West Control Solutions CALogix User Manual

Programming and Installation

CALogix

Manual

DM000M22

Page 1 of 44

Introduction
Installation

Mechanical Installation 4

a) Base-unit 4
b) Control module 4
c) Mounting 4
d) Removing a module 5
e) Removing the base-unit from DIN-rail 5
f) Cleaning 5
g) Dimensions 6

Electrical Installation 7

a) Output devices 7
b) Supply Voltage 7
c) Wiring a connector 7
d) Replacing modules 7
e) Inductive loads 7
f) EN61010 7
g) EMC guidelines 8
h) Supply and RS485 communications connections 9
i) Input options (module) 9
j) Output options (module) 9
k) Example circuit 10
l) Input sensor selection 10

Configuring CALogix 11

a) CALogix network 11
b) Multiple CALogix network 11
c) CALogix-sw minimum PC requirements 12
d) Installing CALogix-sw 12
e) Running CALogix-sw 12
f) Using CALogix-sw 13

Diagnostics 13

CALogix-sw configuration software 14

Starting CALogix-sw 14
Connecting to a controller 14
CALogix-sw toolbar 14
Base-unit setup 15
Configuring a PID module 16

a) Settings menu 16
b) Viewing Parameter settings 16
c) Changing a setting value 16
d) Initial settings 16
e) Park Mode 17
f) Setpoint adjustment 17
g) Autotune 17
h) Proportional cycle time 17
i) Second and third setpoints 18
j) Heat-Cool 18
k) Recalibration 19
l) Linear inputs 19

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m) Error messages 20
n) PID module settings 20

Programmer 25

a) Function overview 25
b) Accessing the programmer interface 25
c) Programmer interface 25
d) Creating a program 25
e) Program segment types 26
f) Program properties 28
g) Reading program data from a controller 28
h) Creating an additional program 29
i) Selecting a program 29
j) Insert segments to a program 29
k) Deleting segments 29
l) Modifying a program 29
m) Running Programs 29
n) Stopping a program 30

Logic I/O module and Logic Programming 31

a) Overview 31
b) Logic I/O module settings 31
c) Accessing logic programming 31
d) The logic toolbar 31
e) Placing a function block on desktop 33
f) Arranging function blocks 33
g) Linking function blocks 33
h) Function blocks - selecting operation 33

− Logic 33

 Boolean 33
 Timer 34
 Counter 34
 Comparator 34

− Input 35

− Output 35

 Physical Output 35
 Changing setpoint 35
 Manual power 35
 Autotune 36
 Event input 36
 Program 36

i) Inverting Inputs 36
j) Validating a logic program 37
k) Writing a logic program to a controller 37
l) Running and stopping a logic program 37
m) Trace mode 38

Appendix

Function Block Operation 39

a) Boolean tables 39
b) Timer charts 40

Technical Specification 43

Safety and Warranty Information

44

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CALogix Installation Instructions
System Overview

CALogix is a modular multi-loop PID controller with logic function capability. The controller consists of a DIN-rail mount
base-unit that incorporates the power supply, RS485 communications ports and slots for up to 4 control modules. The
control modules are available as PID or Logic I/O and can be selected then mounted into the base-unit as required for the
application. Variations in PID control modules include temperature sensor and linear (0-50mV, 4-20mA, 0-5V & 0-10V)
inputs with options for relay, ssd or analog (4-20mA, 0-5V & 0-10V) outputs. Logic I/O modules have user defined 0-5, 0­10, 0-24Vdc inputs with relay or ssd outputs. All wiring connectors to the base unit and control modules are plug-in to
reduce installation and maintenance times.

CALogix is configured using the Windows™ based CALogix-sw configuration tool which is provided with each base-unit.
PID setup, input & output parameter settings, profile creation and writing logic function block diagrams can all be
performed within the software utility. These settings can be read, modified and written to and from the controller and also
saved on the PC as a file to be recalled at a later date when required. The program also provides information on current
process value, set-points and output status which can be useful when commissioning the system.

Mechanical Installation

The controller is designed as two main components

BASE-UNIT

DIN rail mount device containing main CPU and connections for up to 4 control modules.

CONTROL MODULE

PID or Logic control modules can be mixed as required for the application and plugged in to base-unit.

1 base-unit and 1-4 control modules must be used for operation of product. A CALogix system can only be configured
using CALogix-sw pc-based software.

MOUNTING

To mount a base unit with control modules proceed as follows:

1. Affix 35mm type DIN rail securely to mounting surface, minimum length 140mm. The unit should be mounted
vertically as shown.

2. Attach carrier unit to DIN rail ensuring the spring release is at the bottom, facing downward.

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3. Ensuring the input terminals are facing downwards, add the control modules to base unit. Press the top and
bottom tabs on the module lightly and ensuring module is kept straight, push to locate in base unit (see diagram
below).

REMOVING A MODULE

REMOVING BASE-UNIT FROM DIN-RAIL

REPLACING A CONTROL MODULE

When replacing a control module follow the instructions above for removing and installing control modules. If a control
module is being replaced with another that has the same part number, all parameter settings will be automatically
transferred from the base unit to the new module on re-powering the system, no reconfiguration will be required.

Press

4. Pre-wire connectors and plug into the appropriate modules (we suggest wire markers for identification)

1. Isolate supply to CALogix and all module input and output connectors.

2. Unplug connectors to module requiring removal.

3. Press tabs as shown above to release module.

4. Carefully pull the module away from base-unit ensuring tabs are free to remove.

1. Isolate supply to CALogix and all module input and output connectors.

2. Unplug connectors to base-unit and all modules.

3. Insert screwdriver into DIN-rail release block and apply pressure away from the controller, the base-unit can then
be removed.

If a module is being replaced with a module that has a different part number, ensure that the system is

re-wired accordingly and the module settings are modified to reflect the changes made, before running your
system. Failure to do so may result in dangerous operation or damage to the system.

If you are replacing logic modules with PID modules, it is important to turn off or delete any associated logic.
CLEANING

Wipe down with damp cloth (water only).

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DIMENSIONS

Note Ensure adequate clearance for connectors and wiring

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Electrical Installation

The system is designed to be installed in an enclosure which provides adequate protection against electrical shock. The
enclosure should also be of a sufficient IP (NEMA) rating for protection against water and dust.
mounted in an enclosure with minimum internal dimensions of 160 wide x 125 high x 85 mm deep.

OUTPUT DEVICES

Three types of output are available on an output module: relay, solid state relay drive (ssd) and analog. Output 1 may be
any one of the three options, output 2 can be relay or ssd and output 3 is always relay. Any of these outputs can be
assigned as SP1, SP2 and SP3 using the CALogix-sw software. Check the model number and output configuration before
wiring the instrument and applying power. See section on output options for more details.

1. Solid state relay drive

12Vdc +10/-15% (nominal), 20mA
To switch remote SSR

2. Miniature power relay

2A/250Vac resistive, Form A

3. Analog Output (Isolated) - NOT AVAILABLE WITH LOGIC I/O MODULE

Specify 4-20mA 500Ω max, ±0.1% fs typical

0-5Vdc 10mA (500Ω min). ±0.1% fs typical
0-10Vdc 10mA (1KΩ min). ±0.1% fs typical

/SPST contacts

SUPPLY VOLTAGE

18-30Vdc, 8 watts ±10% fluctuation permitted

WIRING A CONNECTOR

Prepare the cable carefully, remove between 6 and 8mm insulation and ideally tin or terminate to avoid bridging. Prevent
excessive cable strain. Maximum recommended wire size 32/0.2mm 1.0mm² (18 AWG)

REPLACING MODULES

Hot plugging of modules should not be carried out. To change a module always depower the base-unit. Once power is re­applied the carrier will reload the settings for that module and continue with the original module settings. Hotplugging can
cause the carrier to fail and is potentially dangerous.

INDUCTIVE LOADS

To prolong relay contact life and suppress interference, it is recommended engineering practice to fit a snubber
(0.1µF/100Ω) between relay output terminals.

CALogix should be

CAUTION
Snubber leakage current can cause some electro-mechanical devices to be held ON. Check with
manufacturers specification.

EN61010 - 1 / UL61010C-1/ CSA22.2 No 1010

Compliance shall not be impaired when fitted to the final installation.
Designed to offer a minimum of basic insulation only.

The body responsible for the installation is to ensure suitable for measurement category II or III

To avoid possible hazards, accessible conductive parts of the installation should be protectively earthed in accordance
with EN61010 for Class 1 equipment.

Output wiring should be within a protectively earthed cabinet.

*Sensor sheaths should be bonded to protective earth or not be accessible

Live parts should not be accessible without the use of a tool.

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EMC GUIDELINES

We make a number of general recommendations that can reduce the possibility of EMC problems

.

1) It is important to suppress CALogix relay contacts, this will reduce switching interference and also prolongs life
of the contacts.

RC Networks fitted across the relay contacts are recommended for resistive and larger inductive loads, values
such as 0.1μF capacitor in series with a 100Ω resistor.

For small inductive loads, a suitable rated VDR is recommended.

For small inductive dc loads, relays etc, a suitably rated diode fitted in parallel with the load is recommended.

2) CALogix should be mounted into a metal cabinet which is properly earthed, good all round metal shielding is
important.

3) It should be borne in mind that the wiring of the installation can significantly reduce the efficiency of the
instrumentation immunity. This is due to the ease with which high frequency RF can enter via unprotected
incoming and outgoing cables.

Earthed thermocouples or sensors with screened cable, should be earthed at the cabinet entry point.

Any long cables entering the control cabinet should be protected at the point where they enter the cabinet, large
diameter ferrite sleeves are an economical and effective method of reducing high frequency RF, looping the
cables through ferrite sleeves a number of times will improve the efficiency of the filtering.

Alternatively for mains cables, the fitting of a suitable mains filter can provide good results.

Data or communications cables should be screened. If using Belden 8132 connect drain wire to PIN 5 of a
shielded RJ45 connector.

Ideally data and sensor cables should be routed separately from power cables and away from inverters or other
high power/frequency devices.

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SUPPLY AND RS485 COMMUNICATIONS CONNECTIONS (BASE-UNIT)

INPUT OPTIONS (MODULE)

7P---0A000 7P---0A000 7P---0A000

OUTPUT OPTIONS (MODULE)

7P---0B000 = 4-20mA
7P---0C000 = 0-5V
7P---0D000 = 0-10V

7P111----­7L111-----

7P211----­7L211-----

7PB11----- = 4-20mA
7PC11----- = 0-5V
7PD11----- = 0-10V

7PB21 = 4-20mA
7PC21 = 0-5V
7PD21 = 0-10V

7L---0E000

7P221----­7L221-----

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EXAMPLE CIRCUIT

The circuit below shows an example applicaion which includes a base-unit that has one PID module and one logic module
fitted.

FS1 Fuse = 1A time lag type to IEC127. CSA/UL rating 250V
FS2 Fuse = 2A time lag type to IEC127. CSA/UL rating 250V
FS3 Fuse = High rupture capacity (HRC). Suitable for maximum rated load current

S1 switch = IEC/CSA/UL approved disconnection device must be used

It is strongly recommended that the power supply zero volts and all logic module zero volts are common to prevent ground
loops.

INPUT SENSOR SELECTION

Thermocouple type Description Sensor Range (°C) Sensor Range (°F)

Resistance Thermometer

B Pt-30% Rh/Pt-6%Rh 0 to1800°C* 32 to 3272°F*
E Chromel/Con 0 to 600°C 32 to 1112°F
J Iron/Constantan 0 to 800°C 32 to 1472°F
K Chromel/Alumel -50 to 1200°C -58 to 2192°F
L Fe/Konst 0 to 800°C 32 to 1472°F
N Nicrosil/NiSil -50 to 1200°C -58 to 2192°F
R Pt-13%Rh/Pt 0 to 1600°C 32 to 2192°F
S Pt10%Rh/Pt 0 to 1600°C 32 to 2192°F
T Copper/Con -200 to 250°C -273 to 482°F

rtd 2/3 wire

Pt100/RTD-2/3 -200 to 800°C -273 to 1472°F

* Note : Type-B accuracy not specified below 100°C/212°F

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Configuring CALogix

CALogix is configured using Windows-based CALogix-sw software. Before using CALogix–sw, connect CALogix to a PC
as shown below:

CALOGIX NETWORK

RS485 from PC

CALogix uses RS485 full duplex serial communications link which is the standard most commonly used for industrial
applications due to high noise immunity and multi-drop capability. It enables a PC to communicate with up to 31 CALogix
base-units over distances up to 1200 metres, and requires the addition of an RS485 interface card, or a separate RS232 /
485 converter connected to the RS232 port of the PC. RS485 converters that derive power from the RS232 port must have
all 9 pins (RS232) connected for full operation of the converter.

RS485 cards and converters can differ greatly in their requirements and therefore the installation instructions supplied with
the interface should be read carefully.

2m CALogix-PC cable (part number - CAB RJ45 2M 01) and a RS232/485 converter (part number 3C 25 000 K 3X) that
fits directly on to the RS232 serial port on a PC are available from your nearest CAL Controls distributor.

If wiring your own cable the RS485 connections are as follows.

RJ45 PIN

2 RX+
3 RX­ 4 / 5 GND
6 TX­ 7 TX+

As CALogix is designed for an industrial environment, CAL recommends using a 4 wire shielded RS485 cable such as
Belden 8132. Ensure that connectors are suitable for use with shielded cable and are correctly bonded.

Auto-baud rate function. On power up CALogix detects the network speed and automatically adjusts its baud rate
accordingly. If the network baud rate is later modified, remove the power and reapply so that CALogix can resynchronise to
the new baud rate.

MULTIPLE CALOGIX NETWORKS

Each CALogix unit has an RS485-in and RS485-out RJ45 socket. To connect a number of CALogix units on a network,
wire as shown below. The cables should be wired so that the corresponding pins of RS485-out are connected to the same
pin number on RS485-in of the next controller i.e. Pin 2 (out) to Pin 2 (in), Pin 3 (out) to Pin 3(in), Pin 5(out) to Pin 5(in),
Pin 6(out) to Pin 6(in) and Pin 7(out) to Pin 7(in).

To other
CALogix
controllers

RS232/485 converter

<15m <1200m

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For multiple instrument networks each transmission line must be properly terminated to prevent reflections. 120Ω
termination resistors should be fitted between TX+ & TX- and RX+ & RX- at the connection to the PC in addition to the last
instrument in the chain. See example below.

When transmission lines are not transmitting, they remain in an intermediate state which can allow receivers to receive
invalid data bits due to electrical noise on the cable. To prevent this bias resistors may be required to force the lines into a
known state. Some RS485 interface cards and converters may have bias resistors fitted please check manufacturer’s
specification and recommendations for use of bias resistors.

Note: The default Modbus address for each base-unit is 1, for a network with a number of CALogix units, power-up each
unit individually and configure them with a unique Modbus address using CALogix-sw configuration tool. (See section on
base-unit set-up in manual)

CALOGIX-SW MINIMUM PC SYSTEM REQUIREMENTS

As a general requirement, we would recommend a minimum of Pentium 450MHz with 256MB RAM, Windows
and screen resolution, 1024 x 768.

INSTALLING CALOGIX-SW

1. Insert CALogix-sw disk into CD-drive.

2. CALogix-sw install program should auto-run. If this does not happen, manually run ‘setup.exe’ on CALogix-sw
cd.

3. Follow on screen instructions to complete installation.

RUNNING CALOGIX-SW

1. Click ‘start’ on Windows toolbar.

2. Mouse-over ‘all programs’.

3. Mouse-over ‘CALogix folder’ in menu.

TM

2000/XP

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4. Click on ‘CALogix’ icon.

5. CALogix program should now run.

USING CALOGIX-SW

1. Refer to on-screen help or CALogix programming manual contained on CALogix-sw CD.

Diagnostics

Each control module has LEDs to indicate when each of the outputs are on (or relay closed). If an analogue output option
is fitted the LED dims proportionately with the output level, e.g. a PID module with a 4-20mA output, the LED will be dim at
4mA and bright at 20mA.
Note: The output and the LED indicator are physically linked and always represent the true state of the output.

CALogix base-unit has three status LED’s to assist with diagnosing problems

LED 1 – Communications

Off No communications
On/Pulsing Communications active

LED 2 – CALogix healthy (Heartbeat)

Slow pulse Unit operating correctly
Fast Pulse Base-unit emergency (comms still running)
On Base-unit lock-up

When base-unit emergency/lock-up conditions exist recycle power to clear. If the
problem does not clear on power recycle contact CAL controls for technical support.

LED 3 – Logic

Off Logic not active
On Logic active

To start logic program running refer to section on running logic programs

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CALogix-sw Configuration Software

STARTING CALOGIX-SW

1. Click ‘start’ on Windows toolbar

2. Mouse-over ‘all programs’

3. Mouse-over ‘CALogix folder’ in menu

4. Click on ‘CALogix’ icon

5. CALogix program should now run

CONNECTING TO A CONTROLLER

1. Click on to add a new instrument

2. Click on browse

3. Select communications port, baud rate and Modbus address (default 1). Once settings are entered click on
browse.

4. CALogix unit is then shown in device list when detected. Click on OK.

5. Window now opens showing CALogix unit with data on installed modules

.

THE CALOGIX-SW TOOLBAR

New meter (visible when no controller open)

Search for a CALogix system on a network.

New device (visible when controller open)

Access a different CALogix base-unit.

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