Watlow PPC-2000 User guide

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

Copyright

©

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

PPC-2000 User’s Guide Table of Contents

Doc.# 30002-00 Rev 2.3 Watlow Anafaze v

Operating with AnaWin3 89

Type Definitions 89

Closed-Loop Control 89

Feedback 90

Control Algorithm 90

Control Output Signal Forms 90

Heat and Cool Outputs 90

Prerequisites 93

Background 93

Using

AnaWin3

to Tune 94

Alarms 95

Failed Sensor Alarms 95

Global Alarm 95

Process Alarms 95

Alarm Delay 96

Setting up Process and Deviation Alarms 97

Setting Input Signal Lo and Input Signal Hi 99

Setting Engineering Units 99

Setting PV Lo and PV Hi 99

Setting Decimal Places 100

Linear 4-20mA Input Example 101

Process Variable Retransmit 102

Setting up Process Variable Retransmit 103

Process Variable Retransmit Example 104

Cascade Control 105

Setting up Cascade Control 106

Cascade Control Example 106

Ratio Control 109

Setting up Ratio Control 110

Differential Control 112

Remote Set Point 112

Logic Programs 112

Setting up Outputs for Use with a Logic Program 113

Using Logic to Set an Analog Input 113

Starting and Stopping Logic Programs 113

Controller Parameters 115

Channels 115

Digital I/O 132

Soft Integer 136

Soft Boolean 137

Table of Contents PPC-2000 User’s Guide

vi Watlow Anafaze Doc.# 30002-00 Rev 2.3

Troubleshooting 141

General Description 141

PPC-2010 Processor 141

Processor Module LEDs 147

PPC-2040 Digital I/O 151

PPC-207x Digital In 153

Troubleshooting and Corrective Actions 154

Digital Inputs and Outputs 154

Process Variable 154

Communications 155

Resetting Closed-Loop Control Parameters 156

Disabling Control 157

LogicPro and Modbus Reference 159

Overview 159

Text Conventions in the Database Sections 159

The PPC-2000 Database 160

Data Table Organization 161

How LogicPro Accesses the Database 162

Analog and Counter Input Parameters in the Database 163

Accessing Analog and Counter Input Parameters with Modbus 163

Accessing Analog and Counter Input Parameters with

LogicPro 163

Analog Input Numbers and Address Offsets 164

Analog and Encoder Input Parameters 168

Channel Parameters in the Database 172

Accessing Channel Parameters with Modbus 172

Accessing Channel Parameters with

LogicPro 173

Channel Parameters for Heat and Cool Outputs 173

Channel Parameters 173

State and Logic 195

Accessing Digital I/O Parameters with Modbus 195

Digital I/O Numbers and Address Offsets 196

Digital I/O Parameters 200

Accessing Analog Outputs with Modbus 202

Accessing Analog Outputs with

LogicPro 202

Analog Outputs and Modbus Addresses 202

Analog Output Value 204

Soft Bool and Soft Int Registers in the Database 205

Accessing Soft Bool and Soft Int Registers with Modbus 205

Accessing Soft Bool and Soft Int Registers with

LogicPro 205

Soft Bool and Soft Int Registers 205

Global Parameters in the Database 206

Accessing Global Parameters with Modbus 206

Communications Parameters 207

Global Database Parameters 209

PPC-2000 User’s Guide Table of Contents

Doc.# 30002-00 Rev 2.3 Watlow Anafaze vii

Tuning and Control 219

Introduction 219

Control Algorithms 220

On/Off Control 220

Output Control Forms 224

Output Filter 225

Proportional Band (PB) Settings 226

Integral Settings 226

Derivative Settings 227

General PID Constants by Application 228

Proportional Band Only (P) 228

Proportional with Integral (PI) 228

PI with Derivative (PID) 228

Specifications 229

System Specifications 229

Safety and Agency Approvals 229

Physical Specifications 230

Power Specifications 230

PPC-2010 Processor Specifications 231

PPC-205x Analog Out Specifications 247

PPC-206x Digital Output Specifications 250

PPC-207x Digital In Specifications 253

PPC-EITB-1 Encoder Input Terminal Block Specifications 258

PPC-TB50-SCSI, 50-Pin Specifications 261

SDAC Specifications 265

Inputs 266

Analog Outputs 267

Appendix A: Modbus Protocol 269

Query 270

Response 270

Message Framing 271

Address Field 272

Function Field 272

Data Field 273

Error Checking Field 273

Field Format 273

Parity Checking 274

CRC Checking 275

Read Examples 280

Appendix B: Declaration of Conformity 283

Glossary 285

Table of Contents PPC-2000 User’s Guide

viii Watlow Anafaze Doc.# 30002-00 Rev 2.3

Doc.# 30002-00 Rev 2.3 Watlow Anafaze ix

List of Figures

Overview 1

Figure 1.1—System Diagram 4

Figure 1.2—Sample PPC-2000 System 6

Hardware Installation 13

Figure 2.1—PPC-IPS-2 DIN Mounting Dimensions 15

Figure 2.2—PPC-IPS-2 Panel Mounting Dimensions 16

Figure 2.3—Sample Addresses 17

Figure 2.4—PPC-2010 Jumpers 19

Figure 2.5—PPC-2030 Jumpers and Switches 20

Figure 2.6—PPC-2040 Jumper Settings 21

Figure 2.7—PPC-205x Jumpers 23

Figure 2.8—Assembled Modules Top View 24

Figure 2.9—Assembled Modules Bottom View 25

Figure 2.10—Modules Bottom/Side View 25

Figure 2.11—DIN Rail Latches 27

Figure 2.12—Mounting Assembled PPC Modules on a DIN rail (side) 27

Figure 2.13—AITB Dimensions / Clearances 29

Figure 2.14—EITB Dimensions / Clearances 30

Figure 2.15—TB50 Dimensions / Clearances 31

Figure 2.16—TB50 Mounted on DIN Rail (Front) 32

Figure 2.17—TB50 Mounted on DIN Rail (Side) 32

Figure 2.18—TB50 Panel Mounted 33

Figure 2.19—SDAC Dimensions 34

Figure 2.20—PPC-2010 Connection to TB50 38

Figure 2.21—Wiring Digital Inputs 41

Figure 2.22—Encoder with 5Vdc TTL Signal 41

Figure 2.23—Powering Output with 5Vdc from PPC Supply 42

Figure 2.24—Powering Output with 12-24Vdc from PPC supply 42

Figure 2.25—Powering Output with Separate Power Supplies 42

Figure 2.26—Recommended circuitry for CPUWatchdog 43

Figure 2.27—Wiring Single/Multiple SDACs 44

Figure 2.28—PPC-2021 — 2025 Connection to AITB 45

Figure 2.29—Inserting Sensor Keys in AITB 46

Figure 2.30—An Input Key 47

Figure 2.31—Thermocouples Connected to Differential Inputs 1 and 2 49

Figure 2.32—Thermocouples Connected to Single-ended Inputs 1 and 2 50

Figure 2.33—Wiring 2-Wire RTDs: Input 1 and 2 Shown 51

Figure 2.34—Wiring 3-Wire RTDs: Input 1 and 2 Shown 51

List of Figures PPC User’s Guide

x Watlow Anafaze Doc.# 30002-00 Rev 2.3

Figure 2.35—Connecting Linear Voltage Signals to Differential Inputs 1 and 2 52

Figure 2.36—Connecting Linear Voltage Signals to Single-ended Inputs 1 and 2 53

Figure 2.37—Connecting Current Inputs to a Differential Input Module:

Input 1, 2, and 3 Shown 53

Figure 2.38—Connecting Current Inputs to a Single-ended Analog Input

Module: Input 1 and 2 Shown 54

Figure 2.39—PPC-2030 Connections (Bottom View) 55

Figure 2.40—PPC-EITB-1 56

Figure 2.41—EITB Single-ended Single Phase Connections: Input 1 and 2 Shown 57

Figure 2.42—EITB Single-ended Quadrature Connections: Input 1 and 2 Shown 58

Figure 2.43—EITB Differential Single Phase Connections: Input 1 and 2 Shown 58

Figure 2.44—EITB Differential Quadrature Connections: Input 1 and 2 Shown 59

Figure 2.45—PPC-2030 Analog Out Terminal Block 60

Figure 2.46—Analog Output Connections on a PPC-2030: Outputs 1 and 2 Shown 61

Figure 2.47—PPC-2040 Connection to TB50 62

Figure 2.48—Wiring Digital Inputs 64

Figure 2.49—Single Phase Connections: Input 1 and 2 Shown 64

Figure 2.50—Quadrature Connections: Inputs 1 and 2 Shown. 65

Figure 2.51—Powering Output with 5Vdc from PPC Supply 65

Figure 2.52—Powering Output with 12-24Vdc from PPC supply 66

Figure 2.53—Powering Output with Separate Power Supplies 66

Figure 2.54—PPC-205x Connections (Bottom View) 67

Figure 2.55—Analog Output Connections on a PPC-2050 Configured for Current:

Outputs 1 and 2 Shown 68

Figure 2.56—Analog Output Connections on a PPC-2050 Configured for Voltage:

Outputs 1 and 2 shown 69

Figure 2.57—Analog Output Connections on a PPC-2051 Configured for Current and

Voltage: Outputs 1 and 2 shown 69

Figure 2.58—PPC-206x Connections (bottom view) 70

Figure 2.59—Relay Output Connections on a PPC-2061:

Outputs 1, 2, 9 and 10 shown 71

Figure 2.60—Relay Output Connections on a PPC-2062: Outputs 1 and 2 Shown 72

Figure 2.61—Snubber Connections 73

Figure 2.62—PPC-207x Connections (bottom view) 74

Figure 2.63—Input Connections to a PPC-2070 or PPC-2072:

Inputs 1 and 2 shown 74

Figure 2.64—Input Connections to a PPC-2071 or PPC-2073:

Inputs 1,2, 9 and 10 Shown 75

Figure 2.65—Connecting a Current Sinking Field Device to a PPC-2072 or PPC-2073:

Input 1 Shown 75

Figure 2.66—Connecting a Current Sourcing Field Device to a PPC-2072 or

PPC-2073: Input 1 Shown 76

Figure 2.67—PPC-IPS-2 Power Connections 78

Figure 2.68—RS-232 and RS-485 RJ-Type Connectors 79

Figure 2.69—Connecting One PPC to a Computer Using RS-232 81

Figure 2.70—Connecting Multiple PPCs to a Computer Using RS-485 81

Figure 2.71—RS-485 Wiring 82

Figure 2.72—Two Wire RS-485 Wiring 84

Figure 2.73—Connecting Several PPCs with Short Cable Runs 84

PPC User’s Guide List of Figures

Doc.# 30002-00 Rev 2.3 Watlow Anafaze xi

Operating with AnaWin3 89

Figure 3.1—Sample Screen Text 89

Figure 3.2—Process Variable Alarms 96

Figure 3.3—Linear Input Example 98

Figure 3.4—Linear Scaling of the Analog Input for Retransmit on the Heat or Cool

Output 102

Figure 3.5—Sample Application Using Process Variable Retransmit 104

Figure 3.6—How the Secondary Channel’s Set Point is Determined When the

Primary Channel Has Heat and Cool Outputs 105

Figure 3.7—How the Secondary Channel’s Set Point is Determined When the Primary

Channel Has Only a Heat Output 106

Figure 3.8—Sample Application Using Cascade Control 107

Figure 3.9—The Secondary Channel’s Set Point is Determined by the Primary

Channel’s Process Variable 109

Figure 3.10—Relationship between the Master Channel’s Process Variable and the

Ratio Channel’s Set Point. 110

Figure 3.11—Sample Application Using Ratio Control 111

Figure 3.12—Channels Spreadsheet 115

Figure 3.13—Output Scaling (Heat/Cool) Curves 121

Figure 3.14—Alarms Spreadsheet 123

Figure 3.15—Inputs Spreadsheet 127

Figure 3.16—Analog Input Names 127

Figure 3.17—Pulse Input Names 128

Figure 3.18—Soft Input Names 128

Figure 3.19—Channel Output Names 129

Figure 3.20—Dig I/O Spreadsheet 132

Figure 3.21—PPC-2010 and PPC-204X Digital I/O Names 133

Figure 3.22—PPC-206X and PPC-207X Digital I/O Names 133

Figure 3.23—Outputs Spreadsheet 135

Figure 3.24—Analog Output Names 135

Figure 3.25—Soft Int Spreadsheet 136

Figure 3.26—Soft BOOL Spreadsheet 137

Figure 3.27—PPC Globals Screen 138

Troubleshooting 141

Figure 4.1—Assembled Modules Top View 143

Figure 4.2—Assembled Modules Bottom View 143

Figure 4.3—PPC-2010 Internal View 144

Figure 4.4—PPC Assembled Modules Top View 145

Figure 4.5—PPC Assembled Modules Bottom View 146

List of Figures PPC User’s Guide

xii Watlow Anafaze Doc.# 30002-00 Rev 2.3

LogicPro and Modbus Reference 159

Figure 5.1—Sample Text 160

Figure 5.2—Output Scaling Curves 185

Tuning and Control 219

Figure 6.1—On/Off Control 220

Figure 6.2—Proportional Control 221

Figure 6.3—Proportional and Integral Control 222

Figure 6.4—Proportional, Integral and Derivative Control 223

Figure 6.5—Example Time Proportioning and Distributed Zero Crossing

Waveforms 224

Specifications 229

Figure 7.1—System Footprint 230

Figure 7.2—PPC-2010 Front View 231

Figure 7.3—PPC-2010 Bottom View 232

Figure 7.4—PPC-2021 Front View 236

Figure 7.5—PPC-2021 - 2025 Bottom View 236

Figure 7.6—PPC-2030 Front View 240

Figure 7.7—PPC-2030 Bottom View 241

Figure 7.8—PPC-2040 Front View 244

Figure 7.9—PPC-2050 Front View 247

Figure 7.10—PPC-2050 Bottom View 248

Figure 7.11—PPC-206x Front View 250

Figure 7.12—PPC-206x Bottom View 251

Figure 7.13—PPC-2070, PPC-2071 Front Views 253

Figure 7.14—PPC-207x Bottom Views 254

Figure 7.15—PPC-AITB-1 256

Figure 7.16—PPC-AITB Dimensions with Straight SCSI Cable 257

Figure 7.17—PPC-EITB-1 258

Figure 7.18—PPC-EITB Dimensions with HD-Type Cable 260

Figure 7.19—PPC-TB50-SCSI Dimensions 261

Figure 7.20—PPC-TB50-SCSI Dimensions with Straight SCSI Cable 262

Figure 7.21—PPC-TB50-SCSI Dimensions with Right-Angle SCSI Cable 263

Figure 7.22—PPC-IPS-2 264

Figure 7.23—SDAC Dimensions 266

Appendix A: Modbus Protocol 269

Figure A.1—Query—Response Cycle 270

Doc.# 30002-00 Rev 2.3 Watlow Anafaze xiii

List of Tables

Overview 1

Table 1.1—PPC-2000 System Modules 5

Table 1.2—PPC-2000 Terminal Boards and Peripheral Modules 5

Table 1.3— Analog Terminal Board Keys 5

Hardware Installation 13

Table 2.2—Power Supply Current Requirements at 24Vdc 14

Table 2.3—Power Supply Screw Mounting 16

Table 2.4—System Modules and Addressing 18

Table 2.5—PPC-2010 Processor Module Jumpers 18

Table 2.6—PPC-2030 Analog Output Jumpers 21

Table 2.7—PPC-2040 Counter Input Jumpers 21

Table 2.8—PPC-205x Analog Out Jumpers 22

Table 2.9—Cable Recommendations 35

Table 2.10—Processor Module I/O Connections 39

Table 2.11—Sensor Keys 46

Table 2.12—Numbers and Types of Inputs by Module Type 47

Table 2.13—Sensor Connections to the AITB 48

Table 2.14—Power Connections on AITB 49

Table 2.15—Encoder Connections to the EITB Connected to J3 on the PPC-2030 56

Table 2.16—Encoder Connections to the EITB Connected to J4 on the PPC-2030 56

Table 2.17—Power Connections on EITB 57

Table 2.18—HD-15 Encoder Signal Connections 59

Table 2.19—HD-15 Power Connections 60

Table 2.20—Analog Output Connections on Encoder In Analog Out Module 60

Table 2.21—Digital I/O Module Connections 63

Table 2.22—Analog Output Connections on Analog Out Module 67

Table 2.23—Relay Output Connections on PPC-206x Digital Output Modules 72

Table 2.24—Digital Input Connections on PPC-207x Modules 76

Table 2.25—PPC-IPS-2 Voltage Input Switch Settings 77

Table 2.26—Power Supply Connections 77

Table 2.27—RS-232 Connector Pin Outs 79

Table 2.28—RS-485 Connector Pin Out and Connections 80

Table 2.29—RTS/CTS Pins in DB-9 and DB-25 Connectors 80

Table 2.30—485 Terminal Block Pin Assignment 83

Table 2.31—PPC-2010 Rotary Switch Configuration 86

List of Tables PPC User’s Guide

xiv Watlow Anafaze Doc.# 30002-00 Rev 2.3

Operating with AnaWin3 89

Table 3.1—Control Types PID1 and PID2 91

Table 3.2—Alarm Types 95

Table 3.3—Range and Sensitivity of theCustom Linear Input Types 99

Table 3.4—PV Range permitted for various Decimal Places Settings 100

Table 3.5—Scaling Parameters for 0-10Vdc Linear Input Example 101

Table 3.6—Scaling Parameters for 4-20mA Linear Input Example 101

Table 3.7—Scaling Parameters for 0-1Vdc Linear Input Example 102

Table 3.8—Retransmit Channel Parameter Settings 104

Table 3.9—Primary Channel Parameter Settings 107

Table 3.10—Secondary Channel Parameter Settings 108

Table 3.11—Ratio Channel Parameter Settings 111

Table 3.12—AnaWin3 Control Types 118

Table 3.14—Module Abbreviations Seen on the Inputs Spreadsheet 127

Table 3.16—Units 131

Table 3.18—Function Values 134

Table 3.19—Module Abbreviations Seen on the Outputs Spreadsheet 135

Table 3.20—System Status 139

Table 3.21—Global Settings 139

LogicPro and Modbus Reference 159

Table 5.1—Parameter Names & Abbreviations 159

Table 5.2—Example Database Table 160

Table 5.3—Addresses for Analog Inputs on the PPC-202x Modules 164

Table 5.4—Addresses for Encoder Inputs on the PPC-2030 Encoder In Analog Out

Module 165

Table 5.5—Addresses for Counter Inputs on the PPC-2010 Processor Module 166

Table 5.6—Addresses for Soft Inputs and Channel Outputs 166

Table 5.7—Addresses for Encoder Inputs on the PPC-2040 Digital I/O Modules 167

Table 5.8—Input Parameters 168

Table 5.9—Input Status 169

Table 5.11—Temperature Scale Conversion 171

Table 5.13—Process Variable and Setpoint Source Settings for Analog Inputs on the

PPC-202x Modules 176

Table 5.16—Process Variable and Setpoint Source Settings for Soft Input and

Channel Out Registers 178

Table 5.18—Control Mode 180

Table 5.19—Control Types 181

Table 5.21—Heat/Cool Curve 184

Table 5.22—Output Destinations for Digital Outputs on the PPC-2010 Module 186

Table 5.26—Output Destinations for Analog Outputs on the PPC-205x Modules 189

Table 5.27—Output Destinations for Soft Boolean and Soft Integers 190

Table 5.28—Alarm Status 190

Table 5.30—Alarm and Control Functionality 192

Table 5.31—Alarm Acknowledge 192

Table 5.32—Alarm Enable/Disable 192

Table 5.33—Database Offsets and Sample Modbus Addresses for Digital I/O 196

Table 5.37—Digital I/O Uses 200

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Watlow PPC-2000 User guide

Watlow PPC-2000 User guide

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