 Oto 100 Write all parameters Read all parameters Monitor 8 Ladder Programming Create a ladder program to control the PID module Ladder Program Example r000 gagad ga l 01022 00 01025 00 0i0i0 7 gogog 01019 07 ga l r000 TL 0D1i022 01 LIUOO SOT D1i009 01 Notes While external input I0 is on the control of the PID module is enabled When OU CHO control upper limit alarm output is on or when Q1 CH1 control upper limit alarm output is on the control of the PID module is disabled When the process variable PV of CHO control exceeds 205 C D1010 7 Alarm 1 output is turned on which turns QO on When the process variable PV of CH1 control exceeds 215 C D1019 7 Alarm 1 output is turned on which turns Q1 on When external input 11 is turned on D1022 1 Auto tuning A
128. ed The set point SP can be configured as shown in the following diagram Temperature Stepi 1 12131415 6 2 Control Register 53 Control Action Selects either direct control action or reverse control action In direct control action the output manipulated variable MV increases when the process variable PV is higher than the set point SP positive deviation For example freezers perform the direct control cooling action Output Manipulated Variable MV 100 0 f Process Variable PV Low lt A gt High Set Point SP In reverse control action the output manipulated variable MV increases when the process variable PV is lower than the set point SP negative deviation For example electric furnaces perform the reverse control heating action Output Manipulated Variable MV 100 S P Variable PV rocess Variable Low lt A gt High NG Set Point SP FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 35 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 3 Control Register 54 Heating Cooling Control The heating cooling control can be enabled When it is difficult to control a target process with heating control only cooling control can be added to perform the heating cooling control Example Heating Cooling control uses both heating and cooling outputs and is suitable for the heat producing
129. ed the control action becomes similar to the ON OFF control action e If the proportional band is broadened Proportional gain is made smaller Because the control output starts turning on off at the significantly low temperature from the set point SP overshoot or hunting is reduced however it takes time for the process variable PV to reach to the set point SP and the offset between the process variable PV and the set point SP becomes broadened The offset caused by the P control action can be corrected by configuring the reset value If the reset value is configured the proportional band range can be shifted as shown in the figure below The reset value can be automatically calculated by the auto reset function Output Manipulated GEES Band Variable um H 2 N Output Manipulated Variable ON A 100 50 N B 50 S N C 0 K 0 set Point SP _ A B Proportional band area that can be configured with reset function Offset can be corrected within proportional band from the set point SP PI Control Action Proportional Integral Action Integral action automatically corrects the offset caused by P control action and temperature control is performed at the set point SP However it takes time for the process variable PV to be stable if the process variable PV is changed rapidly due to disturbance PI control action is suitable for the processes in which the temperature slowl
130. ed value control mode the following 8 internal relays are allocated 2 RW 3 RW 4 When either CHO or CH1 is in program control mode the following 32 internal relays are allocated RW 23 Block 35 CH1 Step 5 writing R W Block 38 CH1 Step 8 writing FC5A MicroSmart PID Module User s Manual FC9Y B1283 5 3 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Block 39 CH1 Step 9 writing For details about blocks see page 5 7 to 5 24 Notes about the control relays e The control relay 0 Reading all parameters When this bit is turned off to on all parameters stored in the ROM of the PID module are read out and stored in the data registers in the CPU module e The control relay 1 Loading initial values When the user program is downloaded to the CPU module the initial values of all parameters for the PID module are also downloaded and stored in the ROM of the CPU module When this bit is turned off to on the initial values stored in the ROM are loaded into the data registers RAM e The control relay 2 Writing all parameters When this bit is turned off to on all parameters stored in the data registers are written to the ROM of the PID module e The control relay 3 through 27 Writing blocks 2 to 5 10 to 19 and 30 to 39 When the writing bit is turned off to on the corresponding block parameters stored in the data registers are wri
131. egral action corrects the offset The integral action is disabled when the integral time is 0 The integral time is a coefficient to determine the output manipulated variable MV of the integral action If the integral time is shortened too much the integral action becomes strong The offset can be corrected in a shorter time however the hunting phenomenon may be caused over a long cycle On the contrary if the integral time is extended too much the integral action becomes weak and it takes time to correct the offset An appropriate integral time for the control target can be automatically calculated using auto tuning AT function It is unnecessary to configure the integral time in the WindLDR when using the auto tuning AT function 6 36 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 8 Control Register 28 Derivative Time When the set point SP is changed or when the deviation between the set point SP and the process variable PV is increased due to a disturbance the derivative action increases the output manipulated variable MV to rapidly correct the deviation between the process variable PV and the set point SP The derivative time is a coefficient to determine the output manipulated variable MV of the derivative action The derivative action is disabled when the derivative time is 0 If the
132. egral time derivative time and ARW are automatically configured by performing auto tuning AT For P control or PD control action the reset value is automatically configured by performing auto reset A Caution Perform auto tuning AT auto reset during the trial run e If the auto tuning AT is performed near the ambient temperature sufficient fluctuations cannot be given to the process and auto tuning AT may fail In such case configure the P D and ARW values manually e Perform auto reset when the process variable PV is stabilized within the proportional band e Once auto tuning AT auto reset is performed it is unnecessary to perform auto tuning AT auto reset again as long as the process is unchanged e When voltage or current input is selected and the auto tuning AT is performed fluctuations are given to the process at the set point SP regardless of AT bias e During program control fluctuations are given to the process as soon as auto tuning AT is started Auto tuning AT In order to configure P proportional band integral time D derivative time and ARW Anti Reset Windup automatically with optimal values the auto tuning AT can be performed The auto tuning AT gives temperature fluctuation to the process to calculate those parameters To perform an optimal auto tuning AT temperature fluctuation is given to the process when the process variable PV reaches near the set point SP
133. en input is voltage current 1000 to 1000 Output ON OFF When input range unit is Celsius hysteresis 0 1 to 100 0 C When input range unit is Fahrenheit 0 1 to 100 0 F When input is voltage current 1 to 1000 Output When output type is relay or voltage manipulated Upper limit variable MV Output manipulated variable lower limit value to 100 upper limit Lower limit lower limit 0 to output manipulated variable upper limit value When output type is current Upper limit Output manipulated variable lower limit value to 105 Lower limit 5 to output manipulated variable upper limit value Output 0 to 100 sec manipulated variable rate of change The alarm range can be configured with the alarm value When the process variable PV goes outside of the range the alarm output turns on or off Alarm type can be selected from upper limit alarm lower limit alarm upper lower limits alarm upper lower limit range alarm process low alarm process high alarm upper limit alarm with standby lower limit alarm with standby upper lower limits alarm with standby and no alarm action For details about the alarm see pages 6 26 to 6 28 Setting accuracy Action Hysteresis When input is thermocouple or resistance thermometer 0 1 to 100 0 C F When input is voltage current 1 to 1000 Output Alarm Delay time FC5A MicroSmart PID Module User s Manual FC9Y B1283 9 1 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com
134. enixType _ _ Al TWIN2x0 75 8 GY UL1007AWG18 PAI TWIN2x0 5 8WH _ Al TWIN2x0 5 8 WH UL1015AWG22 Cable Size Note The above ferrules crimping tool and screwdriver are made by Phoenix Contact and are available from Phoenix Contact FC5A MicroSmart PID Module User s Manual FC9Y B1283 3 3 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INSTALLATION AND WIRING Terminal Arrangement h Caution e Connect an IEC 60127 approved fuse appropriate for the applied voltage and current draw at the position shown in the diagram This is required when equipment containing the MicroSmart is destined for Europe e Do not connect a thermocouple to hazardous voltage 60V DC 42 4V DC peak or higher e Be sure to check the wiring before the power is turned on Faulty wiring may result in damage to the PID module e Applicable electric cables are listed below Cable size AWG16 Single cable Cable size AWG18 AWG22 Single cable Twisted cable DC Voltage Current C SR Fuse B0V 1 2A RTD Resistance thermometer 5 Sa Terminal Channel TC oo ll ESO d GR d Se sie Gi Analog current input instr
135. eriod to a suitable value END 4 For detail about the control period see page 6 46 FC5A MicroSmart PID Module User s Manual FC9Y B1283 8 3 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com TROUBLESHOOTING The PID Module input does not operate normally Input does not operate normally NO Is the input wiring correct Correct the input wiring YES Does the sensor YES malfunction Replace the sensor NO NO Is the sensor or external device connected to the PID Connect them securely module securely YES YES Replace the sensor if it is burnt out or disconnected Make sure of input status Is the sensor burnt out or the input signal source abnormal NO Are sensor specifications suitable with the PID module NO Use a sensor with suitable specifications YES Does AC leak into the NO sensor circuit Use an ungrounded type sensor YES S there equipment tha NO interferes with or makes noise near the PID module Take countermeasures against inductive interference or noise YES NO Are the input type and unit selected correctly SSES YES Is the PV correction NO value suitable Set it to a suitable value YES Call IDEC for assistance EN
136. errors or problems occur while operating the PID module If any problem occurs take actions described in the flowchart corresponding to the problem The PID Module Power LED PWR is OFF or Flashing The Power LED PWR does not go oni is flashing NO Is the power supplied Supply the external power YES s the Power LED PWR on Is the power voltage correct Supply the rated voltage 24V DC s the Power LED PWR on Is the PID module NO connected to the FC5A CPU module securely Connect the PID module to the FCSA CPU module securely s the Power LED PWR on Call IDEC for assistance END FC5A MicroSmart PID Module User s Manual FC9Y B1283 8 1 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com TROUBLESHOOTING The PID Module output does not operate normally 8 2 Output does not operate normally is the RUN LED of the NO CPU module ON YES s Control Enable bi NO ON in the operation parameter YES Is the parameter error YES occurring NO NO Is the control output OFF YES YES s the output manipulated variable upper limit value less than 0 NO NO the output signal type suitable for the FC5A F2M2 used YES YES Is the allocated data register used for other functions N
137. ersion minimum and maximum values corresponding to 4mA is indicated the PID module is operating normally and the signal wire may be disconnected FC5A MicroSmart PID Module User s Manual FC9Y B1283 8 5 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com TROUBLESHOOTING Loop break alarm turns on even though the actuator operates normally Loop break alarm turns on even though the actuator is operating normally Is the loop break alarm time too short 1 Set the loop break alarm time to a suitable value Is the loop break alarm span too great 2 Set the loop break alarm span to a suitable value NO Call IDEC for assistance END 1 Loop break alarm time may be too short compared to the loop break alarm span 2 Loop break alarm span may be too great compared to the loop break alarm time Note Loop break alarm time and loop break alarm span Set the loop break alarm span to a value around 1 25 times bigger than the operation span in normal operation Example Heater in which temperature rises 150 C in 30 minutes When the loop break alarm time is 10 minutes the operation span in normal operation is 50 C 150 C 30 minutes x 10 minutes Set the loop break alarm span to 65 C which is about 1 25 times bigger than 50 C Program control is terminated earlier than the configured time Program control
138. escribed here When the heating cooling control is enabled the control period and the output manipulated variable MV upper and lower limits of CH1 are disabled The parameters 5 to 7 are enabled Output parameters for CH1 control are the same as those of CHO control except the cooling control parameters However the positions from the control register for each parameter differs For details about the positions from the control register of CH1 control see 5 17 to 5 20 1 Control Register 99 Output Type Select the output type for the FC5A F2M2 Voltage or current output can be selected Voltage output 12V DC 15 Current output 4 to 20mA DC FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 45 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 2 Control Register 30 Control Period The control period determines the duration of the ON OFF cycle of the control output that is turned on and off according to the output manipulated variable MV calculated by the PID control action The ON pulse duration of the control output is determined by the product of the control period and the output manipulated variable MV When the heating cooling control is enabled the control period will be the heating control period When the output type is current the control period is disabled Example When the control period is 5 sec Output Manipulated Output Manipula
139. ess Low Alarm Alarm Hysteresis Alarm Hysteresis ON __ ON OFF SE Ort Alarm Value Alarm Value Setting Example Setting Example Alarm 1 Value 205 C Alarm 1 Value EES Alarm 1 Hysteresis 2 0 C Alarm 1 Hysteresis 2 0 C Alarm Action Alarm Action 205 C lt Process Variable PV Alarm Output ON Process Variable PV S195 C Alarm Output ON Process Variable PV S 203 C Alarm Output OFF 197 CSProcess Variable PV Alarm Output OFF 2 0 C 2 0 C 203 C 205 C 195 C 197 C Upper Limit Alarm with Standby Lower Limit Alarm with Standby Alarm Hysteresis Alarm Hysteresis gt NNNNA IAN S UR cn L gl Alarm Value SP Alarm Value Alarm Value SP Alarm Value Setting Example Setting Example Set Point SP 200 C Set Point SP 200 C Alarm 1 Value 0 Alarm 1 Value 5 C Alarm 1 Hysteresis 2 0 C Alarm 1 Hysteresis 2 0 C Alarm Action Alarm Action 205 C lt Process Variable PV Alarm Output ON Process Variable PV S 195 C Alarm Output ON Process Variable PV S 203 C Alarm Output OFF 197 C S Process Variable PV Alarm Output OFF Note When the set point SP is changed the standby function is enabled Once the process variable PV enters the alarm output off range the standby function is canceled FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 27 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr co
140. ession of the overshoot is intermediate When ARW is 100 the integral action area becomes the maximum and the suppression of the overshoot is minimized An appropriate ARW for the control target can be automatically calculated using auto tuning AT function It is unnecessary to configure the ARW in the WindLDR when using the auto tuning AT function 10 Control Register 89 AT Bias Auto tuning AT starting point can be specified with the AT bias When Process variable PV lt Set point SP AT bias AT starting point Set point SP AT bias When Process variable PV 2 Set point SP AT bias AT starting point Set point SP AT bias When Set point SP AT bias lt Process variable PV lt Set point SP AT bias AT starting point Set point SP For details about the AT bias see page 4 6 11 Control Register 31 Reset The reset corrects the offset between the set point SP and the process variable PV generated in P or PD control action Reset can be configured only in P integral time and derivative time are 0 or PD integral time is 0 control action P or PD control action is used for the control target in which overshoot caused by the integral action is hard to be suppressed When the reverse control action is selected the manipulated variable is calculated with the ratio of the reset to the proportional band and the calculated manipulated variable is added to the output manipulated variable
141. form Cancel The Auto tuning AT Auto reset function can be performed or cancelled by turning on off the operation parameter bits allocated to each channel For the operation parameter bits see page 5 10 Perform Auto tuning AT To perform auto tuning AT turn on the control enable disable bit Bit0 and auto tuning AT auto reset bit Bit1 of the operation parameter P I D and ARW values will automatically be configured When auto tuning AT is performed during the program control P D and ARW values of the current step are configured While auto tuning AT is performed the Auto tuning AT Auto reset LED ATO AT 1 flashes When auto tuning AT is completed the operation parameter Bit1 is automatically turned off and the CPU module reads all parameters of the AT performed channel from the PID module and store those parameters in the data registers If any parameters in the data registers of the CPU module have been changed but have not been written to the PID module those parameters will be overwritten with the parameters read from the PID module when auto turning AT is finished FC5A MicroSmart PID Module User s Manual FC9Y B1283 4 7 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com PID MODULE MAIN FUNCTIONS Cancel Auto tuning AT To cancel auto tuning AT while it is performed turn off Auto tuning AT Auto reset bit Bit1 of the operation parameter When the operation par
142. g to OV or 1V for input CH1 Example When input type is current 4 to 20mA DC if external SP input linear conversion minimum value is 0 C external SP input 4mA corresponds to the set point SP 0 C for CHO control When input type is voltage 0 to 1V DC if external SP input linear conversion maximum value is set to 20 C external SP input OV corresponds to the set point SP 20 C for CHO control 6 Control Register 177 External SP Input Bias The external SP input bias is added to the set point SP obtained after the linear conversion for the external SP input The set point SP is then used as the set point SP for CHO control Examples When the input type is current 4 to 20mA DC the linear conversion maximum value is 1000 C the linear conversion minimum value is 0 C and the external SP input bias is 50 C the set point SP of CHO control corresponding to 12mA of external SP input will be 550 C When the input type is voltage 0 to 1V DC the linear conversion maximum value is 1000 C the linear conversion minimum value is 0 C and the external SP input bias is 50 C the set point SP of CHO control corresponding to 0 5V of external SP input will be 550 C FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 31 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 7 Control Register 65 Control Register 66 Control Register 67 Co
143. gain from step 0 The program end output and program hold bit are turned off While the program control is being held the parameters of Blocks 10 to 19 and 30 to 39 can be changed The program control can be executed again after changing the program parameters such as the set point SP or step time of each step Hold program control 27 Control Register 97 Number of Repeats The number of repeats for the program control can be configured FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 43 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR Control Parameters when Cascade Control is Selected PID Module Configuration Slot 1 2 x Module Type No FCSA F2M2 a Input Parameters Control Parameters Output Parameters CHO Input CHO _h CHO output CHO oo CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Control Parameters CH1 Cascade Control CH1 Type K thermocouple Celsius Reverse Control Action Heating Input
144. ged 2 CHO CH1 PV Process Variable The process variable PV of CHO or CH1 is indicated 3 CHO CH1 MV Output Manipulated Variable The output manipulated variable MV of CHO or CH1 is indicated The bar graph on the right is also updated according to the output manipulated variable MV While the output is on the OUT indicator turns green While CHO or CH1 is in manual mode output manipulated variable can be changed 4 CHO CH1 Step The current step number 0 to 9 is indicated when CHO or CH1 is in program control mode 5 CHO CH1 Repeat The remaining repeat number is indicated when CHO or CH1 is in program control mode 6 CHO CH1 Time The remaining time in the current step is indicated when CHO or CH1 is in program control mode 6 52 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 7 CHO CH1 Send Command When a menu is selected a command to control the PID module is sent Control Enable Disable the control to the PID module AT Auto reset Perform auto tuning AT auto reset or cancel auto tuning AT Manual Mode Enable manual auto mode External SP Input CHO only Enable Disable the external SP input Program Control Run Stop the program control advance next previous step or hold run the program control 8 CHO CH1 Status Indicators Control Turns green while the
145. harges Continuously According to Deviation LED Indicator CHOOUT RT Green Lit __ Turns ON or OFF Proportional Band Cycle Action is Performed ccording to Deviation OV DC 0 12V DC 12V DC e C cle Action is Perfomed ccording to Deviation eng a e 4mA DC A0 m DC 20mA DC ot tee ee Chahges Continuously According to Deviation Lit CHO CH1 Output Action of ON OFF Control Action SS Heating Reverse Control Action Cooling Direct Control Action Hysteresis Control Action Relay Output Non contact Voltage Output Current LED Indicator CHO OUT Green Cl Turns ON or OFF FC5A MicroSmart PID Module User s Manual FC9Y B1283 Hysteresis Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 9 5 APPENDIX Output Action of Heating Cooling Control Control Action Voltage Output CHO Current Output CH1 Current Output LED Indicator CHO OUT Green LED Indicator CH1 OUT Green Heatin Coolin Popon oni Gand Proportional Band ON SG VE Heating Coolng Control Action Control Action OFF Cycle Action is Performed ccording to Deviation Cycle Action is Performed ccording to Deviation 12VDC 12 0VDC Cycle Action is Performed ccording to Deviation 0 12V DC Cycle Action is Performed ccording to Deviation 20mADC i 20to4mADC 4mA DC
146. he ON OFF control action when the proportional band or proportional gain is 0 16 Control Register 21 Manual Mode Output Manipulated Variable The output manipulated variable MV for the manual mode can be configured 6 38 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 17 Control Register 35 Loop Break Alarm Time Configure the loop break alarm time to detect the loop break alarm The loop break alarm is disabled when the loop break alarm time is 0 When one of the following conditions is met the PID module considers that heater burnout sensor burnout or actuator trouble is detected and triggers the loop break alarm When the reverse control action is selected e The loop break alarm is triggered when the process variable PV does not rise as much as the loop break alarm span within the loop break alarm time while the output manipulated variable MV is 100 or the output manipulated variable upper limit e The loop break alarm is also triggered when the process variable PV does not fall as much as the loop break alarm span within the loop break alarm time while the output manipulated variable MV is 0 or the output manipulated variable lower limit When the direct control action is selected e The loop break alarm is triggered when the process variable PV does not fall as much as the loop brea
147. he output type is relay Output CH1 is turned off When heating cooling control is enabled output CH1 is used as the cooling output Output manipulated variable MV 0 to 100 of the master CH1 is converted using the external SP input linear conversion minimum and maximum values and is used as the set point SP of the slave CHO Example When the external SP input linear conversion minimum value is 0 C and the external SP input linear conversion maximum value is 1000 C the set point SP of the slave CHO is decided as follows When master CH1 output manipulated variable MV is 0 0 C When master CH1 output manipulated variable MV is 50 500 C When master CH1 output manipulated variable MV is 100 1000 C Combination of Input CHO and Input CH1 Functions The possible combinations of Input CHO and CH1 Functions are shown below O Possible X Impossible CHO CH1 CH1 CHO CHO CH1 SP Input Control E e SE e a co SE GE Input CHO Difference CHO CH1 O O O O X X Difference CH1 CH0 O 0O O O xXx X Addition CH0 CH1 O 0O 0O Io X X 3 Control Register 57 Output CHO Function The one of the following output functions can be selected as the Output CHO Function Output CHO The output of the CHO control is outputted from output CHO rom Control P t Input Parameters Input CHO oni Wee ers CHO Output Parameters output
148. hed the Program End Action program end output bit is turned on and maintained Hold When the program control is terminated the program control program is held at the last status of step 9 The program end output control and program hold bit are turned on and maintained While the program control is held the fixed value control is performed with the set point SP of step 9 If advance next function operation parameter Bit6 is turned off to on is executed while the program control is held the program control is started again from step 0 The program end output and program hold bit are turned off While the program control is being held the parameters of Blocks 10 to 19 and 30 to 39 can be changed The program control can be executed again after changing the program parameters such as the set point SP or step time of each step Repeat Function FC5A MicroSmart PID Module User s Manual FC9Y B1283 9 3 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPENDIX 9 4 Output Manipulated Variable MV Rate of Change PV Correction PV Filter Time Constant Automatic Cold Junction Temperature Compensation Burnout Over Range Control Range PID Module Standby The maximum change of the output manipulated variable in one second can be configured If the sensor cannot be installed to the location of the control target the temperature measured by the sensor may deviate from
149. imit alarm Upper limit alarm Program Pattern Settings are common between CHO and CH1 Set Point SP 100 C 100 C 800 C 800 C Step Time 300 minutes Wait Value Alarm 1 Value FC5A MicroSmart PID Module User s Manual FC9Y B1283 7 9 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPLICATION EXAMPLES Parameter Configuration Procedure 1 Expansion Modules Configuration Select Configuration gt Expansion Modules from the WindLDR menu bar to open the Expansion Modules Configuration dialog box In the Expansion Modules Configuration dialog configure the quantity of modules slot number module type number control register data register and control relay internal relay Click on Configure Parameters button to open the PID Module Configuration dialog box Expansion Modules Configuration Dialog Box 1 Expansion Modules Quantity of modules 4 CPU module Slot 1 Slot 2 Slot 3 Slot 4 c FC5A C24R2X D1000 to D1189 Other modules Other modules Other modules M1000 to M1007 3 Module Settings 4 d m Module Type No FCSA F2M2 5 w Data Register D1000 D1000 to D1189 Internal Relay m1000 M1000 to M1007 Slot No j Copy Parameters To OK Cancel 2 I O Function Selection Select I O function for each channel in the PID Module Configuration dialog box PID Module Configuration Dialog Box I O Func
150. in the PID Module Configuration dialog box PID Module Configuration Dialog Box I O Function Selection PID Module Configuration Slot 1 2 xi 4 Module Type No FCSA F2M2 iri 3 Input ane Input CHO Hafen Output CHO Gemeng 2 Type K thermocouple Celsius Reverse Control Action Heating Voltage Output 4 D Control Parameters tput Parameters CH1 Input CH1 wel ec CH1 Output CHL X CH1 Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input CHO Control CH Output CHO Input CH1 Control CH1 Output CH1 Monitor Input Range Type K thermocouple eil Celsius el 200 to 1370 c PV Correction 0 0 100 0 to 100 0 C PV Filter Time Constant 0 0 a 0 0 to 10 0 sec Set Point SP Upper Limit 1370 H 200 to 1370 C Set Point SP Lower Limit 200 200 to 1370 C Alarms pf em Setting O Input CHO Function Input CHO Input CH1 Function Input CH1 Output CHO Function Output CHO Output CH1 Function Output CH1 3 Input CHO Parameters Configure the Input CHO parameters in the PID Module Configuration dialog box To open Input CHO Parameters in the PID Module Configuration dialog box click on Input Parameters CHO button or Input CHO tab
151. in the PID Module Configuration dialog box To open Input CHO Parameters in the PID Module Configuration dialog box click on Input Parameters CHO button or Input CHO tab PID Module Configuration Dialog Box Input CHO Parameters PID Module Configuration Slot 1 2 xi Module Type No FCSA F2M2 bd Input eae Input CHO eege ee Output CHO SR Type K thermocouple with decimal point Celsius Reverse Control Action Heating Voltage Output Input cil aoe Input CH1 capital Barnet Output CH1 b Warden Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input CHO N Control CH0 Output CHO Input CH1 Control CH1 Output CH1 Monitor 1 Input Range Type K thermocouple with decimal point Celsius 200 0 to 400 0 C PV Correction 0 0 LG 100 0 to 100 0 C PV Filter Time Constant DD 0 0 to 10 0 sec SH air OD E Point SP Upper Limit 400 0 0 0 to 400 0 C 2 Set Point SP Lower Limit 0 0 200 0 to 400 0 C 3 ge gem Alarm Type Alarm Yalue Hysteresis 0 1 to 100 0 C Delay Time 0 to 10000 sec i pper Lower Limits Alarm with Standby 4 No Alarm Action No Alarm Action 5 No Alarm Action No Alarm Ac
152. in the control range the PID module controls the temperature based on the process variable PV after the PV correction When the process variable PV after the PV correction is out of the control range the under or over range error occurs and the control output is turned off The process variable PV after the PV correction can be calculated using the following formula Process variable PV after the PV correction Process variable PV PV correction value Example 1 When process variable PV is 198 C If the PV correction value is 2 0 C the process variable PV will be 200 0 C 198 C 2 0 C If the PV correction value is 2 0 C the Process variable PV will be 196 0 C 198 C 2 0 C 6 24 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR Example 2 By setting the PV correction value for the PID module to 10 0 C the process variable PV of the PID module is adjusted from 190 C to 200 C Sensor PID Module REESEN Process Variable PV 200 C WONEN NN PV correction value 10 0 C 3 Control Register 63 PV Filter Time Constant The PV filter function is a software filter to stabilize the process variable PV affected by fluctuating processes such as the pressure or flow rate by calculating first order lag of the process variable PV Even if the process varia
153. inear conversion MINIMUM value eee 6 46 cold JUNCTION compensation 9 4 confirming system program version 1 2 control action E 5 20 6 36 9 1 ON OFF control action AA 4 3 8 3 P control action ME 4 3 PD control action seesesssresessrresseresercosereressersseeeesseres 4 5 PI control action NEE 4 4 PID control action EEN 4 5 7 1 control poarameters 6 13 ECH 6 35 Sslzittalbet ger BE 5 18 6 48 Single et 9 4 OVEN ANG Cvs eege Ae 5 10 Treff EE 5 10 eeler 5 2 6 6 contol TEY EE 5 3 6 6 loading ILR TT 5 4 6 5 reading all oarameters 5 4 6 5 writing all parameters cccceeececeeeseeeeeeeeeeeeeees 5 4 6 5 gll 5 4 cooling control period EE 5 19 6 48 output manipulated variable MV 5 7 FC5A MicroSmart PID Module User s Manual FC9Y B1283 output manipulated variable lower limit 6 48 output manipulated variable upper limit 6 48 output ON OFF hysteresiS serren 6 41 proportional band EE 5 19 D decimal e 5 5 5 6 5 23 derivative me 5 5 5 18 6 38 difference input Control 4 14 6 21 6 22 direct control ACTION EE 6 36 E expansion modules configuration dialog box 6 1 external bi 5 11 5 20 6 11 6 22 6 31 9 2 enable disable LED 2 2 input e 5 21 6 32 linear conversion maximum value eesse 5 21 6 32 linear conversion minimum value essees 5 22 6 32 F factory default settings veces scsccssssuncssvsnccesnsdocssstinestanceuee 9 9 fixed value Control 4 3
154. is 1 sec the trace end time will be 9000 sec The trace will be finished in 150 minutes x27000 Interval x 27000 Trace end time Example If the interval time is 1sec the trace end time will be 27000 sec The trace will be finished in 450 minutes 6 54 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR Monitoring Screen Example PID Module Configuration Slot 7 FC5A F2M2 FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 55 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 6 56 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPLICATION EXAMPLES APPLICATION EXAMPLES This chapter describes the PID modules application examples Application Example 1 This application example demonstrates the temperature control for a system using two electric furnaces The set point SP of CHO control is 200 C The set point SP of CH1 control is 210 C e PID control is performed based on the temperature input to the PID module The control output is turned on or off in accordance with the output manipulated variable MV e PID parameters proportional band proportional gain integral time derivative time and ARW are
155. is 60 C SP Start Action Set point SP when Program Control Starts is 0 C StepNumber 0 Jaf Set Point SP l l I I l l i 1 150 C KEEN GE I I I 1 I i 1 1 l i l J l l i 100 C i i 1 1 l 1 l l I 1 l 1 1 I I I 1 50 C f 4 Ge eee EE i I l 1 1 1 l 1 l l i I i 1 0 C Time 60 min 60 min 30 30 60 min min min When the program control is started the program control will start from 0 C of the set point SP configured with Set Point SP when Program Control Starts regardless of the current process variable PV 6 42 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 24 Control Register 96 Set Point SP when Program Control Starts The set point SP when program control starts can be configured The program control starts with this set point SP when the SP start is selected as the program control mode start type 25 Control Register 92 Step Time Unit Minute or second can be selected as the unit of program control progressing time 26 Control Register 93 Program End Action The action to be taken when the program control is terminated can be selected The program control is terminated when all steps 0 to 9 are performed and finished Each step is performed with the parameters
156. is Fahrenheit 100 0 to 100 0 F When input is voltage or current input 1000 to 1000 0 to 100 sec When input range unit is Celsius 0 to 10000 C min Range with a decimal point 0 0 to 1000 0 C min When input range unit is Fahrenheit O to 10000 F min Range with a decimal point 0 0 to 1000 0 F min When input is voltage or current input O to 10000 min When input range unit is Celsius 0 to 10000 C min Range with a decimal point 0 0 to 1000 0 C min When input range unit is Fahrenheit O to 10000 F min Range with a decimal point 0 0 to 1000 0 F min When input is voltage or current input O to 10000 min O to 200 minutes When input range unit is Celsius O to 150 C Range with a decimal point 0 0 to 150 0 C When input range unit is Fahrenheit O to 150 F Range with a decimal point 0 0 to 150 0 F When input is voltage or current input O to 1500 See 5 18 for the valid range of alarm 1 to alarm 8 values FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 5 17 DEVICE ALLOCATION OF PID MODULE Output manipulated variable lower limit to 105 When output type is relay or voltage Output Manipulated Variable 0 to output manipulated variable upper limit 47 124 Wee l Lower Limit When output type is current 5 to output manipulated variable upper limit 0 0 to 10 0 times Cooling propo
157. is turned on the progression of the program control is moved back If the elapsed time in the current step is less than 1 minute the program control Advance Previous goes back to the start of the previous step If the elapsed time in the current step is Step more than or equal to 1 minute the program control goes back to the start of the current step Even when the advance previous function is executed at Step 0 the program control does not move back to Step 9 regardless of the program end action When the program control is terminated the program control can be repeated from step 0 as many times as the number of repeats configured The action to be taken when the program control is terminated can be selected Terminate When the program control is terminated the program end program output bit is turned on and maintained and the PID module control will be in standby status The program control can be executed again by turning off to on the program control bit operation parameter bit3 During the program control standby waiting for program control run status the control output is turned off and the operating status is not updated except the over range the under range and the program end output Continue When the program control is terminated the program program control is repeated from step 0 as many times as the control configured number of repeats When the step 9 of the last Repeat program control cycle is performed and finis
158. it 7 cono S dearen l Normal operation Bit1 Aomin AT AUO RESE BI Auto tuning AT Auto reset is being performed Auto mode Bit2 Auto Manual Mode Bit H __ Auto mode 1 Manual mode Manual mode o Z S O 0 Program control is stopped ee Programi CONO Si Program control is running 0 Normal operation ole prem O B Program control is held External SP Input Enable Bit 0 External SP input is disabled BitS CHO only External SP input is enabled 0 All parameters are within the valid range E EE All parameters are out of the valid range P Set point SP Range Error Bit 0 Set point SP is within the valid range Set point SP is within the valid range Manual mode output manipulated variable is within the valid range Manual mode output manipulated variable is out of the valid range Proportional band integral Time derivative time ARW or control period is within the valid range Proportional band integral Time derivative time ARW or control period is out of the valid range Reset setting is within the valid range Reset setting is out of the valid range Cooling proportional band or cooling control period is within the valid range Cooling proportional band or cooling control period is out of the valid range Overlap dead band is within the valid range Overlap dead band is out of the valid range Alarm 1 to Alarm 8 values are within the valid range Alarm 1 to Alarm 8 values are out of th
159. ith the PID Modules through the allocated data registers After the user program download the following actions will be taken depending on whether Write PID Module parameters after download in the Download dialog box is checked or not When Write PID Module parameters after download is checked After the user program is downloaded to the CPU module the PID module parameters configured in the PID Module Configuration dialog box are written to the CPU module and the connected PID modules When Write PID Module parameters after download is not checked After the user program is downloaded to the CPU module the PID module parameters are not written to the PID module Transfer Mode Binary ASCII Download Options Automatic start after download ICT Keep output during download O Suspend 1 0 force before download ICT Automatic device clear after download E Write PID module parameters after download O Write device datafile to the PLC after download Setting ICT Download comment data Setting Download systemprogram Detail Program Information Program Size 1142 bytes Comment Size 0 bytes Total 1142 bytes communication Settings When Write PID Module parameters after download is checked after the user program is downloaded to the CPU module the PID module parameters configured in the PID Module Configuration dialog box will be written to the data registers in the CPU module and all PID modules configured in the
160. k alarm span within the loop break alarm time while the output manipulated variable MV is 100 or the output manipulated variable upper limit e The loop break alarm is also triggered when the process variable PV does not rise as much as the loop break alarm span within the loop break alarm time while the output manipulated variable MV is 0 or the output manipulated variable lower limit value Even when the loop break alarm is triggered the PID module continues its control To stop the control ladder programming is needed Ladder Program Example The control register is D1000 in this example When external input I0 is turned on CHO control is enabled When QO loop break alarm output of CHO control is turned on CHO control is disabled T0000 OOOO b1022 00 When loop break alarm is triggered D1010 2 loop break alarm 01010 02 output is turned on and OU is turned on 18 Control Register 36 Loop Break Alarm Span Configure the loop break alarm span to detect the loop break alarm The loop break alarm is disabled when the loop break alarm span is 0 19 Control Register 95 Cooling Method When the heating cooling control is enabled select the cooling method from air cooling oil cooling or water cooling The output characteristics for the cooling output manipulated variable MV are shown below Air cooling linear characteristic Oil cooling 1 5th power of the linear characteristic Water cooling 2nd power of th
161. kly as possible by raising the temperature rapidly even if overshoot is generated as shown in Figure 4 In general however Figure 2 is regarded as an optimal temperature control The PID module is designed to raise the process variable PV to the set point SP as quickly as possible in order to stabilize the process variable PV at the set point SP so as to perform the optimal temperature control If the temperature fluctuates due to sudden disturbances the PID module responds to the fluctuation with speedy response in the shortest possible time and performs quick control to stabilize the temperature Temperature Set point SP Time Figure 3 Stable but slow temperature rise control Temperature Set point SP Time Figure 4 The temperature rises rapidly however the control stabilizes after overshoot and undershoot Characteristics of the Control Target To perform optimal temperature control it is necessary to have a good knowledge of the thermal characteristics of the PID module sensors actuators as well as control targets For example the PID module controls a constant temperature oven and its temperature can rise up to 100 C Even if the set point SP of the PID modules is configured as 200 C the temperature of the constant temperature oven rise only up to 100 C due to its static characteristic The characteristic of the control target is determined by the combination of the following 4 factors 1 Thermal capacity
162. l The output manipulated variable MV 0 to 100 of the master CH1 corresponds to the set point SP of the slave CHO The range of the set point SP of the slave CHO is the external SP input linear conversion minimum value to the external SP input linear conversion maximum value Configure the external SP input linear conversion maximum value for when the output manipulated variable MV of the master CH1 is 100 2 Control Register 179 External SP Input Linear Conversion Minimum Value Configure the external SP input linear conversion minimum value for the cascade control The output manipulated variable MV 0 to 100 of the master CH1 corresponds to the set point SP of the slave CHO The range of the set point SP of the slave CHO is the external SP input linear conversion minimum value to the external SP input linear conversion maximum value Configure the external SP input linear conversion minimum value for when the output manipulated variable MV of the master CH1 is 0 6 44 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR PID Module Configuration Output Parameters Details PID Module Configuration Slot 1 FC5A F2M2 Input CHO D Input CH1 Out PID Module Configuration Slot 1 Input CHO Hi Voltage Output E Output parameters of CHO control are d
163. l Settings Proportional Band 10 0 0 0 to 1000 0 C Cooling Method Air Cooling M Integral Time 200 0 to 10000 sec Cooling Proportional Band 1 0 S 0 0 to 10 0 Derivative Time 50 1 0 to 10000 sec Cooling Output ON OFF Hysteresis 1 0 0 1to 100 0 c 3 ARW Anti Reset Windup 50 0 to 100 Overlap Dead Band 0 0 S 200 0 to 200 0 C nsis 20 0 F 0 0 to 50 0 c Reset 0 0 100 0 to 100 0 c die i Progra lod rt Typ PY Start Set Point SP Rise Rate 0 0 0 0 to 1000 0 C min Set Point SP Fall Rate o oon 0 0 to 1000 0 C min SW oi Gs Output MV Rate of Change 0 0 to 100 sec SE ogran Terminate Program Control Output ON OFF Hysteresis 1 0 0 1 to 100 0 C Manual Mode Output MV 0 0 0 0 to 100 0 EE Write all parameters Read all parameters Monitor OK Cancel 1 Heating Cooling Control 1 3 ATBias 200 0 AT Bias 20 0 C 5 Saving Parameters Click OK button to save the configured parameters 6 Ladder Programming Create a ladder program for heating cooling control of the PID module Ladder Program Example While external input I0 is on CHO control is enabled When QO CHO control upper lower limits alarm output is on CHO control is disabled 10000 naaa DUU DU When external input 11 is turned on D1022 1 auto tuning AT perform bit is turned on When the process variable Di022 01 PV reaches 180 0 C auto tu
164. l actions that can be used for fixed value control and program control are described below ON OFF Control Action In the ON OFF control action when the process variable PV is lower than the set point SP the control output is turned on and when the process variable PV exceeds the set point SP the control output is turned off Overshoot undershoot and hunting are generated ON OFF control is suitable for processes which do not require accuracy If the proportional band or proportional gain of the PID module parameter is set to 0 the control action becomes ON OFF control Overshoot Undershoot Se Hunting As the temperature of the control target J rises as shown in the figure on the right the process variable PV sometimes Set Point SP A a N Z Ca Ge exceeds the set point SP greatly This is called overshoot If the process variable PV drops below the set point SP this is called undershoot Temperature Undershoot Hunting The control result oscillates as shown ON 7 Time in the figure on the right This is the the hunting Control Output OFF P Control Action Proportional Action P control action outputs the manipulated variable MV in proportion to the deviation between the process variable PV and the set point SP within the proportional band The control output is ON until the process variable PV reaches the point A that is determined by
165. l is selected as the program end action the program control is held and the fixed value control is performed with the parameters of step 9 after all steps are executed FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Data Register Allocation Blocks 2 3 Basic Parameters SHOT Action Block 2 CHO and block 3 CH1 parameters are shown in the table below The parameters of block 2 and 3 can be changed while the control of the PID module is enabled Offset from the Control Register 26 Proportional Term Integral Time Derivative Time ARW Anti Reset Windup Control Period 8 Output Manipulated Variable Set Point SP Rise Rate Set Point SP Fall Rate Loop Break Alarm LA Time Loop Break Alarm LA Span Alarm 1 Value Alarm 2 Value Alarm 3 Value Alarm 4 Value Alarm 5 Value Alarm 6 Value Alarm 7 Value Alarm 8 Value Reserved Parameter Description Proportional band When input range unit is Celsius O to 10000 C Range with a decimal point 0 0 to 1000 0 C When input range unit is Fahrenheit O to 10000 F Range with a decimal point 0 0 to 1000 0 F When input is voltage or current input 0 0 to 1000 0 Proportional gain 0 00 to 100 00 O to 10000 sec O to 10000 sec O to 100 1 to 120 sec When input range unit is Celsius 100 0 to 100 0 C When input range unit
166. larm Action dee Monitor l OK Cancel Write all parameters Read all parameters Control Registers Input CHO Difference input Input CHO Input CH1 Difference input Input CH1 Input CHO Addition input Input CHO Input CH1 Input CH1 Difference input Input CHO Input CH1 Difference input Input CH1 Input CHO Addition input Input CHO Input CH1 Disabled External SP input 4 to 20mA DC Note External SP input 0 to 20mA DC Offset from the control GE register External SP input 1 to 5V DC BEID Input CHO Function External SP input 0 to 1V DC o Input CH1 Function 2 Cascade control Note 58 OBRWN A O WDND OCO W DN CH External SP Input Note When External SP input is selected in Input CH1 Function 1 External SP input 4 to 20mA DC is selected as the default When Cascade Control is selected in Input CH1 Function 5 Cascade control is selected 0 Output CHO Output CHO Function 1 Output CH1 2 Both outputs Output CHO Output CH1 0 Output CH1 i l R 135 Input Range See page 6 10 for the detail about the input range ul When input is thermocouple resistance thermometer Set Point SP EES ell Set point SP lower limit to input range upper limit Linear Conversion R W When input is voltage current Maximum Value l l S l o Linear conversion minimum to input range upper limit 56
167. lated variable upper limit FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR PID Module Configuration Program Parameters List CHO and CH1 Program parameters for CHO and CH1 are described here PID Module Configuration Slot 1 FCS4 F2M2 Module Type No Range 200 to 1370 C 0 to 6000 min Oto 100 C 0 to 10000 c 0 to 10000 sec 0 to 10000 sec Oto 100 0 to 100 sec 1570 to 1570 C 1570 to 1570 C 1570 to 1570 C 1570 to 1570 C 1570 to 1570 C 1570 to 1570 C 1570 to 1570 C 1570 to 1570 C Oto 100 Oto 100 0 0 to 10 0 times Set Point SP Step Time Wait value Proportional Band Fr T T li tli tl Integral Time Derivative Time ARW Anti Reset Windup Output MY Rate of Change Alarm 1 Yalue Alarm 2 value 11 Alarm 3 Value 1 2 Alarm 4 Value 13 Alarm 5 Value 1 4 Alarm 6 Value Alarm 7 Value Alarm 8 Value 1 6 Output MY Upper Limit D Output MY Lower Limit ON NN Nan nn o CO OO JO Om P Go gt 8 Cooling Proportional Band 9 Overlap Dead Band 0 ON Oo aoa a ann ara N o Input CHO Control CHO Program CHO Output CHO Input CH1 Output CH1 Monitor Step 0 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 0
168. le 12 Expansion Connector Connects to the CPU module and other expansion modules FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Specifications PID Module Specifications Rating MODULE SPECIFICATIONS Type No FC5A F2MR2 FC5A F2M2 Rated Scale Power Supply Voltage Allowable Voltage Range Thermocouple Input Value Measurement Range of LSB Ke L n 328 to 2498 F TC F K with decimal point 200 0 to 400 0 C 328 0 to 752 0 F 0 1 C F Roo Oto 1760 C 32 to 3200 F_ IPC PF 1 C F BoC to 1820 C 32 to 3308 F_ PC F 1 C F Resistance Thermometer Input Value Measurement Range of LSB Pt100 200 to 850 C 328 to 1562 F Pt100 with decimal point 200 0 to 850 0 C 328 0 to 1562 0 F 0 1 C F _ 200 to 500 C 828 to 992 F VC CF JPt100 with decimal point 200 0 to 500 0 C 328 0 to 932 0 F DICH __ Current Voltage Input Value Measurement Range of LSB 4 to 20mA DC 2000 to 10000 12000 increments 1 1 333p Oto20mA C 2000 to 10000 12000 increments 1 1 666uA 0 to 1V DC 2000 to 10000 12000 increments 1 0 083mA 0 to 5V DC 2000 to 10000 12000 increments 1 0 416mA 1 to 5V DC SC to 100 O 12000 increments 0 333MmA O to 10V DC 2000 to 10000 12000 increments 1 0 833mA 1 Linear conversion possible Input type Thermocouple K J R S B E T N PL Il
169. lsius Reverse Control Action Heating Voltage Output Output Parameters CH0 ch Output CHO gt Input Parameters CH1 External SP Input Type K thermocouple Celsius 1 Input CHO Control CHO Output CHO Input CH1 Monitor Input Range 4 to 20 m 2000 to 10000 2 LS PV Correction PV Filter Time Constant 0 0 3 E Linear Conversion Maximum Value 1370 4 ri Linear Convers ion Minimum Value 200 CH lt gt air air air air 1000 to 1000 0 0 to 10 0 sec 200 to 1370 c 200 to 1370 C External SP Input Bias 0 314 to 314 C 5 Alarms 6 ar arm vale Hysteresis 0 1 to 100 0 C Delay Time 0 to 10000 sec SIS No Alarm Action 7 No Alarm Action No Alarm Action No Alarm Action No Alarm Action No Alarm Action 4 4 4 4 4 4 4 oo eo EN a eo E E oo OO OO co CO 8 No Alarm Action Write all parameters Read all parameters Monitor OK Cancel 1 Control Register 55 Input Range Select input type for the external SP input Current 4 to 20mA DC or 0 to 20mA DC or voltage 0 to 1V DC or 1 to 5V DC can be selected 2 Control Register 62 PV Correction If the sensor cannot be installed to the location of the control target the temperature measured by the sensor may devi
170. m CONFIGURING PID MODULE USING WINDLDR Upper Lower Limits Alarm with Standby Alarm Hysteresis Yy Gj TAN Alarm Value SP Alarm Value Setting Example Set Point SP lt 200 C Alarm 1 Value 5 C Alarm 1 Hysteresis 2 0 C Alarm Action 205 C lt Process Variable PV or Process Variable PV S 195 C Alarm Output ON 197 C lt Process Variable PV S 203 C aan 195 C 197 C 200 C 203 C 205 C EEZ CALLA YZ Standby functions Notes When the set point SP is changed the standby function is enabled Once the process variable PV enters the alarm output off range the standby function is canceled Even when an alarm output is triggered the PID module continues its control To stop the control when an alarm is triggered ladder programming is needed For a ladder program example see 7 6 7 Control Register 37 Alarm 1 Value Control Register 38 Alarm 2 Value Control Register 39 Alarm 3 Value Control Register 40 Alarm 4 Value Control Register 41 Alarm 5 Value Control Register 42 Alarm 6 Value Control Register 43 Alarm 7 Value Control Register 44 Alarm 8 Value There are two types of alarms Deviation alarm and process alarm Alarm Type Alarm Value Alarm Action The alarm output turns off if the Upper Lower limit range alarm process variable PV exceeds the range Upper limit alarm Deviation Lower limit alarm Alarm Upper Lower limits alarm Deviation from the set point SP
171. meters All PID module parameters are read out from the PID module and stored in the data registers i 2 Store 150 in D1027 integral time of CHO and 45 in D1028 derivative time of CHO 3 Turn on M503 Block 2 writing The integral time 150 sec and derivative time 45 sec will be written to the PID module Ladder Program Example LR Mo5o0 MOVI Si Di REF 150 D1027 2nd Scan m0100 At the falling edge of M100 M500 is turned off 150 is stored in D1027 integral time of CHO 45 is stored in D1028 derivative time of CHO MOWIT 5S1 Diy REP E 45 D1028 5 M503 Block 2 writing is turned on to write block 2 parameters stored in D1026 to D1052 to the PID module 1st Scan At the rising edge of M100 M500 is turned on to read all parameters from the PID module ES M100 is turned off m0100 4 Ifthe reading all parameters bit M500 is turned on all PID module parameters are read out from the PID module and stored in the data registers Block 2 parameters are stored in D1026 to D1052 2 Block 2 parameters stored in D1026 to D1052 are written to the PID module The parameters of the other blocks are not written FC5A MicroSmart PID Module User s Manual FC9Y B1283 5 5 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Example 3 Changing Block 4 Parameter The PV filter time constant D1063 of CHO is changed to 1 5 seconds In
172. minute can be configured This function is disabled when the value is O In the case of heating control when there is a large deviation between the process variable PV and the set point SP the output immediately changes from off to on as shown in the diagram below Normal Output By configuring the output manipulated variable rate of change the maximum change of the output manipulated variable MV in 1 minute can be changed as shown in the diagram below Output When Output Manipulated Variable Rate of Change is Configured This function can be used for a high temperature heater used at approximately 1500 to 1800 C which has to be heated gradually as the heater can be burnt out if the power is supplied rapidly Normal Output Output When Output Manipulated Variable Rate of Change is Configured ON 100 sec 20 sec 10 sec OFF 1 second 5 seconds 10 seconds 9 Control Register 188 Alarm 1 Value 10 Control Register 189 Alarm 2 Value 11 Control Register 190 Alarm 3 Value 12 Control Register 191 Alarm 4 Value 13 Control Register 192 Alarm 5 Value 14 Control Register 193 Alarm 6 Value 15 Control Register 194 Alarm 7 Value 16 Control Register 195 Alarm 8 Value There are two types of alarms Deviation alarm and process alarm Alarm Type Alarm Value Alarm Action The alarm output turns off if Upper Lower limit range alarm the process variable PV exceeds the range Upper limit alarm Deviation Lower li
173. mit alarm Alarm Upper Lower limits alarm Deviation from the set PONE SP iS tae alarm The alarm output turns on if Upper limit alarm with standby MAINE the process variable PV Lower limit alarm with standby exceeds the range Upper Lower limits alarm with standby Process Process high alarm The alarm action point is EE Gi Et the process variable PV Alarm Process low alarm the alarm value exceeds the alarm value When the alarm value is 0 the alarm action is disabled except process high alarm and process low alarm 17 Control Register 197 Output Manipulated Variable Upper Limit This value specifies the upper limit of the output manipulated variable MV The output manipulated variable upper limit is used to suppress the output manipulated variable MV Example When the output manipulated variable MV upper limit is 80 the control output will be 80 even when the output manipulated variable MV reaches 100 18 Control Register 19 Output Manipulated Variable Lower Limit This value specifies the lower limit of the output manipulated variable MV Example When the output manipulated variable MV lower limit is 20 the control output will be 20 even when the output manipulated variable MV is 0 6 50 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 19 Control Registe
174. mum value is used as the upper limit of the set point SP When input type is voltage current configure the maximum value of input CHO as the linear conversion maximum value Any value within the valid input range can be configured Set Point SP Lower Limit Linear Conversion Minimum Value When input type is thermocouple or resistance thermometer the linear conversion is disabled The linear conversion minimum value is used as the lower limit of the set point SP When input type is voltage current configure the minimum value of input CHO as the linear conversion minimum value Any value within the valid range can be configured FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 25 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 6 Control Register 65 Alarm 1 Type Control Register 66 Alarm 2 Type Control Register 67 Alarm 3 Type Control Register 68 Alarm 4 Type Control Register 69 Alarm 5 Type Control Register 70 Alarm 6 Type Control Register 71 Alarm 7 Type Control Register 72 Alarm 8 Type Select one of the alarm types from upper limit alarm lower limit alarm upper lower limits alarm upper lower limit range alarm process high alarm process low alarm upper limit alarm with standby lower limit alarm with standby upper lower limits alarm with standby and no alarm action The same alarm type can be selected in multiple alarms Alarm Actio
175. n all four PID modules Control Mode Occupied Data Register CHO CH1 Word PID Module Total The configurations shown in the example 3 and 4 are possible because the total number of occupied data registers is less than 2000 Module Type Type No Example 3 Program control mode is selected in three PID modules Control Mode Occupied Module Type Data Register FC5A F2MR2 FC5A F2M2_ Program control mode Program control mode PID Module EC5A F2MR2 FC5A F2M2 FC5SA F2MR2 FC5A F2M2 FCSA F2MR2 FC5A F2M2 Total 1960 5 2 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Example 4 Program control mode is selected in two PID modules Control Mode Occupied Data Register CHO CH1 Word Module Type FC5A F2MR2 FC5A F2M2_ Program control mode Fixed value control mode PID Module EC5A F2MR2 FC5A F2M2 FC5A F2MR2 FC5A F2M2 FC5A F2MR2 FC5A F2M2 Total 1560 Control Relay The PID module occupies a maximum of 32 internal relays minimum 8 internal relays per module The occupied number of internal relays varies between the fixed value control mode and program control mode When both CHO and CH1 are in fixed value control mode 8 internal relays are occupied When either CHO or CH1 is in program control mode 32 internal relays are occupied Internal Relay Allocation When both CHO and CH1 are in fix
176. n the program control will start from this point FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 41 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR PV Start Action Process variable PV is 170 C Step Number Set Point SP 170 C 150 C 100 C 50 C E Time lt gt 180 60 min mun When the program control is started the time will be advanced shown in dotted line to the start of step 4 falling gradient step and then the program control starts from this point 1 Program Control Run 1 In the above program pattern if the set point SP of step 4 is 0 C and the step time of step 4 is 0 minutes falling gradient step does not exist the time will be advanced to the end of Step 3 and the program control will be terminated PVR Start Action Process variable PV is 25 C Step Number UI 4 J 09 1 l Set Point SP 150 C Time When the program control is repeated the time will be advanced until the set point SP becomes equal to 60 C of the process variable PV and then the program control starts from this point When the program control is started the time will be advanced shown in dotted line until the set point SP becomes equal to 25 C of the process variable and then the program control starts from this point Program Control Run Program control is repeated The process variable
177. nce previous step are executed simultaneously they are executed as The program hold is canceled and the follows program control is started from 40 minutes 1 Program Hold of remaining time The program control is held at 20 minutes of remaining time 2 Advance Next Step The program hold is canceled and the program control is proceeded to the start of step 2 3 Advance Previous Step The program control is moved back to the start of step 1 The control is enabled and the program control is started As a result only the execution of the advance previous step is The program control is held and the resulted in fixed value control is performed with the parameters of step 9 If the program hold and advance previous step are executed simultaneously they are executed as follows 1 Program Hold The program control is held at 30 minutes Note of remaining time 2 Advance Previous Step The program control is proceeded to the start of step 1 while the program hold is maintained Note If minute is selected as the step time unit the remaining time is handled with the unit of minute If the remaining time is between 29 minutes 1 second and 30 minutes 0 second the remaining time will be 30 minutes FC5A MicroSmart PID Module User s Manual FC9Y B1283 5 15 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE 5 16 Example 6 Hold Program Control when Prog
178. nd CH1 are used for the corresponding output CHO parameters are used for all other parameters such as the output manipulated variable rate of change output on off hysteresis and manual mode output manipulated variable Input Parameters Control Parameters Output Parameters CHO zech Input CHO ch CHO F Both outputs m CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Output Parameters CH1 Leen Input CH1 CH1 Type J thermocouple Celsius Voltage Output 4 Control Register 134 Output CH1 Function Output CH1 is always selected as Output CH1 Function The output of the CH1 control is outputted from output CH1 Output CHO Function has priority Input cco Input CHO E canal pacemetsis Output CHO E Output Parameters CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output ETET Dink egeier Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Input CHI e Mperien CH1 FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 23 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR PID
179. ning AT is performed r000i When the process variable PV is out of the range between 194 5 C and 205 5 C D1010 7 Alarm 1 output 01010 07 is turned on which turns QO on Notes e The temperature at which Auto tuning AT is performed is determined by the set point SP and AT bias In the above example auto tuning AT will be performed when the process variable PV reaches 180 0 C e When upper lower limits alarm with standby is selected as the alarm type the alarm is not activated until the process variable PV enters the alarm output OFF range 194 5 C to 205 5 C Once the process variable PV enters the alarm output OFF range the standby is cancelled and the alarm is activated e The ladder program should be customized depending on actual applications 7 18 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPLICATION EXAMPLES 7 User Program Download From the WindLDR menu bar select Online gt Transfer gt Download to open Download dialog box Click the check box on the left of Write PID Module parameters after download and click OK button The user program will be downloaded to the CPU module After downloading the user program the PID module parameters will be written to the data registers in the CPU module and the PID module connected to the CPU module Transfer Mode Binary ASCII Download Options A
180. ns Upper Limit Alarm Lower Limit Alarm Alarm Hysteresis Alarm Hysteresis OFF e 7 Alarm Value SP Alarm Value Alarm Value SP Alarm Value Setting Example Setting Example Set Point SP 200 C Set Point SP 200 C Alarm 1 Value 1500 Alarm 1 Value 5 C Alarm 1 Hysteresis 2 0 C Alarm 1 Hysteresis 2 0 C Alarm Action Alarm Action 205 C S Process Variable PV Alarm Output ON Process Variable PV S 195 C Alarm Output ON Process Variable PV S 203 C Alarm Output OFF 197 C SProcess Variable PV Alarm Output OFF OFF 200 203 C 205 C 195 c 197 C 200 C Alarm Value SP Alarm Value Alarm Value SP Alarm Value Setting Example Setting Example Set Point SP 200 C Set Point SP 200 C Alarm 1 Value 5 C Alarm 1 Value 1500 Alarm 1 Hysteresis 2 0 C Alarm 1 Hysteresis 2 0 C Alarm Action Alarm Action 205 C S Process Variable PV or 195 C Process Variable PV lt 205 C Alarm Process Variable PV lt 195 C Alarm Output ON Output ON O 197 C lt Process Variable PV S203 C Alarm 207 C S Process Variable PV or Output OFF Process Variable PV S 193 C Alarm Output OFF 195 C 197 C 200 C 203 C 205 C 193 C 195 C 200 C 205 C 207 C 6 26 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR Process High Alarm Proc
181. ntrol Register 68 Control Register 69 Control Register 70 Control Register 71 Control Register 7 2 Alarm 1 Type Alarm 2 Type Alarm 3 Type Alarm 4 Type Alarm 5 Type Alarm 6 Type Alarm 7 Type Alarm 8 Type Select one of the alarm types from process high alarm process low alarm and no alarm action The same alarm type can be selected in multiple alarms Alarm Actions Process High Alarm Process Low Alarm Alarm Hysteresis Alarm Hysteresis ON OFF Alarm Value Setting Example Alarm 1 Value 205 Alarm 1 Hysteresis 2 0 Alarm Action 205 lt Process Variable PV Alarm Output ON Process Variable PV S 203 Alarm Output OFF 2 0 8 Control Register 37 Alarm 1 Value Control Register 38 Alarm 2 Value Control Register 39 Alarm 3 Value Control Register 40 Alarm 4 Value 6 32 Control Register 41 Control Register 42 Control Register 43 Control Register 44 Alarm 5 Value Alarm 6 Value Alarm 7 Value Alarm 8 Value ON OFF Alarm Value Setting Example Alarm 1 Value 195 Alarm 1 Hysteresis 2 0 Alarm Action Process Variable PV S 195 Alarm Output ON 197 lt Process Variable PV Alarm Output OFF 2 0 ee Alarm Type Alarm Value Alarm Action Process Alarm Process high alarm l The alarm output turns on if the The alarm action point is able PV a e anaue process variable PV exceeds l the alarm value Process low alarm FC5A MicroSmart PID Module Use
182. o tuning AT for the master CH1 4 Turn off the CH1 control enable bit of the operation parameter to disable the CH1 control 5 Store the original values in the external SP input linear conversion maximum and minimum values 6 Turn on the CH1 control enable bit and CH1 auto tuning AT auto reset bit of the operation parame ter to enable the CH1 control and start the auto tuning AT for the master CH1 When auto tuning AT is completed P D and ARW values of the master CH1 will be automati cally configured Notes e When using the cascade control store the same set point of the master CH1 to the set point SP of the slave CHO e The output manipulated variable MV 0 to 100 of the master CH1 corresponds to the set point SP of the slave CHO The range of the set point is the external SP input linear conversion minimum value to the external SP input linear conversion maximum value e Depending on each control target optimum values of P D and ARW may not be calculated with the auto tuning AT In such case configure those parameters manually based on the P I D and ARW values calculated with the auto tuning AT Program Example of Auto tuning AT for Cascade Control A sample ladder program to execute the auto tuning AT for the master CH1 and slave CHO in the cascade control is described in the following page 4 16 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax
183. oO 6 min Step Time J a a Program Control Status gt Saved Point o l i i Elapsed Time l i from Program Control Start l 0 min 6 min f min 18 min IR ii 30min 34 min 10 min 24min 28min For example if the power to the PID module is turned off in 7 minutes after the program control is started at step 0 the PID module resumes the program control at the status 1 when the power is restored If the power to the PID module is turned off in 4 minutes after the program control enters step 1 the PID module resumes the program control at the status 2 when the power is restored If the power to the PID module is turned off in 2 minutes after the program control enters step 2 the PID module resumes the program control at the status 3 which is the start of step 2 when the power is restored To restart the program control from the start of step 0 turn off and on the program control bit operation parameter Bit3 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com PID MODULE MAIN FUNCTIONS Program Pattern Example The set point SP configured for each step is handled as the set point SP at the end of the step The time configured for each step is the process time of each step Program Pattern StepNow 0 1 2 3 k fe e em Feocesseecesessesdesedeee9 Set Point SP EE
184. ol The output manipulated variable MV of the master CH1 control becomes the set point SP of the slave CHO control and the control result of CHO is outputted from the CHO output The output manipulated variable MV 0 to 100 of the master CH1 control is corresponded to the set point SP of the slave CHO according to the external SP input linear conversion minimum and maximum values For example when the external SP input linear conversion minimum value is 100 C and the maximum value is 400 C the output manipulated variable MV 0 to 100 of the master CH1 control is converted as follows 0 is converted to 100 C 50 is converted to 250 C and 100 is converted to 400 C When a system using the cascade control is designed it is required that the slave CHO control have smaller delay time and faster response comparing to the master CH1 control Example The cascade control is used for an application in which the heat quantity of a heater is controlled using a power controller in order to control the temperature of the control target as shown in the figure below It is also possible to utilize the heating cooling control to prevent a rapid temperature rise of the control target by using a fan as the cooling output PID Module with Cascade Control Master Primary Control CH1 Input Control Target PID S E CH1 Output System Configuration and Wiring Wiring Example of the FC5A F2M2 Current Output Typ
185. ontrol bit Monitor D1009 3 Program hold bit D1022 4 Advance next step bit D1022 6 Advance previous step bit D1022 7 Program end output D1010 6 oes 30 min 5 min 30sec 15sec 45min l 20 min E l I l ON l l OFF i I l 1 HAE l hia liq Per ii Ge l l SG l lga Bi iy OFF 1 ott Lt i l l E ll l K l ey ON l l OFF l l i 3 ON i WK i OFF l i i i E S ia 4 ON d 2 l S IEE ll OFF 5E i i i i The program control is started The program control is held at the from the start of Step 1 40 minutes of remaining time The program control is proceeded to the start of step 1 while the program hold is maintained The program control is proceeded to the start of step 2 while the program hold is maintained The program hold is canceled and the program control is started from the start of step 2 Note The PID module executes all steps 0 to 9 even if the step times of steps are zero When the program control is terminated nine is stored in the current step number of block 0 FC5A MicroSmart PID Module User s Manual FC9Y B1283 5 11 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE 9 12 Example 2 Continue Program Control Repea
186. ontrol is stopped Ca When CH1 alarm 1 is triggered Q2 is turned on D1019 07 Qo002 De pioisHLc lt Ww O While external input I5 is on auto tuning AT is o D1014 5 10005 p1025 01 performed in each step of the program control as follows e Step 0 When the remaining time is 5 minutes e Step 1 When step 1 is started e Step 2 When the remaining time is 5 minutes e Step 3 When step 3 is started DC D1015H Les W 2 D1014 5 When CH1 program control is completed Q3 is D1019 06 90003 turned on Notes e The ladder program should be customized depending on actual applications e Perform the auto tuning AT near the set point SP If auto tuning AT is performed near the ambient temperature temperature fluctuation cannot be given to the process In such case the auto tuning AT may not finish normally e Once auto tuning AT is performed it is unnecessary to perform auto tuning AT again as long as the process is unchanged FC5A MicroSmart PID Module User s Manual FC9Y B1283 7 13 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPLICATION EXAMPLES 9 User Program Download From the WindLDR menu bar select Online gt Transfer gt Download to open Download dialog box Click the check box on the left of Write PID Module parameters after download and click OK button The user program will be downloaded to the CPU module After downloading the user program the PID
187. processing instructions clock instructions computer link communication modem communication Modbus TCP communication expansion RS232C RS485 communication modules and AS Interface master modules Describes FC5A Slim Type Web Server CPU Module specifications and functions Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Vi FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION c0scececceccncnecnecusnesnecesnecuenusnecnecuenecnensesesuesaesessesaeausnensensess 1 1 About the Gi Ree 1 1 Quantity of Applicable PID modules E 1 1 Applicable CPU and WindLDR version EE 1 2 Confirming System Program Version 1 2 CHAPTER 2 MODULE SPECIFICATIONS 0c0scsccersrceccnsansnncnsansnncasanrensascarsnsosensanccccnsancuscnsancneaanas 2 1 PP MO EE 2 1 EE 2 3 Bie E 2 6 CHAPTER 3 INSTALLATION AND WIRING scceccecnccnecusnecnecnsnecnecusnecnecusnnsuecunsennesansesnesansesnecaenenss 3 1 Mounting Hole Layout for Direct Mounting on Panel Surface ccccecccceeeeeeeeeeeseeeeeseeeeesaeeseeseeeeeaaeeeeseeees 3 1 E de lt E ele E e EE 3 3 TERMINal AMAR GEMEN EE 3 4 Type Of OC ON rset acceptor Sign ec erence GNA ge ie NE ce easels ce EEEE EEEE 3 5 Power SUD DIY for FMD Ree OU 3 6 CHAPTER 4 PID MODULE MAIN FUNCTIONS cscccceccscnecnccnnsecnecaecnsnecnsnneaecnnsa
188. program Detail Program Information Program Size 1142 bytes Comment Size 0 bytes Total 1142 bytes Communication Settings Cancel Click the check box on the left of Write PID Module parameters after download and click OK button The user program will be downloaded After downloading the user program the PID module parameters will be automatically written to the data registers in the CPU module and the PID module connected to the CPU module Note The CPU module and the connected PID module exchange data through the allocated data registers in the CPU module In order for the CPU module to communicate with the PID Module it is required that the user program be downloaded to the CPU module after configuring the PID Module in the Expansion Modules Configuration dialog box In order for the PID module to operate it is required that the parameters be written to the data registers in the CPU module and the PID module FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR Writing and Reading Parameters When Write All Parameters or Read All Parameters is executed in the PID Module Configuration dialog box all parameters will be written to read from the PID module as follows WindLDR T gt Flow of the parameters when executing Write All Parameters I
189. r s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 9 Control Register 73 Alarm 1 Hysteresis Control Register 74 Alarm 2 Hysteresis Control Register 75 Alarm 3 Hysteresis Control Register 76 Alarm 4 Hysteresis Control Register 77 Alarm 5 Hysteresis Control Register 78 Alarm 6 Hysteresis Control Register 79 Alarm 7 Hysteresis Control Register 80 Alarm 8 Hysteresis When an alarm turns from on to off and vice versa the span between on and off is called alarm hysteresis If the alarm hysteresis is narrowed the alarm output switches to on or off even by a slight variation of temperature at around the alarm action point This frequent on off of an alarm may negatively affect the connected equipment To prevent that harmful effect configure the alarm hysteresis for alarm on off action 10 Control Register 81 Alarm 1 Action Delay Time Control Register 82 Alarm 2 Action Delay Time Control Register 83 Alarm 3 Action Delay Time Control Register 84 Alarm 4 Action Delay Time Control Register 85 Alarm 5 Action Delay Time Control Register 86 Alarm 6 Action Delay Time Control Register 87 Alarm 7 Action Delay Time Control Register 88 Alarm 8 Action Delay Time The alarm is not triggered until the configured time elapses after the process variable PV enters the alarm output range The input fluctuation due to noise may result in alarm outpu
190. r s Manual FC9Y B1283 5 13 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Example 4 Hold Program Control when Program Ends The following diagram shows an example of the program control when hold program control is selected as the program end action Time of steps Step 0 and 1 60 minutes Step 2 30 minutes Steps 3 to 9 0 minute In this example D1000 is allocated to the control register and M500 is allocated to control relay Current step number po fr fz e D1006 e CC l Kaf Control enable bit 7 D1022 0 OFF Program control bit i D1022 3 OFF Program control bit ON Monitor i D1009 3 OFF Program hold bit a i D1022 4 OFF Advance next step bit SR l D1022 6 OFF 4 ON Advance previous step bit D1022 7 OFF Program end output SR D1010 6 OFF i After all steps are executed the program While the program hold is maintained at the control is held and the fixed value control end of the program control the program hold bit is performed with the parameters of step 9 and advance previous step bit have no effect The program hold is canceled by executing advance next step and the program control is started from the start of step 0 After all steps are executed the program control is held and the fixed value control is performed with the parameters of step 9 The program control is started from the
191. r Remaining Repeat Number O to 10000 0 Fixed value Operating Status See 5 9 for detail about the operating status mometer When input is voltage or current input See 5 8 for detail about the operation parameter When input is normal Current Process Variable PV Value within the control range see 9 4 When input is invalid Unknown value Current Output Manipulated Output manipulated variable lower limit to Variable MV upper limit Set point SP lower limit to set point SP Linear conversion min to linear conversion max Current Step Remaining Time 0 to 6000 minutes seconds Operation Parameter Monitor D d r D 10 1 2 3 4 5 6 7 8 9 11 12 13 monitor When input is thermocouple or resistance ther Current Set Point SP upper limit CHO CH1 max Current Step Remaining Time 0 to 6000 minutes seconds 14 15 16 17 Current Step Number Remaining Repeat Number O to 10000 0 Fixed value See 5 8 for detail about the operation parameter monitor Operating Status See 5 9 for detail about the operating status 18 Operation Parameter Monitor 19 FC5A MicroSmart PID Module User s Manual FC9Y B1283 5 7 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Operation Parameter Monitor Operation Parameter Monitor 1 word Parameter Status Description BitO Control Enable B
192. r the time for the process variable PV to reach the set point SP is shortened however overshoot can occur e If the derivative time is extended the derivative action becomes strong The response to the rapid temperature change becomes faster Because the action to suppress the rapid temperature rises becomes strong the time for the process variable PV to reach the set point SP is extended however overshoot can be decreased The offset caused by the PD control action can be corrected by configuring the reset value The reset value can be automatically calculated by the auto reset function PID Control Action Proportional Integral Derivative Action P action suppresses the overshoot and the hunting action corrects the offset and D action corrects rapid temperature change due to disturbance in shorter time Thus using PID control action optimal temperature control can be performed The proportional band integral time derivative time and ARW can be automatically calculated by the auto tuning AT Temperature Set Point SP D lt x j Disturbance Time FC5A MicroSmart PID Module User s Manual FC9Y B1283 4 5 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com PID MODULE MAIN FUNCTIONS Auto Tuning AT Auto Reset The optimal temperature control parameters differ depending on the characteristics of the process to control For PID control action the proportional band int
193. r 199 Cooling Proportional Band The cooling proportional band can be configured when the heating cooling control is enabled The cooling proportional band is the multiplication of the heating proportional band Example When the heating proportional band is 10 C and the cooling proportional band is 2 0 the cooling proportional band will be 20 C If cooling proportional band value is 0 5 the cooling proportional band will be 5 C If the cooling proportional band is 0 the cooling side control will be ON OFF control action If the heating proportional band is 0 both heating and cooling side controls will be ON OFF control action 20 Control Register 200 Overlap Dead Band The overlap dead band of the heating and cooling outputs can be configured when heating cooling control is enabled When the configured value is bigger than 0 the value is used as the dead band When the configured value is less than 0 the value is used as overlap band When the overlap band is configured the area in which both heating and cooling control outputs are turned on is generated and the energy loss is caused However the overlap helps enhance the control accuracy and accelerate the response When the dead band is configured the area in which neither heating nor cooling control outputs are turned on is generated In the dead band the control accuracy and responsiveness is lowered however the energy loss can be suppressed Output manipulated variable M
194. ram Ends The following diagram shows an example of the program control when hold program control is selected as the program end action Time of steps Step 0 and 1 60 minutes Step 2 30 minutes Steps 3 to 9 0 minute In this example D1000 is allocated to the control register and M500 is allocated to control relay Current step number D1006 Control enable bit D1022 0 Program control bit D1022 3 Program control bit Monitor D1009 3 l Program hold bit i D1022 4 OFF l Advance next step bit ON D1022 6 OFF l l Advance previous step bit ON D1022 7 OFF 1 I Program end output D1010 6 OFE l The program control is held at the ten minutes of remaining time and the fixed value control is performed with the current parameters The program control is proceeded to the start of step 3 and the fixed value control is performed with the parameters of step 3 After all steps are executed the program control is held and the fixed value control The fixed value control is performed is performed with the parameters of step 9 with the parameters of step 9 The program hold is canceled and the program control is started from the start of Step 0 Notes e The PID module executes all steps 0 to 9 even if the times of steps are zero When the program control is terminated nine is stored in the current step number of block 0 e When hold program contro
195. rameters Offset from the Control Register Parameter Default Value Set Point SP 0 C 0 Manual Mode Output Manipulated Variable 0 0 Operation Parameter 1 ee 4 For details about the operation parameter see page 5 10 Blocks 2 3 Basic Parameters Offset from CHO 103 104 105 106 103 Proportional Term Proportional band 10 C 10 104 Integral Time L sec 200 gt 105 Derivative Time SO ec 50 106 ARW Anti ResetWindup J p 50 _ S FC5A F2MR2 Relay output 30 sec 30 30 107 Control Period FC5A F2M2 Non contact voltage output 3 sec 3 31 32 Set Point SP Rise Rate 0 C minute 0 g S E 45 122 Reseved ID Cooling Proportional Band CHO only e k times 10 CHO FCS5SA F2MR2 Relay output 30 sec 30 49 126 Cooling Control Period CHO only FCSA F2M2 Non contact voltage output 3 sec 3 26 27 28 29 CA oO CH1 0 CHO 0 0 C 0 CH1 0 Overlap Dead Band CHO only S cH Limit CHO only CH1 0 SEN Limit CHO only CH1 0 FC5A MicroSmart PID Module User s Manual FC9Y B1283 9 9 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPENDIX Blocks 4 5 Initial Setting Parameters Offset from pee Parameter Default Value Control Action 0 Reverse action Heating Heating Cooling Control CHO only a 7 Disable External SP Input CHO only ay Disable Input Function CHO CH1
196. roSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INSTALLATION AND WIRING 3 2 Example Mounting hole layout for FC5A C24R2 and four PID modules All dimensions in mm FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INSTALLATION AND WIRING Terminal Connection h Ca ution e Make sure that the operating conditions and environments are within the specified values e Be sure to connect the grounding wire to a proper ground otherwise electrical shocks may be caused e Do not touch live terminals otherwise electrical shocks may be caused e Do not touch terminals immediately after power is turned off otherwise electrical shocks may be caused e When using ferrules insert a wire to the bottom of the ferrule and crimp the ferrule e When connecting a stranded wire or two solid wires to single pole terminal block be sure to use a ferrule Otherwise the wire may slip off the terminal block Ferrule for Terminal block To cramp the following ferrules use the specified crimping tool CRIMPFOX ZA 3 For 1 cable connection For 2 cable connection 6 0mm 8 0mm 7 0mm 8 0mm D For 1 cable connection Phoenix Type Al 1 8 RD Al 0 5 8 WH Cable Size UL1007AWG18 UL1015AW G22 For 2 cable connection Phoenix Type Pho
197. rol target can be automatically calculated using auto tuning AT function It is unnecessary to configure the derivative time in the WindLDR when using the auto tuning AT function 7 Control Register 186 ARW Anti Reset Windup When the control is started there is a large deviation between the set point SP and the process variable PV The integral action continues its action in a given direction until the process variable PV reaches the set point SP As a result an overshoot is caused by the excessive integral action ARW suppresses the overshoot by limiting the integral action area When ARW is 0 the integral action area becomes the minimum and the suppression of the overshoot is maximized When ARW is 50 the integral action area becomes the intermediate and the suppression of the overshoot is intermediate When ARW is 100 the integral action area becomes the maximum and the suppression of the overshoot is minimized An appropriate ARW for the control target can be automatically calculated using auto tuning AT function It is unnecessary to configure the ARW in the WindLDR when using the auto tuning AT function FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 49 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR 8 Control Register 187 Output Manipulated Variable Rate of Change The maximum change of the output manipulated variable in 1
198. roportion to the deviation between the set point SP and the process variable PV When the heating cooling control is enabled this parameter becomes the heating proportional band The control action will be ON OFF control when the proportional band proportional gain is 0 If the proportional band is broadened proportional gain is made smaller the control output starts turning on or off at the significantly low temperatures from the set point SP overshoot or hunting is reduced however it takes time for the process variable PV to reach the set point SP and the offset between the process variable PV and the set point SP is broadened If the proportional band is narrowed proportional gain is made larger the control output starts turning on or off at around the set point SP the time until the process variable PV reaches the set point SP is shortened and the offset is small however the hunting phenomenon is frequent If the proportional band is greatly narrowed the control action becomes similar to the ON OFF control action An appropriate proportional band proportional gain for the control target can be automatically calculated using auto tuning AT function It is unnecessary to configure the proportional band proportional gain in the WindLDR when using the auto tuning AT function 7 Control Register 27 Integral Time In the proportional control action the offset is generated even when the control is stabilized The int
199. rtional band is the multiplication of heating When output type is relay or voltage Output Manipulated Variable Output manipulated variable lower limit to 100 46 123 ae Upper Limit When output type is current Cooling Proportional Band nen proportional band Cooling Control Period 49 CHO only 1 to 120 sec When input range unit is Celsius 200 0 to 200 0 C 50 127 Overlap Dead Band When input range unit is Fahrenheit CHO only 200 0 to 200 0 F When input is voltage or current input 2000 to 2000 When output type is relay or voltage Cooling output manipulated variable lower limit to 100 When output type is current Cooling output manipulated variable lower limit to 105 When output type is relay or voltage 0 to cooling output manipulated variable upper limit When output type is current 5 to cooling output manipulated variable upper limit Cooling Output Manipulated 51 128 Variable Upper Limit CHO only Cooling Output Manipulated 52 129 Variable Lower Limit CHO only Valid Range for Alarm 1 to Alarm 8 Settings Alarm Type Upper Limit Alarm Lower Limit Alarm Upper Lower Limits Alarm Upper Lower Limit Range Alarm Full scale to full scale 1 Full scale to full scale 1 1 When input is voltage current full scale is the linear conversion span 2 When input is voltage current the valid range is the linear conversion minimum value to linear conversion maximum value 5 1
200. s Celsius 0 1 to 100 0 C Coaling eu one When input range unit is Fahrenheit 98 175 Hysteresis 0 1 to 100 0 F CHO only dee When input is voltage or current input 1 to 1000 9 Output Type 0 Non contact voltage output for SSR drive 176 FC5A F2M2 only 1 Current output RAN EE 20 of the external SP input linear conversion span CH1 only R W R W External SP Input Linear External SP input Linear conversion min to input range 101 178 Conversion Maximum Value en p g upper limit CH1 only AEE pU nar Input range lower limit to external SP input linear conversion 102 179 Conversion Minimum Value d s g p CH1 only 5 20 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Input Range Input Type and Range Unit Range OOh Type K Thermocouple 200 to 1370 C 01h Type K Thermocouple with Decimal Point 200 0 to 400 0 C 02h Type J Thermocouple 200 to 1000 C Celsius l 03h 04h 05h 06h 07h 08h 09h OAh OBh OCh ODh OEh JPt100 200 to 500 C OFh_ Type K Thermocouple 328 to 2498 F O to 2315 C 10h Type K Thermocouple with Decimal Point 328 0 to 752 0 F 200 0 to 850 0 C 200 0 to 500 0 C 200 to 850 C 11h 12h 13h 14h 15h 16h Fahrenheit 17h 18h 19h 1Ah 1Bh JPt100 with Decimal Point 1Ch 1Dh IER 4to20MmADC 2000to
201. s a master primary control and CHO as a slave Secondary control to control one process The output manipulated variable MV calculated according to the process variable PV and the set point SP of the master CH1 is used as the set point SP of the slave CHO for control The control results will be outputted from the output CHO When it is difficult to control the target process with heating control only cooling control can be added to perform the heating cooling control Cooling 0 0 to 10 0 times Cooling proportional band is the proportional band product of this value and the heating proportional band The cooling control becomes ON OFF control when the cooling proportional band is 0 Integral time l O to 10000 seconds Derivative time D 0 to 10000 seconds period When input is thermocouple RTD 200 0 to 200 0 C F band When input is voltage current 2000 to 2000 ON OFF hysteresis When input is voltage current input 1 to 1000 Cooling output When output type is voltage manipulated Upper limit Cooling output manipulated variable lower variable MV limit to 100 upper limit Lower limit 0 to cooling output manipulated variable lower limit upper limit When output type is current Upper limit Cooling output manipulated variable lower limit to 105 Lower limit 5 to cooling output manipulated variable upper limit Cooling method Air cooling Linear characteristic Oil cooling 1 5th power of the linear charac
202. saesnenanaesaenansnsaess 4 1 Temperature Control Using the PID Bel 4 1 Fixed Value Control ne ee 4 3 Auto Tuning K N RER 4 6 Programi OVO EE 4 9 Pr tM ONAN EEO EE 4 14 Difference Input ONO EE 4 14 Cacade ONION EE 4 15 CHAPTER 5 DEVICE ALLOCATION OF PID MODULE csceccscsecnecnccusnecnecusencnecuenesnenansesnesansansess 5 1 Device Allocation of PID Module 5 1 HAEE EEE E 5 2 Elle ee 5 2 EE GO SN ae cect EE EAA A EA A AEEA EREE E AA A 5 2 CONTO RSE E 5 3 Data Register Allocation Block 0 Read Only Parameters cccccccseccceeseeceeeeecseseesseeecseeeseseessaesessaaees 5 7 Data Register Allocation Block 1 Write Only Parameter 5 10 Data Register Allocation Blocks 2 3 Basic Parameters SHOT Action cccceccceeeeeseeeeeeaeeeeeseeeesaeees 5 17 Data Register Allocation Blocks 4 5 Initial Setting Parameters SHOT Action ccccccecceeseeeeeeeeeeeeees 5 19 Data Register Allocation Blocks 10 19 CHO Program Parameters SHOT Achon 5 22 Data Register Allocation Blocks 30 39 CH1 Program Parameters SHOT Achon 5 24 CHAPTER 6 CONFIGURING PID MODULE USING WINDLDR c1cecceccncnsenecnecsnnesnenensesnecaensssess 6 7 Procedure to configure the PID module EE 6 1 Expansion Modules Configuration Dialog Box 6 6 PID Module Configuration Dialog BOX EE 6 7 PID Module Configuration Input Parameters List CHO and CH 6 8 PID Module Configuration Control Parameters List CHO and CH 6 13 PID Modul
203. scale or 1 C 2 F whichever is Thermometer greater Voltage Current 0 2 of full scale S Maximum Error at 25 C Thermocouple 0 7 of full scale However R S input 0 to 200 C 0 to 400 F 6 C 12 F B input O to 300 C 0 to 600 F Accuracy is Input Accuracy at 0 to 55 C not guaranteed K J E T N inputs Less than 0 C 32 F 0 9 of full scale Resistance 0 GE of full scale Thermometer Voltage Current 0 ee e of full scale Data Accuracy Maximum error at 25 C Minimum digital resolution of each input range Cold Junction Temperature 1 C at 0 to 55 C Compensation Accuracy Sampling Period Output Specifications Type No FC5A F2MR2 FC5A F2M2 Relay output 1a Non contact voltage for SSR drive Rated load 12V DC 15 5A 250V AC resistive load Current Control Output 5A 30V DC resistive load 4 to 20mA DC 3A 250V AC inductive load cos 0 4 Program Control Specifications Type No FC5A F2MR2 FC5A F2M2 Time Setting Accuracy 0 5 of setting time After Power is Restored Write Limit 2 4 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Insulation Dielectric Strength Insulation Dielectric Strength Type No o FC5A F2MR2 FC5A F2M2 Dielectric Strength Other Type No FC5A F2MR2 Power Consumption Module Power 5V DC Consumption Interior 24V DC Ambient Temper
204. set Perform Cancel bit cannot perform D1022 1 is turned off to on while Control is disable If auto tuning AT is cancelled while When auto tuning AT is completed it is performed the P D and ARW The P I D and ARW values values will be reverted to the original will be updated values at the time that auto tuning e Auto tuning AT Auto reset AT was started Perform Cancel bit D1022 1 will be automatically turned off Notes e Auto tuning AT Auto reset bit is automatically turned off when Auto tuning AT Auto reset is completed e If Auto tuning AT Auto reset bit is kept on Auto tuning AT Auto reset will be performed continuously Use SOTU and SET instructions to turn on Auto tuning AT Auto reset bit so that auto tuning AT auto reset is performed only once e If auto tuning AT is cancelled while it is performed P I D and ARW values will be reverted to the original values at the time that auto tuning AT was started e Auto reset cannot be cancelled FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com PID MODULE MAIN FUNCTIONS Program Control The program control allows you to define the set point SP that changes as the time progresses so that the process variable PV can be controlled to match the set point SP changing as the time progresses The set point SP and time can be configured for each step
205. set point SP proportional band proportional gain or integral time are disabled Program Control Mode Reverse Control Action Heatin kb gt Ea Ea 5 Disable ea Proportional Band Terminate Program Control EI EEE E e 0 Fixed value control mode 1 Program control mode When the cascade control is selected as Input CH1 Function only the fixed value control mode can be selected for CHO control If program control is selected external SP input will not work 0 Reverse control action Heating R W 1 Direct control action Cooling 6 13 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR l 0 Disable 3 54 EN Heating Cooling Control 1 Enable When input is thermocouple resistance thermometer 20 23 Set Point SP Set point SP lower limit to set point SP upper limit When input is voltage current Linear conversion min to linear conversion max 0 Proportional band 94 171 Proportional Term 1 Proportional gain Proportional band When input range unit is Celsius 0 to 10000 C Range with a decimal point 0 0 to 1000 0 C When input range unit is Fahrenheit O to 10000 F Range with a decimal point 0 0 to 1000 0 F When input is voltage current 0 0 to 1000 0 Proportional gain 0 00 to 100 00 lt S Proportional Band 6 Ken HES Proportional Gain 104 Integral Time 0 to
206. ster is maintained If the power is failed and restored while the PID module performs the program control the PID module starts its operation in accordance with the original PID module status before the power failure as shown in the table below 4 2 ECK PID Module Status before the Power Failure Program End ie Standby FIRSTS FEM Program Control is Program Control is Action Control is Status 1 suspended Hold Terminated Performing Terminate Program Control Continue Program Control Repeat Standby status is maintained The program control is started from the Step 0 The program The program hold is control is canceled and the continued program control is ker continued 2 3 The program hold is maintained Fixed value control is performed with the set point SP at the time that the power is turned off Hold Program Control The PID module is in standby status when the control enable bit is on but the program control bit is off While in standby status the PID module performs no control While the program control is running the PID module saves the program control status every 6 minutes after the program control is started after the program control bit is turned on The program control status is also saved at the start of each step If the power to the PID module is turned off while the program control is running the PID module resumes the program control from the latest saved point
207. t when Program Ends The following diagram shows an example of the program control when continue program control repeat is selected as the program end action Time of steps Step 0 and 1 60 minutes Step 2 30 minutes Steps 3 to 9 0 minute Number of repeats 1 In this example D1000 is allocated to the control register and M500 is allocated to control relay Current step number ofr e o a fz D1006 l l l l Number of repeats remaining NN NEO D1007 l l l l l l l l Control enable bit E D1022 0 S l l l l ON Program control bit D1022 3 OFF i i l d Program control bit ON Monitor D1009 3 OFF ON Program hold bit D1022 4 OFF E Advance next step bit D1022 6 grt l l l Advance previous step bit ON l f D1022 7 OFF l ON Program end output D1010 6 Sek After the steps 0 to 2 are The program control is not executed the program control is moved back to step 2 even if repeated from the step 0 the advance previous step is executed in step 0 While the program hold is executed If the control is disabled after the program end output is turned when step 2 is terminated on the program hold bit has no effect the program end output does not turn on FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Example 3 Continue
208. t Alarm Upper Limit Alarm Upper Limit Alarm Upper Limit Alarm Upper Limit Alarm Write all parameters Read all parameters Monitor OK Cancel 1 Control Register 56 Input CHO Function The one of the following input functions can be selected as the Input CHO Function Input CHO Input CHO is used as the process variable PV for CHO control Input Parameters Control Parameters Output Parameters CHO gt Input CHO Dik CHO e Output CHO CHO Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Control Parameters Output Parameters CHI gt Input CHL CHI gt output CH1 Lag CHI Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Difference CH0 CH1 The difference between input CHO and input CH1 is used as the process variable PV for CHO control Process variable PV of CHO control Input CHO input value Input CH1 input value Input Parameters Control Parameters Output Parameters CHO Difference CHO CH1 fwi CHO Output CHO Sch CHO Type K thermocouple Celsius Reverse Control
209. t turning on This can be prevented by configuring the alarm delay time When an alarm output is changed from on to off status the alarm output turns off and the alarm action delay time is reset When the alarm output is changed from off to on status the time counting starts FC5A MicroSmart PID Module User s Manual FC9Y B1283 6 33 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR PID Module Configuration Control Parameters Details PID Module Configuration Slot 1 FCSAa F2M2 Input CHO iji i Input CH1 1 2 3 Reverse Control Action Heating 4 5 6 Proportional Band 7 8 9 10 11 12 13 14 15 16 i Fixed Value Control Mode B OF ProportionalBand je EE Lob Lob WE WW Oe ook been emm Am Agen Ee kemmer mm meeega sen tee Ee Control Parameters when Program Control Mode Is Selected Program Control Mode Reverse Control Action Heating Disable Proportional Band PY Start Terminate Program Control SSS GENEE E e Control parameters of CHO control are described here When the program control mode is selected as the control mode parameters for the fixed value control mode such as the set point SP proportional band proportional gain or integral time are disabled The parameters for the program control mode 23 to 27 are enabled Control parame
210. tascrentapsedavecahvententatcececs 5 10 reverse control action sssesssseeesssresserressrrrsserrsseerese 6 36 device allocation 5 1 alte oniran e 2 6 S bl WON tae seaeeunesvencucsconeee 5 11 Greg o Ser set point SP cccccsccsseseescssseeessceeseeeeseesee 5 5 5 7 5 11 6 37 EE EUR 5 18 6 39 ele In E 6 3 Sak ae lower mit 6 25 parts description EE 2 1 ame tinction 9 2 ege E E EE ane al l IS OT EE 5 18 6 39 i a a Ne Ger HMM eese 6 8 6 9 6 25 erte EE 6 6 Ee when program Control starte 6 45 BCCI a ee 2 3 ee aion standby EE 9 4 Se w 3 4 BEE 5 4 5 7 d op REENEN ji GP GAR ONE SEENEN Aa Eeer type NUMbeTrS ssessssssssnssseensseerssrersssrrrsserrsseereserresserese 1 1 T PID module cofiguration dialog DOX cseceeesseeeeeees 6 1 terminal process Variable DN 5 7 lge 3 4 program CONC CO EEN 4 9 6 35 7 8 CONE OI WE 3 3 SUE 4 10 5 11 ee 35 advance Drevlous 4 10 5 11 yP Pa A aa auto tuning AT veccersnensiencessapesncaneateaesdeneressenedatiecen 7 13 U maa E sas USF program download and leed number of repeats 5 21 V S a Ee Valid devilces cccccccscccescceescecescceessceeetsceescecetecestuecetseess 5 2 OWEN TANS cies ccshesinGactecauetarseacceesdnednewwioosusanteaiesdcewis 4 12 program end action 4 11 4 12 5 21 6 45 W cance ein lea a pe Te E 3 6 Pe Oe Gury EE fest Write only Darameters 5 11 9 9 ji FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 8
211. tched to the set point SP Example 1 Controlling the liquid level difference of 2 tanks The PID module measures the liquid levels of 2 tanks and controls output to keep liquid level difference between Tank A and Tank constant PID Module Input CH1 Input CHO Example 2 Cabinet Interior Dew Condensation Prevention The PID module measures interior and external temperatures of the cabinet and controls output to keep the temperature difference between interior and external cabinet constant so that dew condensation inside the cabinet can be prevented PID Module Output CHO Input CH1 Temperature external a Temperature Cabinet 4 14 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com PID MODULE MAIN FUNCTIONS Cascade Control The cascade control combines two PID controls to form one feedback loop to control a single target The cascade control is effective for applications in which the delay time or dead time is considerably large When delay time is large it takes a long time for the process variable PV to change after the output manipulated variable MV is changed By using the cascade control highly stable control can be realized for such applications though it takes time for the process variable PV to reach the set point SP CH1 control is used as the master and CHO control as the slave of the cascade contr
212. ted Output Manipulated Variable MV 80 Variable MV 60 Variable MV 50 Control Output OFF ON 4sec OFF ON 3 sec OFF ON 2 5sec OFF ON KEE OS EE 5 sec 5 sec 5 sec 3 Control Register 46 Output Manipulated Variable Upper Limit This value specifies the upper limit of the output manipulated variable MV The output manipulated variable upper limit is used to suppress the output manipulated variable MV Example When the output manipulated variable MV upper limit is 80 the control output will be 80 even when the output manipulated variable MV reaches 100 4 Control Register 47 Output Manipulated Variable Lower Limit This value specifies the lower limit of the output manipulated variable MV Example When the output manipulated variable MV lower limit is 20 the control output will be 20 even when the output manipulated variable MV is 0 5 Control Register 49 Cooling Control Period When the heating cooling control is enabled the cooling control period determines the duration of the ON OFF cycle of the cooling control output that is turned on and off according to the cooling output manipulated variable MV calculated by the PID control action 6 Control Register 51 Cooling Output Manipulated Variable Upper Limit This value specifies the upper limit of the cooling output manipulated variable MV The cooling output manipulated variable upper limit is used to suppress the cooling output manipulated
213. teristic or Water cooling 2nd power of the linear characteristic Cooling output CH1 output The input value of input CH1 is used as the set point SP of CHO control When the external SP input bias is configured it is added to the set point SP of CHO control The input types that can be selected are shown in the following table Input type Current 4 to 20mA or 0 to 20mA Voltage 1 to 5V or 0 to 1V Allowable input Current 50mA DC maximum Voltage 0 to 1V 5V DC maximum Voltage 1 to 5V 10V DC maximum Input impedance Current 500 Voltage 100kQ FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPENDIX During the program control running when a step is finished the program control does not proceed to the next step until the deviation between the process variable PV and set point SP becomes less than the wait value During the program control running when the program control is held the Program Hold progression of the program control is suspended While the program control is held the fixed value control is performed with the set point SP at the hold point During the program control running when the advance next step bit is turned on Advance Next Step the current step is terminated and the program control is proceeded to the next step During the program control running when the advance previous step bit
214. ters for CH1 control are the same as those of CHO control except cascade control parameters However the position from the control register for each parameter differs For details about the positions from the control register for CH1 control see pages 5 17 to 5 20 1 Control Register 90 Control Mode Either fixed value control mode or program control mode can be selected When the external SP input or the cascade control is selected in Input CH1 Function the program control mode cannot be used for CHO control Select fixed value control mode for control mode of CHO control If the program control mode is selected the external SP input does not function 6 34 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com CONFIGURING PID MODULE USING WINDLDR The fixed value control is a normal temperature control that the PID module controls the output to eliminate the deviation between a single set point SP and the process variable PV The following diagram shows an example of the fixed value control Temperature Set point SP gt Time The program control allows you to define the set point SP that changes as the time progresses so that the process variable PV can be controlled to match the set point SP changing as the time progresses The set point SP and time can be configured for each step A maximum of 10 steps can be configured and perform
215. ters for CHO control are described here Input parameters for CH1 control are the same as those of CHO control However the position from the control register for each parameter differs For details about the positions from the control register for CH1 control see 5 17 to 5 20 1 Control Register 58 Input Range Select input type and input range unit Celsius or Fahrenheit For details about the input range see 6 10 2 Control Register 62 PV Correction If the sensor cannot be installed to the location of the control target the temperature measured by the sensor may deviate from the actual temperature of the control target When a target is controlled with multiple PID modules the measured temperatures may not match due to the differences in sensor accuracy or dispersion of load capacities even though the set points SP of those PID modules are the same In such cases the process variable PV of the PID module can be adjusted to the desired temperature by using the PV Correction The process variable PV after the PV correction should be within the control range See 9 4 For example when type K thermocouple 200 to 1370 C is selected as input type configure an appropriate PV correction value so that the process variable PV after the PV correction does not exceed the control range 250 to 1420 C Input range lower limit 50 C to Input range upper limit 50 C When the process variable PV after the PV correction is with
216. the proportional band If the process variable PV exceeds the point A enters the proportional band the control output starts turn on off according to the control period and the manipulated variable MV If the process variable PV exceeds the set point SP the control output is completely turned off While the process variable PV rises from the point A to the set point SP the control output ON time decreases and the control output OFF time increases Compared to ON OFF control action there is no overshoot in P control action and hunting becomes less frequent however the offset is generated The P control action is suitable for processes such as gas pressure control or level control in which there is no dead time If the integral time and derivative time of the PID module parameter are set to 0 the control action becomes the P control action Offset Proportional Band Temperature Set Point SP Point A Time FC5A MicroSmart PID Module User s Manual FC9Y B1283 4 3 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com PID MODULE MAIN FUNCTIONS e If the proportional band is narrowed Proportional gain is made larger Because the control output starts turning on off at around the set point SP the time until the process variable PV reaches the set point SP is shortened and the offset is small however hunting is frequent If the proportional band is greatly narrow
217. this example D1000 is allocated to the control register and M500 is allocated to control relay The parameter can be changed with the following procedure 1 Turn on M500 Reading all parameters All PID module parameters are read out from the PID module and stored in the data registers of the CPU module 2 Turn off D1022 0 Control enable bit of CHO CHO control of the PID module will be disabled 3 Store 15 in D1063 PV filter time constant of CHO 4 Turn on M505 Block 4 writing 5 Turn on D1022 0 Control enable bit of CHO CHO of the PID module will be enabled Ladder Program Example 3rd Scan At the rising edge of M102 D1022 0 is turned on to enable CHO control M102 is turned off 2nd Scan At the falling edge of M101 M500 is turned off Movil S1 Di 15 D1063 15 is stored in D1063 PV filter time constant of CHO M505 Block 4 writing is turned on to write block 4 parameters stored in D1053 to D1102 to the PID module M102 is turned on 1st Scan At the rising edge of M101 D1022 0 is turned off to disable CHO control M500 is turned on to read all parameters from the PID module M101 is turned off 4 Ifthe reading all parameters M500 is turned on all PID module parameters are read out from the PID module and stored in the data registers Block 4 parameters are stored in D1053 to D1102 2 For a value with a decimal point store the value multiplied by 10 in the data register
218. tion No Alarm Action Write all parameters Read all parameters Monitor OK Cancel Input Range Type K thermocouple with decimal point Celsius Set Point SP Upper Limit 400 0 C Set Point SP Lower Limit 4 Alarm 1 Type Upper Lower limits alarm with standby Alarm 1 Value FC5A MicroSmart PID Module User s Manual FC9Y B1283 7 17 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPLICATION EXAMPLES 4 Control CHO Parameters Configure the Control CHO parameters in the PID Module Configuration dialog box To open Control CHO Parameters in the PID Module Configuration dialog box click on Control Parameters CHO button or Control CHO tab PID Module Configuration Dialog Box Control CHO Parameters Input CHO Control CHO Output CHO Input CHL Output CH1 Monitor _ A Control Mode Fixed value Control Mode 1 Control Action Reverse Control Action Heating 2 Control Enable 7 Loop Break Alarm LA Time 0 0 to 200 min Point SP 200 0 FS 0 0 to 400 0 C Loop Break Alarm LA Span 0 0 0 0 to 150 0 c Proportional Term Proportional Band Cooling Contro
219. tion Selection 4 PID Module Configuration Slot 1 aixi 1 Module Type No FCSA F2M2 3 Input Parameters Control Parameters Output Parameters CHO Input CHO ror CHO Output CHO CHO 2 Type K thermocouple Celsius Reverse Control Action Heating Voltage Output Input Parameters Control Parameters put Parameters CH1 Input CH1 el E CH1 Output CH1 CH1 Reverse Control Action Heating Voltage Output Type K thermocouple Celsius Input CHO Control CHO Output CHO Input CHL Control CH1 Output CHL Monitor Input Range PV Correction PV Filter Time Constant Set Point SP Upper Limit Set Point SP Lower Limit Alarms Type K thermocouple Celsius sl 200 to 1370 C 0 0 E 0 0 Fy 1370 fe 200 L 100 0 to 100 0 C 0 0 to 10 0 sec 200 to 1370 C 200 to 1370 C 1 Input CHO Function Input CHO 2 Input CH1 Function Input CH1 3 Output CHO Function Output CHO 4 Output CH1 Function Output CH1 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPLICATION EXAMPLES 3 Input CHO Parameters Configure the Input CHO
220. tr com Email info clrwtr com INSTALLATION AND WIRING Power Supply for PID Modules 3 6 When supplying power to the PID modules take the following into consideration Using the same power supply for the MicroSmart CPU and the PID module is recommended to suppress the influence of noise If the same power source is used for the PID module and MicroSmart CPU module after the MicroSmart CPU is started to run the PID module performs initialization for a maximum of 5 seconds During this period each parameter has an indefinite value Design the user program to make sure that each parameter is referred in the CPU module after the PID module operating status is changed to 0001h Normal operation Wiring of Power Line and I O Lines for the PID Module Separate the I O lines particularly resistance thermometers from the power line as much as possible to suppress the influence of noise DC Voltage Current Fuse 50V 1 2A RTD Resistance thermometer ae Terminal Channel TC Thermocouple r Load Separate the UO lines SE GC Analog current input instrument from the power line 1 Fuse as much as possible EES EES i 4 Terminal Channel EE EE No
221. tten to the ROM of the PID module Data Flow of the PID module parameters CPU Module PID Module RAM Data Registers 1 All parameters are read out from the PID module and stored in the data registers in the CPU module when the reading all parameters bit is turned off to on 2 Initial values stored in the ROM of the CPU module are loaded to the data registers when the loading initial values bit is turned off to on 3 All parameters stored in the data registers are written to the PID module when the writing all parameters bit is turned off to on 4 The block parameters stored in the data registers are written to the PID module when the block writing bit is turned off to on Note The communication status between the CPU module and the PID module can be confirmed with the following data register e When both CHO and CH1 are in fixed value control mode First data register 189 e When CHO or CH1 is in program control mode First data register 589 Data Register Se Normal operation Turn off the MicroSmart and connect the PID module again number number O invalid module The PID module is not connected to the configured slot number Turn off 3 the MicroSmart and connect the PID module to the appropriate slot 5 4 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Examples of changing the
222. um TIM CNT Change Status Unchanged Clear Confirm Calendar 2011 03 18 09 49 02 Change Write Protection Unprotected Read Protection Unprotected Error Status 1 2 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com MODULE SPECIFICATIONS 2 MODULE SPECIFICATIONS This chapter describes parts names functions specifications and dimensions of the PID modules PID Module Parts Description 12 Expansion Connector 1 Module Label 2 Power LED PWR 3 Control Output LED OUTO OUT1 4 Event Output LED EVTO EVT1 5 Auto tuning AT Auto reset LED ATO AT1 6 Manual Mode LED MTO MT1 7 Fixed Value Control Mode Program Control Mode LED F PO F P1 8 Program Control RUN HOLD LED R HO R H1 9 External SP Enable Disable LED R L GE LUE LUG UTE Eug ug ru e e ee e HERE Y 10 Terminal No 11 Cable Terminal LED Details 2 PWR 3 OUTO 4 EVTO 5 ATO 6 MTO 7 F PO 8 R HO 9 R L 3 OUT1 4 EVT1 5 AT1 6 MI 7 F P1 8 R H1 jo000000000000000 1 Module Label Indicates the PID module type No and specifications 2 Power LED PWR ON Power is normally supplied Flashes External power supply 24V DC error OFF Power is not supplied FC5A MicroSmart PID Module User s Manual FC9Y
223. ument Zi Ee FG Fuse Behl H PRCT P SR A SR A Terminal Channel B r Ze NC No SCH S Sai NC gi 7 0 to 5V e i TE P Se 1 to DV 0 to 20mA A 4 A H ne A dy e Sei 0 to 10V 4 to 20mA 0 o 1V i e B INO Ne G eo B r o e P OB oi Sg G t E Is OUTO zl Bot Dal Ba A RTD NC 7 D E 4 S Si SEI a ine p Bae ll BE 0 to 5V NC i a O 0 to 20mA i SCH SE A 10V 4 to 20mA A SS D EL GO o que O10 1V L B G i D NC OUT1 DC DC DC TC B J 1 JE RTD 4 OUTO is a connection example of relay output OUT1 is a connection example of non contact voltage current output The PID module having both outputs is non existent 3 4 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com INSTALLATION AND WIRING Type of Protection Input Circuits FCS5A F2MR2 FC5A F2M2 P Input Selection Signal me hise E kQ 160 Wa a mA D x lt 0 A QO 2 Input 3 BIC 10082 B O _ Output Circuits FC5A F2MR2 gt O O _ CL fei gt O FC5A F2M2 Non contact Voltage Output for SSR drive FC5A F2M2 Current Output Current Detection Short Circuit Protected Output Circuit gt O O D gt Q Bei gt O FC5A MicroSmart PID Module User s Manual FC9Y B1283 3 5 Phone 800 894 0412 Fax 888 723 4773 Web www clrw
224. use fire hazard e Use an IEC 60127 approved fuse on the power line outside the MicroSmart This is required when equipment containing the MicroSmart is destined for Europe e Use an IEC 60127 approved fuse on the output circuit This is required when equipment containing the MicroSmart is destined for Europe e Use an EU approved circuit breaker This is required when equipment containing the MicroSmart is destined for Europe e Make sure of safety before starting and stopping the MicroSmart or when operating the MicroSmart to force outputs on or off Incorrect operation on the MicroSmart may cause machine damage or accidents FC5A MicroSmart PID Module User s Manual FC9Y B1283 i Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com e H relays or transistors in the MicroSmart output modules should fail outputs may remain on or off For output signals which may cause serious accidents provide a monitor circuit outside the MicroSmart e Do not connect the ground wire directly to the MicroSmart Connect a protective ground to the cabinet containing the MicroSmart using an M4 or larger screw This is required when equipment containing the MicroSmart is destined for Europe e Do not disassemble repair or modify the MicroSmart modules e When disposing of the MicroSmart do so as an industrial waste il FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 We
225. uspended while the program hold bit is on 3 During the program control the current step is terminated and the program control is proceeded to the start of the next step when the advance next step bit is turned off to on 4 During the program control the progression of the program control is moved back when the advance previous step bit is turned off to on If the elapsed time in the current step is less than 1 minute the program control goes back to the start of the previous step If the elapsed time in the current step is more than or equal to 1 minute the program control goes back to the start of the current step Even when the advance previous step is executed at Step 0 the program control does not move back to Step 9 regardless of the program end action 5 10 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Examples of Program Control Progress Example 1 Terminate Program Control when Program Ends The following diagram shows an example of the program control when terminate program control is selected as the program end action Time of steps Step 0 and 1 60 minutes Step 2 30 minutes Steps 3 to 9 0 minute In this example D1000 is allocated to the control register and M500 is allocated to control relay Current step number D1006 Control enable bit D1022 0 Program control bit D1022 3 Program c
226. utomatic start after download Keep output during download Suspend 1 0 force before download Automatic device clear after download I L i Write PID module parameters after download O Write device datafile to the PLC after download Setting Download comment data Setting Download systemprogram Detail Program Information Program Size 1142 bytes Comment Size 0 bytes Total 1142 bytes Communication Settings l i Cancel When program download is successfully completed the following message will appear Click OK button to close the message Program Download Eki E i Program Download Succeeded 8 Starting Heating Cooling Control 1 Confirm that 2000 is stored in D1020 of CPU module 2 Turn on the external input I0 to enable CHO control 3 Turn on the load circuit power The PID module starts the heating cooling control action to keep the temperature of the control target at the set point SP Turn on 11 to perform the auto tuning AT for CHO control whenever necessary see pages 4 6 to 4 8 FC5A MicroSmart PID Module User s Manual FC9Y B1283 7 19 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com APPLICATION EXAMPLES 7 20 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com TROUBLESHOOTING 8 TROUBLESHOOTING This chapter describes the countermeasures when any
227. witches to on or off even by a slight variation of temperature at around the set point SP This frequent on off shortens the output relay life and may negatively affect the connected equipment To prevent that harmful effect the hysteresis is provided for on off control action Cooling output on off hysteresis can be configured only when cooling control action is in ON OFF control when cooling proportional band is 0 22 Control Register 50 Overlap Dead Band The overlap dead band of the heating and cooling outputs can be configured when heating cooling control is enabled When the configured value is bigger than 0 the value is used as the dead band When the configured value is less than 0 the value is used as overlap band When the overlap band is configured the area in which both heating and cooling control outputs are turned on is generated and the energy loss is caused However the overlap helps enhance the control accuracy and accelerate the response When the dead band is configured the area in which neither heating nor cooling control outputs are turned on is generated In the dead band the control accuracy and responsiveness is lowered however the energy loss can be suppressed Output manipulated variable MV 100 Heating Output Cooling Output 7 A Set Point lt gt SP Temperature Ku Overlap Band Overlap Band Action Output manipulated variable MV 100 Heating Cooling
228. y be disconnected D ce D DI r de LO er DI c N Bit3 Over Range Input value is below the lower limit of the control l range See page 9 4 el Seer Range Voltage input 0 to 5V DC may be disconnected Current input 4 to 20mA DC may be discon D ele Programa Program wait is functioning OFF Bit6 Program End Output E Bit7 Alarm 1 Output Bits Alarm 2 Output Bit9 Alarm 3 Output Bit10 Alarm 4 Output Bit11 Alarm 5 Output Bit12 Alarm 6 Output Bit13 Alarm 7 Output Alarm 8 Output Reserved 0 Fixed value FC5A MicroSmart PID Module User s Manual FC9Y B1283 5 9 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com DEVICE ALLOCATION OF PID MODULE Data Register Allocation Block 1 Write Only Parameters The CPU module writes the following parameters stored in the data registers to the PID module every scan Offset from the Control Parameter Description Register When the input is thermocouple or resistance thermometer Set point SP lower limit to set point SP upper limit When the input is voltage or current input Linear conversion min to linear conversion max When heating cooling control is disabled Output manipulated variable lower limit to output manipulated Manual Mode Output variable upper limit Manipulated Variable When heating cooling control is enabled Cooling output manipulated variable upper limit to heating output
229. y changes If the derivative time of the PID module parameter is set to 0 the control action becomes the PI control action Temperature Proportional Band Set Point SP A Disturbance Time e If the integral time is shortened too much the integral action becomes strong The offset can be corrected in a shorter time however hunting with a long cycle may be caused e If the integral time is extended too much the integral action becomes weak and it takes time to correct the offset 4 4 FC5A MicroSmart PID Module User s Manual FC9Y B1283 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com PID MODULE MAIN FUNCTIONS PD Control Action Proportional Derivative Action Compared with P action the response to rapid temperature change due to disturbance is faster the temperature control can be stabilized in a shorter time and transitional response characteristic can be improved in PD control action PD control action is suitable for the processes in which the temperature rapidly changes If the integral time of the PID module parameter is set to 0 the control action becomes the PD control action Temperature Proportional Band Set Point SP A w Disturbance Time e If the derivative time is shortened the derivative action becomes weak The response to the rapid temperature change becomes slower Because the action to suppress the rapid temperature rises becomes weake

IDEC MicroSmart Pentra PID Module User`s Manual

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