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FACTS Engineering Direct Logic 405, Manual

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D i r e c t   L o g i c  4 0 5

                      

F o u r   L o o p  T e m p e r a t u r e   C o n t r o l l e r

F 4 - 4 L T C

Manual Order Number:  F4-4LTC-M

Summary of Contents for Direct Logic 405

Page 1: ...Automationdirect com D i r e c t L o g i c 4 0 5 F o u r L o o p T e m p e r a t u r e C o n t r o l l e r F 4 4 L T C Manual Order Number F4 4LTC M...

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Page 3: ...y Florida 34655 World rights reserved No part of this publication may be stored in a retrieval system transmitted or reproduced in any way including but not limited to photocopy photograph magnetic or...

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Page 5: ...ll applicable codes and standards We do not guarantee the products described in this publication are suitable for your particular application nor do we assume any responsibility for your product desig...

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Page 7: ...TD Inputs 2 2 Voltage or Thermocouple Inputs 2 2 UNUSED TEMPERATURE INPUTS 2 2 INSTALL F4 4LTC IN CPU BASE 2 3 LED STATUS INDICATORS 2 3 RTD CONNECTION DIAGRAM 2 4 THERMOCOUPLE CONNECTION DIAGRAM 2 5...

Page 8: ...V5017 2 19 PID Control Period V5020 2 20 ON OFF Hysteresis V5021 2 20 Temperature Calibration Adjustment V5022 2 21 TEMPERATURE CONTROLLER MEMORY MAP 4 LOOPS 2 21 CHAPTER 3 SUPPORTING LADDER LOGIC 3...

Page 9: ...P OPERATING MODES 5 2 PID Control 5 2 ON OFF Control 5 2 LOOP ALGORITHM 5 2 Loop Variables 5 2 PID Control 5 2 PID equation 5 3 Reverse Acting Loop Cooling 5 4 RESET WINDUP PROTECTION 5 4 Freeze Bias...

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Page 11: ...or direct connection to either RTD or Thermocouple temperature sensors On board solid state outputs are used to cycle heater or cooler relays using either time proportioning pulse PID or ON OFF contro...

Page 12: ...agnostics Possible low level diagnostic errors include CPU Error Firmware Error Watchdog time out circuit Incorrect ROM Checksum RAM Error and Analog Circuit Error These errors are reported to PLC CPU...

Page 13: ...n is stopped when the PID output reaches 0 or 100 Rate Specify the derivative time 0 to 65535 in units of seconds Rate may be determined automatically by using the Auto Tuning feature Auto Tune Auto T...

Page 14: ...sformer input to output current ratio is approximately 400 1 Minimum Output ON time 300 msec to sense heater current Mounting Single slot in CPU base up to eight modules per system I O Points Required...

Page 15: ...300 EC 94 2372 EF Type C 65 2320 EC 149 4208 EF Input Fault Protection 60 Vrms or 50 Vdc maximum Cold Junction Compensation Automatic Input Impedance 20 MS Resolution 0 1 EC Relative accuracy Warm Up...

Page 16: ...INTRODUCTION 1 6...

Page 17: ...TD or Thermocouple 2 Install F4 4LTC in the CPU Base and Note the Slot Number 3 Connect Temperature Sensors to TEMP Inputs 4 Connect SSR Controller Outputs to SSRs 5 Connect CT Inputs to Current Trans...

Page 18: ...uts Voltage or Thermocouple Inputs UNUSED TEMPERATURE INPUTS Unused temperature inputs should be shorted together and connected to 24V common For example if only three temperature loops are required t...

Page 19: ...K On after Controller completes self diagnostics OUT On when corresponding heater Output is on AT On when corresponding loop is Auto Tuning HB On when corresponding Heater Burn out has been detected W...

Page 20: ...ect an RTD to the Controller be exactly the same resistance a 3 7 difference in 26 AWG lead length will introduce a 2 EF error If a four wire RTD is used leave unconnected one of the positive side lea...

Page 21: ...e shield drain wire at one end only For grounded thermocouples connect shield at the sensor end For ungrounded thermocouples connect shield to the COM terminal of the F4 4LTC Temperature Controller mo...

Page 22: ...stable and accurate measurement in an electrically noisy area Exposed Grounded Thermocouple In some cases the thermocouple does not have a protective case and is connected directly to a device at a s...

Page 23: ...variations may occur Heat generating devices should generally be mounted above and away from the Temperature Controller If the module is exposed to abrupt temperature changes such as opening the cont...

Page 24: ...7730 1 V7661 V7671 V7711 V7731 2 V7662 V7672 V7712 V7732 3 V7663 V7673 V7713 V7733 4 V7664 V7674 V7714 V7734 5 V7665 V7675 V7715 V7735 6 V7666 V7676 V7716 V7736 7 V7667 V7677 V7717 V7737 Table Beginni...

Page 25: ...Control Period see page 2 20 is large more than 4 seconds then slow mode may be considered Fast A 2 in the high byte selects a faster 32 msec per channel conversion time If fast mode is selected the...

Page 26: ...tarting address is too high for number of loops 0020 5 On if Dedicated V Memory Configuration Error 0040 6 On if Temperature Controller Configuration Error 0080 7 On if ROM Error Incorrect Checksum Wa...

Page 27: ...will not display negative numbers with a minus sign Hegative numbers will appear as values greter than 32768 For example 0 1 32768 08001H and 3276 7 65535 0FFFFH The values in parenthesis in the follo...

Page 28: ...onal 0 0 6553 5 7 V5007 Reset Integral 0 65535 seconds 8 V5010 Rate Derivative 0 65535 seconds 9 23 Read if Mode Word bit 0 is set 9 V5011 Low Alarm 3276 7 EC EF 10 V5012 High Alarm 3276 7 EC EF 11 V5...

Page 29: ...Direct Acting heating 0004 2 ON Temperature Units EC OFF Temperature Units EF 0008 3 ON Output Format is analog value 0 4095 V5003 OFF Output Format is 0 0 100 0 V5003 0010 4 ON PID Control OFF ON OFF...

Page 30: ...on bit 7 to enable heater current alarms Open and shorted heater outputs can be detected when an external current transformer is used Turn on bit 8 to enable automatic calculation of the PID controlle...

Page 31: ...ocation as the temperature approaches the SetPoint Output Bias is also used to provide Feed Forward in anticipation of a process disturbance For example this disturbance could be the addition of colde...

Page 32: ...0010 4 ON No Heater Current Alarm open or disconnected 0020 5 ON No Heater Current Control Alarm output shorted 0040 6 ON Auto Tune Fault unable to tune loop 0080 7 Watch Dog Bit Toggles every tempera...

Page 33: ...1310 7 100 13 1 V5006 131 PB EC or EF 1310 7 Gain Example Default Gain 200 0 V5006 2000 PB 1310 7 200 0 6 6 EC or EF Reset V5007 Reset specifies the Integral action used in the PID control algorithm...

Page 34: ...Deadband V5014 The Alarm Deadband lets you program a deadband around each alarm Deadband prevents alarms from chattering when near an alarm limit This value is read by the temperature controller when...

Page 35: ...for 100S platinum RTDs are 8 European and 9 American The Input Type code for a 1000S European curve platinum RTD is 10 All RTDs used on the same module must be the same resistance range you can mix t...

Page 36: ...seconds V5020 30 Therefore a shorter Control Period of 2 seconds should be used b Minimum Control Period Use 2 seconds V5020 20 for the minimum Control Period unless the temperature speed of response...

Page 37: ...shows the addressing for all four loops of a Temperature Controller Module with a Table Beginning Address of V5000 Any V Memory address maybe specified as the loop table starting address for a given m...

Page 38: ...INSTALLATION AND WIRING 2 22...

Page 39: ...e PID or alarm parameters are changed then bit 0 of the mode word must be set in order for the Temperature Controller module to apply these new values The logic below shows an example that uses X0 to...

Page 40: ...s on then the BCD number for the least significant bit in the Alarm Word will be returned Thus a Low Temperature Alarm will override a Temperature Deviation Alarm A Broken Transmitter Alarm will alway...

Page 41: ...then manual over ride is disabled if it is ON then manual over ride is enabled If X10 is ON then X11 selects which state to force the output X11 OFF forces the output OFF X11 ON forces the output ON...

Page 42: ...e a heater The following example copies the output status from the Alarm Words of all four loops to the discrete outputs Y10 to Y13 NEGATIVE TEMPERATURES The following example is useful if you are wor...

Page 43: ...e input via a 4 20 mA signal derived from a slidewire connected to the actuator mechanism A scaled BCD output of an absolute encoder connected to the motor might also be used to determine the actuator...

Page 44: ...ed from the Temperature Controller parameter table for loop 1 V5005 The final SetPoint is in V1400 and the ramp time in minutes is stored in V1401 The holding time at each step is fixed at one minute...

Page 45: ...SUPPORTING LADDER LOGIC 3 7...

Page 46: ...n the SetPoint the Process Variable must be within a specified band around the SetPoint in order for the Soak time to be measured In this example the step change in the SetPoint is stored in V1400 The...

Page 47: ...SUPPORTING LADDER LOGIC 3 9...

Page 48: ...SUPPORTING LADDER LOGIC 3 10...

Page 49: ...Output Bias is nearly the same each time the Output cycles proceed to step 4 b If the process will not tolerate the Temperature Controller operating in ON OFF control mode then select PID Gain and Re...

Page 50: ...s on minimize oscillation then the controller settings are calculated after the temperature stabilizes at the new output this can take a very long time If bit 10 of the mode word is off faster respons...

Page 51: ...programmed PID Gain Reset and Rate values are inadequate Solution 2 Set Rate to zero and select PID Gain and Reset values until the Temperature Controller begins to move the temperature closer to the...

Page 52: ...on increase with increasing gain 4 Short reset times cause oscillations 5 Long reset times cause slow response After changing a PID setting V5006 V5010 remember to set bit 0 in the Mode Word so that t...

Page 53: ...able all integral and derivative action Set the Gain V5006 to 0200 20 0 Set the PID Control Period V5020 to 20 2 0 seconds 4 Make the temperature stabilize near the most commonly used SetPoint two met...

Page 54: ...Reset V5007 5Pu Rate V5010 Pu 8 For example if the ultimate period is 140 seconds then the Reset value is 70 and the Rate value is 17 9 Monitor the operation of the Temperature Controller with the new...

Page 55: ...called offset Integral Control Integral Control action is dependent upon time It responds over time to the offset inherent in the proportional only controller It will accommodate SetPoint and load cha...

Page 56: ...ture Controller Loop Variables All loop calculations are performed using normalized Reals A normalized Real is a floating point number in the range of 0 0 to 1 0 High precision is maintained since the...

Page 57: ...rivative of the Process Variable instead of the error as follows M Kc e Ki e Kr PV PV M n n i i n n n 1 1 0 These two forms are equivalent unless the SetPoint is changed In the original equation a lar...

Page 58: ...until the error is positive for long enough to cause the bias to become positive again This will cause the controller to overshoot the SetPoint One way to solve the problem is to simply clamp the bias...

Page 59: ...can be found on page 2 8 The Output Auto Tuning Heater Burn Out and Alarm LEDs come ON as appropriate to the current conditions of the enabled temperature loops Bit 15 of the Alarm Word for each enabl...

Page 60: ...type to view the temperature loop parameters Cause 3 The temperature is negative and the sign bit is not being taken into consideration If a temperature is negative it will be displayed as a decimal...

Page 61: ...Solution Set bit 0 of the Mode Word see the example on page 3 1 If you have any installation or operation questions or if you need additional information please call 1 800 633 0405 To receive the fas...

Page 62: ...TROUBLESHOOTING 6 4...

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