Rockwell Automation Allen-Bradley 1746-BTM Bedienungsanleitung

BarrelTemperature

Control Module

1746-BTM

User Manual

Important User Information

Because of the variety of uses for the products described in this

publication, those responsible for the application and use of this

control equipment must satisfy themselves that all necessary steps

have been taken to assure that each application and use meets all

performance and safety requirements, including any applicable laws,

regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown

in this guide are intended solely for purposes of example. Since there

are many variables and requirements associated with any particular

installation, Allen-Bradley does not assume responsibility or liability

(to include intellectual property liability) for actual use based upon

the examples shown in this publication.

Allen-Bradley publication SGI-1.1, Safety Guidelines for the

Application, Installation and Maintenance of Solid-State Control

(available from your local Allen-Bradley office), describes some

important differences between solid-state equipment and

electromechanical devices that should be taken into consideration

when applying products such as those described in this publication.

Reproduction of the contents of this copyrighted publication, in whole

or part, without written permission of Rockwell Automation, is

prohibited.

Throughout this manual we use notes to make you aware of safety

considerations:

Attention statements help you to:

•identify a hazard

•avoid a hazard

•recognize the consequences

Allen-Bradley is a trademark of Rockwell Automation

ATTENTION Identifies information about practices or

circumstances that can lead to personal injury or

death, property damage or economic loss

IMPORTANT Identifies information that is critical for successful

application and understanding of the product.

European Communities (EC)

Directive Compliance

If this product has the CE mark it is approved for installation within

the European Union and EEA regions. It has been designed and

tested to meet the following directives.

EMC Directive

This product is tested to meet the Council Directive 89/336/EC

Electromagnetic Compatibility (EMC) by applying the following

standards, in whole or in part, documented in a technical

construction file:

•EN 50081-2 EMC — Generic Emission Standard, Part 2 —

Industrial Environment

•EN 50082-2 EMC — Generic Immunity Standard, Part 2 —

Industrial Environment

This product is intended for use in an industrial environment.

Low Voltage Directive

This product is tested to meet Council Directive 73/23/EEC Low

Voltage, by applying the safety requirements of EN 61131-2

Programmable Controllers, Part 2 - Equipment Requirements and

Tests. For specific information required by EN 61131-2, see the

appropriate sections in this publication, as well as the Allen-Bradley

publication Industrial Automation Wiring and Grounding Guidelines

For Noise Immunity, publication 1770-4.1.

This equipment is classified as open equipment and must be

mounted in an enclosure during operation to provide safety

protection.

1Publication 1746-6.10 - September 1999

Summary of Changes

This manual has been revised extensively. Major changes include:

•Ladder code addresses have been changed.

•The sample ladder code has been extensively changed. As a

result, Chapter 9 has been extensively changed.

•Examples outlining the mathematical relationships involved in

Startup Aggressiveness Factor and Ramp Rates have been

included in Chapter 3

•Appendixes A and B have been omitted. Module specifications

can be found in the BTM Installation Instructions, Publication

1746-5.20

Publication 1746-6.10 - September 1999

Summary of Changes 2

1Publication 1746-6.10 - September 1999

Preface

Using This Manual

This manual shows you how to use the Barrel Temperature Control

Module (cat. no. 1746-BTM) in an Allen-Bradley SLC system for barrel

temperature control and other injection molding or extrusion related

temperature control applications. The manual explains how to install,

program, calibrate, and troubleshoot the BTM module.

Audience

You must be able to program and operate an Allen-Bradley SLC

programmable controller to make efficient use of this module. In

particular, you must know how to configure M0 and M1 files. For

more information, see the appropriate SLC programming manual

before you generate a program for this module.

System Compatibility

System compatibility involves data table use as well as compatibility

with a local I/O chassis and SLC processor.

Data Table

Communication between the module and processor is bi-directional.

The processor transfers output data through the output image table to

the BTM module and transfers input data from the BTM module

through the input image table. The BTM module also requires M files

for configuration and calibration values.

I/O Chassis

You can use this module with 1746-A4, -A7, -A10, -or -A13 chassis,

provided there is an SLC controller in the chassis (local system). You

can place the BTM module in any I/O slot except for the first slot

which is reserved for the processor.

ATTENTION Use the 1746-BTM module in a local I/O chassis only

for barrel temperature control of injection molding

applications or extruders. Any other applications are

not supported.

Publication 1746-6.10 - September 1999

Preface 2

SLC Processor

The 1746-BTM module is compatible with any SLC processor that

supports M0/M1 files, such as the SLC 5/05, SLC 5/04, SLC 5/03, and

SLC 5/02 controllers.

Vocabulary

In this manual, we refer to:

•the barrel temperature control module at the “1746-BTM

module,” the “BTM module,” or as “the module”

•the programmable controller as the “SLC processor”, or “the

processor”

•a thermocouple as a “TC”

•a time-proportioned output as “TPO”

•the tuning-assisted processes as “TAP”

•proportional-integral-derivative as “PID”

•cold-junction compensation as “CJC”

iPublication 1746-6.10 - September 1999

Table of Contents

Chapter 1

Getting Started

Temperature Control Using a BTM Module in an SLC System 1-1

Features of the Temperature Control Module . . . . . . . . . . . 1-2

Module Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Current CV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

TPO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Module Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Response to Slot Disabling . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Input response. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Output response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Chapter 2

Installing and Wiring

Avoiding Electrostatic Damage. . . . . . . . . . . . . . . . . . . . . . 2-1

European Communities (EC) Directive Compliance . . . . . . 2-2

EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Determining Power Requirements . . . . . . . . . . . . . . . . . . . 2-3

Choosing a Module Slot in a Local I/O Chassis. . . . . . . . . . 2-3

Installation considerations . . . . . . . . . . . . . . . . . . . . . . 2-3

Installing the Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Removing the terminal block . . . . . . . . . . . . . . . . . . . . 2-5

Wiring the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Cold Junction Compensation (CJC) . . . . . . . . . . . . . . . . 2-6

Wiring considerations. . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Preparing and Wiring the Cables . . . . . . . . . . . . . . . . . 2-8

Chapter 3

Configuring the Module

Loop Operation Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Word 1, Bits 0 and 1 for Channel 1. . . . . . . . . . . . . . . . 3-1

Type of Loop Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Word 1, Bits 2-5 for Channel 1 . . . . . . . . . . . . . . . . . . . 3-1

Enable Loop Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Word 1, Bit 6 for Channel 1 . . . . . . . . . . . . . . . . . . . . . 3-2

TC Break Response. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Word 1, Bits 7 and 8 for Channel 1. . . . . . . . . . . . . . . . 3-2

Loop Autotune Gains Level . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Word 1, Bits 10 and 11 for Channel 1 . . . . . . . . . . . . . . 3-2

Barrel/Non-barrel Control . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Word 1, Bit 12 for Channel 1 . . . . . . . . . . . . . . . . . . . . 3-3

Barrel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Non–barrel control. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Switching the barrel control . . . . . . . . . . . . . . . . . . . . . 3-3

Inner/Outer Zone Selection . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Word 1, Bit 13 for Channel 1 . . . . . . . . . . . . . . . . . . . . 3-4

Publication 1746-6.10 - September 1999

Table of Contents ii

High/Low CV Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Words 2 and 3 for Channel 1 . . . . . . . . . . . . . . . . . . . . 3-5

TC Break Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Word 4 or O:e.8 for Channel1 . . . . . . . . . . . . . . . . . . . 3-5

Standby Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Word 5 for Channel 1 . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Heat/Cool Minimum On-times. . . . . . . . . . . . . . . . . . . . . . 3-5

Words 6 and 8 for channel 1 . . . . . . . . . . . . . . . . . . . . 3-5

Heat/Cool TPO Period . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Words 7 and 9 for Channel 1 . . . . . . . . . . . . . . . . . . . . 3-6

PV Rate and Associated Alarm . . . . . . . . . . . . . . . . . . . . . . 3-6

Word 10 and Alarm Bit I:e.4/05 for Channel 1. . . . . . . . 3-6

High/Low Temperature and Deviation Alarms . . . . . . . . . . 3-6

Words 11-14 for Channel 1. . . . . . . . . . . . . . . . . . . . . . 3-6

Alarm Dead Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Word 15 for Channel 1. . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Thermal Integrity Loss Detection . . . . . . . . . . . . . . . . . . . . 3-7

Words 16 and 17 for Channel 1 . . . . . . . . . . . . . . . . . . 3-7

Ramp Rates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Words 18 for Channel 1 . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Non-barrel Autotune Disturbance Size . . . . . . . . . . . . . . . . 3-8

Word 20 for Channel 1. . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Implied Decimal Point . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Configuration Block, M1 File, Loops 1-4 N10:0-100. . . . . . . 3-10

Startup Aggressiveness factor. . . . . . . . . . . . . . . . . . . . . . . 3-10

Ramp Rates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Chapter 4

Setting Autotune and Gains Values

Sequence of Setting PID Gains . . . . . . . . . . . . . . . . . . . . . 4-1

Autotuning the Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Fine-Tuning the Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Using the PID Equation. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Entering Autotune/Gains Values with Implied Decimal Point 4-5

Gains/Autotune Block, M0 File, for Loops 1–4 . . . . . . . 4-6

Chapter 5

Control and Autotune a Loop

Controlling a Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

M1 Configuration File. . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Output Image Table. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Autotune a Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Requirements for Autotune. . . . . . . . . . . . . . . . . . . . . . 5-2

Items to check before autotune . . . . . . . . . . . . . . . . . . 5-4

Autotune barrel control applications . . . . . . . . . . . . . . . 5-4

Autotune non–barrel control applications . . . . . . . . . . . 5-7

Items to check if autotune was not successful . . . . . . . . 5-7

Publication 1746-6.10 - September 1999

Table of Contents iii

Using the Output Image Table. . . . . . . . . . . . . . . . . . . . . . 5-8

Operating Commands to Loops 1-4. . . . . . . . . . . . . . . . 5-8

Global Commands to All Loops . . . . . . . . . . . . . . . . . . 5-9

BTM Auto Tune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Chapter 6

Monitoring Status Data

Input Image Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Implied Decimal Point . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Chapter 7

Calibrating the Module

About the Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Calibration Codes and Status . . . . . . . . . . . . . . . . . . . . 7-1

Calibration Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Chapter 8

Troubleshooting the Module

Troublshooting with LED Indicators. . . . . . . . . . . . . . . . . . 8-1

Locating Error Code Information . . . . . . . . . . . . . . . . . . . . 8-2

Chapter 9

Sample Program

Obtaining the Sample Program from the Internet . . . . . . . . 9-1

To Access the Internet:. . . . . . . . . . . . . . . . . . . . . . . . . 9-1

RSLogix500 Version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

BTM Firmware Revision . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Support for 5/03, 5/04, 5/04P, 5/05, and 5/05P Processors

Using BTM20.RSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

BTM20.RSS Data Table Layout . . . . . . . . . . . . . . . . . . . 9-2

Download and Upload Settings . . . . . . . . . . . . . . . . . . 9-3

BTM20.RSS Programming Notes . . . . . . . . . . . . . . . . . . 9-5

Support for 5/02 Processors

Using BTM50220.RSS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

BTM50220.RSS Data table layout. . . . . . . . . . . . . . . . . . 9-7

Download and Upload Settings . . . . . . . . . . . . . . . . . . 9-8

General Notes For Programming The 1746-BTM. . . . . . . . . 9-10

Index

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