Watlow Anafaze PPC-2000 Bedienungsanleitung

PPC-2000

User’s Guide

WATLOW

1241 Bundy Boulevard

Winona, Minnesota USA 55987

Phone: +1 (507) 454-5300,

Fax: +1 (507) 452-4507

Part No. 0600-3000-2000 Rev 2.3d

http://www.watlow.com

Adaptive Addendum PPC-2000 User's Guide

0600-0049-0001 rev C Watlow Anafaze 1

PPC-2000 Adaptive Control

Addendum

Scope This document describes the additional features and functionality found

in the PPC-2010-xxB with adaptive control. Refer to the PPC-2000

User’s Guide regarding all other functionality which is the same as the

standard version.

Introduction The Watlow Anafaze PPC-2000 controller offers these standard options:

•Forty-eight loops of conventional PID control with auto-tuning

capability

-or-

•Eight loops of adaptive control plus 24 loops of conventional PID

control with auto-tuning for a total of 32 loops (the option described

in this document)

ANAWIN3 HMI software is available to support either option. A mix of

these options is not supported by ANAWIN3.

ANAWIN3 Software Installation

Follow the standard instructions to install and setup ANAWIN3. In the

setup program select the Adaptive Control option.

Spreadsheet Overview Screen

Several new parameters and options appear on the Spreadsheet Overview

screen in support of the adaptive control option. These parameters and

options are applicable only for the first eight channels and are omitted or

ignored for channels 9 to 32.

Control Type An additional option appears for Control Type. Select Adaptive to enable

adaptive control and tuning on a channel. This option is only valid for

channels 1 to 8.

Values: PID1 (0), PID2 (1), Adaptive (2) and Retransmit (3)

Default: PID1 (0)

Modbus Address (Channels 1 to 32): 46401 to 46432

Parameter Number: 19

LogicPro Driver: Database

LogicPro Address (Channels 1 to 32): 19.1 to 19.32

Adaptive Addendum PPC-2000 User's Guide

0600-0049-0001 rev C Watlow Anafaze 2

Adaptive Mode When Control Type is set to Adaptive, this parameter can be used to

pause tuning or to reset the adaptive algorithm and have it relearn the

system. This parameter has no effect on control if the Control Type for

the loop is set to an option other than Adaptive.

Values: Adapt (0), Reset (1) and Hold (2)

Default: Reset (1)

Modbus Address (Channels 1 to 32): 49001 to 49032

Parameter Number: 21

LogicPro Driver: Database

LogicPro Address (Channels 1 to 32): 21.1 to 21.32

Table 1. Adaptive Mode Settings

Setting Description

Adapt The normal setting for a loop with Control Type set to

Adaptive. The loop is adapting and tuning while controlling.

Reset Select this option to have the control loop start from scratch

and relearn the load characteristics. The Control Mode must

be set to Off or Manual to select this option for an adaptive

loop. This is the normal setting for a loop with Control Type

set to a value other than Adaptive.

Hold Select this option to have the control loop stop learning

temporarily but retain the learned load characteristics. For

example in the event that maintenance will be performed, it

may be advantageous to pause adapting to avoid false data

being introduced. Select this option anytime you want the

controller to stop adapting and continue to control with the

parameters learned up to that point.

Plant Delay This parameter indicates the amount of delay in seconds in the load. This

characteristic of the load or plant has a significant impact on adaptive

control. A larger number indicates a longer delay between, for example

an increase in heater power and an increase in the temperature.

Choose Automatic and then set the Control Mode to Auto to have the

adaptive algorithm determine the plant delay for the loop. The loop must

be at least 40 degrees below set point and the controller must observe a

temperature change of at least 20 degrees to determine the Plant Delay.

If you have determined the Plant Delay with the PPC-2000's adaptive

control previously and found the performance acceptable, you may

choose the delay directly and the loop will use the value you choose

rather than measure it.

This setting is not reset by the Adaptive Mode parameter's Reset option.

To have the controller relearn the Plant Delay, set the loop's Control

Mode to Manual or Off, set the Plant Delay to Automatic, and then set

the Control Mode to Auto again.

Adaptive Addendum PPC-2000 User's Guide

0600-0049-0001 rev C Watlow Anafaze 3

This parameter has no effect on control if the Control Type for the loop is

set to an option other than Adaptive.

Values: Automatic (0) and 1 (1) to 600 seconds (600)

Default: Automatic (0)

Modbus Address (Channels 1 to 32): 49051 to 49082

Parameter Number: 28

LogicPro Driver: Database

LogicPro Address (Channels 1 to 32): 28.1 to 28.32

Tuning Gain This parameter indicates the amount of delay in seconds in the load. This

characteristic of the load or plant has a significant impact on adaptive

control. A larger number indicates a longer delay between, for example

an increase in heater power and an increase in the temperature.

Values: Aggressive (0), Nominal (1), Damped 1 (2), Damped 2 (3),

Damped 3 (4) and Damped 4 (5)

Default: Nominal (1)

Modbus Address (Channels 1 to 32): 46551 to 46682

Parameter Number: 29

LogicPro Driver: Database

LogicPro Address (Channels 1 to 32): 29.1 to 29.32

Figure 1. The Effect of Tuning Gain on Recovery from a

Load Change

Using Adaptive Control

To set up adaptive control on one or more channels:

1. Open the Spreadsheet Overview screen in ANAWIN3.

2. On the Inputs spreadsheet for each analog input you have wired:

a. Choose the appropriate Input Type for the sensor.

b. Choose Units.

c. For any linear voltage, current, or pulse sensors, set the linear

scaling parameters (Input Signal Lo, Input Signal Hi, PV Lo,

and PV Hi). See Setting up User Selectable Linear Inputs on

page 98 of the PPC-2000 User's Guide.

3. On the Channels spreadsheet for each channel:

Adaptive Addendum PPC-2000 User's Guide

0600-0049-0001 rev C Watlow Anafaze 4

a. In the PV Source field, choose the input that you want to

monitor or use as feedback for closed-loop control.

b. In the Heat Output Dest and/or Cool Output Dest fields,

choose the outputs that you want to use for closed-loop control.

c. Choose a Heat/Cool Output Type for each output.

d. Set the Heat/Cool Cycle Time for any outputs with Heat/ Cool

Output Type set to Time Prop.

4. On the Digital I/O spreadsheet:

a. Set the Direction for each I/O point to be used for control to

Output.

5. On the Channels spreadsheet:

a. For channels other than the adaptive ones, if both heat and cool

outputs are used, set the Spread.

b. For each channel that will perform adaptive control, for the

Control Type, choose Adaptive.

c. Set the Set Point to the desired value at least 40 engineering

units (typically degrees) above the process variable.

d. Set the Control Mode to Auto to begin adaptive closed-loop

control.

NOTE: Only channels 1 to 8 can be selected for adaptive control.

PPC-2000 User's Guide

Addendum

Overview

This document contains additional specifications for the PPC-2000 system.

Environmental Specifications

Table 1 here contains specifications in addition to those found in tables 7.4, 7.15, 7.23,

7.31, 7.39, 7.46, 7.52, 7.57, 7.62, 7.67 in the PPC-2000 User's Guide.

TABLE 1. Environmental Specifications

Altitude 2000 meters max

Non-Condensing Humidity 10 to 95%

Relative Humidity 80% max (ambient temperature <= 31° C)

50% max (ambient temperature = 40° C)

Pollution Category Degree 2 (per IEC 664)

Operating Temperature Range 0 to 60° C (32 to140° F)

Storage Temperature Range -20 to 70° C (-4 to 158° F)

PPC IPS International Power Supply Specifications

Table 2 here contains specifications in addition to those found in table 7.75 in the PPC-

2000 User's Guide.

TABLE 2. Power Specifications

Input (Mains Supply) 88 to 132 Vac (120 Vac nominal)

176 to 264 Vac (240 Vac nominal)

Voltage Fluctuation < +10% of nominal voltage

Transient Over-Voltage Category II per IEC 664

Output V1: +5 Vdc @ 6 A

V2: +24 Vdc @ 4 A

Input Frequency 47 to 440 Hz

Peak Current Output 9A @ 5Vdc

6A @ 24 Vdc

1241 Bundy Blvd.

Winona, MN 55987

Phone: (507) 494-5656

Fax: (507) 452-4507

1998-2002

Watlow Anafaze

Information in this manual is subject to change without notice. No part of this publication may be

reproduced, stored in a retrieval system, or transmitted in any form without written permission

from Watlow Anafaze.

Warranty

Watlow Anafaze, Incorporated warrants that the products furnished under this Agreement will be

free from defects in material and workmanship for a period of three years from the date of ship-

ment. The Customer shall provide notice of any defect to Watlow Anafaze, Incorporated within one

week after the Customer's discovery of such defect. The sole obligation and liability of Watlow

Anafaze, Incorporated under this warranty shall be to repair or replace, at its option and without

cost to the Customer, the defective product or part.

Upon request by Watlow Anafaze, Incorporated, the product or part claimed to be defective shall

immediately be returned at the Customer's expense to Watlow Anafaze, Incorporated. Replaced or

repaired products or parts will be shipped to the Customer at the expense of Watlow Anafaze,

Incorporated.

There shall be no warranty or liability for any products or parts that have been subject to misuse,

accident, negligence, failure of electric power or modiﬁcation by the Customer without the written

approval of Watlow Anafaze, Incorporated. Final determination of warranty eligibility shall be

made by Watlow Anafaze, Incorporated. If a warranty claim is considered invalid for any reason,

the Customer will be charged for services performed and expenses incurred by Watlow Anafaze,

Incorporated in handling and shipping the returned unit.

If replacement parts are supplied or repairs made during the original warranty period, the warranty

period for the replacement or repaired part shall terminate with the termination of the warranty

period of the original product or part.

The foregoing warranty constitutes the sole liability of Watlow Anafaze, Incorporated and the Cus-

tomer's sole remedy with respect to the products. It is in lieu of all other warranties, liabilities, and

remedies. Except as thus provided, Watlow Anafaze, Inc. disclaims all warranties, express or

implied, including any warranty of merchantability or ﬁtness for a particular purpose.

Please Note

: External safety devices must be used with this equipment.

Doc.# 30002-00 Rev 2.3 Watlow Anafaze iii

Table of Contents

Table of Contents iii

List of Figures ix

List of Tables xv

Overview 1

Manual Contents 1

Getting Started 2

Safety symbols 2

Contacting Watlow Anafaze 2

Initial Inspection 2

Product Features 3

System Components 3

PPC-2000 Modules 6

PPC-2000 Terminal Boards 8

Additional Components 9

Safety 9

External Safety Devices 10

External Switch Disconnect 11

Battery Safety 11

Product Markings and Symbols 11

Hardware Installation 13

Power Supply Requirements 13

Mounting the Power Supply 15

Hardware Configuration 17

Module Addresses 17

PPC-2010 Jumper Settings 18

PPC-2030 Dip Switch Settings 19

PPC-2030 Jumper Settings 20

PPC-2040 Jumper Settings 21

PPC-205x Jumper Settings 22

Module Disassembly 26

Mounting Modules 26

DIN Rail Mounting 27

Table of Contents PPC-2000 User’s Guide

iv Watlow Anafaze Doc.# 30002-00 Rev 2.3

Mounting Terminal Boards 28

DIN Rail Mounting 31

DIN Rail Removal 32

Panel Mounting 33

System Wiring 34

Wiring Recommendations 35

Noise Suppression 35

Avoiding Ground Loops 37

Connecting I/O to the PPC-2010 37

Connecting the TB50 to the PPC-2010 Module 37

TB50 Connections 38

Connecting Digital Inputs 40

Connecting Counter or Frequency Inputs 41

Connecting Digital Outputs 41

SDAC Connections 43

Connecting Analog Inputs to the PPC-2021 — 2025 45

Connecting the AITB to the PPC-202x 45

Sensor Keys 46

AITB Connections 47

Connecting Thermocouples 49

Connecting RTDs 50

Connecting Sensors with Linear Voltage Signals 52

Connecting Sensors with Linear Current Signals 53

Connecting the Encoder Input Cable to the PPC-2030 55

Encoder Wiring 57

Encoder Connections without the EITB 59

Analog Output Connections 60

Connecting I/O to the PPC-2040 61

Connecting the TB50 to the PPC-2040 Module 61

TB50 Connections 62

Connecting Digital Inputs 64

Connecting Counter or Frequency Inputs 64

Connecting Digital Outputs 65

Connecting to the Relay Outputs on the PPC-206x 70

Wiring PPC-2062 Relay Outputs 71

Using Snubbers for Relay Outputs 73

Connecting Power 77

PPC-IPS-2 Power Supply 77

Processor Module 77

Connecting Communication Ports 78

Communication Ports 78

Connecting RS-485 Communications 81

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