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Manuals and User Guides for Watlow Anafaze PPC-2000. We have
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Watlow Anafaze PPC-2000 manual available for free PDF download: User Manual
Watlow Anafaze PPC-2000 User Manual (320 pages)
Brand:
Watlow
| Category:
Controller
| Size: 2 MB
Table of Contents
Table of Contents
9
Table of Contents III
15
List of Figures
15
List of Tables XV
25
Overview
25
Manual Contents
25
Getting Started
26
Safety Symbols
26
Contacting Watlow Anafaze
26
Initial Inspection
26
Overview
26
Product Features
27
System Components
27
Overview
27
Table 1.1-PPC-2000 System Modules
29
Table 1.2-PPC-2000 Terminal Boards and Peripheral Modules
29
Table 1.3 Analog Terminal Board Keys
29
Figure 1.2-Sample PPC-2000 System
30
PPC-2000 Modules
30
PPC-2000 Terminal Boards
32
Additional Components
33
Safety
33
External Safety Devices
34
External Switch Disconnect
35
Battery Safety
35
Product Markings and Symbols
35
Hardware Installation
37
Power Supply Requirements
37
Mounting the Power Supply
39
Hardware Installation 13
40
Figure 2.2-PPC-IPS-2 Panel Mounting Dimensions
40
Table 2.3-Power Supply Screw Mounting
40
Hardware Installation 13
40
Hardware Configuration
41
Module Addresses
41
Figure 2.3-Sample Addresses
41
PPC-2010 Jumper Settings
42
Table 2.4-System Modules and Addressing
42
Table 2.5-PPC-2010 Processor Module Jumpers
42
PPC-2030 Dip Switch Settings
43
Figure 2.4-PPC-2010 Jumpers
43
PPC-2030 Jumper Settings
44
PPC-2040 Jumper Settings
45
PPC-205X Jumper Settings
46
Figure 2.7-PPC-205X Jumpers
47
Figure 2.9-Assembled Modules Bottom View
49
Figure 2.10-Modules Bottom/Side View
49
Module Disassembly
50
Mounting Modules
50
DIN Rail Mounting
51
Figure 2.11-DIN Rail Latches
51
Figure 2.12-Mounting Assembled PPC Modules on a DIN Rail (Side)
51
Mounting Terminal Boards
52
Figure 2.13-AITB Dimensions / Clearances
53
Figure 2.14-EITB Dimensions / Clearances
54
DIN Rail Mounting
55
Figure 2.15-TB50 Dimensions / Clearances
55
DIN Rail Removal
56
Figure 2.16-TB50 Mounted on DIN Rail (Front)
56
Figure 2.17-TB50 Mounted on DIN Rail (Side)
56
Figure 2.18-TB50 Panel Mounted
57
Panel Mounting
57
System Wiring
58
Figure 2.19-SDAC Dimensions
58
Noise Suppression
59
Table 2.9-Cable Recommendations
59
Wiring Recommendations
59
Avoiding Ground Loops
61
Connecting I/O to the PPC-2010
61
Connecting the TB50 to the PPC-2010 Module
61
TB50 Connections
62
Figure 2.20-PPC-2010 Connection to TB50
62
Connecting Digital Inputs
64
Connecting Counter or Frequency Inputs
65
Connecting Digital Outputs
65
Figure 2.21-Wiring Digital Inputs
65
Figure 2.22-Encoder with 5Vdc TTL Signal
65
Figure 2.23-Powering Output with 5Vdc from PPC Supply
66
Figure 2.24-Powering Output with 12-24Vdc from PPC Supply
66
Figure 2.25-Powering Output with Separate Power Supplies
66
SDAC Connections
67
Figure 2.26-Recommended Circuitry for Cpuwatchdog
67
Figure 2.27-Wiring Single/Multiple Sdacs
68
Connecting Analog Inputs to the PPC-2021 - 2025
69
Connecting the AITB to the PPC-202X
69
Figure 2.28-PPC-2021 - 2025 Connection to AITB
69
Sensor Keys
70
Figure 2.29-Inserting Sensor Keys in AITB
70
Table 2.11-Sensor Keys
70
AITB Connections
71
Figure 2.30-An Input Key
71
Connecting Thermocouples
73
Figure 2.31-Thermocouples Connected to Differential Inputs 1 and
73
Table 2.14-Power Connections on AITB
73
Connecting Rtds
74
Connecting Sensors with Linear Voltage Signals
76
Figure 2.35-Connecting Linear Voltage Signals to Differential Inputs 1 and
76
Connecting Sensors with Linear Current Signals
77
Figure 2.36-Connecting Linear Voltage Signals to Single-Ended Inputs 1 and
77
Figure 2.38-Connecting Current Inputs to a Single-Ended Analog Input Module: Input 1 and 2 Shown
78
Connecting the Encoder Input Cable to the PPC-2030
79
Figure 2.39-PPC-2030 Connections (Bottom View)
79
Figure 2.40-PPC-EITB-1
80
Encoder Wiring
81
Encoder Connections Without the EITB
83
Analog Output Connections
84
Figure 2.45-PPC-2030 Analog out Terminal Block
84
Connecting I/O to the PPC-2040
85
Connecting the TB50 to the PPC-2040 Module
85
Figure 2.46-Analog Output Connections on a PPC-2030: Outputs 1 and 2 Shown
85
TB50 Connections
86
Figure 2.47-PPC-2040 Connection to TB50
86
Connecting Digital Inputs
88
Connecting Counter or Frequency Inputs
88
Figure 2.48-Wiring Digital Inputs
88
Connecting Digital Outputs
89
Figure 2.50-Quadrature Connections: Inputs 1 and 2 Shown
89
Figure 2.51-Powering Output with 5Vdc from PPC Supply
89
Figure 2.52-Powering Output with 12-24Vdc from PPC Supply
90
Figure 2.53-Powering Output with Separate Power Supplies
90
Figure 2.54-PPC-205X Connections (Bottom View)
91
Figure 2.55-Analog Output Connections on a PPC-2050 Configured for Current: Outputs 1 and 2 Shown
92
Figure 2.56-Analog Output Connections on a PPC-2050 Configured for Voltage: Outputs 1 and 2 Shown
93
Figure 2.57-Analog Output Connections on a PPC-2051 Configured for Current and Voltage: Outputs 1 and 2 Shown
93
Connecting to the Relay Outputs on the PPC-206X
94
Figure 2.58-PPC-206X Connections (Bottom View)
94
Figure 2.59-Relay Output Connections on a PPC-2061: Outputs 1, 2, 9 and 10 Shown
95
Wiring PPC-2062 Relay Outputs
95
Figure 2.61-Snubber Connections
97
Using Snubbers for Relay Outputs
97
Figure 2.62-PPC-207X Connections (Bottom View)
98
Figure 2.64-Input Connections to a PPC-2071 or PPC-2073: Inputs 1,2, 9 and 10 Shown
99
Figure 2.65-Connecting a Current Sinking Field Device to a PPC-2072 or PPC-2073: Input 1 Shown
99
Connecting Power
101
PPC-IPS-2 Power Supply
101
Processor Module
101
Connecting Communication Ports
102
Communication Ports
102
Figure 2.67-PPC-IPS-2 Power Connections
102
Figure 2.68-RS-232 and RS-485 RJ-Type Connectors
103
Connecting RS-485 Communications
105
Figure 2.69-Connecting One PPC to a Computer Using
105
Figure 2.70-Connecting Multiple Ppcs to a Computer Using
105
Figure 2.71-RS-485 Wiring
106
Table 2.30-485 Terminal Block Pin Assignment
107
Figure 2.72-Two Wire RS-485 Wiring
108
Figure 2.73-Connecting Several Ppcs with Short Cable Runs
108
Table 2.31-PPC-2010 Rotary Switch Configuration
110
Operating with Anawin3 89
113
Operating with Anawin3
113
Type Definitions
113
Closed-Loop Control
113
Figure 3.1-Sample Screen Text
113
Control Algorithm
114
Control Output Signal Forms
114
Feedback
114
Heat and Cool Outputs
114
Table 3.1-Control Types PID1 and PID2
115
Background
117
Prerequisites
117
Using Anawin3 to Tune
118
Operating with Anawin3 89
115
Alarms
119
Failed Sensor Alarms
119
Global Alarm
119
Process Alarms
119
Table 3.2-Alarm Types
119
Alarm Delay
120
Setting up Process and Deviation Alarms
121
Figure 3.3-Linear Input Example
122
Setting Input Signal lo and Input Signal Hi
123
Setting Engineering Units
123
Setting PV lo and PV Hi
123
Table 3.3-Range and Sensitivity of Thecustom Linear Input Types
123
Setting Decimal Places
124
Table 3.4-PV Range Permitted for Various Decimal Places Settings
124
Linear 4-20Ma Input Example
125
Table 3.5-Scaling Parameters for 0-10Vdc Linear Input Example
125
Table 3.6-Scaling Parameters for 4-20Ma Linear Input Example
125
Process Variable Retransmit
126
Setting up Process Variable Retransmit
127
Process Variable Retransmit Example
128
Cascade Control
129
Figure 3.6-How the Secondary Channel's Set Point Is Determined When the Primary Channel Has Heat and Cool Outputs
129
Cascade Control Example
130
Figure 3.7-How the Secondary Channel's Set Point Is Determined When the Primary Channel Has Only a Heat Output
130
Setting up Cascade Control
130
Ratio Control
133
Setting up Ratio Control
134
Figure 3.10-Relationship between the Master Channel's Process Variable and the Ratio Channel's Set Point
134
Figure 3.11-Sample Application Using Ratio Control
135
Differential Control
136
Remote Set Point
136
Logic Programs
136
Setting up Outputs for Use with a Logic Program
137
Using Logic to Set an Analog Input
137
Starting and Stopping Logic Programs
137
Controller Parameters
139
Channels
139
Figure 3.12-Channels Spreadsheet
139
Table 3.12-Anawin3 Control Types
142
Figure 3.13-Output Scaling (Heat/Cool) Curves
145
Figure 3.14-Alarms Spreadsheet
149
Figure 3.15-Inputs Spreadsheet
153
Figure 3.16-Analog Input Names
153
Table 3.14-Module Abbreviations Seen on the Inputs Spreadsheet
153
Figure 3.17-Pulse Input Names
154
Figure 3.18-Soft Input Names
154
Figure 3.19-Channel Output Names
155
Table 3.16-Units
157
Digital I/O
158
Figure 3.20-Dig I/O Spreadsheet
158
Figure 3.21-PPC-2010 and PPC-204X Digital I/O Names
159
Figure 3.22-PPC-206X and PPC-207X Digital I/O Names
159
Table 3.18-Function Values
160
Figure 3.23-Outputs Spreadsheet
161
Figure 3.24-Analog Output Names
161
Table 3.19-Module Abbreviations Seen on the Outputs Spreadsheet
161
Soft Integer
162
Figure 3.25-Soft Int Spreadsheet
162
Soft Boolean
163
Figure 3.26-Soft BOOL Spreadsheet
163
Figure 3.27-PPC Globals Screen
164
Table 3.20-System Status
165
Table 3.21-Global Settings
165
Troubleshooting
167
General Description
167
PPC-2010 Processor
167
Figure 4.3-PPC-2010 Internal View
170
Figure 4.4-PPC Assembled Modules Top View
171
Figure 4.5-PPC Assembled Modules Bottom View
172
Processor Module Leds
173
Troubleshooting 141
170
PPC-2040 Digital I/O
177
PPC-207X Digital in
179
Troubleshooting and Corrective Actions
180
Digital Inputs and Outputs
180
Process Variable
180
Communications
181
Resetting Closed-Loop Control Parameters
182
Disabling Control
183
Logicpro and Modbus Reference
185
Overview
185
Text Conventions in the Database Sections
185
Logicpro and Modbus Reference 159
186
The PPC-2000 Database
186
Figure 5.1-Sample Text
186
Table 5.2-Example Database Table
186
Data Table Organization
187
How Logicpro Accesses the Database
188
Logicpro and Modbus Reference 159
186
Analog and Counter Input Parameters in the Database
189
Accessing Analog and Counter Input Parameters with Modbus
189
Accessing Analog and Counter Input Parameters with Logicpro
189
Analog Input Numbers and Address Offsets
190
Table 5.4-Addresses for Encoder Inputs on the PPC-2030 Encoder in Analog out Module
191
Table 5.7-Addresses for Encoder Inputs on the PPC-2040 Digital I/O Modules
193
Analog and Encoder Input Parameters
194
Table 5.9-Input Status
195
Table 5.11-Temperature Scale Conversion
197
Channel Parameters in the Database
198
Accessing Channel Parameters with Modbus
198
Accessing Channel Parameters with Logicpro
199
Channel Parameters for Heat and Cool Outputs
199
Channel Parameters
199
Table 5.13-Process Variable and Setpoint Source Settings for Analog Inputs on the PPC-202X Modules
202
Table 5.16-Process Variable and Setpoint Source Settings for Soft Input and Channel out Registers
204
Table 5.18-Control Mode
206
Table 5.19-Control Types
207
Figure 5.2-Output Scaling Curves
213
Table 5.22-Output Destinations for Digital Outputs on the PPC-2010 Module
214
Table 5.26-Output Destinations for Analog Outputs on the PPC-205X Modules
217
Table 5.28-Alarm Status
218
State and Logic
223
Accessing Digital I/O Parameters with Modbus
223
Digital I/O Numbers and Address Offsets
224
Digital I/O Parameters
228
Table 5.38-Digital I/O Parameters
228
Table 5.40-Direction
229
Table 5.41-Logic
229
Accessing Analog Outputs with Modbus
230
Accessing Analog Outputs with Logicpro
230
Analog Outputs and Modbus Addresses
230
Soft Bool and Soft Int Registers in the Database
233
Accessing Soft Bool and Soft Int Registers with Modbus
233
Accessing Soft Bool and Soft Int Registers with Logicpro
233
Soft Bool and Soft Int Registers
233
Global Parameters in the Database
234
Accessing Global Parameters with Modbus
234
Communications Parameters
235
Table 5.48-Communications Parameters
236
Table 5.49-Database Offsets for Baud Rate
236
Table 5.50-Baud Rate
236
Global Database Parameters
237
Table 5.57-Module Types
240
Tuning and Control
247
Introduction
247
Tuning and Control 219
248
Control Algorithms
248
On/Off Control
248
Figure 6.1-On/Off Control
248
Figure 6.2-Proportional Control
249
Figure 6.3-Proportional and Integral Control
250
Figure 6.4-Proportional, Integral and Derivative Control
251
Output Control Forms
252
Figure 6.5-Example Time Proportioning and Distributed Zero Crossing Waveforms
252
Output Filter
253
Proportional Band (PB) Settings
254
Integral Settings
254
Table 6.1-Proportional Band Settings
254
Derivative Settings
255
Tuning and Control 219
254
General PID Constants by Application
256
Proportional Band Only (P)
256
PI with Derivative (PID)
256
Specifications 229
257
Specifications
257
System Specifications
257
Safety and Agency Approvals
257
Table 7.1-Safety and Agency Approvals
257
Physical Specifications
258
Power Specifications
258
PPC-2010 Processor Specifications
259
Table 7.7-Power Specifications
261
Table 7.8-Capacity and Programming
261
Table 7.12-Digital Output Specifications
263
Table 7.13-Serial Interface
263
Table 7.14-Model Numbers
265
Table 7.15-Environmental Specifications
265
Table 7.16-Physical Specifications
265
Table 7.17-Connections
265
Table 7.18-Power Specifications
265
Figure 7.6-PPC-2030 Front View
268
Figure 7.7-PPC-2030 Bottom View
269
Table 7.22-Model Number
269
Table 7.29-Safety and Agency Approvals
271
Figure 7.8-PPC-2040 Front View
272
Table 7.30-Model Number
272
Table 7.31-Environmental Specifications
272
Table 7.32-Physical Specifications
273
Table 7.33-Connections
273
Table 7.34-Power Specifications
273
Table 7.35-Counter/Frequency Specifications
273
PPC-205X Analog out Specifications
275
Figure 7.10-PPC-2050 Bottom View
276
Table 7.41-Connections
277
Table 7.42-Power Specifications PPC-2050
277
Table 7.43-Power Specifications PPC-2051
277
Table 7.44-Output Specifications
277
PPC-206X Digital Output Specifications
278
Figure 7.11-PPC-206X Front View
278
Figure 7.12-PPC-206X Bottom View
279
PPC-207X Digital in Specifications
281
Figure 7.13-PPC-2070, PPC-2071 Front Views
281
Figure 7.14-PPC-207X Bottom Views
282
Table 7.54-Connections
283
Table 7.55-Power Specifications
283
Table 7.56-Digital Input Specifications
283
Figure 7.15-PPC-AITB-1
284
Figure 7.16-PPC-AITB Dimensions with Straight SCSI Cable
285
Table 7.59-Connections
285
PPC-EITB-1 Encoder Input Terminal Block Specifications
286
Figure 7.17-PPC-EITB-1
286
Table 7.62-Environmental Specifications
287
Table 7.63-Physical Specifications
287
Table 7.64-Connections
287
Table 7.65-PPC-EITB with HD-Type Cable
287
Table 7.66-Safety and Agency Approvals
287
Figure 7.18-PPC-EITB Dimensions with HD-Type Cable
288
PPC-TB50-SCSI, 50-Pin Specifications
289
Figure 7.19-PPC-TB50-SCSI Dimensions
289
Figure 7.20-PPC-TB50-SCSI Dimensions with Straight SCSI Cable
290
Figure 7.21-PPC-TB50-SCSI Dimensions with Right-Angle SCSI Cable
291
Figure 7.22-PPC-IPS-2
292
Table 7.23-Environmental Specifications
292
Table 7.24-Physical Specifications
292
SDAC Specifications
293
Table 7.76-Connections
293
Figure 7.23-SDAC Dimensions
294
Inputs
294
Analog Outputs
295
Table 7.81-Inputs
295
Table 7.82-Power Requirements
295
Table 7.83-Analog Output Specifications
295
Appendix A: Modbus Protocol
297
Appendix A: Modbus Protocol 269
298
Query
298
Response
298
Figure A.1-Query-Response Cycle
298
Appendix A: Modbus Protocol 269
299
Message Framing
299
Table A.1-Example Message Frame
299
Address Field
300
Function Field
300
Data Field
301
Error Checking Field
301
Field Format
301
Parity Checking
302
CRC Checking
303
Table A.2-Function Codes
304
Read Examples
308
Appendix B: Declaration of Conformity
311
Glossary
313
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