IDEC MicroSmart Pentra User Manual

FC9Y-B1283

FC5A

SERIES

PID Module

User’s Manual

Warning notices are used to emphasize that improper operation may cause severe personal injury or death.

Caution notices are used where inattention might cause personal injury or damage to equipment.

SAFETY PRECAUTIONS

• Read this user’s manual to make sure of correct operation before starting installation, wiring, operation,

maintenance, and inspection of the FC5A series MicroSmart PID modules.

• All MicroSmart modules are manufactured under IDEC’s rigorous quality control system, but users must add a backup or failsafe provision to the control system using the MicroSmart in applications where heavy damage or personal injury may be caused in case the MicroSmart should fail.

• In this user’s manual, safety precautions are categorized in order of importance from Warning to Caution.

Warning

• Turn off the power to the MicroSmart before starting installation, removal, wiring, maintenance, and inspection of the MicroSmart. Failure to turn power off may cause electrical shocks or fire hazard.

• Special expertise is required to install, wire, program, and operate the MicroSmart. People without such expertise must not use the MicroSmart.

• Emergency stop and interlocking circuits must be configured outside the MicroSmart. If such a circuit is configured inside the MicroSmart, failure of the MicroSmart may cause a malfunction of the control system, damage, or accidents.

• Install the MicroSmart according to the instructions described in this user’s manual. Improper installation will result in disattachment, failure, or malfunction of the MicroSmart.

Caution

• The MicroSmart is designed for installation in a cabinet. Do not install the MicroSmart outside a cabinet.

• Install the MicroSmart in environments described in this user’s manual. If the MicroSmart is used in places where

the MicroSmart is subjected to high-temperature, high-humidity, condensation, corrosive gases, excessive vibrations, and excessive shocks, then electrical shocks, fire hazard, or malfunction will result.

• The environment for using the MicroSmart is “Pollution degree 2.” Use the MicroSmart in environments of pollution degree 2 (according to IEC 60664-1).

• Prevent the MicroSmart from being dropped while moving or transporting the MicroSmart, otherwise damage or

malfunction of the MicroSmart will result.

• Prevent metal fragments and pieces of wire from dropping inside the MicroSmart housing. Put a cover on the MicroSmart modules during installation and wiring. Ingress of such fragments and chips may cause fire hazard, damage, or malfunction.

• Use a power supply matching the rated value. Use of an incorrect power supply may cause fire hazard.

• Use an IEC 60127-approved fuse on the power line outside the MicroSmart. This is required when equipment

containing the MicroSmart is destined for Europe.

• Use an IEC 60127-approved fuse on the output circuit. This is required when equipment containing the

MicroSmart is destined for Europe.

FC5A MicroSmart PID Module User’s Manual FC9Y-B1283 i

• Use an EU-approved circuit breaker. This is required when equipment containing the MicroSmart is destined for

Europe.

• Make sure of safety before starting and stopping the MicroSmart or when operating the MicroSmart to force

outputs on or off. Incorrect operation on the MicroSmart may cause machine damage or accidents.

• If relays or transistors in the MicroSmart output modules should fail, outputs may remain on or off. For output signals which may cause serious accidents, provide a monitor circuit outside the MicroSmart.

• Do not connect the ground wire directly to the MicroSmart. Connect a protective ground to the cabinet containing the MicroSmart using an M4 or larger screw. This is required when equipment containing the MicroSmart is destined for Europe.

• Do not disassemble, repair, or modify the MicroSmart modules.

• When disposing of the

MicroSmart

, do so as an industrial waste.

ii FC5A MicroSmart PID Module User’s Manual FC9Y-B1283

NOTICE

1. This publication is not to be, nor any parts of it, photocopied, reprinted, sold, transferred, or rented out without the specific written permission and consent of IDEC.

2. The contents of this user’s manual are subject to change without notice.

3. Care has been taken to ensure that the contents of this user’s manual are correct, but if there are any doubts, mistakes or questions, please inquire our sales department.

Category

Modules

MicroSmart (FC5A Series MicroSmart)

FC5A series MicroSmart pentra

FC5 Series CPU Modules

All-in-One Type

FC5A-C10R2, FC5A-C10R2C, FC5A-C16R2, FC5A-C16R2C, FC5A-C24R2, FC5A-C24R2C

Slim Type

FC5A-D16RK1, FC5A-D16RS1, FC5A-D32K3, FC5A-D32S3, FC5A-D12K1E, FC5A-D12S1E

PID Modules

FC5A-F2MR2, FC5A-F2M2

Expansion Communication Modules

FC5A-SIF2, FC5A-SIF4

Memory Cartridge

FC4A-PM32, FC4A-PM64, FC4A-PM128

Expansion Modules

Expansion I/O module, Function module

Expansion I/O Modules

Input modules, Output modules, Mixed I/O modules

Function Modules

Analog modules, AS-Interface master module, PID module

Communication Expansion Modules

HMI base module, expansion RS232C communication module, expansion RS485 communication module

Optional Modules

HMI module, Memory cartridge, Clock cartridge, RS232C communication adapter, RS485 communication adapter

WindLDR

Application software [WindLDR]

IMPORTANT INFORMATION

Under no circumstances shall IDEC Corporation be held liable or responsible for indirect or consequential damages resulting from the use of or the application of IDEC PLC components, individually or in combination with other equipment.

All persons using these components must be willing to accept responsibility for choosing the correct component to suit their application and for choosing an application appropriate for the component, individually or in combination with other equipment.

All diagrams and examples in this user’s manual are for illustrative purposes only. In no way does including these diagrams and examples in this manual constitute a guarantee as to their suitability for any specific application. To test and approve all programs, prior to installation, is the responsibility of the end user.

The PID modules is used by connecting to the FC5A series CPU module.

Use this product after thoroughly understanding the specifications of the FC5A series CPU module.

ABOUT THIS MANUAL

Thank you for purchasing FC5A series MicroSmart PID Module. This user’s manual primarily describes system configuration, specifications, installation, programming, application examples, and trouble shooting of the PID module. Read this user’s manual to ensure the correct understanding of the entire functions of the PID module.

MicroSmart Modules

Caution

FC5A MicroSmart PID Module User’s Manual FC9Y-B1283 iii

REVISION HISTORY

Date

Manual No.

Description

March, 2011

FC9Y-B1283-0

First print

Revision history of this user’s manual is described here.

iv FC5A MicroSmart PID Module User’s Manual FC9Y-B1283

Type No.

Manual Name

Description

FC9Y‐B1283

FC5A Series PID Module User's Manual (this manual)

Describes PID Module specifications and functions.

FC9Y‐B1268

FC5A Series MicroSmart Pentra User's Manual Basic Volume

Describes module specifications, installation instructions, wiring instructions, basic operation, special function, device addresses, instruction list, basic instructions, analog modules, user communication, data link communication, Modbus ASCII/RTU communication, and troubleshooting.

FC9Y‐B1273

FC5A Series MicroSmart Pentra User's Manual Advanced Volume

Describes instruction list, move instructions, data comparison instructions, binary arithmetic instructions, boolean computation instructions, shift/rotate instructions, data conversion instructions, week programmer instructions, interface instructions, program branching instructions, refresh instructions, interrupt control instructions, coordinate conversion instructions, average instructions, pulse output instructions, PID instructions, dual/teaching timer instructions, intelligent module access instructions, trigonometric function instructions, logarithm/power instructions, file data processing instructions, clock instructions, computer link communication, modem communication, Modbus TCP communication, expansion RS232C/RS485 communication modules, and AS‐Interface master modules.

FC9Y‐B1278

FC5A Series MicroSmart Pentra User's Manual Web Server CPU Module Volume

Describes FC5A Slim Type Web Server CPU Module specifications and functions.

RELATED MANUALS

The following manuals related to the FC5A series MicroSmart are available. Refer to them in conjunction with this manual.

FC5A MicroSmart PID Module User’s Manual FC9Y-B1283 v

vi FC5A MicroSmart PID Module User’s Manual FC9Y-B1283

TABLE OF CONTENTS

CHAPTER 1: GENERAL INFORMATION ...................................................................................... 1-1

About the PID Modules .................................................................................................................................... 1-1

Quantity of Applicable PID modules ................................................................................................................ 1-1

Applicable CPU and WindLDR version ........................................................................................................... 1-2

Confirming System Program Version .............................................................................................................. 1-2

CHAPTER 2: MODULE SPECIFICATIONS ................................................................................... 2-1

PID Module ...................................................................................................................................................... 2-1

Specifications ................................................................................................................................................... 2-3

Dimensions ...................................................................................................................................................... 2-6

CHAPTER 3: INSTALLATION AND WIRING ................................................................................. 3-1

Mounting Hole Layout for Direct Mounting on Panel Surface ......................................................................... 3-1

Terminal Connection ........................................................................................................................................ 3-3

Terminal Arrangement ..................................................................................................................................... 3-4

Type of Protection ............................................................................................................................................ 3-5

Power Supply for PID Modules ....................................................................................................................... 3-6

CHAPTER 4: PID MODULE MAIN FUNCTIONS .......................................................................... 4-1

Temperature Control Using the PID Module .................................................................................................... 4-1

Fixed Value Control ......................................................................................................................................... 4-3

Auto-Tuning (AT)/Auto-Reset .......................................................................................................................... 4-6

Program Control .............................................................................................................................................. 4-9

Heating/Cooling Control ................................................................................................................................ 4-14

Difference Input Control ................................................................................................................................. 4-14

Cascade Control ............................................................................................................................................ 4-15

CHAPTER 5: DEVICE ALLOCATION OF PID MODULE ................................................................ 5-1

Device Allocation of PID Module ..................................................................................................................... 5-1

Program Size ................................................................................................................................................... 5-2

Valid Devices ................................................................................................................................................... 5-2

Control Register ............................................................................................................................................... 5-2

Control Relay ................................................................................................................................................... 5-3

Data Register Allocation - Block 0 Read Only Parameters ............................................................................. 5-7

Data Register Allocation - Block 1 Write Only Parameters............................................................................ 5-10

Data Register Allocation - Blocks 2, 3 Basic Parameters (SHOT Action) ..................................................... 5-17

Data Register Allocation - Blocks 4, 5 Initial Setting Parameters (SHOT Action) ......................................... 5-19

Data Register Allocation - Blocks 10-19 CH0 Program Parameters (SHOT Action) ..................................... 5-22

Data Register Allocation - Blocks 30-39 CH1 Program Parameters (SHOT Action) ..................................... 5-24

FC5A MicroSmart PID Module User’s Manual FC9Y-B1283 vii

CHAPTER 6: CONFIGURING PID MODULE USING WINDLDR .................................................... 6-1

Procedure to configure the PID module .......................................................................................................... 6-1

Expansion Modules Configuration Dialog Box ................................................................................................ 6-6

PID Module Configuration Dialog Box ............................................................................................................. 6-7

PID Module Configuration - Input Parameters List (CH0 and CH1) ................................................................ 6-8

PID Module Configuration - Control Parameters List (CH0 and CH1) .......................................................... 6-13

PID Module Configuration - Output Parameters List (CH0 and CH1) ........................................................... 6-17

PID Module Configuration - Program Parameters List (CH0 and CH1) ........................................................ 6-19

PID Module Configuration - I/O Function Selections ..................................................................................... 6-21

PID Module Configuration - Input Parameters Details .................................................................................. 6-24

PID Module Configuration - Control Parameters Details ............................................................................... 6-34

PID Module Configuration - Output Parameters Details ............................................................................... 6-45

PID Module Configuration - Program Parameters Details ............................................................................ 6-47

Monitoring PID Module .................................................................................................................................. 6-52

CHAPTER 7: APPLICATION EXAMPLES ..................................................................................... 7-1

Application Example 1 ..................................................................................................................................... 7-1

Application Example 2 ..................................................................................................................................... 7-8

Application Example 3 ................................................................................................................................... 7-15

CHAPTER 8: TROUBLESHOOTING ............................................................................................ 8-1

The PID Module Power LED (PWR) is OFF or Flashing. ................................................................................ 8-1

The PID Module output does not operate normally. ........................................................................................ 8-2

Hunting phenomenon is occurring while in ON/OFF control action ................................................................ 8-3

Hunting phenomenon is occurring while in PID, PI, PD, or P control action ................................................... 8-3

The PID Module input does not operate normally. .......................................................................................... 8-4

Loop break alarm turns on even though the actuator operates normally. ....................................................... 8-6

Program control is terminated earlier than the configured time. ..................................................................... 8-6

CHAPTER 9: APPENDIX ........................................................................................................... 9-1

PID Module Function References ................................................................................................................... 9-1

Output Action ................................................................................................................................................... 9-5

Factory Default Settings of the PID Module .................................................................................................... 9-9

viii FC5A MicroSmart PID Module User’s Manual FC9Y-B1283

GENERAL INFORMATION

Module Type

I/O Points

I/O Signal

Type No.

Relay Output 2 inputs

Thermocouple [K, J, R, S, B, E, T, N, PL- II, C (W/Re5-26)] Resistance thermometer (Pt100, JPt100) Voltage (0 to 1V DC, 0 to 5V DC, 1 to 5V DC, 0 to 10V DC) Current (0 to 20mA DC, 4 to 20mA DC)

FC5A-F2MR2

2 outputs

Relay contact

Non-Contact Voltage (for SSR drive)/ Current Output

2 inputs

Thermocouple [K, J, R, S, B, E, T, N, PL- II, C (W/Re5-26)] Resistance thermometer (Pt100, JPt100) Voltage (0 to 1V DC, 0 to 5V DC, 1 to 5V DC, 0 to 10V DC) Current (0 to 20mA DC, 4 to 20mA DC)

FC5A-F2M2

2 outputs

Non-contact voltage(for SSR drive)/Current

Type

All-in-One Type

Slim Type

FC5A MicroSmart CPU

FC5A-C10R2 FC5A-C10R2C FC5A-C10R2D

FC5A-C16R2 FC5A-C16R2C FC5A-C16R2D FC5A-C24R2D

FC5A-C24R2 FC5A-C24R2C

FC5A-D16RK1 FC5A-D16RS1 FC5A-D32K3 FC5A-D32S3 FC5A-D12K1E FC5A-D12S1E

Number of PID Modules

1: GENERAL INFORMATION

This chapter describes general information and specifications of the FC5A series PID modules. Make effective use of the PID modules after reading and understanding thoroughly functions and characteristics.

About the PID Modules

The PID module performs control actions to eliminate the deviation between the set point (SP) and process variable (PV). The PID module, which is an expansion module, is required to connect to the FC5A series CPU for use. Depending on the difference of output specifications, the PID modules are categorized into two types, and can be used by connecting to a FC5A slim type CPU, or 24-I/O all-in-one type CPU (except 12V DC CPU). The input channel can accept voltage, current, thermocouple or resistance thermometer signals. The output channel generates relay output, non-contact voltage (for SSR drive), or current signals. To configure the PID modules, the Expansion Modules Configuration dialog box in WindLDR is used. The following table shows the PID module type numbers.

PID Module Type Numbers

Quantity of Applicable PID modules

The maximum number of PID modules that can be connected to the MicroSmart CPU differs depending on the CPU type. The following table shows the maximum number of the PID modules.

FC5A MicroSmart PID Module User’s Manual FC9Y-B1283 1-1

GENERAL INFORMATION

Type

All-in-One Type

Slim Type

FC5A MicroSmart CPU

FC5A-C10R2 FC5A-C10R2C FC5A-C10R2D

FC5A-C16R2 FC5A-C16R2C FC5A-C16R2D FC5A-C24R2D

FC5A-C24R2 FC5A-C24R2C

FC5A-D16RK1 FC5A-D16RS1 FC5A-D32K3 FC5A-D32S3 FC5A-D12K1E FC5A-D12S1E

CPU System Program Version

230 or higher *1

WindLDR Version

6.40 or higher

Applicable CPU and WindLDR version

PID modules can be used with the following FC5A CPU module system program version and WindLDR version as listed below.

*1: The PID module can be used with FC5A-D12K1E/-S1E with the system program version 100 or higher.

Confirming System Program Version

The system program version can be confirmed using WindLDR.

1. Connect a PC to port 1 or 2 of the FC5A CPU using serial computer link cable I/F (FC2A-KC4C) or USB cable HG9Z-XCM2A for FC5A-D12x1E CPU.

2. From the WindLDR menu bar, select Online > Monitor.

3. From the WindLDR menu bar, select PLC > Status. The PLC Status dialog box appears and system program version is shown.

1-2 FC5A MicroSmart PID Module User’s Manual FC9Y-B1283

MODULE SPECIFICATIONS

(12) Expansion Connector

(1) Module Label

(2) Power LED (PWR) (3) Control Output LED (OUT0, OUT1) (4) Event Output LED (EVT0, EVT1) (5) Auto-tuning (AT)/Auto-reset LED (AT0, AT1) (6) Manual Mode LED (MT0, MT1) (7) Fixed Value Control Mode/Program

Control Mode LED (F/P0, F/P1)

(8) Program Control RUN/HOLD LED

(R/H0, R/H1)

(9) External SP Enable/Disable LED (R/L)

(10) Terminal No.

(11) Cable Terminal

(2) (3) (4) (5) (6) (7) (8) (9) (3) (4) (5) (6) (7) (8)

2: MODULE SPECIFICATIONS

This chapter describes parts names, functions, specifications, and dimensions of the PID modules.

PID Module

Parts Description

(1) Module Label Indicates the PID module type No. and specifications.

(2) Power LED (PWR) ON : Power is normally supplied.

Flashes : External power supply (24V DC) error. OFF : Power is not supplied.

LED Details

FC5A MicroSmart PID Module User’s Manual FC9Y-B1283 2-1

MODULE SPECIFICATIONS

(3) Control Output LED (OUT0, OUT1)

ON : Control output is turned on. OFF : Control output is turned off. Flashes : When current output is used, the LED flashes in a cycle of 125 ms

according to the duty ratio of the output manipulated variable (MV). When output manipulated variable (MV) is 20%, the LED turns on for 25 ms and off for 100 ms continuously.

(4) Event Output LED (EVT0, EVT1)

ON : Any alarm out of alarm 1 to alarm 8, loop break alarm is triggered. OFF : None of the alarms is triggered.

(5) Auto-tuning (AT)/Auto-reset LED (AT0, AT1)

Flashes : Auto-tuning (AT) or auto-reset is performing.

OFF : Auto-tuning (AT) or auto-reset is stopped.

(6) Manual Mode LED (MT0, MT1)

ON : Manual mode

OFF : Auto mode

(7) Fixed Value Control Mode/Program Control Mode LED (F/P0, F/P1)

ON : Program control mode

OFF : Fixed value control mode

(8) Program Control RUN/HOLD LED (R/H0, R/H1)

ON : Program control is performing, or while in fixed value control enabled. Flashes : Program control is held, or power is restored. OFF : Program control is stopped, or while in fixed value control disabled.

(9) External SP Enable/Disable LED (R/L)

ON : External SP input is enabled.

OFF : External SP input is disabled.

(10) Terminal No. Indicates terminal numbers.

(11) Cable Terminal Spring clamp type terminal for connecting a cable.

(12) Expansion Connector Connects to the CPU module and other expansion modules.

2-2 FC5A MicroSmart PID Module User’s Manual FC9Y-B1283

Type No.

FC5A-F2MR2

FC5A-F2M2

Rated Scale

Thermocouple

Type

Measurement Range

Input Value

of LSB

-200 to 1370°C

-328 to 2498°F

1°C (°F)

K (with decimal point)

-200.0 to 400.0°C

-328.0 to 752.0°F

0.1°C (°F)

-200 to 1000°C

-328 to 1832°F

1°C (°F)

0 to 1760°C

32 to 3200°F

1°C (°F)

0 to 1760°C

32 to 3200°F

1°C (°F)

0 to 1820°C

32 to 3308°F

1°C (°F)

-200 to 800°C

-328 to 1472°F

1°C (°F)

-200.0 to 400.0°C

-328.0 to 752.0°F

0.1°C (°F)

-200 to 1300°C

-328 to 2372°F

1°C (°F)

PL-II

0 to 1390°C

32 to 2534°F

1°C (°F)

C(W/Re5-26)

0 to 2315°C

32 to 4199°F

1°C (°F)

Resistance Thermometer

Type

Measurement Range

Input Value

of LSB

Pt100

-200 to 850°C

-328 to 1562°F

1°C (°F)

Pt100 (with decimal point)

-200.0 to 850.0°C

-328.0 to 1562.0°F

0.1°C (°F)

JPt100

-200 to 500°C

-328 to 932°F

1°C (°F)

JPt100(with decimal point)

-200.0 to 500.0°C

-328.0 to 932.0°F

0.1°C (°F)

Current/Voltage

Type

Measurement Range

Input Value

of LSB

4 to 20mA DC

-2000 to 10000 (12000 increments) *1

1.333μ

0 to 20mA C

-2000 to 10000 (12000 increments) *1

1.666μA

0 to 1V DC

-2000 to 10000 (12000 increments) *1

0.083mA

0 to 5V DC

-2000to 10000 (12000 increments) *1

0.416mA

1 to 5V DC

-2000 to 1000 (12000increments) *1

0.333mA

0 to 10V DC

-2000 to 10000 (12000 increments) *1

0.833mA

*1: Linear conversion possible

Input

Input type

Thermocouple

K, J, R, S, B, E, T, N, PL-II, C (W/Re5-26)

External resistance: 100Ω maximum However, B input, External resistance: 40Ω

maximum

Resistance Thermometer

Pt100, JPt100, 3-wire type Allowable conductor resistance (per wire): 10Ω maximum Sensor (detection) current: 0.2A

Current

0 to 20mA DC, 4 to 20mA DC Input impedance: 50Ω Maximum permanent allowed overload (No damage): 50mA maximum

Voltage

0 to 1V DC Input impedance: 1MΩ minimum Maximum permanent allowed overload (No damage): 5V DC maximum Allowable output impedance: 2kΩ maximum

0 to 5V DC, 1 to 5V DC, 0 to 10V DC Input impedance: 100kΩ minimum Maximum permanent allowed overload (No damage): 15V DC maximum Allowable output impedance: 100Ω maximum

Power Supply Voltage

24V DC (External power), 5V DC (Internal power)

Allowable Voltage Range

20.4 to 28.8V DC

Specifications

PID Module Specifications

Rating

MODULE SPECIFICATIONS

FC5A MicroSmart PID Module User’s Manual FC9Y-B1283 2-3

MODULE SPECIFICATIONS

Type No.

FC5A-F2MR2

FC5A-F2M2

Connector

Connector on MotherBoard

Input : F6018-17P (Fujicon) Output : F6018-11P (Fujicon)

Connector Insertion/Removal Durability

Type No.

FC5A-F2MR2

FC5A-F2M2

Maximum Error at 25°C

Thermocouple

±0.2% of full scale or ±2°C (4°F), whichever is greater However, R, S inputs, 0 to 200°C (0 to 400°F): ±6°C (12°F)

B input, 0 to 300°C (0 to 600°F): Accuracy is

not guaranteed. K, J, E, T, N inputs, Less than 0°C (32°F): ±0.4% of full scale

Resistance Thermometer

±0.1% of full scale or ±1°C (2°F), whichever is greater

Voltage, Current

±0.2% of full scale

Input Accuracy (at 0 to 55°C)

Thermocouple

±0.7% of full scale However, R, S input, 0 to 200°C (0 to 400°F): ±6°C (12°F) B input, 0 to 300°C (0 to 600°F): Accuracy is not guaranteed. K, J, E, T, N inputs, Less than 0°C (32°F): ±0.9% of full scale

Resistance Thermometer

±0.6% of full scale Voltage, Current

±0.7% of full scale

Data Accuracy

Maximum error at 25°C±Minimum digital resolution of each input range

Cold Junction Temperature Compensation Accuracy

±1°C at 0 to 55°C Sampling Period

125 ms

Type No.

FC5A-F2MR2

FC5A-F2M2

Control Output

Relay output 1a Rated load:

5A 250V AC (resistive load)

5A 30V DC (resistive load)

3A 250V AC (inductive load

cosφ=0.4)

Non-contact voltage (for SSR drive)

12V DC±15%

Current :

4 to 20mA DC

Type No.

FC5A-F2MR2

FC5A-F2M2

Time Setting Accuracy

±0.5% of setting time

Progressing Time Error After Power is Restored

Maximum 6 minutes

Non-volatile Memory Write Limit

1,000,000 times

General Specifications

Input Specifications

Output Specifications

Program Control Specifications

2-4 FC5A MicroSmart PID Module User’s Manual FC9Y-B1283

Type No.

FC5A-F2MR2

FC5A-F2M2

Isolation

Photocoupler-isolated between input and internal circuit Photocoupler-isolated between input and power circuit Photocoupler-isolated between input and internal circuit Photocoupler-isolated between output and internal circuit

Dielectric Strength

Output terminal - External power:

1500kV AC 5mA for 1 minute

Output terminal - Internal power:

1500kV AC 5mA for 1 minute

Input power - Output power:

1500kV AC 5mA for 1 minute

FG - External power:

548V AC 5mA for 1 minute

Input terminal - External power:

548V AC 5mA for 1 minute

Input terminal - Internal power

548V AC 5mA for 1 minute

Output terminal - External power:

2500V AC 5mA for 1 minute

Output terminal - Internal power

2500V AC 5mA for 1 minute

External power -Internal power

548V AC 5mA for 1 minute

Input terminal - Output terminal

548V AC 5mA for 1 minute

FG - External power:

548V AC 5mA for 1 minute

I/O terminal - External power:

548V AC 5mA for 1 minute

I/O terminal - Internal power:

548V AC 5mA for 1 minute

External power - Internal power:

548V AC 5mA for 1 minute

Input terminal - Output terminal:

548V AC 5mA for 1 minute

Type No.

FC5A-F2MR2

FC5A-F2M2

Power Consumption

Approx. 3.5W maximum

Module Power Consumption (Interior)

5V DC

65mA

24V DC

0mA

Ambient Temperature

0 to 55°C (No icing)

Ambient Humidity

10 to 95%RH (Non-condensing)

Weight

Approx. 140g

Environmental Specifications

Conforms to RoHS directive.

Recommended Cable

Twisted pair cable

Insulation, Dielectric Strength Insulation, Dielectric Strength

MODULE SPECIFICATIONS

Other

FC5A MicroSmart PID Module User’s Manual FC9Y-B1283 2-5

MODULE SPECIFICATIONS

4.5

Dimensions

(All dimensions in mm) * 8.5mm when the clamp is pulled out

2-6 FC5A MicroSmart PID Module User’s Manual FC9Y-B1283

INSTALLATION AND WIRING

Caution • Assemble the CPU module and PID modules before installing them on a DIN rail.

Otherwise, they may break.

• Do not lay out or wire the modules while power is supplied to them. Otherwise, they may be damaged.

• When installing modules, follow the instructions described in the FC5A MicroSmart user’s manual. If there are flaws in the installation, it may cause disattachment, failure or malfunction.

Direct mounting strip

FC4A-PSP1P

3: INSTALLATION AND WIRING

This chapter describes how to install and wire the PID modules. For general methods and precautions for installation and wiring of the PID modules, see chapter 3 in the FC5A MicroSmart user’s manual (FC9Y-B1268). Be sure to use the PID modules properly after understanding installation and wiring thoroughly.

Mounting Hole Layout for Direct Mounting on Panel Surface

To mount the PID module on a panel surface, use the direct mounting strip and two M4 screws (6 or 8 mm long). For details about the direct mounting strip, see the FC5A MicroSmart user’s manual (FC9Y-B1268).

(All dimensions in mm)

FC5A MicroSmart PID Module User’s Manual FC9Y-B1283 3-1

INSTALLATION AND WIRING

Example: Mounting hole layout for FC5A-C24R2 and four PID modules

(All dimensions in mm)

3-2 FC5A MicroSmart PID Module User’s Manual FC9Y-B1283

Caution • Make sure that the operating conditions and environments are within the specified

values.

• Be sure to connect the grounding wire to a proper ground, otherwise electrical shocks may be caused.

• Do not touch live terminals, otherwise electrical shocks may be caused.

• Do not touch terminals immediately after power is turned off, otherwise electrical

shocks may be caused.

• When using ferrules, insert a wire to the bottom of the ferrule and crimp the ferrule.

• When connecting a stranded wire or two solid wires to single-pole terminal block, be

sure to use a ferrule. Otherwise the wire may slip off the terminal block.

Phoenix Type

Cable Size

AI 1-8 RD

UL1007AWG18

AI 0.5-8 WH

UL1015AWG22

Phoenix Type

Cable Size

AI-TWIN2x0.75-8 GY

UL1007AWG18

AI-TWIN2x0.5-8 WH

UL1015AWG22

Ferrule for

Terminal block

Terminal Connection

To cramp the following ferrules, use the specified crimping tool (CRIMPFOX ZA 3).

For 1-cable connection For 2-cable connection

For 1-cable connection

INSTALLATION AND WIRING

Note: The above ferrules, crimping tool, and screwdriver are made by Phoenix Contact and are available from Phoenix

For 2-cable connection

Contact.

FC5A MicroSmart PID Module User’s Manual FC9Y-B1283 3-3

INSTALLATION AND WIRING

Caution • Connect an IEC 60127-approved fuse appropriate for the applied voltage and

current draw, at the position shown in the diagram. (This is required when equipment containing the MicroSmart is destined for Europe.)

• Do not connect a thermocouple to hazardous voltage (60V DC, 42.4V DC peak or higher).

• Be sure to check the wiring before the power is turned on. Faulty wiring may result in damage to the PID module.

• Applicable electric cables are listed below. Cable size AWG16: Single-cable

Cable size AWG18, AWG22: Single-cable/Twisted cable

NC -

NC NC NC -

FG NC

B B

RTD

B B

RTD

NC NC

”

’

”

’

-B

’

DC DC DC

24V DC

IN0

IN1

OUT1

OUT0

Channel

Terminal

No.

Terminal

No.

Channel

0 to 5V

4 to 20mA

1 to 5V 0 to 10V

0 to 20mA

0 to 1V

0 to 5V

4 to 20mA

1 to 5V 0 to 10V

0 to 20mA

0 to 1V

Fuse (50V-1.2A)

DC : Voltage/Current RTD : Resistance thermometer TC : Thermocouple

: Load : Analog current input instrument : Fuse

Terminal Arrangement

*1: OUT0 is a connection example of relay output.

OUT1 is a connection example of non-contact voltage/current output. The PID module having both outputs is non-existent.

3-4 FC5A MicroSmart PID Module User’s Manual FC9Y-B1283

Output Circuit

(A)

(B)

160k

Multiplexer

Input Selection Signal

Input

20M 15k 15k

5040k

100

Output Circuit

Current

Detection

Output Circuit

Short Circuit

Protected

Type of Protection

Input Circuits

FC5A-F2MR2、FC5A-F2M2

INSTALLATION AND WIRING

Output Circuits

FC5A-F2MR2

FC5A-F2M2 [Non-contact Voltage Output (for SSR drive)] FC5A-F2M2 (Current Output)

FC5A MicroSmart PID Module User’s Manual FC9Y-B1283 3-5

INSTALLATION AND WIRING

Separate the I/O lines from the power line as much as possible.

DC : Voltage/Current RTD : Resistance thermometer TC : Thermocouple

: Load : Analog current input instrument

: Fuse

NC -

NC NC NC -

FG NC

B B

RTD

B B

RTD

NC NC

”

’

”

’

-B

’

DC DC DC

24V DC

IN0

IN1

OUT1

OUT0

Channel

Terminal

No.

Terminal

No.

Channel

0 to 5V

4 to 20mA

1 to 5V 0 to 10V

0 to 20mA

0 to 1V

0 to 5V

4 to 20mA

1 to 5V 0 to 10V

0 to 20mA

0 to 1V

Fuse (50V-1.2A)

Power Supply for PID Modules

When supplying power to the PID modules, take the following into consideration.

Using the same power supply for the MicroSmart CPU and the PID module is recommended to suppress the influence of noise. If the same power source is used for the PID module and MicroSmart CPU module, after the MicroSmart CPU is started to run, the PID module performs initialization for a maximum of 5 seconds. During this period, each parameter has an indefinite value. Design the user program to make sure that each parameter is referred in the CPU module after the PID module operating status is changed to 0001h (Normal operation).

Wiring of Power Line and I/O Lines for the PID Module

Separate the I/O lines, particularly resistance thermometers, from the power line as much as possible to suppress the influence of noise.

3-6 FC5A MicroSmart PID Module User’s Manual FC9Y-B1283

PID MODULE MAIN FUNCTIONS

B. PID Module

A. Thermocouple

Control Target, such as Electric Furnace or Constant Temperature Oven.

Heater

C. Actuator

200V AC

Temperature

Set point (SP)

Time

Temperature

Set point (SP) B

Time

Set point (SP) A

4: PID MODULE MAIN FUNCTIONS

This chapter describes the temperature control, fixed value control, auto-tuning (AT), program control, heating/cooling control, difference input control, and cascade control of the PID module.

Temperature Control Using the PID Module

Temperature Control Configuration Example Using the PID Module

A. Sensor

Measures temperature of the control target. Thermocouple, resistance thermometer, voltage input, or current input can be used as the sensor.

B. PID module

Receives the temperature measured by the sensor as the process variable (PV), and calculates the output manipulated variable (MV) so that temperature difference (deviation) between the process variable (PV) and the set point (SP) can be eliminated. The output manipulated variable (MV) is outputted to the actuator as a control signal. Relay output, non-contact voltage output, or current output can be used as the control signal.

C. Actuator

Receives a control signal from the PID module and turns on the load power supply to the heater. Electromagnetic switches, SSR, or power controllers can be used as the actuator.

Optimal Temperature Control

The ideal temperature control, as shown in Figure 1, is to control the temperature to correspond with the set point (SP) regardless of any disturbances. There should be no overshoot or response delay of time until the temperature reaches the set point (SP).

Figure 1. Ideal Temperature Control Figure 2. Optimal Temperature Control

FC5A MicroSmart PID Module User’s Manual FC9Y-B1283 4-1

PID MODULE MAIN FUNCTIONS

Temperature

Set point (SP)

Time

Temperature

Set point (SP)

Characteristics of Control Target

Thermal Capacity

Static

Characteristic

Disturbance

Dynamic

Characteristic

In reality, the ideal temperature control shown in Figure 1 on the previous page is almost impossible to achieve due to a number of complicated factors such as thermal capacity, static characteristics, dynamic characteristics and disturbances. Figure 2 is regarded as an optimal temperature control result. Depending on the usage and objective, for some temperature control applications, suppression of overshoot is required even if the temperature rises very slowly as shown in Figure 3. For some temperature control applications, it is necessary to stabilize the temperature as quickly as possible by raising the temperature rapidly even if overshoot is generated as shown in Figure 4. In general, however, Figure 2 is regarded as an optimal temperature control. The PID module is designed to raise the process variable (PV) to the set point (SP) as quickly as possible in order to stabilize the process variable (PV) at the set point (SP) so as to perform the optimal temperature control. If the temperature fluctuates due to sudden disturbances, the PID module responds to the fluctuation with speedy response in the shortest possible time and performs quick control to stabilize the temperature.

Figure 3. Stable but slow temperature rise control

Figure 4. The temperature rises rapidly; however, the control stabilizes after overshoot and undershoot.

Characteristics of the Control Target

To perform optimal temperature control, it is necessary to have a good knowledge of the thermal characteristics of the PID module, sensors, actuators as well as control targets. For example, the PID module controls a constant temperature oven and its temperature can rise up to 100°C. Even if the set point (SP) of the PID modules is configured as 200°C, the temperature of the constant temperature oven rise only up to 100 °C due to its static characteristic. The characteristic of the control target is determined by the combination of the following 4 factors.

1. Thermal capacity: This represents how the target is easily heated, and has a relation with the volume size of the control target.

2. Static characteristic: This represents the capability of heating, and is determined by the size of the heater capacity.

3. Dynamic characteristic: This represents the rising characteristic (transitional response) during initial heating. This is a complicated process involving heater capacity, furnace capacity size and sensor location.

4. Disturbance: Any change in control temperature causes disturbance. For example, the change of ambient temperature or supply voltage can cause disturbance.

4-2 FC5A MicroSmart PID Module User’s Manual FC9Y-B1283

PID MODULE MAIN FUNCTIONS

Set Point (SP)

Temperature

Time

Control Output

OFF

Undershoot

Overshoot

Hunting

Set Point (SP)

Temperature

Time

Proportional Band

Offset

Point A

Fixed Value Control

The PID module provides 2 control modes, one is the fixed value control and the other is the program control. The fixed value control is a standard temperature control which performs to eliminate the deviation between the single set point (SP) and process variable (PV). The program control allows you to define the set point (SP) that changes as the time progresses so that the process variable (PV) can be controlled to match the set point (SP) changing as the time progresses. For detail about the program control, see 4-9. Control actions that can be used for fixed value control and program control are described below.

ON/OFF Control Action

In the ON/OFF control action, when the process variable (PV) is lower than the set point (SP), the control output is turned on, and when the process variable (PV) exceeds the set point (SP), the control output is turned off. Overshoot, undershoot, and hunting are generated. ON/OFF control is suitable for processes which do not require accuracy. If the proportional band or proportional gain of the PID module parameter is set to 0, the control action becomes ON/OFF control.

Overshoot, Undershoot

As the temperature of the control target rises as shown in the figure on the right, the process variable (PV) sometimes exceeds the set point (SP) greatly. This is called overshoot. If the process variable (PV) drops below the set point (SP), this is called undershoot.

Hunting

The control result oscillates as shown in the figure on the right. This is the the hunting.

P Control Action (Proportional Action)

P control action outputs the manipulated variable (MV) in proportion to the deviation between the process variable (PV) and the set point (SP) within the proportional band. The control output is ON until the process variable (PV) reaches the point A that is determined by the proportional band. If the process variable (PV) exceeds the point A (enters the proportional band), the control output starts turn on/off according to the control period and the manipulated variable (MV). If the process variable (PV) exceeds the set point (SP), the control output is completely turned off. While the process variable (PV) rises from the point A to the set point (SP), the control output ON time decreases and the control output OFF time increases. Compared to ON/OFF control action, there is no overshoot in P control action, and hunting becomes less frequent; however, the offset is generated. The P control action is suitable for processes such as gas pressure control or level control, in which there is no dead time. If the integral time and derivative time of the PID module parameter are set to 0, the control action becomes the P control action.

FC5A MicroSmart PID Module User’s Manual FC9Y-B1283 4-3

PID MODULE MAIN FUNCTIONS

Output Manipulated Variable

100

Proportional Band

Set Point (SP)

Proportional band area that can be configured with reset function. Offset can be corrected within ±proportional band from the set point (SP).

Output Manipulated Variable A: 100% B: 50% C: 0%

Set Point (SP)

Temperature

Time

Proportional Band

Disturbance

• If the proportional band is narrowed (Proportional gain is made larger)

Because the control output starts turning on/off at around the set point (SP), the time until the process variable (PV) reaches the set point (SP) is shortened, and the offset is small; however, hunting is frequent. If the proportional band is greatly narrowed, the control action becomes similar to the ON/OFF control action.

• If the proportional band is broadened (Proportional gain is made smaller)

Because the control output starts turning on/off at the significantly low temperature from the set point (SP), overshoot or hunting is reduced; however, it takes time for the process variable (PV) to reach to the set point (SP), and the offset between the process variable (PV) and the set point (SP) becomes broadened.

The offset caused by the P control action can be corrected by configuring the reset value. If the reset value is configured, the proportional band range can be shifted as shown in the figure below. The reset value can be automatically calculated by the auto-reset function.

PI Control Action (Proportional + Integral Action)

I (Integral) action automatically corrects the offset caused by P control action, and temperature control is performed at the set point (SP). However, it takes time for the process variable (PV) to be stable if the process variable (PV) is changed rapidly due to disturbance. PI control action is suitable for the processes in which the temperature slowly changes. If the derivative time of the PID module parameter is set to 0, the control action becomes the PI control action.

• If the integral time is shortened too much, the integral action becomes strong. The offset can be

corrected in a shorter time; however, hunting with a long cycle may be caused.

• If the integral time is extended too much, the integral action becomes weak and it takes time to correct

the offset.

4-4 FC5A MicroSmart PID Module User’s Manual FC9Y-B1283

Set Point (SP)

Temperature

Time

Proportional Band

Disturbance

Set Point (SP)

Temperature

Time

Disturbance

PD Control Action (Proportional + Derivative Action)

Compared with P action, the response to rapid temperature change due to disturbance is faster, the temperature control can be stabilized in a shorter time, and transitional response characteristic can be improved in PD control action. PD control action is suitable for the processes in which the temperature rapidly changes. If the integral time of the PID module parameter is set to 0, the control action becomes the PD control action.

• If the derivative time is shortened, the derivative action becomes weak. The response to the rapid

temperature change becomes slower. Because the action to suppress the rapid temperature rises becomes weaker, the time for the process variable (PV) to reach the set point (SP) is shortened; however, overshoot can occur.

• If the derivative time is extended, the derivative action becomes strong. The response to the rapid

temperature change becomes faster. Because the action to suppress the rapid temperature rises becomes strong, the time for the process variable (PV) to reach the set point (SP) is extended; however, overshoot can be decreased.

The offset caused by the PD control action can be corrected by configuring the reset value. The reset value can be automatically calculated by the auto-reset function.

PID Control Action (Proportional + Integral + Derivative Action)

P action suppresses the overshoot and the hunting, I action corrects the offset, and D action corrects rapid temperature change due to disturbance in shorter time. Thus, using PID control action, optimal temperature control can be performed. The proportional band, integral time, derivative time, and ARW can be automatically calculated by the auto-tuning (AT).

PID MODULE MAIN FUNCTIONS

FC5A MicroSmart PID Module User’s Manual FC9Y-B1283 4-5

PID MODULE MAIN FUNCTIONS

(1) (2) (3)

SP+20

(4) (4)

Time

Temperature

SP-20

(1) (2) (3)

(4)

Temperature

Time

Caution • Perform auto-tuning (AT)/auto-reset during the trial run.

• If the auto-tuning (AT) is performed near the ambient temperature, sufficient

fluctuations cannot be given to the process, and auto-tuning (AT) may fail. In such case, configure the P, I, D, and ARW values manually.

• Perform auto-reset when the process variable (PV) is stabilized within the proportional band.

• Once auto-tuning (AT)/auto-reset is performed, it is unnecessary to perform auto-tuning (AT)/auto-reset again as long as the process is unchanged.

• When voltage or current input is selected and the auto-tuning (AT) is performed, fluctuations are given to the process at the set point (SP) regardless of AT bias.

• During program control, fluctuations are given to the process as soon as auto-tuning (AT) is started.

Auto-Tuning (AT)/Auto-Reset

The optimal temperature control parameters differ depending on the characteristics of the process to control. For PID control action, the proportional band, integral time, derivative time, and ARW are automatically configured by performing auto-tuning (AT). For P control or PD control action, the reset value is automatically configured by performing auto-reset.

Auto-tuning (AT)

In order to configure P (proportional band), I (integral time), D (derivative time), and ARW (Anti-Reset Windup) automatically with optimal values, the auto-tuning (AT) can be performed. The auto-tuning (AT) gives temperature fluctuation to the process to calculate those parameters. To perform an optimal auto-tuning (AT), temperature fluctuation is given to the process when the process variable (PV) reaches near the set point (SP). By setting the AT bias, the temperature to start giving fluctuation can be configured. The relation between the set point (SP), AT bias, auto-tuning (AT) starting point, and fluctuation starting point are shown below.

[Process variable (PV) ≤ Set point (SP) - AT bias value]

When AT bias is set to 20°C, the PID module starts giving the temperature fluctuation to the process at the temperature 20°C lower from the set point (SP).

(1) Fluctuation period. PID parameters are measured. (2) PID parameters are calculated and auto tuning (AT) is finished. (3) Temperature is controlled with the PID parameters configured with auto-tuning (AT).

(4) AT bias value (20°C)

▲ AT: Auto-tuning (AT) perform bit is turned on

[Set point (SP) - AT bias value < Process variable (PV) < Set point (SP) + AT bias value]

The PID module starts giving the temperature fluctuation to the process when the process variable (PV) reaches the set point (SP).

(4) AT bias value (20°C) ▲ AT: Auto-tuning (AT) perform bit is turned on

4-6 FC5A MicroSmart PID Module User’s Manual FC9Y-B1283

SP+20

Temperature

(4)

Time

(1) (2) (3)

Time

Temperature

Offset Span

Offset is Corrected.

Auto-reset is Performed.

PID MODULE MAIN FUNCTIONS

[Process variable (PV) ≥ Set point (SP) + AT bias value]

When AT bias is set to 20°C, the PID module starts giving the temperature fluctuation to the process at the temperature 20°C higher from the set point (SP).

(4) AT bias value (20°C) ▲ AT: Auto-tuning (AT) perform bit is turned on

Auto-reset

During the P control or PD control action, the deviation (offset) between the process variable (PV) and the set point (SP) is generated when the process variable (PV) is stabilized. By performing auto-reset, the reset value can automatically be calculated to correct the offset. It is required to perform auto-reset when the process variable (PV) is stabilized within the proportional band. When the auto-reset is completed, the CPU module automatically reads all parameters including the calculated reset value from the PID module and stores those parameters in the data registers. It is unnecessary to perform the auto-reset again as long as the process is unchanged. When the proportional band (P) is set to 0 or 0.0, the reset value is cleared.

Auto-tuning (AT)/Auto-reset Perform/Cancel

The Auto-tuning (AT)/Auto-reset function can be performed or cancelled by turning on/off the operation parameter bits allocated to each channel. For the operation parameter bits, see page 5-10.

Perform Auto-tuning (AT) To perform auto-tuning (AT), turn on the control enable/disable bit (Bit0) and auto-tuning (AT)/auto-reset bit (Bit1) of the operation parameter. P, I, D and ARW values will automatically be configured. When auto-tuning (AT) is performed during the program control, P, I, D and ARW values of the current step are configured. While auto-tuning (AT) is performed, the Auto-tuning (AT)/Auto-reset LED (AT0/AT1) flashes. When auto-tuning (AT) is completed, the operation parameter Bit1 is automatically turned off, and the CPU module reads all parameters of the AT performed channel from the PID module and store those parameters in the data registers. If any parameters in the data registers of the CPU module have been changed but have not been written to the PID module, those parameters will be overwritten with the parameters read from the PID module when auto-turning (AT) is finished.

FC5A MicroSmart PID Module User’s Manual FC9Y-B1283 4-7

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