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Chapter 7. TROUBLESHOOTING

7- 1

Chapter 7. TROUBLESHOOTING

The followings explain errors that could occur during operating the PID control module and their troubleshooting.

7.1 Errors Indicated by RUN LED Flickering

Errors indicated by PID control module RUN LED flickering are given below.

RUN LED Status

Error Type

Loop RUN LED status

Flickering

(cycle: 0.1 sec)

WDT Error

Loop “0” RUN LED ON

System Error

All Loops RUN LED OFF

Flickering

(cycle: 0.2 sec)

Buffer Memory Error

Loop “1” RUN LED ON

7.2 Troubleshooting Procedure

7.2.1 RUN LED Flickering

7.2.2 RUN LED Off

RUN LED flickering

Is the PID control module is correctly mounted on the base unit?

Mount correctly the PID control module.

The PID control module hardware defect. If the loop run LED
is turned ON, write down their error numbers and see Section
7.2.5.

Is the PID control module is correctly mounted on the base unit?

Mount correctly the PID control module.

See Section 7.2.5.

RUN LED off

Summary of Contents for K4F-PIDA

Page 1: ...User s s s s Manual LG Programmable Logic Controller K7F PIDA K4F PIDA MASTER K LG LG LG LG Industrial Systems ...

Page 2: ...4 2 4 1 Processing Type 2 4 1 Velocity Type Processing 2 4 2 Measured Value Derivative Type Pre Derivative Type 2 4 2 4 2 Control Actions 2 5 1 Proportional Action P Action 2 5 2 Integral Action I Action 2 7 3 Derivative Action D Action 2 9 4 PID Action 2 10 5 PID Processing Expression 2 10 6 Forward Reverse Actions 2 11 Chapter 3 INSTALLATION 3 1 Installation Ambience 3 1 3 2 Handling Precautions...

Page 3: ... 4 K7F PIDA addresses 4 and 5 K4F PIDA address 2 4 2 4 Specifying SET Data Enable Disable 4 4 K7F PIDA addresses 6 and 7 K4F PIDA address 3 4 2 5 Loop Run Information 4 5 K7F PIDA addresses 8 and 9 K4F PIDA address 4 4 2 6 Setting PID Control Data 4 5 4 2 7 Outputting Manipulated Value 4 6 K7F PIDA addresses 202 and 203 K4F PIDA addresses 53 to 60 4 2 8 Setting Error Information 4 6 K7F PIDA addre...

Page 4: ...rol Module and D A Conversion Module 6 2 3 A Program for Control Using a Thermocouple 6 8 with Applying the TC Input Module PID Control Module and D A Conversion Module Chapter 7 TROUBLESHOOTING 7 1 Errors Indicated by RUN LED Flickering 7 1 7 2 Troubleshooting Procedure 7 1 7 2 1 RUN LED Flickering 7 1 7 2 2 RUN LED Off 7 1 7 2 3 Unreadable Processing Result of PID Control Module 7 2 7 2 4 Run LE...

Page 5: ...nd precautions are represented as follows according to the degree of hazard However a precaution followed with can also result in serious conditions Both of two symbols indicate that an important content is mentioned therefore be sure to observe it Keep this manual handy for your quick reference in necessary SAFETY PRECAUTIONS WARNING If not provided with proper prevention it can cause death or fa...

Page 6: ...e and fixed Improper installation of the module can cause malfunction disorder or falling Test Run and Maintenance Precautions CAUTION Do not separate the module from the printed circuit board PCB or do not remodel the mod ule They can cause disorder malfunction damage of the module or a fire When mounting or dismounting the module perform them after the power has been turned off Do not perform wo...

Page 7: ... makes PV come to be SV by adjusting output to eliminate the difference The PID control is composed of combinations of Proportional P Integral I and Derivative D actions When a difference between SV and PV occurs proportional integral differential quantities are calculated upon that difference and a MV Manipulated Value is output The features of the PID control module are as follows 1 One module c...

Page 8: ...ic discharge Voltage 4kV contact discharge IEC 1131 2 IEC 801 2 Radiated electromagnetic field 27 500 MHz 10 V m IEC 1131 2 IEC 801 3 Severity Level All power modules Digital I Os Ue 24 V Digital I Os Ue 24 V Analog I Os communication I Os 7 Noise immunity Fast transient burst noise Voltage 2 kV 1 kV 0 25 kV IEC 1131 2 IEC 801 4 8 Operating atmosphere Free from corrosive gases and excessive dust 9...

Page 9: ...tive constant is set to 0 0 sec derivative action shall not be applied Setting range SV Set Value 0 16 000 Input range PV Process Value 0 16 000 Output range MV Manipulated Value 0 16 000 Setting range M_MV Manually Manipulated Value 0 16 000 RUN STOP RUN The run LED of corresponding loops ON STOP The run LED of corresponding loops OFF LED NORMAL ERROR Normal RUN LED ON Error RUN LED flickering Nu...

Page 10: ...arts No Descriptions Loop Run LED It shows the PID control module run status ON The corresponding loop is running OFF The corresponding loop is running Flickering Error status Error Value is displayed RUN LED It shows the PID module Operating status ON Normal Flickering Error K7F PIDA K4F PIDA ...

Page 11: ...is used in the derivative processing the output of the derivative term changes rapidly when the deviation occur due to alteration of set value SV So to prevent raid changes like that this processing uses the process value PV for the derivative term MVn MVn 1 MVn MVn Present Manipulated Value MVn 1 Previous Manipulated Value MVn Variation of the Previous Manipulated Value MVn MVn 1 Kp En En 1 Kp S ...

Page 12: ... shown in Fig 2 1 Fig 2 1 MV with the proportional action 4 As shown in Fig 2 1 the larger the proportional constant Kp the larger the MV that is the stronger the P action when the deviation E is same Also the smaller the Kp the smaller the MV after P action 5 If the Kp is too large PV reaches SV swiftly but can make bad effects like oscillations shown in Fig 2 2 and cause damage in control stabil...

Page 13: ...Chapter 2 SPECIFICATIONS 2 6 Fig 2 2 When the proportional constant Kp is large Fig 2 3 When the proportional constant Kp is small ...

Page 14: ... following Fig 2 4 Fig 2 4 Integral action at a constant deviation 4 Expression of Integral Action is as follows As shown in the expression Integral action can be made stronger or weaker by adjusting integration time Ki in I action That is the more the integration time the longer the integration time as shown in Fig 2 5 the lesser the quantity added to or subtracted from the MV and the longer the ...

Page 15: ...Chapter 2 SPECIFICATIONS 2 8 Fig 2 5 When a long integration time is given Fig 2 5 When a short integration time is given Set Value ...

Page 16: ...trol object due to external conditions 2 The period of time from when the deviation has occurred to when the MV of D action become the MV of P action is called derivative time and represented as Kd 3 The D action when a given deviation occurred is shown as Fig 2 7 Fig 2 7 Derivative action at a constant deviation 4 The expression of D action is represented as follows In this expression an output p...

Page 17: ...Processing Expression PID expressions are of measured value derivative type Expressions Parameters names En SV PVn MVn MVn 1 Kp En En 1 Kp S KI En Kp Kd S 2PVn PVn 1 PVn 2 MVn MVn 1 En En 1 Kp Ki Kd S PVn PVn 1 PVn 2 Present Manipulated Value One step previous Manipulated Value Present deviation Previous deviation Proportional constant Integral constant Derivative constant Control cycle 100 ms Pro...

Page 18: ...ess than SV b Reverse action makes PV reach SV by outputting MV when PV is more than SV 2 A diagram in which forward and reverse actions are drawn using MV PV and SV is shown as Fig 2 9 Fig 2 9 Forward and reverse action with MV PV and SV 3 Fig 2 10 shows examples of process control by forward and reverse actions respectively Fig 2 9 Examples of process control by forward and reverse actions ...

Page 19: ...er work do not allow any wire scraps to enter into the PLC Install it on locations that are convenient for operation Make sure that it is not located near high voltage equipment on the same panel Make sure that the distance from the walls of duct and external equipment be 50 mm or more Be sure to be grounded to locations that have good noise immunity 3 2 Handling Precautions From unpacking to inst...

Page 20: ...6 Set data enable disable Specification area loop 0 to 15 7 Set data enable disable Specification area loop 16 to 31 Bit On 1 Set each content of address 0 1 4 5 10 to 41 and 74 to 201 to a new setting Bit Off 0 The previous values of address 0 1 4 5 10 to 41 and 74 to 201 remains without change No Setting Values R W 8 Loop run information loop 0 to 15 9 Loop run information loop 16 to 31 Bit On 1...

Page 21: ...vious values of address 0 2 5 to 12 and 21 to 52 remains without change No Setting Values R W 4 Loop run information Bit On 1 Run Bit Off 0 Stop Read Only 5 to 12 SV of each loop Setting range 0 to 16000 0 R W 13 to 20 PV of each loop Input range 0 to 16000 0 R W 21 to 28 M_MV of each loop Setting range 0 to 16000 0 R W 29 to 36 P of each loop Setting range 0 to 10000 500 R W 37 to 44 I of each lo...

Page 22: ...able K7F PIDA Addresses 0 1 K4F PIDA Address 0 1 Loop enable disable specification is possible on every channel 2 Disabled loops will not be used in processing 3 The followings show the bit corresponding to each loop 4 2 2 Specifying Auto Manual Processing K7F PIDA Addresses 2 3 K4F PIDA Address 1 1 Turn the corresponding bit Off 0 if a loop runs with auto processing Turn the corresponding bit On ...

Page 23: ...IDA Addresses 6 7 K4F PIDA Address 3 1 If a bit corresponding to each loop in Set Data specification area is turned On 1 then the PID processing is executed with new user defined data due to loop enable disable specification forward reverse action specification setting SV setting M_MV and change of P I D constants 2 If the bit corresponding to each loop is not turned On 1 then the PID processing i...

Page 24: ...ows Address 10 decimal K7F PIDA K4F PIDA Item Setting range Default 10 41 5 12 SV 42 73 13 20 PV 74 105 21 28 M_MV 0 16000 0 106 137 29 36 P constant Kp 1 10000 500 138 169 37 44 I constant Ki 0 30000 1000 170 201 45 52 D constant Kd 0 30000 0 2 If PID control data is outside the range the execution continues with the setting range of the previous processing 3 If PID control data is outside its se...

Page 25: ...MV output range is 0 to 16000 4 2 8 Setting Error Information K7F PIDA Addresses 234 to 265 K4F PIDA Addresses 61 to 68 1 When setting the control data for each loop if any setting exceeds its range the error information is indicated on this area 2 Bit 0 to 5 are used to indicate error information for each loop The following shows the error information indicated by each bit when it turns On 1 ...

Page 26: ...C D D n3 Number of data to be read Integer The difference between GET and GETP GET Always executed if the execution condition turns on GETP Executed if the execution condition is triggered Example 1 In this example the PID control module is mounted on the slot 3 in the base unit and the data of buffer memory addresses 202 and 203 will be read to the CPU module addresses D202 and D203 PID control m...

Page 27: ...nteger The difference between PUT and PUTP PUT always executed if the execution condition turns on PUTP executed if the execution condition is triggered Example 1 In this example the PID control module is mounted on the slot 6 in the base unit and the data of CPU module addresses D0 and D1 will be written to the buffer memory addresses D202 and D203 address CPU module D area PID control module buf...

Page 28: ...running conditions in the buffer memories of the PID control module The PID control module is already mounted on the slot 0 The PID control module occupies 16 I O points 6 1 1 K7F PIDA SET data are processed with triggering P21 whenever the contents in the buffer memories addresses 1 1 4 5 10 41 and 74 202 are changed ...

Page 29: ...Chapter 6 PROGRAMMING 10 2 6 1 2 K4F PIDA SET data are processed with triggering P21 whenever the contents in the buffer memories addresses 1 1 4 5 10 41 and 74 202 are changed processing ...

Page 30: ...annel 0 B Specifying output data type 192 to 16191 C Setting filter constant 50 3 D A conversion module A Specifying used channel channel 0 B Specifying input data type 192 to 16191 C Output when no channel is used or the CPU module is in the stop state The median value of the output range is output 2 Descriptions of the Program 1 A temperature 0 to 200 C from the temperature sensor is converted i...

Page 31: ...e D A conversion module 4 If P0023 turns on initial setting of the A D conversion module PID control module and D A conversion module is executed 3 Modules and their Signal Processing Sensor measuring temperature range 0 200 C Signal converter current output range DC 4 20 mA A D conversion module input current range DC 20 20 mA A D conversion module digital output range 9600 16000 PID control modu...

Page 32: ...Chapter 6 PROGRAMMING 10 5 5 Program D A conversion Module initialization switch Making the PV of PID control module be set to the A D conversion value ...

Page 33: ...riptions of the Program 1 The channel 0 of the RTD input module detects a temperature of the electric furnace through Pt100 and receives it as a digital value 2 The Set Value of PID control module loop 0 is set to 8000 where the temperature is 100 C With regards to P I D constants the manipulated value in the BCD digital switch is set to the proportional constant when P0022 turns on to the integra...

Page 34: ...PROGRAMMING 10 7 4 Program RTD RTD input module RTD RTD RTD Reading the BCD digital Switch value and then using it as P or I or D value Making the PV of PID Control module be set to the detected temperature value ...

Page 35: ...nel channel 0 B Specifying input data type 192 16191 C The output when no channel is used or the CPU module is in the stop state The median value of the output range 3 Descriptions of the Program 1 The temperature of the electric furnace is converted into a digital value through the channel 0 of the TC input module and the digital value stored at address 18 is used as PV of the PID control module ...

Page 36: ...of the TC input module M10 turns on If the channel 0 of the TC input module runs normally auto processing is specified in the PID control module If an error occurs at the channel of the TC input module manual processing is specified in the PID control module Using manual processing when an error occurs in the TC input module Reading the temperature to digital conversion value and Error detection W...

Page 37: ...Loop 0 RUN LED ON System Error All Loops RUN LED OFF Flickering cycle 0 2 sec Buffer Memory Error Loop 1 RUN LED ON 7 2 Troubleshooting Procedure 7 2 1 RUN LED Flickering 7 2 2 RUN LED Off RUN LED flickering Is the PID control module is correctly mounted on the base unit Mount correctly the PID control module The PID control module hardware defect If the loop run LED is turned ON write down their ...

Page 38: ...the numbers of the loops used in the processing correctly specified See Section 7 2 5 Specify correctly the loop numbers See Section 7 2 2 Is RUN LED turned OFF See Section 7 2 1 Is RUN LED flickering Are the loops that should be executed correctly specified See Section 7 2 5 Check the numbers of the loops which are actually being executed and specify them correctly PID control module hardware def...

Page 39: ...Chapter 8 DIMENSIONS 8 1 Chapter 8 DIMENSIONS 8 1 K7F PIDA Dimensions K7F PIDA ...

Page 40: ...Chapter 8 DIMENSIONS 8 2 8 2 K4F PIDA Dimensions K4F PIDA ...

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