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Multifunction Programmable Controller Installation and User manual

1. DEY a xx TRANSMITTER z L TRANSMITTER wer acs sala E B 24v a gt 2 26 24v so 2 cfa 9 26 _24v 3 J SER 3 9 27 i lt o 3 28 S a 3 cle 5 28 2 gt 5 2 o 29 5 2 o 29 4 lt a 8 4 a 8 6 2 2 B0 3 6 Z aBa 5 n c 7 8 3 31 lt st Ze 2 81 lt 4 nc 8 3 I 32 eo lz I B2 N C 9 33 9 ao N C 10 a lt 10 34 A N C 11 35 a 35 _NC 12 Ig 12 a 113 E 37 lt 13 5 87 lt Sm 3 38 3 TS fa 8 iss 2 f5 E 39 215 Epa lt a 8 40 lt SEE a lt 17 5 41 gt 17 5 41 4 mg a 4 18 2 alo 9 2 43 19 aa a 520 a 44 5S Rg da lt e 21 La POWER a ya POWER 7 7122 1 q 6c 46 N F 7 22 EA a 60 46 N gt 23 2 2 5 Va gt 23 J 2Z5 Va BN a 3 9 a 4 L 8 al c59 Bi L y Si Figure 2 3 Terminatio
2. 29 99 29000 299 Y Y Y Y y y ooo gt e UNDERFLOW wsp pvi a WSP PVI Pv2 wsp DRSP L WSP PVI H SET YYYY SET mM 11 YYYY AL AL DEV 1 2 2 DEV RSP AL AL AL 7 i 7 6 Kt ae ol a fk a belo Sole cost MUX y DB y OR1 ahv PD Ly a E PD ve Je pet I oT or 5 q 7 7 Heat Cool m 4Y PID cost e Vv 0 E visu 4 14 os 4 el E E Qa Oo p Ok Coot N eH Ok Heat I CONTROL TRK _ e y OUT elit Y DB Ja PTRK TRK DHOLD AIM DTRK A N CONTROL Mis OUT H C YMIN QU AIM o LI T m Y Y AL AL 4 NA 5 visu Y y Y y A Y Y Y Eo E E a OOOO HEAT ACT COOL ACT This configuration is suitable for those processes requiring two actuators in order to control the process variable For instance a temperature control that needs both a heating function and a cooling function The configuration consists of a single Set Dev module generating an unique setpoint both for the cool and the heat channel two PID and an Heat Cool output module It has the advantage of allowing a separate set of the three terms parameters for the cool and the heat channel this feature improves
3. 8 IN A UNA QJ 25 24 PV1 measure Si 26 1424 LOOP 1 lt Remote SP AP A A 27h A Feed Forw lt e t EK ae SES O fa Retr PVI L Loop 1 LOOP2 PV2 measure K reie so o gt Retr WSP 7 U BIK T gt Actuator 2 LOOP 2 8 32 g N 33 N Pl Al 1 Pvt ou p B4 a Es Al 2 Pvi gt LOOP 1 1 36K 12 T gt Al 3 Pvt 113 K Loc Rem Sig taal Und F Pvt J Rem Mem lt 5 p Ly AL4 Pv2 gt 6 o 40 p LOOP 1 lt Hold n T F y J gt Al 5 Pv2 Track lt A a2 eae ae e Al 6 Pv2 Y min M lt S eee Sa a gt Und F Pv2 Loc Rem ENE N S U 22 46 lt T LOOP 2 Hold Power Supply Track 4 17 2LoopsC 17 1 Annex A Resident Configurations Description The drawings below are providing the following informations Block Diagram User interface consisting in a set of display panels Termination unit for the connection to the field 17 2 Block Diagram In the following block diagram the interconnections between the various modules and the display panels are not indicated in order to improve the understanding of the functionality performed Rone visu
4. OR 4 z Ne 1 l DRSP l E y DRSP YY Y Y Y VISU Y SET fate SET RSP ALM ALM ALM DEV RSP La ALM ALM ALM a lt A DEV 3 2 1 i 6 5 4 Mux f 3 WSP T COST i y i COST 4 1 2 Ema z HY 2er PID FF _ 65 PID 3144 Ki gt pt 7 74 e DB Y DB MUX 91 ala A S E OR 1 t t DB p OR 1 T CONTROL lg TRK CONTROL x TRK vs 1 out pe HOLD E 4 11 12 AIM DTRK IAM DTRK YMAX po 1 visu2 lt ag HOLD visu 2 ji fg YMIN L2 j L1 SCH SCH WSP PV1 7 VISU 3 L1 Y Y V Yyy y Y Vv Y y Yy v v NA wisu3 es ee ho a Re Be m ORRO 0 172 16 3 Control Annex A Resident Configurations Referring to loop 1 the process variable PV1 is acquired by the Al1 module providing the conversion in engineering units and the out of range detection It is transmitted to the SET DEV module that with the PID and CONTROL OUT modules makes up the core PID block The output is transmitted out on the terminal blocks through the AO1 module for driving the external actuator 16 4 Remote Setpoint This feature is supported on both the loops but with the
5. pod IDO3 DO2 po 15 3 Control OR2 DRSP Y Y Y Y a OFS ALM ALM ALM fea 6 5 4 VISU i FRL4 3 5 ae eko 7 e e ape OR1 Y SCH SCH PV L1 VISU 2 Pv L2 L2 VISU 3 L2 Vv Y Vv Y NA 102 pos IDO7 bod ia laos The Al module performs the A D the scaling and the conversion in engineering unit of the controlled variable and detects the out of range of the signal presumably caused by a sensor failure The output value of the Al module PV1 is fed into the three modules which implement the core of the PID loop 1 SET DEV 1 PID 1 and CONTROL OUT 1 The output of the PID 1 is connected to the terminal blocks of the instrument through the output module AO1 in order to drive the external actuator 15 4 Remote Setpoint This functionality is provided for both the loops Referring to loop1 the following description applies Activating DI1 i e closing the contact as in the picture 2 4 4 the Remote Setpoint is the one selected for the loop otherwise the Local Setpoint is selected In fact the setpoint mode selection as illustrated in the SDV module description is more complicated because it is based on the arbitration of the requests coming from various sources The Remote Setpoint can be the signal at the input Al2 RSP if the digital input DI2 is inactive or the cons
6. 1 gt 3 A A 27 N N E gt 4 A A 28 F gt 5 6 29 26 g IT gt 7 U BIK 8 321 fo N 33h 9 N o 10 Y p ld 11 Es 12 L 36 y 13 A 37 LS gt 14 38 15 p 39K 6 4 o 401 7 17 1 41 d T 18 A 42 L 43 44 Ratio Loop Actuator Loop 2 Actuator Alarm 1 Pv Alarm 2 Pvi Alarm 3 Pv1 Und F Pv1 RATIO LOOP Alarm 4 Pv2 Alarm 5 Pv2 Und F Pv2 Alarm6 Loop 2 POWER SUPPLY 19 Cascade 19 1 Descripti Annex A Resident Configurations on The drawings below are providing the following informations Block Diagram User interface consisting in a set of display panels Termination unit for the connection to the field This configuration consists of two loops interconnected in a cascade configurations The first loop is named Master while the second loop is named Slave The control output of the Master becomes the setpoint of the Slave entering as a Remote Setpoint The Slave loop is in the Remote Setpoint mode during the normal working conditions and it is switched to Local mode during transient situations like start up operator manoeuvre etc The displays related to this configuration include the usual single loop bargraph and trend panel one dual loop panel and an alarm list global to both the loops 19 2 Block Diagram Underflow PV Master In the following bl
7. 43 Installation and User manual of the AC10 AC20 AC30 controller 44 4 6 AC Prograph AC_Edit Software AC Edit AC Prograph run on a PC or a compatible PC with Windows operating system version 3 x or later for basic editing of the AC controller strategies It allows to analyze the strategy in a controller and to change the parameters values of the various modules and other strings like tags Furthermore it allows to save the parameters on a disk file display them again and download them into the controller For more information refer to the AC Edit AC Prograph User Manual 4 7 Sampling time TAG 0000 0 The resident configurations have a predefined sampling time of 300 msec that is perfectly suitable for most of the processes Anyway you can change this time by mean of the SYS module and set it to a new value with range 0 1 to 10 0 seconds at steps of 0 1 seconds The sampling time must be carefully set because a too large value slows the response time of the control strategy risking the incapability of the control of the process while if the sampling time is too short the response of the control strategy tends to overreact to process variations The following picture illustrate the procedure to use in order to modify the sampling time Main Prog Sel Sampling T Menu 8 I O Test 53 Sampling T Samp T 0 3 P E E rog 8 Test R RR RR
8. 157 5 mm 105 mm 58 mm lt gt 4 gt A a Do 2 k 2 20 E e E U 88 4 AAC EU 88 E o Address 0 wi Address 1 All s 22 esjeso ecojoceajesoe oscojocajeso esojecojeso y 77 mm 48 8 mm 14 8mm 63 6 mm 145 Installation and User manual of the AC10 AC20 AC30 controller 8 4 Electrical Connections 8 4 1 RS 485 The Expansion Units are connected to the AC controller through a RS 485 serial communication bus This communication has a Plug and Play capability because the setting of the baud rate and the other communication parameters is embedded in the firmware of the controller and doesn t require any customization by the user The user has just to set the address on the expansion units make the cabling and use the additional I O in the strategy he she is developing with the AC Prograph It is important to remind that e the digital I O from 1 to 8 and the 4 analog outputs from 1 to 4 are on the AC controller e the digital I O from 9 to 16 and possibly the analog outputs from 5 to 8 are on the Expansion Unit with address 0 e the digital I O from 17 to 24 are on the Expansion Unit with address 1 e the digital I O from 25 to 32 are on the Expansion Unit with address 2 The maximum distance between the AC Controller and the farthest expansion unit is limited by the RS 485 standard to about 1 000 mt When the line is at the maximum limits of length the layout of the
9. Chapter 5 Modules 5 Modules This chapter describes all the functional modules available in the AC controllers in order to provide you all the detailed informations you need to built up your control strategy 5 1 Rules used throughout this chapter The following rules have been used in this chapter to describe the modules The values in engineering units of parameters input and output signals have by default and unless differently specified the allowed range 9999 to 999999 The values in percentage of parameters input and output signals have by default and unless differently specified an allowed range 0 0 to 100 0 The two status of a digital output are indicated by H or Active for the status 1 L or Inactive for the status 0 In the drawing of the module symbol the input signals are always on the left while the output signals are on the right 45 Installation and User manual of the AC10 AC20 AC30 controller 46 5 2 I O Modules 5 2 1 Analog Input Al Description This module converts one of the four eight analog input signals connected to the termination unit of the controller into a number in engineering units The hardware range of the signal is 0 5V or 1 5V Beyond the conversion process this module provides conditioning filtering percentage ranging linearization and out of range detection on the input signal The avai
10. Modello AC30 Supply 100 240 V 50 60 Hz 3 18 28 V 50 60 Hz o 20 30 Vdc Spare Lamp optional Not supplied 0 Supplied 1 External Unit Port optional Not supplied Supplied LAN Port optional Not supplied Supplied ARCNET type 9 2 Auxiliary Units Expansion Unit with 8 digital I O AAC EU 88 00 0000 Code of the Control Strategy 00 0000 Code of the Control Strategy Expansion Units with 8 digital I O and 4 4 20 mA outputs AAC EU 88 4 Power supply for 1 3 Auxiliary Units mod AAC EU 88 and AAC EU 88 4 Supply 220 240 Vac 50Hz AAC TA Annex A Resident Configurations 10 Annex A Resident Configurations 149 Installation and User manual of the AC10 AC20 AC30 controller TABLE OF CONTENTS 10 ANNEX A RESIDENT CONFIGURATIONS cccscccsssssccssssscccsssscccssssccsssssccsssssccsssssscesesssscsssssscssssseeee 149 11 HOW TO IMPLEMENT A PID CONTROLLER sessessooeeccssssocceceessscooocecessssoceeceessscoocceessssosocecessssosecceesssssose 153 12 POO PA A aa 155 12 1 DESCRIPTIONS A od 155 12 2 FUNCTIONAL BLOCK DIAGRAM cccccccccscsssssececececsensnecececeesescaececececsesaaueeeccecsesaaececececeeseaaeaecseceseseneaececeeeees 155 JAS AEE OIH H La ESEA A E A A id 155 IQA REMOTE E PON iio 155 12 5 FORCING OPERATIONS asta A Ge
11. In the following pages all the various commands of the menu Program No n allowing to operate with the PRG programs are described in detail Program No n Edit Program This command allows you to edit all the data of an existing program The first display Prg No n presents the basic data of a program while the second one presents one at a time the data regarding one segment The panel Edit Seg allows you to choose the segment to edit Once the segment to edit has been selected its data are presented on the PRG NO n panel where they can be easily modified Program No 2 Prg No 2 Edit Seg PRG NO 2 mis 0 Edit Progra S P Val 50 aah Time mis ES Seg No 0 E E E a EJ E RJ 129 Installation and User manual of the AC10 AC20 AC30 controller 130 Detailed view of the PRG NO n display panel Selected Programmer PRG NO 2 Selected Program Selected Segment Final Setpoint S P Val 50 Auxiliary Setpoint Segment Execution Time Digital Outputs pattern Allowed Deviation Last Segment Flag Setpoint High Range Profile Window Enter the modifications and go back to the previous page Increase the number of the Segment to edit Decrease the number of the Previous Segment Segment to edit Currently Edited Segment Cancel the modifications and go back to the previous page Next Segment Program
12. Underflow PV2 Reference variable Y ENE DMUX y WSR PV1 y Y ALM ALM 5 4 Y 20 tom VISU FORZ A VISU FORZ L1 A i 4 MCNS gt 1 on1 e o 2 3 e 4 5 D6 7 8 Y OR1 E VISU ALL OR VISUALI lt 4 L visu FRL4 Vv 7 Y i 2 Sad ad This configuration consists of 1 Ratio Loop 1 Standard loop The first loop is the main loop of the instrument it implements fully the ratio control algorithm where the setpoint is derived through a ration operation from the reference analog input signal PV2 and it is equipped with the following list of important functionalities Bias on the Local Setpoint Output forcing modes Alarms on PV1 Alarms on PV2 The second loop is a basic PID loop with the following functionalities Memorised Setpoint Remote setpoint through AI3 if this signal is not used for the bias Output forcing modes Alarm on the controlled variable PV3 183 Installation and User manual of the AC10 AC20 AC30 controller 184 18 3 Control 18 4 Bias Ratio Loop PV1 the controlled variable is acquired through the Al1 module providing the conversion in engineering units and the out of range detection PV2 the reference variable of the ratio loop is acquired through the Al2 module providing the conversion in engineering units and the out of range detection These two variables are transmitted to the SP DEV module that computes the Working Setpoin
13. In the following block diagram the interconnections between the various modules and the display panels are not indicated in order to improve the understanding of the functionality performed All Di DI2 Al2 DI3 DI4 Al3 DI5 Di6 Al DI7 DI8 1 8 WSP wsP WSP SP WSP PV gt py WSP PV py WSP PV py WSP PV py ji OR8 M ALL Pvt PV2 Pv3 Pv4 SET SET at a SET 1 Y SET ALM ALM ALM ALM visu ALM ALM ALM ALM 1 DEV1 3 4 DEV2 5 6 DEV3 7 8 DEV4 1 8 VISU 3 VISU 3 VISU 3 VISU 3 ply PIDA i ply PID2 sone ply PID3 X ply PIDA f DB DB DB DB HOLD HOLD HOLD HOLD CONTROLK CONTROLG CONTROL CONTROU OUT OUT OUT cost OUT cost cost cost 1 2 3 4 AIM TRK AIM TRK AM TRK AM TRK it q k DTRK la DTRK la DTRK la DTRK 2 E at Y Y Y Y Y Y bof pod hor pod pog ho poq fog hod Po ol od DO 0 D C o Q 21 3 Control
14. pD07 pDO8 pD09 D010 D011 D012 D013 D014 D015 D016 Description of connections DO1 DO16 Digital outputs on which to generate the command Installation and User manual of the AC10 AC20 AC30 controller Parameters 16SW_1 Items No 3 Multiswitch panel Command number to display on the panel Select a number using the arrows on the keyboard 66 Chapter 5 Modules 5 4 Selector Panel SELP Description This module provides the functionality of a control panel for digital commands It has 4 outputs that are driven all together by the pattern selected through one of the 3 supported selection modes Keyboard Supervisory Computer and the 4 Digital Inputs Through these modes a number from 0 to 15 is specified that forces the 4 digital outputs to assume a well defined pattern also named item corresponding to the binary coding of the number Each of these three different selection modes is enabled to select and has a custom specified priority as specified through the SELP module parameters the mode that has the highest priority makes the selection first In the case the selection mode with the highest priority has the no choice status the selection is done by the one with the immediately lower priority and so on The priority order can be changed further directly from the controller front panel as described at Chapter 3 Start up assigning the highest
15. Alarm 4 Heat OR of Forcing modes OR of Forcing modes COOL Alarm 5 Cool e Tracking e Alarm 1 e Alarm 1 Hold e Out Max e OR of the Alarms OR of the Alarms e Out Min Aut Man station Aut Man Station e Alarm 6 L2 e Alarm 7 L2 TSP TSP HEAT COOL _WSP LOOP 2 __wsP RSP RSP SP1 Al4 SP2 gt CSP SP3 LSP Loc Current operating mode Loc Current Operating mode Requested Requested operating mode operating mode OR of Forcing modes OR of Forcing modes Alarm 1 e Alarmi OR of the Alarms OR of the Alarms Aut Man Station Aut Man Station Loop H C The pictures above show the different types of display panels providing the most effective interface for this strategy configuration The most used panels are the single bargraph display and the single pen trend that provides the same functionalities of the previous panel but the addition of a programmable time width chart with the trend profile of the controlled variables The main controlled variable is displayed both in the large size digits display and through the bargraph the Working Setpoint WSP is displayed by the slider The outputs are displayed both numerically and by the horizontal bargraph with the value of 0 in the central position the output of the cool actuator on the left and t
16. VISU 1 VISU 2 v VISU 3 SSE H Ok SE HE 12 3 Control Control of the variable connected to the analog input Al1 The Al module performs the A D the scaling and the conversion in engineering unit of the controlled variable and detects the out of range of the signal presumably caused by a sensor failure The output value of the Al module PV1 is fed into the three modules which implement the core of the PID loop The output of the PID is connected to the terminal blocks of the instrument through the output module AO1 12 4 Remote Setpoint Activating D1 i e closing the contact as in the picture 2 4 4 the Remote Setpoint is the one selected for the loop otherwise the Local Setpoint is selected In fact the setpoint mode selection as illustrated in the SDV module description is more complicated because it is based on the arbitration of the requests coming from various sources The Remote Setpoint can be the signal at the input Al2 RSP if the digital input DI2 is inactive or the constant stored in the MCNS module MSP if the digital input DI2 is active The truth table below lists all the various combinations of setpoint 155 Installation and User manual of the AC10 AC20 AC30 controller 156 12 5 12 6 12 7 12 8 om Di2 sp Forcing Operations Alarms These operations are related to the loop output and consist of the Hold and Tracking mode The Hold m
17. the output bits D016 D01 are moved one position backward and the DO16 output is put to the value present on DIN1 SHIFT DOWN DO1 DO2 DO3 DIN1 gt SHFT DO4 DO5 DO6 DO7 DOs DO9 DO10 DO11 DO12 DO13 DO14 DO15 DO16 UP gt DN gt RES gt 125 Installation and User manual of the AC10 AC20 AC30 controller Description of connections DIN Shiftregisterimput UP SHIFT UP Input DNS SHIFT DNInput O output reset DO1 DO16 Outputs as a result of the ERA Parameters This block has no parameters and is not displayed on the Controller 126 Chapter 5 Modules 5 9 Programmer Functions 5 9 1 Real Time Clock with 8 outputs R T C Description This modules available on the AC30 controller only provides the functionalities of a weekly timer It has 8 digital outputs that can be pulsed independently each other once a day and for all the day of the week at predefined times The generated pulse has a fixed time duration of 1 minute You configure the timer specifying for each output the day of the week it must be activated and if it must be enabled or disabled DO1 DO2 DO3 DO4 RTC a DO6 DO7 DO8 I O Connections DO1 DO8 Digital Outputs Parameters Displayed Parameters DOO DO7 Digital output activated at predefined time and date Active Enable Disable of the activation 5 9 2 Setpoint Programmer PRG Description This module available on the
18. ALL FORZ L1 ALL FORZ L2 LOOP1 _WSP el PV of the RSP selected a Requested operating mode CSP LSP e TAG loops Loc Current operating mode Requested Aut Man Station MV loop 2 operating mode e OR of the forcing modes e Alarm 1 e OR of the alarms Aut Man station LOOP 1 Annex A Resident Configurations TSP TSP TSP WSP LOOP2 WSP LOOP 2 WSP RSP RSP RSP Al Al4 Al4 e CsP e CSP e CSP LSP LSP LSP Loc Current operating mode Loc Current operating mode Loc Current operating mode Requested e Requested Requested operating mode operating mode operating mode OR of the Forcing modes e OR of the Forcing modes OR of the Forcing modes Alarm 1 e Alarm 1 Alami OR of the Alarms OR of the Alarms OR of the Alarms Aut Man station Aut Man station Aut Man station The panel with the dual bargraph provides a complete view of both the loop with a fine level of details on the most important parameters The left bargraph relates to loop 1 while the right relates to loop2 If you want to operate on a loop first you have to select it by pressing the A button The loop selected is highlighted by the fact that both the tag and t
19. Aut Man station Aut Man station The pictures above show the different types of display panels providing the most effective interface for this strategy configuration The first 3 panel consisting in the 3 bargraph display the alarm list and the Forcing mode list provide by themselves a complete interface for this configuration Referring to the 3 bargraph display the two bargraphs in the centre reference variable PV2 and on the left with the RAT tag and related to the PV1 variable belong to the Ratio loop while the one on the right with the L2 tag belongs to Loop 2 If you want to operate on a loop first you have to select it by pressing the O button The loop selected is highlighted by the fact that both the tag and the output operating mode are displayed in reverse Once the loop has been selected it is possible to change either the Setpoint or the A M station operating mode Furthermore the parameters shown in the upper part of the panel relates to the selected loop The status of the alarms is flagged by the small box on the upper left part of the panel When an alarm or a forcing mode is activated the box blinks continuously to alert the operator Next the operator can get a more detailed view of the alarms by looking at the ALLARMS and FORZAM panels Furthermore this configuration provides other 4 additional panels 2 for each loop with the well know bargraph and trend displays as shown in the
20. Dig Delay Slope Limit Digital Soft Multiplexer DMUX Dig Select Digital Hard Multiplexer DMX8 Mass flow compensation AGA Flow compensation MEL fs gt gt Totaliser TOT Signal Limiter LMT Alarms ALM Rate alarm SALM Analog Software Demux ASEL Set page sere Timer TMR O Servomotor Open Closed Loop SRV2 Soe 9 O gt S ied S Q 3 9 oO 9 O 5 Q 11 Installation and User manual of the AC10 AC20 AC30 controller 12 Control and Processing Description Mnemonic Information displayed Code on the controller panel Analog Hardw Demux ee 2 O O Digital Software Demux DSEL Dig DeSel Digital Hardware Demux pss Digital decoder pecs Math and Logic Code on the controller URNA a Da A y aciates ey 2222 Leste ott comoler FAL System Configuration sys h ___ Setpoint Control Key Lock seke i Output Control Key Lock i opk oo Math and Logic Functions Code on the controller panel Expression ee fo 3 UM MN Arithmetic operation OPR MathOperat Math operation Math Funct Single Constant Persan axe gt Monostable mst Monostable Counter do OR Binpus ors 3 ES AND_8 AND_8 smeT Chapter 2 Installation 2 Installation 2 1 Dimensions Overall dimensions of the controller compliant to the DIN 43700 standard MIN 100 g fel i WN OS OS pagodo 00000 0000000000000 LH
21. Y Max Y Min LOOP 2 Loc Rem limit Rem Mem 00 X om faja foo mn QOr gt z gt D I G 1 T A L aco Qor gt z gt Acuz Actuator PV1 retransmission PV2 retransmission Alarm 1 Pvt Alarm 2 Pv1 LOOP 1 main Alarm 3 Pv1 Und F Pv1 Alarm 4 Pv2 Alarm 5 Pv2 LOOP 2 limit Und F Pv2 Alarm 6 main limit Power Supply 199 Installation and User manual of the AC10 AC20 AC30 controller 21 4 Loops 200 21 1 Description The drawings below are providing the following informations Block Diagram User interface consisting in a set of display panels Termination unit for the connection to the field This configuration provides 4 basic independent PID loops equipped with forcing modes on the output and 2 absolute or deviation alarms each The description of the control functionalities is reported in the following pages related to the loop1 only The functionality of the other loops is perfectly identical but with the index numbers of the modules different To the get the proper index numbers for the other loops refer to the Block Diagram 21 2 Block Diagram
22. where the operator has to set specific parameters In this case in order to clearly flag that the functionality of the key has been changed an icon of a button with the mnemonic of the new functionality is displayed on the display panel close to the pushbutton When the display panel changes the icon disappears and the pushbutton returns back to its original functionality The following ones are these new buttons as they appear on the various panels Enter It allows to input a value in a variable or simply to proceed with the next step in a parameter definition procedure Page It allows to go to the next page when the values of parameters are listed on more than one page o Return or Reject It allows in any step of a parameter definition procedure to abort the current entry and go back to the previous display without changing any value T Y Scroll keys They allow picking up a choice from a list of various possibilities NOTE During the calibration procedure the following buttons are displayed Input Calibration N N gt Proceeds to the next step C gt Performs the calibration and stores the calibration coefficients Output Calibration E S gt Select Selects Deselects the output R R gt Return Returns back to the previous display panel 3 3 Display Chapter 3 Commissioning and start up The display panel consists of a graphic LCD display backlighted with high resolution 128 x
23. Delay T Sampling T 49 Installation and User manual of the AC10 AC20 AC30 controller 5 2 4 Analog Output AO Description This module converts a percentage value range O 100 of the IN input in a signal generated on the termination unit of the instrument Beyond the conversion this module provides the inversion of the signal complement to 100 the filtering and the selection of the hardware characteristics of the signal between various choices AO 1 AO 5 IN gt AOEX AO 4 AO 8 IO Connections Input signal with the percentage value of the output Parameters RT SP L1 0 5V Out Type 0 5V Displayed Parameters 20 mA 4 20 mA Time constant value of the filter applied to the IN value The range is between 0 and 30 seconds When selected it inverts the value of the IN input The math expression for this inversion operation is 100 IN The choices are No or Yes 50 Chapter 5 Modules 5 2 5 Digital Output DO Description This module transfers the status of a digital variable IN generated by the strategy to a physical output of the controller Beyond this basic output task this module performs the inversion and the delay of the output signal DO1 DO9 gt IN D DOEX A DO8 DO32 I O connections m Doaa Parameters DO1 ALARM 0 Delay T 0 Displayed Parameters Delay T Defines the time the IN signal must be delayed before b
24. The Al module performs the A D the scaling and the conversion in engineering unit of the controlled variable and detects the out of range of the signal presumably caused by a sensor failure The output value of the Al module PV1 is fed into the three modules which implement the core of the PID loop 1 SET DEV 1 PID 1 and CONTROL OUT 1 The output of the PID 1 is connected to the terminal blocks of the instrument through the output module AO1 in order to drive the external actuator Annex A Resident Configurations 21 4 Forcing modes 21 5 Alarms These operations are related to the loop output and consist of the Hold and Tracking mode a Tracking the Tracking mode sets the output to the value of constant until DI2 is active b Hold The Hold mode freezes the loop output until the DI1 digital input is active When the forcing mode cease the transfer to the normal operating mode is bumpless There are two alarms either on the controlled variable PV1 or the deviation according to the parameters selected in each of the ALM modules The module WSP PV computes the deviation in the same engineering units of the controlled variable PV The status of each alarm is retransmitted out through the DO1 and DO2 modules 21 6 Graphic Displays m TSP TAG of the panel p ALARMS FORZAM LOOP 1 L_wsP CSP OR ALL te D Requested DEV LSP loop sel e operatin
25. VISU y Y Y y SCH SCH SCH SCH PVI Pv2 PV3 PV4 S k 22 3 Alarms eJ eJ bol oeoo Bao o e pa 0 o 0 00 Each analog input is connected to 2 alarms modules with absolute programmable threshold The status of the alarm is retransmitted out of the digital outputs 22 4 Variables Retransmission All the 4 analog inputs are retransmitted out after a reranging operated by the SCH PV modules This SCH PV modules allow the modification of the ranges of the retrasmitted outputs that are not necessarily the same of the inputs This is achieved by setting the input range parameters of the SCH module to different values than the output range parameters In this way the retrasmitted variable can be limited to a portion of the input signal scale with the advantage of an improved resolution Annex A Resident Configurations 22 5 Graphic Displays Panel TAG OR of Alarms lo LSP Sel Loop WSP Sel Loop Selected Indicator ALARMS VARIABLE 1 e AO1 e Indicator tag area Loc Current operating mode Requested operating mode OR of Forcing modes PV loop 1 e PV loop 2 0 l Aami PVlop3 4 PVloop 4 E ie ie ie OR of Alarms Aut Man Station PV1 m PVI PV1 VARIABLE 2 PV2 VARIABLE 3 Leva VARIABLE 4 _pva PV3 PV3 PV3
26. om i Ter sn l Fig 4 4 Supervisory port specification Interface RS485 differential 2 wires Baud Rate 110 19200 Bit per Seconds Type of connection Multidrop Max n of controllers on a cable 31 plus the Supervisory computer Note It is strongly suggested to insert the termination resistors of 120Q at both ends of the cable where the Supervisory computer and the last instrument of the multidrop chain are located Furthermore to improve the noise rejection figures it is possible to bias the two wires of the differential line with the insertion of a pull up resistors on a wire and a pull down resistors on the other This is achieved by moving the on board switch S3 to position A and S4 to position B Obviously the bias must be enabled on one instrument only If there are more than one controller is preferable to apply the bias by setting the switches as described above on the last one 41 Installation and User manual of the AC10 AC20 AC30 controller 42 e Example 1 There is a Supervisory computer connected with a controller only The termination resistors must be applied both on computer and the controller e Example 2 There are n controllers on the line The termination resistors must be applied both on the Supervisory computer and the last controller on the line On the controller the insertion of the termination resistors is achieved by moving the on board switch S1 to position B The on board swi
27. 2 When the Alarm 1 is active the label AL1 is visible 3 When a forcing mode is active the label FOR is displayed A more detailed view of the alarms and the forcing status is presented on the ALL FORZ L r display panels each one is associated to a loop 175 Installation and User manual of the AC10 AC20 AC30 controller 176 16 10 Applications This two loops configuration is particularly suitable for controlling processes with predictive variables being the main loop equipped with the feed forward For instance in a boiler control system this configuration is dedicated both to the control of the 2 elements boiler barrel and to the more simple control of the air pressure or to another basic loop In a preheating furnace for instance this configuration is dedicated both to the control of the pressure of the furnace using the global fuel flow as the predictive feed forward magnitude and to the more basic control of the fuel air pressure Electrical Connections The following picture provides a clear view of all the termination blocks with the associated functionality and it is specific of this configuration No signals must be connected to the termination blocks not used by the strategy The termination blocks 25 and 26 are providing a 24V DC output particularly suitable to supply of the 2 wires transmitters
28. Installation and User manual of the AC10 AC20 AC30 controller 160 13 4 Remote Setpoint This configuration supports the Remote Setpoint providing sophisticated features selectable through the external digital inputs DI1 DI3 as illustrated in the table below The features offered are a The Remote Setpoint value is selected among four different possibilities through the MUX SP module by mean of the DI2 and DI3 inputs b The Remote Setpoint is enabled by activating the digital input DI1 in fact the setpoint mode selection as illustrated in the SDV module description is more complicated because it is based on the arbitration of the requests coming from various sources c When the DI2 and DI3 inputs are both inactive the Remote Setpoint corresponds to the signal at the analog input Al2 d The other three combinations of DI2 and DI3 selects three different predefined values stored in the MCNS analog constant module x Loc x teo On Of Of Remote from Al2 On On Off Memt On of On Mem2 On On On Mem3 x Don t care 13 5 Feed Forward This feature provides a lead action to the control algorithm consisting in anticipating the response of the loop to a change of the controlled variable It is enabled by a parameter of the multiplexer MUX FF module and it consists in connecting the analog input Al3 to the Feed Forward input of the PID module 13 6 Forcing Operations
29. LOGIC a a fos PT NI Nee a 1 a KELN HAT 7 NA Another application of the ratio loop is in controlling the dosing of an additive to a fluid with variable flow In this application Loop 2 can be used for the control of the level of the tank where the fluid enters PV1 e pee PV3 Y Y T o LOGIC L Ll ir V IN pA S N AON FT FT N a ow ae ean a ate N gt a PE PER gt lt nen 187 Installation and User manual of the AC10 AC20 AC30 controller 188 18 10 Electrical Connections The following picture provides a clear view of all the termination blocks with the associated functionality and it is specific of this configuration No signals must be connected to the termination blocks not used by the strategy The termination blocks 25 and 26 are providing a 24V DC output particularly suitable to supply of the 2 wires transmitters PV1 measure RATIO _ PV2 measure LOOP N LOOP 2 RATIO LOOP LOOP 2 lt Bias Rsp PV3 measure Y Y Max Y Min Hold Track Bias Loc Rem Hold Track 25 26 CUZ
30. ORof the forcing mode Alarm 1 OR of Alarms Aut Man Station LOOP 2 TSP __wsP RSP Al e _ CSP LSP Loc Current operating mode Requested operating modes OR of the forcing modes e Alarm 1 OR of Alarms Aut Man station The panel with the dual bargraph provides a complete view of both the loop with a fine level of details on the most important parameters The left bargraph relates to loop 1 while the right relates to loop2 If you want to operate on a loop first you have to select it by pressing the O button The loop selected is highlighted by the fact that both the tag and the output operating mode are displayed in reverse Once the loop has been selected it is possible to change either the Setpoint or the A M station operating mode Furthermore the parameters shown in the upper part of the panel relates to the selected loop The status of the alarms is flagged by the small box on the upper left part of the panel When an alarm or a forcing mode is activated the box blinks continuously to alert the operator Next the operator can get a more detailed view of the alarms by looking at the ALL e FOR panel Furthermore this configuration provides other 4 additional panels 2 for each loop with the well know bargraph and trend displays with the following functionality The main controlled variable is disp
31. PV4 PV4 PV4 e _ AO2 AO3 e 1 AO4 Loc Current operating mode L LSP LSP Loc Current operating mode Loc Current operating mode Requested operating mode e OR of Forcing modes e Alarm 1 OR of Alarms Aut Man Station Requested operating mode k OR of Forcing modes ng Alarm 1 OR of Alarms Aut Man Station Requested operating mode e OR of Forcing modes e Alarm 1 OR of Alarms Aut Man Station This configuration offers 6 display panels The panel with the four bargraphs gives a complete view of all the 4 input measures lt provides the bargraph indication of all the variables plus the numeric indication with large size digits of the selected variable You select the variable by pressing the A as you do when you operate with the configurations with multiple loops The measure that has been selected is highlighted by the fact that the tag is displayed in reverse The span of the bargraph can be different to the original one of the analog input For instance you can display only a portion of the full span in order to have a better resolution This Zoom effect applies only to the bargraph while the numeric indication always reflects the full value of the variable The status of the alarms is flagged by the small box on the upper left part of the pa
32. Retra Pva J A M 1 QoOr gt z A M 2 Pva input Station pv4 TRK 4cO orPZz gt Actuator 2 Station Retra PV4 J A M 2 q 10 AL ee 11 2 12 A 3L oyo HOLD Al 4 A M1_ TRK Al 5 gt PV 3 Station are ps J Y Min AL 7 SPV 4 HOLD nee A M 2 TRK Station Y Max pe Y Min
33. SetHi 100 Displayed Parameters Seth High range of the slider variable C O burgh High range of the bargraph variable BIN Format defines the number of digits of the Al2 variable note 1 Format defines the number of digits of the Al3 variable note 1 Format defines the number of digits of the Al5 variable note 1 Time span of the trend chart Possible choices 1 2 5 10 30 minutes or 1 2 5 hours For Al4 Format defines the number of digits of the Al4 variable note 1 Note 1 The 3 characters mnemonic of these 5 analog inputs is defined in the configuration by the user 61 Installation and User manual of the AC10 AC20 AC30 controller 5 3 6 Four Trend Panel 4TP Description This module has the same basic functionalities of the TRP module and is intended for displaying on a single panel up to 4 trended analog variables lts main purpose is to provide a complete user interface for the Setpoint Programmer providing graphically the trend of the Profile Setpoint and the process variable the display of the program and segment number in execution the visualisation of the status of digital outputs controlled by the program and a 10 characters title of each chart Tag 10 characters Label 1 Max 10 characters PGNA SP1 PV1 High Range B G 1 SGNA PV1 Digital Input 2 SP1 Digital Input 1 Low Range B G 1 Time span B G 1 P
34. These operations are related to the loop output that can be driven by other sources than the straight PID algorithm This configuration allows the following 4 modes Tracking Hold Hold Y Max Hold Y Min a Tracking it is enabled by the DI6 digital input and it consists in setting the control output either to a predefined value or to the value of the analog input Al4 The selection between these two choices is operated by the MUX TRK multiplexer module by mean of the DI4 digital input When DI4 is active the control output value is provided by the analog constant of the MCNS module while when the DI4 is inactive it is provided by Al4 signal after being properly ranged to percentage units by the SCH TRK module Hold when DI5 is active the control output is frozen at the value it had at the time of the rising transition c Hold Ymax When both DI5 Hold and DI7 are active the control output is forced to its maximum value defined by the parameters of the CONTROL OUT module d Hold Ymin When both DI5 Hold and DI8 are active the control output is forced to its minimum value defined by the parameters of the CONTROL OUT module An important point to bear in mind is that all these forcing modes are handled by the module according to the following priority A M Ymin Ymax Hold and Track b gt Annex A Resident Configurations 13 7 Alarms There are 5 alarms either on the controlled variable PV1 o
35. automatically at the beginning of each segment and it is kept constant for the entire segment DO1 DO16 Digital outputs set at the beginning of the segment to the pattern configured These values are hold for the entire segment Run mode This digital output is active when the program is running and becomes inactive when the Programmer enters in Hold mode Chapter 5 Modules Hold mode This digital output is active when the Programmer is in Hold mode due either to an excessive deviation between SP and PV or other causes Operativity The following picture explains the procedure to follow in order to edit the parameters of a program in a PRG module First you reach the panel with the list of all the modules Menu of All Block here you select the Programmer module Second in the Program Block panel you choose which of the 4 PRG modules of the strategy houses the program you want to edit Next you continue by selecting the program to edit in the example the program n 2 of the PRG module n 1 has been chosen At this point you reach the Program No n display panel consisting in a menu of all the operations you can do on the selected program TAG 0000 0 Main Menu Tune amp Views Parameters amp Comms Parameters Menu of All Blocks Program Block PRG_1 PRG_1 N Program No m Programmer R R R R R R
36. both at the top with large size digits and with the larger bargraph on the left while the Master Working Setpoint WSPM is displayed by the slider About the Slave loop the controlled variable PV SL is displayed by the thinner bargraph on the right and the setpoint WSP SL is displayed by the slider The Slave control output driving the external actuator is displayed by the horizontal bargraph and numerically The following variables consisting of the setpoints and process variables are displayed one at a time in the scrollable display area LSP Local setpoint of the Master loop 191 Installation and User manual of the AC10 AC20 AC30 controller 192 WSm Working setpoint of the Master loop RSm Remote setpoint of the Master loop Csm Computer setpoint of the Master loop PVs Process variable of the Slave loop WSs Working setpoint of the Slave loop The displayed Setpoint operating mode is the one of the Master loop its mode indicated by the Loc Rem and Com mnemonic is displayed in reverse on the panel at the same height of the L R key that is used to change the mode The squared digital indications on the right side of the panel are flagging the status of the alarm and the forcing mode of the loop More precisely they highlight the following general situations 1 When an alarm is active the label ALL is visible 2 When the Alarm 1 is active the label AL1 is visible 3 When a forcing mode is active the label FOR is d
37. by writing in the input ones and reading the output ones A maximum of 4 modules of this type can be included in the strategy kt 101 Dio2 COMPUTER ne gt CDIO K DIO5 Do6 Dio7 Dios I O Connections DIO 1 8 Digital I O JBUS Addresses of the register with the I O values Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument panel Chapter 5 Modules 5 7 System Modules 5 7 1 Computer Timeout CALM Descriptions This module monitors the communication activity with the Supervisory Computer activating the DOUT alarm output if the computer stops to interrogate the instrument for a time greater than the specified timeout CALM DOUT I O Connections DOUT Alarm output flagging the lack of communication Parameters CALM _ 1 30 Time Out 30 Displayed Parameters Minimum lack of communication time O to 600 seconds 5 7 2 LAN Timeout LALM Description This module generates an alarm activating the DOUT output if the controller doesn t receive on the LAN the values of consumer type variables for a time greater than the specified timeout LALM DOUT I O Connections DOUT Alarm output flagging the lack of LAN communication Parameters LALM 30 Time Out 30 Displayed Parameters Minimum lack of LAN communication time 0 to 600 seconds 111 Installation and User manual of the AC10 A
38. corresponding digital input e Selector Panel Control panel allowing the user to set the pattern of 4 digital outputs by choosing from a list of predefined patterns Each pattern performs a predefined operation on the process and is labeled with a symbolic name for an immediate understanding e 12 Analog Display Indicator panel displaying the value of up to 12 analog signal inputs Each input is identified by a 6 character label for an immediate understanding e 4 Analog Display Indicator panel displaying the value of up to 4 analog inputs Compared to the 12 Analog Display module this module provides more informations longer tag and engineering units and the visualization of the variables with big size characters apx 1 cm high that can be seen far away 21 Installation and User manual of the AC10 AC20 AC30 controller e 4 Writable Analog Display This display panel allows the display or generation of 4 analog variables directly from the front panel For each generated variable it will be possible to define an identification tag with its own engineering unit of measurement 3 3 1 1 Bar Panel EA Soy gt SI NP KR gt N yo This tag is the identifier of the panel and consists of up to 10 alphanumeric characters It is assigned automatically when the module is created and can be modified through AC_Edit AC Prograph 2 Engineering Units Engineering units mnemonic consisting of a
39. elele ele e o o elele ele 8 5 Auxiliary Units Addressing Each Auxiliary Unit has an address with range from 0 to 2 set by the user generally at the installation time by mean of 4 switches located on the unit The address must be unique among the various Units connected to the line In setting the address the following simple rules must be complied e The first unit must always be set to address 0 e If there is an AAC EU 88 4 Unit these one must be set to address 0 e The only valid addresses are 0 1 2 and are set according to the following drawing ADDRESS 0 ADDRESS 1 ADDRESS 2 ON ON ON 147 Installation and User manual of the AC10 AC20 AC30 controller 9 148 Ordering Data Multifunction multi I O Unit ASCON AC10 AC20 AC30 series 9 1 Ordering Code Model AC10 0000 Supply 100 240 V 50 60 Hz 3 18 28 V 50 60 Hz o 20 30 Vdc Spare lamp optional Not supplied 0 Supplied a Model AC20 Supply 100 240 V 50 60 Hz 18 28 V 50 60 Hz o 20 30 Vdc 5 Spare Lamp optional Not supplied 0 Supplied 1 External Units Port optional Not supplied Supplied LAN Port optional Not supplied Supplied ARCNET type
40. whose stability is influenced by external events An example is shown in the picture below Loop Master Loop Slave SET aol SET CON pio H gt Po gt Pp wis J A o y ye S E FLOW la The target is to control the tank temperature by controlling the flow rate of hot fluid to the heat exchanger This can be achieved using just one loop by measuring the temperature of the tank and controlling the valve regulating the flow rate of hot fluid Such a solution in most cases is unsatisfactory because it generates continuous unstability on the controlled variable This is due to the fact that when the pressure of the fluid increases the flow rate increases but it takes a lot of time for the temperature to raise in order to have a response on the control output to the valve The effect is a big accumulation of heat in the tank that creates the unstability The Cascade control provides a perfect solution because the Temperature loop with its slow inertia is controlled by a separate loop whose output defines the target flow rate of the fluid This target flow rate is the set of the Slave loop controlling the flow rate that having as measured variable the instantaneous flow rate is capable to compensate immediately the changes of pressure of the fluid 193 Installation and User manual of the AC10 AC20 AC30 controller 194 19 10 Electrical C
41. 12 Auto Man Display of the Out station operating mode The possible modes are AUT or MAN 13 Output bargraph Horizontal bargraph showing the loop 2 Slave control output value in steps of 1 Chapter 3 Commissioning and start up 14 Output Value Numerical display of the loop 2 Slave control output in percentage 15 Alarms and Digital Display by mean of user defined 3 characters mnemonics of the status of the 3 digital inputs of the module These inputs are used for representing alarms or simple logic status 16 Setpoint Operating Mode This short mnemonic reports the current Setpoint operating mode of the loop 1 Master The various modes are Loc Rem Com 3 3 3 4 Bar Panel This display type is less rich of informations than the previous ones because it lacks the output bargraph and the main variable engineering units but surely it is the most versatile as soon as you connect the signals of a loop it adds the bargraph and the slider related to it This way to operate improves dramatically the readability because the panel is not always filled with 4 bargraphs when you need just two Furthermore for each bargraph you can choose if you want the slider or not so that if you want to display just a measure you do not have a meaningless slider around And you can mix as you like bargraphs with the slider for control loops and without for measures and A M stations 4 TAG 000 00
42. 320 pixels On the AC controller there are several types of active panels each one corresponding to a functional module of the strategy These panel displays have a complete user interface allowing you to have detailed informations about process variables to issue commands and to set parameters The definition of the types and the quantities of these display panels are set in the selected or designed strategy When the pushbutton is pressed the panels will be displayed in the order set in the Tools Edit Modules menu of the AC Prograph AC Edit programme For the above refer to section 7 6 2 of the manual The active panels are the following e 1 Bar Panel front panel of a control loop with numeric indication of the relevant variables bargraph display for the main ones process variable setpoint output and status display of logical signals or alarms e 2 Bar Panel front panel of two control loops usually connected in cascade with numeric and bargraph indication of the most relevant variables and status display of logical signals or alarms e 4 Bar Panel front panel of four control loops with bargraph indication of the process variable and setpoint numeric indication of the relevant variables and a cumulative alarms display common to all the 4 loops This panel automatically omits the display of the signals not connected to its functional module in order to avoid meaningless information Therefore it is a suitable disp
43. 6 12 Trend of PV Recent Trend display of the PV1 and PV2 analog input signals 7 13 Time Scale Numerical display of the time span of the trend chart 14 20 Trend Chart Low Limit They define the values of the low limits of the scale Each value consists of 6 characters including the sign and the decimal point 15 21 Digital Display by mean of user defined 3 characters mnemonics of the status of 4 digital input signals The user can define a mnemonic for each state of the digital signal 16 19 22 25 4 Variables Values Numerical display of the value of the 4 trended variables The ones with big size numbers correspond to PV while the others correspond to SP It consists of 3 characters including the sign and it doesn t allow the decimal point 17 23 Trend Chart High Limits They define the values of the high limits of the scale Each value consists of 6 characters including the sign and the decimal point 18 24 PV Values Numerical values of the analog input signals PV1 and PV2 These signals are trended in the chart too 3 3 7 12 Analog Display Panel This display provides the functionalities of a set of analog indicators It displays both the value and the 6 characters tag of up to 12 analog variables connected to it as analog inputs D TAG 0000 0 1 Tag This tag is the identifier of the panel and consists of up to 10 alphanumeric characters It is assigned automatically when the module is created and can be modified
44. AC30 controller only provides the functionalities of a Setpoint Programmer generating the profile of an analogue setpoint SP organized as a series of segments and setting the status of 16 segments related digital outputs DO1 DO 16 and the level of an auxiliary analog output AUX The module can store up to 100 segments and a maximum of 16 programs Each program has a variable number of segments but the overall number of segments of all the programs cannot exceed the limit above A strategy can house up to 4 PRG modules Therefore the maximum capability of an AC30 controller is to house up to 64 programs with an total number of segments of up to 400 and driving up to 64 digital outputs 127 Installation and User manual of the AC10 AC20 AC30 controller 128 Despite the sophisticated performance of this programmer it is easily programmed both through the AC Prograph or the controller keyboard in a friendly simple and guided environment The use of AC Prograph is very effective and strongly recommended A wide selection of strategies is offered by the PRG to recover the program from anomalous situations of the process For instance you choose among several possibilities the actions to take after a power failure Briefly you can chose if your Programmer must be Reset Hold or Resumed on the basis of the time the power has stayed off on the basis of the deviation of the process variable PV from the last Setpoint generated o
45. EEE AE AE T EEE EES TE EE TA E E E N 191 19 9 APPLICATION Serea ld doit int did deidades 193 19 10 ELECTRICAL CONNECTIONS iaa 194 20 OVERRIDE oii ccscsceicsescccecsnscstincdecececcechttietetcococcesescdnccvesceucdtecescccescesovoesdesscostcscssscdsscdeccscssceseacdsscsenesecaseseosscesscentese 195 ZO LA DESCRIPTION A o cates 195 202 BLOCK DIAGRAMA deca 195 20235 ICONTRO a a hte he e o e eto a e lo o ede ke 195 20 4 REMOTE SETPO NN EA e AEE EEE ad bits 196 20 30 510 LINTE LO B EES E E A ia deste 196 20 6 A A a E a r aE a e AN ES 196 207 NARIABLE RETRANSMISSIONS a a A O arras 197 PNE E GRAPHIC DISPEAY aii EE AA A E cia 197 P1 OE O 198 20 10 ELECTRICAL CONNECTIONS a A AE E A EEr E E E aS 199 21 C OO e EEE TEETE T E E E E STEA 200 PP PA CR ON ai 200 21 2 BLOCK DIAGRAMA RE E EAE E Iii 200 AE O PEE LE E E E EE E EE E E E E NE OR 200 Installation and User manual of the AC10 AC20 AC30 controller 21 4 21 5 21 6 21 7 21 8 22 22 1 22 2 22 3 22 4 22 5 22 6 22 7 23 23 1 23 2 23 3 23 4 23 5 23 6 23 7 23 8 152 FORGING MODES dai 201 NTA RIMS 2 02255 obese Ger EES E A EE eevee ake ES EE eds 201 GRAPHIC DISPLAYS as o ot hes oir ete ae ark o oe A cle os sete ace E 201 APPISIGA TIONS tddi tdt EOE 202 ELECTRICALACONNECTION Sidi 203 4 INDICATORS vescscccvcscsctsscsssccussentetsesssvcuesucdecdsscsecsucvussessesusteuedssdeguenseveveeddssegussueucesesbestesadededsseveddvscaeceessessatevs 204 DESCRIP
46. Input DID e roa tt de pe cee ed e ee En a a do a 49 5 2 4 Analog Qutput AO 00 A A Me a hie oh ete 50 5 2 5 Digital Output DOs e e a aaa o a a aaa a a a e E E EEES 51 T DISPLAY PANEL 0 E E E T ol id 52 5 3 1 Single barsraph panel IBP oi At te TAA ON o I OE Sats 52 3 3 2 Double bargraph panel 2BP cccccccecceceseeseeseesevsesneenscescuseeseeseseeecneseecusseseesessesesnesnesnesesseseeseeseseeneeneeated 54 5 3 3 Quadruple bargraph panel ABP once 56 5 3 4 VEZICA AAA TRP ETE T A Aia 58 5 3 5 Dual Lrend Panel ZP a o os 60 5 3 6 Hour Trend Pane l 4 TR aiii aiii cute hasten sioid E EEE siesbaade ce teeeten deed 62 5 3 7 Alarm Lag ALP ao 64 5 3 8 Multiswitch panel 165W c ccccccccccscseescescesesseenesseesecnecesceceeseesecseesecesnecneceecesesseesesseseseseeceeeeseesesseeesnesaeed 65 5 4 SELECTOR PANEL SEEP e E ob 67 5 4 1 Four Analog Display Panel 4AADP o cccccccccsccssseesesseeseeseuseeseeseveeececnecnecesensessessesesnesneseseesenseeseseeeseeated 68 5 4 2 4 Writable Analog values 4ADP c cccccceccssseseesesseenetseteeeueeecccesseesessesecsececececeesessesseeececeaeeaeesesseeseeneeas 69 5 4 3 Analog Display Panel ADP aeea ae aame e a ae aaa a aa aaaea a aaan aaaea oaee naana 70 5 4 4 System CLK Date and time display panel cccccccccccecsesseseeseeseetevseesesneceecnscescesesessecneseesneeesenseseeeeneeaeed 71 5 5 PROCESSING AND CONTROL FUNCTIONS ccccsssesssseseescseeseeecsessesecsesesecsessesecsessesecses
47. Main variable that must be kept at the setpoint and a Limit one that must not exceed a predefined threshold during normal operations start up or when abruptly changes occurs This configuration controls two variables in override It is based on 2 PID loops each one controlling a process variable but only one output to the external actuator The output to the actuator is computed as the minimum or the maximum of the two control output of the loops The two loops are dedicated to the Main variable and the Limit one 20 2 Block Diagram 20 3 Control In the following block diagram the interconnections between the various modules and the display panels are not indicated in order to improve the understanding of the functionality performed 1 Gere ee oe sana UNDERFLOW Y Y Yy Yy O mmo A proe a pron een eee lt SP DEV e Ld RSP TEF 1e ALM 3 ALM ALM 2 1 D B ES limit 4 5 E e La e gt e M L visu lt 4 st gt visu 7 e y ALM 6 gt VISU SCI EA 7 v v y V 7 Y y AO2 pod poz IDO2 DO1 DOs DO6 ji i ooo 0 OOO 0 The main variable PV1 is acquired by the Al1 module providing the conversion in engineering units and the out of ran
48. PV computes the deviation in the same engineering units of the controlled variable PV1 The status of each alarm is retransmitted out through the DO1 DO2 and DO3 modules for the Master loop and DO5 DO6 and DO7 for the Slave loop A fourth alarm for each loop flags Annex A Resident Configurations the out of range of the controlled variable underflow detected on 1 5V 4 20mA inputs and it is transmitted out on the DO4 Master and DO8 Slave modules 19 7 Variables Retransmission The Master controlled variable PV MST is transmitted out after a rerange operated by the SCH RTX PVM module on the AO2 output The Slave controlled variable PV SLV is transmitted out after the rerange operated by the SCH RTX PV SL module on the AO3 output The SCH modules allow the modification of the ranges of the retrasmitted output that are not necessarily the same of the input variable This is achieved by setting the input range parameters of the SCH module to different values than the output range parameters In this way the range of the variable can be changed in order to consider only a part of the original signal scale with sensible advantages on the resolution of the output 19 8 Graphic Displays TSP MAST SLAVE L_wsr ALARMS MASTER _WSP RSP RSP E U PV Master p CSP csP PV Master Meee PVS e mspP e WSS LSP Master scale High limit e Slave scale High Limit Loc C
49. RD Aie OS d 3 fe Gl TN e MENTA P E a 2 J F E a SL 4 5 a pS SE E 8 o h 4 N i ard ES N SE 7 pr fo 9 Lm on PE e A 0 1 Tag This tag is the identifier of the panel and consists of up to 10 alphanumeric characters It is assigned automatically when the module is created and can be modified through AC_Edit AC Prograph 2 Main Variable Value Numerical visualization of the controlled variable of the selected loop consisting of 6 characters including the sign and the decimal point Each loop is selected cyclically and the one selected has its tag displayed in reverse 3 Setpoint Label LSP Local Set Point Mnemonic label of the setpoint value n 5 WSP Working Set Point Mnemonic label of the setpoint value n 4 4 Working Setpoint Value Numerical display of the value of the Working Setpoint of the selected loop 25 Installation and User manual of the AC10 AC20 AC30 controller 5 Local Setpoint Value Numerical display of the value of the Local Setpoint of the selected loop The Local setpoint is entered by the user through the front keyboard 6 Loops tag This 3 characters label specified by the Customer identifies the tag of the loop The loop selected has its tag displayed in reverse 7 Bargraphs Bargraph indication of the process variables 1 2 3 4 of the loops 8 Set point sliders Graphic representation through a moving slider of the real time value of the Setpoints
50. SP 0 generating a control output that driving dedicated actuators acts on the manipulated variables This control output is named M V manipulated value and not having a well defined engineering unit is indicated in percentage Regulator A SOO SORES TA EE SPY ORES Manipulated Variables Sensor Fig 2 cotos eco Ja Variables Fig 2 shows the process with the various magnitudes types and an elementary PID regulator Following the considerations above a block diagram of this PID loop can be easily determined First of all the PID must have an analog input circuit capable to acquire from the field the PV signal connected to the termination unit of the loop Second the PV value is compared with the SP Setpoint in the node at the PID input The result of this comparison is named error or deviation and is fed into the PID algorithm 153 Installation and User manual of the AC10 AC20 AC30 controller 154 The output of the PID algorithm is the signal MV that usually is not connected directly with the termination blocks of the controller because the output signal needs in some cases when operator interventions are required to be generated manually Therefore a special module named Auto Manual Station is inserted between the MV output and the instrument terminations blocks The MV output of the PID module is connected to the input of the Auto Manual Station The output of the Auto Manual Station is
51. SUPPLY 90 264 V ac L The frequency input signal must not exceed the range 8 36 V Pulse T 2 4 6 RS485 Serial Port Main Comm F gt 0 U 3CUZ Connector AC Connector Supervisory 6 O OJ Cc 6 O CN2 oO 09 485 99 O O 54 O o 95 O os o O5 Female Connector D SUB DIN 41652 2 4 7 ARCNET Network Male Connector D SUB DIN 41652 Connector AC Connector Supervisory O52 o 32 O 53 053 O O TO 20 o o 5 C o o5 CN1 Female Connector LAN 16 NFC 93425 Chapter 2 Installation 2 4 8 Connection to a PC via the programming port PROGRAMMER Connector ASCON Blocking screw In the figure below the details of the connection to a 9 and a 25 pole connector are shown RS232 Connection RS232 Connection 9 pole connector 25 pole connector blue o O O o o o O o O O o Controller PC connector Controller PC Connector e Front Panel Front Panel ro 2 4 9 Connection to the Expansion Unit via the RS485 port AUX Comm W ED f enzo rom _EN2 2 ON 3 am amp GC Terminatore RS 485 da 120 Q ra gt jJojaonele ojeocaj
52. Single Constant CNS 5 8 5 AND Description This module generates a fixed analog signal on the output Y1 whose value is specified by the user through AC Prograph AC Edit I O Connections Output with the constant value Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument panel Description This module performs the Boolean AND operation between two digital inputs DIN1 D AND DOUT DIN2 I O Connections DOUT Truth Table AND Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument panel 117 Installation and User manual of the AC10 AC20 AC30 controller 5 8 6 NOT Description This module perform the Boolean NOT of a digital input DIN1 gt NOT DOUT I O Connections Dni Doan O Truth Table NOT DIN1 DOUT o 1 1 o Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument panel 5 8 7 EOR XOR Description This module performs the Boolean XOR Exclusive OR between two digital inputs DIN1 gt DOUT DIN2 gt I O Connections DINA Digital Input DIN2 DigitalImput 2 Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument panel 118 5 8 8 OR Chapter 5 Modules Description This module performs the Boolean OR between two digi
53. abruptly the control capabilities because of the compensation of the mismatch of the two channel Furthermore a basic standard loop is available in the controller 177 Installation and User manual of the AC10 AC20 AC30 controller 178 17 3 Control Loop H C The process variable PV1 is acquired by the Al1 module providing the ranging the conversion in engineering units and the out of range detection It is transmitted to the SET DEV module that computes the deviation for the two PID modules controlling both the Heat channel with inverse action and the Cool channel with direct action The outputs of the two PID are connected to the single H C output station through two MUX multiplexer modules required for properly selftuning the loops These two multiplexers interfere with the control output only when the Tune operation has been started on one of the PID modules as flagged out by the Dtune signal The H C Out station offers a wide range of forcing strategies and first of all a phase slitter providing a deadband or a crossover between the two outputs Loop 2 The variable PV2 is acquired though the Al4 analog input module providing the conversion in engineering units and the out of range detection It is transmitted to the SET DEV module that with the PID and CONTROL OUT modules makes up the core PID block The output is transmitted out on the terminal blocks through the AO4 module for driving the external actuato
54. at a time in the scrollable display area LSP Local setpoint WSP Working setpoint MSP Memorised set YS2 Tracking value PV1 Process variable of the Loop H C WS1 Working set of the Loop H C The squared digital indications on the right side of the panel are flagging the status of the alarm and the forcing mode of the loop More precisely they highlight the following general situations 1 When an alarm is active the label ALL is visible 2 When the Alarm 1 is active the label AL1 is visible 3 When a forcing mode is active the label FOR is displayed These are global flags the detailed cause of the event is shown in the ALARMS panel where the digital status of each alarm and forcing input is clearly shown 17 9 Applications The typical application of this configuration is in the temperature control area where both the heat and the cool actions are required for keeping the temperature at the setpoint The availability in the same box of another basic PID loop is an advantage because of the better the price performance figures 181 Installation and User manual of the AC10 AC20 AC30 controller 182 17 10 Electrical Connections The following picture provides a clear view of all the termination blocks with the associated functionality and it is specific of this configuration No signals must be connected to the termination blocks not used by the strategy The termination blocks 25 and 26 are providing a 24V DC out
55. at one sample and at the next sample and comparing it with the slope limit dIN Ts IN T Ts IN T Ts lt Slope where Ts is the sampling time of the controller at runtime According to the result of the comparison the module takes two different actions If the increment of input signal IN during the TS time exceeds Slope Ts then OUT is set to Slope Ts If the increment of input signal IN during the TS time doesn t exceed Slope Ts then OUT is set to the value of IN n MSL OUT VO Connections IN Analog Input in engineering units Analog output in engineering units Parameters MSL _1 1 Slope 1 Displayed Parameters Slope Limit corresponding to the maximum allowed rate of change of the IN signal in the time Ts Range from 0 to 9999 Format Format it defines the number of digits of the Slope value 87 Installation and User manual of the AC10 AC20 AC30 controller 88 5 5 12 Linearizator CHAR Description This module provides the same functionality of an analog characterizer with up to 12 breakpoints Each breakpoint is defined by a coordinate pair X Y specifying the value of the IN input variable X and the corresponding value of the OUT output variable Y The function OUT F IN for all the values of IN is derived by the characterizer breakpoints list by mean of simple linear interpolation calculation The minimum number of breakpoint is 2 The o
56. confirm the successful operation Next you must press any key for the message to disappear and return back to the Program No menu e The segment specified doesn t exist because its number is greater than the total number of segments the program consist of The message Segment not Available will be displayed to flag that the operation cannot be carried on At this point you must press a key to return back to the Program No menu 133 Installation and User manual of the AC10 AC20 AC30 controller 134 Program No Insert Seg Insert Seg 2 1 1 Seg No 1 pan Seg No m m Insert Seg R Any key After the insertion of the segment all the other segments of the program following the new one have its numbers incremented by one To enter the data in the new segment you must select the command Edit Program from the Program No n selection menu and follow the instructions given above for that command Program No n Delete Segment This command allows you to delete an existing segment of a program After issuing the command you define the segment which should be deleted from the Delete Seg panel You confirm the entry by pressing the E button Two potential situations can occur e The segment to delete is existing The alert message All Done is displayed in order to confirm the successful operation Next you must press any key for the mess
57. connected to the termination blocks providing an electrical signal capable to drive the external actuator Fig 3 shows the block diagrams of the complete loop OUTPUT MANAGEMENT w2 BUMPLESS FIG 3 This is a simple PID with an Auto Manual station and consists of the following modules The PV signal is applied to the Al module that converts the signal in a number The module SET DEV computes the error between the SP and PV The PID module computes the control output on the basis of the error input The OUT MANAGEMENT module handles the manipulated variable together with others control signals Aut Man Hold Tracking Bumpless etc supporting various operating modes The AO modules converts the calculated value in an electric signal available at the termination blocks Annex A Resident Configurations 12 1LoopA 12 1 Description The drawings below are providing the following informations Block Diagram User interface consisting in a set of display panels Termination unit for the connection to the field 12 2 Functional Block Diagram In the following block diagram corresponding to the configuration of a simple loop the interconnections between the various modules and the display panels are not indicated in order to improve the understanding of the functionality performed 0000 y V ati
58. cool actions are required for keeping the temperature at the setpoint when there are material changes line speed variation and peculiar chemical reactions A few examples of the process using this configurations are the continuous heat treatment furnaces and most of the chemical reactors y Cale a as o gt E oa ot sk E Pk Jey Bl T BN N Sole A P N gt lt J a COOLING Y Y v y SSeS O O O See 5 gt 14 10 Electrical connections The following picture provides a clear view of all the termination blocks with the associated functionality and it is specific of this configuration No signals must be connected to the termination blocks not used by the strategy The termination blocks 25 and 26 are providing a 24V DC output particularly suitable to supply of the 2 wires transmitters 1 C 25 24 PV 2 26 24 RSP 3 Al Aral lt TN A Heat Actuator L y A O Or 29 PV retransmission Tracking G a g A WSP retransmission sii T Cool Actuator 9 N 33 T y m
59. display Analog Input displayed in percentage numerically and by an horizontal bargraph at the bottom of the display It is intended for the control output of a loop Analog Input displayed together with Y at the lower part of the display both numerically and by an horizontal bargraph While Y is intended for a normal loop or for the Heat output this variable is intended for displaying the Cool output of an Heat Cool loop Operating mode of the Out station Manual active Auto inactive Local setpoint value entered through the keyboard Special I O signal handling the Setpoint operating mode change Parameters MASTER 100 Pv1Hi 100 Displayed Parameters PviHi Main variable high range SetHi Maximum value of the Local Setpoint BaGrHi High range of the bargraph variable For BGr___ Format defines the number of digits of the Bargraph variable For WSP___ Format defines the number of digits of the Al2 variable note 1 For RSP____ Format defines the number of digits of the Al3 variable note 1 For MSP_ Format defines the number of digits of the Al4 variable note 1 For CSP Format defines the number of digits of the Al5 variable note 1 Time span of the trend chart Possible choices 1 2 5 10 30 minutes or 1 2 5 hours Note 1 The 3 characters mnemonic of these 5 analog inputs is defined in the configuration by the user 59 Installation and User manual o
60. display both numerically and by an horizontal bargraph While Y is intended for a normal loop or for the Heat output this variable is intended for displaying the Cool output of an Heat Cool loop Operating mode of the Out station Manual active Auto inactive Local setpoint value entered through the keyboard MOD Special I O signal handling the Setpoint operating mode change Parameters LOOP 1 100 Pv1H 100 Displayed parameters PviHi Main variable high range BaGrHi High range of the bargraph variable For BGr______ Format defines the number of digits of the Bargraph variable For WSP____ Format defines the number of digits_of the Al2 variable note 1 For RSP____ Format defines the number of digits_of the Al3 variable note 1 For MSP____ Format defines the number of digits_of the Al4 variable note 1 Note 1 The 3 characters mnemonic of these 5 analog inputs is defined completely in the configuration by the user 53 Installation and User manual of the AC10 AC20 AC30 controller 54 5 3 2 Double bargraph panel 2BP Description This module has the same functionalities of the previous one the 1BP The only difference is that it accommodates a second bargraph with its slider and therefore it has additional inputs Its main purpose is to provide the front panel of a cascade loop In this case the setpoint and the measured variable of the Master loop
61. following different performances Loop 1 a The remote setpoint is enabled by mean of the DI1 input b The Remote Setpoint source Al2 analog input or a stored constant is selected through the MUX RSP multiplexer by mean of the DI2 input Selected Value Set Loc Setloc Input Al2 Loop 2 a The Remote Setpoint is enabled by mean of the DI6 input b The source of the Setpoint can be a stored constant with label Setmem 2 DIG Selected Setpoint Off On Setmem 2 16 5 Feed Forward This features is provided on loop 1 only and it provides a lead action to the control algorithm consisting in anticipating the response of the loop to a future change of the controlled variable It is enabled by a parameter of the multiplexer MUX module and it consists in connecting the analog input Al3 to the Feed Forward input of the PID module 16 6 Forcing Modes These operations are related to the loop output that can be driven by other sources than the straight PID algorithm The functionality provided by the two loop are slight different as described below Loop1 This configuration allows the following 4 modes Tracking Hold Hold Y Max Hold Y Min a Tracking it is enabled by the DI4 digital input and it consists in setting the control output to a predefined constant value b Hold when DI3 is active the control output is frozen at the value it had at the time of the rising transition c Hold Ymax When both DI
62. inputs is associated with a position on the panel where its value and its tag is displayed 68 Chapter 5 Modules Parameters 4 Display 4 Input 2 XXXXX Displayed Parameters Input 1 Input 4 Format defines the number of digits of the 4 measured variables Both the tag and the engineering units of each measure are configured through the AC Prograph and AC Edit only Number of the variables displayed on the panel 5 4 2 4Writable Analog values 4ADP Description This display panel allows to display or generate 4 analog type variables contemporaneously Each variable is characterized by a tag max 10 characters and an engineering unit max 3 characters Tag 10 caratteri max Titolo uscita 1 10 caratteri max Ree aoe Variabile impostata Unita di misura 3 caratteri max Titolo uscita 2 10 caratteri max Variabile impostata Unita di misura 3 caratteri max Titolo uscita 3 10 caratteri max Variabile impostata Unita di misura carane ma Seleziona la variabile Titolo uscita 4 ie 10 caratteri max Variabile impostata Unita di misura 3 caratteri max gt AO1 gt AO2 gt AO3 gt AOS I O Connections AO1 AO4 Analog values outputs 69 Installation and User manual of the AC10 AC20 AC30 controller 5 4 3 Analog Display Panel ADP Description This module provides the functionalities of a set of analog indicators It displays both the value and the 6 charac
63. of the A M station is directly driven by the front panel of the instrument while when in Auto the output corresponds to the analog input Al1 optionally divided by a ratio value This ratio value can be either the Al2 analog input or a constant value store in a module The Forcing modes are Tracking Hold Ymax and Y min The alarms are on the input variables and of absolute type 23 3 Forcing Modes These operations are related to the A M station output that can be driven by other sources than the keyboard or the input variable 207 Installation and User manual of the AC10 AC20 AC30 controller The A M station allows the following 4 forcing modes selected through the DI1 DI2 DI3 and DI4 when the operating mode is AUTO Tracking It is enabled by the DI2 digital input and it consists in setting the output to a predefined constant value or to the Al2 value Hold When DI1 is active the control output is frozen at the value it had at the time of the rising transition Hold Ymax When both DI1 Hold is active and DI3 is active the output is forced to its maximum value defined by the parameters of the CONTROL OUT module Hold Ymin When both DI1 Hold is active and DI4 is active the control is forced to its minimum value defined by the parameters of the CONTROL OUT module 23 4 Alarms Four alarm modules are provided two for the Al1 and two for the Al2 analog input The status of the alarms is transmitted out thro
64. of the controlled variable 20 9 Applications The override control is the right solution for controlling processes where more than one variable must be controlled at the same time For instance the process consists of a Main variable that must be kept at the setpoint and a Limit one that must not exceed a predefined threshold during normal operations start up or when abruptly changes occurs A few examples of a process requiring the override are Flow control with a maximum limit on the pressure Control of the pressure with a limit on the flow Control of the temperature of an object with limit on the maximum temperature of the heating elements v Y lt N J LOGIC PA le 00000000 lt Pi vu 4 SZ NON Pv2 PV1 LOGIC lt 00000000 lt Ly 20 10 Electrical connections Annex A Resident Configurations The following picture provides a clear view of all the termination blocks with the associated functionality and it is specific of this configuration No signals must be connected to the termination blocks not used by the strategy The termination blocks 25 and 26 are providing a 24V DC output particularly suitable to supply of the 2 wires transmitters Loop 1 PV1 measurd main SP Rem Loop2 SP Rem limit PV2 measure Loc Rem Rem Mem Loop1 Hold main Tracking
65. of the loops 1 2 3 and 4 9 Auto Man Display of the Out station operating mode The possible modes are A Auto or M Manual 10 Output Value Numerical display of the loop control output in percentage 11 Setpoint Operating Mode This short mnemonic reports the current Setpoint operating mode of the loop 1 Master The various modes are Loc Rem Com 12 Loc Rem Com Display of the Setpoint operating mode that the user has requested from the controller keyboard The Setpoint refers to loop 1 Master The mode is indicated by the mnemonics Loc Rem and Com 13 Alarms Blinking box usually flagging anomalous conditions requiring the operator attention It is activated by a digital input signal The following are few examples of the types of display you can achieve with this panel The type of visualization is automatically selected according to the connections performed on the module inputs through AC_Edit AC Prograph 2 LOOPS 3 LOOPS LOOPS 4 DISPLAY ST1 2 ST3 4 Loc Loc Rem LP1 TEM L1 PV1 TEM M M M M 2 Loops 3 Loops 4 Loops 4 Indicators A M stations 26 3 3 4 Trend Panel This display has almost the same functionality of the 1 Bar Panel module with the addition of a trend chart of an analog variable Its main purpose is to provide the front panel of a simple control loop The trend indication gives the operator a better understanding of the situation of the proc
66. or to a computer for the backup of the data Galvanic isolated from the controller I O signal AC20 and AC30 only RS232 Port programming Port to a computer running the AC Prograph AC20 and AC30 for the design and the test of control strategies or running AC_EDIT for saving of the strategy parameters AC10 AC20 and AC30 Configurable Inputs 0 5 V 0 1 of the span Outputs 0 20 mA 0 5 V 0 1 of the span Inputs 0 005 C maximum Outputs 0 01 C maximum LCD graphic display backlighted by EL cool cathode lamp 128 x 320 pixel resolution Control of the contrast from the keyboard with automatic environmental temperature compensation Duration of the lamp gt 20 000 hours Keyboard Supply Maximum Power consumption Transmitter Power Supply Isolation Electromagnetic compatibility Operating Conditions Environmental Conditions Protection Material Dimension Panel mounting Weight 1 3 Hardware Description Chapter 1 General Information 8 multifunction keys 90 264 Vac 48 63 Hz optionally 24 Vac VDC 20 20 VA 24 V cc 5 regulated 300 mA maximum with short circuit protection EN 61010 EN 55011 EN 50081 2 EN 50082 2 IEC801 2 801 3 801 4 801 5 Level IV KWF for DIN 40040 Temperature 0 50 C Relative Humidity 10 to 90 without condensation IP30 for the case IP20 for the termination unit IP54 front panel protection S
67. power on Standard or custom configuration 2 Standard Custom Pick up one of the resident strategies Design the Custom strategy by mean of AC PROGRAPH Download the strategy Set the parame ter values Y Startup the controller and tune the P I D Check the whole functionality Fig 3 1 3 1 Keyboard Fig 3 2 The keyboard is located on the right side of the front panel It consists of 8 pushbuttons whose functionality is described in the following pages 19 Installation and User manual of the AC10 AC20 AC30 controller 20 3 2 Pushbuttons Functionality Increases the value of the selected variable i e the Local Setpoint Lowers the value of the selected variable i e the Local Setpoint Changes the Setpoint operating mode Selects the next variable of the scrolled variable list and displays it in the corresponding field in the upper part of the panel Forces the controller to present on the display the next display panel configured in the strategy Selects the Out station operating mode between AUTO and MAN When the controller is in MAN it decreases the value of the output When the controller is in MAN it increases the value of the output The usual functionality of these 8 pushbuttons is described above In same peculiar circumstances they perform differently This occurs with some panel i e Selector System Clock Dual Trend etc
68. priority to the keyboard This mechanism of overriding the priority scheme defined in the strategy configuration allows the user to operate when the process condition requires his intervention leaving the control in the hands of the strategy at the end of the user operations Each of the 16 states of the digital outputs is indicated on the display through an alphanumeric string called item name intended to provide an immediate perception of what that pattern does on the process For instance one item name can be Valve XX open flagging that when selected the digital outputs will assume the status required by the strategy to open the valve XX Selection Modes The three selection modes supported are e Supervisory Computer Through the serial communication line a computer selects the item that is the pattern of the outputs by writing into a particular register Please refers to the Communication manual for the details about the location and the format of the register to write e Through a four bit code specified by the DI1 DI4 digital inputs of the SELP module providing the item number e Through the front panel keyboard of the AC controller by mean of the Scroll keys By pressing this key you choose the item to select and after you confirm the choice by pressing Enter Tag ot the Panel 10 Characters Current priority Requested priority Item name 14 char Display area of the 16 items pa
69. set the engineering units of the totalizer The totalization is carried on every time sample according to the following formula Ts Out oy Out yy In SF oo Out Output with the current value of the totalizer new current one old previous calculation In Input with the value to totalize Ts Sampling time in seconds SF Scale Factor for ranging the value to the totalization engineering units IN OUT TOT DRES DO I O Connections Note The module generates a pulse with time width equal to the controller sampling time every time the OUT totalization value reaches the threshold or its multiple specified by the value of the Pulse V parameter The DO pulse output allows external counting device like mechanical counters to further totalize with a greater number of digits the IN signal Example Let us totalize the quantity in liters of a fluid during an entire year guessing that the average instantaneous flow rate is 30 l h Considering that the maximum value the totalizer can reach before a rollover is 99999 the Scale Factor SF should be set to the value computed in the following formula in order to prevent a rollover before the end of the year 99999 30 365 24 0 3805 Setting SF to the value above the totalizer will be set to the value of 0 3805 after 1 hour assuming for the flow a constant value of 1 I h In order to have the totalizer engineering unit immediately und
70. show the procedure for the access modes setting in either in presence of password or without it With Password Forno 3A Main Enter the Keyb Perm Permission Menu Password amp Password Vi amp Mo Group Perm GroupA Vi8Mo O E E E a Keyb Perm R R R R 136 Cap 6 Password and Access Control Without Password amp Password Tune amp Views Group A VigMo Par 8 Comms Change Passwd GroupB VigMo Prog amp Test GroupC Ulock Ulock Keyb Perm Set Pnt R MENTE By default the AC controller doesn t have the password protection You can easily add it by following the procedure below for Password Change Note e The password consists of 5 alphanumeric characters e The AC controller doesn t have the password protection when shipped Once a password has been defined it operates unchanged up to the next modification or deletion 137 Installation and User manual of the AC10 AC20 AC30 controller 6 2 Forno 3A O 6 3 138 Password Change The following picture shows the steps required to insert the password for the first time You access the Key Perm menu select the Change Passwd command enter the password and confirm with the E button Keyb Perm Main Keyb Perm Enter new Enter new Menu amp Password Password Password E Change
71. simpler 2 Loops C Heat Cool Loop plus 1 simple Loop Ratio 1 Ratio Loop plus 1 simple Loop Cascade Cascade loop with Remote Setpoint and PV retransmission Override 2 Loops interconnected as override controllers 4 Loops 4 simple Loops independent each other 4 Indicators 4 measure indication with retransmission and alarms 2 A M Station 2 A M stations with alarms and retransmission More information about this strategies are illustrated in Annex A Resident configurations Chapter 1 General Information 1 5 Library of the functional modules of the AC10 AC20 and AC30 controllers Input Output and Display Code on the controller panel Digital input inputs Freq Input A Outputs Digital Output DO D Outputs Time proport Output T Prop Out Bargraph Display 4 Bar Panel Alarms Display ap gt Analog meas display Analog meas display Analog values Setting Multiswitch esw 35 3 Description Mnemonic Information displayed Code on the controller panel Setpoint and Deviation calculation SDV Set amp Deviation PID algorithm PID Output MV Heat Cool output HCMV Motor positioner SRV Setpoint Programmer PRG Time Clock RTC Range Change SCH Filter FILT Analog signal delay ADLY Digital signal delay DDLY Rate limiter MSL Characterisation CHAR Minimum or Maximum MAX Analog Soft Multiplexer AMUX Analog Hard Multiplexer AMX8 Sample and Hold HLD Analog Delay Analog Mux
72. us guess to have calculated three sets of the 3 terms parameters each one related to well defined setpoint range You can imagine that each set has been computed automatically by the controller Tuning facility as described in the Chapter 4 1 Setpoint Range Optimal PB pto 0 300 1 0 300 500 500 700 The best result is achieved if the Gain parameter is set according to the value of the setpoint This can be implemented automatically exploiting the scheduling facility as llustrated below A linearizator module whose input variable is the PID Working Setpoint selects the appropriate coefficient that through the KP input multiplies the predefined value of PB that is 20 achieving the Gain value in the table above 2 0 300 500 700 Characterization curve of the Linearizator module WSP Block diagram of the strategy for implementing a variable gain PID 4 3 PID with two degree of freedom In order to provide very effective control capabilities the AC controllers are supplied with a PID algorithm with two degree of freedom This second degree corresponds to the Beta parameter that provides a sort of weighting of the setpoint that goes in the PID formula The benefit of using this parameter is a consistent lowering of the overshoot and the undershoot during the setpoint changes 39 Installation and User manual of the AC10 AC20 AC30 controller 40 This Beta parameter also named Set Point Weighting h
73. where the measure becomes meaningless when too low 4 Any change of these two values automatically affects the values of the Scale range of the display panel modules Bar panel e Trend and the SDV module Setpoint and Deviation calculation related to the analog input 47 Installation and User manual of the AC10 AC20 AC30 controller 48 5 2 2 Frequency Input Fl Description This module converts a frequency signal input with range O to 20 000 Hz to a number in engineering unit The signal is applied to the termination unit of the digital input n 1 D1 of the AC controller The range of the output signal doesn t necessarily start from 0 while the module provide a filtering of the output value to properly process the signal OUT DOVR DI 1 I O Connections Value in engineering unit of the frequency input signal Out of range detector Active 1 logic if the signal is out of the configured range like in the case of some failure on the transmitter device Parameters Hz INPUT 0 00 Freq Lo 0 00 Displayed Parameters 20 000 Hz 1 ib e 20 000 Hz 1 Scale Selects the hardware range of the signal 2 Low range in engineering units of the signal 3 High range in engineering units of the signal 3 Format Defines the number of digits format of the output value Filter Filter time constant if the value is 0 the filter is disabled Note I
74. 117 5 8 6 NOT CGO ae a aaa a aaa aa ET Ls 118 5 8 7 FOR COR ora E STEE 118 5 8 8 OR A AAA A Ae dtd E AE betes 119 5 8 9 O Input OR ORS e ir oi 119 JOJO Fip Fop TAE TATO OR P a s a tae tail aol tee a siete SEN doe 120 ISAL D EATCHEFNP Flop renan a act es ators Than oh ate ee den tad e ee a aloe o Nee lee te 120 3 86 12 lt Monostable CMST Jia A datada pha eee eh cin spo BTL Me eta 121 30 13 Counter ENTIDAD ah ashe ee wena ae NAT DA 122 5 8 14 Multiple Analog Constants MCNS ccccccccsscssseseeseescesesseeneeeeecnecescuseeseesesaeeaesesenecseeseeseeaeeesnesnrenteses 122 S419 Analog Single Constant CNS Jura iste eee es ae lei tb 123 5 8 16 Multiple Digital Constant MDCN 0 ccccccccccccesseesseeseesesseeceeseenecnesnecneceseesesseeesesecnesesseseeseeseseeneeeeetes 123 5 8 17 Analog To Digital converter A D reiii E AE E EE E Saa ee AE S 124 5 8 18 Digital To Analog Converter D A ecccceccsccsscseesseeseesensesseesecseesecnecnecneceseesesseeesnesesneseeseseeseesesaeeaeseeeees 124 3 819 AND 8 Block ANDE ici A A A IE En ee dd eo 125 9 020 Shift Block SHED ri E a LE HENS N Gs ane at ie cd 125 5 9 PROGRAMMER FUNCTIONS se 0scatedicesssuseetcateesvessentiee sees seven seneevevdcedanacteedevevacedavea S EE EEE TEE E 127 5 9 1 Real Time Clock with 8 outputs R T C cccccccccecccccescseseesenseeseenecseesecnecneenecescesecseseeecnseneseseesesaeeesesaeents 127 5 9 2 Setpoint Programmer PRO a oa eras 127 6 PASSWORD AND ACCESS CO
75. 2 Track T gt LOOP 2 F ii Al6 Pv2 Loc Rem Rem Mem K panera LOOP 2 3 P Hold T Track Power Supply 171 Installation and User manual of the AC10 AC20 AC30 controller 16 2 Loops B 16 1 Description This configuration provides two loops 1 with basic characteristics 1 with additional performing features The loop 1 is the main one it is the more powerful and it supports the following additional functionalities Remote Setpoint from an analog input Remote Setpoint from stored constants Feed Forward Forcing of the output 3 alarms on PV1 Out of range detection underflow of PV1 Retransmission of both PV1 and WSP The loop 2 is the basic one and provides the following basic functionalities Remote Setpoint from stored constants Forcing of the output 3 alarms on PV2 Out of range detection underflow of PV2 The description of the control functionalities is reported in the following pages related to the loop1 only The functionality of the second loop is perfectly identical but with the index numbers of the modules different To the get the proper index numbers for the second loop refer to the Block Diagram 16 2 Block Diagram In the following block diagram the interconnections between the various modules and the display panels are not indicated in order to improve the understanding of the functionality performed UNDERFLOW Y Y Y T Vv I Dit DI2 UNDERFLOW
76. 2 wires transmitters PV1measur SP Remote Feed Forward Tracking Input DRSP Rem Mem SP Sel SP Sel Hold Tracking Mv Max Mv Min CN dEl Ny 25 24 Sa 26 24 Saf a lt 4 f A 281 EB 29 S AQ e oN 7 O N y 3T 8 LAN 32 9 N 33 gt 1 UN Jp BK 17 Z El 12 EN Wie A BTK gt p A tE NEB p Bo ig enz o ok gt h7 ti es Y a gt is A az N Ape Vc a3 gt B y YY ra 21 5 lt 22 Y 46 JE Sel A Actuator Retrasm PV1 Retrasm WSP Retransm Al4 Alarm 1 Pv1 Alarm 2 Pv1 Alarm 3 Pv1 Und F Pv1 Alarm 4 Pv1 Alarm 5 Pv1 Alarm 6 Al4 Alarm 7 Al4 POWER SUPPLY 163 Installation and User manual of the AC10 AC20 AC30 controller 14 1Loop C 14 1 Description The drawings below are providing the following informations Block Diagram User interface consisting in a set of display panels Termination unit for the connection to the field 14 2 Block Diagram In the following block diagram the interconnections between the various modules and the display panels are not indicated in order to improve the understanding of the functionality performed c
77. 3 Hold is active the selector module DSEL is on position 1 and DI5 is active the control output is forced to its maximum value defined by the parameters of the CONTROL OUT module d Hold Ymin When both DI3 Hold is active the selector module DSEL is on position 2 and DI5 is active the control output is forced to its minimum value defined by the parameters of the CONTROL OUT module Selected Value A M or TRK Output frozen On On 2 MinOut 173 Installation and User manual of the AC10 AC20 AC30 controller 16 7 Alarms Loop 2 This configuration allows only the following 2 modes Tracking e Hold a Tracking the Tracking mode set the output to the value of the constant n 2 named Trk L2 of the module MCNS until DI8 is active b Hold The Hold mode freezes the loop output until the DI3 digital input is active c These 2 forcing modes are handled by the module according to the following priority A M Hold and Track Loop 1 There are three alarms either on the controlled variable PV1 or the deviation according to the parameters selected in each of the ALM modules The module WSP PV computes the deviation in the same engineering units of the controlled variable PV1 The status of each alarm is retransmitted out through the DO1 DO2 and DO3 modules A fourth alarm the digital output DO4 flags the out of range of the variable PV1 underflow Loop 2 There are three alarms either on the controlled var
78. 6 bit A D conversion resolution Input impedance DC gt 1000 MQ Frequency Input This feature is provided on the D1 input of the AC20 and AC30 controllers only Minimum input signal amplitude 8Vpp Input 7 Installation and User manual of the AC10 AC20 AC30 controller Analog Output AO Logic Inputs DI Logic Outputs DO Serial Communication Failure Digital Output DO Accuracy Class Temperature Drift Display ranges 0 01 200 Hz 0 1 2000 Hz 1 20 Khz When the range 0 01 200 Hz is selected an antibounce filter of 1 5 ms is automatically inserted on the input signal Ranges 0 5 V 1 5 V 0 20 mA 4 20 mA software selectable Output load drive 500 Q minimum for voltage output 500 Q maximum for current output Resolution 13 bit Input range 24 VDC min 8 VDC max 36 VDC for logic 1 Optoisolated current sinking 4700 Q input impedance bidirectional no polarity driven both by positive and negative voltages Output level 24 V cc ca max 36 V cc ca Maximum current 300 mA Normally open output Protection against surges and short circuits through automatically armed fuses RS485 port Main Com to a Supervisory Computer Protocol supported MODBUS RTU Line length 1200 metres maximum Units per line 32 controllers with twisted pair cable and 120 termination resistors Transmission rate 19200 baud RS485 Port Aux Com to Expansion Units
79. AA AA AAA RdA Aid 168 JSI DESCRIPTION 5 23 decdesdestectecddccodesteewededdeves thoes gesteadeedadslscstes cede dees thoes dit tddi 168 TL BLOCK DIA GRAM a da 168 1553 CONTRO acia 168 PA REMOTE SETPON Tte sss sop 255 seo sek E OSS CANOSA OE AE 168 155 FORCING OPERATIONS 2 ii ina A ideas Eta 169 1526 ALARMS OA 169 15 7 VARIABLES RETRANSMISSION vs 03c0sedsdestvonaetsce voce densecstecsevovesdecncedece ovesederearedeveavecesdeceasescsecbetdesessevencdebueedevesssees 169 1528 GRAPHIC DISPIEAY 3 ts bets coset seek e ee hatte as ROS ake e E old ees ek Na 169 19 9 APPIGATIONS SAET D EEE EE E ET A EEE id cta 171 15 10 ERECTRICAL CONNECTIONS E E A E E TA E A A 171 16 ASA RAS 172 16 1 DESCRIPTION A A rai 172 16 2 BLOCK DIAGRAMA a dani 172 16233 O TON 173 Annex A Resident Configurations 16 4 REMOTE SETPOINT 5 03045 c5cssceset0s A a e aaa 173 16 5 FEED FOR WARD ESN EEE ASCE Seve be ea ALS oes ca edie The E dai 173 16 67 FORCINGMODES 4 E EE es A a A es eo as a as 173 16 7 ALARMS srt did 174 16 8 VARIABLES RETRANSMISSION scsscccsccccessssecececcecscesaececececsensseaesececeeceesaeeeeececeeaaeseeececseseuuseaecescsenenneaeeeeeees 174 16 9 GRAPHIC DISPLAYS A A SNS bd Sooo 174 16 10 ANPPEICATIONS a DA A REE PES 176 16 11 ELECTRICAL CONNECTIONS is 176 17 PA OIO a E OPATAIA EPRE EEE E E AORE ON E A A A 177 Vile 1 DESCRIPTIONS AAEE e E A O EEE 177 172 BEOCK IDIAGRAM sa aaa aa as ie did 177 IA ICON H H
80. C Prograph AC Edit 4 4 2 Handling the Main Comm Supervisory Computer The AC controller communicates through this port with a Supervisory Computer with the MODBUS and JBUS protocols The physical media is a twisted pair and up to 31 devices can be connected on a cable The setting of this port is as follows Chapter 4 PID Tune and Communications TAG 0000 0 Main Parameters Comms Sup Menu amp Comms 9600 B Rate Loc 7 Par amp Comms E Main Comm El R R R MAN Main Comm port Setting Baud rate setting Allowed values 110 300 600 1200 2400 4800 9600 19200 D Bits _ Fixed value set to 8 S Bits Stop bits the choice is between 1 or 2 The choice is None Odd Even MODBUS JBUS address of the controller It is a number from 1 to 247 Mode ModBus or Jbus protocol _CN2 4 CN2 5 E CN2 6 am acon sl z a CN2 4 CN2 4 CN2 4 CN2 4 E a CN2 5 CN2 5 me _CN2 8 CN2 5 CN2 6 CN2 6 a CN2 6 CN2 6 a ES E 1 gt a a
81. C20 AC30 controller 112 5 7 3 Expansion Unit Timeout AALM Description This modules activates a digital alarm output when there is not communication between the AC controller and its Expansion units for a time greater than the specified timeout AALM DOUT I O Connections DOUT Alarm output flogging the lack of communication with the Expansion Units Parameters AALM Time Out 5 Displayed Parameters Minimum lack of communication time 0 to 600 seconds 5 7 4 System Configuration SYS Description This module configurable through the AC Prograph only defines the optional characteristics and the configurable behaviors of the AC30 controller It specifies e the characteristics of the communication protocol of Main Comm e the characteristics and the addressing of the LAN e the sampling time e the levels of access of some operations and the password SYS Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument panel Chapter 5 Modules 5 7 5 Key Selector KEY Description This module provides the functionality of the key pressing simulation allowing the strategy to press the keys on the AC30 controller When its DIN digital input goes active the result will be the same than pressing the corresponding key of the AC 30 8 buttons keyboard The configuration of this module is carried out through the AC PROGRAPH only on
82. Chapter 5 Modules If DHLD Hold is active the output is frozen If both DHLD Hold and DYMN Force Min are active the output Y is set to the minimum forcing value If both DHLD Hold and DYMX Force Max are active the output Y is set to the maximum forcing value If the DA M input is active Manual mode request the current output Y is not changed any longer according to the MV input but it is changed only from the keyboard All these digital inputs are connected to an OR logic gate whose output is the signal DBMP This signal active when the module status is either manual or track or hold or forced is connected with the PID block to stop the PID execution and to perform BUMPLESS transition on the change from the active to the inactive state Note the modules MV N 1 and 2 are alternative to the modules HCMV N 1 while the modules MV N 3 and 4 are alternative to the module HCMV N 2 KEYBOARD ymax VA YMIN ds Y OR DTRK DHLD DYMX DYMN DA M AZ NZ NZ NZ N MV w MV TRK y gt DBMP 77 Installation and User manual of the AC10 AC20 AC30 controller I O Connections Controlled variable also named manipulated variable It is generated by the PID module as a percentage value of the span Track input It enables the Track functionality Track value Analog signal with the value to set the output Y when the Tr
83. D COMMUNICATION ccsssccssssssscssssccccscscscssssccscssscccesscscssssssccscsssccsssssscssssssscsssssscsssssecssssees 37 4 1 TUNING 3 Sande dad it et tad didas 37 4 2 GAIN SCHEMA eat 38 4 3 PID WITH TWO DEGREE OF FREEDOM ccccccsccecesssssscecececeesssaececececsesasesesecececsesasecececeesesseaesececeesesaaeeeeececeensaaees 39 4 4 COMMUNICATIONS cta ita adios 40 4 4 1 Handling the Programming Port errereen a 40 4 4 2 Handling the Main Comm Supervisory Computer cccccccccccccccsccecesseesessesescusceseesesseesesnesneenseeseeseneeesneeaeed 40 1 1 3 Handling the Aux COMME as GS T BB 42 1 1 4 Handling the LAN ARENET e deo is as gn tne dei in 43 1 5 PARAMETER CHANGE 2s ccccctcostesuscdeccotuesseccuces daria lidad 43 1 6 AC PROGRAPH AC_EDIT SOFTWARE ccccccecessssssceeececeesesececececsenesseaecececeesesaaeceeececeeeaaeeeeececsesesaesesececeeneaaees 44 1 7 SAMPLING TIME dais 44 MODULES Ln e Tedueteesuvdedecdotsesteasocdscetecasteudetacedessscusccsesessuetessetentesdecussorsectesscedbentecustestoacdueders 45 5 1 RULES USED THROUGHOUT THIS CHAPTER csssessssccececeesssaececececsenssececececeesesasecececeeseseaeseceeeesesesaeeeeececeensaaees 45 Installation and User manual of the AC10 AC20 AC30 controller AZ O MODULES a A A Bote OR A ah Ole Ades E Oe Sun Selene 46 5 2 1 Analog Input AL ca 0 A A A aire 46 5 2 2 Frequency Input ED cani Seon a ae cadences Watton aa ana iE ua Shea aaa a aKa aiii 48 5 2 3 Digit l
84. DBMP Digital input indicating through its negative transition when the adjustment of the PID terms for the BUMPLESS transition must be performed Control output in percentage of the Heat channel Control output in percentage of the Cool channel Parameters MCF _1 100 Max Heat 100 Displayed Parameters A Maximum forcing value of the heat channel with range from 0 to 100 Max Cool Maximum forcing value of the cool channel with range from 0 to 100 Dead Band Deadband with range from 10 0 to 10 0 81 Installation and User manual of the AC10 AC20 AC30 controller 82 5 5 5 Servomotor Output SRV Description This module is a servo positioner like a valve positioner that controls by mean of a raise and lower digital output the movement of the actuator up to the target position specified by the IN analog input The IN analog input provides the position in percentage units with range from 0 to 100 the actuator has to assume DO IN gt SRV pc I O Connections Analog input specifying the actuator position Digital Output enabling the movement in the Open direction DC Digital Output enabling the movement in the Close direction Parameters SRV _ 1 60 Travel T 60 Displayed Parameters Travel T Travel time with range from 15 to 600 seconds required by the servomotor to go from the zero position to the full travel end Dead Band Dead band of the actuator with rang
85. DD ODODODOO owa L F 4 examen Tef Z 72 68 97 34 5 Spessore max 20mm 2 44 5 o MIN 80 MIN 310 0 M 1 N 2 2 Panel Mounting 1 Insert the instrument in the aperture on the panel fig 2 1 2 Fit the two mounting clamps fixing them in the slots of the instrument case on the top and on the bottom of the instrument walls To hook firmly the clamps slide them away from the panel in the direction of the termination unit fig 2 2 3 Rotate clockwise the clamps screws up to when the instrument front panel sticks completely on the panel wall Do not tight the screws too strongly to avoid panel distortion A Y Screwdriver Figure 2 1 Insertion into the panel aperture Figure 2 2 Hooking the clamps and blocking with the screws 13 Installation and User manual of the AC10 AC20 AC30 controller 14 2 3 Connections and terminations The screw terminals located at the rear of the controller can be accessed by removing the transparent protective terminal cover This cover is secured in position by two screws On the transparent cover all the terminals are labelled together with some functional information as shown in figure 2 3 Screw Terminals AC 10 Screw Terminals AC 20 AC 30
86. DO4 digital output flags the out of range of the variable PV underflow 165 Installation and User manual of the AC10 AC20 AC30 controller 166 Two alarms are related to the control outputs of the two actuators Their status is transmitted out to the DO5 6 digital outputs and are used to flag which of the two channel is operating 14 7 Variables Retransmissions The controlled variable PV is transmitted out after the reranging operated by the SCH PV module to the output AO2 The WSP working set point is retransmitted out though the analog output AO3 properly reranged by the SCH WSP module the range of the variable can be changed in order to consider only a part of the original signal scale with sensible advantages on the resolution of the output 14 8 Graphic Displays E LSP LSP WSP L WSP RSP RSP MS1 MS1 MS2 e MS2 MS3 MS3 Current operating mode Current operating mode Requested Requested operating mode operating mode OR of the forcing modes e OR of the forcing modes Alarm 1 e Alarm 1 OR of the alarms OR of the alarms Aut Man station e Aut Man station The pictures above show the different types of display panels providing the most effective interface for this strategy configuration The most used panels are the single bargraph display and the single pen trend that provides the same functionalities of the previous panel with the
87. E Alarm 1 11 E Alarm 2 E T 36 Alarm 3 13 A 37 RSP Sm A Underflow eae lt Sel D Alarm 4 16 cn2 of 40 RSP Mem lt a Il ass SA Alarm 5 A TRK M TRK a a 19 Y 43 Hold lt L of Tracking lt 21 N PI 22 Y 46 T Y max 23 POWER SUPPLY Y min lt O 3 167 Installation and User manual of the AC10 AC20 AC30 controller 15 168 2 Loops A 15 1 Description This configuration consists of 2 separate basic PID loop not interconnected each other Each loop provides the following functionality Remote Setpoint Output Forcing modes 3 alarms and the PV out of range underflow detection The description of the control functionalities is reported in the following pages related to the loop1 only The functionality of the loop 2 is perfectly identical but with the index numbers of the modules different To the get the proper index numbers for loop 2 refer to the Block Diagram 15 2 Block Diagram UNDERFLOW In the following block diagram the interconnections between the various modules and the display panels are not indicated in order to improve the understanding of the functionality performed a e e 5 i e igs ae E OR 1 DB1 DB2 Y Y ALM ALM ALM 3 2 1
88. E O EAEN EENE OA NE SE EA E A E AAI A E AE E 178 17 4 jJREMOTE SETPOINT rd 178 IAEN AOLE B IEEE ETE E E oO RRA ES ETS 178 LO ALARM A A E EE 179 17270 VW ARTABLES RETRANS M SON 0 cubes tubes suse cuusiecesubstend ca coedvseine duke saddens cabdebcetcgesdeesvod coseceevs 179 1728 gt GRAPHIC DISPLAYS aces pescecact E EA E co ladies Wave ib 180 19 lt APREICATIONS is hes eect sts Ls ed hs tees ts ch oth cod cea has ea 181 17 10 ELEGTRICAL CONNECTIONS ANEETA EEP TANO EEEE dali titi 182 18 AA NO 183 1851 DESCRIPTION ai AAA 183 182 BLOCK DIAGRAM e e e 183 18 3 CONTROL AA la ene Litas 184 IA BAS e A a A Ao 184 18 5 REMOTE SETPOINT T ooreen doit tddi les 184 18 0 FORGING MODES ida 184 ISZ ATA RMS A Cas eevee Su Eag AE O A E 185 19 3 UGRAPHIG DISPLAYS a aio a OO OES 186 1 829 APPRICATIONS 83 sesesccossecevaihes chavo Sudecssueeeseaeobe ss tunics AS rea ca vO ste 187 18 10 ELECTRICAL CONNECTIONS ii ii ins 188 19 CASCADE cccccisteccciccesesvvesvecschsvedensvenvecechuunsvesteccevssescavussescesvuscdbesvesbeccevbsedacdessveucscacssesvscuvacevsdetesdeguseecevess S esvseues 189 19 10 DESCRIPTION dorado E EEEE EEEE EE EEE tddi 189 O7 BEOCRDIA GRAM a Ea a e a Ee EEA 189 UA CONTRO OAA SE A EEE E TE ESES cet nse apa EE E E AEST EEA EASE EEEE 189 194 REMOTE SEIPON Talaia aia llibre 190 19 3 FORCING MODES A A A o 190 LU AA MS a a e a e e e a 190 19 7 VARIABLES RETRANSMISSION oo tala eiii 191 19 8 GRAPHIC DISPLAYS EE EEEE A
89. GNB Label 2 Max 10 characters PV2 SPF High Range B G 2 SP2 SGNB Digital Input 4 PV2 Digital Input 3 Low Range B G 2 Time span B G 2 62 Chapter 5 Modules I O connections i ia They usually flag alarms events and status LN ae the PRG module It s displayed in the upper chart La rc the PRG module It is displayed in the lower chart AN the PRG module It s displayed in the upper chart AA PON the PRG module It is displayed in the lower chart PV1 PV2 SP4 Analog input providing one of the two trended variables in the upper chart sP2______ Analog input providing one of the two trended variables in the lower chart Parameters Program 100 BG1Hi 100 Displayed parameters Low limit of the scale of the upper chart BG4Hi High limit of the scale of the upper chart For BG1 Format defines the number of digits of the upper chart variables Low limit of the scale of the lower chart High limit of the scale of the lower chart Format defines the number of digits of the lower chart variables Time span of the lower trend chart Possible choices 1 2 5 10 30 minutes or 1 2 5 hours Time span of the upper trend chart Possible choices 1 2 5 10 30 minutes or 1 2 5 hours 63 Installation and User manual of the AC10 AC20 AC30 controller 5 3 7 Alarm TagList ALP Description This module provides the functionalities of an alarm annunciator w
90. Master scale High Limit e Slave scale High Limit Reme Current operating mode Requested ESA operating mode WSP Slave ae OR of Forcing modes WSP Master p ALLARME 5 Lmt PV Master PV Slave a Alarm 1 a Eg OR of Alarms Aut Man station Master scale Low Limit e a Slave scale Low Limit i ES a Valve position LSP LSP MAIN _WSP LIMIT _WSP RSP RSP m CSP m CSP e M L e M L Loc Current operating mode Loc Current operating mode Requested Requested operating mode operating mode OR of Forcing modes OR of Forcing modes Alarm 1 Alarm 1 OR of Alarms OR of Alarms Aut Man station Aut Man Station The pictures above show the different types of display panels providing the most effective interface for this strategy configuration The panel with the two bargraph gives a complete overview of the main variables involved in this configuration The PVMain controlled variable is 197 Installation and User manual of the AC10 AC20 AC30 controller 198 displayed both in the large size digits display and through the larger bargraph on the left while the Working Setpoint WSPMain is displayed by the slider The PVLimit limit variable is displayed on the thinner bargraph on the
91. Multifunction Programmable Controller STATION Installation and User manual of the AC10 AC20 AC30 controller USER MANUAL M I U ACMO 11 00 03 Cod J30 304 1AMIAC ING UNI EN ISO 9001 Installation and User manual of the AC10 AC20 AC30 controller Copyright 1996 ASCON spa All rights reserved No part of this document may be stored in a retrieval system or transmitted in any form electronic or mechanical without prior written permission of ASCON SpA ASCON has used the best care and efforts in preparing this book and believes the information in this publication are accurate The ASCON Products are subjected to continuous improvement in order to pursue the technological leadership these improvements could require changes to the information of this book ASCON reserves the right to change such information without notice ASCON makes no warranty of any kind expressed or implied with regard to the documentation contained in this book ASCON shall not be liable in any event technical and publishing error or omissions for any incidental and consequential damages in connection with or arising out of the use of this book AC STATION AC PROGRAPH and AC EDIT are trademarks of ASCON spa All the other tradenames or product name are trademark or registered trademarks ASCON spa 20021 Ospiate di Bollate Milano Italy Via Falzarego 9 11 Tel 39 02 333371 Fax 39 02 3504243 http Awww a
92. NTROL ccsssscssssssscssssssccsssscccssssesesscsessssssscsssssscsessssessssssacssssssssessssascssoness 135 6 1 SETTING ACCESS MODES ti o a e ibas 135 6 2 PASSWORD CHANGE uc A caes 138 6 3 PASSWORD DELETE A A ia aa as 138 6 3 1 Don EPA A Se esas TT Ta Seah ey Uae a 138 7e MAINTENANCE AND DIAGNOSTIC rar coc scecccencctentvccccesssacccsscescesssssctiesseccceseseecoteszeasdeseadesceassosaesoccesoaecsseseses 139 7 1 ADJUSTMENT OF THE DISPLAY CONTRAST ccscssssssecececsesssaeceeccecsessesececcceceesasececececsesssaeceeeceeseneaassesececeeneaaees 139 TD ERROR MESSAGE Sta EA 139 7 3 MASTERRESE Ti A 140 7 4 DIAGNOSTIC TEST AND CALIBRATION cccccccccsesssscccececeessssnaececececsessnaececccecsesaaesecececneaaeaeceeecsessaaeaeeececeeneaaees 140 7 4 1 Diagnostic TESTS Soc A da ns 14 7 4 2 CONDENSA er ee Nc ah aint thea teeth a nna Suse Pty Ae Oh Mall nace Toe ete ai 142 7 5 REPLACEMENT OF FAULTY COMPONENTS ssssssssseseceesesscsececcceceesseaececcceceesaaececececsessaeeecececeessaasseeececeeneaees 144 7 6 SPARE PARTS 2 52 55e0 2s Seek oes rote 144 7 7 MANUALS a a 144 8 EXPANSION UNUD wcisscescscdecceciieceecscettscccvecnsasescdonceesceseseusnsnccoescaceeecsssvececnssteecccesesenencaseneasvensceescensoosssanscesecsinverseess 145 8 1 GENERAL INFORMATIONS a iones 145 8 2 TECHNICAL CHARACTERISTICS 3 2500 a a a a a a a a s a 145 8 3 ENESA WAN B eA HO Ia EEA E EEE E E AEEA E as ta le AE E E AEE 145 8 4 ELECTRIGAT CONNECTIONS S ostia
93. Passwd E R R R lt lt Y y Any key In the case of an already existing password the procedure slightly changes To reach the Key Perm menu in order to modify the password the user must enter the old password otherwise the procedure is aborted Anyway in both cases once the new password has been entered a confirmation is required to the user in order to avoid to accept wrongly typed passwords Password Delete To delete the password the user must change the existing password to the new value of 00000 as illustrated above Once this new value has been entered the password won t be asked any further 6 3 1 Don t panic If you have forgotten the password don t panic because you have not lost your data In fact through the Supervisory Computer Comm line you can read at predefined addresses the password value Refer to the Communication Manual in order to get the proper informations Once the password is read you must enter it from the AC controller panel and operate as you like Furthermore the value of the password can be read from the Programming port by mean of the AC_Edit too Cap 7 Maintenance and Diagnostic 7 Maintenance and Diagnostic 7 1 Adjustment of the display contrast The contrast of the front panel LCD display can be adjusted in order to perfectly match it with the light at the installation site This operation is carried out from the controller keyboard carrying on the follo
94. Setpoint handling and the Out station For all these 5 groups the picture below lists all the possible modes the user can assign separately to each of them Possible Modes Tuning procedure Tune amp Views N Visa Visabl Vi amp Mo Parameters Modules and Par amp Comms N Visa Visabl Communication Vi amp Mo Prog i Configuration and Diagnostics Prog amp Test Visabl N Visa Setpoint modification from keyboard Set Pnt Lock Unlock Auto Manual Station Lock Unlock Display A brief explanation of the modes is as follows Not visible means that the display panel is hidden to the user Visible means that the display panel is presented on the screen but the user cannot enter any data or command Visible and modifiable means that the display panel is presented on the screen and the user can fully operate with it Blocked means that the panel is displayed but the user cannot enter any value or setting Unblocked means that the panel is displayed and the user can fully operate with it Prog allows to display change the programmers PRG parameters and to lock all the other parameters 6 1 Setting Access Modes The following drawing shows the basic menu structure on the AC Controller Starting from the Main Menu 4 submenu are accessible Keyb Perm amp Password allowing password definitions and access mode setting Program Select amp l O allowing diagnostic and calibrations Parameters amp Comms al
95. Supervisory Computer that selects the Setpoint choosing the Local Setpoint DssP__ f DLSP i PDEV DRSP gt IDEV D p DDEV DBIA y pa LSP WSP RSP gt SDV OS CSP BIAS D p PVI as pecan PV2 D K gt MOD I O Connections DSSP__ Digital Input forcing the Safety Setpoint as the loop setpoint Setpoint according to the table above 2 lA e Setpoint according to the table above 2 calculate the Working Setpoint RSP Remote Setpoint analog input BIAS Analog input with the value of the bias to add to the Local or Remote Setpoint SsP__ Analog input with the value ofthe Safety Setpoint CS MOD Special bidirectional signal controlling the operating mode of the Setpoint Working Setpoint value in case of a standard loop It corresponds to the Target Setpoint after the rate limiting operation Computer Setpoint Local Setpoint WSR__ Working Setpoint value in case of a ratio loop 1 Note 1 WSR is PV2 WSP in case of a direct ratio loop PV2 WSP in case of a inverse ratio loop 2 DLSP_ RSP Action No Setpoint selection o Local Setpoint request 0 1 Remote Setpoint request Computer Setpoint request 73 Installation and User manual of the AC10 AC20 AC30 controller 74 Parameters SDV 1 100 Displayed Parameters Format Format defines the number of digits of the controlled variable CNT Ago Selection of the type
96. TION o a 204 BOCK DAG A ia 204 ALARMS ann a a a a a E ba a E A ace Gea AE N 204 VARIABLES RETRANSMISSION scsescsccceceesessececececenssscecececeeseseseseeeceesesseaececececeesaaececececeenssaeceseeeceesenssaeeeeeeeenes 204 GRAPHIC DISPLAY S rea r E a ra ere a e ea ese aane ideo 205 APPLICA TIONS OR EAE E E E A EA EE E EE E EA EE 206 ELECTRICAL CONNECTIONS e E E E A EA OAE ar Eaa iot 206 AIM STATION icccessesscssdanteccdscevceesduvesccssetessedasesectesussvesdosssscvisstestssotuesivizenedceiesisstesectesteseievteletssdeisnbesiosettesieves 207 DESCRIPTION A EE EEE A EE A EE E E E E E EEA 207 BIEOCKDIAGRAMsirs ss a tt a Lct Pto a TE Lo e tn ds 207 BORCING MODES tooo dica 207 AA nas 208 VARIABLES RETRANSMISSION iis se0sdceeescedvesssteece dorada nidad ia E a EE EANA EES 208 GJIN eN DI H ES AE EA sia da o 208 APPEICATION EE E E E A nai 209 ELECTRICALCONNECTIONS dal ited 210 Annex A Resident Configurations 11 How to implement a PID controller Process disturbances Fig 1 Controlled Variables Manipulated Variables The purpose of a PID loop is to control a variable of an industrial process The purpose of an industrial process is to produce materials products or energy using the minimum quantity of energy and providing the maximum level of safety To achieve this target with an high level of quality standard each single element of the process must work precisely That means that each variable of the process must be finel
97. Yes or No Low Defines the low limit of the actual hardware range of the signal It is ETA entered as a percentage 0 to 100 of the standard hardware range specified Defines the high limit of the actual hardware range of the signal It is entered as a percentage 0 to 100 of the standard hardware range specified Specifies the standard hardware range of the signal The choices are 0 5V 1 5V Defines the linearization curve to apply to the input signal 2 Specifies the Cutoff value used with flow measurement 3 Filter time constant if the value is O the filter is disabled Low range in engineering units of the signal 4 High range in engineering units of the signal 4 Format Defines the number of digits format of the output value Note 2 No linearization is performed Square Root Thermocouple T Range 200 400 C Thermocouple J Range 40 760 C Thermocouple K Range 40 1200 C Thermocouple S Range 50 1650 C Thermocouple R Range 50 1650 C Thermocouple B Range 400 1800 C Thermocouple N Range 0 1300 C Thermocouple P Platinel Range 50 1250 C Thermocouple L Range 40 760 C PT100 Resistance thermometer PT100 Range 200 850 C NI100 Resistance thermometer NI100 Range 60 180 C Note 3 The Cutoff value that is continuously compared with the input signal If the input signal falls below this value it is considered 0 This is particularly useful with flow measurement
98. ack is enabled DA M DHLD Hold input When active the output Y is frozen DYMX Digital input enabling the forcing of the Y to the Max Forcing value DA M___ Digital input selecting the Auto and Manual mode Digital input enabling the forcing of the Y to the Min Forcing value DBMP Digital input indicating through its negative transition when the adjustment of the PID terms for the BUMPLESS transition must be performed Control output in percentage Parameters OUT 1 100 Max Out 100 Displayed Parameters Minimum Forcing value of the control output with range from 0 to 50 Maximum forcing value of the control output with range from 0 to 100 78 Chapter 5 Modules 5 5 4 Heat Cool Output Station HCMV Description This module is an Output station for an Heat Cool loop providing the functionalities the operator needs to interact with the loop The loop is controlled by two PIDs connected downstream to this module each one is dedicated to one channel The module provides auto manual track hold force operating mode output limits and the keys for incrementally set the output The operating modes that are unique for both the Cool and the Heat output are defined by a set of digital inputs as listed above ordered according to their priority level Auto Manual DA M Hold DHDL Force Ymin DMIN Force Ymax DMAX Tracking DTRK Depending on these digital inputs the functionality of the modu
99. addition of a programmable time width chart with the trend profile of the controlled variables The main controlled variable is displayed both in the large size digits display and through the bargraph while the Working Setpoint WSP is displayed by the slider The outputs are displayed both numerically and by the horizontal bargraph with the value of 0 in the central position the output of the cool actuator on the left and the output of the heat actuator on the right The following variables consisting of the entire set of Setpoints Local plus other 5 setpoints are displayed one at a time in the scrollable display area LSP Local setpoint WSP Working setpoint RSP Remote setpoint MS1 Memorised set 1 MS2 Memorised set 2 MS3 Memorised set 3 The squared digital indications on the right side of the panel are flagging the status of the alarm and the forcing mode of the loop More precisely they highlight the following general situations 1 When an alarm is active the label ALL is visible 2 When the Alarm 1 is active the label AL1 is visible 3 When a forcing mode is active the label FOR is displayed These are global flags the detailed cause of the event is shown in the ALARMS panel where the digital status of each alarm and forcing input is clearly shown Annex A Resident Configurations 14 9 Applications The typical application of this configuration is in the temperature control area where both the heat and the
100. ads 146 8 4 1 MUSAS Poach BE a A e a de e es ae den a Os nt 146 8 4 2 ROWERSUppiV sio at 147 8 4 3 ANDUTS and Dip oo aid 147 8 5 AUXILIAR Y UNITS ADDRESSING coi iii 147 9 ORDERING DATA cacccccceccesccesccttdssesestevcsceseestorseseddscstdcsctaccuessececsvescesecescosscsseseatevcndeusdstoscesecebestsesscecstescocerteseees 148 9 1 ORDERING CODE AEAEE NE EEEE E EA ETE dalt 148 9 2 AUXTETARY UN S A n RANES 148 10 ANNEX A RESIDENT CONFIGURATIONS ccsssssssssscccsssscccsssscscsssscscssssccssssscssssssscssssscessssecssssnes 149 Installation and User manual of the AC10 AC20 AC30 controller I N T R O D U C T I O WN Congratulation for having chosen an ASCON instruments This instruction manual is dedicated to the Multifunction Controllers Model AC 10 with 4 loops preconfigured with simple functionality Model AC 20 with 4 loops custom configurable by mean of a PC Model AC 30 Programmer with Real Time Clock 4 loops custom configurable by mean of a PC NOTE A Be sure that this manual is available to the user of the instrument B The manual refers to a family of multifunction controllers suitable for panel mounting and supplied with high innovative graphic display This effective user interface provides a huge amount of quality information the user perceive more immediately than other technologies C The configuration software for the AC20 and AC30 controllers is supplied on floppy disks You must keep
101. age to disappear and return back to the Program No menu e The segment to delete doesn t exist because its number is greater than the total number of segments the program consists of The message Segment not Available will be displayed to flag that the operation cannot be carried on At this point you must press a key to return back to the Program No menu Program No Delete Seg Delete Seg 2 pan Seg No Seg No Delete Seg R A Any key After the deletion of the segment all the other segments of the program following the new one have its numbers decremented by one Cap 6 Password and Access Control 6 Password and Access Control Description This chapter refers to an innovative feature of the AC Controller consisting in customizing the access mode for each display panel in order to prevent unauthorized intervention of the user You can easily configure for each display panel if the user can recall it on the screen and if he she can change the values and the parameters In order to facilitate the configuration of the access modes most of the operations performed by the AC Controller are classified in just 3 groups A B C Furthermore two more operations consisting in the typical operator front panel setting and not included in these groups are considered as two separate groups they are the Setpoint Management and the Auto Manual station involving the
102. al scale Analog inputs displayed graphically by mean of a sliders moving along the decimal scale Y1 Y4 Analog Input displayed numerically in percentage at the bottom of the display It is intended for the control output of a loop MOD1 MOD4 Special I O signals handling the Setpoint operating mode change Alarm input activating the corresponding flag on the display A M1 A M4 Operating mode of the Out stations Manual active Auto inactive LSP1 LSP4 Local setpoint values entered through the keyboard Parameters MULTI LOOP 100 Displayed Parameters PV1Lo PV4Lo Low range of the analog inputs PV1 PV4 PV1Hi PV4Hi High range of the analog inputs PV1 PV4 For PV1Lo PV4Lo Format defines the number of digits of the Local Setpoint SetLo1 SetLo4 Minimum value of the Local Setpoint 1 4 SetHi1 SetHi4 Maximum value of the Local Setpoint 1 4 57 Installation and User manual of the AC10 AC20 AC30 controller 58 5 3 4 Trend Panel TRP Description This module has almost the same functionality of the 1BP panel module with the addition of a trend chart of an analog variable Its main purpose is to provide the front panel of a simple control loop The trend is referred to the most recent values of the variable during the last minutes It is continuously scrolled on the left as soon as new more recent samples are acquired On the right side a bargraph at the beginning of the t
103. alues of upper and lower limits of the scale Each value consists of 6 characters including the sign and the decimal point 8 Set point Slider Graphic representation through a moving slider of the real time value of the Setpoint The slider is moved in steps of 0 5 9 Bargraph Bargraph indication of the process variable The bargraph shows the process variable value in 200 steps providing a resolution of 0 5 10 Output bargraph Horizontal bargraph showing the loop control output value in steps of 1 11 Output Value Numerical display of the loop control output in percentage 12 Auto Man Display of the Out station operating mode The possible modes are AUT or MAN 13 Loc Rem Com Display of the Setpoint operating mode that the user has requested from the controller keyboard The mode is indicated by the mnemonics Loc Rem and Com 14 Alarms and Digital Display by mean of user defined 3 characters mnemonic of the status of the 3 digital inputs of the module These inputs are used for representing alarms or simple logic status 3 3 2 2 Bar Panel The main purpose of this display is to provide the front panel for a cascade loop Master and Slave In this case the setpoint and the measured variable of the Master loop is on the left Loop1 while the ones of the Slave are on the right Loop2 The control output manipulated variable displayed belongs to the Slave while the output of the Master that becomes the Se
104. annot be used for other purposes on the Master it available for the user needs The Master Remote Setpoint feature is enabled both by the DI1 input active and by the priority based arbitration logic governing the operating mode change The Setpoint source is selected between an analog constant stored in the MCNS module and the Remote signal from the analog input Al2 by mean of the DI2 digital input As shown in the table below when DI2 is active the stored constant is selected as the Remote Setpoint Con Di2 Selectedvalue Off Off Input Al2 Constant SP MEM 19 5 Forcing modes 19 6 Alarms These operations are related to the loop output that can be driven by other sources than the straight PID algorithm This feature is provided on the Slave loop where the following 2 modes are supported Tracking Hold a Tracking it is enabled by the DI8 digital input and it consists in setting the control output to a predefined constant value of the MCNS module b Hold when DI7 is active the control output is frozen at the value it had at the time of the rising transition An important point to bear in mind is that all these 4 forcing modes are handled by the module according to the following priority A M Ymin Ymax Hold and Track There are three alarms for each loop either on the controlled variables PV SLV and PV MST or the deviations according to the parameters selected in each of the ALM modules The module WSP
105. aracters It is assigned automatically when the module is created and can be modified through AC Prograph AC Edit e 2 Selection Priority Display of the selection mode that currently has the highest priority and that as a consequence is selecting the output pattern The priority is defined by the user by mean of the AC_Prograph to the 3 potential selection modes Keyboard Digital Inputs and Computer 3 Selection Request Display of the selection mode that has been requested by the user and should be granted By mean of the L R button the user can modify the priority scheme defined through the AC_Prograph giving the highest priority to the keyboard This mechanism allows that the control of the Selector is usually performed by the strategy and or the Supervisory computer leaving the possibility of operators interventions through the keyboard when required The number at the right of this field indicates the item number of the last selected pattern 4 Item Area This area consists of 16 lines each associated to a defined output pattern named item and identified by an alphanumeric custom defined tag In AC_Prograph the user configures the Item from 1 to 16 The star symbol on the right of the item name specifies the last item selected whose pattern has set the digital outputs 5 Enter Key Enter key required to confirm the choice operated with the button 6 and 7 in order to proceed with the execution 6 7 Item Sel
106. as been selected as described at Point 1 It causes the starting of its execution 15 Operating mode Display of the operating mode of the Programmer Run or Hid The user can change the operating mode forcing the program to A M run or holding it by mean of the button 16 Digital Display by mean of user defined 3 character mnemonics of the status of 2 digital input signals The user can define a mnemonic for each state of the digital signal 17 Setpoint slider Graphic representation through a moving slider of the real time value of the Setpoint corresponding to the analog input signal Cl1 18 Loc Rem Com Display of the Setpoint operating mode that the user has requested from the controller keyboard by mean of the L R key The choices are 29 Installation and User manual of the AC10 AC20 AC30 controller 30 LOC Local Setpoint REM Remote Setpoint COM Computer Setpoint 19 Setpoint Operating Mode This short mnemonic reports the current Setpoint operating mode of the loop 20 Scrolled Variable Value Numerical display of the selected scrolled variable selected by mean of the 2 key The list of the variables includes the Local Setpoint and other analog input signals of the module It consists of 6 characters including the sign and the decimal point 21 PV Variable Value Numerical visualization of the PV variable consisting of 6 characters including the sign and the decimal point Usually this varia
107. as the same characteristics of the Set Point Filtering that is used by other Vendors because it doesn t change the response at steady conditions It modifies the position of some zeroes in the closed loop transfer function and this causes a more beneficial response to the overshoot The following picture illustrates the concept and the better response achieved with an optimal value of Beta Fig 4 3 Various simulation studies have demonstrated that the Set Point Weighting is more effective than the Set Point Filtering because in identical conditions of dumping amplitude it reaches the target setpoint in a shorter time 4 4 Communications The AC series controllers are supplied with 3 serial ports e RS232 serial port for instrument programming e RS485 serial port to the Supervisory Computer e RS485 serial port to auxiliary units Expansion Units e LAN network ARCNET type for peer to peer communication and to the Supervisory Computer 4 4 1 Handling the Programming port The programming port named service port too is mainly used to download and upload strategies in the AC controller by mean of the AC_Prograph or to modify the parameters of a strategy by mean of the AC_Edit This RS232 serial port is configured with the fixed settings 9600 E 7 2 9600 baud even parity 7 data bits 2 stop bits that cannot be changed by the user because its use is reserved to A
108. at defines the number of digits of the Al2 variable note 1 For CSm Format defines the number of digits of the Al3 variable note 1 Format defines the number of digits of the Al4 variable note 1 Format defines the number of digits of the Al5 variable note 1 Note 1 The 3 characters mnemonic of these 5 analog inputs is defined in the configuration by the user 55 Installation and User manual of the AC10 AC20 AC30 controller 56 5 3 3 Quadruple bargraph panel 4BP Description These module has the same basic functionalities of the 1BP panel module and it is intended for displaying on an unique panel more than one loop together with some analog measures or outputs Obviously it is less rich of information than 1BP it lacks the output bargraph and the main variable engineering units But surely it is the most versatile as soon as you connect the signals of a loop it adds the bargraph and the slider related to it Furthermore for each bargraph you can choose if you want the slider or not so that if you want to display just a measure you do not have a meaningless slider around And you can mix as you like bargraphs with the slider for control loops and without for measures and A M station At last an alarm display is available This is connected to a digital inputs in order to flag anomalous conditions requiring the operator attention When the alarm occurs a rectangle blinks at th
109. ation and User manual of the AC10 AC20 AC30 controller 190 The process variable PV SLV is acquired by the Al4 module providing the conversion in engineering units and the out of range detection It is transmitted to the SET DEV module that with the PID and CONTROL OUT modules makes up the core PID block The output is transmitted out on the terminal blocks through the AO4module for driving the external actuator The controlled variable PV SLV after being adjusted to the Master range by the SCH TRK MAST module is connected to the Track input of the Master Loop Furthermore the DB out of the Slave Loop is connected both to the Track enable of the Master loop and to the Bumpless input of the Slave loop These two connections are required in order to perform bumpless transfers in case of Auto Manual and forcing modes changes Every time there is a change the output of the Master is aligned with the instantaneous value of the controlled variable of the Slave The following important functionalities are added to the basic cascade control feature Remote and Memorised Setpoint for the Master Forcing modes on the Slave Alarms on the variable and deviation both on the Master and the Slave Retransmission both of the PV MST and the PV SLV variable 19 4 Remote Setpoint This feature is supported in both the loops but while on the Slave the Remote Setpoint is completely dedicated to the implementation of the Cascade configuration and c
110. ay panels providing a complete and optimal operator interface The two bargraph panel provides a complete view of both the A M stations with a fine level of details on the most important parameters It provides the bargraph indication of the outputs plus the numeric indication with large size digits of the variable of the selected A M station You select the station by pressing the A key as you do when you operate with the configurations with multiple loops The A M station that has been selected is highlighted by the fact that the tag is displayed in reverse The status of the alarms is flagged by the small box on the upper left part of the panel When an alarm or a forcing mode is activated the box blinks continuously to alert the operator Next the operator can get a more detailed view of the alarms by looking at the ALLARMS panel Furthermore a trend panel is available for each of the A M station This page similar to the one used for loops has a trend chart with programmable time width that presents the recent trend profile of the MV output variable At the top of the panel the numeric indication with large size digits of the variable is displayed together with all the variables of the scroll list related to the A M station 23 7 Applications LOGIC amp SHUTDOWN L n 4 The most common application of A M station is when an actuator must be driven directly or in ratio either of an inpu
111. ble corresponds to the one at input Bl1 3 3 6 4 Trend Panel This panel is intended for displaying on a single panel up to 4 trended analog variables Furthermore it display the numeric value of these 4 analog input signals and the logic status of 4 digital input signals Available only on the AC30 controller Its main purpose is to provide a complete user interface for the Setpoint Programmer The time span of each trend chart is defined by the user independently from the other by choosing between the following set 1 2 5 10 30 min 1 2 5 hours Q TAG 0000 0 f 35 Tm 2 f 3 lt e A 23 4 22 5 gt 21 6 7 a 20 7 8 19 9 E 10 da 16 42 be 45 AM 14 1 Tag This tag is the identifier of the panel and consists of up to 10 alphanumeric characters It is assigned automatically when the module is created and can be modified through AC_Edit AC Prograph 2 8 Chart title String of up to 10 alphanumeric characters with the name of the trend chart below The string can be entered or modified through AC_Edit AC Prograph 3 9 SP values Numeric display of the values of the analog input signals SP1 and SP2 These signals are trended in the chart too 4 10 Trend Chart Area dedicated to the graphic display of the recent trend curve of the variables Chapter 3 Commissioning and start up 5 11 Trend of SP Recent trend display of the SP1 and SP2 analog input signals
112. button The loop selected is highlighted by the fact that both the tag and the output operating mode are displayed in reverse Once the loop has been selected it is 201 Installation and User manual of the AC10 AC20 AC30 controller possible to change either the Setpoint or the A M station operating mode Furthermore the parameters shown in the upper part of the panel relates to the selected loop The numeric indication with large size digits at the top of the panel is always displaying the controlled variable value of the selected loop The status of the alarms is flagged by the small box on the upper left part of the panel When an alarm or a forcing mode is activated the box blinks continuously to alert the operator Next the operator can get a more detailed view of the alarms by looking at the ALLARMS and FORZAM panels Furthermore this configuration provides other 4 additional panels with the well know bargraph and trend displays one for each loop The picture above list all the parameters accessible from the various panel 21 7 Applications LOGICA BLOCCHI i 202 This easy to use configuration is for simple applications where standard PIDs are required to control up to 4 independent variables It has the big advantage of providing 4 loops in just one box with perfectly identical characteristics providing an attractive price performance solution Furthermore the loops have some additional functi
113. c representation through a moving slider of the real time value of the Setpoint The slider is moved in steps of 0 5 8 Bargraph Bargraph indication of the process variable The bargraph shows the process variable value in 200 steps providing a resolution of 0 5 9 Output bargraph Horizontal bargraph showing the loop control output value in steps of 1 10 Output Value Numerical display of the loop control output in percentage 11 Auto Man Display of the Out station operating mode The possible modes are AUT or MAN 27 Installation and User manual of the AC10 AC20 AC30 controller 28 12 Loc Rem Com Display of the Setpoint operating mode that the user has requested from the controller keyboard The mode is indicated by the mnemonics Loc Rem and Com 13 Alarms and Digital Display by mean of user defined 3 characters mnemonics of the status of the 3 digital inputs of the module These inputs are used for representing alarms or simple logic status 14 Trend Chart Area dedicated to the graphic display of the recent trend curve of a variable The time width of the chart corresponds to 75 samples 15 Time Scale Numerical display of the time span of the trend chart The user defines this value by choosing between the following set 1 2 5 10 30 min 1 2 5 hours 3 3 5 2 Trend Panel This display provides a suitable interface to the Setpoint programmer module available on the AC30 controller only I
114. ccording to the parameter controlling the switch of the MUX module between the constant value stored in the MCNS module and the analog input Al3 The latter choice is alternative to using Al3 as the Bias input of the Ratio loop 18 6 Forcing modes These operations are related to the loop output that can be driven by other sources than the straight PID algorithm The functionality provided by the two loops are slight different as described below Ratio Loop This configuration allows the following 4 modes selected through the DI1 DI2 DIS and DIA4 Tracking Hold Hold Y Max Hold Y Min a Tracking it is enabled by the active state of the DI4 digital input and it consists in setting the control output to the constant value stored in the MCNS module b Hold when DI3 is active the control output is frozen at the value it had at the time of the rising transition 18 7 Alarms Annex A Resident Configurations c Hold Ymax When both DI3 Hold and DI1 are active the control output is forced to its maximum value defined by the parameters of the CONTROL OUT module d Hold Ymin When both DI3 Hold and Dl2 are active the control output is forced to its minimum value defined by the parameters of the CONTROL OUT module Di3 om Diz Selected Value A M_ TRK On On On On Of Of Hold On On Of Ymaxx On Of On Ymin An important point to bear in mind is that all these 4 forcin
115. communication cable and the choice of the cable type must be carried out carefully MOBO 8 OS Terminatore RS 485 da 120 Q E E oooJocclesoJesojessleso ocolecolosa oscoloco ooo soojosoleso ovolevoleso eocojoscojeso Out o o eer amp 58 amp 58 AAC EU 88 4 AAC EU 88 AAC EU 88 NU Address o Wii Address 1 Bild Address 2 ABN ocojecojoso occojeoceajecoe oscojesojeoso ococojeoeceojooo ocojeococloso osoljeocojeoso oocojocojeoso Note This drawing reports the configuration with the maximum number of expansion units an AC controller can support If among the Expansion units there is the AAC EU 88 4 model this latter one unit must be compulsory set to the address 0 setting the address of the others to 1 and 2 If only one Expansion Unit is connected its address must be set to 0 Furthermore don t forget to add a termination resistor of 1200 1 4W to the unit at the other end of the line opposite to the AC controller 146 Cap 8 Expansion Units 8 4 2 Power Supply The power supply of the Auxiliary Units must be p
116. ctive the output Yc is set to the maximum Cool Forcing value If both DHLD Hold and DYMX Force Max are active the output Y is set to the maximum Heat Forcing value If the DA M input is active Manual mode request the current outputs are not driven any longer according to the MV inputs but they are changed only from the keyboard 79 Installation and User manual of the AC10 AC20 AC30 controller 80 gt DYMX D A M D HLD D YMN D TRK TRK 100100 D CAM CTRK 100 100 YMIN 100 o A AV KEYBOARD Y Yc Y gt DBMP Chapter 5 Modules I O Connections Analog input corresponding to the control output also named manipulated output of the Heat PID module Value in percentage manipulated output of the Cool PID module Value in percentage Analog input corresponding to the control output also named DTRK Track input It enables the Track functionality TRK Track value Analog signal with the value to set the outputs Y and Yc when the Track is enabled DHLD Hold input When active the output Y and Yc are frozen DYMX Digital input enabling the forcing of the Y to the Max Forcing value Digital input selecting the Auto and Manual mode DYMN Digital input enabling the forcing of the Yc to the Min Forcing value
117. curve of one or more variables 6 Trend of BI1 Recent trend curve display of the analog input signal BI1 7 Trend of CH Recent trend curve display of the analog input signal Cl1 8 Bargraph Bargraph indication of the analog input signal Bl1 9 Time scale Numerical display of the time span of the trend chart 10 Normal Fast Function Display of the running mode of the Programmer The running mode can be changed by mean of the two button gt and pl selecting respectively the Fast and the Normal mode After pressing the button push the Enter key to confirm 11 Selection Cursor Highlighting of the selected command From this panel you can enter some commands to the Programmer These are the ones listed at the lower line of the display Normal Fast Next Reset To do it you must first select the command by moving the cursor with the gt J button The selected command is the one displayed in reverse Once you have selected the command follow the instruction related to it to proceed 12 Next Function Next command mnemonic To send a Next command that forces the Programmer to skip to the next segment you must select this field and confirm with Enter 13 Reset Function Reset command mnemonic To send a Reset command you must select this field and confirm with Enter 14 Enter OK function Icon of the Enter button corresponding to the physical button LSJ This button must be pressed to confirm the command that h
118. d cade 16 1 1 6 RS485 Serial ROrt Main COMM 2d a A A ae Rv BRE oa 16 1 1 7 AN AN A AA E A O cece oak ee 16 1 1 8 Connection to a PC via the programming port cccceccecceccecesseesevseeesenscescnseeseeesseesesneseseneeeseesenseeteeneeeeatens 17 1 1 9 Connection to the Expansion Unit via the RS485 port AUX Comm 17 1 1 10 RS485 Main Comm serial connection expansion unit iii 18 STAR DUR AA O ON O OO 19 1 1 KEYBOARD Fo da dd e Se 19 1 2 PUSHBUTTONS KOIN GHLOIN N D i ia AE 20 1 3 DISPLA dd E EAO LE EATEN 21 1 3 1 LB A PANEL AAEE SE EEE E EAA a 22 1 3 2 A PANEL is AST TA 23 1 3 3 ABar RANEI A meaa a T A Id aA aA a a ea A A PO REDS MEE acne A 25 1 3 4 Trend PONE yerin n aT AN der eee T rt AN ase ae AT AN o A T A 26 1 3 5 DTPENE Baneao ee CIN a e a a TEE O SESE a a R 28 1 3 6 AMENA PAN AA EE a E ET E o elit cre rt SEE E og te E 30 1 3 7 LLANOS Display Ear 31 1 3 8 4 Anglos Display RARE a tit o ra Dd 32 1 3 9 4 Writable Analog Display Panel ooionnnnninivnnionionnonniiccc rr 32 TESLOS ALONE a dos so oul el oad taal 33 3d vSelector PANEL Actas ve Dos py sr Lacio do de ei MIN Jl y pe LLL sch a de Ll a statin Aa e LIN al a 1h Y 34 1 4 MANAGEMENT OF THE ACTIVE PANELS ccccccecesssssececececeesssaececccecsensaececececsesesueaecececseseaeaeeeeeceesesaaeeeeeeeeeensaaeas 35 1 5 SELECTION OF A RESIDENT CONFIGURATION scsscscccceceesessececececsesssecesececseseseeeseeccseseseseceeseeceesesasceeececeesnaaseeeess 35 PID TUNE AN
119. d of the Tuning procedure Man MAN 4 2 Gain Scheduling Gain scheduling is based on the technique of changing the value of the 3 terms parameters of the PID algorithm according to the value of a variable like the setpoint the manipulated variable the controlled variable and other process signals The main purpose of this functionality is to adjust automatically the 3 terms parameters when dynamic changes occur in the process to control as for instance a load change The gain scheduling is a very effective control technique with superb results but its diffusion has been limited by the high skills and the considerable development efforts required to implement it Chapter 4 PID Tune and Communications The word Gain scheduling is the historical name and it doesn t mean absolutely that only the Proportional band value can be changed because this technique is now extended to all the 3 terms including the integral time and the derivative time The PID module of the AC series controllers has 3 analog inputs named KP KI KD whose values multiply the configured 3 terms parameters Gain Integral Time and Derivative Time to determine the coefficients values to use in the PID formula as explained below PB PB TI TI KI TD TD KD u KP u P u p where PBu Tlu and TDu are the coefficients of the 3 terms used in the PID formula while the PBp Tlp and TDp are the values set by the user For instance let
120. d temperature in Celsius degree PIN Relative pressure measure in engineering units Compensated flow output The compensation formula is illustrated below you can select if you want to have temperature compensation or pressure compensation or both TR 273 14 PIN PABS TEONA E Pete 4 ees Qu Q TiN 57314 G PABS Parameters MFL _1 T amp P Compens T amp P Displayed parameters Selection of the type of compensation temperature pressure or both Ref T Reference Temperature in C considered in the design of the primary measuring device ESA Reference Pressure considered in the design of the primary measuring device Abs P Absolute atmospheric Pressure relative to vacuum Format Format it defines the number of digits of the values above 95 Installation and User manual of the AC10 AC20 AC30 controller 96 5 5 20 Analog Totalizer TOT Description This module performs the totalization of the analog input IN retransmitting the totalizer results on the output OUT This modules includes other functionalities related to the flow totalization like the generation of a pulse output for driving external counters a cutoff threshold on the Input Dropout that stops the totalization when the Input signal is below it the alarming when the counter reaches a predefined level Pulse V and Rollover and the scaling of the Input signal before the totalization in order to
121. d test Keyboard It tests the keyboard by lighting a rectangle on the display when the corresponding key is pressed e Display test Display It tests the display by switching on and off alternatively contiguous pixels of the LCD panel e Input test Input It displays a panel with 8 4 for the AC10 analog inputs in Volt and 8 digital inputs By exercising externally this inputs by mean of the calibrator and checking the results on the display the faulty inputs are detected e Voltage output Out V Out mA You access the test page of the analogue and digital outputs At the beginning of the test all the digital and analogue outputs are locked on the last value calculated by the strategy The analogue outputs may be changed as V or mA depending on their configuration The non configured outputs may be changed both as V and as mA Main Prog Sel System A Outs V Menu 8 1 O Test Test l O Test Prog 8 Test E gt Out Volt 5 fa When the A Outs V panel has been displayed the analog output to exercise is selected through the lt and gt buttons followed by the OY button for confirming the operation The voltage value the output is set is shown in the lower right corner of the display 141 Installation and User manual of the AC10 AC20 AC30 controller 142 Now you can drive the output at various level by changing this valu
122. e in order to take different measures with the external multimeter This is done through the lt and gt buttons followed by the O confirmation button The procedure is quite the same for the digital outputs Once the output has been selected pressing the A key causes its status to complement e Current Output test Out mA It s like the previous one but related to the current outputs only Note A To abort one of these test functions press at the same time both the LON and the Lo key 7 4 2 Calibrations TAG 0000 0 Main Prog Sel Calibrat Menu 8 1 O Test Page Calib Input fay E E Prog amp Test Ca Calibration R R R The AC controller allow the on site calibration of the analog inputs and outputs As shown in the picture below the first step consists in reaching the Calibr Page menu with all the various calibration functions Inputs calibration Calib Input This calibration procedure involves the analog input 1 and calibrates all the analog inputs at the same time To perform the procedure you must connect a Calibrator to input 1 terminals 1 and 2 and apply the voltages asked on the display You will be asked to apply O Volt Once you have done it press the N Next key You will be asked to apply 5 Volt Once you have done it press C to compute the calibration coefficients and store them permanently N gt Next
123. e status of the alarm and the forcing mode of the loop More precisely they highlight the following general situations 1 When an alarm is active the label ALL is visible 2 When the Alarm 1 is active the label AL1 is visible 3 When a forcing mode is active the label FOR is displayed These are global flags the detailed cause of the event is shown in the ALARMS panel where the digital status of each alarm and forcing input is clearly shown These are ALL 1 PV Alarm 1 ALL 2 PV Alarm 2 ALL 3 PV Alarm 3 ALL 4 PV Alarm 4 ALL 5 PV Alarm 5 ALL 6 RTX Alarm 6 on the variable Al4 ALL 7 RTX Alarm 7 on the variable Al4 UNDERFL Input Al1 out of range for 1 5V or 4 20 mA signals only TRACKING Force the control output to a predefined value HOLD Freeze the control output Y MAX Force the control output to the maximum value Y MIN Force the control output to the minimum value 13 10 Applications This easy to use single loop configuration provides a wide set of additional functionalities than the basic classic PID loop like the availability of multiple setpoints chosen between 3 predefined values and a remote one generated by an analog input This feature is strongly used in the discontinuous processes like the management of both solid and liquid materials The feed forward functionality is an useful feature when the process provides a variable that can anticipate the future changes of the controlled variable The following p
124. e 2 D gt o 2 e eo 2 o 2 20 osejeos ooa eses o o o 223 20 no fr no Y Y N ANN A aN AAC EU 88 4 AAC EU 88 AAC EU 88 MIL Address o wid Address 1 Hill Address 2 WANN oja eo oeojeooejeooo ocojoceojeooa 12 212020 ocojecojoso ocojocneajeso esoo Note The figure above illustrates a controller with the maximum number of Expansion Units connected to it If there is an Expansion Unit model AAC EU 88 4 the one supporting analog signals it must have assigned the address 0 while the others the addresses 1 and 2 If there is only one Expansion Unit it must have assigned always the address 0 Furthermore the last unit in the serial link must have a termination resistor of 1200 1 4W 17 Installation and User manual of the AC10 AC20 AC30 controller 2 4 10 RS485 Main Comm serial connection expansion unit CN1 AC SUPERVISOR Al ti Oo 44 AAC EUJBS AAC ELSA barnes 1 Ayes 2 ie Sssfesajesa eesleccleag 18 Chapter 3 Commissioning and start up 3 Startup STARTUP PROCEDURE The flowchart of Figure 3 1lists all the steps you must carry out to have your AC10 AC 20 and AC30 controller installed on the plant and properly controlling the Customer process Unpack and check the instrument Install connect and wire J Switch the
125. e Input to retransmit is selected by one of the two following modes a Static mode by mean of a parameter set during the configuration of the strategy b Dynamic mode through a 3 bit code from the DS1 DS3 inputs specifying the input number according to the following table Input transmitted to OUT ING IN 3 IN1 IN2 IN3 IN4 IN5 IN6 OUT DS1 DS2 DS3 I O Connections IN 1 6 Analog inputs to multiplex DS1 3 Selectionimputs __ OUT Parameters AMUX _ 1 Dig Sel Code Dig Displayed parameters Sel Code Specification of the selection mode to use dynamic or static Chapter 5 Modules 5 5 15 Hardware Analog Multiplexer AMX8 Description This module is an 8 to 1 multiplexer One of the 8 inputs IN1 IN8 selected by mean of the 3 bit code on the DS1 DS3 inputs is retransmitted on the OUT output Furthermore the module can be selected or deselected through an external input DSEL Once the module is deselected its OUT output will hold the value it had before the deselection until further selected The input to multiplex is selected with the DSEL signal in the active state by mean of the inputs DS1 DS3 as in the following table IN4 OUT I O Connections LIN1 8 Inputs to multiplex DS1 3 Selection Inputs DSEL Selection enable input Output 91 Installation and User manual of the AC10 AC20 AC30 controller 92 5 5 16 Analog Hold HLD Descr
126. e from 0 1 to 5 0 1 1 To assure a correct operation of this module you must check that the dead band value you configure satisfies the following relationship 100 Ts Dead Band gt iS Travel T Where Ts Sampling Time in seconds Chapter 5 Modules 5 5 6 Time Proportioning Output TPO Descriptions This modules converts an analog signal IN generated by the strategy in a rectangular wave digital signal with variable mark space ratio proportional to the input The digital signal is generated on a physical digital output of the AC controller only with the exclusion of the outputs of the Auxiliary Units The cycle time of the rectangular wave is configured by the user while the duty cycle is controlled by IN The IN signal is in percentage with range O to 100 The maximum number of blocks of this type in a strategy is limited to 8 DO1 IN gt TPO DO8 I O Connections IN Analog input in percentage DO1 DO8 Time proportioning digital output Parameters TPO _1 Cycle T 30 Displayed Parameters Cycle time in seconds of the period of the rectangular wave with variable mark space ratio The range is between 1 to 100 seconds The mark part of the rectangular wave is proportional to IN 83 Installation and User manual of the AC10 AC20 AC30 controller 84 5 5 7 Scale Changer SCH Descriptions This modules re ranges an analog signal accordin
127. e top of the display panel The modules settles automatically the display detecting which are the signals connected to it It checks for each bargraph that the signals B bargraph value Y manipulated variable and A M operating mode are connected and according to the result sets the display as follows For each B signal connected a bargraph is displayed If the Y signal is connected then the slider is displayed too because it is assumed the presence of a control loop otherwise the slider is not displayed at all because it is assumed the presence of a measure If the A M signal is connected then the operating mode is displayed The lack of this connection doesn t affect the bargraph and the slider display for instance the lack of A M with the presence of Y is recognized as the presence of a loop without the Out station with fixed Auto operating mode Tag 10 char Main variable of the Alarm display ALM selected loop BI 1 2 3 4 Requested Setepoint mode Working Setpoint c urrent Setpoint WSP 1 2 3 4 mode MOD 1 2 3 4 Loop tags 3 char Main variable bargraph BI 1 2 3 4 Out Station Operatind Mode A M 1 2 3 4 When the loop is selected this dispaly is reverted Output value in Y 1 2 3 4 Chapter 5 Modules MOD1 MOD2 MOD3 MOD4 ALM I O connections BI1 Bl4 Analog Inputs displayed graphically on a bargraphs with a decim
128. ection Key Through this key the user scrolls the cursors on all the items to point to the item to select This selection operation is possible only if the highest priority has been assigned to the keyboard 3 4 Management of the active panels Forno 3A Each active panel can be set in the following way R W Panel and keyboard enabled Read Panel enabled and keyboard locked NO Panel not displayed To set the panel s active modalities do the following Main Tuning and Act Panels Menu View No Tune amp Views Forno 3A_ No ta El El gt z TERET e F Panel View R R R 4 R q RJ 3 5 Selection of a resident configuration At power up the controller can either show on the display the first panel of the selected configuration or display the NO Program Found message when no configuration has been already selected In both cases you can select a new configuration as shown below 35 Installation and User manual of the AC10 AC20 AC30 controller A The controller has already a configuration TAG 0000 0 Prog Sel Program Wn 573 8 1 O Test Selection an oe Tune amp Views Sampling T Par amp Comms O Test 1 Loop B Fos 1 Loop C Keyb Perm Calibration 2 Loop A 2 Loop B 2 Loop C R R Ratio Cascade Override 4 Loops 4 Indicators A M STation Program Selection 1 Loop B 1 Loop C 2LoopA 2 Loop B x 2 Loop C AC Series Ratio Cascade Over
129. ed through one of the following 3 ways directly from the instrument panel through the serial comm Main Com and by mean of the AC Prograph AC Edit running on Windows Beyond the AC10 characteristics this version offers the feature of custom defined strategies defined by mean of the AC_PROGRAPH software running on a Windows PC 4 control loops 8 analog inputs 4 analog outputs 8 digital I O and Real Time Clock with 12 control strategies stored in the instrument memory and recalled from the front panel The parametrisation of the controller is performed through one of the following 3 ways directly from the instrument panel through the serial comm Main Com and by mean of the AC Prograph AC Edit running on Windows Beyond the AC20 characteristics this version offers the feature of Setpoints Programmers generating time dependant setpoint profiles and time sequenced digital outputs 1 2 Technical specification 1 2 1 Analog Inputs Al N Analog Outputs AO N Logic Inputs DI N Frequency Input N Logic Outputs DO N Main Comm RS 485 N Aux Comm RS 485 N Serial port RS 232 N ARCNET LAN N I O maximum capabilities N 4 only for AC10 8 4 8 1 AC20 and AC30 8 1 1 only for AC20 and AC30 4 only for AC20 and AC30 Analog Inputs Al Voltage input with range 0 5 V or 1 5 V cc software selectable Current input with range Al 0 20 mA or 4 20 mA with external 250 burden resistors 1
130. ed up therefore it works even if the instrument supply is disconnected Tag of the panel Increment decrement fixed the selected value Clock dial l Confirm the new setting A Remove the new setting and restores the previous ones Digital clock ES Select the digit to change Day mnemonic Year Date Month 71 Installation and User manual of the AC10 AC20 AC30 controller 5 5 Processing and Control Functions TAG 0000 0 MAN 72 5 5 1 Setpoint and Deviation Calculation SDV LIR Description This module generates some preliminary processing of the signals required in a PID algorithm consisting of the calculation of the internal Working Setpoint of the loop according to the operating mode and the calculation of the deviation variables The module receives 3 possible initial Setpoints by the Operator Local by the Computer Computer or by a Remote signal Remote The selection of the Working Setpoint from the three setpoints above is done by a selection strategy consisting of three different modes to operate with a custom specified priority assigned to each of them These modes are Keyboard Supervisory Computer and Digital Inputs The mode that has the highest priority makes the selection first In the case the selection mode with the highest priority has the no choice status the selection is done by the one at the immediately lower priority and
131. eeesenseeseeseeseeececeeesesceseeseesesseenesesessuseeseeseseeeseeates 93 5 5 18 Hardware Digital Multiplexer DMXS cccceccecccccsseseseeseeseesenesseeessececnecesenseesesesseeesneseeenseeseeseseeneseeates 94 IILI Mass Flow MEE 2 i S00 is AN erin ik o aN O O dos Ms Se aot 95 3 5 20 Analog Totalizer LOT lt a RL IG GA ne laa 96 D021 Analog Limiter EMD lt A AD ea a ek ioe ee 98 DSi 22 gt Alarms ALMA aaah she dentine wu aaah T A Seb aca ddan Seeds hg hee EN abe tt 99 3 923 Rate Alarmi AMI adas 101 5 5 24 Analog Software Demultiplexer ASEL cceccccccccsecsesseeeseeseesesseesessecseenecesensenseeesiesesnesetcnseeseeseeeeeeneeas 102 5 5 25 Analog Hardware Demultiplexer AS8 ccccccccccccsssesseseeseeseesevseesecsecscneeescesenseesesesnesnesesenseeseeesneeaeeaeens 103 5 5 26 Digital Software Demultiplexer DSEL cccccccccccescssseeseeeeseesevseenevnesneenecescesesseesesesesnesesenseeseeesneeneeneeas 104 5 5 27 Hardware Digital Demultiplexer DSS ccccccccccccseseseseeseeseesesseenesnesusenecesensenseeesiesesnesetenseeseeseeneeeeneeas 105 9 5 28 Decoder DECS ad alan 106 10 29 Ser pace block SEER 2 TS AA A A AER 107 IO TAMEEBLOC IMR lt A A T E A eae ES 108 5 5 31 Servomotor in Open Close loop Block SRV2 ccccscseseessessesesseesevseenseneeeseesesseeesnesnesnesesenseeseeseneeneeneeas 109 3 6 SUPERVISORY VO MODULES oi an A eh ieee ed 110 5 6 1 Analog I O to Computer CAIO ccccccceccscceccesessses
132. eing retransmitted to the physical output It is entered as a multiple of the sampling time of the controller If it is set to 0 then the signal is not delayed Range from 0 to 30 1 When selected the modules performs an inversion of the status of the DIN digital input The physical output corresponds to the Boolean NOT of the IN input signal DIN DOUT Delay sec Delay T Sampling T 51 Installation and User manual of the AC10 AC20 AC30 controller 52 5 3 Display panel The maximum number of active panels is 12 including the REAL TIME CLOCK for AC30 The display sequence of the front display panels can be set in the Tools Edit Modules menu of AC Prograph AC Edit For the above refer to Section 7 6 2 of the manual 5 3 1 Single bargraph panel 1BP Description This module provides the display both by bargraph and numerically of a analog variables logic variables by symbolic names of the states and alarms by messages Furthermore this module is not just a display device It s a front panel providing all the functionalities to carry out all the basic operations required to interact with the loop In fact it allows e the setting of the Local Setpoint e the change of the Setpoint operating mode between Local Remote and Computer e the change of the Output operating mode between Auto and Local Tag 10 char Main Variable in engin units 3 char Scrolled Variables Mnem
133. el 5 8 16 Multiple Digital Constant MDCN Description This modules generates a fixed digital signal on the 5 outputs DCN 1 5 whose values are specified by the module parameters DCN1 DCN2 MDCN DCN3 DCN4 DCN5 I O Connections DCN 1 5 Digital Outputs Parameters MDCN _ 1 0 CNS 1 0 Displayed Parameters CNS 1 5 1 Status to set the digital outputs 1 The tag of the 5 digital constants as displayed on the controller panel is directly configured by the AC Prograph 123 Installation and User manual of the AC10 AC20 AC30 controller 124 5 8 17 Analog To Digital converter A D Description This module performs the conversion of a number provided as an input signal to the module to a 16 bit binary number specified through 16 digital outputs The range of the input number is O 65535 If the input number exceeds this range it is still converted in binary number but the 16 digital outputs corresponds to the status of the least significant bits The Carry output is not available to flag the overrange therefore the strategy must provide the actions to avoid or take care of this situation gt DO1 DO2 DO3 DO4 DO5 DO6 DO7 DOs DO9 DO10 D011 D012 D013 D014 D015 DO16 IN gt A D IR III I O Connections N TAnalog input DO1 DO16 Digital Output Parameters This module doesn t have any parameter and therefore it is not displayed on
134. elf extinguishing 94VI DIN standard 72 x 144 x 260 mm Through adjustable mounting clamps fitted on the top and the bottom of the controller 1 7 Kg approximately The AC10 AC20 and AC30 controllers consists of FRONT PANEL e LCD graphic display with automatic and manual adjustment of the contrast Keyboard for issuing commands and for changing parameters e Plug in connector for programming the controller ELECTRONIC BOARD e CPU board with analog and digital inputs e LAN Board with the serial interface to the LAN optional for AC20 and AC30 Power supply board REAR UNIT Output board with digital and analog outputs Display board with intelligent graphic display controller LCD supply board with the LCD lamp voltage booster circuit e Termination unit with M3 terminals and connectors e Transparent terminal cover with connections indication Installation and User manual of the AC10 AC20 AC30 controller 10 1 4 Resident Strategies Description The multifunction AC controllers are supplied with the following resident configurations already stored in the memory 1 Loop A Simple loop with Remote Setpoint and Controlled Variable retransmission 1 Loop B Loop with Remote Setpoint and predefined stored Setpoints Feedforward PV retransmission 1 Loop C Typical Heat Cool Loop 2 Loops A 2 simple Loops with Remote Setpoint and PV retransmission 2 Loops B 2 Loops one complex and the other
135. ent 0 and put in hold waiting for an operator intervention Parameter of a recovery strategy based on the time the power has been off If this interruption time has been greater than the value set in this parameter the SP output is set equal to PV input and the program restarts from the point at power off Parameter of a recovery strategy based on the time the power has been off If this interruption time has been greater than the value set in this parameter the programmer is reset to segment 0 and put in hold waiting for an operator intervention Low range of the Setpoint output Format Format it defines the number of digits of the Setpoint output Program No n Delete Program This command allows you to delete an existing program First you must select the program to delete from the panel PRG specifying its number Next you select the Delete Prg item form the Program No n menu At this point the alert message If Sure Press Enter is displayed You must confirm the delete command by pressing the E button in order to proceed with the delete operation Otherwise you can abort the delete operation and return back to the Program No n menu by pressing the R button PRG_1 Program No Program No 2 2 2 Prg No 2 Delete Prg RJ EJ RJ Chapter 5 Modules Program No n Copy Program This command allows you to duplicate a program by copyi
136. erstandable it is better to set SF to a lower value than above and precisely to 0 1 Chapter 5 Modules In this way we achieve that the totalizer doesn t roll over in one year and that its engineering unit are immediately related to the flow engineering unit Setting SF to 0 1 the totalization unit is tens liters and after one hour of totalization the value is assuming a constant flow of 1 I h 0 1 SF 0 1 1 1 Parameters TOT 1 1 Scale F 1 Displayed Parameters Scale F Scale factor in engineering units with range from 0 to 99999 Format Format it defines the number of digits of the Scale Factor value Dropout Minimum value of the input signal for enabling the totalization If IN is below this value the totalization is unchanged Range from 0 to 99999 Format Format it defines the number of digits of the Dropout value restart from 0 Range from 0 to 99999 Pulse V Value of totalization corresponding to one pulse Every time the totalization value reaches this threshold or its multiple a pulse is sent out on the Output DO Format Format it defines the number of digits of the Rollover and Pulse V value 97 Installation and User manual of the AC10 AC20 AC30 controller 5 5 21 Analog Limiter LMT Description This modules retransmits the input signal to the output limiting it to a predefined range set by the user You define the minimum and the maximum allowed va
137. esecsessesessessenecsesssesseeaeaeeaey 72 5 5 1 Setpoint and Deviation Calculation SDV c cccccccccsscsssseseeesseeseesesseenesneseecneeeseesesessesesessneeeseesenaeeesneeaeed 72 5 5 2 PID AISOIthIN P ID E A aa dal ool oh 75 5 5 3 Output Station MV 2 Day SS A TS NA ad AES wt A 76 5 5 4 Heat Cool Output Station HCMV ceccecceccscccseeseessenseescnseeseeseseeecnecneceeseseesesseesesesnesnesesenseeseeseseeeseeated 79 5 5 5 Servomotor Output SRV iis scsi Gis AAG toa Se a cae vd ee A on a ee 82 5 5 6 Time Proportioning Output TPO cccccccccccsccesesscesseseeeseuseeseeseseeesneseecnecescesesseesesnesesnesesenseeseesesieeeeeeated 83 5 5 7 ScaleiChanger SC A O ct 84 5 5 8 Filter LLETRES A R 85 5 5 9 Analog Delay ADELY lt A A es 86 32 10 Digital Dela DDE EAE AEEA E A E A ANNA ET 86 DOS gt Rate Limite MS araa iaa a A T aN 87 35 39 12 Einearizator GHAR coccion ad E a EE E E ai a eds 88 5 5 13 Minimum and Maximum Selector MAX ccccccccccccssseeseeseeseecesseesecseeecneceseeseeseesesieeesiesescnseeseeseseenesteates 89 5 5 14 Software Analog Multiplexer AMUX eccccceccccccscsssesseeseeseeseesesseesessesecneceseeseeseeseseeesnesessnseeseeseseeneeeeaees 90 5 5 15 Hardware Analog Multiplexer AMX8 cccccccccssssssssstssesececcecceseesesseeseesececeneeceesesseesecsececaceneesesaeesesseeaees 91 5 93 16 gt Andlo Hold HED goiter Rinia a a ian a aa a ia Rao eels i 92 5 5 17 Software Digital Multiplexer DMUX u ecccceccecccsesets
138. ess than just the real time display of process data This display is provided in all the resident strategies of the AC controller Chapter 3 Commissioning and start up fa A of RN ax 3 2 NI SIN 4 TS 6 5 NES NN 44 42 7 Wan Jj 4 PEN 8 NL N 15 pas a 44 9 ar B 6 ex NT 10 1 Tag This tag is the identifier of the panel and consists of up to 10 alphanumeric characters It is assigned automatically when the module is created and can be modified through AC_Edit AC Prograph 2 Engineering Units Engineering units mnemonic consisting of a string of 3 characters maximum lt is entered and modified through AC_Edit AC Prograph 3 Main Variable Value Numerical visualization of the main variable consisting of 6 characters including the sign and the decimal point 4 Scrolled Variable Value Numerical display of the selected scrolled variable The list of the variables includes the Local Setpoint and other analog input signals of the module It consists of 6 characters including the sign and the decimal point 5 Setpoint Operating Mode This short mnemonic reports the current Setpoint operating mode of the loop The various modes are Loc Rem Com 6 Scale high low Limits They define the values of upper and lower limits of the scale Each value consists of 6 characters including the sign and the decimal point 7 Set point Slider Graphi
139. etseesecuececceceescesessessecseeecaeeeeesesseesesseeseseaeeneesesaseaesaeeaees 110 5 6 2 Digital 1 0 to Computer EDO Aida la 110 IT SYSTEM MODULES ia 111 5 7 1 Computer Timeout CALM u cccccccccecsescssescesesseesecsecseeececccesseesessececseceecaeeseesessessesseseecneeeseesesaeesesaeeaeed 111 37 2 EAN Timeout CEAEM IA ee oa aa DE ta ead Lhasa de ao ee 111 5 7 3 Expansion Unit Timeout AALM eccccceccscsscesesecessesseeseeseeseeecseeeceseecueeeseesessessecesecneseseeseeseesesaeeaeeneeas 112 5 7 4 System Configuration SYS A A a E 112 STI Key Selector REY escorts frais icest eei A A EAEE 113 Installation and User manual of the AC10 AC20 AC30 controller 5 7 6 Failure Module FAIL Juicio di da AA a ains 113 5 7 7 Power Failure AC Restart flag PWRE ccceccescssssssssseseuceeseeseeseeesseeececeeceseeseesesessececeecaeeseeeraeeaeenes 113 5 7 8 Setpoint control key lock Block SPKL ccccccccsccssssseesesseeseuseeseesesseeuesuecesenseeseeeeeeesnesetenseeseeseseeneeaeeates 114 5 7 9 Q tp t Change Key Lock Block OPKL ecrane a sea ees ee ene 114 5 8 MATH AND LOGIC FUNCTION Soc e e E ee 115 5 8 1 Expression IIOP ed ad ai te Ais A e Da a e es da e ds 115 5 8 2 AVUhMeticsGOPR Mle aa eet al Al Aisle SEMEN AS st AAI tad SEANAD Se SAA eA 115 5 8 3 PUNCHON EN tics Gti isis ea AS aE Se A til ae eee ee tens eh ea es 116 5 8 4 Analog Single Constant CNS nesies iiei e E E a E A a 117 5 8 5 AND OEE EEE E OEE O ETE TE A EE E REE
140. ews Main Tuning and PID PID_LOOP 1 Menu View Block PID_LOOP 1 Action Rev E EJ PID Param gt 37 Installation and User manual of the AC10 AC20 AC30 controller 38 TAG 0000 0 Once terminated this configuration step the Tune procedure is launched by carrying on the following steps that allow you to specify the loop to be tuned Main Tuning and Tuning Menu View Choice Tune amp Views Tuning Auto PID_LOOP 1 E p E R Elo R During the Tuning process the message Tune PID LOOP appears in the tag field at the top of the display panel of the loop under tuning It is possible to abort the Tuning procedure anytime before the completion forcing the loop to Manual or returning back to the Main Menu display The controllers recognizes the abort of the Tuning by displaying the message Tuning Aborted This message disappears after the user has acknowledge it by stroking any key You can select between two operating modes of the Tune algorithm according to the way the computed PID terms values are used an AUTO mode that at the end of the processing writes the computed PID terms values in the loop parameters directly and a MAN Manual one that presents the values on the display asking the user to confirm or cancel before writing them in the loop Tuning PID 1 Display panel at the en
141. f a lo a ES E EAEI EA a as UNDERFLOW ct J H SET y 1 a o RSP DRSP 7 cost al py E OSEA DEN qe ALM ALM ALM a sp o MUX t 3 2 1 it J L DB 1 e e Y PID t 4 41 PID Y i DTun DTune pl AS Y vy v Heat Cool fo b MUX 0 d vy Qo p Ok Cool N D Y Ok Heat i DB DTRK TRK gt CONTROL E OUT H C 4 4 YMIN AM ALM ALM 4 TT 5 q e A El v VISU SCH WSP Y Y Y Y Do1 Dos Ao 404 Dos aos O O O HEAT ACTUAT COOL ACTUAT This configuration is suitable for those processes which require two actuators in order to control the process variable For instance a temperature control that needs both a heating function and a cooling function The configuration consists of a single Set Dev module generating an unique setpoint both for the cool and the heat channel two PID and an Heat Cool output module lt has the advantage of allowing a separate set of the three terms parameters for the cool and the heat channel This characteristic improves abruptly the control capabilities because of the compensation of the mismatch of t
142. f the AC10 AC20 AC30 controller 60 5 3 5 Dual Trend Panel 2TP Description This panel modules it s almost identical to the TRP module but it provides both the trend on a second variable Cl1 and a suitable interface to the Setpoint Programmer module PRG available in the AC30 controller The second trend on the variable Cl1 in the TRP module Cl1 was dedicated to move just the slider is intended for the setpoint output of the Setpoint Programmer In this way you have on the same trend chart both the setpoint and the process variable situation particularly useful when you deal with Setpoint profile This panel module is available only on the AC30 controller When you add this module in your strategy you must be sure that the target is an AC30 controller Tag of the Panel 10 Char Main Variable BI1 Main variable engineering units 3 char Scrolled variables mnemonic 3 char Scrolled variable values Alt 2 3 4 5 and LSP Setpoint Operating mode Scale High Range 6char with sign and dp Requested operating mode Trend of the C11 input Logic variables display 3 char strings DI1 and DI2 Chart area 200x75 pixels Slider C11 Trend of the BI input Program operating mode Time span of the chart Next segment Advance Selection of the running mode Enter key to set FST NORM NXT and RST Scale Low range Program Reset of t
143. f the entered value exceeds the high range of the signal as specified in the parameter Scale after pressing the E enter button the value is automatically clamped to the range limit Note 2 The choice is between the following ranges Display Range Sampling 200 Hz 0 01 200 Hz 10 msec 100 sec 2 000 Hz 0 1 2 000 Hz 1 msec 10 sec 20 kHz 1 20 kHz Note 3 Any change of these two values automatically affects the values of the Scale range of the display panel modules Bar panel e Trend and the SDV module Setpoint and Deviation calculation related to the analog input Chapter 5 Modules 5 2 3 Digital Input DI Description This module acquires one digital input and output it to the control strategy Beyond the basic acquisition task this module performs some processing on the digital signal like inversion and delay DI 1 DI 9 gt DOUT DIEX gt DOUT DI8 DI 32 I O Connections DOUT Parameters DI1 DRSP L 0 Delay T 0 Displayed Parameters Defines the time the input signal must be delayed before being retransmitted to the output It is entered as a multiple of the sampling time of the controller If itis set to 0 then the signal is not delayed Range from 0 to 30 When selected the modules performs an inversion of the status of the digital input The output signal corresponds to the Boolean NOT of the input signal DIN DOUT Delay sec
144. first time is pressed it selects the first calibration signal next it confirms the measured value just entered R gt Return Terminate the calibration procedure Calibrat Calibrat Calibrat Page Out No 1 Out No 1 5 volt 5 volt Calib Out 1 El 5 p R Read Volt Pressing the R key Display for the calibration of the analog outputs 143 Installation and User manual of the AC10 AC20 AC30 controller 144 7 5 Replacement of Faulty Components Some components require continuous maintenance and they are therefore designed to be easily replaced by the user These components are the cool cathode backlight lamp and the supply fuse The lamp requires to be changed every 20 000 hours because of the aging To replace the lamp follow this simple and safe procedure e Switch the power of the AC controller off e Unscrew the blocking screw in the lower part of the instrument and pull it out Remove the front panel cover sliding it in the direction of the arrow Unplug the lamp connector and remove the lamp from the socket Insert the new lamp and insert the connector Adjust if required the LCD display contrast following the procedure listed at Chapter 7 1 The fuse must be checked either every time the AC controller doesn t light up when switched on or in the case it simply switch off when operating regularly with the power connected The fuse is
145. g mode Requested operating mode OR of the forcing modes e Alarm1 OR of all the alarms Aut Man Station Low range of the scale Scale low range The pictures above show the different types of display panels providing the most effective interface for this strategy configuration The most used panels are the single bargraph display and the single pen trend that provides the same functionalities of the previous panel with the addition of a programmable time width chart displaying the trend profile of the controlled variables The main controlled variable is displayed both in the large size digits display and through the bargraph the Working Setpoint WSP is displayed by the slider and the output by the horizontal bargraph and numerically Annex A Resident Configurations The following variables consisting of the entire set of Setpoints are displayed one at a time in the scrollable display area LSP Local setpoint TSP Target setpoint WSP Working setpoint RSP Remote setpoint MSP Memorised setpoint CSP Computer setpoint The squared digital indications on the right side of the panel are flagging the status of the alarms and the forcing mode of the loop More precisely they highlight the following general situations When an alarm is active the label ALL is visible 2 When the Alarm 1 is active the label AL1 is visible 3 When a forcing mode is ac
146. g mode o ISA WSP loop sel Current operating mode e a Selected loop p e TAG area Loc Current operating mode Requested operating mode WSP loop 1 Je ALL6 PV3 HOLD L3 d OR of Forcing modes PV loop 1 WSP loop 2 0 PV loop 2 0 1 ALL1 WSP loop 3 0 PV loop 3 RA Hala WSP loop 4 o OR of Alarms PVloop 4 Mp ee ae 4 Aut Man station e Aut Man station Output value m TSP m TSP m TSP LOOP 2 _WSP LOOP 3 WSP LOOP 4 L WSP CSP CSP CSP DEV DEV DEV e YSA e _ YSA YSA LSP LSP LSP Loc Current operating mode Loc Current operating mode Loc Current operating mode Requested Requested Requested operating mode operating mode operating mode OR of Forcing modes OR of Forcing modes OR of Forcing modes e ALL1 e ALL1 e ALL1 OR of Alarms OR of Alarms OR of Alarms Aut Man station Aut Man station Aut Man station The panel with the 4 bargraphs provides a complete view of all the 4 loops with a fine level of details on the most important parameters For each loop the PV is represented by the bargraph and the Working Setpoint by the slider The left bargraph relates to loop 1 while the right relates to loop4 If you want to operate on a loop first you have to select it by pressing the O
147. g modes are handled by the module according to the following priority A M Ymin Ymax Hold and Track Standard Loop Only the Hold and the Tracking mode are supported by this module The Hold mode freezes the loop output until the DI7 digital input is active The Tracking mode set the output to the value of the constant stored in the MCNS module until DI8 is active D7 Dis Selected Value On Of Hold EA ee ef TRK Constant MV STBY On On Hold because of the higher priority than TRK Ratio Loop There are three alarms either on the controlled variable PV1 or the deviation according to the parameters selected in each of the ALM modules The module WSP PV computes the deviation in the same engineering units of the controlled variable PV1 The status of each alarm is retransmitted out through the DO1 DO2 and DO3 modules Two alarms are implemented by the additional ALM modules on the reference variable PV2 Their status is retransmitted out through the DO6 and DOS digital outputs The out of range of respectively the variable PV1 controlled variable and the variable PV2 reference variable is detected and retransmitted out through the digital outputs DO4 and DO7 Loop Standard This loop is provided with an unique alarm either on the controlled variable PV3 or the deviation according to the parameters selected in the ALM module The module WSP PV computes the deviation in the same engineering units of
148. g to the new range limits set by the user The applications of this modules are quite extensive among the many the most important conversions are From an engineering unit to another From an engineering unit to a percentage unit From a percentage unit to an engineering unit N SCH OUT I O Connections IN Input signal in engineering units 1 Analog output in engineering units 1 1 The relationship between IN and OUT implementing the range conversion is as follows FSu ISu OUT IN ISi ISu FSi ISi where FS High range IS Low range i Input u Output Parameters SCH RTX WS 0 ScinLo 0 Displayed Parameters Low range of the input signal ScinHi High range of the input signal Format Format it defines the number of digits of the input signal ScOutLo Low range of the output signal ScOutHi High range of the output signal Format Format it defines the number of digits of the output signal Chapter 5 Modules 5 5 8 Filter FILT Descriptions This modules implements a first order RC filter with the filter time constant defined by the user IN gt FILT OUT IO Connections IN Input signal in engineering units OUT Output signal in engineering units Parameters FILT 1 1 0 Cst Time 1 0 Displayed Parameters Cst Time Time constant of the filter in seconds with range from 0 to 30 seconds If set to 0 the filter is disab
149. ge detection lt is transmitted to the loop 1 consisting of the SET DEV and PID module The limit variable is acquired by the Al4 modules and it is transmitted to the loop 2 195 Installation and User manual of the AC10 AC20 AC30 controller 196 The outputs of the two PID modules are connected to a Selector module that according to the selection criteria configured chooses one of the two outputs and transmits them to the CONTR OUT module common to both the loops The output of this module through the AO1 module drives the actuator All the forcing modes are acting on the unique CONTROL OUT module and therefore common to both the loops The Bumpless transfer output is common to both the loops in order to keep the two PID aligned 20 4 Remote Setpoint This feature is supported identically by both the loops It is enabled both by the DI1 Main or DI8 Limit and by the priority based arbitration logic governing the Setpoint mode change The Remote setpoint is selected between an analog constant stored in the CONST module and the remote signal from the analog input Al2 Main or Al3 Limit The selection between these two Setpoint sources is operated by the inputs DI2 Main or DI7 Limit as shown in the table below DI1 DI8 DI2 DI7 Selected value InputAl2 Input AI3 On On Constant MSP Main MSP LMT 20 5 Forcing modes 20 6 Alarms These operations are related to the loop output that can be driven by o
150. gnals must be connected to the termination blocks not used by the strategy The termination blocks 25 and 26 are providing a 24V DC output particularly suitable to supply of the 2 wires transmitters r PS 1 25 24 PV1 measure Sz 76 24 Remote SP 31A Ah N N gt Actuator A A 28 lt 510 o Retransmitted PV1 G c Ha T T 8 32 g N 331 Pit gt Alarm 1 Pv1 10 U p 84K T 1 gt Alarm 2 Pv1 11 6 B57 1 36 1 Alarml 3 Pv1 13 A 37 lt f i gt DRSP S ma 38 Y Und F Pv1 Rem Mem lt p 39 I 16 6 o 40 117 i T 41 18 A A 19 E 43 Hold S i Tracking lt y U T POWER SUPPLY 158 13 1Loop B 13 1 Description The drawings below are providing the following informations ALM 6 Block Diagram User interface consisting in a set of display panels Termination unit for the connection to the field 13 2 Block Diagram In the following block diagram the interconnections between the various modules and the display panels are not indicated in order to improve the understanding of the functionality performed This configuration is a single loop with enriched functionalities than the previous o
151. go to the next calibration value C gt Calib store the calibration coefficients Cap 7 Maintenance and Diagnostic The following picture illustrate this procedure Calibrat Inputs Inputs Page Calibrat Calibrat Calib Input cia IN g Pressing the N or C key Outputs N 1 2 3 4 Calib Out This procedure must be followed for each of the 4 analog outputs separately and works as follows The AC controller generates on the selected output a voltages that the user must measure with the multimeter entering the read value in the controller Four signal are generated by the AC controller to complete a calibration two voltages one at 5 and the other at 95 of the span and two corresponding currents The picture below illustrates the procedure In the Calibrat Out No menu the list of the 4 calibration signals appears Pressing S Select the first signal is generated on the output At this point the user must measure the signal at the controller terminal and enter the measured value in the controller that is displayed with big size digits in the lower part of the display Press again S Select to proceed to the next signal and carry out the operations as listed above for the first signal up to completion Do it for all the four calibration signals The calibration signal currently in use is marked with an in the Calibrat Out No menu S gt Select The
152. gt KEY I O Connections DIN Digital Input forcing the pressing of the key Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument panel 5 7 6 Failure Module FAIL Description This module once the diagnostic of the AC controller has detected a failure activates a digital output in order to trigger the safety logic external to the instrument The user chooses which of the 8 digital outputs of the controller must be activated DO 1 FAIL DO 8 Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument panel 5 7 7 Power Failure AC Restart flag PWRF Description This module generates a pulse on its output every time a power up or a strategy download occurs on the controller The pulse duration corresponds to 3 times the parameter T Sample sampling time of the controller specified in the SYS module DOUT Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument panel 113 Installation and User manual of the AC10 AC20 AC30 controller 5 7 8 Setpoint control key lock Block SPKL Description By switching DSEL from OFF to ON the keys that control the Setpoints Increase Decrease and L R on all active panels of the active strategy are locked SPKL DSEL y Parameters This block has no parameters and is not present in the Co
153. he output operating mode are displayed in reverse Once the loop has been selected it is possible to change either the Setpoint or the A M station operating mode Furthermore the parameters shown in the upper part of the panel relates to the selected loop The status of the alarms is flagged by the small box on the upper left part of the panel When an alarm or a forcing mode is activated the box blinks continuously to alert the operator Next the operator can get a more detailed view of the alarms of each loop by looking at the ALL FORZ L r panels Furthermore this configuration provides other 4 additional panels 2 for each loop with the well know bargraph and trend displays with the following functionality The main controlled variable is displayed both in the large size digits display and through the bargraph the Working Setpoint WSP is displayed by the slider and the output by the horizontal bargraph and numerically The following variables consisting of the entire set of Setpoints are displayed one at a time in the scrollable display area LSP Local setpoint TSP Target setpoint WSP Working setpoint RSP Remote setpoint MSP Memorised setpoint CSP Computer setpoint The squared digital indications on the right side of the panel are flagging the status of the alarm and the forcing mode of the loop More precisely they highlight the following general situations 1 When an alarm is active the label ALL is visible
154. he output of the heat actuator on the right The following variables consisting of the Local Setpoint plus other 5 analog variables are displayed one at a time in the scrollable display area LSP Local setpoint WSP Working setpoint RSP Remote setpoint MSP Memorised set TRK Tracking value PV2 Variable of loop 2 The squared digital indications on the right side of the panel are flagging the status of the alarm and the forcing mode of the loop More precisely they highlight the following general situations 1 When an alarm is active the label ALL is visible 2 When the Alarm 1 is active the label AL1 is visible 3 When a forcing mode is active the label FOR is displayed These are global flags the detailed cause of the event is shown in the ALARMS panel where the digital status of each alarm and forcing input is clearly shown Annex A Resident Configurations Loop 2 The most used panels are the single bargraph display and the single pen trend that provides the same functionalities of the previous panel but the addition of a programmable time width chart with the trend profile of the controlled variables The main controlled variable is displayed both in the large size digits display and through the bargraph the Working Setpoint WSP is displayed by the slider and the output by the horizontal bargraph and numerically The following variables consisting of the Local Setpoints plus other 5 analog variables are displayed one
155. he program NRM or FST Normal Fast DI1 Dia LSP DRUN DFST MODE AN gt R H ne gt RST ae gt FST at gt NXT AI5 Bl Cm Chapter 5 Modules I O Connections most common use is to flag alarms or other digital events Run digital input When this input goes active the digital output R H goes active with the effect of running the program Fast digital input When this input goes active the digital output FST goes active forcing the programmer to run in Fast mode Analog variables displayed numerically in the scrolled list with a short 3 characters mnemonic The number of displayed inputs can be set though the parameter items in the module Dual Trend Panel of AC Prograph AC Edit For the above refer to Section 9 11 2 of the manual Analog Input displayed graphically on a bargraph and trended in the chart as the Process Variable Analog Input displayed graphically on a bargraph and trended in the chart as the Setpoint value Local setpoint value entered through the keyboard Special I O signal handling the Setpoint operating mode change Run Hold digital output It must be connected to the R H input of the PRG module Reset digital output It must be connected to the RST input of the PRG module Fast digital output It must be connected to the FST input of the PRG module Next digital output It must be connected to the NXT input of the PRG module Parameters Program 100
156. he two channel 164 14 3 Control Annex A Resident Configurations The process variable PV is acquired by the Ali module providing the ranging the conversion in engineering units and the out of range detection It is transmitted to the SET DEV module that computes the deviation for the two PID modules controlling both the Heat channel with inverse action and the Cool channel with direct action The outputs of the two PID are connected to the single H C output station through two MUX multiplexer modules required for properly selftuning the loops These two multiplexers interfere with the control output only when the Tune operation has been started on one of the PID modules as flagged out by the Dtune signal The H C Out station offers a wide range of forcing strategies and first of all a phase slitter providing a deadband or a crossover between the two outputs 14 4 Remote Setpoint This configuration supports Remote Setpoints both from an analog input Al2 and a set of 3 predefined values The Remote Setpoint functionality is enabled by the DI1 digital input while the DI2 and DI3 inputs select the source of the Setpoint as illustrated in the following table Di2 Di3 SelectedValue ImputAla Input Al2 14 5 Forcing Operations 14 6 Alarms These operations are related to the loop output that can be driven by other sources than the straight PID algorithm This configuration allows the following 4 m
157. iable PV2 or the deviation according to the parameters selected in each of the ALM modules The module WSP PV computes the deviation in the same engineering units of the controlled variable PV2 The status of each alarm is retransmitted out through the DOS DO6 and DO7 modules A fourth alarm the digital output DO8 flags the out of range of the variable PV2 underflow 16 8 Variables Retransmission The controlled variable PV1 is retrasmitted out to the termination unit through the SCH PV1 and AO2 modules The module SCH allows the modification of the ranges of the retrasmitted output that are not necessarily the same of the PV1 input This is achieved by setting the input range parameters of the SCH module to different values than the output range parameters In this way the range of the variable can be changed in order to consider only a part of the original signal scale with sensible advantages on the resolution of the output The WSP working set point of loop 1is retransmitted out though the analog output AO3 properly reranged by the SCH WSP module with the previously described advantages in term of resolution 16 9 Graphic Displays ORof the alarms LSP loop sel WSP loop sel LOC Current operating mode Selected Loop gt TEM WSP loop 1 e PV loop 1 EE WSP loop2 e PV loop 2 o Aut Man Station A rr MV loop 1 e e 174 PID1 PID2 TSP
158. ical Connections The following pages illustrate the most common examples of connection between the instrument and the field 2 4 1 Passive Transmitter Carico TAO Tr bA 0 0 ACTZ ico Alimenta zio ne Alimentazione esterna esterna 24 Y cc 24 Veciac ALIMENTAZIONE 90 264 Y ac Note Use the 24 VDC power supply on the terminals 25 and 26 only for powering the passive transmitter Do not use this power supply for the digital inputs and outputs of the AC controller 2 4 2 Active transmitter The shunt resistor shown in the figure below is not required if the output of the transmitter is already in voltage In case of trasmitter with output in current 0 20mA or 4 20mA a shunt resistor of 2504 0 1 3W must be installed on the terminal unit of the AC controller NJ 25 LU Ps 2 4 3 Analog output The setting of the output type between 0 5 V or 1 5 V voltage and 0 20 mA or 4 20 mA current is performed by the AO Analog Output module r A 250 20 1 i 3W a Pi A N Load 1 A L Load 2 O G O z Load 3 Load 4 15 Installation and User manual of the AC10 AC20 AC30 controller 2 4 4 Digital Inputs and Outputs The power is provided by an external power supply with range 8 36 VDC Power a l N P U T External Supply 24 VDC 2 4 5 Frequency Input T gt 0 U o External Supply 24 VDC N
159. inactive This display can be used not only for alarms but for listing digital status too 33 Installation and User manual of the AC10 AC20 AC30 controller 4 TAG 000 0 Alarm 4 1 Tag This tag is the identifier of the alarm panel and consists of up to 10 alphanumeric characters It is assigned automatically when the module is created and can be modified through AC Prograph AC Edit 2 Alarm Messages The alarm message is a 12 alphanumeric character string including space and symbols associated to a digital input signal If this signal is in the active state the message is displayed in reverse otherwise in normal 3 Message Area This display is reserved for 12 alarm messages each on a line of the display 3 3 11 Selector Panel This display provides the functionality of a control panel for digital commands It has 4 outputs that are driven all together by the pattern selected through one of the 3 supported selection modes Keyboard Supervisory Computer and the 4 Digital Inputs Through these modes a number from 0 to 15 is specified that forces the 4 digital outputs to assume a well defined pattern corresponding to the binary coding of the number and identified by an alphanumeric label for immediate understanding 1 SELECTOR 2 ePrio None On Hold Out 34 Chapter 3 Commissioning and start up 1 Tag This tag is the identifier of the panel and consists of up to 10 alphanumeric ch
160. ions iN Analogue input for panel selection DSEL Digital input for panel activation 7 The multiswitch panel cannot be used to generate the DSEL digital command Parameters This block has no parameters and is not present in the Controller s menus 107 Installation and User manual of the AC10 AC20 AC30 controller 108 5 5 30 Timer Block TMR Description This module performs a Timer function with the possibility of setting a pre set value PRS _ OUT TMR DRES Description of connections Analogue input for second preselection Digital input for Timer activation Digital input for Timer reset Digital output This output is activated when the Timer reaches the pre set value w DRES OUT Analogue output for the Timer instantaneous value in seconds This output is reset with the DRES command Parameters This block has no parameters and is not present in the Controllers configuration menu Chapter 5 Modules 5 5 31 Servomotor in Open Close loop Block SRV2 Description This module generates the valve open and close commands in relation to the position required by the IN signal and to the present valve position as detected by the APOS signal DOPN DCLS Description of connections IN Required position 0100 EA Minimum duration of open command in seconds Minimum duration of close command in seconds LAPOS Vaie position ITIM Integral time OCDL Minimum
161. iption This module has the functionality of a Sample and Hold circuit It latches the value of the analog input IN on the output OUT in correspondence of the rising edge of the latch digital input DHLD When DHLD is inactive the value of the output OUT is identical with the signal at the input IN that is OUT IN When DHLD goes active the OUT output is latched and this value is hold until the DHLD signal goes inactive again IN OUT DSEL IN gt HLD OUT DHLD gt I O Connections IN input CCS Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument panel Chapter 5 Modules 5 5 17 Software Digital Multiplexer DMUX Description This module is a 6 to 1 multiplexer of digital signals One of the 6 inputs is retransmitted on the digital DOUT output The Input to retransmit is selected by one of the two following modes a Static mode by mean of a parameter set during the configuration of the strategy specifying which of the inputs DIN1 to DIN6 must be selected b Dynamic mode through a 3 bit code from the DS1 DS3 inputs specifying the input number according to the following table DIN1 DIN2 DIN3 DIN4 DIN5 DIN6 DS1 DS2 DS3 I O Connections DIN 1 6 Digital Inputs to the multiplexer DS 1 3 Selection inputs OUT Output Parameters DMUX _1 Din 1 Sel Code Din1 Displayed Parameters Sel Code Specification of the selection mode
162. is active the control output is frozen at the value it had at the time of the rising transition c Hold Ymax When both DI3 Hold and DI5 are active the control output is forced to its maximum value defined by the parameters of the CONTROL OUT H C module d Hold Ymin When both DI3 Hold and DI6 are active the control output is forced to its minimum value defined by the parameters of the CONTROL OUT H C module Di3 Di5 Die SelectedValue On Of Of Hold Off On Off Ymax Maximum Heat Ymin Maximum Cool Loop 2 Only the Tracking mode is supported by this loop The tracking is enabled by the digital input DI8 and set the output to the value specified by the constant labelled TRK L2 An important point to bear in mind is that all these 4 forcing modes are handled by the module according to the following priority A M Ymin Ymax Hold and Track Loop H C There are three alarms either on the controlled variable PV1 or the deviation according to the parameters selected in each of the ALM modules The module WSP PV computes the deviation in the same engineering units of the controlled variable PV1 The status of each alarm is retransmitted out through the DO1 DO2 and DO3 modules A fourth alarm the digital output DO4 flags the out of range of the variable PV2 underflow Two alarms are related to the control outputs of the two actuators Their status is transmitted out to the DO5 6 digital out
163. isplayed These are global flags the detailed cause of the event is shown in the ALARMS panel where the digital status of each alarm and forcing input is clearly shown The status of the digital signal is indicated by the type of display of the alarm message in reverse if active normal if inactive On the ALARMS panel the following alarms and forcing status are displayed ALM1 PV MAST Alarm 1 loop Master ALM2 PV MAST Alarm 2 loop Master ALM3 PV MAST Alarm 3 loop Master UNDERFL MAST Out of range of the Al1 input only for 1 5V or 4 20 mA input signals ALM4 PV SLAV Alarm 4 loop Slave ALM5 PV SLAV Alarm 5 loop Slave ALM6 PV SLAV Alarm 6 loop Slave UNDERFL SLAV Out of range of the Al4 input only for 1 5V or 4 20 mA input signals TRACKING Output forced to a predefined value HOLD Output frozen at the value of activation of the forcing condition Furthermore this configuration provides the well known single bargraph display and the single pen trend that provides the same functionalities of the previous panel but the addition of a programmable time width chart with the trend profile of the controlled variables The picture provides details about the displayed variables Annex A Resident Configurations 19 9 Applications A typical case where the cascade control provides excellent results is when the manipulated variable influences the process variable indirectly through other process variables dynamically mismatched
164. ital outputs are provided with a normally open contact from a relay The relay can support resistive load of up to 220Vac 5A The 4 analog outputs on the AAC EU 88 4 Expansion Units are of 4 20 mA type 8 2 Technical Characteristics 8 3 The AAC EU 88 4 and AAC EU 88 Expansion Units have been designed for properly working in harsh environment typical of the industrial plants These units complies completely to the IEC 801 4 level 4 standard Max n of units One AAC EU 88 4 unit and two AAC EU 88 units or 3 AAC EU 88 units Digital Inputs 8 Optoisolated Digital Outputs 8 relays type with N A contact 220 Vac 5A Analog Outputs 4 20 mA 4 on the AAC EU 88 4 only Power supply 2 supplies for each unit 11Vac 600mA for the I O section and 11Vac 200mA for the CPU card Led 8 led for the inputs 8 led for the outputs 1 led for Run and 1 led for Alarm Failure Serial Line RS 485 standard with ModBus protocol Noise Immunity Level IV of the IEC 801 4 standard Case unit AAC EU 88 DIN 6 modules 105 mm Case unit AAC EU 88 4 DIN 9 modules 157 5 mm Installation The Expansion units are suitable to be installed into a cubicle mounted on a rail of type omega or Top Hat Dimension of the units and of the supply transformer
165. ith 12 alarm messages Each message is connected with a digital input that defines the visualization of the message All the 12 messages are listed on the display at a predefined position on the display in a different mode according to the status of the associated digital input in reverse if the input is active or in normal if it is inactive The messages are 14 characters strings configured by the user Tag of the panel max 10 char Alphanumeric message associated to a digital input Area for the visualisation of up to 12 logic signals DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 DI9 DI10 DI11 DI12 I O connections Digital input controlling the display of the associated message string The string is displayed in reverse if the input is active or in normal if it is inactive The string is configured by the user through the AC Prograph or AC Edit program only 64 Chapter 5 Modules 5 3 8 Multiswitch panel 16SW Description With this active panel it is possible to activate up to 16 digital keyboard commands Use the arrows to select the command and ENTER to confirm Upon activation the corresponding output is put to ON and an asterisk appears to the right of the message to identify the command To lock the command press ENTER again 2 E LX NY Page name max 10 characters Command area max 16 commands Activated command UNa DO1 DO2 DO3 DO4 __ DO5 pDO6
166. l for monitoring continuously the controlled variable and detect anomalous changes The retransmission of the controlled variable over a different range improves the resolution of the signal because it is limited to the meaningful portion of the original range zoom effect Furthermore this configuration has the advantage of providing 2 loops in a single box with perfectly identical characteristics providing an attractive price performance solution 15 10 Electrical Connections The following picture provides a clear view of all the termination blocks with the associated functionality and it is specific of this configuration No signals must be connected to the termination blocks not used by the strategy The termination blocks 25 and 26 are providing a 24V DC output particularly suitable to supply of the 2 wires transmitters 3 LOOP1 2 PV1 measure 5 SP remote k 2553 A A gt 7 N N Actuator 1 fae 5 L i Loop2 J SP remote ms 5 Retrans PV O PV2 measure E G 4 J o Retrans PV2 7 yu gt LOOP 2 A T Actuator 2 J Al 1 Pvi gt D 1 Al 2 Pv1 G l gt LOOP 1 Ze H AL 3 Pvi cil L Und F Pv1 em Mem LOOP1 lt D Al 4 Pv2 Hold F Al 5 Pv
167. l point 3 3 9 4 Writable Analog Display Panel This panel allows the contemporaneous display or generation of up to 4 analog type variables Each variable is characterized by a tag max 10 characters and an engineering unit max 3 characters 32 Chapter 3 Commissioning and start up TAG 0000 0 1 Tag This tag is the identifier of the panel and consists of up to 10 alphanumeric characters It is assigned automatically when the module is created and can be modified through AC_Edit AC Prograph 2 4 6 8 Variable Tags This 10 alphanumeric character label specified by the Customer identifies the displayed variable 3 5 7 9 Engineering Units Engineering units mnemonic consisting of a string of 3 alphanumeric characters maximum 10 11 12 13 Variables Values Numerical display of the analog input signal It consists of 6 characters including the sign and the decimal point 14 Cursor positioning Through these keys the user scrolls the cursors on all the variables to point to the variable to modify 3 3 10 Alarm Panel This module provides the functionalities of an alarm annunciator with 12 alarm messages Each message is connected with a digital input that defines the visualization of the message All the 12 messages are listed at a predefined position on the display with different visualization modes according to the status of the associated digital input in reverse if the input is active or in normal if it is
168. l4 e CSP e CSP LSP LSP Current operating mode Current Operating Mode Requested Required Operating mode Operating mode OR of the forcing modes OR of the forcing modes Alarm 1 Alarms 1 OR ofall the alarms OR of all the alarms Aut Man Station Aut Man Station Scale low limit Scale low limit The pictures above show the different types of display panels providing the most effective interface for this strategy configuration The most used panels are the single bargraph display and the single pen trend that provides the same functionalities of the previous panel with the addition of a programmable time width chart with the trend profile of the controlled variables The main controlled variable is displayed both in the large size digits display and through the bargraph the Working Setpoint WSP is displayed by the slider and the output by the horizontal bargraph and numerically The following variables consisting of the entire set of Setpoints are displayed one at a time in the scrollable display area LSP Local setpoint TSP Target setpoint WSP Working setpoint RSP Remote setpoint CSP Computer setpoint Al4 Multifunction Analog input 4 161 Installation and User manual of the AC10 AC20 AC30 controller 162 The squared digital indications on the right side of the panel are flagging th
169. lable linearization curves include the square root and the most diffused thermocouple and resistance thermometer If the range of the signal is less than the standard hardware one 0 5V or 1 5V you configure directly this not standard range in order to transform the measure in engineering units avoiding any further interpolation calculation For instance if your signal is the output of a transmitter with an actual range of 2 to 4 V while the standard is O to 5 V you select the 0 5V standard and you enter in the Input Scaling Parameter the actual range of your signal 40 and 80 of the standard scale that corresponds to the specified engineering units range It is strongly recommended that the hardware range of the signal is greater than 1 5 Volt Al 1 Al 4 gt OUT gt DOVR Al 8 I O Connections Value in engineering unit of the input signal DOVR Out of range detector Active 1 logic if the signal is out of the configured range like in the case of some failure on the transmitter device 1 Note 1 The detection is operating only if the selected range is 1 5 V 4 20 mA In this case the out of range is detected when the signal is lower than 0 875 Volt or 3 5 mA Parameters PV LOOP 1 No Scaling No Chapter 5 Modules Displayed Parameters PER Enables disables the selection of the actual hardware range of the signal when different from the standard hardware range The choice is
170. lay from 2 to 4 loops e Trend Panel lt is the front panel of a single loop It provides all the numeric and bargraph displays of the 1 Bar Panel with the addition of a trend chart reporting graphically the recent trend of an analog signal like the Process Variable The user selects the time span of the chart between the following 8 choices 1 2 5 10 30 minutes 1 2 5 hours e 2 Trend Panel It is the front panel of a Setpoint Programmer lt provides a trend chart with the recent trend of 2 variables usually the Setpoint and the Process variable together with the display of the status of 2 digital signals and the visualization and the command of the various operating modes of the Programmer It is available only on the AC30 controller where the Programmer module is supported The time span of the chart is selected by the user between the following 8 choices 1 2 5 10 30 minutes 1 2 5 hours e 4 Trend Panel This panel provides 2 trend chart with the recent trend of 2 variables each the real time display of the values of the trended variables and the visualization of the status of 4 digital signals The time span of the chart is selected by the user between the following 8 choices 1 2 5 10 30 minutes 1 2 5 hours e Alarm Panel Alarm annunciator displaying the status of 12 alarm signals Each alarm is displayed with a message of 12 alphanumeric characters maximum in reverse or normal according to the status of the
171. layed graphically on a bargraph 1 with a decimal scale Analog input displayed graphically by mean of a slider 1 moving along the decimal scale Analog Input displayed graphically on a bargraph 2 with a decimal scale Analog input displayed graphically by mean of a slider 2 moving along the decimal scale Main Variable displayed numerically with big digits at the top of the display Y Analog Input displayed in percentage numerically and by an horizontal bargraph at the bottom of the display It is intended for the control output of a loop Analog Input displayed together with Y at the lower part of the display both numerically and by an horizontal bargraph While Y is intended as the output of either a normal or a Heat loop this variable is intended for displaying the Cool output of an Heat Cool loop Operating mode of the Out station Manual active Auto inactive Special I O signal handling the Setpoint operating mode change Parameters MASTER SLV 0 PviLo 0 Displayed Parameters PviHi___ Mainvariable highrange____________________ SetHi_______ Maximum value of the Local Setpoint BGHi1 2 For BGr_____ Format defines the number of digits of the Bargraph 1 variable BGHi3 4 High range of the bargraph 2 variable For BGr Format defines the number of digits of the Bargraph 2 variable For WSm Format defines the number of digits of the Al1 variable note 1 Form
172. layed both in the large size digits display and through the bargraph the Working Setpoint WSP is displayed by the slider and the output by the horizontal bargraph and numerically The following variables consisting of the entire set of Setpoints are displayed one at a time in the scrollable display area LSP Local setpoint TSP Target setpoint WSP Working setpoint RSP Remote setpoint MSP Memorised setpoint CSP Computer setpoint The squared digital indications on the right side of the panel are flagging the status of the alarm and the forcing mode of the loop More precisely they highlight the following general situations When an alarm is active the label ALL is visible 2 When the Alarm 1 is active the label AL1 is visible 3 When a forcing mode is active the label FOR is displayed A more detailed view of the alarms and the forcing status is presented on the ALL e FOR display panel Annex A Resident Configurations 15 9 Applications This easy to use configuration is for simple applications where the control requirements needs some additional functionalities than the basic classic PID loop like the availability of multiple setpoints remote or predefined selectable through an external digital signal Furthermore this configuration offers the possibility to acts on the control output both by forcing it to a predefined value and by freezing it upon an external command The multiple alarm modules offer an effective too
173. le changes as follows If none of these digital signals are active the module doesn t alter the control output signals that are led unchanged directly from the input MVC and MVH to the output Y and Yc The Deadband parameter defines how the Cool and the Heat channel interact each other in the phase splitter The phase splitter is used when a single output value like in Manual mode or Track mode needs to drive both the Heat and Cool output When it is positive this parameter defines the deadband width centered around a value O of the output lt means that for each output value included in the deadband both the Yc and the Y output are O When it is negative the opposite occurs for each value included in the deadband now named cross band both the Yc and the Y are different from 0 If DTRK Track is active the outputs are set according to the value of the analog input TRK This signal that has a range from 100 to 100 drives through a phase splitter both Y and Yc When its value is in the range 100 to 0 it means that a Cool action must be taken therefore Y is set to 0 while Yc is set to the value of TRK with the sign inverted Inversely when it is in the range 0 to 100 Yc is set to 0 while Y is set to TRK These values are valid if the deadband of the phase splitter is set to 0 otherwise they slightly change IfDHLD Hold is active both outputs are frozen If both DHLD Hold and DYMN Force Min are a
174. led 85 Installation and User manual of the AC10 AC20 AC30 controller 5 5 9 Analog Delay ADLY Descriptions This module is a delay line reproducing on the output OUT the signal on the input IN delayed by a predefined time named Delay Time IN ADLY OUT I O Connections IN _ Input signal in engineering units Output signal in engineering units Parameters ADLY_1 0 Delay T 0 Displayed Parameters Delay T Delay time to apply to the input signal with range from 0 to 3 600 sec 5 5 10 Digital Delay DDLY Descriptions This module reproduces on the output DOUT the digital signal on the input DIN delayed by a predefined time named Delay Time DIN DDLY DOUT I O Connections DIN Digital input signal DOUT Digital output signal Parameters DDLY_1 5 Delay T 5 Displayed Parameters Delay T Delay time to apply to the input signal with range from 0 to 3 600 sec 86 Chapter 5 Modules 5 5 11 Rate Limiter MSL Descriptions This module provides a rate limiting functionality It retransmits the input IN to the output OUT by limiting it to a predefined value the rate of change The effect is that OUT ramps continuously towards the signal IN but limited to a specified rate of change The formula below explains the module functionality The module continuously computes the derivative of the IN signal by calculating the difference of the value
175. located into the controller on the power supply card To replace the fuse follow this simple and safe procedure e Disconnect the power supply from the instrument e Unscrew the blocking screw in the lower part of the instrument and pull it out e Remove the protective cover of the fuse e Plug the fuse out and check that is not an open circuit by mean of a simple tester or a digital multimeter If it is broken replace it with a glass fuse of 5x20 1A 250V delayed 7 6 Spare Parts Pos Description _____ Note Partnumber 9 poles female connector Kit LAN 7 7 Manuals po H10 301 DO9FD Connection kit for inst programming H10 395 1A41D9 3 CCFLlamp Sl CCFL lamp A61 259 7A0 Pos 1 User manual of the AC10 AC20 J30 304 1AMIAC ME IN a MEA ge SE Re RPS software User Manual Description Note Partnumber T aR AC controllers Introduction to the control of an O O E industrial process Cap 8 Expansion Units 8 Expansion Unit 8 1 General Informations The Expansion units AAC EU 88 4 and AAC EU 88 series provide the AC controller with an additional number of analog and digital I O up to a maximum expansion of 8 analog outputs 32 digital inputs and 32 digital outputs The analog inputs are not supported by the available Expansion Units The digital inputs can be directly connected to a free voltage contact or can be driven by an open collector NPN transistor The dig
176. lowing the setting of Comms parameters and the access to modules data and parameters Tuning amp Views allowing the self tuning procedure and other display setting 135 Installation and User manual of the AC10 AC20 AC30 controller The last 3 submenu correspond to the operations of groups A B and C Main Menu Tune amp Views Par amp Comms Progr amp Test Keyb Perm Keyb Perm Prog Sel Parameters Tuning and amp Password amp l O Test amp Comms Views Change Passwd l O Test Main Comm Tuning Man Prg Select LAN Addr PID Param Calibration F Panel View LCD Contrast To set the access mode you must select the Keyb Perm item from the Main menu and reach the Permission display panel where all the 5 groups are listed with their mode on the left side The modes can be easily changed with the scroll buttons followed by a confirmation by mean of the E button in order to permanently store the modifications The setting choices for each of the 5 groups are listed in the column Possible Modes of the table above For a better security of important features like the access modes customization it is possible to insert an optional password in order to allow the modification of the setting to authorized people only In this case to reach the Keyb Pem menu the user must enter the proper password if the password is not the correct one the access to the menu is denied The following pictures
177. lue When the signal exceeds one of the two limits it is clamped to them IN gt LMT OUT I O Connections iN input o O OUT Parameters LMT_1 0 Lo Limit 0 Displayed Parameters Value of the minimum limit to apply to the output value of the maximum limit to apply to the output Format Format it defines the number of digits of the values above 98 Chapter 5 Modules 5 5 22 Alarms ALM Description This module is an alarm comparator that can be configured to flag either absolute or deviation alarms with an hysteresis band defined by the user Being structured internally as a comparator its use is not limited to alarms in fact it can be used also as a control element of the strategy performing real time comparisons on process variables The status of the digital output is fully programmable in order to support all the various combinations of high low deviation alarm The diagram below illustrates the operating principle of the ALM module valid for all the alarm configurations When the module is configured as a deviation alarm with the band defined by the two thresholds MIN VAL and MAX VAL if the signal DEV is inside the band the alarm is off otherwise is on The off status corresponds to the state inactive on the output DOUT outside gt alarm On Max Val Inside gt alarm Off Min Val outside gt alarm On In the next page a few examples
178. m 0 5 to 9999 Value of the Integral time in seconds with range from 0 to 9999 Value of the derivative time with range from 0 to 9999 Low limit of the control output in percentage with range from 0 to 100 High limit of the control output in percentage with range from 0 to 100 M Reset Manual Reset value with range from 0 to 100 G Sch Enable disable of the gain scheduling functionality More information about the PID and the Tuning process are provided in Chapter 4 5 5 3 Output Station MV Description This module is an Auto Man station to be connected downstream a PID module providing the functionalities the operator needs to interact with the loop The module provides auto manual track hold force operating mode output limits and the keys for incrementally set the output The operating modes are defined by a set of digital inputs as listed above ordered according to their priority level 1 Auto_Manual DA M 2 Hold DHLD 3 Force Ymax DYMX 4 Force Ymin DYMN 5 Tracking DTRK Depending on these digital inputs the functionality of the module changes as follows If none of these digital signals are active the module doesn t alter the control output signal that is led unchanged directly from the input MV from the PID module to the output Y If DTRK Tracking is active the output Y assumes the value of the analog input TRK
179. me units for all the time values of the program The choices are h m hours minutes and m s minutes seconds a eco eames this parameter The effect is that the program will be executed in a shorter time terminating it Restart These parameters allow to define the recover strategy after a power failure choosing between a wide range of possibilities The 4 possible choices are 1 Resume Automatic restart of the program at power on from the same status the Programmer was at power off SP PV Automatic restart of the program at power on after setting the SP output at the measured value of PV If the segment in execution at the power off time was a dwell the program restarts from the previous ramp segment Hold The Programmer is forced in the Hold mode at power on The Programmer stays in the Hold status until an operating or a running mode change occurs Reset The Programmer is automatically reset forcing it to segment 0 and in hold until an operating or a running mode change occurs Parameter of a recovery strategy based on the deviation value between SP and PV at the power on time lf the deviation exceeds the value set in this parameter the SP output is set equal to PV input and the program restarts from the point at power off Parameter of a recovery strategy based on the deviation value between SP and PV at the power on time lf the deviation exceeds the value set in this parameter the programmer is reset to segm
180. med Setpoint Profile Move the cursor up Setpoint Low Range Move the cursor down Previous Segment Currently edited Segment number Next Segment Description of the Parameters S P Val Value in engineering units specifying the target value of the SP Setpoint output at the end of the segment Aux V Value in engineering units specifying the level the AUX analog output Auxiliary Setpoint value will assume at the beginning of the segment and will hold for the entire segment Time This is the time assigned for the execution of the entire segments The format of the time is hh mm or mm ss according to the setting operated in the display panel Prg No n Digital Outputs Pattern of the 16 digital outputs O Off 1 On At the beginning of the segment execution the digital output will assume the specified pattern and will hold it for the entire segment The upper row is for Outputs 1 to 8 while the lower one is for the Outputs 9 to 16 This parameter specifies the maximum allowed deviation between the SP Setpoint output and the PV Main variable input This deviation is continuously monitored during the execution of the segment If the deviation value exceeds the configured threshold the program goes automatically in Hold It returns back to the Run mode when PV reenters in the allowed range Last Sg Setting Yes you flag this segment as the last one of the Program while setting No you specify that ano
181. n Units To avoid misunderstanding the input and output terminals are functionally grouped Therefore the left side of the termination unit houses the input signals while the outputs are on the right side This organisation facilitates the installation of the signal cable because inputs and outputs have different cable paths In the central part of the termination unit the following connectors for the serial communication are located e inthe upper part the connector to the LAN network is located e in the lower part the RS485 Aux and Main Comm connector is located Through the controller has been designed to work in the worst conditions typical of the industrial environment the following suggestions must be followed e Keep separate the cable to the controller power supply from the other power cables to the plant e Avoid to install the controller near to power switches electromagnetic contactors high power motors and others power sources e Avoid to install the controller near static power units especially if they are based on phase angle control The terminals are build up according to the UL CSA standard For proper connections it is recommended to use cable with maximum size of 12AWG 2 5 mm to remove the cable insulation cover for approximately 8mm and to insert it completely in the terminal hole before tightening the screw Use an edge screwdriver 0 4 x 2 5 x 75 mm Chapter 2 Installation 2 4 Electr
182. ne suitable for more demanding process control applications f V Y Y Y Y UNDERFLOW An DI1 DI2 DIS Al2 wsp PVI b WSP PV SCH Ald e Y 3 a Y x WSP es ALM Atm ALM ALM ALM a 7 o 42 1 5 4 3 2 1 o 3 l4 muxsp 9 MONS OR OK A OG VISU 2 y VISU 1 13 3 Control SCH WSP v y y y Vv CONTROL OUT DTRK HOLD YMAX YMIN MUXTRK 1 SCH TRK Annex A Resident Configurations Vv VISU 3 Al Y fod The Al module performs the A D the scaling and the conversion in engineering unit of the controlled variable and detects the out of range of the signal presumably caused by a sensor failure The output value of the Al module PV1 is fed into the three modules which implement the core of the PID loop The output of the PID is connected to the terminal blocks of the instrument through the output module AO1 The control loop provides important additional functions than the basic controlling ones like for instance the remote setpoint the forcing modes the feed forward up to 7 alarm modules and the retransmission of the controlled variable 159
183. nel When an alarm or a forcing mode is activated the box blinks continuously to alert the operator Next the operator can get a more detailed view of the alarms by looking at the ALLARMS panel Furthermore a trend panel is available for each of the analog input This page similar to the one used for loops has a trend chart with programmable time width that presents the recent trend profile of the variable At the top of the panel the numeric indication with large size digits of the variable is displayed The squared digital indications on the right side of the panel reports in the order from the top the global alarms flag the status of the first alarm of the variable and the status of the second alarm of the variable By pressing the values of the 5 variables shown in the picture are displayed one at a time in the scrollable display area 205 Installation and User manual of the AC10 AC20 AC30 controller Furthermore on the trend chart the range of the trended profile can be a portion of the full range of the variable in order to enhance the resolution on the interesting part of the span 22 6 Applications Monitoring of 4 variables with alarms and retransmission 22 7 Electrical Connections The following picture provides a clear view of all the termination blocks with the associated functionality and it is specific of this configuration No signals must be connected to the termination blocks not used by the
184. nfiguration e LCD Contrast Adjustment of the display contrast e Calibration Operations for the calibration of the controller e System Test Operations of system test To Reset the instrument you must select the command Clear Config and confirm by pressing the E key The existing configuration will be completely deleted at the end the message No program Found will appear on the display Now the instrument is fully operating and ready to accept a new configuration that will be downloaded as usual 7 4 Diagnostic Test and Calibration This Chapter describes how to perform the autodiagnostic and the calibration procedures It is recommended the use of a digital multimeter for taking precise measures of the signals generated by the AC controller during the test phase as well as a calibrator for testing the analog outputs like the ASCOCAL 10 series model or one with similar performances TAG 0000 0 TAG 0000 0 7 4 1 Cap 7 Maintenance and Diagnostic Diagnostic Tests To execute the self test procedure you have to access to the System Test panel carrying out the following steps P Prog amp Test Z S WY gt gt Input Z E Main Prog Sel System Menu 8 I O Test Test 1 O Test From the System Test you can select 5 test functions capable to exercise most of the hardware of the instruments These functions are e Keyboar
185. ng an existing program in an empty one First you must select the program to copy as illustrated above and select the Copy Program command from the Program No n menu At this point a dialog box will be displayed asking to specify the number of the destination program After entering these data you must confirm the operation by pressing the E button in order to progress Two potential situations can occur e The destination program is empty The message All done its OK is displayed in order to confirm the successful conclusion of the operation e The destination program is not empty The alert message First delete program is displayed to flag that the operation cannot be carried on At this point you must press a key to return back to the Program No menu Program No Cpy Prg 2 Cpy Prg 2 2 3 3 to Prg 3 A to Prg 3 Copy Program R Any key Program No n Insert Segment This command allows you to add to an existing program a new empty segment at a predefined program position Once added the segment is parameterized by mean of the Edit Program command After issuing the command you define the segment which the new one should be inserted p afterward You confirm the entry by pressing the E button Two potential situations can occur e The segment specified is one of the segment of the program The alert message All Done is displayed in order to
186. ntroller s configuration menu 5 7 9 Output Change Key Lock Block OPKL Description By switching DSEL from OFF to ON the keys that control the output change Increase Decrease and A M on all active panels of the active strategy are locked OPKL DSEL Parameters This block has no parameters and is not present in the Controllers configuration menu 114 Chapter 5 Modules 5 8 Math and Logic Function 5 8 1 Expression EXP Description This module allows the entry of an alphanumeric string specifying a mathematical expression manipulating up to 4 input variables Inputs A B C D and involving arithmetic operators math functions and parenthesis The result is returned in the output R The arithmetic operators are addition subtraction multiply division and Exponentiate The math functions are Absolute value Square root Square Sine Cosine Arc Tangent Radians Natural Logarithm base e Logarithm base 10 Exponentiation e 2 71828 CF IO Connections Input corresponding to the variable A of the expression Input corresponding to the variable B of the expression LLL Input corresponding to the variable D of the expression Input corresponding to the variable C of the expression es Result SS Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument panel 5 8 2 Arithmetic OPR Description This module executes a ba
187. ny parameter and therefore it is not displayed on the instrument panel 120 Chapter 5 Modules 5 8 12 Monostable MST Description This modules implements a monostable circuit triggered by the digital inputs and capable to generate pulses of variable delays Through the Parameters of this module you choose between different operating mode Mode and you enter the time values Delay for the generated pulses DIN1 gt MST DOUT RES D I O Connections DIN1 Monostable trigger digital input RES Monostable reset set the output to 0 DOUT Digital Output of the monostable Parameters MST_1 Mode 1 Displayed Parameters Selection of the operating mode The choices are 0 1 2 3 1 Time delay value entered as a number of sampling time Range from O to 300 1 The monostable is supporting 4 different operating modes selected by the codes 0 1 2 3 Their behavior is listed in the following picture DIN 1 Pos itive edge delay Negative edge delay Pulse Shifted delay TIME Chart illustrating the different monostable operating modes 121 Installation and User manual of the AC10 AC20 AC30 controller 122 5 8 13 Counter CNT Description This module counts the input pulses defined by the positive edge of the digital input DIN1 The counter total is returned on the analog output OUT It can be configured as either an up or a down counter and it is contr
188. ock diagram the interconnections between the various modules and the display panels are not indicated in order to improve the understanding of the functionality performed oo 2 F An D1 DI2 Al2 Al4 Dis DI7 4 PV MST gt WSP PV Underflow PV Slave paa Y Y Y SCH Y NA RSP SLAVE 2 4 5 8 gt VISU 1 y La 6 CONTR 7 OR1 SCH 4r visu2 RTX PV SL Y Y Y Y Y Y y A02 DO4 DO3 DO2 DO1 A03 A04 DOS DO6 DO7 DO8 d 5060 19 3 Control g oo oo Loop Master The master process variable PV MS1 is acquired by the Ali module providing the conversion in engineering units and the out of range detection It is transmitted to the SET DEV module that with the PID and CONTROL OUT modules makes up the core PID block The output after being adjusted to the range of the PV SLV by the SCH RSP SLAVE modules enters as a Remote Setpoint RSP into the SLAVE module Loop Slave 189 Install
189. ode freezes the loop output until the DI5 digital input is active while the Tracking mode sets the output to the value of the constant n 2 of the module MCNS until DI6 is active There are three alarms either on the controlled variable PV1 or the deviation according to the parameters selected in each of the ALM modules The module WSP PV computes the deviation in the same engineering units of the controlled variable PV1 The status of each alarm is retransmitted out through the DO1 DO2 and DO3 modules A fourth alarm the digital output DO4 flags the out of range of the variable PV1 Variables Retransmission The controlled variable PV1 is retrasmitted out to the termination unit through the SCH and AO2 modules The module SCH allows the modification of the ranges of the retrasmitted output that are not necessarily the same of the PV1 input This is achieved by setting the input range parameters of the SCH module to different values than the output range parameters In this way the retrasmitted PV1 can be limited to a portion of the input signal scale with the advantage of an improved resolution Graphic Displays TSP WSP RSP MSP __ csP LSP Current operating mode Requested operating mode Alarm 1 ORofall the alarms Aut Man station gt TSP OR of the forcing modes WSP RSP MSP e cP LSP Current operatin
190. odes selected through the DI5 6 7 8 digital inputs Tracking Hold Hold Y Max Hold Y Min a Tracking it is enabled by the DI6 digital input and it consists in setting the control output either to a predefined value from the CONST analog constant module or to the value of the analog input Al4 The selection between these two choices is operated by the MUX multiplexer module by mean of the DI4 digital input The range of the track value is 100 to 100 with 100 corresponding to the maximum cool value b Hold when DI5 is active the control output is frozen at the value it had at the time of the rising transition c Hold Ymax When both DI5 Hold and DI7 are active the control output is forced to its maximum value defined by the parameters of the CONTROL OUT H C module d Hold Ymin When both DI5 Hold and DI8 are active the control output is forced to its minimum value defined by the parameters of the CONTROL OUT H C module An important point to bear in mind is that all these forcing modes are handled by the module according to the following priority A M Ymin Ymax Hold and Track There are 3 alarms either on the controlled variable PV or the deviation according to the parameters selected in each of the ALM modules The module WSP PV computes the deviation in the same engineering units of the controlled variable PV The status of all these alarms is retransmitted out through the DO1 to DO3 digital output The
191. of PID loop Stand standard PID Rt x direct ratio Rt 1 x inverse ratio Low limit of the secondary variable reference of a ratio loop Format Format defines the number of digits_of the ratio loop secondary variable Format Format defines the number of digits ofthe rate limits selection process 1 SwtPrio _ Priority assigned to the selection mode Digital Inputs 2 1 The possible choices are Loc Local Rem Remote LocRem Local and Remote LocSup Local and Supervisory Computer LoReSu Local Remote and Supervisory Computer 2 The choices for the priority level are None Low Medium High It is strongly recommended to avoid that two selection modes have the same level of priority Chapter 5 Modules 5 5 2 PID Algorithm PID Description This module implements the PID algorithm and generates the control output starting from the deviation value between the Setpoint and the controlled variable The control output drives the external actuator in order to keep the controlled variable at the target Setpoint level The PID algorithm with the derivative term on the process variable is illustrated in the following picture 100 The derivative term includes a filter in order to reject as much as possible noise a 1 10 In lack of this filter being this term computed as the derivative of the process variable the noise would be the major source of the derivative term with unsucces
192. of alarm configurations are shown ABS ALM DOUT DEV y I O Connections ABS Absolute alarm analog input Deviation alarm analog input Digital output with the result of the alarm comparison Parameters ALM _1 Min Val 0 Displayed Parameters Low alarm threshold High alarm threshold Alarm Hysteresis Format it defines the number of digits of the values above Input Selection of the type of alarm absolute independent or deviation 99 Installation and User manual of the AC10 AC20 AC30 controller 100 Examples 1 ABS 2 ABS 3 DEV 4 DEV Absolute independent high alarm VMAX 300 C Active if ABS gt 300 C ALM DOUT Inactive if ABS lt 300 C VMIN Low range Absolute independent low alarm IVMAX High range Inactive if ABS gt 300 C ALM DOUT Active if ABS lt 300 C VMIN 300 C Deviation alarm active when out of the deviation band VMAX 30 0 ALM DOUT Inactive if VMIN gt DEV gt VMAX VMIN 15 0 Deviation alarm active when in the deviation band This configuration requires an external module to perform a Boolean NOT operation VMAX 30 0 AL M DOUT Active if VMIN lt DEV lt VMAX VMIN 15 0 Chapter 5 Modules 5 5 23 Rate Alarm SALM Description This module is an alarm comparator that flags rate alarms with an hysteresis band defined by the user This mod
193. olled by a pair of digital inputs defining the operating mode DIN1 UD gt cse CNT e RES I O Connections Counter input Each positive edge increases the counter of one unit DINI CSEL Counting enabling digital input RES Counter Reset digital Input Counting direction select input Up or Down Output with the current value of the counter Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument panel 5 8 14 Multiple Analog Constants MCNS Description This module generates a fixed analog signal on the 5 outputs CNS 1 5 whose values are specified by the module parameters p CNS1 p CNS2 MCNS gt conss p CNS4 m CNS5 I O Connections CN 1 5 Analog Outputs Parameters MCNS _ 1 50 CNS1 50 Displayed Parameters CNS 1 5 1 Values to set the analog outputs Format Format it defines the number of digits of the values above 1 The tag of the 5 analog constants as displayed on the controller panel is directly configured by the AC Prograph Chapter 5 Modules 5 8 15 Analog Single Constant CNS Description This module generates a fixed analog signal on the output CNS whose value is specified by the Value parameter CNS CNS I O Connections Analog output set to the predefined value Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument pan
194. onality like alarms and forcing modes for implementing a more advanced control than the basic PID A typical example of a process where this configuration is targeted is the control of the combustion of a reheating furnace where the 4 loops are controlling Air pressure Air temperature Furnace pressure Fumes temperature at the recuperator AIR TEMPERATURE FUMES TEMPERATURE a FURNACEPRESSURE _ AS 7 SOS PT TAPA TE po T T l Da ff S Aal ll II FUMES Y OS As o f Ae Y ACT AIR OUTLET AIR TEMPERATURE CONTROL FUMES VALVE ACTUATOR FURNACE PRESSURE CONTROL Annex A Resident Configurations 21 8 Electrical Connections The following picture provides a clear view of all the termination blocks with the associated functionality and it is specific of this configuration No signals must be connected to the termination blocks not used by the strategy The termination blocks 25 and 26 are providing a 24V DC output particularly suitable to supply of the 2 wires transmitters PV1 Loop cu gt PV2 Loop2 d A A A N N Actuator 1 PV3 Loop3 ws 5 Act
195. onic 3 char Scale High range 6 char with sign and dp Slider CM Bar graph BI1 Main Variable PV1 6 char with sign and dp Scrolled variables values 6 chars with sign and d p Al 1 2 3 4 5 e LSP Setpoint operating mode MOD Requested Setpoint Mode Loc Rem Com Logic Variables display 3 char strings DI 2 3 Scale Low range Y An Al2 Al3 Al4 Ald Bl cit PV1 Y YC DI1 DI2 DI3 Out station operating mode AUT MAN DA M Output value in LSP MODE gt DA M I O Connections Chapter 5 Modules The most common use is to flag alarms or other digital events Analog variables displayed numerically in the scrolled list with a short 3 characters mnemonic The number of displayed inputs can be set though the parameter items in the module 1 Bargraph Edit of AC Prograph AC Edit For the above refer to Section 9 10 1 of the manual Analog Input displayed graphically on a bargraph with a decimal scale Analog input displayed graphically by mean of a slider moving along the decimal scale Main Variable displayed numerically with big digits at the top of the display Analog Input displayed in percentage numerically and by an horizontal bargraph at the bottom of the display It is intended for the control output of a loop Analog Input displayed together with Y at the lower part of the
196. onnections The following picture provides a clear view of all the termination blocks with the associated functionality and it is specific of this configuration No signals must be connected to the termination blocks not used by the strategy The termination blocks 25 and 26 are providing a 24V DC output particularly suitable to supply of the 2 wires transmitters Master PV measure Master Remote SP 31A A N N 4JA A if L L Master PV retrans Slave PV measure e G N o Slave PV retrans El T Actuator 8 9 Alarm 1 Pv Alarm 2 Pv gt Master Alarm 3 Pv ve Loc Rem Und F Pv aster Rem Me D Alarm 4 Pv T Alarm 5 Pv T gt Slave L Alarm 6 Pv Und F Pv N P i oan Hold POWER SUPPLY L MV Stby 20 Override Annex A Resident Configurations 20 1 Description The drawings below are providing the following informations Block Diagram User interface consisting in a set of display panels Termination unit for the connection to the field The override control is the right solution for controlling processes where more than one variable must be controlled at the same time For instance the process consists of a
197. ons Limit Loop There are two alarms either on the controlled variable PV2 or the deviation according to the parameters selected in each of the ALM modules The module WSP PV computes the deviation in the same engineering units of the controlled variable PV2 The status of each alarm is retransmitted out through the DO5 and DO6 modules An additional alarm performs the comparison between the outputs of the Main loop and the Limit one determining which of the two loop is driving the output and flagging it out through the DO8 output The out of range of the PV2 variable is detected and retransmitted out through the digital output DO7 20 7 Variable retransmissions The Main variable PV1 is retrasmitted out to the termination unit through the SCH PV1 Main and AO2 modules The Main variable PV2 is retrasmitted out to the termination unit through the SCH PV2 Main and AO3 modules The module SCH allows the modification of the ranges of the retrasmitted output that are not necessarily the same of the input This is achieved by setting the input range parameters of the SCH module to different values than the output range parameters In this way the range of the variable can be changed in order to consider only a part of the original signal scale with sensible advantages on the resolution of the output 20 8 Graphic Display OVERRIDE LSP ALARMS WSm E U PV Master 2 RSm PV Master ee PPPE e CSL
198. pictures above Annex A Resident Configurations 18 9 Applications The purpose of the ratio loop is to control processes where it is required to keep at a predefined set the ratio between two controlled variables There are plenty of examples of processes of this type for instance the control of the blending between two fluids and the control of the combustion air and gas mix The second basic PID loop can be used to control an independent variable of the process where the ratio control is required An example is shown in the picture below related to the combustion control of a steam generator The steam pressure is controlled by the Loop2 whose output defines the energy heat amount to supply to the boiler driving the gas valve The ratio loop controls the air flow rate that in order to optimise the combustion must be kept to a predefined ratio with the instantaneous gas flow rate The ratio loop receive the gas flow rate as PV2 and its output drives the air door The control of combustion can be further improved by measuring the oxygen in the fumes and correcting according to the measure the air gas ratio setpoint by mean of the Bias input Furthermore using the digital inputs some additional functionalities can be implemented like forcing the closure of the gas valve tracking the valve at the start up and disabling the oxygen bias when the production is at the minimum level O2 PV1 BIAS Pv2
199. put particularly suitable to supply of the 2 wires transmitters a PV1 Loop1 uw a ae gt 26 24 RSP Loop1 lt SEIA A ZR Heat Actuator a A A 28K TRK Loop1 a 5 5 BV Cool Actuator PV2 Loop2 lt me O S pen A A 9 a gt PV1 retransmission z Tes Loop 2 Actuator 8 9 Alarm 1 10 a Alarm 2 Alarm 13 RSP Underflow RSP Mem Alarm I 4 Hold Alarm 15 Tracking Alarm 6 Loop2 Y max Alarm 7 Loop2 Y min RSP Loop2 Takla POWER SUPPLY Annex A Resident Configurations 18 Ratio 18 1 Description The drawings below are providing the following informations Block Diagram User interface consisting in a set of display panels Termination unit for the connection to the field 18 2 Block Diagram In the following block diagram the interconnections between the various modules and the display panels are not indicated in order to improve the understanding of the functionality performed Underflow PV1 Controlled variable
200. puts Parameters Ds2_ Ds3 Selected Output DO po o DO o 0o DO __ k A ___ AB A META o A 7 Eef o 1 DO5 po 1 lO i 1 OB DO1 DIN1 gt DO2 DO3 DS1 DO4 DS2 DO5 DS3 gt DO6 DO7 DSEL gt Dos This module doesn t have any parameter and therefore it is not displayed on the instrument panel 105 Installation and User manual of the AC10 AC20 AC30 controller 106 5 5 28 Decoder DEC8 Description This modules is a 1 to 8 decoder It selects one of the 8 DO1 DO8 digital outputs according to the 3 bit binary code specified on the DS1 DS3 inputs as listed in the table below The selected output is set to 1 while the others are set to 0 The DSEL digital input enables the module when set to 1 and disables it when 0 Once the module is disabled the output selected doesn t change even if the 3 bit binary code value varies Enabling again the module the output is selected according to the 3 bit binary code Selected Output DO I O Connections __ Selected Output DO pos pos DO1 DO2 DS1 DO3 DS2 gt DEC8 DO4 DS3 gt DO5 DO6 DSEL gt DO7 DOs Select inputs DSEL Selection enable input DO 1 8 Decoder Outputs Chapter 5 Modules 5 5 29 Set page block SETP Description This module allows to set an active panel when DSEL digital input switches from 0 to 1 SETP DSEL D Description of connect
201. puts and are used to flag which of the two channel is operating Loop 2 There are two alarms either on the controlled variable PV2 or the deviation according to the parameters selected in each of the ALM modules The module WSP PV computes the deviation in the same engineering units of the controlled variable PV2 The status of each alarm is retransmitted out through the DO7 and DO8 modules 17 7 Variables Retransmission Loop H C The controlled variable PV1 is retrasmitted out to the termination unit through the SCH PV and AO3 modules The module SCH allows the modification of the ranges of the retrasmitted output that are not necessarily the same of the PV1 input This is achieved by setting the input range parameters of the SCH module to different values than the output range parameters In this way the range of the variable can be changed in order to consider only a part of the original signal scale with sensible advantages on the resolution of the output 179 Installation and User manual of the AC10 AC20 AC30 controller 180 17 8 Graphic Displays TSP HEAT COOL _WSP LOOP2 _WSP ALARMS RSP RSP SP1 km CSP e Alarm1L1 s SES a MSE e Alarm2L1 SP3 LSP Loc Current operating mode Loc Current operating mode e _ __ Alarm 3 L1 Requested Requested e 1 _ Underflow L1 operating mode operating modes e
202. r 17 4 Remote Setpoint This feature is supported on both the loop but with the following different performances Loop H C a The remote setpoint is enabled by mean of the DI1 input b The Remote Setpoint source Al2 analog input or a stored constant is selected through the MUX RSP multiplexer by mean of the DI2 input om D2 Selected Value x Input Al2 On On Constant SPM H C Loop 2 a The Remote Setpoint is enabled by mean of the DI7 input b The source of the Setpoint can be a stored constant named SPM L2 17 5 Forcing modes These operations are related to the loop output that can be driven by other sources than the straight PID algorithm The functionality provided by the two loop are slight different as described below Loop H C This configuration allows the following 4 modes selected through the DI3 DI4 DI5 and DI6 Tracking Hold Hold Y Max Hold Y Min a Tracking it is enabled by the DI4 digital input and it consists in setting the control output either to a predefined value from the analog constant module or to the value of the analog input Al3 The selection between these two choices is operated by the MUX multiplexer module by mean of a parameter The range of the track value is 100 to 100 with 100 corresponding to the maximum cool value 17 6 Alarms Annex A Resident Configurations Selected Value A M_ Hold Input Al3 Constant YSIC H b Hold when DIS
203. r simply always R H SP RST AUX FST NXT DO1 DO2 DO3 DO4 DO5 DO6 DO7 DO8 DO9 DO10 DO11 DO12 DO13 DO14 DO15 DO16 PV SEL1 SEL2 SEL3 SEL4 DHLD RUN HLD NPGM NSGM SRT TCYC ACYC I O Connections Run Hold I O Bidirectional signals specifying the operating status of the Programmer When in Hold mode the Programmer doesn t progress and all the outputs are frozen When in Run mode the Programmer executes the predefined program stepping between the segments up to the end Fast Input When inactive the program is executed on the basis of the configured times values Otherwise Fast mode all the times are scaled by a predefined factor and the program segments are executed very rapidly Next Digital input forcing on the rising edge inactive to active the Programmer to go to the next segment Main Variable This analog input is intended for acquiring the process variable that is continuously compared with the Setpoint output of the Programmer in order to detect an excessive deviation SEL1 SEL4 Select digital inputs These 4 digital inputs specify a 4 bit code corresponding to the program to be selected DHLD Hold Input This digital input on the rising edge inactive to active forces the Programmer to the Hold mode stopping the execution of the current segment Analog output with the Setpoint value generated by the module Auxiliary Setpoint output This analog output is set
204. r only a part of the original signal scale with sensible advantages on the resolution of the output 15 8 Graphic Display TSP PID1 PID2 ALL e FORZ LOOP1 WSP i PV of the RSP OR of the alarms Sele ted 100p e Alarm 1L1 m CSP Requested LSP loop sel operating mode e _ Alarm2L1 sj MSP WSP loop sel LOCe Current Operating mode Alarm 3 L1 SE A Selected Loop Prev l TAG loops Loc Current operating mode e Underflow L1 Requested operating mode e Alarm 4 L2 WSP loop 1 e ALLARME 5 L2e gt 3 gt Alarm 5 L2 1 OR of the forcing modes PV loop 1 ma gt WSP loop 2 0 e Alarm 6 L2 PV loop 2 PE hme el UnderflowL2 e Alarm 1 e Tracking L1 e OR of alarms e Hold L1 e Tracking L2 Aut Man Station X e Hold L2 Aut Man Station A Ae Aut Man Station MV loop 1 e e MVloop2 169 Installation and User manual of the AC10 AC20 AC30 controller 170 LOOP 1 TSP WSP RSP Al4 gt CSP LSP Loc Current operating mode Requested operating mode OR of the forcing modes Alarm 1 OR of Alarms Aut Man station LOOP2 TSP WSP RSP CSP e MSP LSP Loc Current operating mode Requested operating mode
205. r the deviation according to the parameters selected in each of the ALM modules The module WSP PV computes the deviation in the same engineering units of the controlled variable PV The other 2 alarms are related to the analog input Al4 that has multiple functionalities The status of all these alarms is retransmitted out through the DO1 to DO8 digital output The DO4 digital output flags the out of range of the variable PV1 13 8 Variables Retransmissions The controlled variable PV1 is retrasmitted out to the termination unit through the SCH and AO2 modules The module SCH allows the modification of the ranges of the retrasmitted output that are not necessarily the same of the PV1 input This is achieved by setting the input range parameters of the SCH module to different values than the output range parameters In this way the range of the variable can be changed in order to consider only a part of the original signal scale with sensible advantages on the resolution of the output The WSP working set point is retransmitted out though the analog output AO3 properly reranged by the SCH WSP module with the previously described advantages in term of resolution The Al4 analog input suitable for multiple functionalities tracking retransm all can be retransmitted out to output AO4 after the rerange operated by the SCH Al4 module 13 9 Graphic Displays TSP TSP WSP WSP RSP RSP Al4 A
206. rend curve shows the real time value of the trended variable Tag 10 char Main Variable in engin units 3 char Scrolled Variables Mnemonic 3 char Scale High range 6 char with sign and dp Chart area with the trend of BI1 200 x 75 pixel Bargraph of the trended variable B1 Time span of the chart Y Alt Al2 Al3 Al4 Al5 BI cl1 PV1 Y YC DI1 DI2 DI3 Main Variable PV1 6 char with sign and dp Scrolled variables values 6 chars with sign and d p Al 1 2 3 4 5 e LSP Setpoint operating mode MOD Requested Setpoint Mode Loc Rem Com Logic Variables display 3 char strings DI 1 2 3 Slider Cl1 Out station operating mode AUT MAN DA M Scale Low range Output value in LSP MODE gt DA M Chapter 5 Modules I O Connections most common use is to flag alarms or other digital events Analog variables displayed numerically in the scrolled list with a short 3 characters mnemonic The number of displayed inputs can be set though the parameter items in the module 2 Trend Panel of AC Prograph AC Edit For the above refer to Section 9 10 4 of the manual Analog Input displayed graphically on a bargraph with a decimal scale Analog input displayed graphically by mean of a slider moving along the decimal scale Main Variable displayed numerically with big digits at the top of the
207. riable 1 value of the main variable n 1 PV2 Process Variable 2 value of the main variable n 2 WSR Working Set Ratio value of the ratio setpoint 5 Scrolled Variable Value Numerical display of the selected scrolled variable The list of the variables includes the Local Setpoint and other analog input signals of the module It consists of 6 characters including the sign and the decimal point 6 Scale high low Limits They define the values of upper and lower limits of the scale Each value consists of 6 characters including the sign and the decimal point 7 Variable 1 Bargraph Bargraph indication of the process variable n 1 controlled by the Master loop The bargraph shows the process variable value in 200 steps providing a resolution of 0 5 8 Variable 2 Bargraph Bargraph indication of the process variable n 2 controlled by the Slave loop 9 Set point Slider 1 Graphic representation through a moving slider of the real time value of the Setpoint n 1 corresponding to the Master loop The slider is moved in steps of 0 5 10 Set point Slider 2 Graphic representation through a moving slider of the real time value of the Setpoint n 2 corresponding to the Slave loop The slider is moved in steps of 0 5 11 Loc Rem Com Display of the Setpoint operating mode that the user has requested from the controller keyboard The Setpoint refers to loop 1 Master The mode is indicated by the mnemonics Loc Rem and Com
208. ride NO 4 Loops R 4 Indicators ay Program AIM STation Found Release OUT 63 In this case the page with the standard resident configuration stored in ROM is displayed 36 Chapter 4 PID Tune and Communications 4 PID Tune and Communication 4 1 Tuning The Tuning method used in the AC series controller is an highly sophisticated new generation algorithm that represents the state of the art in this technology area The basic principle this method is based is illustrated below Hysteresis relay Tune active gt f qua NL Fig 4 2 Start of Tune A Variable PV B MV control output In the closed loop configuration illustrated above the hysteresis relay causes a continuous endless oscillation of the measured variable These oscillations are carefully examined in term of amplitude and period by the Tune algorithm that on the basis of this analysis determines the optimal PID terms values The use of the Tune is very simple because it works with every process either in steady conditions or during transients Furthermore the Tune algorithm is automatically fitted to the type of PID P PI PID selected The first step of the Tune procedure is to check and if necessary to change the type of PID by carrying on the following steps TAG 0000 0 5 a Tune amp Vi
209. right while the Working Setpoint WSPLim is displayed by the slider The control output is displayed both numerically and by horizontal bargraph The following variables consisting of the Local Setpoint and other 5 analog variables are displayed one at a time in the scrollable display area LSP Local setpoint of the Main loop WSM Working setpoint of the Main loop RSM Remote setpoint of the Main loop CSM Computer setpoint of the Main loop PVL Limit Process variable WSL Limit Working setpoint The displayed Setpoint operating mode is the one of the Main loop its mode indicated by the Loc Rem and Com mnemonic is displayed in reverse on the panel at the same height of the L R key that is used to change the mode The Setpoint and its operating mode of the Limit loop are displayed and can be changed from the display panel LIMIT The squared digital indications on the right side of the panel are flagging the status of the alarm and the forcing mode of the loop More precisely they highlight the following general situations 1 When an alarm is active the label ALL is visible 2 When the Alarm 1 is active the label AL1 is visible 3 When a forcing mode is active the label FOR is displayed These are global flags the detailed cause of the event is shown in the ALARMS panel where the digital status of each alarm and forcing input is clearly shown This configuration support two trend panels one for each loop with the trend profile
210. rk usually due to memory overflow when receiving large amount of data or a duplication of the addresses of the LAN cards e Net Error This message is usually caused by errors in the configuration data Overflow Invalid Instruct Divide By Zero Address Error This error messages do not appear when the instrument hardware isn t properly working Therefore if they appears on the display please refer to the Technical Service 139 Installation and User manual of the AC10 AC20 AC30 controller 140 7 3 Master Reset This functionality is required when due to a temporary failure of the hardware normally triggered by some anomalous external conditions the AC controller appears completely locked and doesn t allow to operate from the keyboard or the serial ports In most of these cases you can recover the situation by resetting the AC controller When a failure of the type described above occurs the first thing to do is to switch off and on the AC Controller operation that in a lot of cases forces the instrument to start to properly work If the AC controller doesn t restart you must proceed with the Reset operation by switching off the instrument and on again with the two keys iG and W pressed After the power up the following display panel is shown Your Choice Clear Config The 4 commands of this menu perform the following functions e Clear Config Deletion of the existing co
211. rocesses are suitable to benefit from this feature a Control of the pressure of the steam in a boiler master using the steam flow as the feed forward variable b Control of the pressure of the combustion chamber using the fuel flow as the feed forward variable c Control of the level of the two elements boiler barrel of a steam generator using the steam flow as the feed forward variable considering that it generates the major demand of water __ E kil 00000000 f be Pd pf 00000000 0000000 72 These control applications can strongly benefit from the availability of the Remote Setpoint and the forcing modes features provided by the controller and triggered by external signals These features allow effective implementations of automatic operation like the cleaning of the combustion chamber and the automatic forcing to the minimum level during the idle times 13 11 Electrical Connections Annex A Resident Configurations The following picture provides a clear view of all the termination blocks with the associated functionality and it is specific of this configuration No signals must be connected to the termination blocks not used by the strategy The termination blocks 25 and 26 are providing a 24V DC output particularly suitable to supply of the
212. rovided through the transformer with double secondary windings mod AAC TA The picture below illustrates the connections 240 Vac 2 SHC 220 Vac 22 11Vac 1 8A 5 215 i 35 TiVac 0 9A OVac g gt a olose e osoleo occolecajesa esejesesjese eoo ooe eo eoojeeojeoo essjesajesa 3338 RAAR RA AR AAC EU 88 4 AAC EU 88 AAC EU 88 HHI Address 0 m Address 1 ANI Address 2 IBN eoojeoejeoe leasleselese lfooalecoloce eoo0l eceleee ee 200 E x ERRE A o N oO ONS E N Mm Y 6 6 6 6 66668 6 6 6 86 ocojocojecojoecea jecoeo oco0o o i ococjeceojeso ocojecojoso Uscite analogiche AAC EU 88 4 AAC EU 88 Wil Address o Wi Address 1 E 28 22 228 ere e iz SS es eee EPR ER 2Doojecojoo ooojocojeooo oocoojeoevcoljoco ooojocojeoo eccVojeocojosoe one i EFE LAUN a 3 fs 6 BRANIA 3 3 3 BSS 9 1870 819 e
213. s IN Input to demultiplex DS 1 3_ Selection inputs OUT 1 6 Outputs Parameters ASEL _1 Dig Choice Dig Displayed parameters Sel Code Specification of the selection mode to use dynamic or static 102 5 5 25 Analog Hardware Demultiplexer AS8 Description Chapter 5 Modules This module is a 1 to 8 demultiplexer of analog signals It retransmits its IN analog input to one of the 8 OUT1 OUT8 analog outputs The output is selected through the 3 bit code on the DS1 DS3 inputs as listed in the following table The other not selected outputs are set to 0 Furthermore the module can be selected or deselected through an external input DSEL Once the module is deselected its OUT output will hold the value it had before the deselection until further selected I O Connections O N OUT1 OUT2 OUT3 OUT4 DS2 ae DS3 4 OUT6 OUT7 DS1 gt DSEL gt OUT8 IN Input to demultiplex Selection inputs DS4 3 DSEL Selection enable input Parameters Selected Output OUT OUT 1 OUT 2 OUT 3 UTA 5 OUTS OUT 6 Po OUT Pp OUT Selected Output OUT This module doesn t have any parameter and therefore it is not displayed on the instrument panel 103 Installation and User manual of the AC10 AC20 AC30 controller 104 5 5 26 Digital Software Demultiplexer DSEL Description This module is a 1 to 6 demultiplexer of digital signals It retransmits its DIN digi
214. s AEE a ea 156 DA A O ON 156 12 7 VARIABLES RETRANSMISSION ji sssoseessscevesovnsedcediedsvenoesdesiede veeothececasdedeedectheetsosvedsscuctaeedscddedeaceeteecsessundtectedevesevsee 156 TUS GRAPHIC DISPISAYS ea 156 12 9 APPEICATIONS rocio canario desceves guest ndecadeavwedugateevesbuedenaite a EE ia 157 12 10 ETEGTRICAL CONNECTIONS tios sas 158 13 INKOON Eh s EE EEE E A E E L I ENEA EE E E EAEI TATA 159 LM DESCRIPTION di eo T 159 13324 PBLOCKIDIAGRAM a A e a A a TA 159 13 32 CONTR Ob tt dices 159 13 4 REMOTESE PON aci nte 160 13 5 PEED FORA E aida 160 13 6 FORCING OBERATIONS a OA TR 160 13 7 ALARMS A sh iis cob eee beat EE aes eA A A ni 161 13 8 VARIABLES RETRANSMISSIONS did ein did 161 EA GRAPHIC DRA diia 161 13 10 APPLICATION Se o bo loan do dde die eee 162 13 11 EEECTRICAL CONNECTIONS 3 esecszess lan cesessees icono EEE AE TEETE EE liada dicta 163 14 TPL OOP G ian E ESE I AE AE N ESNE E ENSA EEE E S 164 MA SDESGRIPTIONG A A aio ES 164 142 BLOCK DIAGRAMA a a a E A S 164 LA CONTRO A EE E A EASES OE EEEE EE SASE EET 165 14 41 REMOTE SETPON EEA e E TE e a 165 14 5 FORCING OPERATIONS EEEE did addict 165 VE II E AN 165 14 7 VARIABLES RETRANSMISSIONS ccccccecssssssececcecesessnsececececsensasececececseseseaeceeeeseseaaecesececeessaaececececeensaaeceeeeeeeenes 166 14 87 GRAPHICODISPLAYS naaa coil 166 14 9 APPEICATIONS So A A RT aR 167 14 10 ELECTRICAL CONNECTIONS dni idos 167 15 ZEODOPSA uni n AEEA EA AAA
215. scon it support ascon it Installation and User manual of the AC10 AC20 AC30 controller TABLE OF CONTENTS 1 n un GENERAL INFORMATION sccssscciscssecesvccsactessccececancesessasscoesceseseeaesascocesscdescdsssececscadeeacdssnsescocseceebcasscerscotserseceseoss 7 1 1 MAIN DIFFERENCES BETWEEN AC10 AC20 AND AC30 cc cccccccecssssssscecececcecsnececececseseseaesececeeeeesssaeeeeeeeeentaaes 7 1 2 TECHNICAL SPECIFICATION m rora i Tevattetes a a adidas 7 1 2 1 I O MAXIMUM CAP ADULT CS ae ss aioe Sik cade sacs A sats nOn n deg hna cd tae bad 7 1 3 HARDWARE DESCRIPTION ssuceceusenes eccothscsevaesdesesoxheotsesevedeuecseeaue ea e Eaa aoaaa ea E EAEN ENRE eea 9 1 4 RESIDENT STRATEGIES DESCRIPTION l a N a a A AEE 10 1 5 LIBRARY OF THE FUNCTIONAL MODULES OF THE AC10 AC20 AND AC30 CONTROLLERS s sscccceesessseeeeeees 11 INEA AAA A 13 2 1 IBITI OIN E E EEE a aia 13 2 2 PANEL MOUNTINC ds 13 2 3 CONNECTIONS AND TERMINATIONS scssscssececeessssececececeesesececcceceeneaesesececeesesaaeceeecsceeeaaeceeececeeesaseesececeeneaaees 14 2 4 ELECTRICAS CONNECTIONS Ws sssiecccerevacetacsentedecsensistsecndedeccendettcscegecedsestvigededeses aa ar E a a e e A its 15 2 4 1 Passive Transmitter eo oiea a a a r a a a a a a e e e a ea 15 2 4 2 A CEVE TONS MMT a E ATT T 15 1 1 3 ARAU 23 AAAA IA A aL EAD A e elds 15 1 1 4 Dietalinputs andQuipuls detesta iros AN avia AN Oo ves id As me don AN do toad ON et E 16 1 1 5 Erequency Input i
216. sful results in the process control capability MV gt gt DSAT gt DTUN I O connections FFW _ Feed Forwardinputsignal e TE TE module of the controller and it is fed to the actuator of the loop DBMP Digital Input indicating through its negative transition when the adjustment of the PID terms for the BUMPLESS transition functionality must be performed KP KI Integral t Gain coefficient 1 KD Derivative Gain coefficient 1 DIK MV PV1 PDEV IDEV DDEV FFW ACTY KP KI KD DBMP DIH AN Integral term disable MV Control output in percentage also named manipulated variable DSAT Desaturation Output When active this signal flags that the PID is in saturation DTUN Digital Output flagging that the Tune algorithm is active 75 Installation and User manual of the AC10 AC20 AC30 controller 76 Note 1 If the gain scheduling is enabled the three terms of the PID algorithm are computed according to the following formulas PB p PB SHR Ti T Al TD TD KD where PBu Tlu and TDu are the coefficients of the 3 terms used in the PID formula while the PBp Tip and TDp are the values set by the user Parameters PID LEVEL PID Algo PID Displayed Parameters Action Selection of the control output direction direct or inverse Algo Selection of the type of PID algorithm P PI PID Value of the Proportional Band in percentage with range fro
217. sic arithmetic operation on a couple of scaled analog inputs A and B returning the result on the output R IN1 gt R IN2 I O Connections A Input corresponding to the variable A of the expression B Input corresponding to the variable B of the expression Result 115 Installation and User manual of the AC10 AC20 AC30 controller Parameters OPR_1 Add Function Add Displayed Parameters Specification of the Arithmetic operation The choices are Add Sub Mul Divide Power where Add addition A B Y Sub subtraction A B Y Mul multiply AxB Y Divide division A B Y Note Input B cannot be zero B Power Exponentiate A Y 5 8 3 Function FN Description This module executes the selected math operation trigonometric logarithmic or exponential on an analog input I O Connections IN4 Input RFN Output with the result of the execution of the selected function Parameters FN 1 Abs Function Abs 116 Chapter 5 Modules Displayed Parameters Selection of the function to execute The choices are Abs Sart Sqr Sin Cos Atan Loge Log10 Exp Deriv where Abs Absolute value of the input signal Sqrt Square root Sqr Square Sin Sine Radians Cos Cosine Radians Atan Arc tangent Radians Loge Natural logarithm base e Log10 Logarithm base 10 Exp Exponentiation of e 2 71828 5 8 4 Analog
218. so on The priority for each of the selection modes is defined by the user between the choices low medium or high But the user can also disable completely a mode if he she doesn t want to use it To avoid conflicts it is strongly recommended that each selection mode has a different level of priority The Selection mechanism provides a fourth choice beyond the Local Computer and Remote Setpoint This choice consists in not selecting any setpoint and passing the responsibility of the selection to the immediately lower priority mode SetPoint selection mechanism No Setpoint Loc Com i 5 selection Example In the example below the properties are assigned as follows Keyboard Digital Inputs TAG 0000 0 Rem L R TAG 0000 0 Com L R TAG 0000 0 Rem TAG 0000 0 MAN Chapter 5 Modules 1 The Local setpoint is selected pressing the L R key 2 The Remote setpoint is selected pressing the L R key 3 The Computer Setpoint is selected pressing the L R key 4 Pressing again the L R key the no selection option is chosen for the keyboard Therefore the highest priority mode after the keyboard is the one driving the output This mode is the one based on the digital inputs whose status is selecting the Remote Setpoint 5 Later on the digital inputs are set to the no selection status Therefore it is the
219. strategy The termination blocks 25 and 26 are providing a 24V DC output particularly suitable to supply of the 2 wires transmitters 211 Variable 1 NE Variable 2 ca A a N N Var Retr 1 Variable 3 315 5 Var Retr 2 Variable 4 ms G o Var Retr 3 7 U ral T Var Retr 4 2 Al 1 10 gt Var 1 11 2 3 Al Var 2 ar gt 14 Al 15 AlS Var 3 Al 6 Al 7 gt Var 4 Al 8 Power Supply 206 Annex A Resident Configurations 23 A M Station 23 1 Description The drawings below are providing the following informations Block Diagram User interface consisting in a set of display panels Termination unit for the connection to the field The description of the control functionalities is reported in the following pages related to the AM station 1 only The functionality of the AM station 2 is perfectly identical but with the index numbers of the modules different To the get the proper index numbers for AM station 2 refer to the Block Diagram 23 2 Block Diagram In the following block diagram the interconnections between the various modules and the display panels are not indicated in order to improve the understanding of
220. string of 3 characters maximum It is entered and modified through AC_Edit AC Prograph 3 Main Variable Value Numerical visualization of the main variable consisting of 6 characters including the sign and the decimal point 4 Scrolled Variable Tag This 3 character label specified by the Customer identifies the scrolled variable displayed The following ones are some examples of tags as already defined in the resident configurations In the custom strategies these tags are almost defined by the user but the ones related to general variables like the Working Setpoint etc TSP Target Set Point value of the Setpoint WSP Working Set Point value of the Set to the PID module RSP Remote Set Point value of the Setpoint input signal CSP Computer Set Point value set by the Computer PV1 Process Variable 1 value of the main variable n 1 PV2 Process Variable 2 value of the main variable n 2 WSR Working Set Ratio value of the ratio setpoint 5 Scrolled Variable Value Numerical display of the selected scrolled variable The list of the variables includes the Local Setpoint and other analog input signals of the module It consists of 6 characters including the sign and the decimal point 6 Setpoint Operating Mode This short mnemonic reports the current Setpoint operating mode of the loop The various modes are Loc Rem Com 22 Chapter 3 Commissioning and start up 7 Scale high low Limits They define the v
221. t for the loop on the basis of the selected type of ratio direct or reverse as in the following formulas Direct ratio PV2 x Ratio Setpoint WSR Inverse ratio PV2 Ratio Setpoint WSR The Working Setpoint Ratio WSR is the target setpoint for the controlled variable PV1 it is the setpoint considered in the calculation of the PID deviations and in the visualisation of the display panel The output of the loop suitable for driving the actuator is transmitted out through the AO1 module Standard Loop The controlled variable PV3 is acquired though the Al4 module providing the conversion in engineering units and the out of range detection It is transmitted to the SET DEV module that with the PID2 and CONTROL OUT modules makes up the core PID block The output is transmitted out on the terminal blocks through the AO4 module for driving the external actuator The bias feature consists in adding to the ratio setpoint set in the SP DEV module a value provided through the BIAS input AI3 The result of the sum of these two values provides the resultant ratio setpoint that multiplied or divided by the reference variable PV2 gives the Setpoint of the controlled variable This feature is enabled when the digital input DI5 is in the active state 18 5 Remote Setpoint This feature is supported on the standard loop Loop 2 only and it is enabled by the active state of the DI6 digital input The Remote Setpoint is selected a
222. t provides both the trend of 2 variables and the status displays and the user commands to the Setpoint programmer Furthermore it represents the status of 2 general purpose logic signals The time span of the trend chart is defined by the user by choosing between the following set 1 2 5 10 30 min 1 2 5 hours 4 TAG 0000 0 2 oa 3 20 5 48 i 16 CON a 6 E i 16 8 ge _ 15 44 9 4 40 43 41 42 gt gt Q This tag is the identifier of the panel and consists of up to 10 alphanumeric characters It is assigned automatically when the module is created and can be modified through AC_Edit AC Prograph 2 Engineering Units Engineering units mnemonic consisting of a string of 3 characters maximum lt is entered and modified through AC_Edit AC Prograph 3 Scrolled Variable Tag This 3 characters label specified by the Customer identifies the scrolled variable displayed Chapter 3 Commissioning and start up Pressing the Q button the tag together with the corresponding value of each variable of a list is displayed one at a time and sequentially The list includes the LSP and the 5 analog input signals of the module 4 Trend chart high low scale Limits They define the values of upper and lower limits of the scale Each value consists of 6 characters including the sign and the decimal point 5 Trend Chart Area dedicated to the graphic display of the recent trend
223. t signal or the signal from another actuator leaving the possibility of performing manual or automatic forcing operations One example is the control of the lower heating zone of a furnace that must be proportional to the heat demand of the upper zone In this case the PV1 input to the A M station is the control output of the actuator of the upper zone that probably is driven by a temperature PID loop A ratio coefficient can be set in the Constant module of the A M station in order to define the ratio value between the level of outputs of the two actuators The Tracking forcing mode that allows to bypass the normal way to control the actuator from the upper one by driving it directly from the external signal Al2 is particularly useful for handling emergencies and start ups 00000000 209 Installation and User manual of the AC10 AC20 AC30 controller 210 23 8 Electrical Connections The following picture provides a clear view of all the termination blocks with the associated functionality and it is specific of this configuration No signals must be connected to the termination blocks not used by the strategy The termination blocks 25 and 26 are providing a 24V DC output particularly suitable to supply of the 2 wires transmitters o jl in ol lala o n A M 1 PV1 input Station PV2 TRK Actuator 1 Station
224. tal input to one of the 6 DO1 DO6 digital outputs that has been selected The other not selected outputs are set to 0 The output is selected by one of the two following modes a Static mode by mean of a parameter set during the configuration of the strategy specifying the number of the output DO1 DO6 to select b Dynamic mode through a 3 bit code from the DS1 DS3 inputs specifying the output number according to the following table DO1 DO2 DIN gt DSEL DO3 DO4 DO5 DS1 gt DO6 DS2 y DS3 gt I O Connections DIN_____ Input to demultiplex DS1 3 Selection enable inputs DO 1 6 Outputs Parameters DSEL _1 DOut 1 Choice DOut1 Displayed Parameters Sel Code Specification of the selection mode to use dynamic or static 5 5 27 Hardware Digital Demultiplexer DS8 Description Chapter 5 Modules This module is a 1 to 8 demultiplexer of digital signals It retransmits its DIN digital input to one of the 8 DO1 DO8 digital outputs The output is selected through the 3 bit code on the DS1 DS3 input as listed in the following table The other not selected outputs are set to 0 Furthermore the module can be selected or deselected through an external input DSEL Once the module is deselected its DOn output will hold the value it had before the deselection until further selected I O Connections DIN Input to demultiplex Selection inputs DS4 3 DSEL Selection enable input Out
225. tal inputs DIN1 D DOUT DIN2 I O Connections DIN Digital Input 1 DIN2 Digital Input 2 Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument panel 5 8 9 8 Inputs OR OR8 Description This modules performs the Boolean OR between 8 digital inputs DIN1 DIN2 DIN3 DIN4 DIN5 DIN6 DIN7 DIN8 DOUT OR_8 YY WY WY Y YY Y 1 O Connections DIN 1 8 Digital Inputs OUT Output with the result of the OR operation Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument panel 119 Installation and User manual of the AC10 AC20 AC30 controller 5 8 10 Flip Flop J K LATCH JKF Description This module performs a J K Latch Flip Flop with two digital inputs DIN1 gt JKF DOUT DIN2 I O Connections DIN 1 Digital Input 1 DIN2 Digital Input 2 DOUT Output Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument panel 5 8 11 D LATCH Flip Flop Description This module operates as the classical Flip Flop D Latch with 3 digital inputs setting the output according to the timing chart below DT CLK _ DOUT RST 1 O Connections Data digital input Reset DOUT The output is calculated on the basis of the DT Clk and RST digital inputs as illustrated below Parameters This module doesn t have a
226. tant stored in Annex A Resident Configurations the MCNS module MSP if the digital input DI2 is active The truth table below lists all the various combinations of setpoint om D2 Selected value x Input Al2 15 5 Forcing Operations 15 6 Alarms These operations are related to the loop output and consist of the Hold and Tracking mode a Tracking the Tracking mode sets the output to the value of constant named Ysaft until DI4 is active b Hold The Hold mode freezes the loop output until the DI3 digital input is active There are three alarms either on the controlled variable PV1 or the deviation according to the parameters selected in each of the ALM modules The module WSP PV computes the deviation in the same engineering units of the controlled variable PV The status of each alarm is retransmitted out through the DO1 DO2 and DO3 modules A fourth alarm the digital output DO4 flags the out of range of the variable PV 15 7 Variables Retransmission The controlled variable PV1 is retrasmitted out to the termination unit through the SCH PV L1 and AO2 modules The module SCH PV L1 allows the modification of the ranges of the retrasmitted output that are not necessarily the same of the PV1 input This is achieved by setting the input range parameters of the SCH PV L1 module to different values than the output range parameters In this way the range of the variable can be changed in order to conside
227. tches for the bias and the termination of the line are located inside the instrument close to the gold dual edge connector of the CPU card Refer to Fig 4 5 below Termination 3 1 Bias Fig 4 5 Detail of the CPU card with the switches for the termination and the bias of the line For more information on the MODBUS and JBUS protocol consult the Communication manual Cod J30 304 1ACSAC 4 4 3 Handling the Aux Comm This serial port is provided on the AC20 and AC30 controllers only and uses the RS485 standard Its purpose is the transfer of real time data between the Controller and Expansion units mod AAC EU 88 4 or AAC EU 88 or the safety station currently under development To get this connection operating the user has just to make the appropriate cabling because all the hardware and the firmware required is already on board and doesn t require any configuration Refer to Chapter 2 4 9 for the diagram of the connections Once the Expansion unit is connected its I O can be easily used in the strategy you are designing with the AC_Prograph as any other signal from the controller For more detail refer to the AC_Prograph User Manual cod J30 304 AACPROGRAPH Chapter 4 PID Tune and Communications 4 4 4 Handling the LAN ARCNET The interface card to this network is supplied as an option on the AC20 and AC30 controllers only The purpose of this network is to handle the peer to peer communication be
228. ters tag of up to 12 analog variables connected to it as analog inputs The value is shown either as a 6 digits number without decimal point or as a 5 digits number with decimal point Tag of the Panel 10 char max Value max 6 digits a Tag max 6 char Max 12 indicators Al Al2 Al3 Al4 AI5 Al6 Al7 Als Al9 Al10 Al11 Al12 I O Connections Analog Inputs Each of these inputs is associated with a position on the panel where its value and its tag is displayed 70 Chapter 5 Modules Parameters 12 Display XXXXX AIN2 XXXXX Displayed Parameters Format defines the number of digits of the 4 measured variables Both the tag and the engineering units of each measure are configured through the AC Prograph and AC Edit only Number of the variables displayed on the panel 5 4 4 System CLK Date and time display panel Description This display is automatically shown on the AC30 front panel and is not associated with any module of the strategy It s a standard basic function of the instrument that is provided independently of the strategy The display of the panel can be disabled through the F Panel View item of the Tune amp View menu When this display is shown the only operations the user can do is to change the date and time These operations can be done either from the keyboard or through the serial communication Main Comm The clock is battery back
229. the controlled variable PV3 The status of the alarm is retransmitted out through the DO8 module 185 Installation and User manual of the AC10 AC20 AC30 controller 186 18 8 Graphic Displays TSP ALARMS FORZAM RATIO _WSP d PV of the select RSP OR of the alarms e CSP Requested LS Sel Loop operating mode tae WSP loop sel Current operating mode Loc A T t ti di Selected Loop p e Loop TAG area Sa eee A e Requested operating mode WSP loop 1 e UNDERFL PV1 _ OR of Forcing modes PV loop 1 e WSP loop 2 PV loop 2 e e Alarm 1 WSP loop 3 EE EE AM PV loop 3 OR ofthe Alarms e Aut Man stations Aut Man Station 8 MV loops TSP TSP TSP RATIO L WSP LOOP2 L WSP LOOP 2 WSP RSP RSP RSP Al4 CSP Al4 e CSP MSP CSP LSP LSP LSP Loc Current operating mode Loc Current operating mode Loc Current operating mode Requested Requested Requested operating mode OR of Forcing modes Alarm 1 ORof the Alarms Aut Man station operating mode operating mode _ OR of Forcing modes OR of Forcing modes e Alarm 1 Alarmi e OR of the Alarms OR of the Alarms
230. the functionality performed Cees 0 9 9990 Y Y Y Y YN A Al2 An Dn bale DIA Al Al3 os pis os PV3 A pv1 a ji pv2 PV4 Y 2 MUXK n A 2 MUX ol gt x o x y YY Y 107 Es y y Y Y to gt ALM ALM ALM ALM i Y ALM ALM ALM ALM M 1 y 1 2 3 4 pig o 5 lle i 7 8 Lio 1 N W 3 N mu COST q AM a COST AM 2 y 4 DHOLD CONTROL q CONTROL q 2HOLD Y OUT a DIRK e 44 gt a An Y MAX 2 gt TRK L gt DB2 DB2 OR1 ae SCH Y Y Pv2 OR MSL T y Y OR VVISU lt 4 a lt lt 4 4 x o amp y OUT OR1 A Ol I 5 C A M E q ______ gt 2 2 Soltek D6 OSS e 3 ento 7 bo Y MIN gt 4 V eps i VISU MUX TRIS DB1 VISU MUX TRI N SE O 8 lt Ek El Sgk S S S S S This configuration offers 2 A M station for driving two actuators The features of each A M station include the Auto and the Manual operating mode 4 Forcing modes 4 alarms modules and a ratio calculation on the input variable When in MAN mode the output
231. the instrument panel 5 8 18 Digital To Analog Converter D A Description This module converts a 16 bit binary number provided through 16 digital inputs into a number The number is transferred out through the analog output of the module with range O to 65535 The Carry output is not available DI DI2 DI3 DI4 DI5 DI6 DI7 DI8 DI9 D110 D A i gt OUT pe UUUOUOU S354 5 a kwOnND DI16 I O Connections Analog Output Di1 D116 Digital Input Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument panel Chapter 5 Modules 5 8 19 AND_8 Block AND8 Description The block performs the AND logic function of the DIN1 DIN8 inputs The non configured inputs are put to ON DIN1 DIN2 DIN3 DIN4 DINS DIN6 DIN7 DIN8 AND8 DOUT YY Y J NI N Y VY Description of connections Dna Ditaip O DIN2 Digialimputz DNs Digialimput3 DIN4 Digitalinput4 DINS DING DIN7 DIN 7 Dns Digitarimput Parameters This block has no parameters and is not displayed on the Controller 5 8 20 Shift Block SHFT Description The block performs the logic SHIFT function on 16 outputs By switching the UP input from OFF to ON the output bits DO1 D016 are moved one position forward and the DO1 output is put to the value present on DIN1 SHIFT UP By switching the DN input from OFF to ON
232. the one generating the setpoint for the Slave loop are displayed on the left bargraph while the ones of the Slave are on the right The control output of the Slave is displayed in the lower part of the panel Both the setpoints are displayed but only the one of the Master can be changed from the keyboard Main Variable PV1 Tag 10 char 6 char with sign and dp Main Variable Scrolled variables values in engin units 6 chars with sign and d p 3 char Al 1 2 3 4 5 e LSP a Setpoint operating mode M ic 3 ch nemonic 3 char MOL Scale High range Requested Setpoint Mode 6 char with sign and dp Loc Rem Com Logic Variables display Bar graph 2 BI2 3 char strings Slider 2 C12 DI1 2 3 gt Out station operating mode Slider C11 AUT MAN DA M Bar graph BI1 Output value Scale Low range in Y Al Al2 Al3 Al4 AI5 Bl1 BI2 ci Cl2 PV1 Y DI1 DI2 DI3 LSP MODE gt DA M Chapter 5 Modules I O connections Digital inputs whose status is displayed through a 3 characters label The most common use is to flag alarms or other digital events Analog variables displayed numerically in the scrolled list with a short 3 characters mnemonic The number of displayed inputs can be set though the parameter items in the module 2 Bargraph Edit of AC Prograph AC Edit For the above refer to Section 9 10 2 of the manual Analog Input disp
233. the original disks in a safe place Any copy of this software for purposes different than the configuration of the ASCON AC series controllers is forbidden The use of the software is regulated by the licence agreement provided by the Supplier D Package contents verification When you open the package of an AC10 AC20 o AC30 multifunction controller check that all the items correspond to the packing list below If an item is missed or damaged you must contact the nearest ASCON sales office 1 AC station 2 Mounting clamps 3 User and Installation manual consisting of this book 4 Communication manual Chapter 1 General Information MULTIFUNCTION PROGRAMMABLE CONTROLLER 1 General information 1 1 Main differences between AC10 AC20 and AC30 The AC series controllers are supplied in the following 3 versions AC10 AC20 AC30 4 control loops 4 analog inputs 4 analog outputs 8 digital I O with 12 control strategies stored in the instrument memory and executed upon command from the front panel The parametrisation of the controller is performed through one of the following 3 ways directly from the instrument panel through the serial comm Main Com and by mean of the AC Prograph AC Edit running on Windows 4 control loops 8 analog inputs 4 analog outputs 8 digital I O with 12 control strategies stored in the instrument memory and recalled from the front panel The parametrisation of the controller is perform
234. ther sources than the straight PID algorithm by mean of the DI3 4 5 6 digital inputs These modes are related to the CONTR OUT module and therefore are common and influence both the loops a Tracking it is enabled by the DI4 digital input and it consists in setting the control output to a predefined constant value of the MCNS module b Hold when DI3 is active the control output is frozen at the value it had at the time of the rising transition c Hold Ymax When both DI3 Hold and DI5 are active the control output is forced to its maximum value defined by the parameters of the CONTROL OUT module d Hold Ymin When both DI3 Hold and DI6 are active the control output is forced to its minimum value defined by the parameters of the CONTROL OUT module An important point to bear in mind is that all these 4 forcing modes are handled by the module according to the following priority A M Ymin Ymax Hold and Track Di3 os Die SelectedValue Main Loop There are three alarms either on the controlled variable PV1 or the deviation according to the parameters selected in each of the ALM modules The module WSP PV computes the deviation in the same engineering units of the controlled variable PV1 The status of each alarm is retransmitted out through the DO1 DO2 and DO3 modules The out of range of the variable PV1 is detected and retransmitted out through the digital output DO4 Annex A Resident Configurati
235. ther segment will follow the current one Chapter 5 Modules Program No n New Program This command allows you to enter a new program from scratch The first thing to do is to select from the menu Program List the number of the Program This menu will list all the 16 programs of a PRG module reporting the status of each of them the total number of segments used and the quantity of available segments Program No 2 Prg List Prg List RJ After having set the program number you proceed with the definition of the new program by entering first the basic informations and after the data of all the segments of the Program as illustrated in the picture below PRG_1 Prg No 2 m Program No 2 New Program Prg No 2 Edit Seg PRG NO 2 m s 0 x S P Val 50 Time m s Seg No 0 a E E RJ Detail of the PRG No n Through this panel all the basic parameters of your program are provided Selected Time units Time factor for Fast mode N of program cycles Definition of the actions to take after a Power Fail Additional parameters lt related to Power Fail High range of the Setpoint Low range of the Setpoint Format of the Setpoint 131 Installation and User manual of the AC10 AC20 AC30 controller 132 Description of the Parameters Time It specifies the ti
236. through AC_Edit AC Prograph 2 Indicators Area Area for the display of the analog input variables Each line of the display offers both the tag and the value of one of the 12 analog input signals 31 Installation and User manual of the AC10 AC20 AC30 controller 3 Variable Tags This 6 characters label specified by the Customer identifies the displayed variable 4 Variable Values Numerical display of the analog input signal It consists of 6 characters including the sign and the decimal point 3 3 8 4 Analog Display Panel This display provides the functionalities of a set of analog indicators It displays the value the 10 characters tag and the 3 characters engineering units of up to 4 analog variables connected to it as analog inputs The value is shown either as a 6 digits number without decimal point or as a 5 digits number with decimal point This tag is the identifier of the panel and consists of up to 10 alphanumeric characters It is assigned automatically when the module is created and can be modified through AC_Edit AC Prograph 2 4 6 8 Variable Tags This 10 alphanumeric characters label specified by the Customer identifies the displayed variable 3 5 7 9 Engineering Units Engineering units mnemonic consisting of a string of 3 alphanumeric characters maximum 10 11 12 13 Variables Values Numerical display of the analog input signal It consists of 6 characters including the sign and the decima
237. time between an open and a close command and vice versa TRVL Servomotor travel time in seconds DBND Dead band in Open Close Loop selection Parameters This block has no parameters and is not present in the Controllers configuration menu 109 Installation and User manual of the AC10 AC20 AC30 controller 110 5 6 Supervisory I O Modules 5 6 1 Analog I O to Computer CAIO Description This module consists of 8 analog values corresponding to input or output values of the strategy that can be easily accessed through the RS485 JBUS serial port Main Comm by a Supervisory computer The computer accesses the variables by writing in the input ones and reading the output ones A maximum of 4 modules of this type can be included in the strategy gt alo1 K alo2 k _ gt Alo3 COMPUTER 4 gt AOS gt k _ gt AlO5 k _ _ alo6 k _ gt Alo7 K alos I O Connections AlO 1 8 Analog I O Computer JBUS Addresses of the register with the I O values Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument panel 5 6 2 Digital I O to Computer CDIO Description This module consists of 8 digital values corresponding to input or output states of the strategy that can be easily accessed through the RS485 JBUS serial port Main Comm by a Supervisory computer The computer accesses the variables
238. tive the label FOR is displayed These are global flags the detailed cause of the event is shown in the ALARMS panel where the digital status of each alarm and forcing input is clearly shown These are ALL 1 Alarm 1 ALL 2 Alarm 2 ALL 3 Alarm 3 UNDERFL Input Al1 out of range for 1 5V or 4 20 mA signals only TRACKING Force the control output to a predefined value HOLD Freeze the control output 12 9 Applications This easy to use configuration is for simple applications where the control requirements need some additional functionalities than the basic classic PID loop like the availability of multiple setpoints remote or predefined selectable through an external digital signal Furthermore this configuration offers the possibility to acts on the control output both by forcing it to a predefined value and by freezing it upon an external command The multiple alarm modules offer an effective tool for monitoring continuously the controlled variable and for detecting anomalous changes The retransmission of the controlled variable over a different range improves the resolution of the signal because it is limited to the meaningful portion of the original range zoom effect 157 Installation and User manual of the AC10 AC20 AC30 controller 12 10 Electrical Connections The following picture provides a clear view of all the termination blocks with the associated functionality and it is specific of this configuration No si
239. to use dynamic or static 93 Installation and User manual of the AC10 AC20 AC30 controller 5 5 18 Hardware Digital Multiplexer DMX8 Description This module is an 8 to 1 multiplexer One of the 8 inputs DIN1 DIN8 selected by mean of the 3 bit code on the DS1 DS3 inputs is retransmitted on the OUT output Furthermore the module can be selected or deselected through an external input DSEL Once the module is deselected its OUT output will hold the value it had before the deselection until further selected The input to multiplex is selected with the DSEL signal in the active state by mean of the inputs DS1 DS3 as in the following table Input transmitted to OUT Input transmitted to OUT DN8 O DIN 8 I O Connections DIN 1 8 Inputs to multiplex DS 1 3 Selection Inputs DSEL Selection enable input Output Parameters This module doesn t have any parameter and therefore it is not displayed on the instrument panel 94 Chapter 5 Modules 5 5 19 Mass Flow MFL Description This modules converts a raw flow or a differential pressure measurement into a pressure and temperature compensated flow measure in order to compute the exact mass flow of the fluid The compensated flow is retransmitted as an analog value FOUT to other modules like PID or totalizers QIN gt TIN MEL FOUT PIN gt I O Connections Raw flow or differential pressure in engineering units Flui
240. tpoint of the Slave is displayed in engineering units as a Setpoint value The only setpoint the user can change is the one of the Master because the one of the Slave is just displayed 1 4 5 4 0 a 1 9 oN hal N5 8 E O 7 YES Sey 14 23 Installation and User manual of the AC10 AC20 AC30 controller 24 1 Tag This tag is the identifier of the panel and consists of up to 10 alphanumeric characters It is assigned automatically when the module is created and can be modified through AC_Edit AC Prograph 2 Engineering Units Engineering units mnemonic consisting of a string of 3 characters maximum It is entered and modified through AC_Edit AC Prograph 3 Main Variable Value Numerical visualization of the Master controlled variable consisting of 6 characters including the sign and the decimal point 4 Scrolled Variable Tag This 3 characters label specified by the Customer identifies the scrolled variable displayed The following ones are some examples of tags as already defined in the resident configurations In the custom strategies these tags are almost defined by the user but the ones related to general variables like the Working Setpoint etc TSP Target Set Point value of the Setpoint WSP Working Set Point value of the Set to the PID module RSP Remote Set Point value of the Setpoint input signal CSP Computer Set Point value set by the Computer PV1 Process Va
241. tterns of the outputs 67 Installation and User manual of the AC10 AC20 AC30 controller oh DO1 D2 gt DO2 DS _ SELP DO3 D4 gt DO4 I O Connections Digital Inputs specifying a 4 bit number from 0 to 15 corresponding to the output pattern If the Digital Input mode is the selection mode with the highest priority the digital outputs DO1 DO4 will assume the value of the inputs The item name displayed on the panel is configured through the AC Prograph or AC Edit program only DO1 DO4 Digital Outputs set according to the item selected and the priority arbitration result 5 4 1 Four Analog Display Panel 4ADP Description This module provides the functionalities of a set of analog indicators lt displays the value the 10 characters tag and the 3 characters engineering units of up to 4 analog variables connected to it as analog inputs The value is shown as a 6 digits number without decimal point or as a 5 digits number with decimal point Tag of the Panel 10 char max Tag input 1 10 char max Value 1 Engineering units 3 char max Tag input 2 10 char max Value 2 Engineering units 3 char max Tag input 3 10 char max Value 3 Engineering units 3 char max Tag input 4 10 char max Value 4 Engineering units 3 char max Al D Al2 D aig y 4ADP Al4 y I O Connections Analog Inputs Each of these
242. tween all the devices on the LAN Local Area Network This LAN offers two big advantages 1 It allows the softwiring between up to 8 controllers located on 120 mt of cable maximum distance between the first and the last controller without any additional hardware or software This easy to use functionality with the plug and play feature provides the transmission of real time signals among the controllers required for developing global control strategies involving a cluster of AC controllers 2 It provides a communication media 2 5 Mbit s to a Supervisory computer faster than the RS485 serial line This feature that requires an appropriate hardware and software interface on the computer side is particularly useful in high performing application For more details refer to the Communication manual Cod J30 304 1ACSAC The setting of this port is carried on as follows TAG 0000 0 Main Parameters LAN Addr Menu amp Comms i LAN Addr 1 Loc O Par amp Comms El E A LAN Address pa oE a a a 4 5 Parameter change You can modify the parameter values assigned by AC_Prograph to the modules of the strategy by carrying on the following procedure TAG 0000 0 Main Parameters Menu of PID PID_LOOP 1 Menu amp Comms All Blocks Block Rev Tune amp Views Parameters PID_LOOP 1 fay E El E PID Block
243. uator 2 PV4 Loop4 z c o Actuator 3 7 U T Actuator 4 E Al 1 Loop 1 a2 JP Al 3 LL o Loop J Hold Ara K Track Al 5 ij 3 Lool Loop2 4 Hold Al 6 R Track i Al 7 i j Hold dd Loop 3 ANOS p Track ERE Hold POWER SUPPLY Track 203 Installation and User manual of the AC10 AC20 AC30 controller 22 4 Indicators 204 22 1 Description The drawings below are providing the following informations Block Diagram User interface consisting in a set of display panels Termination unit for the connection to the field This configuration provides the monitoring of 4 analog inputs with 2 associated alarms and retransmission of the variable after an optional reranging operation The alarms are fully configurable but usually they are programmed one as a low alarm and the other as an high alarm For this reason this common high low configuration has been used in the picture below 22 2 Block Diagram In the following block diagram the interconnections between the various modules and the display panels are not indicated in order to improve the understanding of the functionality performed Y ALM lt e gt 7 ALM ALM t gt ALM ALM lt t e gt ALM ALM lt t gt ALM 1 2 3 4 5 6 Le 8 OR 4 0 eo lt hg e gt lt La
244. ugh the DO1 2 3 4 digital inputs 23 5 Variables Retransmission Both the input variable Al and Al2 are retrasmitted out to the termination unit through the SCH PV module The SCH PV module allows the modification of the ranges of the retrasmitted output that are not necessarily the same of the original input This is achieved by setting the input range parameters of the SCH module to different values than the output range parameters In this way the retrasmitted variable can be limited to a portion of the input signal scale with the advantage of an improved resolution 23 6 Graphic Display ST1 ST2 i PV of the OR of Alarms Selected Station Requested Var Sel Stat o operating mode Var Sel Stat LOCe Current operating modes Selected Station PV1 e Station TAG MV Station 1 e PV1 Station 1 j MV Station 2 o PV1Statin2 E ES Aut Man Station A Ae Aut Man Station MV Station 1 P e MVSTation 2 PV1 STAM1 eva PV3 PV4 e Ww OR of Forcing modes e Alarm 1 OR of Alarms Aut Man Station 208 ALARMS FORZAM ST A M 2 PV1 H PV2 PV3 PV4 e W OR of Forcing modes e Alarm 1 OR of Alarms Aut Man Station Annex A Resident Configurations This configuration offers 5 displ
245. ule computes the derivative of the signal at the input IN and compares it with a low and high thresholds defined by the user If the derivative of the signal is between the two threshold the alarm is off otherwise is on When the alarm is on the OUT digital output goes in the active state IN gt SALM OUT I O Connections IN input OUT Parameters SALM _1 0 SI Min 0 Displayed parameters High rate alarm threshold Low rate alarm threshold Alarm Hysteresis Format Format it defines the number of digits of the values above 101 Installation and User manual of the AC10 AC20 AC30 controller 5 5 24 Analog Software Demultiplexer ASEL Description This module is a 1 to 6 demultiplexer of analog signals It retransmits its IN analog input to one of the 6 OUT1 OUT6 analog outputs that has been selected The other not selected outputs are set to 0 The output is selected by one of the two following modes a Static mode by mean of a parameter set during the configuration of the strategy specifying the number of the output OUT1 OUTE6 to select b Dynamic mode through a 3 bit code from the DS1 DS3 inputs specifying the output number according to the following table Selected Output OUT OUT 1 1 OUT 2 1 OUT 4 OUT 5 1 OUT 6 DS 1 0 pt oO oras 1 Oo i a OUT1 OUT2 IN Y ASEL OUT3 OUT4 DS1 gt OUTS DS2 gt OUT6 DS3 gt I O Connection
246. urrent operating mode WSP Slave Reme Current operating mode Requested operating mode Requested operating mode y OR of Forcing modes WSP Master ALLARME 5 Slv 1 OR of Forcing modes PV Master Alarm 1 PV Slave LS e ALL 1 OR of Alarms e OR of Alarms Aut Man station e Aut Man Station Master scale Low Limit e e Slave scale Low Limit A DN e gt Valve position TSP TSP TSP MASTER WSP SLAVE L WSP SLAVE L WSP RSP RSP RSP Al CSP Al4 e __ CSP e MSP e CSP LSP LSP LSP Loc Current operating mode Loc Current operating mode Loc Current operating mode Requested e Requested Requested operating mode operating mode operating mode OR of Forcing modes _ OR of Forcing modes OR of Forcing modes Alarm 1 e Alarm 1 Alarm 1 OR of Alarms OR of Alarms OR of Alarms Aut Man station Aut Man station Aut Man Station The pictures above show the different types of display panels providing the most effective interface for this strategy configuration The panel with the 2 bargraph provides by itself a complete interface of both the loop Referring to the 2 bargraph display the Master controlled variable is displayed
247. utput is set continuously to the value OUT F IN Out F In P x1 y1 P x2 y2 P x3 y3 P xn yn Value In IN gt CHAR OUT I O Connections IN Analog input in engineering units Analog output in engineering units Parameters LIN_4 X Pnt 1 0 Displayed Parameters X Pnt 1 12 Value in engineering units of the coordinate IN for a breakpoint Y Pnt 1 12 Value in engineering units of the coordinate OUT for a breakpoint Format it defines the number of digits of the breakpoint coordinates No Pts Number of breakpoints X Y with range form 2 to 12 Chapter 5 Modules 5 5 13 Minimum and Maximum Selector MAX Description This module has two inputs and can be configured to select the minimum or the maximum of these two inputs The input selected is retransmitted out through the OUT output IN1 py MAX OUT I O Connections Analog input signal n 1 IN2 Analog input signal n 2 Output OUT Output Parameters MIN _ 1 Min Function Min Displayed Parameters Function Selection of the operation to perform on the two analog input signals Min for the minimum and Max for the maximum 89 Installation and User manual of the AC10 AC20 AC30 controller 90 5 5 14 Software Analog Multiplexer AMUX Description This module is a 6 to 1 multiplexer of analog signals One of the 6 inputs is retransmitted on the OUT output Th
248. wing steps Once reached the LCD Contrast panel the contrast of the display is changed pressing the ZN and the button The LCD display reflects automatically the new setting When the preferred contrast has been achieved the E button must be pressed in order to store permanently the new setting After the setting the contrast is automatically varied according to the temperature changes in order to compensate the drift caused by the temperature and achieve an optimal readability over the entire temperature range of O 50 C TAG 0000 0 Main Tuning and LCD Menu View Contrast Tune amp Views a E E PID Param E R R E R 7 2 Error messages The AC controller is provided with a diagnostic system capable to detect a wide range of faults and automatically alert the operator Most of this faults are caused by wrong assignment of parameters or other mistakes in the instrument configuration When one of these anomalous situations arises the display is completely blanked and an error message appears in order to alert the user The operator must acknowledge the message by pressing at the same time the a and ka keys As a consequence the message disappears and the display returns to its previous conditions The following are the various error message that the AC controller handles e Net Ovrf e Due to NET This message flags anomalous situations on the netwo
249. y tuned and kept as much as possible close to the predefined setpoint The operation of keeping the variables close to the setpoint is called regulation and the PID is the PID is one of the tool that does it To understand how the regulation process works we have to consider that the process is a system whose behaviour is determined by the 3 class of magnitudes as shown in fig 1 controlled variable manipulated variable and disturbances The controlled variables are the chemical physical and electrical magnitudes that must be controlled and kept at the setpoint in order to produce efficiently and with an high degree of quality For instance pressures levels flows temperature etc are controlled variables They are usually named with the mnemonic PV process value while its setpoint is named SP The manipulated variables are the ones the regulation system moves continuously in order to carry out the control action and keep stable and close the controlled variable to the setpoint For instance air water oil gas energies fuels etc are manipulated variable The disturbances are transient situations related to physical magnitudes that interfere randomly and abruptly with the process and have the effect of moving PV far away from SP For instance the simple change of the Setpoint can be considered a disturbance Therefore the purpose of controller is to carry out all the actions required to satisfy the equation PV

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