This document describes the additional features and functionality found
in the PPC-2010-xxB with adaptive control. Refer to the PPC-2000 User’s Guide regarding all other functionality which is the same as the
standard version.
Introduction
The Watlow Anafaze PPC-2000 controller offers these standard options:
• Forty-eight loops of conventional PID control with auto-tuning
capability
-or-
• Eight loops of adaptive control plus 24 loops of conventional PID
control with auto-tuning for a total of 32 loops (the option described
in this document)
ANAWIN3 HMI software is available to support either option. A mix of
these options is not supported by ANAWIN3.
ANAWIN3 Software Installation
Follow the standard instructions to install and setup ANAWIN3. In the
setup program select the Adaptive Control option.
Spreadsheet Overview Screen
Several new parameters and options appear on the Spreadsheet Overview
screen in support of the adaptive control option. These parameters and
options are applicable only for the first eight channels and are omitted or
ignored for channels 9 to 32.
Control Type
An additional option appears for Control Type. Select Adaptive to enable
adaptive control and tuning on a channel. This option is only valid for
channels 1 to 8.
Values: PID1 (0), PID2 (1), Adaptive (2) and Retransmit (3)
Default: PID1 (0)
Modbus Address (Channels 1 to 32): 46401 to 46432
Parameter Number: 19
LogicPro Driver: Database
LogicPro Address (Channels 1 to 32): 19.1 to 19.32
When Control Type is set to Adaptive, this parameter can be used to
pause tuning or to reset the adaptive algorithm and have it relearn the
system. This parameter has no effect on control if the Control Type for
the loop is set to an option other than Adaptive.
Values: Adapt (0), Reset (1) and Hold (2)
Default: Reset (1)
Modbus Address (Channels 1 to 32): 49001 to 49032
Parameter Number: 21
LogicPro Driver: Database
LogicPro Address (Channels 1 to 32): 21.1 to 21.32
Table 1. Adaptive Mode Settings
Setting Description
Adapt The normal setting for a loop with Control Type set to
Adaptive. The loop is adapting and tuning while controlling.
Reset Select this option to have the control loop start from scratch
and relearn the load characteristics. The Control Mode must
be set to Off or Manual to select this option for an adaptive
loop. This is the normal setting for a loop with Control Type
set to a value other than Adaptive.
Hold Select this option to have the control loop stop learning
temporarily but retain the learned load characteristics. For
example in the event that maintenance will be performed, it
may be advantageous to pause adapting to avoid false data
being introduced. Select this option anytime you want the
controller to stop adapting and continue to control with the
parameters learned up to that point.
Plant Delay
This parameter indicates the amount of delay in seconds in the load. This
characteristic of the load or plant has a significant impact on adaptive
control. A larger number indicates a longer delay between, for example
an increase in heater power and an increase in the temperature.
Choose Automatic and then set the Control Mode to Auto to have the
adaptive algorithm determine the plant delay for the loop. The loop must
be at least 40 degrees below set point and the controller must observe a
temperature change of at least 20 degrees to determine the Plant Delay.
If you have determined the Plant Delay with the PPC-2000's adaptive
control previously and found the performance acceptable, you may
choose the delay directly and the loop will use the value you choose
rather than measure it.
This setting is not reset by the Adaptive Mode parameter's Reset option.
To have the controller relearn the Plant Delay, set the loop's Control Mode to Manual or Off, set the Plant Delay to Automatic, and then set
the Control Mode to Auto again.
This parameter has no effect on control if the Control Type for the loop is
set to an option other than Adaptive.
Values: Automatic (0) and 1 (1) to 600 seconds (600)
Default: Automatic (0)
Modbus Address (Channels 1 to 32): 49051 to 49082
Parameter Number: 28
LogicPro Driver: Database
LogicPro Address (Channels 1 to 32): 28.1 to 28.32
This parameter indicates the amount of delay in seconds in the load. This
characteristic of the load or plant has a significant impact on adaptive
control. A larger number indicates a longer delay between, for example
an increase in heater power and an increase in the temperature.
Values: Aggressive (0), Nominal (1), Damped 1 (2), Damped 2 (3),
Damped 3 (4) and Damped 4 (5)
Default: Nominal (1)
Modbus Address (Channels 1 to 32): 46551 to 46682
Parameter Number: 29
LogicPro Driver: Database
LogicPro Address (Channels 1 to 32): 29.1 to 29.32
Figure 1. The Effect of Tuning Gain on Recovery from a
Load Change
Using Adaptive Control
To set up adaptive control on one or more channels:
1. Open the
2. On the
a. Choose the appropriate
b. Choose
c. For any linear voltage, current, or pulse sensors, set the linear
This document contains additional specifications for the PPC-2000 system.
Environmental Specifications
Table 1 here contains specifications in addition to those found in tables 7.4, 7.15, 7.23,
7.31, 7.39, 7.46, 7.52, 7.57, 7.62, 7.67 in the PPC-2000 User's Guide.
TABLE 1. Environmental Specifications
Altitude2000 meters max
Non-Condensing Humidity10 to 95%
Relative Humidity80% max (ambient temperature <= 31° C)
50% max (ambient temperature = 40° C)
Pollution CategoryDegree 2 (per IEC 664)
Operating Temperature Range0 to 60° C (32 to140° F)
Storage Temperature Range-20 to 70° C (-4 to 158° F)
PPC IPS International Power SupplySpecifications
Table 2 here contains specifications in addition to those found in table 7.75 in the PPC2000 User's Guide.
TABLE 2. Power Specifications
Input (Mains Supply)88 to 132 Vac (120 Vac nominal)
176 to 264 Vac (240 Vac nominal)
Voltage Fluctuation< +10% of nominal voltage
Transient Over-VoltageCategory II per IEC 664
OutputV1: +5 Vdc @ 6 A
V2: +24 Vdc @ 4 A
Input Frequency47 to 440 Hz
Peak Current Output9A @ 5Vdc
Information in this manual is subject to change without notice. No part of this publication may be
reproduced, stored in a retrieval system, or transmitted in any form without written permission
from Watlow Anafaze.
Warranty
Watlow Anafaze, Incorporated warrants that the products furnished under this Agreement will be
free from defects in material and workmanship for a period of three years from the date of shipment. The Customer shall provide notice of any defect to Watlow Anafaze, Incorporated within one
week after the Customer's discovery of such defect. The sole obligation and liability of Watlow
Anafaze, Incorporated under this warranty shall be to repair or replace, at its option and without
cost to the Customer, the defective product or part.
Upon request by Watlow Anafaze, Incorporated, the product or part claimed to be defective shall
immediately be returned at the Customer's expense to Watlow Anafaze, Incorporated. Replaced or
repaired products or parts will be shipped to the Customer at the expense of Watlow Anafaze,
Incorporated.
There shall be no warranty or liability for any products or parts that have been subject to misuse,
accident, negligence, failure of electric power or modification by the Customer without the written
approval of Watlow Anafaze, Incorporated. Final determination of warranty eligibility shall be
made by Watlow Anafaze, Incorporated. If a warranty claim is considered invalid for any reason,
the Customer will be charged for services performed and expenses incurred by Watlow Anafaze,
Incorporated in handling and shipping the returned unit.
If replacement parts are supplied or repairs made during the original warranty period, the warranty
period for the replacement or repaired part shall terminate with the termination of the warranty
period of the original product or part.
The foregoing warranty constitutes the sole liability of Watlow Anafaze, Incorporated and the Customer's sole remedy with respect to the products. It is in lieu of all other warranties, liabilities, and
remedies. Except as thus provided, Watlow Anafaze, Inc. disclaims all warranties, express or
implied, including any warranty of merchantability or fitness for a particular purpose.
Please Note
: External safety devices must be used with this equipment.
Connecting the TB50 to the PPC-2010 Module 37
TB50 Connections 38
Connecting Digital Inputs 40
Connecting Counter or Frequency Inputs 41
Connecting Digital Outputs 41
SDAC Connections 43
Connecting Analog Inputs to the PPC-2021 — 2025 45
Connecting the AITB to the PPC-202x 45
Sensor Keys 46
AITB Connections 47
Connecting Thermocouples 49
Connecting RTDs 50
Connecting Sensors with Linear Voltage Signals 52
Connecting Sensors with Linear Current Signals 53
Connecting the Encoder Input Cable to the PPC-2030 55
Encoder Wiring 57
Encoder Connections without the EITB 59
Analog Output Connections 60
Connecting I/O to the PPC-2040 61
Connecting the TB50 to the PPC-2040 Module 61
TB50 Connections 62
Connecting Digital Inputs 64
Connecting Counter or Frequency Inputs 64
Connecting Digital Outputs 65
Connecting to the Relay Outputs on the PPC-206x 70
Wiring PPC-2062 Relay Outputs 71
Using Snubbers for Relay Outputs 73
Connecting Power 77
PPC-IPS-2 Power Supply 77
Processor Module 77
Connecting Communication Ports 78
Communication Ports 78
Connecting RS-485 Communications 81
ivWatlow AnafazeDoc.# 30002-00 Rev 2.3
PPC-2000 User’s GuideTable of Contents
Operating with AnaWin3 89
Type Definitions 89
Closed-Loop Control 89
Feedback 90
Control Algorithm 90
Control Output Signal Forms 90
Heat and Cool Outputs 90
Prerequisites 93
Background 93
Using AnaWin3 to Tune 94
Alarms 95
Failed Sensor Alarms 95
Global Alarm 95
Process Alarms 95
Alarm Delay 96
Setting up Process and Deviation Alarms 97
Setting Input Signal Lo and Input Signal Hi 99
Setting Engineering Units 99
Setting PV Lo and PV Hi 99
Setting Decimal Places 100
Linear 4-20mA Input Example 101
Process Variable Retransmit 102
Setting up Process Variable Retransmit 103
Process Variable Retransmit Example 104
Cascade Control 105
Setting up Cascade Control 106
Cascade Control Example 106
Ratio Control 109
Setting up Ratio Control 110
Differential Control 112
Remote Set Point 112
Logic Programs 112
Setting up Outputs for Use with a Logic Program 113
Using Logic to Set an Analog Input 113
Starting and Stopping Logic Programs 113
PPC-2040 Digital I/O 151
PPC-207x Digital In 153
Troubleshooting and Corrective Actions 154
Digital Inputs and Outputs 154
Process Variable 154
Communications 155
Resetting Closed-Loop Control Parameters 156
Disabling Control 157
LogicPro and Modbus Reference 159
Overview 159
Text Conventions in the Database Sections 159
The PPC-2000 Database 160
Data Table Organization 161
How LogicPro Accesses the Database 162
Analog and Counter Input Parameters in the Database 163
Accessing Analog and Counter Input Parameters with Modbus 163
Accessing Analog and Counter Input Parameters with LogicPro 163
Analog Input Numbers and Address Offsets 164
Analog and Encoder Input Parameters 168
Channel Parameters in the Database 172
Accessing Channel Parameters with Modbus 172
Accessing Channel Parameters with LogicPro 173
Channel Parameters for Heat and Cool Outputs 173
Channel Parameters 173
State and Logic 195
Accessing Digital I/O Parameters with Modbus 195
Digital I/O Numbers and Address Offsets 196
Digital I/O Parameters 200
Accessing Analog Outputs with Modbus 202
Accessing Analog Outputs with LogicPro 202
Analog Outputs and Modbus Addresses 202
Analog Output Value 204
Soft Bool and Soft Int Registers in the Database 205
Accessing Soft Bool and Soft Int Registers with Modbus 205
Accessing Soft Bool and Soft Int Registers with LogicPro 205
Soft Bool and Soft Int Registers 205
Global Parameters in the Database 206
Accessing Global Parameters with Modbus 206
Communications Parameters 207
Global Database Parameters 209
viWatlow AnafazeDoc.# 30002-00 Rev 2.3
PPC-2000 User’s GuideTable of Contents
Tuning and Control 219
Introduction 219
Control Algorithms 220
On/Off Control 220
Output Control Forms 224
Output Filter 225
Proportional Band (PB) Settings 226
Integral Settings 226
Derivative Settings 227
General PID Constants by Application 228
Proportional Band Only (P) 228
Proportional with Integral (PI) 228
PI with Derivative (PID) 228
Specifications 229
System Specifications 229
Safety and Agency Approvals 229
Physical Specifications 230
Power Specifications 230
PPC-2010 Processor Specifications 231
PPC-205x Analog Out Specifications 247
PPC-206x Digital Output Specifications 250
PPC-207x Digital In Specifications 253
PPC-EITB-1 Encoder Input Terminal Block Specifications 258
PPC-TB50-SCSI, 50-Pin Specifications 261
SDAC Specifications 265
Inputs 266
Analog Outputs 267
Appendix A: Modbus Protocol 269
Query 270
Response 270
Message Framing 271
Address Field 272
Function Field 272
Data Field 273
Error Checking Field 273
Field Format 273
Parity Checking 274
CRC Checking 275
Read Examples 280
Appendix B: Declaration of Conformity 283
Glossary 285
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Table of ContentsPPC-2000 User’s Guide
viiiWatlow AnafazeDoc.# 30002-00 Rev 2.3
Overview 1
Figure 1.1—System Diagram 4
Figure 1.2—Sample PPC-2000 System 6
Hardware Installation 13
Figure 2.1—PPC-IPS-2 DIN Mounting Dimensions 15
Figure 2.2—PPC-IPS-2 Panel Mounting Dimensions 16
Figure 2.3—Sample Addresses 17
Figure 2.4—PPC-2010 Jumpers 19
Figure 2.5—PPC-2030 Jumpers and Switches 20
Figure 2.6—PPC-2040 Jumper Settings 21
Figure 2.7—PPC-205x Jumpers 23
Figure 2.8—Assembled Modules Top View 24
Figure 2.9—Assembled Modules Bottom View 25
Figure 2.10—Modules Bottom/Side View 25
Figure 2.11—DIN Rail Latches 27
Figure 2.12—Mounting Assembled PPC Modules on a DIN rail (side) 27
Figure 2.13—AITB Dimensions / Clearances 29
Figure 2.14—EITB Dimensions / Clearances 30
Figure 2.15—TB50 Dimensions / Clearances 31
Figure 2.16—TB50 Mounted on DIN Rail (Front) 32
Figure 2.17—TB50 Mounted on DIN Rail (Side) 32
Figure 2.18—TB50 Panel Mounted 33
Figure 2.19—SDAC Dimensions 34
Figure 2.20—PPC-2010 Connection to TB50 38
Figure 2.21—Wiring Digital Inputs 41
Figure 2.22—Encoder with 5Vdc TTL Signal 41
Figure 2.23—Powering Output with 5Vdc from PPC Supply 42
Figure 2.24—Powering Output with 12-24Vdc from PPC supply 42
Figure 2.25—Powering Output with Separate Power Supplies 42
Figure 2.26—Recommended circuitry for CPUWatchdog 43
Figure 2.27—Wiring Single/Multiple SDACs 44
Figure 2.28—PPC-2021 — 2025 Connection to AITB 45
Figure 2.29—Inserting Sensor Keys in AITB 46
Figure 2.30—An Input Key 47
Figure 2.31—Thermocouples Connected to Differential Inputs 1 and 2 49
Figure 2.32—Thermocouples Connected to Single-ended Inputs 1 and 2 50
Figure 2.33—Wiring 2-Wire RTDs: Input 1 and 2 Shown 51
Figure 2.34—Wiring 3-Wire RTDs: Input 1 and 2 Shown 51
List of Figures
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List of FiguresPPC User’s Guide
Figure 2.35—Connecting Linear Voltage Signals to Differential Inputs 1 and 2 52
Figure 2.36—Connecting Linear Voltage Signals to Single-ended Inputs 1 and 2 53
Figure 2.37—Connecting Current Inputs to a Differential Input Module:
Input 1, 2, and 3 Shown 53
Figure 2.38—Connecting Current Inputs to a Single-ended Analog Input
Module: Input 1 and 2 Shown 54
Figure 2.39—PPC-2030 Connections (Bottom View) 55
Figure 2.40—PPC-EITB-1 56
Figure 2.41—EITB Single-ended Single Phase Connections: Input 1 and 2 Shown 57
Figure 2.42—EITB Single-ended Quadrature Connections: Input 1 and 2 Shown 58
Figure 2.43—EITB Differential Single Phase Connections: Input 1 and 2 Shown 58
Figure 2.44—EITB Differential Quadrature Connections: Input 1 and 2 Shown 59
Figure 2.45—PPC-2030 Analog Out Terminal Block 60
Figure 2.46—Analog Output Connections on a PPC-2030: Outputs 1 and 2 Shown 61
Figure 2.47—PPC-2040 Connection to TB50 62
Figure 2.48—Wiring Digital Inputs 64
Figure 2.49—Single Phase Connections: Input 1 and 2 Shown 64
Figure 2.50—Quadrature Connections: Inputs 1 and 2 Shown. 65
Figure 2.51—Powering Output with 5Vdc from PPC Supply 65
Figure 2.52—Powering Output with 12-24Vdc from PPC supply 66
Figure 2.53—Powering Output with Separate Power Supplies 66
Figure 2.54—PPC-205x Connections (Bottom View) 67
Figure 2.55—Analog Output Connections on a PPC-2050 Configured for Current:
Outputs 1 and 2 Shown 68
Figure 2.56—Analog Output Connections on a PPC-2050 Configured for Voltage:
Outputs 1 and 2 shown 69
Figure 2.57—Analog Output Connections on a PPC-2051 Configured for Current and
Voltage: Outputs 1 and 2 shown 69
Figure 2.58—PPC-206x Connections (bottom view) 70
Figure 2.59—Relay Output Connections on a PPC-2061:
Outputs 1, 2, 9 and 10 shown 71
Figure 2.60—Relay Output Connections on a PPC-2062: Outputs 1 and 2 Shown 72
Figure 2.61—Snubber Connections 73
Figure 2.62—PPC-207x Connections (bottom view) 74
Figure 2.63—Input Connections to a PPC-2070 or PPC-2072:
Inputs 1 and 2 shown 74
Figure 2.64—Input Connections to a PPC-2071 or PPC-2073:
Inputs 1,2, 9 and 10 Shown 75
Figure 2.65—Connecting a Current Sinking Field Device to a PPC-2072 or PPC-2073:
Input 1 Shown 75
Figure 2.66—Connecting a Current Sourcing Field Device to a PPC-2072 or
PPC-2073: Input 1 Shown 76
Figure 2.67—PPC-IPS-2 Power Connections 78
Figure 2.68—RS-232 and RS-485 RJ-Type Connectors 79
Figure 2.69—Connecting One PPC to a Computer Using RS-232 81
Figure 2.70—Connecting Multiple PPCs to a Computer Using RS-485 81
Figure 2.71—RS-485 Wiring 82
Figure 2.72—Two Wire RS-485 Wiring 84
Figure 2.73—Connecting Several PPCs with Short Cable Runs 84
xWatlow AnafazeDoc.# 30002-00 Rev 2.3
PPC User’s GuideList of Figures
Operating with AnaWin3 89
Figure 3.1—Sample Screen Text 89
Figure 3.2—Process Variable Alarms 96
Figure 3.3—Linear Input Example 98
Figure 3.4—Linear Scaling of the Analog Input for Retransmit on the Heat or Cool
Output 102
Figure 3.5—Sample Application Using Process Variable Retransmit 104
Figure 3.6—How the Secondary Channel’s Set Point is Determined When the
Primary Channel Has Heat and Cool Outputs 105
Figure 3.7—How the Secondary Channel’s Set Point is Determined When the Primary
Channel Has Only a Heat Output 106
Figure 3.8—Sample Application Using Cascade Control 107
Figure 3.9—The Secondary Channel’s Set Point is Determined by the Primary
Channel’s Process Variable 109
Figure 3.10—Relationship between the Master Channel’s Process Variable and the
Ratio Channel’s Set Point. 110
Figure 3.11—Sample Application Using Ratio Control 111
Figure 3.12—Channels Spreadsheet 115
Figure 3.13—Output Scaling (Heat/Cool) Curves 121
Figure 3.14—Alarms Spreadsheet 123
Figure 3.15—Inputs Spreadsheet 127
Figure 3.16—Analog Input Names 127
Figure 3.17—Pulse Input Names 128
Figure 3.18—Soft Input Names 128
Figure 3.19—Channel Output Names 129
Figure 3.20—Dig I/O Spreadsheet 132
Figure 3.21—PPC-2010 and PPC-204X Digital I/O Names 133
Figure 3.22—PPC-206X and PPC-207X Digital I/O Names 133
Figure 3.23—Outputs Spreadsheet 135
Figure 3.24—Analog Output Names 135
Figure 3.25—Soft Int Spreadsheet 136
Figure 3.26—Soft BOOL Spreadsheet 137
Figure 3.27—PPC Globals Screen 138
Figure 5.1—Sample Text 160
Figure 5.2—Output Scaling Curves 185
Tuning and Control 219
Figure 6.1—On/Off Control 220
Figure 6.2—Proportional Control 221
Figure 6.3—Proportional and Integral Control 222
Figure 6.4—Proportional, Integral and Derivative Control 223
Figure 6.5—Example Time Proportioning and Distributed Zero Crossing
Table 1.1—PPC-2000 System Modules 5
Table 1.2—PPC-2000 Terminal Boards and Peripheral Modules 5
Table 1.3— Analog Terminal Board Keys 5
List of Tables
Hardware Installation 13
Table 2.2—Power Supply Current Requirements at 24Vdc 14
Table 2.3—Power Supply Screw Mounting 16
Table 2.4—System Modules and Addressing 18
Table 2.5—PPC-2010 Processor Module Jumpers 18
Table 2.6—PPC-2030 Analog Output Jumpers 21
Table 2.7—PPC-2040 Counter Input Jumpers 21
Table 2.8—PPC-205x Analog Out Jumpers 22
Table 2.9—Cable Recommendations 35
Table 2.10—Processor Module I/O Connections 39
Table 2.11—Sensor Keys 46
Table 2.12—Numbers and Types of Inputs by Module Type 47
Table 2.13—Sensor Connections to the AITB 48
Table 2.14—Power Connections on AITB 49
Table 2.15—Encoder Connections to the EITB Connected to J3 on the PPC-2030 56
Table 2.16—Encoder Connections to the EITB Connected to J4 on the PPC-2030 56
Table 2.17—Power Connections on EITB 57
Table 2.18—HD-15 Encoder Signal Connections 59
Table 2.19—HD-15 Power Connections 60
Table 2.20—Analog Output Connections on Encoder In Analog Out Module 60
Table 2.21—Digital I/O Module Connections 63
Table 2.22—Analog Output Connections on Analog Out Module 67
Table 2.23—Relay Output Connections on PPC-206x Digital Output Modules 72
Table 2.24—Digital Input Connections on PPC-207x Modules 76
Table 2.25—PPC-IPS-2 Voltage Input Switch Settings 77
Table 2.26—Power Supply Connections 77
Table 2.27—RS-232 Connector Pin Outs 79
Table 2.28—RS-485 Connector Pin Out and Connections 80
Table 2.29—RTS/CTS Pins in DB-9 and DB-25 Connectors 80
Table 2.30—485 Terminal Block Pin Assignment 83
Table 2.31—PPC-2010 Rotary Switch Configuration 86
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List of TablesPPC User’s Guide
Operating with AnaWin3 89
Table 3.1—Control Types PID1 and PID2 91
Table 3.2—Alarm Types 95
Table 3.3—Range and Sensitivity of theCustom Linear Input Types 99
Table 3.4—PV Range permitted for various Decimal Places Settings 100
Table 3.5—Scaling Parameters for 0-10Vdc Linear Input Example 101
Table 3.6—Scaling Parameters for 4-20mA Linear Input Example 101
Table 3.7—Scaling Parameters for 0-1Vdc Linear Input Example 102
Table 3.8—Retransmit Channel Parameter Settings 104
Table 3.9—Primary Channel Parameter Settings 107
Table 3.10—Secondary Channel Parameter Settings 108
Table 3.11—Ratio Channel Parameter Settings 111
Table 3.12—AnaWin3 Control Types 118
Table 3.14—Module Abbreviations Seen on the Inputs Spreadsheet 127
Table 3.16—Units 131
Table 3.18—Function Values 134
Table 3.19—Module Abbreviations Seen on the Outputs Spreadsheet 135
Table 3.20—System Status 139
Table 3.21—Global Settings 139
LogicPro and Modbus Reference 159
Table 5.1—Parameter Names & Abbreviations 159
Table 5.2—Example Database Table 160
Table 5.3—Addresses for Analog Inputs on the PPC-202x Modules 164
Table 5.4—Addresses for Encoder Inputs on the PPC-2030 Encoder In Analog Out
Module 165
Table 5.5—Addresses for Counter Inputs on the PPC-2010 Processor Module 166
Table 5.6—Addresses for Soft Inputs and Channel Outputs 166
Table 5.7—Addresses for Encoder Inputs on the PPC-2040 Digital I/O Modules 167
Table 5.8—Input Parameters 168
Table 5.9—Input Status 169
Table 5.11—Temperature Scale Conversion 171
Table 5.13—Process Variable and Setpoint Source Settings for Analog Inputs on the
PPC-202x Modules 176
Table 5.16—Process Variable and Setpoint Source Settings for Soft Input and
Channel Out Registers 178
Table 5.18—Control Mode 180
Table 5.19—Control Types 181
Table 5.21—Heat/Cool Curve 184
Table 5.22—Output Destinations for Digital Outputs on the PPC-2010 Module 186
Table 5.26—Output Destinations for Analog Outputs on the PPC-205x Modules 189
Table 5.27—Output Destinations for Soft Boolean and Soft Integers 190
Table 5.28—Alarm Status 190
Table 5.30—Alarm and Control Functionality 192
Table 5.31—Alarm Acknowledge 192
Table 5.32—Alarm Enable/Disable 192
Table 5.33—Database Offsets and Sample Modbus Addresses for Digital I/O 196
Table 5.37—Digital I/O Uses 200
xivWatlow AnafazeDoc.# 30002-00 Rev 2.3
PPC User’s GuideList of Tables
Table 5.38—Digital I/O Parameters 200
Table 5.39—State and Logic 201
Table 5.40—Direction 201
Table 5.41—Logic 201
Table 5.44—Soft Bool and Soft Int Parameters 205
Table 5.45—Soft Bool Values 205
Table 5.46—Soft Bool and Soft Int Registers 206
Table 5.47—Rotary Switch Configuration 207
Table 5.48—Communications Parameters 208
Table 5.49—Database Offsets for Baud Rate 208
Table 5.50—Baud Rate 208
Table 5.51—System HW Parameters 209
Table 5.52—Miscellaneous System Parameters 209
Table 5.54—Zero Reference Readings 210
Table 5.55—Ambient Temperature Readings 211
Table 5.56—Modules Present 211
Table 5.57—Module Types 212
Table 5.59—System Status 214
Table 5.60—System Status Bits 214
Table 5.63—Real Time Clock Format 218
Tuning and Control 219
Table 6.1—Proportional Band Settings 226
Table 6.2—Integral Term and Reset Settings 227
Table 6.3—Derivative Term vs. Rate 227
Table 6.4—General PID Constants 228
Table A.1—Example Message Frame 271
Table A.2—Function Codes 276
Table A.3—Sample Packet for Host Query 280
Table A.4—Sample Packet for Slave Response 280
Table A.5—Sample Packet for Host Query 281
Table A.6—Sample Packet for Slave Response 281
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xviiiWatlow AnafazeDoc.# 30002-00 Rev 2.3
1
Overview
Manual Contents
This manual describes how to install, set up, and operate a
PPC-2000 controller. Each chapter covers a different aspect of
your control system and may apply to different users. The
following describes each chapter’s purpose.
instructions on installing the PPC-2000 system and its
peripherals.
PPC system with AnaWin3, the Watlow Anafaze HumanMachine Interface (HMI) software.
upgrading and reconfiguring procedures for technical
personnel.
on setting up third-party software or an operator interface
terminal for operating and monitoring a PPC System. Also
provides information needed to address parameters when
writing programs using LogicPro.
control algorithms and provides suggestions for
applications.
of the controller and optional components.
Doc.# 30002-00 Rev 2.3Watlow Anafaze1
Chapter 1: OverviewPPC-2000 User’s Guide
Getting Started
The following sections provide information regarding product
features, system components, safety requirements, and
preparation for operation.
Safety symbols
These symbols are used throughout this manual:
∫
WARNING!
Indicates a potentially hazardous situation which, if
not avoided, could result in death or serious
injury.
ç
CAUTION!
NOTE!
Contacting Watlow Anafaze
Indicates a potentially hazardous situation which, if
not avoided, could result in minor or moderate injury
or property damage.
Indicates pertinent information or an item that may be
useful to document or label for later reference.
To contact Watlow Anafaze, send correspondence to:
Watlow Anafaze, Inc.
314 Westridge Drive
Watsonville, CA 95076
Our technical support and customer service departments may
be reached Monday-Friday, 8 a.m. to 5 p.m. Pacific time:
Be sure to specify PPC2000 when asking for technical support.
Initial Inspection
Accessories may or may not be shipped in the same container
as the PPC-2010 controller, depending upon their size. Check
the shipping invoice carefully against the contents received in
all boxes.
2Watlow AnafazeDoc.# 30002-00 Rev 2.3
PPC-2000 User’s GuideChapter 1: Overview
Product Features
The PPC-2000 (PPC) offers high performance closed-loop (PID)
control and the ability to manipulate process control
algorithms and sequential logic in a very user friendly way. It
is a modular programmable process control system that utilizes
plug-in modules to meet different system requirements. The
controller can be configured for as many as 48 channels of PID
control and supports up to 288 programmable digital I/O
points. A motor interface module allows for operating up to 16
motor speed control systems. Seven types of hardware modules
are supported by the PPC system. AnaWin3 HMI software is
used for configuration, operation and data acquisition.
LogicPro software is available as an option and can be used to
write logic programs for sequential and process control.
The PPC controller includes the following features:
•Multiple channels of closed-loop control and
programmable logic in an integrated package
•Multiple sensor inputs: multiple TC types, RTD, voltage,
current
•As many as 288 digital I/O points
•48 closed-loop control channels with autotune
•Windows
•Third-party operator interface terminal (OIT) support
(option)
®
-based logic programming software (option)
System Components
Any system must include a power supply and a processor
module (PPC-2010) with built-in digital I/O. The appropriate
additional modules are added for analog inputs, analog
outputs, and expanding the digital I/O.
See Figure 1.1 on page 6-4 and Figure 1.2 on page 6-6 for
illustrations of the PPC’s system components and modules.
Refer to Table 1.1 on page 5 for a description of the modules and
their functions.
The number and types of I/O are determined by which modules
are selected for the application. Field wiring connects to DIN
rail or panel mounted terminal block boards. Terminal block
boards connect to I/O modules via 50-pin SCSI cables.
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Chapter 1: OverviewPPC-2000 User’s Guide
The following hardware and software interfaces are provided:
Hardware
•Serial ports for interfacing host computers and thirdparty operator displays
•Analog input and output terminal block connections
•Digital input and output terminal block connections
Software / Firmware
•Remote third-party operator interface panel software
using Modbus protocol (option)
•AnaWin3 Configurator edition: Windows configuration
utility
•LogicPro: Windows logic programming utility (option)
•AnaWin3 Developer edition: Windows user interface, data
monitoring and trend logging utility (option)
PC for AnaWin3 HMI
Software and/or LogicPro
Operator
Interface
Terminal
Power
Supply
PPC-2000
Assembly
TB50 for
Digital I/O
Encoder Input
Terminal Block
(EITB)
Analog Input
Terminal Board
(AITB)
Figure 1.1System Diagram
4Watlow AnafazeDoc.# 30002-00 Rev 2.3
PPC-2000 User’s GuideChapter 1: Overview
Table 1.1PPC-2000 System Modules
ModuleDescription
PPC-2010
PPC-2021, 202216 differential or 32 single-ended analog inputs
PPC-2024, 20258 or 16 highly isolated analog inputs
PPC-20304 encoder inputs and 4 analog outputs
Processor, 48 digital I/O, 2 serial ports,
1 counter/frequency input
32 configurable digital I/O, 2 counter/frequency
inputs
Table 1.2PPC-2000 Terminal Boards and
Peripheral Modules
Terminal BoardDescription
PPC-IPS-2International Power Supply, 120W
PPC-AITB-1Analog Input Terminal Board
PPC-TB50-SCSITerminal board for digital I/O
PPC-EITB-1Encoder Input Terminal Board
Table 1.3 Analog Terminal Board Keys
Key
(Color Code)
PPC-KEY-20
(none)
PPC-KEY-30
(blue)
PPC-KEY-40
(black)
PPC-KEY-50
(red)
Doc.# 30002-00 Rev 2.3Watlow Anafaze5
Adapts AITB for:
Thermocouples (differential or single-ended)
Linear voltages (differential or single-ended)
Adapts AITB for 0-20mA linear current
(differential)
Adapts AITB for 0-20mA linear current
(single-ended)
Adapts AITB for 2-wire RTDs (differential) or
3-wire RTDs (differential)
Descriptions
Chapter 1: OverviewPPC-2000 User’s Guide
Figure 1.2Sample PPC-2000 System
PPC-2000 Modules
The following sections describe the purpose and features of
each type of module available with the PPC-2000 system.
PPC-2010 Processor Module
The PPC-2010 processor module houses the system
microprocessor, memory and controller programs. Modular
communication ports support connections with a PC running
AnaWin3
connections with third-party operator interface panels or other
devices that communicate using Modbus protocol. Communications ports one and two may be used simultaneously.
Additional modules may be connected to the processor module’s
expansion bus to add capabilities to the PPC system.
Precision analog outputs can be provided using Serial Digital to
Analog Converters (SDAC). Each SDAC unit converts a control
output from the processor module to an analog voltage or
current signal. For more specific information, see
Analog-to-Digital Converter on page 9
and
LogicPro
or third-party interface software, and
SDAC Serial
.
6Watlow AnafazeDoc.# 30002-00 Rev 2.3
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