Watlow PPC-2000 User Manual

PPC-2000
User’s Guide
WATLOW
1241 Bundy Boulevard Winona, Minnesota USA 55987
Phone: +1 (507) 454-5300, Fax: +1 (507) 452-4507
Part No. 0600-3000-2000 Rev 2.3d
http://www.watlow.com
PPC-2000 Adaptive Control Addendum
Scope
This document describes the additional features and functionality found in the PPC-2010-xxB with adaptive control. Refer to the PPC-2000 User’s Guide regarding all other functionality which is the same as the standard version.
Introduction
The Watlow Anafaze PPC-2000 controller offers these standard options:
Forty-eight loops of conventional PID control with auto-tuning
capability
-or-
Eight loops of adaptive control plus 24 loops of conventional PID
control with auto-tuning for a total of 32 loops (the option described in this document)
ANAWIN3 HMI software is available to support either option. A mix of these options is not supported by ANAWIN3.
ANAWIN3 Software Installation
Follow the standard instructions to install and setup ANAWIN3. In the setup program select the Adaptive Control option.
Spreadsheet Overview Screen
Several new parameters and options appear on the Spreadsheet Overview screen in support of the adaptive control option. These parameters and options are applicable only for the first eight channels and are omitted or ignored for channels 9 to 32.
Control Type
An additional option appears for Control Type. Select Adaptive to enable adaptive control and tuning on a channel. This option is only valid for channels 1 to 8.
Values: PID1 (0), PID2 (1), Adaptive (2) and Retransmit (3) Default: PID1 (0) Modbus Address (Channels 1 to 32): 46401 to 46432 Parameter Number: 19 LogicPro Driver: Database LogicPro Address (Channels 1 to 32): 19.1 to 19.32
Adaptive Addendum PPC-2000 User's Guide 0600-0049-0001 rev C Watlow Anafaze 1
Adaptive Mode
When Control Type is set to Adaptive, this parameter can be used to pause tuning or to reset the adaptive algorithm and have it relearn the system. This parameter has no effect on control if the Control Type for the loop is set to an option other than Adaptive.
Values: Adapt (0), Reset (1) and Hold (2) Default: Reset (1) Modbus Address (Channels 1 to 32): 49001 to 49032 Parameter Number: 21 LogicPro Driver: Database LogicPro Address (Channels 1 to 32): 21.1 to 21.32
Table 1. Adaptive Mode Settings
Setting Description
Adapt The normal setting for a loop with Control Type set to
Adaptive. The loop is adapting and tuning while controlling.
Reset Select this option to have the control loop start from scratch
and relearn the load characteristics. The Control Mode must be set to Off or Manual to select this option for an adaptive loop. This is the normal setting for a loop with Control Type set to a value other than Adaptive.
Hold Select this option to have the control loop stop learning
temporarily but retain the learned load characteristics. For example in the event that maintenance will be performed, it may be advantageous to pause adapting to avoid false data being introduced. Select this option anytime you want the controller to stop adapting and continue to control with the parameters learned up to that point.
Plant Delay
This parameter indicates the amount of delay in seconds in the load. This characteristic of the load or plant has a significant impact on adaptive control. A larger number indicates a longer delay between, for example an increase in heater power and an increase in the temperature.
Choose Automatic and then set the Control Mode to Auto to have the adaptive algorithm determine the plant delay for the loop. The loop must be at least 40 degrees below set point and the controller must observe a temperature change of at least 20 degrees to determine the Plant Delay. If you have determined the Plant Delay with the PPC-2000's adaptive control previously and found the performance acceptable, you may choose the delay directly and the loop will use the value you choose rather than measure it.
This setting is not reset by the Adaptive Mode parameter's Reset option. To have the controller relearn the Plant Delay, set the loop's Control Mode to Manual or Off, set the Plant Delay to Automatic, and then set the Control Mode to Auto again.
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Tuning Gain
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
3. On the
Adaptive Addendum PPC-2000 User's Guide 0600-0049-0001 rev C Watlow Anafaze 3
Spreadsheet Overview screen in ANAWIN3.
Inputs spreadsheet for each analog input you have wired:
Input Type for the sensor.
Units.
scaling parameters ( and
PV Hi). See Setting up User Selectable Linear Inputs on
page 98 of the PPC-2000 User's Guide.
Channels spreadsheet for each channel:
Input Signal Lo, Input Signal Hi, PV Lo,
a. In the PV Source field, choose the input that you want to
monitor or use as feedback for closed-loop control.
b. In the
Heat Output Dest and/or Cool Output Dest fields,
choose the outputs that you want to use for closed-loop control.
c. Choose a d. Set the
Output Type
4. On the a. Set the
Output.
5. On the
Heat/Cool Output Type for each output.
Heat/Cool Cycle Time for any outputs with Heat/ Cool
set to Time Prop.
Digital I/O spreadsheet:
Direction for each I/O point to be used for control to
Channels spreadsheet:
a. For channels other than the adaptive ones, if both heat and cool
outputs are used, set the
Spread.
b. For each channel that will perform adaptive control, for the
Control Type, choose Adaptive.
c. Set the
Set Point to the desired value at least 40 engineering
units (typically degrees) above the process variable.
d. Set the
Control Mode to Auto to begin adaptive closed-loop
control.
NOTE: Only channels 1 to 8 can be selected for adaptive control.
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PPC-2000 User's Guide Addendum
Overview
This document contains additional specifications for the PPC-2000 system.
Environmental Specifications
Table 1 here contains specifications in addition to those found in tables 7.4, 7.15, 7.23,
7.31, 7.39, 7.46, 7.52, 7.57, 7.62, 7.67 in the PPC-2000 User's Guide.
TABLE 1. Environmental Specifications
Altitude 2000 meters max Non-Condensing Humidity 10 to 95% Relative Humidity 80% max (ambient temperature <= 31° C)
50% max (ambient temperature = 40° C)
Pollution Category Degree 2 (per IEC 664) Operating Temperature Range 0 to 60° C (32 to140° F) Storage Temperature Range -20 to 70° C (-4 to 158° F)
PPC IPS International Power Supply Specifications Table 2 here contains specifications in addition to those found in table 7.75 in the 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-Voltage Category II per IEC 664
Output V1: +5 Vdc @ 6 A
V2: +24 Vdc @ 4 A
Input Frequency 47 to 440 Hz Peak Current Output 9A @ 5Vdc
6A @ 24 Vdc
1241 Bundy Blvd. Winona, MN 55987 Phone: (507) 494-5656 Fax: (507) 452-4507
©2004 Watlow Page 1 of 1
Copyright © 1998-2002 Watlow Anafaze
Information in this manual is subject to change without notice. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form without written permission from Watlow Anafaze.
Warranty
Watlow Anafaze, Incorporated warrants that the products furnished under this Agreement will be free from defects in material and workmanship for a period of three years from the date of 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.
Table of Contents iii
List of Figures ix
List of Tables xv
Overview 1
Manual Contents 1 Getting Started 2
Safety symbols 2 Contacting Watlow Anafaze 2 Initial Inspection 2
Product Features 3 System Components 3
PPC-2000 Modules 6 PPC-2000 Terminal Boards 8 Additional Components 9
Safety 9
External Safety Devices 10 External Switch Disconnect 11 Battery Safety 11 Product Markings and Symbols 11

Table of Contents

Hardware Installation 13
Power Supply Requirements 13
Mounting the Power Supply 15
Hardware Configuration 17
Module Addresses 17 PPC-2010 Jumper Settings 18 PPC-2030 Dip Switch Settings 19 PPC-2030 Jumper Settings 20 PPC-2040 Jumper Settings 21 PPC-205x Jumper Settings 22
Module Disassembly 26 Mounting Modules 26
DIN Rail Mounting 27
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Table of Contents PPC-2000 User’s Guide
Mounting Terminal Boards 28
DIN Rail Mounting 31 DIN Rail Removal 32 Panel Mounting 33
System Wiring 34
Wiring Recommendations 35 Noise Suppression 35 Avoiding Ground Loops 37
Connecting I/O to the PPC-2010 37
Connecting the TB50 to the PPC-2010 Module 37 TB50 Connections 38 Connecting Digital Inputs 40 Connecting Counter or Frequency Inputs 41 Connecting Digital Outputs 41 SDAC Connections 43
Connecting Analog Inputs to the PPC-2021 — 2025 45
Connecting the AITB to the PPC-202x 45 Sensor Keys 46 AITB Connections 47 Connecting Thermocouples 49 Connecting RTDs 50 Connecting Sensors with Linear Voltage Signals 52 Connecting Sensors with Linear Current Signals 53 Connecting the Encoder Input Cable to the PPC-2030 55 Encoder Wiring 57 Encoder Connections without the EITB 59 Analog Output Connections 60
Connecting I/O to the PPC-2040 61
Connecting the TB50 to the PPC-2040 Module 61 TB50 Connections 62 Connecting Digital Inputs 64 Connecting Counter or Frequency Inputs 64 Connecting Digital Outputs 65
Connecting to the Relay Outputs on the PPC-206x 70
Wiring PPC-2062 Relay Outputs 71 Using Snubbers for Relay Outputs 73
Connecting Power 77
PPC-IPS-2 Power Supply 77 Processor Module 77
Connecting Communication Ports 78
Communication Ports 78 Connecting RS-485 Communications 81
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PPC-2000 User’s Guide Table 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
Controller Parameters 115
Channels 115 Digital I/O 132 Soft Integer 136 Soft Boolean 137
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Table of Contents PPC-2000 User’s Guide
Troubleshooting 141
General Description 141 PPC-2010 Processor 141
Processor Module LEDs 147
PPC-2040 Digital I/O 151 PPC-207x Digital In 153 Troubleshooting and Corrective Actions 154
Digital Inputs and Outputs 154 Process Variable 154 Communications 155 Resetting Closed-Loop Control Parameters 156 Disabling Control 157
LogicPro and Modbus Reference 159
Overview 159
Text Conventions in the Database Sections 159 The PPC-2000 Database 160 Data Table Organization 161 How LogicPro Accesses the Database 162
Analog and Counter Input Parameters in the Database 163
Accessing Analog and Counter Input Parameters with Modbus 163 Accessing Analog and Counter Input Parameters with LogicPro 163 Analog Input Numbers and Address Offsets 164 Analog and Encoder Input Parameters 168
Channel Parameters in the Database 172
Accessing Channel Parameters with Modbus 172 Accessing Channel Parameters with LogicPro 173 Channel Parameters for Heat and Cool Outputs 173 Channel Parameters 173 State and Logic 195 Accessing Digital I/O Parameters with Modbus 195 Digital I/O Numbers and Address Offsets 196 Digital I/O Parameters 200 Accessing Analog Outputs with Modbus 202 Accessing Analog Outputs with LogicPro 202 Analog Outputs and Modbus Addresses 202 Analog Output Value 204
Soft Bool and Soft Int Registers in the Database 205
Accessing Soft Bool and Soft Int Registers with Modbus 205 Accessing Soft Bool and Soft Int Registers with LogicPro 205 Soft Bool and Soft Int Registers 205
Global Parameters in the Database 206
Accessing Global Parameters with Modbus 206 Communications Parameters 207 Global Database Parameters 209
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PPC-2000 User’s Guide Table 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 Contents PPC-2000 User’s Guide
viii Watlow Anafaze Doc.# 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 Figures PPC 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
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PPC User’s Guide List 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

Troubleshooting 141

Figure 4.1—Assembled Modules Top View 143 Figure 4.2—Assembled Modules Bottom View 143 Figure 4.3—PPC-2010 Internal View 144 Figure 4.4—PPC Assembled Modules Top View 145 Figure 4.5—PPC Assembled Modules Bottom View 146
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List of Figures PPC User’s Guide

LogicPro and Modbus Reference 159

Figure 5.1—Sample Text 160 Figure 5.2—Output Scaling Curves 185

Tuning and Control 219

Figure 6.1—On/Off Control 220 Figure 6.2—Proportional Control 221 Figure 6.3—Proportional and Integral Control 222 Figure 6.4—Proportional, Integral and Derivative Control 223 Figure 6.5—Example Time Proportioning and Distributed Zero Crossing
Waveforms 224

Specifications 229

Figure 7.1—System Footprint 230 Figure 7.2—PPC-2010 Front View 231 Figure 7.3—PPC-2010 Bottom View 232 Figure 7.4—PPC-2021 Front View 236 Figure 7.5—PPC-2021 - 2025 Bottom View 236 Figure 7.6—PPC-2030 Front View 240 Figure 7.7—PPC-2030 Bottom View 241 Figure 7.8—PPC-2040 Front View 244 Figure 7.9—PPC-2050 Front View 247 Figure 7.10—PPC-2050 Bottom View 248 Figure 7.11—PPC-206x Front View 250 Figure 7.12—PPC-206x Bottom View 251 Figure 7.13—PPC-2070, PPC-2071 Front Views 253 Figure 7.14—PPC-207x Bottom Views 254 Figure 7.15—PPC-AITB-1 256 Figure 7.16—PPC-AITB Dimensions with Straight SCSI Cable 257 Figure 7.17—PPC-EITB-1 258 Figure 7.18—PPC-EITB Dimensions with HD-Type Cable 260 Figure 7.19—PPC-TB50-SCSI Dimensions 261 Figure 7.20—PPC-TB50-SCSI Dimensions with Straight SCSI Cable 262 Figure 7.21—PPC-TB50-SCSI Dimensions with Right-Angle SCSI Cable 263 Figure 7.22—PPC-IPS-2 264 Figure 7.23—SDAC Dimensions 266

Appendix A: Modbus Protocol 269

Figure A.1—Query—Response Cycle 270
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Overview 1

Table 1.1—PPC-2000 System Modules 5 Table 1.2—PPC-2000 Terminal Boards and Peripheral Modules 5 Table 1.3— Analog Terminal Board Keys 5

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 Tables PPC 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
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PPC User’s Guide List 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

Specifications 229

Table 7.1—Safety and Agency Approvals 229 Table 7.2—PPC System Dimensions 230 Table 7.3— Model Number 232 Table 7.4—Environmental Specifications 232 Table 7.5—Physical Specifications 232 Table 7.7—Power Specifications 233 Table 7.8—Capacity and Programming 233 Table 7.9—Control Specifications 234 Table 7.10—Counter/Frequency Input Specifications 234 Table 7.11—Digital Input Specifications 234 Table 7.12—Digital Output Specifications 235 Table 7.13—Serial Interface 235 Table 7.14—Model Numbers 237 Table 7.15—Environmental Specifications 237 Table 7.16—Physical Specifications 237 Table 7.17—Connections 237 Table 7.18—Power Specifications 237 Table 7.21—Sensor Reference Voltage Output 239 Table 7.22—Model Number 241 Table 7.23—Environmental Specifications 241
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List of Tables PPC User’s Guide
Table 7.24—Physical Specifications 241 Table 7.25—Connections 242 Table 7.26—Power Specifications 242 Table 7.27—Input Specifications 242 Table 7.29—Safety and Agency Approvals 243 Table 7.30—Model Number 244 Table 7.31—Environmental Specifications 244 Table 7.32—Physical Specifications 245 Table 7.33—Connections 245 Table 7.34—Power Specifications 245 Table 7.35—Counter/Frequency Specifications 245 Table 7.37—Digital Output Specifications 246 Table 7.38—Model Number 248 Table 7.39—Environmental Specifications 248 Table 7.40—Physical Specifications 248 Table 7.41—Connections 249 Table 7.42—Power Specifications PPC-2050 249 Table 7.43—Power Specifications PPC-2051 249 Table 7.44—Output Specifications 249 Table 7.45—Model Number 251 Table 7.46—Environmental Specifications 251 Table 7.47—Connections 251 Table 7.48—Physical Specifications 252 Table 7.49—Power Specifications 252 Table 7.50—Output Specifications 252 Table 7.51—Model Number 254 Table 7.52—Environmental Specifications 254 Table 7.53—Physical Specifications 254 Table 7.54—Connections 255 Table 7.55—Power Specifications 255 Table 7.56—Digital Input Specifications 255 Table 7.57—Environmental Specifications 256 Table 7.58—Physical Specifications 256 Table 7.59—Connections 257 Table 7.60—PPC-AITB with Straight SCSI 257 Table 7.61—Sensor Key Cards 258 Table 7.62—Environmental Specifications 259 Table 7.63—Physical Specifications 259 Table 7.64—Connections 259 Table 7.65—PPC-EITB with HD-Type Cable 259 Table 7.66—Safety and Agency Approvals 259 Table 7.67—Environmental Specifications 261 Table 7.68—Physical Specifications 261 Table 7.70—PPC-TB50-SCSI with Straight SCSI 262 Table 7.72—Environmental Specifications 264 Table 7.73—Physical Specifications 264 Table 7.74—Dimensions with Din Rail Bracket 265 Table 7.75—Power Specifications 265 Table 7.76—Connections 265 Table 7.77—Safety and Agency Approvals 265
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Table 7.78—Environmental Specifications 265 Table 7.79—Physical Specifications 266 Table 7.80—Safety and Agency Approvals 266 Table 7.81—Inputs 267 Table 7.82—Power Requirements 267 Table 7.83—Analog Output Specifications 267

Appendix A: Modbus Protocol 269

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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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.
Chapter 1: Overview. Provides component list and
Chapter 2: Hardware Installation. Provides detailed
Chapter 3: Software Setup. Describes how to use your
Chapter 4: Troubleshooting. Includes troubleshooting,
Chapter 5: Custom Interfacing. Provides information
Chapter 6: Tuning and Control. Describes available
Chapter 7: Specifications. Lists detailed specifications
summary of features for the PPC-2000.
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.
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Chapter 1: Overview PPC-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:
Telephone: +1 (831) 724-3800 Email: anafazetechsupport@watlow.com
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.
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PPC-2000 User’s Guide Chapter 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
User-programmable, advanced control algorithms
Modular hardware
Bus expansion up to 9 additional modules
Serial communication
AnaWin3 operator interface compatible (single or multiple PPC modbus network capability
Analog inputs (as many as 128) per PPC system
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: Overview PPC-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 1.1 System Diagram
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PPC-2000 User’s Guide Chapter 1: Overview
Table 1.1 PPC-2000 System Modules
Module Description
PPC-2010 PPC-2021, 2022 16 differential or 32 single-ended analog inputs
PPC-2024, 2025 8 or 16 highly isolated analog inputs PPC-2030 4 encoder inputs and 4 analog outputs
PPC-2040 PPC-2050 8 analog outputs
PPC-2051 4 analog outputs PPC-2061 16 relay outputs PPC-2062 8 relay outputs PPC-2070, 2071 8,16 120Vac inputs PPC-2072, 2073 8,16 24V AC/DC inputs
Processor, 48 digital I/O, 2 serial ports, 1 counter/frequency input
32 configurable digital I/O, 2 counter/frequency inputs
Table 1.2 PPC-2000 Terminal Boards and
Peripheral Modules
Terminal Board Description
PPC-IPS-2 International Power Supply, 120W PPC-AITB-1 Analog Input Terminal Board PPC-TB50-SCSI Terminal board for digital I/O PPC-EITB-1 Encoder 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)
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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: Overview PPC-2000 User’s Guide
Figure 1.2 Sample 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
.
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