Rockwell Automation 1746-BTM User Manual

Barrel Temperature Control Module

1746-BTM

User Manual

Important User Information

Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in this guide are intended solely f or purpo ses of ex ample. Since t here are many variables and requirements associated with any particular installation, Allen-Bradley does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication.

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

Application, Installation and Maintenance of Solid-State Control

(available from your local Allen-Bradley office), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication.

Reproduction of the contents of this copyrighted publication, in whole or part, without written permission of Rockwell Automation, is prohibited.

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

ATTENTION

Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss

Attention statements help you to:

• identify a haza r d

• avoid a hazard

• recognize the consequences

IMPORTANT

Allen-Bradley is a trademark of Rockwell Automation

Identifies information that is critical for successful application and understanding of the product.

Publication 1746-UM010B-EN-P - April 2001

iii

European Communities (EC) Directive Compliance

If this product has the CE mark it is approved for installation within the European Union and EEA regions. It has been designed and tested to meet the following directives.

EMC Directive

This product is tested to meet the Council Directive 89/336/EC Electromagnetic Compatibility (EMC) by applying the following standards, in whole or in part, documented in a technical construction file:

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

Industrial Environment

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

Industrial Environment

This product is intended for use in an industrial environment.

Low Voltage Directive

This product is tested to meet Council Directive 73/23/EEC Low Voltage, by applying the safety requirements of EN 61131-2 Programmable Controllers, Part 2 - Equipment Requirements and Tests. For specific information required by EN 61131-2, see the appropriate sections in this publication, as well as the Allen-Bradley publication Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1.

This equipment is classified as open equipment and must be mounted in an enclosure during operation to provide safety protection.

Publication 1746-UM010 B- EN-P - April 2001

Publication 1746-UM010B-EN-P - April 2001

Summary of Changes

Major changes in this revision include:

• Ladder code addresses have been changed.

• The sample ladder code in Chapter 9 has been enhanced.

• Examples outlining the mathematical relationships involved in

Startup Aggressiveness Factor and Ramp Rates have been included in Chapter 3.

• Appendixes A and B have been omitted.

• Module specifications can be found in the 1746-BTM Installation

Instructions, Publication 1746-IN014B-EN-P.

1 Publication 1746-UM010 B- EN-P - April 2001

2 Summary of Changes

Publication 1746-UM010B-EN-P - April 2001

Preface

Using This Manual

This manual shows you how to use the Barrel Temperature Control Module (cat. no. 1746-BTM) in an A llen- Bradley SLC sys tem fo r barrel temperature control and other injection molding or extrusion related temperature control applications. The manual explains how to install, program, calibrate, and troubleshoot the BTM module.

ATTENTION

Use the 1746-BTM module in a local I/O chassis only for barrel temperature control of injection molding applications or extruders. Any other applications are not supported.

Audience

You must be able to program and operate an Allen-Bradley SLC programmable controller to make efficient use of this module. In particular, you must know how to configure M0 and M1 files. For more information, see the appropriate SLC programming manual before you generate a program for this module.

System Compatibility

System compatibility involves data table use as well as compatibility with a local I/O chassis and SLC processor.

Data Table

Communication between the module and processor is bi-directional. The processor transfers output data through the output image table to the BTM module and transfers input data from the BTM module through the input image table. The BTM module also requires M files for configuration and calibration values.

I/O Chassis

You can use this module with 1746-A4, -A7, -A10, -or -A13 chassis, provided there is an SLC controller in the chassis (local system). You can place the BTM module in any I/O slot except for the first slot which is reserved for the processor.

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P-2 Preface

SLC Processor

The 1746-BTM module is compatible with any SLC processor that supports M0/M1 files, such as the SLC 5/05, SLC 5/04, SLC 5/03, and SLC 5/02 controllers.

Vocabulary

In this manual, we refer to:

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

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

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

processor”

• a thermocouple as a “TC”

• a time-proportioned output as “TPO”

• the tuning-assisted processes as “TAP”

• proportional-integral-derivative as “PID”

• cold-junction compensation as “CJC”

Publication 1746-UM010B-EN-P - April 2001

Important User Information. . . . . . . . . . . . . . . . . . . . . . . . . . ii

European Communities (EC) Directive Compliance . . . . . . . iii

EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

Audience. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

System Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

Vocabulary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2

Chapter 1

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

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

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

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

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

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

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

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

Output response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Chapter 2

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

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

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

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

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

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

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

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

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

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

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

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

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

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Chapter 3

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

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

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

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

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

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

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

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

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

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

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TOC-2 Table of Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

Heat/Cool Minimum On-times. . . . . . . . . . . . . . . . . . . . . . 3-6

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

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

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

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

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

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

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

Alarm Dead Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Word 15 for Channel 1. . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Thermal Integrity Loss Detection . . . . . . . . . . . . . . . . . . . . 3-9

Words 16 and 17 for Channel 1 . . . . . . . . . . . . . . . . . . 3-9

Ramp Rates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Words 18 for Channel 1 . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Non-barrel Autotune Disturbance Size . . . . . . . . . . . . . . . . 3-9

Word 20 for Channel 1. . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Implied Decimal Point . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Configuration Block, M1 File, Loops 1-4 N10:0-100. . . . . . . 3-11

Startup Aggressiveness factor. . . . . . . . . . . . . . . . . . . . . . . 3-11

Ramp Rates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

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Chapter 4

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

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

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

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

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

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

Table of Contents TOC-3

Chapter 5

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

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

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

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

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

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

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

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

Troubleshooting Autotune . . . . . . . . . . . . . . . . . . . . . . 5-7

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

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

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

Chapter 6

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

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

Chapter 7

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

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

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

Chapter 8

Troubleshooting with LED Indicators. . . . . . . . . . . . . . . . . 8-1

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

Chapter 9

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

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

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

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

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

5/05P Processors Using BTM201.rss . . . . . . . . . . . . . . . . . . 9-1

BTM201.rss Data Table Layout . . . . . . . . . . . . . . . . . . . 9-2

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

BTM201.rss Programming Notes . . . . . . . . . . . . . . . . . . 9-5

Support for 5/02 Processors Using BTM50220.RSS . . . . . . . 9-7

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

Download and Upload Settings . . . . . . . . . . . . . . . . . . 9-7

General Notes for Programming the 1746-BTM. . . . . . . . . . 9-9

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TOC-4 Table of Contents

Publication 1746-UM010B-EN-P - April 2001

Getting Started

This chapter gives you information on:

• the function of the temperature control module

• features of the temperature control module

• time–proportioned output (TPO)

• module addressing

• response to slot disa bli ng

Chapter

Temperature Control Using a BTM Module in an SLC System

ATTENTION

Use the 1746–BTM module only for barrel temperature control for injection mold ing applications or extruders in a local I/O chassis. Any other applications are not supported.

The temperature control module is an intelligent I/O module that can provide a maximum of 4 PID loops for temperature control. The module has 4 analog thermocouple (TC) inputs. Each analog input functions as the process variable (PV) for a PID loop. The PID algorithm and tuning–assisted–process (TAP) algorithm are performed on the module for each of the loops. The control–variable (CV) output of each loop, either analog output or time–proportioned output (TPO), is sent from the module to the SLC data table. Your application ladder logic must access the CV value in the data table and send the analog or TPO data to an output module to close the loop.

Figure 1.1

A 1746–BTM module with 4 PID logic channels, showing one complete PID loop

SLC data table

1 Publication 1746-UM010 B- EN-P - April 2001

CV CV

output module analog or TPO

loop logic loop logic loop logic loop logic

PV PV PV PV

heater

process to be controlled

1-2 Getting Started

Features of the T emperature Control Module

The 1746–BTM module provides:

• 4 independent temperature control loops

• autotune PID loops (one loop or any combination of loops can

be autotuned while other loops are running)

• a unique start–up algorithm to minimize overshoot

• an isolated thermocouple (J and K) input for each PID loop

• 16–bit analog–to–digital converter resolution (0.1° resolution)

• a heat CV signal (for each PID loop) as a numeric % value

• a cool CV signal (for each PID loop) as a numeric % value

• a heat CV signal (for each PID loop) as a TPO bit

• a cool CV signal (for each PID loop) as a TPO bit

• temperature values in C ° or F °

• self–calibration (external reference required)

• user–selectable high and low alarms with dead band for

hysteresis

• input open–circuit detection

Module Outputs

The BTM module sends the control variable (CV) for heating an d/or cooling each loop to the SLC processor’s input image table as both of:

• numeric value (current CV)

• time–proportioned output (TPO)

Current CV

Y our ladder logic should read the numeric value (current CV), scale it, and send it to an analog output module to generate the control signal to an analog temperature control actuator. If using the sample program look for current CVs in N10:208–211 for loops 1–4. Refer to Sample Program on page 9-1.

TPO

The module returns the heat TPO (bit 6) and cool TPO (bit 7) in input image table words 8–11 for loops 1–4. The sample program sends TPO signals to a digital output module to generate the control signal to a digital temperature control actuator. Refer to Sample Program on page 9-1.

Publication 1746-UM010B-EN-P - April 2001

Figure 1.2 TPO timing diagram

Getting Started 1-3

TPO bit

BTM

Module

Off

SLC 5/0x

I/O Image Table

Output Image

Slot e

See Figure 1.3 on

page 1-4

Input Image

Slot e

See Figure 1.3 on

page 1-4

CV% = (40%)

X = on time (2.0 sec)

Y = TPO period (5.00 sec)

data in parenthesis refers to sample program values.

The TPO duty cycle (Y) must be considerable shorter in time than the system dead time. For additional information, Refer to Autotune a Loop on page 5-2.

The following memory map shows you how the SLC processor’s output and input image tables are defined for the module. See Table

9.A: BTM201.r s s N7 Da t a Table on pag e 9-2.

Bit 15 Bit 0 Address

Loop 1 configuration data word 0 O:e.0

Slot e portion of SLC image table for BTM module

output

image

16 words

input

image

16 words

Loop 2 configuration data word 1 O:e.1 Loop 3 configuration data word 2 O:e.2 Loop 4 configuration data word 3 O:e.3 Loop 1 run setpoint value word 4 O:e.4 Loop 2 run setpoint value word 5 O:e.5 Loop 3 run setpoint value word 6 O:e.6 Loop 4 run setpoint value word 7 O:e.7 Loop 1 manual output value word 8 O:e.8 Loop 2 manual output value word 9 O:e.9 Loop 3 manual output value word 10 O:e.10 Loop 4 manual output value word 11 O:e.11 miscellaneous control bits word 12 O:e.12 not used word 13 O:e.13 not used word 14 O:e.14 not used word 15 O:e.15

Loop 1 temper ature word 0 I:e.0 Loop 2 temper ature word 1 I:e.1 Loop 3 temper ature word 2 I:e.2 Loop 4 temper ature word 3 I:e.3 Loop 1 configuration status word 4 I:e.4 Loop 2 configuration status word 5 I:e.5 Loop 3 configuration status word 6 I:e.6 Loop 4 configuration status word 7 I:e.7 Loop 1 control status and TPO word 8 I:e.8 Loop 2 control status and TPO word 9 I:e.9 Loop 3 control status and TPO word 10 I:e.10 Loop 4 control status and TPO word 11 I:e.11 If using the sample program,

variables in words 12-15, including current CVs, are multiplexed and scanned into N10:200-243

word 12 I:e.12 word 13 I:e.13 word 14 I:e.14 word 15 I:e.15

Publication 1746-UM010 B- EN-P - April 2001

1-4 Getting Started

Module Addressing

Input Image Table Address Output Image Table Address

slot slot

file type file type

When you enter the module ID in processor configuration (off-line), the processor automatically reserves the required number of I/O image table words. In the figure below, that section of the I/O image

table is designated by “slot e”. Its location in the I/O image table is determined by the module’s slot location “e” in the I/O chassis. Slot location “e” is a required addressing unit when referring to the module in ladder logic. For the sample program’s data table layout, See Table 9.A: BTM201.rss N7 Data Table on page 9-2. See Figure 1.3 for an explanation of the image table addresses

Figure 1.3 .

word

I : e . 6 O : e . 6

element delimiter

word delimiter

element delimiter

word

word delimiter

Response to Slot Disabling

By writing to the status file in your modular SLC processor you can disable any chassis slot. See your SLC programming manual for the slot disable/enable procedure.

ATTENTION

Always understand the implications of disabling the module before using the slot disable feature.

Input response

When the slot for this module is disabled, the module continues to update its inputs. However, the SLC processor does not read from a module whose slot is disabled. Therefore, inputs appearing in the processor image table remain in their last state, and the module’s updated inputs are not read. When the processor re–enabl es the module slot, the current state of module inputs are read by the controller during the subsequent scan.

Output response

Publication 1746-UM010B-EN-P - April 2001

When the slot for this module is disabled, configuration words in the SLC processor’s output image table are held in their last state and not transferred to the module. When the slot is re–enabled, output image table words are transferred to the module during the subsequent scan.

Installing and Wiring

This document gives you information about:

• avoiding electrostatic damage

• compliance with European Union directive

• determining the module’s chassis power requirement

• planning for sufficient enclosure depth

• choosing a module slot in a local I/O chassis

• installing the module

• wiring the module

Chapter

Avoiding Electrostatic Damage

Electrostatic discharge can damage semiconductor devices inside this module if you touch backplane connector pins. Guard against electrostatic damage by observing the following precautions:

ATTENTION

Electrostatic discharge can degrade performance or cause permanent damage. Handle the module as stated below.

• Touch a grounded object to rid yourself of charge before

handling.

• Wear an approved wrist strap when handling the module.

• Handle the module from the front, away from the backplane

connector.

• Do not touch backplane connector pins.

1 Publication 1746-UM010 B- EN-P - April 2001

2-2 Installing and Wiring

European Communities (EC) Directive Compliance

If this product has the CE mark it is approved for installation within the European Union and EEA regions. It has been designed and tested to meet the following directives.

EMC Directive

• EN 50081-2 EMC — Generic Emissi on Standard, Part 2 —

Industrial Environment

• EN 5001082-2 EMC — Generic Immunity Standard, Part 2 —

Industrial Environment

This product is intended for use in an industrial environment.

Low Voltage Directive

This product is tested to meet Council Directive 73/23/EC Low Voltage, by applying the safety requirements of EN 61131-2 Programmable Controllers, Part 2 - Equipment Requirements and Tests. For specific information required by EN 61131-2, see the appropriate sections in this publication, as well as the Allen-Bradley publication Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1.

This equipment is classified as open equipment and must be mounted in an enclosure during operation to provide safety protection.

Publication 1746-UM010B-EN-P - April 2001

Installing and Wiring 2-3

Determining Power Requirements

Choosing a Module Slot in a Local I/O Chassis

When computing power supply requirements, add the values shown in Table 2.A to the requirements of all other modules in the SLC chassis to prevent overloading the chassis power supply.

Table 2.A Power Supply Requirements

5V dc amps 24V dc amps

0.110 0.085

Place your module in any slot of an SLC500 module, or modular

expansion chassis, except for the left–most slot (slot 0), reserved for the SLC processor or adapter modules.

IMPORTANT

For proper operation, use this module with a local processor. The module is not designed to operate in a remote chassis.

Installation conside rations

Most thermocouple–type applications require an industrial enclosure to reduce the effects of electrical interference. Thermocouple inputs are highly susceptible to electrical noises due to the small signal amplitudes (microvolt/C °). Isolate them from other input wiring and modules that radiate electrical interference.

Group your modules within the I/O chassis to minimize adverse effects from radiated electrical noise and heat. Consider the following conditions when selecting a slot location. Position the module away from modules that:

• connect to sources of electrical noise such as relays and ac

motor drives

• generate significant heat, such as 32–point I/O modules

Publication 1746-UM010 B- EN-P - April 2001

2-4 Installing and Wiring

Installing the Module

Follow this procedure:

ATTENTION

Never install, remove, or wire modules with power applied to the chassis or devices wired to the module.

1. Align the circuit board of the thermocouple module with the

card guides located at the top and bottom of the chassis.

2. Slide the module into the chassis until both top and bottom

retaining clips are secured. Apply firm even pressure on the module to attach it to its backplane connector. Never force the module into the slot.

3. Cover unused slots with the card slot filler, catalog number

1746–N2.

4. To remove, press the releases at the top and bottom of the

module, and slide the module out of the chassis slot.

retaining clips

card guides

top and bottom releases

Publication 1746-UM010B-EN-P - April 2001

Installing and Wiring 2-5

Removing th e terminal block

When installing the module, it is not necessary to remove the terminal block. But if you need to remove it, follow this procedure:

1. Alternately loosen the two retaining screw s to avoid cracking the

terminal block.

2. Grasp the terminal block at the top and bottom and pull

outward and down. When removing or installing the terminal block be careful not to damage the CJC sensors.

Tip: The R eplacement Part Number for the Terminal Block with the CJCs is 1746-RT32. You cannot purchase a CJC by itself.

CJC sensors

retaining screws

3. Use the write–on label to identify the module and its location.

SLOT

MODULE

RACK

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2-6 Installing and Wiring

Wiring the Module

The module has an 18–position, removable terminal block. The terminal block pin–out is shown below.

ATTENTION

Disconnect power to the SLC before attempting to install, remove, or wire the removable terminal wiring block.

Figure 2.1 Terminal block pin out.

Retaining Screw

Channel 0+

Channel 0Channel 1+ Channel 1-

Channel 2+ Channel 2-

Channel 3+

Channel 3-

spare part catalog number:

n/c

1746-RT32

CJC Assembly

Do NOT use these connections

CJC Assembly

Retaining Screw

CJC A+ CJC A-

CJC B+ CJC B-

Cold Junction Compensation (CJC)

ATTENTION

In case of accidental removal of one or both thermistors, replace them by connecting them across the CJC terminals located at the top and/or bottom left side of the terminal block. Always connect the red lug to the (+) terminal (to CJC A+ or CJC B+).

Do not remove or loosen the cold junction compensating thermistors located on the terminal block. Both thermistors are critical to ensure

accurate thermocouple input readings at each channel. The module will not operate in the

thermocouple mode if a thermistor is removed

Publication 1746-UM010B-EN-P - April 2001

Installing and Wiring 2-7

Figure 2.2 Thermistor place me nt on t he bot t om of the terminal block

Always attach red lug to the CJC+ terminal

Wiring consi derations

Follow the guidelines below when planning your system wiring.

• To limit th e pickup of electrical noise, keep thermocouple and

millivolt signal wires away from power and load lines.

• For high immunity to electrical noise, use Alpha 5121 (shielded,

twisted pair) or equivalent wire for millivolt sensors; or use shielded, twisted pair thermocouple extension lead wire specified by the thermocouple manufacturer. Using the incorrect type of thermocouple extension wire or not following the correct polarity may cause invalid readings. See IEEE Std. 518, Section 6.4.2.7 or contact your sensor manufacturer for additional details.

• When trimming cable leads, minimize the length of unshielded

wires.

• Ground the shield drain wire at only one end of the cable. The

preferred location is at the I/O chassis ground (See Figure 2.4).

• For maximum noise reduction, use 3/8 inch braid wire to

connect cable shields to the nearest I/O chassis mounting bolt. Then connect the I/O chassis to earth ground (See Figure 2.4). These connections are a requirement regardless of cable type.

• Tighten terminal scre ws . Ex ce ss i ve ti gh te ni n g c an stri p th e

screw.

• The open–circuit detector generates approximately 20 nano–

amperes into the thermocouple cable. A total lead resistance of 25 ohms (12.5 one–way) will produce 0.5 mV of error.

• Follow system grounding and wiring guidelines found in your

SLC 500 Modular Hardware Installation and Operation Manual, publication 1747–6.2.

Publication 1746-UM010 B- EN-P - April 2001

2-8 Installing and Wiring

Preparing and Wiring the Cables

To prepare and connect cable leads and drain wires, follow these steps:

Figure 2.3 Cable lead and drain wire preparation

Remove the foil shield and drain wire from sensor-end of the cable

Signal Wires

Extract th e d r ain wire but remove the foil shield, at the module-end of the cable.

Drain Wire

Signal Wires

1. At each end of the cable, s trip s ome casi ng to expo se in divid ual

wires.

2. Trim signal wires to 5–inch lengths beyond the cable casing.

Strip about 3/16 inch (4.76 mm) of insulation to expose the ends of the wires.

3. At the module–end of the cables:

- extract the drain wire and signal wires

- remove the foil shield

- bundle the input cables with a cable strap

4. Connect drain wires together and solder them to a 3/8” wire

braid, 12” long. Keep drain wires as short as possible.

5. Connect the 3/8” wire braid to the nearest chassis mounting

bolt.

Publication 1746-UM010B-EN-P - April 2001

6. Connect the signal wires of each channel to the terminal block.

Installing and Wiring 2-9

7. At the source-end of cables from mV devices (See Figure 2.3

and Figure 2.4):

• remove the drain wire and foil shield

• apply shrink wrap as an option

• connect to mV devices keeping the leads short

Figure 2.4 Cable Preparation to Minimize Electrical Noise Interference

Wires

3/8”

Make unshielded wires as short as possible.

Limit braid length to 12” or less. Solder braid to lug on bottom row of I/O chassis bolts.

IMPORTANT

Make unshielded wires as short as possible.

Solder drain wires to braid at casing.

Connect I/O

chassis bolt to

earth ground

3/8”

Signal Wires

Cables

Terminal Block

Chnl 0

Chnl 1

Chnl 2

Chnl 3

n/c

If noise persists, try grounding the opposite end of the cable. Ground one end only.

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2-10 Installing and Wiring

Specifications

Backplane Current consumption

110 mA at 5V dc 85 mA at 24V dc

Backplane power consumption 0.6W maximum (0.55W @ 5V dc, 2W @ 24V dc) Number of channels 4 (backplane and channel-to-channel isolated) I/O chassis location any I/O module slot except 0 A/D conversion method sigma-delta modulation Input filtering analog filter with low pass digital filter Normal mode rejection

between [+]input and [-]input Common mode rejection

between inputs and chassis

greater than 50 dB at 50 Hz greater than 60 dB at 60 Hz

greater than 120 dB at 50/60 Hz with 1K ohm imbalance

ground Channel bandwidth (-3db) 8 Hz Calibration once every six months Isolation 1000V transient or 150 VAC continuous

channel-to-channel or channel-to-backplane

Agency Certifications

When product or packaging is marked:

Listed Industrial Control Equipment

Certified Process Control Equipment Certified for use in Class I, Division 2, Groups A, B, C, D or nonhazardous locations

Marked for all applicable directives Marked for all applicable acts

N223

Publication 1746-UM010B-EN-P - April 2001

Chapter

Configuring the Module

You configure the module by setting words and bits for each loop in

Configuration Block, N10:0–100, which your ladder logic uses to load the module’s M1 file. We cover bit selections and word descriptions. Refer to Table 3.B on page 3-13 for selections, units, and defaults.

Loop Operation Mode

Type of Loop Input

Word 1, Bits 0 and 1 for Channel 1

Use these bits to select how you want the loop to perform:

Mode of Loop Operation 01 00

monitor the loop to indicate temperature and alarms 0 0 perform PID loop control with temperature indication and

alarms disable the loop 1 0 invalid sett ing 1 1

Word 1, Bits 2-5 for Channel 1

Use the following bits to sel ect type J or K thermocouple; any other bit setting is invalid:

TC 05 04 03 02

type J 0 0 0 0 type K 0 0 0 1

1 Publication 1746-UM010 B- EN-P - April 2001

3-2 Configuring the Module

Enable Loop Alarms

TC Break Response

Word 1, Bit 6 for Channel 1

Set this bit to enable alarms for the designated loop.

Word 1, Bits 7 and 8 for Channel 1

If the module detects a TC open wire for a loop in automatic mode, you can select how the module responds in one of the following ways:

TC Break Response 08 07

disables the loop 0 0 forces CV to TC Break Control value (word 4, below) 0 1 forces CV to manual % output (O:e.8 for loop 1) 1 0 invalid setting 1 1

For additional information, Refer to TC Break Control on page 3-5.

Loop Autotune Gains Level

Word 1, Bits 10 and 11 for Channel 1

You can change and download autotune gains level selection for any or all zones at any time. When changed, you must redownload the M1 file (configuration) followed by the M0 file (autotune/gains) so the module can recalculate PID values based on new loop autotune gains.

You do not need to re–autotune.

Autotune Gain Level 11 10

low 0 0 medium 0 1 high 1 0 very high 1 1

Publication 1746-UM010B-EN-P - April 2001

Configuring the Module 3-3

Barrel/Non-barrel Control

Word 1, Bit 12 for Channel 1

You select between barrel and non–barrel control.

Select: for these applications: 12

barrel control heat–only or heat/cool 0 non–barrel control heat–only, cool–only, or heat/cool 1

Barrel Control

Select barrel control for multiple–zone applications in which there is thermal conduction between the zones. Injection molding and extrusion are good example applications because they use multiple heater bands (zones) mounted on one thermal conductor (the metal barrel). The barrel conducts heat between different zones. If you select barrel control, also select between inner and outer zones (word 1, bit 13 for channel 1). A barrel loop is autotuned as the temperature rises from a cold start to a temperature setpoint during startup.

Non–barrel con tr ol

Select non–barrel control for applications with independent loops and no thermal conduction between zones. If you select non–barrel control, the inner/outer zone selection doesn’t apply.

Switching the barrel control

For some applications, even though the loop s are independent with no thermal conduction between zones, barrel control might provide better performance than non–barrel control. If a loop has any of these characteristics, you might want to use barrel control if the:

• time constant is greater than 10 - 30 seconds

• loop has a problem of overshooting the setpoint

• loop output is saturating (CV is at 100%) for a significant

duration

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3-4 Configuring the Module

)

Inner/Outer Zone Selection

ATTENTION

If you switch a loop between non–barrel and barrel control, you must re–autotune the loop before operating it. If you don’t re–autotune, the autotune values will be wrong for the application and the

gains will be greatly distorted.

Word 1, Bit 13 for Channel 1

If you make a selection for barrel control, you also must select whether the loop is an inner zone or outer zone.

Select: for a zone: 13

inner not at either end of the

barrel

outer at either end of the barrel 1

The PID gain calculation algorithm for an inner zone is slightly different than that for an outer zone to account for an inner zone being more affected by adjacent zones. The inner zones are treated as more of an integrating process than the outer zones.

Typical plastic injection barrel with multiple temperature zones

Publication 1746-UM010B-EN-P - April 2001

Outer

Zone

Nozzle

T = temperature measurement point (thermocouple) H = heater band (element

Inner

Zone

Zone 1 Zone 2 Zone 3

H1 H2 H3

T1 T2 T3

Inner

Zone

Outer

Zone

Ram (Screw)

If you change the inner/outer zone selection after autotune, you must

re–autotune.

Configuring the Module 3-5

High/Low CV Limits

TC Break Control

Words 2 and 3 for Channel 1

Use CV High and Low Limits to set up the loop mode:

For this loop mode:

heat, only 0% 100% cool, only -100% 0 heat/cool -100% +100%

CV Low:

CV High:

Word 4 or O:e.8 for Channel1

If a loop input circuit becomes open (open wire) the loop can not measure temperature. In automatic mode, the lack of temperature feedback makes it impossible to control the temperature. To guard against this condition, the BTM module provides TC break detection. When a break is detected, the module responds in one of these ways:

Standby Setpoint

• disables the loop

• forces CV to this (TC Break Control) value (word 4 for loop 1)

• forces the CV to the manual %–output value (O:e.8 for loop 1)

Once the thermocouple break has been repaired you must d isable the loop and then re-enable it (through the input image table O:e.0/0 loop 1).

For additional information, Refer to TC Break Response on page 3-2.

Word 5 for Channel 1

When not using the runti me setpoi nt (O:e.4 f or loop 1) , use this value to hold a lower temperature for faster warm up and/or optimum standby conditions.

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3-6 Configuring the Module

Heat/Cool Minimum On-times

Heat/Cool TPO Period

PV Rate and Associated

Words 6 and 8 for channel 1

These values determine the minimum cycle time after which loop TPO bits will turn ON. They are used to allow contactors time to close or pull in. If the contactor is energized for less than this value, the contactor will not close, but the attempt will count as a cycle.

For example, suppose you set the TPO period for 10 seconds and the minimum ON time to 1 second. Then if the module calculates a CV% of 10% or less, the TPO bit for that zone will not tur n ON .

Words 7 and 9 for Channel 1

When CV loop output is time–proportioned (TPO), use this value to set the interval between successive turn–ONs. For less than a 100% output level, the output goes OFF for the balance of the interval.

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

Alarm

High/Low Temperature and Deviation Alarms

The PV Rate is a setpoint with an associated alarm that indicate s when the temperature is rising too rapidly. If the zone’s PV has risen more than this setpoint in one second (in auto mode), the module sets the PV rate alarm bit (I:e.4/05, loop 1). The module only reports this alarm - no action is taken.

Words 11-14 for Channel 1

In the configurat ion block (M1 file) yo u select val ues for the follow ing temperature–level alarms:

• low temperature alarm (word 11 for channel 1)

• high temperature alarm (word 12 for channel 1)

• low deviation alarm from the set point(word 13 for channel 1)

• high deviation alarm from the set point(word 14 for channel 1)

Publication 1746-UM010B-EN-P - April 2001

Configuring the Module 3-7

Set Point

Temp

0°

High Temperature Alarm Value (absolute)

High Deviation Alarm Value (track setpoint )

Low Deviation Alarm Value (track setpoint)

Low Temperature Alarm Value (absolute)

Time

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3-8 Configuring the Module

Alarm Dead Band

Word 15 for Channel 1

Once the temperature alarm bits are on, they remain on until the

temperature drops below the high alarm by the alarm dead–band value or rises above the low alarm by this value.

The alarm dead band applies to the CV value at the high and low temperature alarms and deviation alarm values and provides a hysteresis effect. Low and high alarms are defined as:

• Low Alarm With Dead Band — When the temperature falls

below the user–defined low alarm value, the low alarm bit is turned on. When the temperature rises above the level of the low alarm value but still below the level of the dead–band value, the low alarm bit remains on. Only when the temperature rises above the dead–band level will the alarm bit be turned off.

• High Alarm With Dead Band — When the temperature rises

above the user–defined high alarm value, the high alarm bit is turned on. When the temperature falls below the level of the high alarm value but still above the level of the dead–band value, the high alarm bit remains on. Only when the temperature falls below the dead–band level will the alarm bit be turned off.

high (CV) alarm level

low (CV) alarm level

Deadband

Temperature

Time

alarm off alarm on

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Configuring the Module 3-9

Thermal Integrity Loss Detection

Ramp Rates

Words 16 and 17 for Channel 1

The loss of thermal integrity is detected when the loop, in automatic mode, is not responding to a CV at 100% Detecti ng the loss of thermal integrity requires an assumption of a minimum rate of change in the temperature (PV) when the o utput (CV) is at 100%. Exa mples of a loss

of thermal integrity could be the failure of a heating–band contactor to close, or a sensor not in proper position to measure true temperature.

The values you enter in words 16 and 17 for loop 1 establish a minimum rate of change (°/min.) in the temperature input (PV) that you allow when the output (CV) is at 100% in automatic mode. The temperature change value you enter in word 16 divided by the period value you enter in word 17 is the thermal integrity rate.

IMPORTANT

Once loss of thermal integrity is detected, you must clear this condition by disabling the affected loop and then re–enabling it. To disable this feature, enter zero in for both setpoints.

Words 18 for Chann el 1

Non-barrel Autotune Disturbance Size

This value ramp s th e se t poi nt in st ep s to the new setpoint.

Word 20 for Channel 1

This is a pure %–output step function for performing a non-barrel autotune. It is added to the current output (%). It should be applied under steady–state conditions. The loop operating mode must be non–barrel.

EXAMPLE

Consider this:

• CV is 10%

• non-barrel Autotune Disturbance Size is 10%

If an autotune is invoked the CV’s output would go to 20% for the duration of the Autotune.

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3-10 Configuring the Module

Table 3.A Implied Decimal Po i nt Examples

Parameter Given Range

IMPORTANT

Because loop values are stored and reported in integer files, you must understand the meaning of implied decimal point (IDP). Otherwise, the magnitude of your intended value may be in error by as much as 1000, depending on the position of the IDP.

Implied Decimal Point

When entering or reading integer values, the range, given in Table

3.A, provides the implied decimal point. It is the number of digits to the right of the decimal point (for an example (IDP) range of 0.0 thru

3276.7, the implied decimal point is 1).

Status values are similarly read. You must know the range of the value to read it correctly. For example, if reading a heat integral (0.0000 thru

3.2767), a display of 5000 would have a value of 0.5.

(1)

IDP

Example

Thermal Integrity Standby Setpoint TPO Period 0.00 thru 100.00

Cool Proportional 0.000 thru 32.767 3 If you want to store a value of 18, enter 18000. Heat Integral 0.0000 thru 3.2767 4 If you want to store a value of 0.5, enter 05000.

(1)

IDP indicates the number of digits from the right that locates the implied decimal point.

0 thru 100

0.0 thru 32767.7

sec.

If you want to store a value of 66

If you want to store a value of 660.0

2 If you want to store a value of 6 seconds, enter

00600.

, enter 00066.

, enter 06600.

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Configuring the Module 3-11

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

Startup Aggressiveness factor

Configuration block (M1 file) contains 101 words as listed below. Data table location for Loops 1-4 are located in N10. For each additional 1746-BTM, add 1 to N10 (N11:0-100).

The startup aggressiveness factor (SAF) modifies the pre-set point value. The pre-set point value is the temperature at which you switch from the cold startup algorithms to PID control. The pre-set point value is calculated from the auto tune data. The value is returned through the rotator bits. In the example code it would be found in Nxx:236 thru 239, a value for each channel.

The startup aggressiveness factor increases the pre-set point value by percentage. For example:

EXAMPLE

Consider:

• setpoint is 400.0°

• preset point for channel 1 (nxx:236) is 75°

• startup aggressiveness factor is 0%

The point at which you would switch from the cold startup algorithm to PID control would be:

IMPORTANT

SAF

---------- 100

0()









presetpoint×

75.0×

325°=–

343.8°=–



setpoint 1

400.00 1

If the startup SAF factor is set to 25%, the poi nt at which you would switch from the cold startup algorithms to PID control would be:

400.00 1

The higher the startup aggressiveness factor is, the closer to setpoint you will go before you switch from the cold startup algorithms to PID control. If your pre-set point is too close to the actual setpoint you can expect overshoot to occur.

If you change the startup aggressiveness factor you will need to redownload the M1 configuration and the M0 autotune block for the change to take effect.



–

 





-------- -

–



100

25()



----------

–



100

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3-12 Configuring the Module

Ramp Rates

The ramp rate value modifies the setpoint in steps until it reaches the new setpoint. This value works in conjunction with the ramp enable and ramp hold bits in the output image table for each channel.

EXAMPLE

The following outlines the relationship between ramp rate, TPO:

• ramp rate 10 °/min.

• TPO of 10 sec.

• set point of 300°

• current tempe r at ure of 100°

• your goal is to ramp to the setp oint, but hold at

200° for 10 minutes; then continue to ramp to set point.

To set the ramp enable bit, do the following:

1. Go to the output image table to set the ramp

enable bit.

2. A snap shot of the current temperature occurs,

which becomes the current setpoint.

3. A calculation is performed to determine the

amount the setpoint needs to be raised every TPO period, so every TPO period the setpoint increases 1.67° until the setpoint is reached.

1min



------------ 60

TPO×



10 1.67°=sec× TPO⁄

period

1min

------------ 60





 

ramprate



10°



4. Temperature ramps. Ladder logic determines

when you reach 200°. When 200° is reached, ladder logic would set the ramp hold bit in the output image table, and ladder logic would start a 10 minute time.

5. When the 10 minute time runs out, the ladder

logic would reset the ramp hold bit in the output image table.

6. Ramping of the setpoint would continue until

300° is reached. At that point, ladder logic would determine 300° was met, and it would reset the ramp enable bit.

Publication 1746-UM010B-EN-P - April 2001

Table 3.B Block Header (word 0 / N10:0) = 8801 (-30719 decimal)

Configuring the Module 3-13

Loops 1-4

Word #

1 2 3 4 bit to Configure Bit Select or Range 15 14 13 12 11 10 9876543210

1265176

0-1 operati on mo de

2-5 input type

6 alarm enable Disable = 0; Enable = 1 X

7-8 TC break configuration

9reserved

10-11 Autotune gains

12 Barrel control Barrel=0;Non-barrel=1 X 13 Zone I nner=0; Outer=1 X

14-15 reserved 2 27 52 77 0-15 High CV limit % -100.00 thru +100.00% default = +100.00% 3 28 53 78 0-15 Low CV limit % -100.00 thru +100.00% default = 0.00% 4 29 54 79 0-15 CV for TC break -100.00 thru +100.00% default = 0.0 5 30 55 80 0-15 Standby setpoint 0.0 thru 3276.7° default = 0.0

6 31 56 81 0-15 Heat on time (min.) 0.00 thru 100.00 sec. default = 0.00 7 32 57 82 0-15 Heat TPO period 0.00 thru 100.00 sec. default = 5.00 8 33 58 83 0-15 Cool on time (min.) 0.00 thru 100.00 sec. default = 0.00 9 34 59 84 0-15 Cool TPO period 0.00 thru 100.00 sec. default = 5.00 10 35 60 85 0-15 PV alarm rate -3276.8 thru 3276.7°/s default = 0.0 11 36 61 86 0-15 Low temp alarm -3276.8 thru 3276.7°/s default = +999.9 12 37 62 87 0-15 High temp alarm -3276.8 thru 3276.7°/s default = +999.9 13 38 63 88 0-15 Low deviation -3276.8 thru 3276.7°/s default = +999.9 14 39 64 89 0-15 High deviati on -3276.8 thru 3276.7°/s default = +999.9 15 40 65 90 0-15 Alarm dead band 0.0 thru 10.0° default = 0.0 16 41 66 91 0-15 T hermal Inte grity Loss 0 thru 100° de fault = 5 17 42 67 92 0-15 Integrity Rate 0 thru 100 minu tes default = 20 18 43 68 93 0-15 r amping 0 thru 100°/min. default = 0 19 44 69 94 reserved 20 45 70 95 0-15 N on-barrel a utotune

21 46 71 96 0-15 Startup

<=25 <=50 <=75 <=99 reserved

disturb size

aggressiveness factor

Monitor, No PID Control Control loop with PID Disable loop Type J Type K 0001

disable PID loop (CV=0) Use thermal runaway

CV Use manual mode CV 10

low gains medium gains 01 high gains 10 very high gains 11

0.00-100.00% default = 10.00

0 thru 100 default = 0 fo r heat or cool, only; 25 for heat/cool

Set a bit or enter a value

00 01 10

0000

00 01

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3-14 Configuring the Module

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Chapter

Setting Autotune and Gains Values

This chapter shows you how to independently set the gains for each PID loop of the BTM module. This includes:

• setting PID gains

• autotuning the loops

• fine tuning the loops

• using the PID equation

• configuring the autotuning and gains block

Sequence of Setting PID Gains

Any time you successfully au totu ne the lo op, writ e an aut otun e blo ck to the module, or write a gains block to the module, a new set of PID gains is established on the module. The following list summarizes the process:

• Autotuning causes the module to measure the process dynamics

and calculates PID gains.

• Reading the PID gains block from the module copies the PID

gains generated by autotuning into the SLC files.

• Writing the PID gains block to the module overwrites any PID

gains that had been in the module.

• Autotuning or writing the autotune block to the module causes

the module to calculate PID gains and overwrite any PID gains that had been in the module.

At initial start–up, you must write the autotune block to the BTM module or perform autotuning. If you select autotuning, for any loop that is successfully tuned, the gains are calculated by the module. Gains you sent to the module for a loop in any gains block previous to successful autotuning of the loop are superseded by the gains derived from autotuning. If you then read the gains block, it contains the gains derived from autotuning.

If autotuning is not successful for any loops (as i ndicated in the status block) the gains you sent for those loops before autotuning is used by the module.

1 Publication 1746-UM010 B- EN-P - April 2001

4-2 Setting Autotune and Gains Values

Once autotuning is complete, you mus t read th e gain s blo ck from th e module to store it in SLC processor memory.

You can write the autotune and gains block either of these ways:

• Send autotune block to the module in words 1-24

(NXX:110-134). This causes the module to calculate the PID gains. In this case, set the block header in word 0 (NXX:110) to 880A hexadecimal.

• Send PID gains only in words 25-48 (NXX:145-168). This

overwrites the current PID values in the mod ule. In this case, set the block header in word 0 (NXX:120) to 880B hexadecimal.

Autotuning the Loops

IMPORTANT

The module’s memory is volatile. Whenever power to the module is interrupted, you must establish the gains again. If you don’t send an autotune block, PID block, or both blocks to the module, the module will not work in automode. Sending the autotune block establishes the start–up algorithm and the values the module uses to calculate the PID gains, causing the module to recalculate th e PID gains. H owever, you can override the autotune gains by sending the gains block after the autotune block.

IMPORTANT

You select autotuning from the output image table block (Refer to Using the Output Image Table on page 5-8). For each loo p, you must turn on the specific bit to enable autotuning for the corresponding loop. To trigger the start of autotuning, you must also cause a 0–to–1 transition of word 12, bit 1 of the output image table.

When you download either an autotune or gains block, the BTM module’s PID algorithm requires time to adjust, proportional to the thermal mass of the system. This could cause a slow or unexpected system response .

You must initially download M0 and M1 files for the module to operate.

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During autotuning, the module measures system parameters. At the end of autotuning, the module calculates PID gains based on these parameters and your selection of low, medium, or high PID gain level in the configuration block. When autotuning is complete, the PID gains calculated from autotuning are available in the gains block that you can read from the module.

Configuration Block

Your selection of PID gains level:

• low

• medium

• high

Autotune Block

System parameters

Setting Autotune and Gains Values 4-3

Whenever you write autotune values to the module, it recalculates PID gains based on measured system parameters stored in the autotune block and your selection of low, medium, or high PID gain level stored in the latest conf igu rati on b lock. If yo u chan ged th e level of PID gains selection in the configuration block in the mean time, the PID gains calculated would be different from those calculated originally.

Autotuning Calculations

Gains Block

PID gains

Fine-Tuning the Loops

After autotuning, you may want to fine–tune the loops by manually setting the gains. As you fine–tune a loop, first try adjusting the proportional gain; this will have the greatest impact. Your second choice for adjustment should be the integral gain. The derivative gain should be the last choice for fine–tuning a loop.

If the loop over–shoots the set point either at start–up or at a change of set point, (See Figure 4.1) you may be able to dampen the loop response by doing one or more of the following (in order of effectiveness):

1. decrease the proportional gain

2. decrease the integral gain

3. increase the derivative gain

Figure 4.1 Loop Over-shoot

Set Point

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4-4 Setting Autotune and Gains Values

If the loop is slow in reaching the set point either at start–up or at a change of set point, (See Figure 4.2) you may be able to improve the loop response by doing one or more of the following (in order of effectiveness):

1. increase the proportional gain

2. increase the integral gain

3. decrease the derivative gain

Figure 4.2 Loop Slow to Set Point

Set Point

Using the PID Equation

The module provides dependant PID control action. Dependent control action can be represented by the equation



CV KpEKiEDtK



 

The module is capable of performing PID control by calculating the solution to an approximation of the PID equation. The approximation is represented by the equation:

------

∫

+⋅



CV KpEKiE ∆tK



 

Where:

Where: CV = Control variable Kp = Proportional gain (no units)

E = Error (SP-PV or PV-SP) Ki = Integral gain (repeats /seconds)

Kz = Derivative gain (seconds) t = Time

∆E

-------

+⋅

∑

∆t

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∑

∆t⋅ E1∆tE2∆tE3∆tetc+⋅+⋅+⋅=

.....

Setting Autotune and Gains Values 4-5

Entering Autotune/Gains

The autotune/gains block (M0 file) contains 49 words as listed in

Table 4.A below. For each gain value, you enter a 16–bit integer

Values with Implied

value.

Decimal Point

IMPORTANT

When entering or reading integer values, the range, given in the associated table, tells you the implied decimal point. It is the number of digits to the right of the decimal point (for an example range of 0.0 thru 3276.7, the implied decimal point is 1).

Table 4.A Autotune/Gains Values with Implied Decimal Point

Parameter Given Range

Cool Time Constant 0.0 thru 32767.7 sec. 1 If you want to store a value of 660.0, enter 06600. Heat Gain

0.00 thru 327.67

/sec.

Because loop values are stored and reported in integer files, you must understand the meaning of IDP. Otherwise, the magnitude of your intended value may be in error by as much as 1000, depending on the position of the IDP.

(1)

IDP

Example

2 If you want to store a value of 100.00, enter 10000.

Cool Proportional 0.000 thru 32.767 3 If you want to store a value of 18, enter 18000. Heat Integral 0.0000 thru 3.2767 4 If you want to store a value of 0.5, enter 05000.

(1)

IDP indicates the number of digits from the right that locates the implied decimal point.

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4-6 Setting Autotune and Gains Values

PID Gains/Autotune Block, M0 File for Loops 1–4

IMPORTANT

Word numbers for loops 1–4 are in left–most columns. For corresponding NX:xx address, add 110 to word the number.

Table 4.B PID Gains/Autotune (N10:110-158): Block Header (word 0 / N10:110) = 880B (-30709 decimal)

Loops 1-4 Autotune Values (N10:111-134) 1234To Configure Range

1 7 13 19 Heat gain 0.00 thru 327.67°/sec. 2 8 14 20 Heat time constant 0.0 thru 3276.7 sec. 3 9 15 21 Heat dead time 0.0 thru 3276.7 sec. 4 10 16 22 Cool gain 0.00 thru 327.67°/sec. 5 11 17 23 Cool time constant 0.0 thru 3276.7sec 6 12 18 24 Cool dead time 0.0 thru 3276.7 sec.

Loops 1-4 PID Gains Values (N10:135-158) 1234To Configure Range

25 31 37 43 Heat proportional 0.000 thru 32.767 26 32 38 44 Heat integral 0.0000 thru 3.2767 rpts/

sec. 27 33 39 45 Heat derivative 0.0 thru 3276.7 sec. 28 34 40 46 Cool proportional 0.000 thru 32.767 29 35 41 47 Cool integral 0.0000 thru 3.2767 rpts/

sec. 30 36 42 48 Cool derivative 0.0 thru 3276.7 sec.

Note: Refer to Download and Upload Settings on page 9-3 for download command bits.

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Control and Autotune a Loop

This chapter explains how to:

• control loop operation

• autotune a loop

Chapter

Controlling a Loop

At initial start–up, you must write the M1 configuration block to establish the module’s mode of control. Then, you must update the output image table any time you want to change the operating mode.

M1 Configuration File

You select the loop control mode in the configuration file:

Words Bit 01 Bit 00 Lets you select

1, 26, 51, 76 for loops 1-4

0 0 monitor the loop 0 1 control the loop with PID 1 0 disable the loop

Output Image Table

If you select “control–the–loop” mode, you control loop operation with these words and bits in the output image table (abbreviated list):

Words Bit Lets you

0-3 loops 1-4

4-7 n/a enter run temperature setpoints 8-11 n/a enter manual CV% output values 12

global for all loops

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00 enable or disable the loop 03 enable or disable autotune

01 invoke autotune

02 abort autotune 03 reset error codes

5-2 Control and Autotune a Loop

Figure 5.1 Control Mode Selections and Loop Operation

through the M1 configuration bl ock

Control Mode Selectio ns

Disable the Loop Monitor the Loop Control the Loop

Autotune a Loop

through the output image table

Loop Operation

Hold CV=0, and no temperature or al ar ms

Hold CV=0, but monitor temperatur e and provide Disable Loop Control Enable Loop Control

Manual Mode Automatic Mode

temperature and alarms in the status block

The manual output value in the configur at ion block

is used as the CV value

The PID algorithm generates the CV value

The BTM module uses the output image table to control loop operation. See Table 5.C on page 5-8 for the listing of words and bits. Operating Commands to Loops 1-4

Use the following as a guide:

Requirements for Autotune

• Start autotune from a steady–state temperature. For best results,

do a cold start. If the temperature fluctuates, autotune may not provide accurate results.

• The runtime setpoint for autotune must be at least 50

F (28.7o

C) above current temperature or autotune will not start.

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Control and Autotune a Loop 5-3

• Set the TPO period smal ler than the syst em dead time. Autotu ne

algorithm may calculate excessive gains if system dead time is less than the TPO period. This may cause the PV to overshoot

Figure 5.2 Set TPO Period

output (CV) changed

Temperature

Output (CV)

system dead time

System dead time should be larger than one TPO period for autotune to work properly

1 TPO period

Time

• The autotune algorithm does not take the temperature to

setpoint. When autotune is complete, the zones will return to the mode (auto or manual) that was selected before autotune.

Figure 5.3 Autotune setpoint zones

Temperature

system dead

time

maximum slope

Time

Return to the control mode that was selected before autotune

autotune complete

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5-4 Control and Autotune a Loop

Items to check before autotune

Each loop must:

• be configured with a valid M1 file and no errors (N10:212-215)

• be set for barrel mode

• be set in manual mode and that run setpoints are selected,

starting from a cold start. If not starting from a cold start, at a steady state temperature.

• have the TPO period set considerably smaller than the system

dead time. A good place to start is 5 or 10 seconds.

• not have any existing alarm conditions that could cause

problems (such as a TC break)

Autotune barrel control applications

Autotune enables the mod ule to compute PID values for optimum temperature control. You must load the program and use the following procedure to autotune the module.

For barrel control, better results are achieved when you autotune all loops associated with the barrel at the same time. After autotune, each zone will return to the mode (auto or manual) that was selected beforehand.

IMPORTANT

For best results, start from room temperature (cold start).

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Control and Autotune a Loop 5-5

1. Assume using data table N10 in the following example. Set initial

conditions:

Table 5.A Configuration File N10 Data Table Example

N10:1 bits 00 01 set for PID control N10:26 bits 00 01 set for PID control N10:51 bits 00 01 set for PID control N10:76 bits 00 01 set for PID control remaining bits/words set for your application

Table 5.B Data Table Example:

Output image buffer table words 180–183

bits 00–03 for loops 1–4.

bit 00 1 enables PID control bit 01 0 puts loop into manual mode bit 02 1 uses runtime setpoint bit 03 1 enables autotune

• Set to zero Output image buffer table words 188–191 for

loops 1–4.

• In the sample code, it zeros manual outputs to remove

control signals from loops.

2. Download the M1 Configuration File by setting N7:12/00 = 1.

3. Download the M0 Autotune File by setting N7:12/01 = 1.

4. Verify that the M1 Configuration File downloaded:

a. Check input image buffer words 164–167 bits 03, 04 for loops

1–4 to verify:

• bit 03 = 1 module received a valid M1 file for the loop

•bit 04 = 0 no parameter errors for the loop.

If bit 04 (parameter error) is set for any loop, look for the error code in N10:212–215. Refer to Locating Error Code Information on page 8-2.

b. Check input image buffer words 168–171 bits 00–02 for l oops

1–4 to verify that the module:

• bit 00 = 1 enabled PID control

• bit 01 = 0 put loop into manual mode

• bit 02 = 1 used runtime setpoint

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5-6 Control and Autotune a Loop

5. Enter runtime temperature setpoints (at least 50oF (28.7oC)

above current temperature) into output image buffer words 184– 187 for loops 1–4.

IMPORTANT

For implied decimal point, enter 2000 for 200

6. Invoke autotune. (Starts autotu ne for loops enabled in step 1.)

Set output image buffer table word 192, bit 1 = 1.

The module needs a 0–1 transition of this bit.

7. Verify autotune is in progress.

Monitor input image buffer word 168, bit 11 for a 0–1 transition.

8. Reset the autotune invoke bit.

Reset output image buffer table word 192, bit 1 = 0.

9. Enable each loop for automatic mode.

This lets each loop control to run setpoint when autotune completes.

a. Output image buffer words 160–163 bit 01 for loops 1–4 bit

01 = 1 puts loop into automatic mode

10. Verify that autotune is complete and successful.

Input image buffer words 168–171 bits 03 and 04 for loops 1–4 bit 03 = 1 autotune complete bit 04 = 1 autotune successful If bit 04 = 0 (not successful) for any loop, look for the error code in N10:212–215. Refer to Locating Error Code Information on page 8-2.

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11. Upload the autotune/PID gains block to the processor for

storage. Set word N7:12 = 24. Following a power loss or module replacement, you can download the autotune/PID gains block to avoid repeating this procedure.

12. We suggest that you modify our ladder code Refer to Obtaining

the Sample Program from the Internet on page 9-1 to set N7:12 = 3 at power up. This will automatically download M0 autotune data and M1 configuration data files to the module to start module operation.

Control and Autotune a Loop 5-7

Example: Autotune non–barrel control applications

1. Enter a safe non–barrel autotune disturbance size in the M1 file.

• Disturbance size is the step output that the module uses to

autotune. For example, if disturbance size is 15% and current CV is: 0% when autotune is invo ked, the CV changes to 15% 10% when autotune is invoked, the CV changes to 25%

• Optimum disturbance lets temperature rise, then level off. If

too large, temperature will not level off and autotune will be unsuccessful.

2. Make sure all zones have valid M1 fi les and n o parameter e rrors.

3. Start Autotune from a cold start or start from a steady–state

temperature.

• If doing a cold start, invoke autotune after putting loop into

manual mode and setting manual CV output to zero.

• If starting from a steady–state temperature, invoke autotune.

Temperature

4. When autotune completes, upload the autotune and gains block.

5. Return the zone to auto mode.

Temperature for safe autotune disturbance size

Autotune completes when temperature reaches steady state

dead time

Time

Tr o ub l es ho otin g Autotune

The module reports successful completion of autotune in status word N10: 168-171, bits 03, and 04 in the input image buffer table. If autotune was not successful, look for autotune error codes in N10:212-215. Refer to Locating Error Code Information on page 8-2.

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5-8 Control and Autotune a Loop

Using the Output Image

The output image table contains 16 words as shown in Table

5.Cbelow. You must enter a 16–bit signed integer value for the run

Table

temperature setpoint and manual output. If you are using the example code from the manual you will not manipulate the output image table directly. You will manipulate the output image buffer N10:180-195.

• For a run temperature setpoint, the implied decimal point is 1

place from the right (causing the resolution to be 0.1). For example, if you want a value of 499.9, enter 04999.

• For the manual output, the implied decimal point is 2 places

from the right (causing the resolution to be 0.01). For example, if you want a value of 49.99%, enter 04999.

T able 5.C Operating Commands to Loops 1-4

Loops 1-4

Word #

12 3 4 bit to Configure Bit Select or Range1514131211109876543210

0 1 2 3 0 loop control Disable=0; Enable=1

1 Auto/manual Manual =0; Auto =1

(2)

2 Setpoint select 3 Autotune enable Disable=0; Enable=1 X

PID integral reset 5 Ramp enable Disable = 0;Enable =1 X 6 Ramp hold Hold =0; Don’t hold =1 X

7-15 Reserved

4 5 6 7 0-15 Run temp setpoint -3276.7 thru 3276.7 8 9 10 11 0-15 Manual Output -100.00 thru +100.00%

(1)

Requires a 0-to-1 transition for each reset.

(2)

For loops 1-4 standby setpoint is stored in N10:5, 30, 55, 80 respectively.

(3)

Entered bel ow

(1)

Standby=0

Accume = 0;Reset =1 X

; Run=1

(3)

Set a bit or enter a value

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Note: Refer to Download and Upload Settings on page 9-3 for download command bits.

Control and Autotune a Loop 5-9

Global Commands to All Loops

Word Bit To Control Selected By 1514131211109876543210

12 0 Temperature units F =0;C =1

1 Autotune invoke invoke =1;None = 0 2 Autotune abort Abort = 1;None =0 3 Reset error codes None =0; Re set =1 3-7 Reserved

Selection of Reported value if bit 11 is not set in the output image buffer N10:192/11

8-10

Selection of Reported value if bit 11 is set in the output image buffer N10:192/11

11 Advanced Rotator Values Disable = 0;Enable =1 12 MO download request None =0; Download =1 13 M1 download reques t None =0; Down load =1 14 M0 upload request None =0; Upload =1

15 M1 upload request None =0; Upload =1 13 0-15 Reserved 14 0-15 Calibra tion word 15 0-15 Reserved

Current Setpoint Current Erro r Value 010 Current CV (lo op output) 011 Current Erro r Code 100 Cold Junction Temperature 101 Firmware Revision Number 110 P Contributi on I Contribution 010 D Contribution 011 Pre-set Point 100 Wait Period 101 Reserved 110

001

IMPORTANT

The sample program returns all six variables. For their data table locations, Refer to BTM201.rss Data Table Layout on page 9-2 and BTM50220.RSS Data table layout on page 9-7.

Remember that the module returns the control variable (CV) of each loop to the input image table as both a numeric value (current CV)

and a time–proportioned output (TPO). For additional information, Refer to BTM201.rss M1, M0, Input Image, Output Image, and Rotator Code Data Table on page 9-4 and BTM50220.RSS M1, M0, Input Image, Output Image, and Rotator Code Data Table on page 9-8.

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5-10 Control and Autotune a Loop

BTM Auto Tune

The 1746-BTM Auto Tune procedure was designed to be performed as a one-time event from which all characteristics of the system being controlled could be identified and incorporated into the control scheme.

The identification procedure has two critical points:

Before exercising the system with the identification procedure the system in question must be as stable as possible. Essential to a good system identification routine is the assumption that there is a high correlation between excitat ion and system response. The identification procedure tries to identify the system by assuming that an y excitation used to disturb the sys tem is solely responsible for the observed reaction of that same system. If heat or any other form of input is exciting the system other than what th e identi fication rout ine is aware and in control of, the routine will draw erroneous conclusions about its observations and misidentify the system in question. Thus at the onset of auto tune it is desired to let all of the influences other than direct auto-tune excitation dissipate before excitation is applied.

In the BTM there is a wait period at the beginning of the auto tune procedure. Once it is initiated for all of the aforementioned effects to dissipate. Then and only then will the routine qualify the system as stable and begin excitation. This, however, does not mean that the system must have zero output. It does mean that the system must remain at a consistent temperature with very little fluctuation. There are two ways in which this condition can be achieved. The first and most typical, is that of a cold-start condition. In this case there is no energy being inputted to the system and the system is stable with respect to ambient conditions. With regards to the BTM this is achieved easiest by setting all active zones to Manual Mode with 0% (zero percent) output. The second most common way to achieve stability is with a non-zero output being applied to the system, either in Manual or Automatic Modes. It is perfectly acceptable to have a non-zero output applied to the system as long as it is stable: in Automatic Mode this is stability at a setpoint, in Manual Mode this is a single manual output value and a settled response (no temperature variation). A common mistake is to have heat applied to the system prior to auto-tune and turn it off just prior to auto-tune initiation. In a high lag situation where it takes some finite amount of time for that energy to manifest itself as temperature, the result is as follows. The auto-tune routine waits for stability and qualifies it, it then attempts to exercise the system by giving a step output, the heat that was previously introduced into the system finally produces a temperature change, the auto-tune routine marks the rise in temperature as being a direct result of its excitation of the system and records the amount of time from the beginning of its step output to the start of the temperature rise as the deadtime. In this case the system is now misidentified with an artificially short deadtime.

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Control and Autotune a Loo p 5-11

The second critical procedure is that of finding the maximum rate of

change of the system for the given excitation. A number of the BTM’s auto-tune failures are associated with this proce dure: ‘temperature will exceed deadtime’, ‘too much noise in the system’, etc. For any given step change of ex citation for a given system there will ultimately be a maximum rate of change (max slope) attributable to that excitation. This information is used to identify system ‘gain’ and ‘time constant’ information.

When trying to find a max imum slope, th e system must be ab le to rise in temperature sufficiently to guarantee that a maximum slope has been attained. Thus a minimum temperature differential has been identified and documented as being necessary and sufficient to a successful auto-tune. If there is not enough temperature differential between the sta rt in g te mp e ra t ure and the setpoint to achi e v e maximum slope an error is generated and auto-tune is aborted.

Another cause of error here is in having sufficient temperature differential to attain maximum rate of change but not enough differential for the system to recover from the test successfully. The system will overshoot setpoint as a result of the test. The module ‘knows’ when this is going to happen as a result of the gain and time constant information previously learned and flags it as an error if conditions are appropriate.

After these two tests are completed, an identical procedure is applied to exercise the cooling control on the system if it is so configured, in which case the autotune procedure would continue by first stabilizing at setpoint. This is a module-wide event, meaning that all zones enabled on the module must be stable before the procedure will continue.

When all tests have been completed, the module will default to the mode it was set at prior to the auto tune, auto or manual, and behave accordingly.

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5-12 Control and Autotune a Loop

A synopsis of the complete tuning procedure would be as follows:

1. W ait f or all zones to be stable. A module wide event inclusive of

all zones enabled for control and autotune at the time of auto tune invoke.

2. When stability has been qualified, all enabled zones will be

subject to maximum configured output. At this time the system is observed for a departure from stability to quantify the deadtime of the system.

3. The output continues at the same value until a maximum rate of

change for each active zone in the auto tune has been identified and recorded.

4. For heat or cool o nly zones , t he t est is no w compl ete, auto tune

finishes, and the individual zon es revert to their current configuration and mode.

5. For zones designated as heat/cool, they will continue to setpoint

under ‘slow’ closed loop control and stabilize. Again, this stabilization is a module wide event and is inclusive of all heat/ cool zones engage d in the current au to tune .

6. When stability has been qualified, all enabled zones will be

subject to maximum (cool) configured output. At this time the system is observed for a departure from stability to quantify the deadtime of the system.

7. The output continues at the same value until a maximum rate of

change for each zone still active in the auto tune has been identified a nd r e co rded.

8. The test is now complete, auto tune finishes, and the individual

zones revert to their current configuration and mode.

If for any reason the auto tune does no t successful ly complete fo r any individual zone, that zones auto tune and gain parameters will not be updated, and error codes will be displayed. Refer to Locating Error Code Information on page 8-2

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Chapter

Monitoring Status Data

This chapter describes statu s d ata reported by the B TM module i n the input image table (16 words), applicable to the sample program.

Input Image Table

Implied Decimal Point

You must interpret th e val ue of d isp layed 1 6–bit in teger n umbers. For temperature values reported in words 0-3, the implied decimal point is 1 place from the right (for a resolution to be 0.1). For example, if 4999 is displayed, you must interpret it as 499.9.

Table 6.A Status Values from Each Loop

12 3 4 Bit Define M1 Indicated By 1514131211109876543210

0123 Current temperature (-3276.8° thru +3276.°7) 4 5 6 7 0 Open circuit 0 = None; 1 =Error

1 Under range 0 = None; 1 =Error 2 Over range 0 = None; 1 =Error 3 Configuration 0 = None; 1 =Valid 4 Parameter value 0 = None; 1 = Error 5 PV rate a larm 10 0 = None; 1 = Ala rm 6 Thermal Integrity 16 0 = None ; 1 = Alarm 7 High CV limit 2 0 = None; 1 = Alarm 8 Low CV limit 3 0 = None; 1 = Alarm 9 Low temperature 11 0 = None; 1 = Alarm 10 High temperature 12 0 = None; 1 = Alarm 11 Low d eviation 13 0 = None; 1 = Alarm 12 Hig h deviation 14 0 = None; 1 = Al arm >15 Reserved

8 9 10 11 0 Loop control 0 = No; 1 = Enabled

1 Loop mode 0 = Manual; 1 = Auto 2 Setpoint 5 0 = Standby; 1 = Run 3 Autotune

complete 4 Autotune success 0 = No; 1 = Yes 5 Setpoint ramping 0 = No; 1 = Enabled 6 Heat TPO 0 = Off; 1 = On 7 Cool TPO 0 = Off; 1 = On 8-15 SeeTable 6.C on page6-2

12 13 14 15 Function and value of this word set by N10:192, b its 8-10. See Table 6.B

0 = No; 1 = Yes

0 = None; 1 = Alarm

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6-2 Monitoring Status Data

Values reported in words 12-15 for loops 1–4 vary, depending on the bit code set in global commands N10:192/bits 08-10 and reported in input image word N10:168/bits 08-10. You must interpret the reported value according to the implied decimal point:

Table 6.B Interpret Implied Decimal Points

If N10:168/10-09-08 Reports: Implied decimal point is: Interpret:As:

001 010 101

0 1 1 current CV (analog

100 110

current setpoint, current er ror, or

cold–junction temperatur e

output) error code, or

firmware re vision number

1 decimal place (from the right)

2 decimal places 4999 49.99

none 4999 4999

4999 499.9

Table 6.C Global Status from All Loops

Word Bit Define Indicated By 1514131211109876543210

8 upper byte

9 upper byte

Current setpoint

Selection of Reported values

8-10

See Important Below

11 Autotune progress 0 = None; 1 = In progress 12 Cold junction low 0 = None; 1 = Alarm 13 Cold junction hi gh 0 = None; 1 = Alarm 14 Rese rved 15 Advanced rotator

values 8-11 Reserved 12 M0 download 0 = None; 1 = Download 13 M1 download 0 = None; 1 = Download 14 M0 upload 0 = No; 1 = Upload 15 M1 upload 0 = No; 1 = Upload

Current Error value 0 1 0 Current CV (loop output) 0 1 1 Current error code 1 0 0 Cold junction temperature 1 0 1 Firmware revision number 1 1 0

0 = Normal Values 1 = Advanced Diagnostic Values

0 0 1

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IMPORTANT

The sample program returns all six variables. For their data table locations, Refer to BTM201.rss Data Table Layout on page 9-2 and BTM50220.RSS Data table layout on page 9-7.

Remember that the module returns the control variable (CV) of each loop to the input image table as both a numeric value (current CV) and a time–proportioned output (TPO). For additional information, Refer to BTM201.rss Data Table Layout on page 9-2 and

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

Calibrating the Module

Chapter

About the Procedure

Use Word 14 (Out put Image) for entering calibration codes

15 12 11 08 07 04 03 00

Code Word 5

Calibrate the module after the first 6 months of operation. Then check the calibration and re-calibrate only if necessary once a year.

Use this procedure to store calibration values for each channel in EEPROM. Calibration sets channel accuracy at 0.05% of full range regardless of channel circuit tolerances. You can calibrate the input channels individually or in groups. The thermocouple/mV operation of all channels is suspended during calibration.

Calibration Codes and Status

Use the following format for entering calibration code words and reading calibration status bits. Enter calibration values in hexadeci mal. You read channel status bits at different steps in the calibration procedure, one bit for each channel you are calibrating.

1001

Use Words 4 and 5 (Input Ima g e) for rea d ing calibration status

Status Word 4

Status Word 5

Channel status words 6 and 7 display “CAL4” during calibration

1 Publication 1746-UM010 B- EN-P - April 2001

15 12 11 08 07 04 03 00

OK status bits (1=OK) for channels 3,2,1,0 (high-end calibration) @

OK status bits (1=OK) for channels 3, 2,1,0 (low-end calibration) @

15 12 11 08 07 04 03 00

OK status bits (1=OK) for channels 3, 2,1,0 (low-end calibration) @

@ Reads F Hex if all four channels are OK

Calibration codes in Hex

Channel status during calibration

Channel status at

completion of calibration

7-2 Calibrating the Module

Calibration Procedure

To calibrate the module, you need a precision dc voltmeter and precision power supply that can display and maintain a calibration voltage to 1/1000 of a millivolt: at 0.000 mV and 90.000 mV.

For convenience, calibrate all four channels at the same time.

To prepare for the calibration:

• Remove the thermocouple leads from the input terminals of the

channels that you want to calibrate.

• Switch the SLC processor to run mode so it can execute the

calibration ladder logic.

To calibrate the module, follow this procedure:

1. With your programming terminal, enter calibration code 1001

Hex into output word 14.

2. Observe input words 0–3, 6 and 7.

– The module clears words 0-3. The module returns “CA14”

Hex in words 6 and 7.

3. Short circuit the pairs of input terminals for the channels you

want to calibrate. Make the jumper as short as possible.

4. With your programming terminal, enter calibration code 1002

Hex into output word 14.

5. Observe bits 0–3 in input word 4.

– If all the channels you are calibrating see zero voltage, the

module returns status–OK bits set, one bit for each channel (F Hex for all four channels). Otherwise, the module returns channel status bits set to zero.

6. Apply 90.000 mV to the pairs of input terminals, all in parallel,

for the channels you are calibrating. Use short leads.

7. With your programming terminal, enter calibration code 1004

Hex into output word 14.

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8. Observe bits 4–7 in status word 4.

– If all channels being calibrating see 90.000 mV, the module

returns a status–OK bit set for each channel (F Hex for all four channels). Otherwise, the module returns channel status bits set to zero.

Calibrating the Module 7-3

9. Remove the 90.000 mV calibration voltage.

10. With your programming terminal, enter calibration code 1008

Hex into output word 14.

11. Observe bits 0–3 in status word 5.

– After the module burns the calibration values into its

EEPROM, it returns status–OK bits set, one bit for each channel (F Hex for all four channels). If the module could not complete the calibration of one or more channels, it returns a zeroed status bit for that channel (non–F Hex returned)

12. To end the calibration procedure, enter calibration code 0000

Hex into output word 14. During thermocouple/mV operation, word 14 must be zero (which is normal operation).

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7-4 Calibrating the Module

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Troubleshooting the Module

This chapter provides troubleshooting guidelines.

Chapter

Troubleshooting with LED Indicators

Indication Probable Cause Recommended Action:

all indicators are OFF

The front panel of the module contains five green LED indicators for channel status and one green LED indicator for module status.

INPUT

ISOLATED

CHANNEL STATUS

MODULE STATUS

02 13

LED: When: Indicates

Channel Status

Module Status

On channel is correctly configured when you enable the channel

Flashing channel fault condition On self-check completed OK

Flashing communication occurring between SLC processor and BTM module

W e present a table of indications, probable causes, and recommended action. See Table 8.A on page 8-3 and Table 8.B on page 8-4 for a listing of error codes.

no power to module check power to I/O chassis

recycle power as necessary

module performing self–check wait until self check is complete module performing calibration wait until calibration is complete possible short on the module

LED failure

channel status indicator is ON

channel status indicator is flashing

1 Publication 1746-UM010 B- EN-P - April 2001

channel is correctly configured when you enable the channel

during calibration, the channel is properly configured for the high –end of millivolt range

fault condition, such as open circuit or an under/over range condition

during calibration, the channel is properly configured for the low–end of millivolt range

replace module

normal operation

normal calibration

correct fault condition

normal calibration

8-2 Troubleshooting the Module

Indication Probable Cause Recommended Action:

module status indicator is ON

module status indicator is flashing

Locating Error Code Information

Display of error code in N10:212-215 if using example program

self–check is completed satisfactorily module is OK

communication occurring between SLC processor and the BTM module

You configure the 1746-BTM module to report error codes by setting

bits 10–8 to 100 in word 192 of the output image buffer table Refer to Using the Output Image Table on page 5-8. The modul e reports error codes in input image table words 172-175.If using the sample program, error codes are reported in N10:212-215. Location of the 2– digit code in the error word determines its source:

Autotune error code

Autotune error codes only reset when an autotune is invoked.

normal power–up module waiting for channels to be enabled

normal operation

Configuration error code

A configuration error code is only reset when th e reset error code bit is transitioned.

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EXAMPLE

If 002 is displayed, the error code is from the configuration block.

If 6700 is displayed, the error code is from the autotune.

Table 8.A Configur ation Error Codes

Code Description

0 1

2 10 11 12 13 14 15 20 21 22 23 24 25 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51

No error Run setpoint is invalid Manual control value is < -100% or > +100% Heat system gain is less than 0 Heat time constant is less than 0 Heat dead time is less than 0 Cool system gain is less than 0 Cool time constant is less than 0 Cool dead time is less than 0 Heat proportional gain is less than 0 Heat integral gain is less than 0 Heat derivative gain is less than 0 Cool proportional gain is less than 0 Cool integral gain is less than 0 Cool derivative gain is less than 0 Loop operational mode is invalid Thermocouple type is invalid Maximum CV allowable is < -100%, > +100%, or max CV < min. CV Minimum CV allowable is < -100% or > +100% Control value when TC break detected is< -100 or > +100% Standby setpoint is invalid Heat minimum TPO cycle time is < 0 or > 100 Heat maximum TPO cycle time is < 0, > 100, or min. TPO > max TPO Cool minimum TPO cycle time is < 0 or > 100 Cool maximum TPO cycle time is < 0, > 100, or min. TPO > max TPO PV rate alarm degrees per second is invalid Low temperature alarm is invalid High temperature alarm is invalid Low deviation alarm is invalid High deviation alarm is invalid Temperature alarm deadband is < 0 or > 10 Thermal Integrity Loss value is < 0- or > 100 Integrity Rate in minutes < 0 or > 100 Setpoint ramp rate is < 0 reserved Nonbarrel autotune disturbance size is < 0% or greater than 100% Startup aggressiveness factor is <0 or > 100

Troubleshooting the Module 8-3

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8-4 Troubleshooting the Module

Table 8.B Autotune Error Co des

Code Description

66 67 68 69 70 71 72

Autotune terminated because of TC break Start conditions prevent heat autotune Start conditions prevent cool autotune Setpoint will be reached before autotuning is complete Too much noise causing time constant to be 0 Very small gain PV now higher than maximum PV; do not trust PID values

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Chapter

Sample Program

This chapter describes:

• Obtaining the sample program from the internet

• Configuring Your SLC processor, Off–line

• Using the Sample Program

• General Programming Notes

You can obtain the sample program from the Allen–Bradley website on the Internet and download it to your PC as an executable file.

Obtaining the Sample Program from the Internet

RSLogix500 Version

BTM Firmware Revision

To Access the Internet:

1. Access the Sample Program and manuals at the Allen–Bradley

website: http://www.ab.com/appsys/

2. Download the sample program to your PC.

3. Move the sample program into the subdirectory on your hard

drive where your programming software looks for files. For example, with

– C:\program files\rockwell software\rslogix 500

english\projects

The examples in this chapter were built using RSLogix500 version

4.50.00. For other types of programming software, the procedure and/ or prompts may vary.

The examples in this chapter were written for B TM fi rmware Revision

2.00 or greater.

RSLogix500:

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

Using the code in file BTM201.rss you will be able to have multiple BTMs in a SLC system without having to duplicate code for each BTM. The only code that will need to be added will be in the M1/M0

Using BTM201.rss

1 Publication 1746-UM010 B- EN-P - April 2001

9-2 Sample Program

communications program file 4 and in the main program file 2. Later there will be an example for the code that will need to be added.

BTM201.rss Data Table Layout

The data table layout for this version of code has change considerably from the current BTM application code. The biggest change is that the input and output images are now buffered. This means that you will now manipulate all input and output data thru the buffer area, not in the actual input and output images. If you manipulate data in the actual input and output image the buffers will over write them. The following is a layout of the new data tables. Th e M-file and the rot ator information have been move d into a different data table. In the previous version the information was located in N7.

Table 9.A BTM201.rss N7 Data Table

Location Description

N7:0 User request pending N7:1 User request being serviced N7:2 Request mask N7:3 Bit 0 request complete cleanup needed N7:4 Indirect address for pointer in rotator N7:5 Rotator bits N7:6 Bit 0, all requests and acknowledges cleared N7:7 Data table pointer for M1/M0 communications N7:8 Slot pointer for M1/M0 communications N7:9 What BTM are we currently working on for M1/M0

communications N7:10 Data table pointer for rotator code N7:11 What BTM are we working on for rotator code N7:12 Master Command requests for M1M0 communications N7:13 Rotator code input bits = output bits memory N7:14 Rotator initialization data table to use N7:15 Rotator initialization what BTM are we doing N7:16 Data table for first BTM

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N7:17 Slot number for first BTM N7:18 Number of BTMs in system N7:19 Misc control Bits N7:20 Rotator Level 1 or 2 check

Sample Program 9-3

IMPORTANT

In this version of code you do not command M1/M0 file transfers thru N7:0, you will now use N7:12 (master command request).

Download and Upload Settings

Table 9.B Download and Upload Settings

Location Description

N7:12/0 set will download the M1 configuration N7:12/1 set will download the M0 auto tune information N7:12/2 set will download the M0 PID information N7:12/3 set will upload the M0 auto tune information N7:12/4 set will upload the M0 PID information

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9-4 Sample Program

The information for the M1, M0, input image, output image, and the rotator code is pu t in to one da ta ta b le. Th e l ayout of the file is as follows:

Table 9.C BTM201.rss M1, M0, Input Image, Output Image, and Rotator Code Data Table

Location Description See Page

(1)

NXX NXX:1 thru NXX:100 M1 configuration information 3-13 NXX:101 thru NXX:109 Reserved do not use NA NXX:110 Block header for the M0 file 4-6 NXX:111 thru NXX:159 M0 file information 3-11, 4-6 NXX:160 thru NXX:175 Input image buffer 6-2 NXX:176 thru NXX:179 Reserved do not use NA NXX:180 thru NXX:195 Output image table 5-8 NXX:196 thru NXX:199 Reserved do not use NA NXX:200 thru NXX:203 Current set points NA

Block header for the M1 configuration file 3-11

NXX:204 thru NXX:207 Current error PV-SP NA NXX:208 thru NXX:211 Current CVs NA NXX:212 thru NXX:215 Error codes 8-2 NXX:216 thru NXX:219 CJC temperatures 2-6 NXX:220 thru NXX:223 Firmware revision 9-1 NXX:224 thru NXX:227 P contribution 4-4 NXX:228 thru NXX:231 I contribution 4-4 NXX:232 thru NXX:235 D contribution 4-4 NXX:236 thru NXX:239 Pre-set point NA NXX:240 thru NXX:243 Wait period NA NXX:244 thru NXX:247 Reserved for future use NA NXX:248 thru NXX:255 Reserved do not use NA

(1)

The XX in all data table address above will depend on the data table location of the first BTM and which BTM is being manipulated by the code.

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Sample Program 9-5

BTM201.rss Programming Notes

When programming the BTM with the BTM201.rss code there are several things to note:

1. You must in the N7 data table define words 16 thru 18. These

tell the program what the starting data table the BTMs use, the slot location of the first BTM, and how many BTMs are in the system. This information is move into the data table by the initialization code in file 3.

Figure 9.1

2. The data tables that are used to hold the M1, M0, input image,

output image, and rotator information must be consecutive for the ladder code to work.

3. The BTMs must be in consecutive slots for the ladder code to

work.

4. In program file two you will have to add copies for the input

and output images.

5. The example code has five BTMs in it. The BTMs are in slots 2

thru 6. The starting data table file that is used is N10. So the information that needs to be code into N7:16 = 10, N7:17 = 2, and N7:18 = 5

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9-6 Sample Program

6. In program file 4 you will have to add the following rungs for

each BTM added to the system. See 6. and Figure 9.3. You will

need to change the slot reference in the “M” address. You will also need to change Source B of th e equal to match th e “M” slot reference.

Figure 9.2

Figure 9.3

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Sample Program 9-7

Support for 5/02 Processors Using BTM50220.RSS

Using the code in file BTM50220.RSS you will be able to have multiple BTMs in a SLC system, but you will have to duplicate the ladder logic and create new data table locations for each BTM.

BTM50220.RSS Data table layout

The data table layout for this version of code has change considerably from the current BTM application code. The M-file and the rotator information have been move d into a different data table. In the previous version the information was located in N7.

Table 9.D BTM50220.RSS N7 Data Table

Location Description

(1)

N7 N7:1 User request being serviced N7:2 Request mask N7:3 Bit 0, request complete cleanup needed N7:4 Indirect address for pointer in rotator N7:5 Rotator bits

User request pending

N7:6 Bit 0, all requests and acknowledges cleared N7:7 thru N7:18 reserved. Do not use N7:19 Misc control Bits N7:20 Rotator Level 1 or 2 check

(1)

In this version of code you command M1/M0 file transfers thru N7:0.

Download and Upload Settings

Table 9.E Download and Upl oad Settings

Bit

N7:0/0 set will download the M1 configuration N7:0/1 set will download the M0 auto tune information N7:0/2 set will download the M0 PID information N7:0/3 set will upload the M0 auto tune information N7:0/4 set will upload the M0 PID information

The information for the M1, M0, and the rotator code is put into one data table the layout of the file is as follows:

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9-8 Sample Program

Table 9.F BTM50220.RSS M1, M0, Input Image, Output Image, and Rotator Code Data Table

Description See Page

NXX:0 Block header for the M1 configuration file 3-11 NXX:1 thru NXX:100 M1 configuration information 3-13 NXX:101 thru NXX:109 Reserved do not use NA NXX:110 Block header for the M0 file 4-6 NXX:111 thru NXX:159 M0 file information 3-11, 4-6 NXX:160 thru NXX:199 Reserved. Do not use 6-2 NXX:200 thru NXX:203 Current set points NA NXX:204 thru NXX:207 Current error PV-SP 5-8 NXX:208 thru NXX:211 Current CVs NA NXX:212 thru NXX:215 Error codes NA NXX:216 thru NXX:219 CJC temperatures NA NXX:220 thru NXX:223 Firmware revision NA NXX:224 thru NXX:227 P contribution 8-2 NXX:228 thru NXX:231 I contribution 2-6 NXX:232 thru NXX:235 D contribution 9-1 NXX:236 thru NXX:239 Pre-set point 4-4 NXX:240 thru NXX:243 Wait period 4-4 NXX:244 thru NXX:247 Reserved for future use 4-4 NXX:248 thru NXX:255 Reserved do not use NA

IMPORTANT

The XX in the data table address above will depend on the data table location of the 1746-BTM. In the example code it is N10.

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Sample Program 9-9

General Notes for Programming the 1746-BTM

This section outlines general programming information concerning the 1746-BTM module.

Figure 9.4 Correct way to shut down loop

An autotune invoke is an edge triggered event. That is the module only looks to see a 0 to 1 transit ion of b it O:1.12/ 1. Once the auto tune in progress bit I:1.8/11 is on yo u can turn off the autotune invoke bit O:1.12/1.

Figure 9.5 Correct way to turn off Autotune invoke bit

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9-10 Sample Program

The autotune abort bit O:1.12/2 must be turned off after an autotune is aborted, if not the next time you try to enable an autotune it will immediately be aborted. When you set bit O:1.12/2 high you must also check that the au totu ne in progres s bit I :1. 8/11 is lo w. Wh en t hat happens reset the autotune abort bit O:1.12/2.

Figure 9.6 Correct way to abort an Autotune

TIP

• Do not set the Autotuning enabled bits in the

output image table in the same scan that you set the invoke autotune bit.

• Do not perform M1 or M0 file transfers without

using the up/download request bits (output word 12 bits 12 thru 15) and the up/downl oad request ready bits (input word 9 bits 12 thru 15). These bits must be used to insure block integrity.

• When you need to disable a loop of control do

not just put a contact in front of the output TPO bit. This will cause the PID loop to windup, because the loop is still active and wants to control. When you re-enable the loop, it will oscillate about the setpoint then come into control. The correct way to shut down a loop is to put the loop into manual mode with 0% CV output.

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Index

alarm

dead band hysteresis 3-8

autotune block

layout overview 4-1 PID equation 4-4

autotuning

finetuning loops 4-2

3-8

4-5

4-3

calibrating

codes and status procedure 7-2

codes

calibration

configuration block

3-11

layout overview 3-1

configuring

3-1

module

7-1

dead band 3-8 disabling

1-4

slots

finetuning

4-3

loops

gains block

4-5

layout overview 4-1 PID equation 4-4 sequence of setti ng PID gains 4-1

hysteresis 3-8

installing

procedure

2-4

M0/M1 files

configuration block

module

calibrating troubleshooting 8-1

monitoring

status data

7-1

6-1

3-11

operating

5-1

module

overview 1-1

PID

equation gains 4-1 loop 1-1

procedure

calibrating

programming example 9-1

4-4

7-2

response

disabling slots

1-4

sequence

setting PID gains

setting

autotune values gains values 4-1 PID gains 4-1

status words

monitoring

switching

barrel control

4-1

6-1

3-3

TPO timing diagram 1-2, 3-6

Publication 1746-UM010 B- EN - P - April 2001

2 Index

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What is unclear?

1746-BTM Pub. No. 1746-UM010B-EN-P Pub. Date April 2001 Part No. 957555-22

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What is not in the right order?

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Publication 1746-UM010B-EN-P - April 2001 2 PN 957555-22

Rockwell Automation 1746-BTM User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important User Information

European Communities (EC) Directive Compliance

EMC Directive

Low Voltage Directive

Summary of Changes

Preface

Using This Manual

Audience

System Compatibility

Vocabulary

Table of Contents

Temperature Control Using a BTM Module in an SLC System

Features of the T emperature Control Module

Module Outputs

Current CV

Module Addressing

Response to Slot Disabling

Input response

Output response

Avoiding Electrostatic Damage

European Communities (EC) Directive Compliance

EMC Directive

Low Voltage Directive

Determining Power Requirements

Choosing a Module Slot in a Local I/O Chassis

Installation conside rations

Installing the Module

Removing th e terminal block

Wiring the Module

Cold Junction Compensation (CJC)

Wiring consi derations

Preparing and Wiring the Cables

Specifications

Loop Operation Mode

Type of Loop Input

Word 1, Bits 0 and 1 for Channel 1

Word 1, Bits 2-5 for Channel 1

Enable Loop Alarms

TC Break Response

Word 1, Bit 6 for Channel 1

Word 1, Bits 7 and 8 for Channel 1

Loop Autotune Gains Level

Word 1, Bits 10 and 11 for Channel 1

Barrel/Non-barrel Control

Word 1, Bit 12 for Channel 1

Barrel Control

Non–barrel con tr ol

Switching the barrel control

Inner/Outer Zone Selection

Word 1, Bit 13 for Channel 1

High/Low CV Limits

TC Break Control

Words 2 and 3 for Channel 1

Word 4 or O:e.8 for Channel1

Standby Setpoint

Word 5 for Channel 1

Heat/Cool Minimum On-times

Heat/Cool TPO Period

Words 6 and 8 for channel 1

Words 7 and 9 for Channel 1

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

High/Low Temperature and Deviation Alarms

Words 11-14 for Channel 1

Alarm Dead Band

Word 15 for Channel 1

Thermal Integrity Loss Detection

Ramp Rates

Words 16 and 17 for Channel 1

Words 18 for Chann el 1

Non-barrel Autotune Disturbance Size

Word 20 for Channel 1

Implied Decimal Point

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

Startup Aggressiveness factor

Ramp Rates

Sequence of Setting PID Gains