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1746-UM010, Barrel Temperature Control Module User Manual

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1. Configuring the Module 3 13 Table Block Header word 0 10 0 8801 30719 decimal Loops 1 4 Seta bit or enter a value Word 1 2 3 4 bit to Configure BitSelectorRange 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 26 51 76 Monitor PID Control 0 0 0 1 operation mode Control loop with PID 0 1 Disable loop 1 0 2 5 input type a Type K 0 0 JO 1 6 alarm enable Disable 0 Enable 1 X disable PID loop CV 0 0 0 7 8 TC break configuration a thermal runaway 0 j1 Use manual mode CV 110 9 reserved ow gains 0 0 10 11 Autotune gains CaS E high gains 1 0 very high gains 1 1 12 Barrel control Barrel 0 Non barrel 1 X 13 Zone Inner 0 Outer 1 X 14 15 reserved 2 27 52 77 0 15 High CV limit 100 00 thru 100 00 default 100 00 3 28 53 78 0 15 Low CV limit 100 00 thru 100 00 default 0 00 4 29 54 79 0 15 CV for TC break 100 00 thru 100 00 default 0 0 5 30 55 80 0 15 Standby setpoint 0 0 thru 3276 7 default 0 0 6 31 56 81 0 15 Heat on time min 0 00 thru 100 00 sec default 0 00 7 32 57 82 0 15 Heat TPO period 0 00 thru 100 00 sec default 5 00 8 33 58 83 0 15 Cool on time min 0 00 thru 100 00 sec default 0 00 9 34 59 84 0 15 Cool TPO period 0 00 thru 100 00 sec default 5 00 10 35 60 85 0 15
2. 2 3 Choosing a Module Slot in a Local I O Chassis 2 3 Installation considerations 2 3 Installing the 2 4 Removing the terminal block 2 5 Wiring the Module 2 6 Cold Junction Compensation 2 6 Wiring 51 2 7 Preparing and Wiring the Cables 2 8 SDPCIICAUDTIS as 4t eoo SU tub ole Sa Eas 2 10 Chapter 3 Loop Operation 3 1 Word 1 Bits 0 and 1 forChannel1 3 1 Type of Loop 3 1 Word 1 Bits 2 5 forChannel1 3 1 Enable Loop lt 3 2 Word T Bit 6 11 3 2 TC Break Response 3 2 Word 1 Bits 7 and 8 for Channel 1 3 2 Loop Autotune Gains 3 2 Word 1 Bits 10 and 11 forChannel1 3 2 Publication 1746 UM 010B EN P April 2001 TOC 2 Table of Contents Publication 1746 UM 010B EN P April 2001 Barrel Non barrel 3 3 Word 1 Bit 12 for 1 3 3 B rel Contool a cR 3 3 Non barrel 3 3 Switching the barrel
3. Location Description See Page NXx 1 9 Block header for the M 1 configuration file 3 11 NXX 1 thru NXX 100 M 1 configuration information 3 13 NXX 101 thru NXX 109 Reserved do not use NA NXX 110 Block header for the M 0 file 4 6 NXX 111 thru NXX 159 M 0 file information 3 11 4 6 NXX 160 thru NXX 175 Input image buffer 6 2 NXX 176 thru NXX 179 Reserved do not use NA NXX 180 thru NXX 195 Output image table 5 8 NXX 196 thru NXX 199 Reserved do not use NA NXX 200 thru NXX 203 Current set points NA NXX 204 thru NXX 207 Current error PV SP NA NXX 208 thru NXX 211 Current CVs NA NXX 212 thru NXX 215 Error codes 8 2 NXX 216 thru NXX 219 CJ C temperatures 2 6 NXX 220 thru NXX 223 Firmware revision 9 1 NXX 224 thru NXX 227 P contribution 4 4 NXX 228 thru NXX 231 contribution 4 4 NXX 232 thru NXX 235 D contribution 4 4 NXX 236 thru NXX 239 Pre set point NA NXX 240 thru NXX 243 Wait period NA NXX 244 thru NXX 247 Reserved for future use NA NXX 248 thru NXX 255 Reserved do not use NA manipulated by the code Publication 1746 UM 010B EN P April 2001 Sample Program 9 5 201 155 Programming Notes When programming the BTM with the BTM201 rss code there are several things to note 1 You must in the N7 data table define words 16 thru 18 These tell the program what the starting data table the BTMs use the slot location of the first BTM and how many BTMs are in the system This information is move into the d
4. 3 3 Inner Outer Zone 5 3 4 Word 1 Bit 13 for 1 3 4 High Low CV 3 5 Words 2 and 3forChannel 1 3 5 TC Break 3 5 Word 4 or O e 8 for Channel 3 5 Standby 5 3 5 Word 5 for Channel 1 3 5 Heat Cool Minimum 3 6 Words 6 and 8 1 3 6 Heap Coo TPO Period 3 6 Words 7 and 9 for Channel 1 3 6 PV Rate and Associated 3 6 Word 10 and Alarm Bit I e 4 05 for Channel 1 3 6 High Low Temperature and Deviation Alarms 3 6 Words 11 14 for Channel 1 3 6 Alani Dead Band aus P 3 8 Word 15 for 11 3 8 Thermal Integrity Loss 3 9 Words 16 and 17 for Channel 1 3 9 Ramp RAVES ci macer bote Ret a E Ra eee 3 9 Words 18 for 11 3 9 Non barrel Autotune Disturbance 97 3 9 Word 20 for 11 3 9 Implied Decimal 3 10 Configuration Block M1 File Loops 1 4 N10 0 100 3 11 Startup Aggr
5. p i Cables am s SIE 9 S gs unshielded y 9 n c wires as Limit braid length to 12 or short as less Solder braid to lug on possible bottom row of 1 0 chassis bolts If noise persists try grounding the opposite end of e cable Ground one end only IMPORTANT Publication 1746 UM 010B EN P April 2001 2 10 Installing and Wiring Publication 1746 UM 010B EN P April 2001 Specifications Backplane Current consumption 110 mA at 5V dc 85 mA at 24V dc Backplane power consumption 0 6W maximum 0 55W 5V dc 2W 24V dc Number of channels 4 backplane and channel to channel isolated 1 0 chassis location any 1 0 module slot except 0 A D conversion method sigma delta modulation Input filtering analog filter with low pass digital filter Normal mode rejection between input and input greater than 50 dB at 50 Hz greater than 60 dB at 60 Hz Common mode rejection between inputs and chassis ground greater than 120 dB at 50 60 Hz with 1K ohm imbalance Channel bandwidth 3db 8Hz Calibration once every six months Isolation 1000V transient or 150 VAC continuous channel to channel or channel to backplane Agency Certifications When product Listed Industrial Control Equipment packaging is marked N223 Certified Process Control Equipment 5 Certified for use in Class D
6. Installing and Wiring 2 5 Removing the terminal block When installing the module it is not necessary to remove the terminal block But if you need to remove it follow this procedure 1 Alternately loosen the two retaining screws to avoid cracking the terminal block 2 Grasp the terminal block at the top and bottom and pull outward and down When removing or installing the terminal block be careful not to damage the CJC sensors Tip The Replacement Part Number for the Terminal Block with the CJ Cs ce S is 1746 RT32 You cannot purchase by itself S CJ C sensors e 2 retaining screws lt 26 e ZA of 3 Use the write on label to identify the module and its location SLOT RACK MODULE Publication 1746 UM 010B EN P April 2001 2 6 Installing and Wiring Wiring the Module The module has an 18 position removable terminal block The terminal block pin out is shown below Disconnect power to the SLC before attempting to install remove or wire the removable terminal wiring block Figure 2 1 Terminal block pin out Le Retaining Screw Q Assembly
7. Allen Bradley Barrel Temperature Control Module 1746 BTM User Manual Auto ti Importa ntUser Information Because of the variety of uses for the products described in this Publication 1746 UM 010B EN P April 2001 publication those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements including any applicable laws regulations codes and standards The illustrations charts sample programs and layout examples shown in this guide are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Allen Bradley does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Allen Bradley publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Allen Bradley office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Reproduction of the contents of this copyrighted publication in whole or part without written permission of Rockwell Automation is prohibited
8. to the control mode that was selected before emperature system dead autotune time autotune complete Time Publication 1746 UM 010B EN P April 2001 5 4 Control and Autotune a Loop Items to check before autotune Each loop must be configured with a valid M1 file and no errors N10 212 215 be set for barrel mode e be set in manual mode and that run setpoints are selected starting from a cold start If not starting from a cold start at a steady state temperature have the TPO period set considerably smaller than the system dead time A good place to start is 5 or 10 seconds not have any existing alarm conditions that could cause problems such as a TC break Autotune barrel control applications Autotune enables the module to compute PID values for optimum temperature control You must load the program and use the following procedure to autotune the module For barrel control better results are achieved when you autotune all loops associated with the barrel at the same time After autotune each zone will return to the mode auto or manual that was selected beforehand IM PORTANT 4 results start from room temperature cold Publication 1746 UM 010B EN P April 2001 Control and Autotune Loop 5 5 1 Assume using data table N10 in the following example Set initial conditions Table 5 A Configuration File N10 Data Table Example 10 1 bits 00 01 set for PID control
9. i Q Channel 0 G Channel 0 Channel 1 Do NOT use these 9 Channel 1 connections Ie Channel 2 N Channel 2 Ta G Channel 3 CJ C Assembly G Channel 3 n CJ C B e Spare part catalog number Retaining Screw 1746 RT32 Cold J unction Compensation C ATTENTION Do not remove or loosen the cold junction compensating thermistors located on the terminal block Both thermistors are critical to ensure accurate thermocouple input readings at each channel The module will not operate in the thermocouple mode if a thermistor is removed In case of accidental removal of one or both thermistors replace them by connecting them across the CJC terminals located at the top and or bottom left side of the terminal block Always connect the red lug to the terminal to CJC A or CJC B Publication 1746 UM 010B EN P April 2001 Installing and Wiring 2 7 Figure 2 2 Thermistor placement on the bottom of the terminal block E ae Always attach red lug to the C terminal 3 4 Wiring considerations Follow the guidelines below when planning your system wiring To limit the pickup of electrical noise keep thermocouple and millivolt signal wires away from power and load lines e For high immunity to electrical noise use Alpha 5121 shielded twisted pair or equivalent wire for millivolt senso
10. 22 Heat derivative gain is less than 0 23 Cool proportional gain is less than 0 24 Cool integral gain is less than 0 25 Cool derivative gain is less than 0 30 Loop operational mode is invalid 31 Thermocouple type is invalid 32 Maximum CV allowable is lt 100 gt 100 or max CV lt min CV 33 Minimum CV allowable is lt 100 or gt 100 34 Control value when TC break detected is lt 100 or gt 100 35 Standby setpoint is invalid 36 Heat minimum TPO cycle time is lt 0 or gt 100 37 Heat maximum TPO cycle time is lt 0 gt 100 or min TPO gt max TPO 38 Cool minimum TPO cycle time is lt 0 or gt 100 39 Cool maximum TPO cycle time is lt 0 gt 100 or min TPO gt max TPO 40 PV rate alarm degrees per second is invalid 41 Low temperature alarm is invalid 42 High temperature alarm is invalid 43 Low deviation alarm is invalid 44 High deviation alarm is invalid 45 Temperature alarm deadband is lt 0 or gt 10 46 Thermal Integrity Loss value is lt 0 or gt 100 47 Integrity Rate in minutes lt 0 or gt 100 48 Setpoint ramp rate is lt 0 49 reserved 50 Nonbarrel autotune disturbance size is lt 0 or greater than 100 51 Startup aggressiveness factor is lt 0 or gt 100 Publication 1746 UM 010B EN P April 2001 8 4 X Troubleshooting the Publication 1746 UM 010B EN P April 2001 Table 8 B Autotune Error Codes Code Description 66 Autotune terminated because of
11. E At E ACRES At 0 Entering Autotune Gains Values with Implied Decimal Point Setting Autotune and Gains Values 4 5 The autotune gains block 0 file contains 49 words as listed in Table 4 A below For each gain value you enter a 16 bit integer value Because loop values are stored and reported in IMPORTANT integer files you must understand the meaning of IDP Otherwise the magnitude of your intended value may be in error by as much as 1000 depending on the position of the IDP When entering or reading integer values the range given in the associated table tells you the implied decimal point It is the number of digits to the right of the decimal point for an example range of 0 0 thru 3276 7 the implied decimal point is 1 Table 4 A Autotune Gains Values with Implied Decimal Point Parameter Given Range ipp Example Cool Time Constant 0 0 thru 32767 7 sec 1 If you want to store a value of 660 0 enter 06600 Heat Gain 0 00 thru 327 67 sec 2 If you want to store a value of 100 00 enter 10000 Cool Proportional 0 000 thru 32 767 3 If you want to store a value of 18 enter 18000 Heat Integral 0 0000 thru 3 2767 4 If you want to store a value of 0 5 enter 05000 1 DP indicates the number of digits from the right that locates the implied decimal point Publication 1746 UM 010B EN P April 2001 4 6 Setting Autotune and Gains Values Publication 1746 UM 01
12. Throughout this manual we use notes to make you aware of safety considerations ATTENTION Identifies information about practices circumstances that can lead to personal injury death property damage or economic loss Attention statements help you to e identify a hazard e avoid a hazard e recognize the consequences IM PORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley is a trademark of Rockwell Automation European Communities EC Tf this product has the CE mark it is approved for installation within Directive Compliance e European Union and FEA regions It has been designed and tested to meet the following directives EMC Directive This product is tested to meet the Council Directive 89 336 EC Electromagnetic Compatibility EMC by applying the following standards in whole or in part documented in a technical construction file e EN 50081 2 EMC Generic Emission Standard Part 2 Industrial Environment e EN 50082 2 EMC Generic Immunity Standard Part 2 Industrial Environment This product is intended for use in an industrial environment Low Voltage Directive This product is tested to meet Council Directive 73 23 EEC Low Voltage by applying the safety requirements of EN 61131 2 Programmable Controllers Part 2 Equipment Requirements and Tests For specific information required by EN 61131 2 see the appropria
13. provides the implied decimal point It is the number of digits to the right of the decimal point for an example IDP range of 0 0 thru 3276 7 the implied decimal point is 1 Status values are similarly read You must know the range of the value to read it correctly For example if reading a heat integral 0 0000 thru 3 2767 a display of 5000 would have a value of 0 5 Parameter Given Range Example Thermal Integrity 0 thru 100 0 If you want to store a value of 66 enter 00066 Standby Setpoint 0 0 thru 32767 7 1 If you want to store a value of 660 0 enter 06600 TPO Period 0 00 thru 100 00 2 If you want to store a value of 6 seconds enter sec 00600 Cool Proportional 0 000 thru 32 767 3 If you want to store a value of 18 enter 18000 Heat Integral 0 0000 thru 3 2767 4 If you want to store a value of 0 5 enter 05000 indicates the number of digits from the right that locates the implied decimal point Publication 1746 UM 010B EN P April 2001 Configuration Block M1 File Loops 1 4 10 0 100 Startup Aggressiveness factor Configuring the Module 3 11 Configuration block M1 file contains 101 words as listed below Data table location for Loops 1 4 are located in N10 For each additional 1746 BTM add 1 to N10 N11 0 100 The startup aggressiveness factor SAF modifies the pre set point value The pre set point value is the temperature at which you sw
14. 10 26 bits 00 01 set for PID control N10 51 bits 00 01 set for PID control N10 76 bits 00 01 set for PID control remaining bits words set for your application Table 5 B Data Table Example Output image buffer table words 180 183 bits 00 03 for loops 1 4 bit 00 1 enables PID control bit 01 0 puts loop into manual mode bit 02 1 uses runtime setpoint bit 03 1 enables autotune Set to zero Output image buffer table words 188 191 for loops 1 4 In the sample code it zeros manual outputs to remove control signals from loops 2 Download the M1 Configuration File by setting N7 12 00 1 Download the 0 Autotune File by setting N7 12 01 1 4 Verify that the M1 Configuration File downloaded a Check input image buffer words 164 167 bits 03 04 for loops 1 4 to verify e bit 03 1 module received a valid M1 file for the loop 04 0 no parameter errors for the loop If bit 04 parameter error is set for any loop look for the error code in N10 212 215 Refer to Locating Error Code Information on page 8 2 b Check input image buffer words 168 171 bits 00 02 for loops 1 4 to verify that the module bit 00 1 enabled PID control e bit 01 0 put loop into manual mode bit 02 1 used runtime setpoint Publication 1746 UM 010B EN P April 2001 5 6 Control and Autotune a Loop Publication 1746 UM 010B EN P April 2001 5 Enter runtime temperature setpoints at least 50 F 28 7
15. 100 00 thru 100 00 9 For loops 1 4 standby setpoint is stored in N10 5 30 55 80 respectively 9 Entered below Note Refer to Download and Upload Settings on page 9 3 for download command bits Publication 1746 UM 010B EN P April 2001 Control and Autotune a Loop 5 9 Global Commands to All Loops Word Bit To Control Selected By 15 14 13 12 11 10 9 8 7 6 5 4 3 2 0 12 0 Temperature units F 0 C 1 1 Autotune invoke invoke 1 None 0 2 Autotune abort Abort 1 0 3 Reset error codes None 0 Reset 1 3 7 Reserved Current Setpoint 0 0 1 Current Error Value 01110 or Reported ane Current CV loop output 0 1 1 buffer Current Error Code 11010 Cold unction Temperature 11011 a Firmware Revision Number 11110 P Contribution 01011 Contribution 01110 RENE Ce Pre set Point 1 0 Wait Period 11011 Reserved 11110 11 Advanced Rotator Values Disable 0 Enable 1 12 download request None 0 Download 1 13 1 download request None 0 Download 1 14 0 upload request None 0 Upload 1 15 M 1 upload request None 0 Upload 1 13 0 15 Reserved 14 0 15 Calibration word 15 0 15 Reserved IMPORTANT The sample program returns all six variables For their data table locations Refer to BTM201 rss Data Table La
16. M1 configuration data files to the module to start module operation Control and Autotune a Loop 5 7 Example Autotune non barrel control applications 1 Enter a safe non barrel autotune disturbance size in the M1 file Disturbance size is the step output that the module uses to autotune For example if disturbance size is 15 and current CV is 0 when autotune is invoked the CV changes to 15 10 when autotune is invoked the CV changes to 25 Optimum disturbance lets temperature rise then level off If too large temperature will not level off and autotune will be unsuccessful 2 Make sure all zones have valid M1 files and no parameter errors 3 Start Autotune from a cold start or start from a steady state temperature If doing a cold start invoke autotune after putting loop into manual mode and setting manual CV output to zero e If starting from a steady state temperature invoke autotune 4 When autotune completes upload the autotune and gains block 5 Return the zone to auto mode Temperature for safe autotune disturbance size aa completes when temperature reaches steady state Temperature dead time Time Troubleshooting Autotune The module reports successful completion of autotune in status word N10 168 171 bits 03 and 04 in the input image buffer table If autotune was not successful look for autotune error codes in N10 212 215 Refer to Locating Error Code Information on
17. TC Break Control value word 4 below 0 1 forces CV to manual output 0 e 8 for loop 1 1 0 invalid setting 1 1 For additional information Refer to TC Break Control on page 3 5 Loop Autotune Gains Level Word 1 Bits 10 and 11 for Channel 1 You can change and download autotune gains level selection for any or all zones at any time When changed you must redownload the 1 file configuration followed by the MO file autotune gains so the module can recalculate PID values based on new loop autotune gains You do not need to re autotune Autotune Gain Level 11 10 low 0 0 medium 0 1 high 1 0 very high 1 1 Publication 1746 UM 010B EN P April 2001 Barrel Non barrel Control Configuring the Module 3 3 Word 1 Bit 12 for Channel 1 You select between barrel and non barrel control Select for these applications 12 barrel control heat only or heat cool 0 mn non barrel control heat only cool only or heat cool Barrel Control Select barrel control for multiple zone applications in which there is thermal conduction between the zones Injection molding and extrusion are good example applications because they use multiple heater bands zones mounted on one thermal conductor the metal barrel The barrel conducts heat between different zones If you select barrel control also select between inner and outer zones word 1 bit 13 for channel 1 A barrel loop
18. diagram CV 40 X on time 2 0 sec Y TPO period 5 00 sec On data in parenthesis refers to TPO bit sample program values Off The TPO duty cycle Y must be considerable shorter in time than the system dead time For additional information Refer to Autotune a Loop on page 5 2 The following memory map shows you how the SLC processor s output and input image tables are defined for the module See Table 9 A BTM201 rss N7 Data Table on page 9 2 Bit 15 Address Loop 1 configuration data word 0 0 0 Slot e portion of Loop 2 configuration data word 1 0 1 SLC image table Loop 3 configuration data word 2 0 62 for BTM module Loop 4 configuration data word 3 0 3 Loop 1 run setpoint value word 4 0 4 Loop 2 run setpoint value word 5 0 5 Loop 3 run setpoint value word 6 0 e 6 Loop 4 run setpoint value word 7 0 e 7 Loop 1 manual output value word 8 0 e 8 SLC 5 0x output Loop 2 manual output value word 9 0 9 1 0 Image Table image Loop 3 manual output value word 10 0 10 Output Image 16 words Loop 4 manual output value word 11 0 11 miscellaneous control bits word 12 0 e 12 Slot e not used word 13 0 e 13 See Figure 1 3 on not used word 14 0 14 BTM 1 4 not used word 15 0 15 Module Input Image _ Loop 1 temperature w
19. display and maintain a calibration voltage to 1 1000 of a millivolt at 0 000 mV and 90 000 mV For convenience calibrate all four channels at the same time To prepare for the calibration Remove the thermocouple leads from the input terminals of the channels that you want to calibrate Switch the SLC processor to run mode so it can execute the calibration ladder logic To calibrate the module follow this procedure 1 With your programming terminal enter calibration code 1001 Hex into output word 14 2 Observe input words 0 3 6 and 7 The module clears words 0 3 The module retums CA14 Hex in words 6 and 7 3 Short circuit the pairs of input terminals for the channels you want to calibrate Make the jumper as short as possible 4 With your programming terminal enter calibration code 1002 Hex into output word 14 5 Observe bits 0 3 in input word 4 f all the channels you are calibrating see zero voltage the module returns status OK bits set one bit for each channel F Hex for all four channels Otherwise the module returns channel status bits set to zero 6 Apply 90 000 mV to the pairs of input terminals all in parallel for the channels you are calibrating Use short leads 7 With your programming terminal enter calibration code 1004 Hex into output word 14 8 Observe bits 4 7 in status word 4 f all channels being calibrating see 90 000 mV the module returns a status OK bit set fo
20. explanation of the image table addresses Figure 13 Output Image Table Address slot d file type T 0 e 64 element word delimiter delimiter By writing to the status file in your modular SLC processor you can isable any chassis slot See your SLC programming manual for the slot disable enable procedure ATTENTION Always understand the implications of disabling the module before using the slot disable feature Input response When the slot for this module is disabled the module continues to update its inputs However the SLC processor does not read from a module whose slot is disabled Therefore inputs appearing in the processor image table remain in their last state and the module s updated inputs are not read When the processor re enables the module slot the current state of module inputs are read by the controller during the subsequent scan Output response When the slot for this module is disabled configuration words in the SLC processor s output image table are held in their last state and not transferred to the module When the slot is re enabled output image table words are transferred to the module during the subsequent scan Avoiding Electrostatic Damage Chapter 2 Installing and Wiring This document gives you information about avoiding electrostatic damage e compliance with European Union directive e determining the module s chassis power requirement e planning for sufficient enclosu
21. is autotuned as the temperature rises from a cold start to a temperature setpoint during startup Non barrel control Select non barrel control for applications with independent loops and no thermal conduction between zones If you select non barrel control the inner outer zone selection doesn t apply Switching the barrel control For some applications even though the loops are independent with no thermal conduction between zones barrel control might provide better performance than non barrel control If a loop has any of these characteristics you might want to use barrel control if the time constant is greater than 10 30 seconds e loop has a problem of overshooting the setpoint loop output is saturating CV is at 100 fora significant duration Publication 1746 UM 010B EN P April 2001 3 4 Configuring the Module l UE If you switch a loop between non barrel and barrel Inner Outer Zone Selection Word 1 Bit 13 for Channel 1 control you must re autotune the loop before operating it If you don t re autotune the autotune values will be wrong for the application and the gains will be greatly distorted If you make a selection for barrel control you also must select whether the loop is an inner zone or outer zone Select for a zone 13 inner not at either end of the 0 barrel outer at either end of the barrel 1 The PID gain calculation algorithm for an inner zone is slightly diffe
22. shield and drain wire from Sy sensor end of the cable Signal Wires a Extract the drain wire but Drain Wire remove the foil shield at the module end of the cable Signal Wires 1 At each end of the cable strip some casing to expose individual wires 2 Trim signal wires to 5 inch lengths beyond the cable casing Strip about 3 16 inch 4 76 mm of insulation to expose the ends of the wires 3 At the module end of the cables extract the drain wire and signal wires remove the foil shield bundle the input cables with a cable strap 4 Connect drain wires together and solder them to 3 8 wire braid 12 long Keep drain wires as short as possible 5 Connect the 3 8 wire braid to the nearest chassis mounting bolt 6 Connect the signal wires of each channel to the terminal block Installing and Wiring 2 9 7 At source end of cables from mV devices See Figure 2 3 and Figure 2 4 remove the drain wire and foil shield apply shrink wrap as an option connect to mV devices keeping the leads short Figure 2 4 Cable Preparation to M inimize Electrical Noise Interference M ake unshielded wires Terminal as short as possible Block Solder drain wiresto 3 8 Wires braid at casing lt gt Signal Wires Es 3 8 Connect 1 0 are chassis bolt to 6 o ON chi earth ground j one
23. temperature 1 10 1 Firmware revision number 11110 11 Autotune progress 0 None 1 In progress 12 Cold junction low 0 None 1 Alar 13 Cold junction high 0 None 1 Alar 14 Reserved 15 Advanced rotator 0 Normal Values values 1 Advanced Diagnostic Values 9 8 11 Reserved upper bhie 12 M 0 download 0 None 1 Download 13 M 1 download 0 None 1 Download 14 M0 upload 0 No 1 Upload 15 M 1 upload 0 No 1 Upload IMPORTANT The sample program returns all six variables For their data table locations Refer to BTM201 rss Data Table Layout on page 9 2 and BTM50220 RSS Data table layout on page 9 7 Remember that the module returns the control variable CV of each loop to the input image table as both a numeric value current CV and a time proportioned output TPO For additional information Refer to BTM201 rss Data Table Layout on page 9 2 and BTM50220 RSS Data table layout on page 9 7 Publication 1746 UM 010B EN P April 2001 Chapter 7 Calibrating the Module About the Procedure Calibrate the module after the first 6 months of operation Then check the calibration and re calibrate only if necessary once a year Use this procedure to store calibration values for each channel in EEPROM Calibration sets channel accuracy at 0 05 of full range regardless of channel circuit tolerances You can calibrate the input channels individually or in groups The therm
24. turn it off just prior to auto tune initiation In a high lag situation where it takes some finite amount of time for that energy to manifest itself as temperature the result is as follows The auto tune routine waits for stability and qualifies it it then attempts to exercise the system by giving a step output the heat that was previously introduced into the system finally produces a temperature change the auto tune routine marks the rise in temperature as being a direct result of its excitation of the system and records the amount of time from the beginning of its step output to the start of the temperature rise as the deadtime In this case the system is now misidentified with an artificially short deadtime Control and Autotune a Loop 5 11 The second critical procedure is that of finding the maximum rate of change of the system for the given excitation A number of the BTM s auto tune failures are associated with this procedure temperature will exceed deadtime too much noise in the system etc For any given step change of excitation for a given system there will ultimately be a maximum rate of change max slope attributable to that excitation This information is used to identify system gain and time constant information When trying to find a maximum slope the system must be able to rise in temperature sufficiently to guarantee that a maximum slope has been attained Thus a minimum temperature differential has been iden
25. 001 Sample Program 9 7 Support for 5 02 Processors Using the code in file BTM50220 RSS you will be able to have Using 50220 RSS multiple BTMs in a SLC system but you will have to duplicate the ladder logic and create new data table locations for each BTM BTM 50220 RSS Data table layout The data table layout for this version of code has change considerably from the current BTM application code The M file and the rotator information have been moved into a different data table In the previous version the information was located in N7 Table 9 D BTM 50220 RSS N7 Data Table Location Description 170 User request pending N7 1 User request being serviced N7 2 Request mask N7 3 Bit 0 request complete cleanup needed 7 4 Indirect address for pointer in rotator N7 5 Rotator bits N7 6 Bit 0 all requests and acknowledges cleared N77 thru N7 18 reserved Do not use N7 19 M isc control Bits N7 20 Rotator Level 1 or 2 check 7 Tn this version of code you command M 1 M 0 file transfers thru N7 0 Dow nload and Upload Settings Table 9 E Download and Upload Settings Bit N7 0 0 set will download the M 1 configuration N7 0 1 set will download the M 0 auto tune information N7 0 2 set will download the M 0 PID information N7 0 3 set will upload the M 0 auto tune information N7 0 4 set will upload the M 0 PID information The information for the M1 0 and the ro
26. 0B EN P April 2001 PID Gains Autotune Block File for Loops 1 4 IMPORTANT Word numbers for loops 1 4 are in left most columns For corresponding NX xx address add 110 to word the number Table 4 B PID Gains Autotune 10 110 158 Block Header word 0 N 10 110 8808 30709 decimal Loops 1 4 Autotune Values N10 111 134 1 2 3 4 To Configure Range 1 7 13 19 Heat gain 0 00 thru 327 67 sec 2 8 14 20 Heat time constant 0 0 thru 3276 7 sec 3 9 15 21 Heat dead time 0 0 thru 3276 7 sec 4 10 16 22 Cool gain 0 00 thru 327 67 sec 5 11 17 23 Cool time constant 0 0 thru 3276 7sec 6 12 18 24 Cool dead time 0 0 thru 3276 7 sec Loops 1 4 PID Gains Values 10 135 158 1 2 3 4 To Configure Range 25 31 37 43 Heat proportional 0 000 thru 32 767 26 32 38 44 Heat integra 0 0000 thru 3 2767 rpts 27 33 39 45 Heat derivative 0 0 thru 3276 7 sec 28 34 40 46 Cool proportional 0 000 thru 32 767 29 35 41 47 Cool integra 0 0000 thru 3 2767 rpts 30 36 42 48 Cool derivative 0 0 thru 3276 7 sec Note Refer to Download and Upload Settings on page 9 3 for download command bits Controlling a Loop Chapter 5 Control and Autotune a Loop This chapter explains how to e control loop operation e autotune a loop At initial start up you must
27. C above current temperature into output image buffer words 184 187 for loops 1 4 We decimal point enter 2000 for 200 6 10 11 12 Invoke autotune Starts autotune for loops enabled in step 1 Set output image buffer table word 192 bit 1 1 The module needs a 0 1 transition of this bit Verify autotune is in progress Monitor input image buffer word 168 bit 11 for a 0 1 transition Reset the autotune invoke bit Reset output image buffer table word 192 bit 1 0 Enable each loop for automatic mode This lets each loop control to run setpoint when autotune completes a Output image buffer words 160 163 bit 01 for loops 1 4 bit 01 1 puts loop into automatic mode Verify that autotune is complete and successful Input image buffer words 168 171 bits 03 and 04 for loops 1 4 bit 03 1 autotune complete bit 04 1 autotune successful If bit 04 0 not successful for any loop look for the error code in N10 212 215 Refer to Locating Error Code Information on page 8 2 Upload the autotune PID gains block to the processor for storage Set word N7 12 24 Following a power loss or module replacement you can download the autotune PID gains block to avoid repeating this procedure We suggest that you modify our ladder code Refer to Obtaining the Sample Program from the Internet on page 9 1 to set N7 12 3 at power up This will automatically download MO autotune data and
28. PV alarm rate 3276 8 thru 3276 7 s default 0 0 11 36 61 86 0 15 Low temp alarm 3276 8 thru 3276 7 s default 4999 9 12 37 62 87 0 15 High temp alarm 3216 8 thru 3276 7 s default 4999 9 13 38 63 88 0 15 Low deviation 3216 8 thru 3276 7 s default 4999 9 14 39 64 89 0 15 High deviation 3216 8 thru 3276 7 s default 4999 9 15 140 65 90 0 15 Alarm dead band 0 0 thru 10 0 default 0 0 16 41 66 91 0 15 Thermal Integrity Loss 0 thru 100 default 5 17 02 67 92 0 15 Integrity Rate 0 thru 100 minutes default 20 18 43 68 193 0 15 ramping 0 thru 100 min default 0 19 44 69 94 reserved 20 4 70 95 0 15 Non barrel autotune 0 00 100 00 default 10 00 disturb size 21 46 71 1 0 15 Startup 0 thru 100 default 0 for heat or cool only 25 for heat cool aggressiveness factor lt 25 lt 50 lt 75 lt 99 reserved Publication 1746 UM 010B EN P April 2001 3 14 Configuring the M odule Publication 1746 UM 010B EN P April 2001 Sequence of Setting PID Gains Chapter 4 Setting Autotune and Gains Values This chapter shows you how to independently set the gains for each PID loop of the BTM module This includes e setting PID gains autotuning the loops e fine tuning the loops e using the PID equation e configuring the autotuning and gains block Any time you successfully autotune the loop write an autotune block to the module or write a gain
29. TC break 67 Start conditions prevent heat autotune 68 Start conditions prevent cool autotune 69 Setpoint will be reached before autotuning is complete 70 Too much noise causing time constant to be 0 71 Very small gain 72 PV now higher than maximum PV do not trust PID values Obtaining the Sample Program from the Internet RSLogix500 Version BTM Firmware Revision Support for 5 03 5 04 5 04P 5 05 and 5 05P Processors Using BTM 201 155 Chapter 9 Sample Program This chapter describes e Obtaining the sample program from the internet Configuring Your SLC processor Off line e Using the Sample Program e General Programming Notes You can obtain the sample program from the Allen Bradley website on the Internet and download it to your PC as an executable file To Access the Internet 1 Access the Sample Program and manuals at the Allen Bradley website http www ab com appsys 2 Download the sample program to your PC 3 Move the sample program into the subdirectory on your hard drive where your programming software looks for files For example with RSLogix500 CA program files rockwell software rslogix 500 english projects The examples in this chapter were built using RSLogix500 version 4 50 00 For other types of programming software the procedure and or prompts may vary The examples in this chapter were written for BTM firmware Revision 2 00 or greater Using the code in file BTM201 rss yo
30. TM module Locating Error Code Information program Publication 1746 UM 010B EN P April 2001 Display of error code in N10 212 215 if using Autotune error wa lores iguration You configure the 1746 BTM module to report error codes by setting bits 10 8 to 100 in word 192 of the output image buffer table Refer to Using the Output Image Table on page 5 8 The module reports error codes in input image table words 172 175 If using the sample program error codes are reported in N10 212 215 Location of the 2 digit code in the error word determines its source error code Autotune error codes only reset A configuration error code is when an autotune is invoked only reset when the reset error code bit is transitioned EXAMPLE If 002 is displayed the error code is from the configuration block If 6700 is displayed the error code is from the autotune Troubleshooting the Module 8 3 Table 8 A Configuration Error Codes Code Description 0 No error 1 Run setpoint is invalid 2 Manual control value is lt 100 or gt 100 10 Heat system gain is less than 0 11 Heat time constant is less than 0 12 Heat dead time is less than 0 13 Cool system gain is less than 0 14 Cool time constant is less than 0 15 Cool dead time is less than 0 20 Heat proportional gain is less than 0 21 Heat integral gain is less than 0
31. a 0 to 1 transition of word 12 bit 1 of the output image table During autotuning the module measures system parameters At the end of autotuning the module calculates PID gains based on these parameters and your selection of low medium or high PID gain level in the configuration block When autotuning is complete the PID gains calculated from autotuning are available in the gains block that you can read from the module Publication 1746 UM 010B EN P April 2001 Configuration Block e low medium high Your selection of PID gains level Autotune Block System parameters Fine Tuning the Loops Setting Autotune and Gains Values 4 3 Whenever you write autotune values to the module it recalculates PID gains based on measured system parameters stored in the autotune block and your selection of low medium or high PID gain level stored in the latest configuration block If you changed the level of PID gains selection in the configuration block in the mean time the PID gains calculated would be different from those calculated originally Autotuning Gains Block Calculations PID gains After autotuning you may want to fine tune the loops by manually setting the gains As you fine tune a loop first try adjusting the proportional gain this will have the greatest impact Your second choice for adjustment should be the integral gain The derivative gain should be the last cho
32. abled for control and autotune at the time of auto tune invoke When stability has been qualified all enabled zones will be subject to maximum configured output At this time the system is observed for a departure from stability to quantify the deadtime of the system The output continues at the same value until a maximum rate of change for each active zone in the auto tune has been identified and recorded For heat or cool only zones the test is now complete auto tune finishes and the individual zones revert to their current configuration and mode For zones designated as heat cool they will continue to setpoint under slow closed loop control and stabilize Again this stabilization is a module wide event and is inclusive of all heat cool zones engaged in the current auto tune When stability has been qualified all enabled zones will be subject to maximum cool configured output At this time the system is observed for a departure from stability to quantify the deadtime of the system The output continues at the same value until a maximum rate of change for each zone still active in the auto tune has been identified and recorded The test is now complete auto tune finishes and the individual zones revert to their current configuration and mode If for any reason the auto tune does not successfully complete for any individual zone that zones auto tune and gain parameters will not be update
33. ata table by the initialization code in file 3 0001 Figure 9 1 2 The data tables that are used to hold the M1 MO input image output image and rotator information must be consecutive for the ladder code to work 3 The BTMs must be in consecutive slots for the ladder code to work 4 In program file two you will have to add copies for the input and output images 5 The example code has five BTMs in it The BTMs are in slots 2 thru 6 The starting data table file that is used is N10 So the information that needs to be code into N7 16 10 N7 17 2 and N7 18 5 Publication 1746 UM 010B EN P April 2001 Sample Program 6 In program file 4 you will have to add the following rungs for each BTM added to the system See 6 and Figure 9 3 You will need to change the slot reference in the M address You will also need to change Source of the equal to match the slot reference N N7 7 192 N N7 7 169 Copy File 12 0 Source N N7 7 110 Dest 0 2 0 Length 49 N N7 71192 N N7 7 169 SF N73 13 13 Source amp N N7 7 0 O lt Dest M1 2 0 2 Length 101 2 N73 Figure 9 2 N N7 7 192 N N 7 169 P COP JE JE Copy File 14 14 0 Source M0 2 0 Dest amp N N7 7 110 Length 25 N71 Copy File 4 Source 0 2 25 Dest N N7 7 135 Length 24 Figure 9 3 Publication 1746 UM 010B EN P April 2
34. ature falls below the user defined low alarm value the low alarm bit is turned on When the temperature rises above the level of the low alarm value but still below the level of the dead band value the low alarm bit remains on Only when the temperature rises above the dead band level will the alarm bit be turned off High Alarm With Dead Band When the temperature rises above the user defined high alarm value the high alarm bit is turned on When the temperature falls below the level of the high alarm value but still above the level of the dead band value the high alarm bit remains on Only when the temperature falls below the dead band level will the alarm bit be turned off high CV alarm level low CV alarm level Time alarm off alarmon Publication 1746 UM 010B EN P April 2001 Thermal Integrity Loss Detection Ramp Rates Non barrel Autotune Disturbance Size Configuring the Module 3 9 Words 16 and 17 for Channel 1 The loss of thermal integrity is detected when the loop in automatic mode is not responding to a CV at 100 Detecting the loss of thermal integrity requires an assumption of a minimum rate of change in the temperature PV when the output CV is at 100 Examples of a loss of thermal integrity could be the failure of a heating band contactor to close or a sensor not in proper position to measure true temperature The values you enter in words 16 and 17 for
35. d and error codes will be displayed Refer to Locating Error Code Information on page 8 2 Chapter 6 Input Image Table Table 6 A Status Values from Each Loop Monitoring Status Data This chapter describes status data reported by the BTM module in the input image table 16 words applicable to the sample program Implied Decimal Point You must interpret the value of displayed 16 bit integer numbers For temperature values reported in words 0 3 the implied decimal point is 1 place from the right for a resolution to be 0 1 For example if 4999 is displayed you must interpret it as 499 9 1 2 3 4 Bit Define M1 Indicated By 15 14 13 12 11 10 8 7 6 5 4 3 2 1 0 0 1 2 3 Current temperature 3276 8 thru 3276 7 4 5 6 7 0 Open circuit 0 None 1 Error 1 Under range 0 None 1 2 Over range 0 None 1 3 Configuration 0 None 1 Valid 4 Parameter value 0 None 1 Error 5 PV rate alarm 10 0 None 1 Alari 6 Thermal Integrity 16 0 None 1 Alar 1 High CV limit 2 0 None 1 Alar 8 Low CV limit 3 0 None 1 Alari 9 Low temperature 11 0 z None 1 Alan 10 High temperature 12 0 None 1 Alar 11 Low deviation 13 0 None 1 Alari 12 High deviation 14 0 None 1 Alar gt 15 Reserved 8 9 10 11 10 Loop control 0 No 1 Enabled 1 Loo
36. essiveness 3 11 ates ace ita Val WE Bab eee 3 12 Chapter 4 Sequence of Setting PID Gains 4 1 Autotuning 10 4 2 Fine Tuning the Loops 4 3 Using PID 4 4 Entering Autotune Gains Values with Implied Decimal Point 4 5 PID Gains Autotune Block MO File for Loops 1 4 46 Table of Contents 3 Chapter 5 Controlling 5 1 MI Configuration 5 1 Output Image Table ede as 5 1 Autotune 1 5 2 Requirements for 5 2 Items to check before autotune 5 4 Autotune barrel control applications 5 4 Example Autotune non barrel control applications 5 7 Troubleshooting 9 7 Using the Output Image 5 8 Global Commands to All loops 5 9 BEIM Auto Cort cusa et ee ird Cd 5 10 Chapter 6 Input Image 6 1 Implied Decimal 6 1 Chapter 7 About the 7 1 Calibration Codes and Status 7 1 Calibration 7 2 C
37. ew setpoint This value works in conjunction with the ramp enable and ramp hold bits in the output image table for each channel EXAMPLE The following outlines the relationship between ramp rate TPO e ramp rate 10 min TPO of 10 sec set point of 300 current temperature of 100 e your goal is to ramp to the setpoint but hold at 200 for 10 minutes then continue to ramp to set point To set the ramp enable bit do the following 1 2 3 4 5 Go to the output image table to set the ramp enable bit A snap shot of the current temperature occurs which becomes the current setpoint A calculation is performed to determine the amount the setpoint needs to be raised every TPO period so every TPO period the setpoint increases 1 67 until the setpoint is reached 1 ramprate 60 x TPO 10sec 1 67 period Temperature ramps Ladder logic determines when you reach 200 When 200 is reached ladder logic would set the ramp hold bit in the output image table and ladder logic would start a 10 minute time When the 10 minute time runs out the ladder logic would reset the ramp hold bit in the output image table Ramping of the setpoint would continue until 300 is reached At that point ladder logic would determine 300 was met and it would reset the ramp enable bit
38. g the 1746 BTM 1746 BTM module 0001 0002 0002 Figure 9 4 Correct way to shut down loop An autotune invoke is an edge triggered event That is the module only looks to see a 0 to 1 transition of bit O 1 12 1 Once the autotune in progress bit 1 1 8 11 is on you can tum off the autotune invoke bit 0 1 12 1 Start Aytotume Auto Time In Progress Push Button For All Loops B3 0 1 18 0 1 OTHER rior one Auton For All Loops All Loops Figure 9 5 Correct way to turn off Autotune invoke bit Publication 1746 UM 010B EN P April 2001 9 10 Sample Program The autotune abort bit O 1 12 2 must be turned off after an autotune is aborted if not the next time you try to enable an autotune it will immediately be aborted When you set bit O 1 12 2 high you must also check that the autotune in progress bit I 1 8 11 is low When that happens reset the autotune abort bit O 1 12 2 0001 0002 Figure 9 6 Correct way to abort an Autotune TIP Do not set the Autotuning enabled bits in the output image table in the same scan that you set the invoke autotune bit gt e Do not perform M1 file transfers without using the up download request bits output word 12 bits 12 thru 15 and the up download request ready bits input word 9 bits 12 thru 15 These bits must be used to insure block integrity When you need to disable a loop of control do not just put a contact in front of the output TPO bit This wi
39. hapter 8 Troubleshooting with LED Indicators 8 1 Locating Error Code Information 8 2 Chapter 9 Obtaining the Sample Program from the Intemet 9 1 To Access the 9 1 RSLogix500 9 1 BTM Firmware Revision 9 1 Support for 5 03 5 04 5 04P 5 05 and 5 05 Processors Using 201 56 9 1 201 155 Data Table 9 2 Download and Upload Settings 9 3 BTM201 rss Programming 5 9 5 Support for 5 02 Processors Using BTM50220 RSS 9 7 BTM50220 RSS Data table 9 7 Download and Upload Settings 9 7 General Notes for Programming the 1746 BTM 9 9 Publication 1746 UM 010B EN P April 2001 TOC 4 Table of Contents Publication 1746 UM 010B EN P April 2001 Temperature Control Using BTM Module in an SLC System SLC data table 1 Getting Started This chapter gives you information on e the function of the temperature control module e features of the temperature control module e time proportioned output TPO e module addressing response to slot disabling MILIA Usc the 1746 BTM module only for barrel temperature control for injection molding applications or extruders in a
40. he configuration block gt Manual Mode TP is used as the CV value gt Automatic ode The PID algorithm generates the CV value Autotune a Loop The BTM module uses the output image table to control loop operation See Table 5 C on page 5 8 for the listing of words and bits Operating Commands to Loops 1 4 Use the following as a guide Requirements for Autotune e Start autotune from a steady state temperature For best results do a cold start If the temperature fluctuates autotune may not provide accurate results e The runtime setpoint for autotune must be at least 50 F 28 79 C above current temperature or autotune will not start Publication 1746 UM 010B EN P April 2001 Control and Autotune Loop 5 3 Set the TPO period smaller than the system dead time Autotune algorithm may calculate excessive gains if system dead time is less than the TPO period This may cause the PV to overshoot Figure 5 2 Set TPO Period output CV changed system dead time Temperature 4 p System dead time should be larger than TPO period for autotune to work properly N 1 TPO period B x gt N Output CV N to Time e The autotune algorithm does not take the temperature to setpoint When autotune is complete the zones will return to the mode auto or manual that was selected before autotune Figure 5 3 Autotune setpoint zones maximum slope
41. ice for fine tuning a loop If the loop over shoots the set point either at start up or at a change of set point See Figure 4 1 you may be able to dampen the loop response by doing one or more of the following in order of effectiveness 1 decrease the proportional gain 2 decrease the integral gain 3 increase the derivative gain Figure 4 1 Loop Over shoot Set Point Publication 1746 UM 010B EN P April 2001 4 4 Setting Autotune and Gains Values Using the PID Equation Publication 1746 UM 010B EN P April 2001 If the loop is slow in reaching the set point either at start up or at a change of set point See Figure 4 2 you may be able to improve the loop response by doing one or more of the following in order of effectiveness 1 increase the proportional gain 2 increase the integral gain 3 decrease the derivative gain Figure 4 2 Loop Slow to Set Point Set Point The module provides dependant PID control action Dependent control action can be represented by the equation 1 Where dE CV Control variable CV K E Diet Kei Proportional gain no units 0 E Error SP PV or PV SP K Integral gain repeats seconds K Derivative gain seconds t The module is capable of performing PID control by calculating the solution to an approximation of the PID equation The approximation is represented by the equation t AE CV K E K E A Ky 0 Where t
42. itch from the cold startup algorithms to PID control The pre set point value is calculated from the auto tune data The value is returned through the rotator bits In the example code it would be found in Nxx 236 thru 239 a value for each channel The startup aggressiveness factor increases the pre set point value by percentage For example EXAMPLE Consider e setpoint is 400 0 preset point for channel 1 nxx 236 is 75 startup aggressiveness factor is 0 The point at which you would switch from the cold startup algorithm to PID control would be setpoint resetpoint P 100 400 00 153 75 0 325 If the startup SAF factor is set to 25 the point at which you would switch from the cold startup algorithms to PID control would be 400 00 E x 75 0 343 8 IM PORTANT The higher the startup aggressiveness factor is the closer to setpoint you will go before you switch from the cold startup algorithms to PID control If your pre set point is too close to the actual setpoint you can expect overshoot to occur If you change the startup aggressiveness factor you will need to redownload the M1 configuration and the MO autotune block for the change to take effect Publication 1746 UM 010B EN P April 2001 3 12 Configuring the M odule Ramp Rates Publication 1746 UM 010B EN P April 2001 The ramp rate value modifies the setpoint in steps until it reaches the n
43. ivision 2 Groups A D or nonhazardous locations C M arked for all applicable directives M arked for all applicable acts Chapter 3 Configuring the Module You configure the module by setting words and bits for each loop in Configuration Block N10 0 100 which your ladder logic uses to load the module s M1 file We cover bit selections and word descriptions Refer to Table 3 B on page 3 13 for selections units and defaults Loop Operation Mode Word 1 Bits 0 and 1 for Channel 1 Use these bits to select how you want the loop to perform Mode of Loop Operation 01 00 monitor the loop to indicate temperature and alarms 0 0 perform PID loop control with temperature indicationand 0 1 alarms disable the loop 1 0 invalid setting 1 1 Type of Loop Input Word 1 Bits 2 5 for Channel 1 Use the following bits to select type J or K thermocouple any other bit setting is invalid TC 05 4 03 0 type 0 0 0 0 type K 0 0 0 1 Publication 1746 UM 010B EN P April 2001 3 2 Configuring the Module Enable Loop Alarms Word 1 Bit6for Channel 1 Set this bit to enable alarms for the designated loop TC Break Response Word 1 Bits 7 and 8 for Channel 1 If the module detects a TC open wire fora loop in automatic mode you can select how the module responds in one of the following ways TC Break Response 08 07 disables the loop 0 0 forces CV to
44. k to the module in words 1 24 NXX 110 134 This causes the module to calculate the PID gains In this case set the block header in word 0 NXX 110 to 880A hexadecimal or Send PID gains only in words 25 48 NXX 145 168 This overwrites the current PID values in the module In this case set the block header in word 0 NXX 120 to 880B hexadecimal IM PORTANT When you download either an autotune or gains block the BTM module s PID algorithm requires time to adjust proportional to the thermal mass of the system This could cause a slow or unexpected system response The module s memory is volatile Whenever power to the module is interrupted you must establish the gains again If you don t send an autotune block PID block or both blocks to the module the module will not work in automode Sending the autotune block establishes the start up algorithm and the values the module uses to calculate the PID gains causing the module to recalculate the PID gains However you can override the autotune gains by sending the gains block after the autotune block You must initially download 0 and M1 files for the module to operate Autotuning the Loops You select autotuning from the output image table block Refer to Using the Output Image Table on page 5 8 For each loop you must turn on the specific bit to enable autotuning for the corresponding loop To trigger the start of autotuning you must also cause
45. ll cause the PID loop to windup because the loop is still active and wants to control When you re enable the loop it will oscillate about the setpoint then come into control The correct way to shut down a loop is to put the loop into manual mode with 0 CV output Publication 1746 UM 010B EN P April 2001 A alarm dead band 3 8 hysteresis 3 8 autotune block layout 4 5 overview 4 1 PID equation 4 4 autotuning finetuning 4 3 loops 4 2 C calibrating codes and status 7 1 procedure 7 2 codes calibration 7 1 configuration block layout 3 11 overview 3 1 configuring module 3 1 D dead band 3 8 disabling slots 1 4 F finetuning loops 4 3 G gains block layout 4 5 overview 4 1 PID equation 4 4 sequence of setting PID gains 4 1 H hysteresis 3 8 Index installing procedure 2 4 M M0 M 1 files configuration block 3 11 module calibrating 7 1 troubleshooting 8 1 monitoring status data 6 1 0 operating module 5 1 overview 1 1 P PID equation 4 4 gains 4 1 loop 1 1 procedure calibrating 7 2 programming example 9 1 R response disabling slots 1 4 sequence setting PID gains 4 1 setting autotune values 4 1 gains values 4 1 PID gains 4 1 status w ords monitoring 6 1 switching barrel control 3 3 T TPO timing diagram 1 2 3 6 Publication 1746 UM 010B EN P April 2001 2 Index Publication 1746 UM 010B EN P April 2001 AB Allen Bradley Publication P
46. local I O chassis Any other applications are not supported The temperature control module is an intelligent I O module that can provide a maximum of 4 PID loops for temperature control The module has 4 analog thermocouple TC inputs Each analog input functions as the process variable PV fora PID loop The PID algorithm and tuning assisted process TAP algorithm are performed on the module for each of the loops The control variable CV output of each loop either analog output or time proportioned output TPO is sent from the module to the SLC data table Your application ladder logic must access the CV value in the data table and send the analog or TPO data to an output module to close the loop Figure 11 1746 module with 4 PID logic channels showing one complete PID loop output module heater analog or TPO process to be controlled loop logic PV TC Lap CV looplogic loop logic 4 AAA A AAA La loop logic Publication 1746 UM 010B EN P April 2001 12 Getting Started Features ofthe Temperature 1746 BTM module provides Control Module Module Outputs Publication 1746 UM 010B EN P April 2001 e 4 independent temperature control loops autotune PID loops one loop or any combination of loops be autotuned while other loops are runni
47. loop 1 establish a minimum rate of change min in the temperature input PV that you allow when the output CV is at 100 in automatic mode The temperature change value you enter in word 16 divided by the period value you enter in word 17 is the thermal integrity rate IM PORTANT Once loss of thermal integrity is detected you must clear this condition by disabling the affected loop and then re enabling it To disable this feature enter zero in for both setpoints Words 18 for Channel 1 This value ramps the setpoint in steps to the new setpoint Word 20 for Channel 1 This is a pure output step function for performing a non barrel autotune It is added to the current output It should be applied under steady state conditions The loop operating mode must be non barrel EXAMPLE Consider this e CV is 10 non barrel Autotune Disturbance Size 15 10 If an autotune is invoked the CV s output would go to 20 for the duration of the Autotune Publication 1746 UM 010B EN P April 2001 3 10 Configuring the M odule Table 3 A Implied Decimal Point Examples IMPORTANT Because loop values are stored and reported in integer files you must understand the meaning of implied decimal point IDP Otherwise the magnitude of your intended value may be in error by as much as 1000 depending on the position of the IDP Implied Decimal Point When entering or reading integer values the range given in Table 3 A
48. m Bit e 4 05 for Channel 1 The PV Rate is a setpoint with an associated alarm that indicates when the temperature is rising too rapidly If the zone s PV has risen more than this setpoint in one second in auto mode the module sets the PV rate alarm bit I e 4 05 loop 1 The module only reports this alarm no action is taken Words 11 14 for Channel 1 In the configuration block M1 file you select values for the following temperature level alarms low temperature alarm word 11 for channel 1 high temperature alarm word 12 for channel 1 low deviation alarm from the set point word 13 for channel 1 e high deviation alarm from the set point word 14 for channel 1 Configuring the Module 3 7 Temp High Temperature Alarm Value absolute Set High Deviation Alarm Value track setpoint Point ow Deviation Alarm Value track setpoint 0 Low Temperature Alarm Value absolute Time Publication 1746 UM 010B EN P April 2001 3 8 Configuring the Module Alarm Dead Band Word 15 for Channel 1 Once the temperature alarm bits are on they remain on until the temperature drops below the high alarm by the alarm dead band value or rises above the low alarm by this value The alarm dead band applies to the CV value at the high and low temperature alarms and deviation alarm values and provides a hysteresis effect Low and high alarms are defined as Low Alarm With Dead Band When the temper
49. ng e a unique start up algorithm to minimize overshoot an isolated thermocouple J and input for each PID loop e 16 bit analog to digital converter resolution 0 1 resolution e a heat CV signal for each PID loop as a numeric value e a cool CV signal for each PID loop as a numeric value a heat CV signal for each PID loop as TPO bit e a cool CV signal for each PID loop as a TPO bit e temperature values in C or F self calibration external reference required user selectable high and low alarms with dead band for hysteresis input open circuit detection The BTM module sends the control variable CV for heating and or cooling each loop to the SLC processor s input image table as both of e numeric value current CV e time proportioned output TPO Current CV Your ladder logic should read the numeric value current CV scale it and send it to an analog output module to generate the control signal to an analog temperature control actuator If using the sample program look for current CVs in N10 208 211 for loops 1 4 Refer to Sample Program on page 9 1 TPO The module returns the heat TPO bit 6 and cool TPO bit 7 in input image table words 8 11 for loops 1 4 The sample program sends TPO signals to a digital output module to generate the control signal to a digital temperature control actuator Refer to Sample Program on page 9 1 Getting Started 1 3 Figure 1 2 TPO timing
50. o the small signal amplitudes microvolt C Isolate them from other input wiring and modules that radiate electrical interference Group your modules within the I O chassis to minimize adverse effects from radiated electrical noise and heat Consider the following conditions when selecting a slot location Position the module away from modules that e connect to sources of electrical noise such as relays and ac motor drives e generate significant heat such as 32 point I O modules Publication 1746 UM 010B EN P April 2001 2 4 Installing and Wiring Installing the Module Publication 1746 UM 010B EN P April 2001 Follow this procedure ATTENTION Never install remove or wire modules with power applied to the chassis or devices wired to the module 1 Align the circuit board of the thermocouple module with the card guides located at the top and bottom of the chassis 2 Slide the module into the chassis until both top and bottom retaining clips are secured Apply firm even pressure on the module to attach it to its backplane connector Never force the module into the slot 3 Cover unused slots with the card slot filler catalog number 1746 N2 4 To remove press the releases at the top and bottom of the module and slide the module out of the chassis slot UN retaining clips card guides top and bottom releases A oo U
51. ocouple mV operation of all channels is suspended during calibration Calibration Codes and Status Use the following format for entering calibration code words and reading calibration status bits Enter calibration values in hexadecimal You read channel status bits at different steps in the calibration procedure one bit for each channel you are calibrating Use Word 14 Output Image for entering calibration codes 15 12 1 08 07 04 03 00 Code Word 5 1 0 0 1 Calibration codes in Hex Use Words 4 and 5 Input Image for reading calibration status 15 12 1 08 07 04 03 00 Status Word 4 Channel status during calibration OK status bits 1 for channels 3 2 1 0 high end calibration OK status bits 1 for channels 3 2 1 0 low end calibration 15 12 1 08 07 04 03 00 Status Word 5 Channel status at NT completion of calibration OK status bits 1 for channels 3 2 1 0 low end calibration Channel status words 6 and 7 display CAL4 during calibration Reads F Hex if all four channels are OK Publication 1746 UM 010B EN P April 2001 7 2 Calibrating the odule Publication 1746 UM 010B EN P April 2001 Calibration Procedure To calibrate the module you need a precision dc voltmeter and precision power supply that can
52. ord 0 0 Loop 2 temperature word 1 1 Slot gt Loop 3 temperature word 2 9 2 See Figure 1 3 on Loop 4 temperature word 3 3 page 1 4 input Loop 1 configuration status word 4 4 image Loop 2 configuration status word 5 5 16 words Loop 3 configuration status word 6 e 6 Loop 4 configuration status word 7 7 Loop 1 control status and word 8 e 8 Loop 2 control status and TPO word 9 9 Loop 3 control status and word 10 e 10 Loop 4 control status and TPO word 11 911 f using the sample program word 12 e 12 qae M ei scanned into N10 200 243 word 14 14 word 15 e 15 Publication 1746 UM 010B EN P April 2001 1 4 Getting Started Module Addressing Input Image Table Address slot file type 7 element word delimiter delimiter Response to Slot Disabling Publication 1746 UM 010B EN P April 2001 word 1 0647 When you enter module ID in processor configuration off line the processor automatically reserves the required number of I O image table words In the figure below that section of the I O image table is designated by slot Its location in the I O image table is determined by the module s slot location e in the I O chassis Slot location e is a required addressing unit when referring to the module in ladder logic For the sample program s data table layout See Table 9 A BTM201 rss N7 Data Table on page 9 2 See Figure 1 3 for an
53. p mode Manual 1 Auto 2 Setpoint 5 0 Standby 1 Run 3 Autotune 0 No 1 Yes complete 4 Autotune success 0 No 1 Yes 5 Setpoint ramping 0 No 1 Enabled 6 Heat TPO 0 Off 1 On 7 Cool TPO 0 Off 1 On 8 15 See Table 6 C on page 6 2 0 None 1 Alarm 12 13 15 Function and value of this word set by N 10 192 bits 8 10 See Table 6 B Publication 1746 UM 010B EN P April 2001 6 2 Monitoring Status Data Values reported in words 12 15 for loops 1 4 vary depending on the bit code set in global commands N10 192 bits 08 10 and reported in input image word N10 168 bits 08 10 You must interpret the reported value according to the implied decimal point Table 6 B Interpret Implied Decimal Points If N10 168 10 09 08 Reports Implied decimal pointis Interpret As 001 current setpoint 1 decimal place 4999 499 9 010 current error or from the right 101 cold junction temperature 011 current CV analog 2 decimal places 4999 49 99 output 100 error code or none 4999 4999 110 firmware revision number Table 6 C Global Status from All Loops Word Bit Define Indicated By 15 14 13 12 11 10 9 8 7 6 5 4 3 2 11 0 8 Current setpoint 0 0 1 byte Current Error value 0 1 0 Selection of Reported en values Current CV loop output 0 1 1 See Important Below Current error code 1 0 0 Cold junction
54. page 8 2 Publication 1746 UM 010B EN P April 2001 5 8 Control and Autotune a Loop Using the Output Image The output image table contains 16 words as shown in Table Table 5 Cbelow You must enter a 16 bit signed integer value for the run temperature setpoint and manual output If you are using the example code from the manual you will not manipulate the output image table directly You will manipulate the output image buffer N10 180 195 e Fora run temperature setpoint the implied decimal point is 1 place from the right causing the resolution to be 0 1 For example if you want a value of 499 9 enter 04999 e For the manual output the implied decimal point is 2 places from the right causing the resolution to be 0 01 For example if you want a value of 49 99 enter 04999 Table 5 C Operating Commands to Loops 1 4 coope Lt Seta bit or enter a value 1 2 3 4 bit to Configure Bit Selector Range 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 0 1 2 3 0 loop control Disable 0 Enable 1 X 1 Auto manual anual 0 Auto 1 X 2 Setpoint select Standby 0 Run 1 X 3 Autotune enable Disable 0 Enable 1 X 4 PID integral reset Accume 0 Reset 1 X 5 Ramp enable Disable 0 Enable 1 X 6 Ramp hold Hold 0 Don t hold 1 X 7 15 Reserved 4 5 6 7 0 15 Run temp setpoint 3276 7 thru 3276 7 8 9 10 11 0415 Manual Output
55. pointer for M 1 M 0 communications N7 9 What BTM are we currently working on for M 1 M 0 communications N7 10 Data table pointer for rotator code N7 11 What BTM are we working on for rotator code N7 12 M aster Command requests for M 1M 0 communications N7 13 Rotator code input bits output bits memory N7 14 Rotator initialization data table to use N7 15 Rotator initialization what BTM are we doing N7 16 Data table for first BTM N7 17 Slot number for first BTM N7 18 Number of 5 in system N7 19 M isc control Bits N7 20 Rotator Level 1 or 2 check In the IMPORTANT Sample Program 9 3 In this version of code you do not command 1 0 file transfers thru N7 0 you will now use N7 12 master command request Download and Upload Settings Table 9 Download and Upload Settings Location Description N7 12 0 set will download the M 1 configuration N7 12 1 set will download the M 0 auto tune information N7 12 2 set will download the M 0 PID information N7 12 3 set will upload the M 0 auto tune information N7 12 4 set will upload the M 0 PID information Publication 1746 UM 010B EN P April 2001 9 4 Sample Program The information for the M1 MO input image output image and the rotator code is put into one data table The layout of the file is as follows Table 9 C BTM 201 rss M 1 MO Input Image Output Image and Rotator Code Data Table
56. r Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 PN 957555 22 2001 Rockwell International Corporation Printed in the U S A Publication 1746 UM 010B EN P April 2001 Supersedes Publication 1746 6 10 September 1999
57. r as the module the programmable controller as the SLC processor or the processor a thermocouple as a TC e a time proportioned output as TPO e the tuning assisted processes as proportional integral derivative as PID cold junction compensation as CJC Table of Contents Important User ii European Communities EC Directive Compliance iii f pos d Oe d er EUR Low Voltage Directive Using This Manual 2x95 7 ere et EE eis P 1 1 System 1 P 1 Vocabula 2 1 Temperature Control Using BTM Module in an SLC System 1 1 Features of the Temperature Control Module 1 2 Module 1 2 dU MR as Sonne ce RE 1 2 TPO sos a waged e are ae d 1 2 Module 1 4 Response to Slot Disabling 1 4 1 4 Output reSDDHSO s c 1 4 Chapter 2 Avoiding Electrostatic 2 1 European Communities EC Directive Compliance 2 2 EMC Die CVG 6s iride top exe S parked Hand xo e etta 2 2 Low Voltage Directive 2 2 Determining Power
58. r each channel F Hex for all four channels Otherwise the module returns channel status bits set to zero 10 11 12 Calibrating the Module 7 3 Remove the 90 000 mV calibration voltage With your programming terminal enter calibration code 1008 Hex into output word 14 Observe bits 0 3 in status word 5 After the module burns the calibration values into its EEPROM it returns status OK bits set one bit for each channel F Hex for all four channels If the module could not complete the calibration of one or more channels it returns a zeroed status bit for that channel non F Hex returned To end the calibration procedure enter calibration code 0000 Hex into output word 14 During thermocouple mV operation word 14 must be zero which is normal operation Publication 1746 UM 010B EN P April 2001 7 4 Calibrating the Module Publication 1746 UM 010B EN P April 2001 Chapter 8 Troubleshooting the Module This chapter provides troubleshooting guidelines Troubleshooting with LED Indicators INPUT The front panel of the module contains five green LED indicators for channel status and one green LED indicator for module status LED When indicat On channel is correctly configured when you enable the channel Flashing channel fault condition ISOLATED Channel Status CHANNEL ma STATUS Modul MopuLe statusL_ Status On self check completed OK Flashing communication occur
59. rd 4 for loop 1 e forces the CV to the manual output value O e 8 for loop 1 Once the thermocouple break has been repaired you must disable the loop and then re enable it through the input image table O e 0 0 loop 1 For additional information Refer to TC Break Response on page 3 2 Word 5 for Channel 1 When not using the runtime setpoint 4 for loop 1 use this value to hold a lower temperature for faster warm up and or optimum standby conditions Publication 1746 UM 010B EN P April 2001 3 6 Configuring the Module Heat Cool Minimum On times Heat Cool TPO Period PV Rate and Associated Alarm High Low Temperature and Deviation Alarms Publication 1746 UM 010B EN P April 2001 Words 6 and 8 for channel 1 These values determine the minimum cycle time after which loop TPO bits will turn ON They are used to allow contactors time to close or pull in If the contactor is energized for less than this value the contactor will not close but the attempt will count as a cycle For example suppose you set the TPO period for 10 seconds and the minimum ON time to 1 second Then if the module calculates a CV of 10 or less the TPO bit for that zone will not tum ON Words 7 and 9 for Channel 1 When CV loop output is time proportioned TPO use this value to set the interval between successive turn O Ns For less than a 100 output level the output goes OFF for the balance of the interval Word 10 and Alar
60. re depth choosing a module slot in a local I O chassis e installing the module wiring the module Electrostatic discharge can damage semiconductor devices inside this module if you touch backplane connector pins Guard against electrostatic damage by observing the following precautions ATTENTION Electrostatic discharge can degrade performance or cause permanent damage Handle the module as stated below Touch a grounded object to rid yourself of charge before handling e Wear an approved wrist strap when handling the module e Handle the module from the front away from the backplane connector Do not touch backplane connector pins Publication 1746 UM 010B EN P April 2001 2 2 Installing and Wiring European Communities EC 1 this product has the CE mark it is approved for installation within Directive Compliance Publication 1746 UM 010B EN P April 2001 e European Union and EEA regions It has been designed and tested to meet the following directives EMC Directive This product is tested to meet the Council Directive 89 336 EC Electromagnetic Compatibility EMC by applying the following standards in whole or in part documented in a technical construction file e EN 50081 2 EMC Generic Emission Standard Part 2 Industrial Environment EN 5001082 2 EMC Generic Immunity Standard Part 2 Industrial Environment This product is intended for use in an industrial environmen
61. rent than that for an outer zone to account for an inner zone being more affected by adjacent zones The inner zones are treated as more of an integrating process than the outer zones Typical plastic injection barrel Outer Inner Inner Outer with multiple temperature zones Ed e xd Zone 1 Zone 2 Zone 3 Moz H2 H3 Hn eas Ram Screw 1 so 5 T2 T3 T temperature measurement point thermocouple H heater band element If you change the inner outer zone selection after autotune you must re autotune Publication 1746 UM 010B EN P April 2001 High Low CV Limits TC Break Control Standby Setpoint Configuring the Module 3 5 Words 2 and 3 for Channel 1 Use CV High and Low Limits to set up the loop mode For this loop mode Low High heat only 0 100 cool only 100 0 heat cool 100 100 Word 4 or 0 e 8 for Channel1 If a loop input circuit becomes open open wire the loop can not measure temperature In automatic mode the lack of temperature feedback makes it impossible to control the temperature To guard against this condition the BTM module provides TC break detection When a break is detected the module responds in one of these ways disables the loop forces CV to this TC Break Control value wo
62. ring between SLC processor and BTM module We present a table of indications probable causes and recommended action See Table 8 A on page 8 3 and Table 8 B on page 8 4 for a listing of error codes Indication Probable Cause Recommended Action all indicators are OFF no power to module check power to 1 0 chassis recycle power as necessary module performing self check wait until self check is complete module performing calibration wait until calibration is complete possible short on the module LED failure replace module channel status indicator is ON channel is correctly configured when you enable the channel normal operation during calibration the channel is properly configured for the high end of millivolt range normal calibration channel status indicator is flashing fault condition such as open circuit or an under over range condition correct fault condition during calibration the channel is properly configured for the low end of millivolt range normal calibration Publication 1746 UM 010B EN P April 2001 8 2 Troubleshooting the M odule Indication Probable Cause Recommended Action module status self check is completed satisfactorily normal power up indicator is ON module is OK module waiting for channels to be enabled module status communication occurring between normal operation indicator is flashing SLC processor and the B
63. roblem Report If you find a problem with our documentation please complete and return this form Pub Title Type Barrel Temperature Control Module User M anual Cat No 1746 BTM Pub No 1746 UMO10B EN P Pub Date April 2001 PartNo 957555 22 Check Problem s Type Describe Problem s Internal Use Only Technical Accuracy C text illustration Completeness procedure step illustration definition info in manual What information is missing example guideline feature accessibility explanation other info not in manual Clarity What is unclear Sequence W hat is not in the right order Other Comments Use back for more comments Your Name Location Phone Returate M arketing Communications Allen Bradley 1 Allen Bradley Drive Mayfield Hts OH 44124 6118Phone 440 646 3176 FAX 440 646 4320 Publication ICCG 5 21 August 1995 PN 955107 82 PLEASE FASTEN HERE DO NOT STAPLE Other Comments PLEASE FOLD HERE NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 18235 CLEVELAND OH POSTAGE WILL BE PAID BY THE ADDRESSEE Allen Bradley DO DGE 2 Rockwell Automation 1 ALLEN BRADLEY DR MAYFIELD HEIGHTS OH 44124 9705 www rockwellautomation com Powe
64. rs or use shielded twisted pair thermocouple extension lead wire specified by the thermocouple manufacturer Using the incorrect type of thermocouple extension wire or not following the correct polarity may cause invalid readings See IEEE Std 518 Section 6 4 2 7 or contact your sensor manufacturer for additional details e When trimming cable leads minimize the length of unshielded wires e Ground the shield drain wire at only one end of the cable The preferred location is at the I O chassis ground See Figure 2 4 e For maximum noise reduction use 3 8 inch braid wire to connect cable shields to the nearest I O chassis mounting bolt Then connect the I O chassis to earth ground See Figure 2 4 These connections are a requirement regardless of cable type e Tighten terminal screws Excessive tightening can strip the screw e The open circuit detector generates approximately 20 nano amperes into the thermocouple cable A total lead resistance of 25 ohms 12 5 one way will produce 0 5 mV of error Follow system grounding and wiring guidelines found in your SLC 500 Modular Hardware Installation and Operation Manual publication 1747 6 2 Publication 1746 UM 010B EN P April 2001 2 8 Installing and Wiring Publication 1746 UM 010B EN P April 2001 Preparing and Wiring the Cables To prepare and connect cable leads and drain wires follow these Steps Figure 2 3 Cable lead and drain wire preparation Remove the foil
65. s are not supported Audience You must be able to program and operate an Allen Bradley SLC programmable controller to make efficient use of this module In particular you must know how to configure 0 and 1 files For more information see the appropriate SLC programming manual before you generate a program for this module System Compatibility System compatibility involves data table use as well as compatibility with a local I O chassis and SLC processor Data Table Communication between the module and processor is bi directional The processor transfers output data through the output image table to the BTM module and transfers input data from the BTM module through the input image table The BTM module also requires M files for configuration and calibration values 1 0 Chassis You can use this module with 1746 A4 A7 A10 or A13 chassis provided there is an SIC controller in the chassis local system You can place the BTM module in any I O slot except for the first slot which is reserved for the processor Publication 1746 UM 010B EN P April 2001 P 2 Preface Vocabulary Publication 1746 UM 010B EN P April 2001 SLC Processor The 1746 BTM module is compatible with any SLC processor that supports 0 1 files such as the SLC 5 05 SLC 5 04 SLC 5 03 and SLC 5 02 controllers In this manual we refer to e the barrel temperature control module as the 1746 BTM module the BTM module o
66. s block to the module a new set of PID gains is established on the module The following list summarizes the process e Autotuning causes the module to measure the process dynamics and calculates PID gains e Reading the PID gains block from the module copies the PID gains generated by autotuning into the SLC files e Writing the PID gains block to the module overwrites any PID gains that had been in the module e Autotuning or writing the autotune block to the module causes the module to calculate PID gains and overwrite any PID gains that had been in the module At initial start up you must write the autotune block to the BTM module or perform autotuning If you select autotuning for any loop that is successfully tuned the gains are calculated by the module Gains you sent to the module for a loop in any gains block previous to successful autotuning of the loop are superseded by the gains derived from autotuning If you then read the gains block it contains the gains derived from autotuning If autotuning is not successful for any loops as indicated in the status block the gains you sent for those loops before autotuning is used by the module Publication 1746 UM 010B EN P April 2001 4 2 Setting Autotune and Gains Values Once autotuning is complete you must read the gains block from the module to store it in SLC processor memory You can write the autotune and gains block either of these ways e Send autotune bloc
67. t Low Voltage Directive This product is tested to meet Council Directive 73 23 EC Low Voltage by applying the safety requirements of EN 61131 2 Programmable Controllers Part 2 Equipment Requirements and Tests For specific information required by EN 61131 2 see the appropriate sections in this publication as well as the Allen Bradley publication Industrial Automation Wiring and Grounding Guidelines publication 1770 4 1 This equipment is classified as open equipment and must be mounted in an enclosure during operation to provide safety protection Determining Power Requirements Choosing a Module Slotin a Local 1 0 Chassis Installing and Wiring 2 3 When computing power supply requirements add the values shown in Table 2 A to the requirements of all other modules in the SLC chassis to prevent overloading the chassis power supply Table 2 Power Supply Requirements 5V dc amps 24V dc amps 0 110 0 085 Place your module in any slot of an SLC500 module or modular expansion chassis except for the left most slot slot 0 reserved for the SLC processor or adapter modules IM PORTANT For proper operation use this module with a local processor The module is not designed to operate in a remote chassis Installation considerations Most thermocouple type applications require an industrial enclosure to reduce the effects of electrical interference Thermocouple inputs are highly susceptible to electrical noises due t
68. tator code is put into one data table the layout of the file is as follows Publication 1746 UM 010B EN P April 2001 9 8 Sample Program Table 9 F BTM50220 RSS M1 MO Input Image Output Image and Rotator Code Data Table Description See Page NXX 0 Block header for the M 1 configuration file 3 11 NXX 1 thru NXX 100 1 configuration information 3 13 NXX 101 thru NXX 109 Reserved do not use NA NXX 110 Block header for the M 0 file 4 6 NXX 111 thru NXX 159 M 0 file information 3 11 4 6 NXX 160 thru N XX 199 Reserved Do not use 6 2 NXX 200 thru NXX 203 Current set points NA NXX 204 thru NXX 207 Current error PV SP 5 8 NXX 208 thru NXX 211 Current CVs NA NXX 212 thru NXX 215 Error codes NA NXX 216 thru NXX 219 CJ C temperatures NA NXX 220 thru NXX 223 Firmware revision NA NXX 224 thru NXX 227 P contribution 8 2 NXX 228 thru NXX 231 contribution 2 6 NXX 232 thru NXX 235 D contribution 9 1 NXX 236 thru NXX 239 Pre set point 4 4 NXX 240 thru NXX 243 Wait period 4 4 NXX 244 thru NXX 247 Reserved for future use 4 4 NXX 248 thru NXX 255 Reserved do not use NA The in the data table address above will depend on the data table location of the 1746 BTM In the example code it is N10 Publication 1746 UM 010B EN P April 2001 Sample Program 9 9 ral 85 for This section outlines general programming information concerning the a 1 Programmin
69. te sections in this publication as well as the Allen Bradley publication Industrial Automation Wiring and Grounding Guidelines publication 1770 4 1 This equipment is classified as open equipment and must be mounted in an enclosure during operation to provide safety protection Publication 1746 UM 010B EN P April 2001 Publication 1746 UM 010B EN P April 2001 Summary of Changes Major changes in this revision include e Ladder code addresses have been changed e The sample ladder code in Chapter 9 has been enhanced e Fxamples outlining the mathematical relationships involved in Startup Aggressiveness Factor and Ramp Rates have been included in Chapter 3 e Appendixes A and B have been omitted e Module specifications can be found in the 1746 BTM Installation Instructions Publication 1746 IN014B EN P Publication 1746 UM 010B EN P April 2001 2 Summary of Changes Publication 1746 UM 010B EN P April 2001 Using This Manual Preface This manual shows you how to use the Barrel Temperature Control Module cat no 1746 BTM in an Allen Bradley SLC system for barrel temperature control and other injection molding or extrusion related temperature control applications The manual explains how to install program calibrate and troubleshoot the BTM module ATTENTION Use the 1746 BTM module in a local I O chassis only for barrel temperature control of injection molding applications or extruders Any other application
70. tified and documented as being necessary and sufficient to a successful auto tune If there is not enough temperature differential between the starting temperature and the setpoint to achieve maximum slope an error is generated and auto tune is aborted Another cause of error here is in having sufficient temperature differential to attain maximum rate of change but not enough differential for the system to recover from the test successfully The system will overshoot setpoint as a result of the test The module knows when this is going to happen as a result of the gain and time constant information previously learned and flags it as an error if conditions are appropriate After these two tests are completed an identical procedure is applied to exercise the cooling control on the system if it is so configured in which case the autotune procedure would continue by first stabilizing at setpoint This is a module wide event meaning that all zones enabled on the module must be stable before the procedure will continue When all tests have been completed the module will default to the mode it was set at prior to the auto tune auto or manual and behave accordingly Publication 1746 UM 010B EN P April 2001 5 12 Control and Autotune a Loop Publication 1746 UM 010B EN P April 2001 A synopsis of the complete tuning procedure would be as follows 1 Wait for all zones to be stable A module wide event inclusive of all zones en
71. u will be able to have multiple BTMs in a SLC system without having to duplicate code for each BTM The only code that will need to be added will be in the 1 0 Publication 1746 UM 010B EN P April 2001 9 2 Sample Program Publication 1746 UM 010B EN P April 2001 communications program file 4 and in the main program file 2 Later there will be an example for the code that will need to be added BTM 201 155 Data Table Layout The data table layout for this version of code has change considerably from the current BTM application code The biggest change is that the input and output images are now buffered This means that you will now manipulate all input and output data thru the buffer area not in the actual input and output images If you manipulate data in the actual input and output image the buffers will over write them The following is a layout of the new data tables The M file and the rotator information have been moved into a different data table previous version the information was located in N7 Table 9 A 201 155 7 Data Table Location Description N7 0 User request pending N71 User request being serviced N72 Request mask N7 3 Bit 0 request complete cleanup needed 7 4 Indirect address for pointer in rotator N7 5 Rotator bits N7 6 Bit 0 all requests and acknowledges cleared N77 Data table pointer for M 1 M 0 communications N7 8 Slot
72. us conclusions about its observations and misidentify the system in question Thus at the onset of auto tune it is desired to let all of the influences other than direct auto tune excitation dissipate before excitation is applied In the BTM there is a wait period at the beginning of the auto tune procedure Once it is initiated for all of the aforementioned effects to dissipate Then and only then will the routine qualify the system as stable and begin excitation This however does not mean that the system must have zero output It does mean that the system must remain at a consistent temperature with very little fluctuation There are two ways in which this condition can be achieved The first and most typical is that of a cold start condition In this case there is no energy being inputted to the system and the system is stable with respect to ambient conditions With regards to the BTM this is achieved easiest by setting all active zones to Manual Mode with 0 zero percent output The second most common way to achieve stability is with a non zero output being applied to the system either in Manual or Automatic Modes It is perfectly acceptable to have a non zero output applied to the system as long as it is stable in Automatic Mode this is stability at a setpoint in Manual Mode this is a single manual output value and a settled response no temperature variation A common mistake is to have heat applied to the system prior to auto tune and
73. write the M1 configuration block to establish the module s mode of control Then you must update the output image table any time you want to change the operating mode 1 Configuration File You select the loop control mode in the configuration file Words Bit01 Bit 00 Lets you select 1 26 51 76 0 0 monitor the loop for loops 1 4 0 1 control the loop with PID 1 0 disable the loop Output Image Table If you select control the loop mode you control loop operation with these words and bits in the output image table abbreviated list Words Bit Lets you 0 3 00 enable or disable the loop loops 1 4 03 enable or disable autotune 4 1 n a enter run temperature setpoints 8 11 enter manual CV output values 12 01 invoke autotune global for all loops 02 abort autotune 03 reset error codes Publication 1746 UM 010B EN P April 2001 5 2 Control and Autotune a Loop Figure 5 1 Control Mode Selections and Loop Operation through the M 1 configuration block through the output image table 7 Control Mode Selections Loop Operation Disable the Loop p gt Hold CV 0 and no temperature or alarms Monitor the Loop p gt Hold CV 0 but monitor temperature and provide temperature and alarms in the status block Control the Loop p gt Disable Loop Control L Enable Loop Control The manual output value in t
74. yout on page 9 2 and BTM50220 RSS Data table layout on page 9 7 Remember that the module returns the control variable CV of each loop to the input image table as both a numeric value current CV and a time proportioned output TPO For additional information Refer to BTM201 rss M1 MO Input Image Output Image and Rotator Code Data Table on page 9 4 and BTM50220 RSS M1 MO Input Image Output Image and Rotator Code Data Table on page 9 8 Publication 1746 UM 010B EN P April 2001 5 10 Control and Autotune a Loop BTM Auto Tune Publication 1746 UM 010B EN P April 2001 The 1746 BTM Auto Tune procedure was designed to be performed as a one time event from which all characteristics of the system being controlled could be identified and incorporated into the control scheme The identification procedure has two critical points Before exercising the system with the identification procedure the system in question must be as stable as possible Essential to a good system identification routine is the assumption that there is a high correlation between excitation and system response The identification procedure tries to identify the system by assuming that any excitation used to disturb the system is solely responsible for the observed reaction of that same system If heat or any other form of input is exciting the system other than what the identification routine is aware and in control of the routine will draw erroneo

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