CPC400 Series User’s Guide Watlow Controls 1241 Bundy Blvd. Winona, MN 55987 Repairs and Returns: 334 Westridge Drive Watsonville, CA 95076 Customer Service: Phone.....1-800-414-4299 Fax .........1-800-445-8992 Technical Support: Phone.....(507) 494-5656 Fax .........(507) 452-4507 Email ......wintechsupport@watlow.com Part No. 0600-2900-2000 Rev. 2.
Copyright © 2005, Watlow Anafaze, Incorporated 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. Anafaze is a registered trademark, and LogicPro is a trademark, of Watlow Electric Manufacturing Company. Modbus is a trademark of Schneider Automation Incorporated.
Table of Contents List of Figures v List of Tables ix 1 System Overview 1 Manual Contents 1 Getting Started 2 Product Features 2 CPC400 Parts List 4 Technical Description 6 Safety 9 2 Installation 11 Typical Installation 12 Mounting Controller Components 13 System Wiring 20 Power Connections 23 Testing the System 26 Sensor Wiring 27 Wiring Control and Digital I/O 32 Analog Outputs 39 Serial Communications 41 3 Operation and Setup 47 General Navigation Map 48 Keypad 49 Displays 50 Changing the Set Point 54
Table of Contents CPC400 Series User’s Guide Setting Up Remote Analog Set Point 76 Setting Parameters Through Serial Communications or a LogicPro Program 78 4 Tuning and Control 81 Control Algorithms 81 Manually Tuning PID Loops 85 Control Outputs 88 5 Menu and Parameter Reference 91 Operator Parameters 92 Overview of the Setup Menus 94 Global Setup Menu 96 Input Menu 104 Channel Menu 109 Control Menu 111 Output Menu 116 Alarms Menu 121 Process Variable Retransmit Menu 125 Cascade Menu 127 Ratio Menu 12
CPC400 Series User’s Guide Table of Contents Glossary 195 Index 201 Parameter Address Reference 209 Declaration of Conformity 215 Menu Structure 216 Doc.
Table of Contents iv CPC400 Series User’s Guide Watlow Anafaze Doc.
List of Figures 1 System Overview 1 Figure 1.1—CPC400 Standard Parts List 5 Figure 1.2—CPC400 Special Inputs Parts List Figure 1.3—CPC400 Rear Views 6 Figure 1.4—CPC400 Front Panel 7 Figure 1.5—TB50 8 6 2 Installation 11 Figure 2.1—CPC400 System Components 12 Figure 2.2—Clearance with Straight SCSI Cable (L) and Right-Angle SCSI Cable (R) 14 Figure 2.3—Wiring Clearances 14 Figure 2.4—Mounting Bracket 15 Figure 2.5—Mounting the TB50 16 Figure 2.6—TB50 Mounted on a DIN Rail (Front) 16 Figure 2.
List of Figures CPC400 Series User’s Guide Figure 2.30—Connecting One CPC400 to a Computer Using EIA/TIA-232 Figure 2.31—Four-Wire EIA/TIA-485 Wiring 43 Figure 2.32—Two-Wire EIA/TIA-485 Wiring 43 Figure 2.33—Recommended System Connections 44 42 3 Operation and Setup 47 Figure 3.1—General Navigation Map 48 Figure 3.2—Keypad Navigation 49 Figure 3.3—Loop Display 50 Figure 3.4—Loop Display with Alarm Code 51 Figure 3.5—Display for Failed Sensor Alarm 51 Figure 3.6—Input Scaling 59 Figure 3.
CPC400 Series User’s Guide List of Figures 7 Specifications 165 Figure 7.1—CPC400 Module Dimensions 166 Figure 7.2—CPC400 Clearances with Straight SCSI Cable 167 Figure 7.3—CPC400 Clearances with Right-Angle SCSI Cable 167 Figure 7.4—TB50 Dimensions 169 Figure 7.5—TB50 Dimensions with Straight SCSI Cable 170 Figure 7.6—TB50 Dimensions with Right-Angle SCSI Cable 171 Figure 7.7—Power Supply Dimensions (Bottom View) 177 Figure 7.8—Dual DAC Dimensions 179 Figure 7.
List of Figures viii CPC400 Series User’s Guide Watlow Anafaze Doc.
List of Tables 2 Installation 11 Table 2.1—Cable Recommendations 21 Table 2.2—Power Connections 24 Table 2.3—Digital Output States and Values Stored in the Controller 33 Table 2.4—Digital Input States and Values Stored in the Controller 36 Table 2.5—TB18 Connections 37 Table 2.6—TB50 Connections 38 Table 2.7—EIA/TIA-232 Connections 42 Table 2.8—RTS/CTS and DSR/DTR Pins in DB-9 and DB-25 Connectors 42 3 Operation and Setup 47 Table 3.1—Control Modes on the Loop Display 50 Table 3.
List of Tables CPC400 Series User’s Guide 5 Menu and Parameter Reference 91 Table 5.1—Control Mode Menu Options 93 Table 5.2—CPC400 Setup Menus 94 Table 5.3—Values for BCD Job Load 97 Table 5.4—Digital Input States Required to Load Each Job 98 Table 5.5—Power Up Loop Modes 100 Table 5.6—Digital Output Alarm Polarity 103 Table 5.7—Input Types and Ranges 104 Table 5.8—Calibration Offset Ranges 106 Table 5.9—Display Formats 107 Table 5.10—Characters for the Loop Name and Input Units Parameters 110 Table 5.
CPC400 Series User’s Guide List of Tables Table 7.15—RTD Range and Resolution 173 Table 7.16—Input Resistance for Voltage Inputs 174 Table 7.17—Digital Inputs 174 Table 7.18—Digital Outputs Control / Alarm 175 Table 7.19—CPU Watchdog Output 175 Table 7.20—5VÎ (dc) Output (Power to Operate Solid-State Relays) 175 Table 7.21—CPC400 Serial Interface 176 Table 7.22—CPC400 Power 176 Table 7.23—Power Supply Environmental Specifications 176 Table 7.24—Power Supply Agency Approvals / Compliance 176 Table 7.
List of Tables xii CPC400 Series User’s Guide Watlow Anafaze Doc.
1 System Overview Manual Contents This manual describes how to install, set up, and operate a CPC400 series controller. Each chapter covers a different aspect of your control system and may apply to different users: • • • • • • • • • Doc. 0600-2900-2000 Chapter 1: System Overview provides a component list and summary of features for the CPC400 series controllers. Chapter 2: Installation provides detailed instructions on installing the CPC400 series controller and its peripherals.
Chapter 1: System Overview CPC400 Series User’s Guide Getting Started 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. CAUTION! Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury or property damage. NOTE! Indicates pertinent information or an item that may be useful to document or label for later reference.
CPC400 Series User’s Guide Chapter 1: System Overview • • • • • • • • • • • Doc. 0600-2900-2000 TRU-TUNE+™Adaptive Control: Enable adaptive control using the unique TRU-TUNE+™ adaptive algorithm and optimize even difficult-to-control or dynamic processes. TRU-TUNE+™ monitors the process variable and adjusts the control parameters automatically to keep your process at set point and optimize for set point and load changes.
Chapter 1: System Overview CPC400 Series User’s Guide • • • • • • • • • • Keypad or Computer Operation: Set up and run the controller from the keypad or from a local or remote computer. Use WATVIEW HMI software to set up the controller, manage jobs (recipes), log data or monitor system performance. Modbus RTU Protocol, EIA/TIA-232 and 485 Communications: Connect operator interface terminals and third-party software packages using the widely supported Modbus RTU protocol.
CPC400 Series User’s Guide Chapter 1: System Overview 40 _ -1 _ _ _ _ _ _ Number of Loops 4 = 4 loops 8 = 8 loops Controller Type 1 = Standard firmware Terminal Block 0 = No terminal block accessory 1 = 18-terminal block 2 = 50-terminal block, includes 3-foot (0.9 m) 50-pin SCSI cable (TB50-SCSI) Power Supply 0 = No power supply 2 = 120/240VÅ (ac), 50/60 Hz power supply adapter (5VÎ [dc] @ 4 A, 15VÎ [dc] @ 1.2 A), CE approved SCSI Cables (for use with TB50-SCSI) 0 = No special SCSI cable (3-foot [0.
Chapter 1: System Overview CPC400 Series User’s Guide CPCSI _ _ - _ _ - _ _ Special/Process Input Type (Not required for thermocouple sensor inputs) 23 = RTD 43 = 0 to 10 mAÎ (dc) 44 = 0 to 20 mAÎ (dc) or 4 to 20 mAÎ (dc) 50 = 0 to 100 mVÎ (dc) 52 = 0 to 500 mVÎ (dc) 53 = 0 to 1 VÎ (dc) 55 = 0 to 5 VÎ (dc) 56 = 0 to 10 VÎ (dc) 57 = 0 to 12 VÎ (dc) Start Loop XX = Loop number XX End Loop XX = Loop number XX Figure 1.
CPC400 Series User’s Guide Chapter 1: System Overview The CPC400 has the following features: • • • • • • • Keypad and two-line, 16-character display. Screw terminals for the power and analog inputs and communications. Input power of 12 to 24 VÎ (dc) at 1 Amp. 50-pin SCSI cable to connect the digital inputs and outputs to the 50-terminal block (TB50). The CPC400 is available with an 18-terminal block (TB18) in place of the SCSI connector, as shown in Figure 1.3 on page 6.
Chapter 1: System Overview CPC400 Series User’s Guide TB50 The TB50 is a screw-terminal interface for control wiring. It allows you to connect relays, encoders and discrete I/O devices to the CPC400. The screw terminal blocks accept wires as large as 18 AWG (0.75 mm2). A 50-pin SCSI cable connects the TB50 to the CPC400. Figure 1.5 TB50 CPC400 Cabling Watlow Anafaze provides cables required to install the CPC400. A 50-pin SCSI cable connects the TB50 to the CPC400.
CPC400 Series User’s Guide Chapter 1: System Overview Safety Watlow Anafaze has made every effort to ensure the reliability and safety of this product. In addition, we have provided recommendations that will allow you to safely install and maintain this controller. External Safety Devices The CPC400 controller may fail full-on (100 percent output power) or full-off (0 percent output power), or may remain full-on if an undetected sensor failure occurs.
Chapter 1: System Overview CPC400 Series User’s Guide Power-Fail Protection In the occurrence of a sudden loss of power, the CPC400 controller can be programmed to reset the control outputs to off (this is the default). The controller can also be configured to restart to data stored in memory. A memory-based restart might create an unsafe process condition for some installations. Use a memory-based restart only if you are certain your system will safely restart. See Power Up Loop Mode on page 100.
2 Installation This chapter describes how to install the CPC400 series controller and its peripherals. Installation of the controller involves the following procedures: • • • • • • Determining the best location for the controller Mounting the controller and TB50 Power connection Input wiring Communications wiring (EIA/TIA-232 or EIA/TIA485) Output wiring WARNING! Risk of electric shock. Shut off power to your entire process before you begin installation of the controller.
Chapter 2: Installation CPC400 Series User’s Guide Typical Installation Figure 2.1 shows typical installations of the controller with the TB50 and the TB18 terminal blocks. The type of terminal block you use greatly impacts the layout and wiring of your installation site. See Figure 2.2 to Figure 2.10 to determine potential space requirements. We recommend that you read this entire chapter before beginning the installation procedure. This will help you to carefully plan and assess the installation.
CPC400 Series User’s Guide Chapter 2: Installation Mounting Controller Components Install the controller in a location free from excessive heat (>50º C), dust and unauthorized handling. Electromagnetic and radio frequency interference can induce noise on sensor wiring. Choose locations for the CPC400 and TB50 such that wiring can be routed clear of sources of interference such as high voltage wires, power switching devices and motors. NOTE! For indoor use only.
Chapter 2: Installation 1.0 in. (25 mm) Figure 2.2 CPC400 Series User’s Guide 7.0 in. (178 mm) 1.6 in. (41 mm) 1.0 in. (25 mm) 7.0 in. (178 mm) 0.6 in. (15 mm) Clearance with Straight SCSI Cable (L) and Right-Angle SCSI Cable (R) Maximum Panel Thickness 0.2 in. (5 mm) 1.80 ± 0.020 in. (45.7 ± 0.5 mm) Figure 2.3 3.63 ± 0.020 in. (92.2 ± 0.5 mm) Wiring Clearances We recommend you mount the controller in a panel not more than 0.2 in. (5 mm) thick. 1.
CPC400 Series User’s Guide Chapter 2: Installation Allow for an additional 0.60 to 1.60 in. (15 to 41 mm) beyond the connectors.) 2. Temporarily cover any slots in the metal housing so that dirt, metal filings, and pieces of wire do not enter the housing and lodge in the electronics. 3. Cut a hole in the panel 1.80 in. (46 mm) by 3.63 in. (92 mm) as shown below. Use caution; the dimensions given here have 0.02 in. (0.5 mm) tolerances. 4.
Chapter 2: Installation CPC400 Series User’s Guide Mounting the TB50 There are two ways to mount the TB50: Use the pre-installed DIN rail mounting brackets or use the plastic standoffs. TB50 Mounted with Standoffs TB50 Mounted to DIN Rail Figure 2.5 Mounting the TB50 DIN Rail Mounting Snap the TB50 on to the DIN rail by placing the hook side on the rail first, then pushing the snap latch side in place. See Figure 2.6. Figure 2.6 16 TB50 Mounted on a DIN Rail (Front) Watlow Anafaze Doc.
CPC400 Series User’s Guide Chapter 2: Installation To remove the TB50 from the rail, use a flathead screw driver to unsnap the bracket from the rail. See Figure 2.7. Removal Catch for Screwdriver DIN Rail Snap Latch Hook Side Figure 2.7 TB50 Mounted on DIN Rail (Side) Mounting with Standoffs 1. Remove the DIN rail mounting brackets from the TB50. 2. Choose a location with enough clearance to remove the TB50, its SCSI cable and the controller itself. 3. Mark the four mounting holes. 4.
Chapter 2: Installation CPC400 Series User’s Guide Mounting the Power Supply If you use your own power supply for the CPC400, refer to the power supply manufacturer’s instructions for mounting information. Choose a Class 2 power supply that supplies an isolated, regulated 12 to 24VÎ (dc) at 1 A. Mounting Environment Leave enough clearance around the power supply so that it can be removed. 0.3 inch (8 mm) 2 Holes for #10 (4.5 mm) Bolts or Screws 1.4 inch (36 mm) 7.5 inches (191 mm) 0.
CPC400 Series User’s Guide Chapter 2: Installation Mounting the Dual DAC or Serial DAC Module This section describes how to mount the optional Dual DAC and Serial DAC digital-to-analog converters. Mounting of the Dual DAC and Serial DAC is essentially the same, except that the dimensions differ. Jumpers The output signal range of the Dual DAC and Serial DAC modules is configured with jumpers.
Chapter 2: Installation CPC400 Series User’s Guide System Wiring Successful installation and operation of the control system can depend on placement of the components and on selection of the proper cables, sensors and peripheral components. Routing and shielding of sensor wires and proper grounding of components can insure a robust control system. This section includes wiring recommendations, instructions for proper grounding and noise suppression, and considerations for avoiding ground loops.
CPC400 Series User’s Guide Chapter 2: Installation Table 2.1 Function Mfr. P/N Cable Recommendations No. of Wires AWG mm2 Maximum Length Analog Inputs Belden 9154 Belden 8451 2 2 20 22 0.5 0.5 — RTD Inputs Belden 8772 Belden 9770 3 3 20 22 0.5 0.5 — Thermocouple Inputs T/C Ext. Wire 2 20 0.5 — Control Outputs and Digital I/O Belden 9539 Belden 9542 Ribbon Cable 9 20 50 24 24 22 to 14 0.2 0.2 0.5 to 2.5 — Analog Outputs Belden 9154 Belden 8451 2 2 20 22 0.5 0.
Chapter 2: Installation CPC400 Series User’s Guide Avoiding Noise To avoid or eliminate most RFI/EMI noise problems: • • • • • Connect the CPC400 case to earth ground. The CPC400 system includes noise suppression circuitry. This circuitry requires proper grounding. Separate the 120VÅ (ac) and higher power leads from the low-level input and output leads connected to the CPC400 series controller. Do not run the digital I/O or control output leads in bundles with ac wires.
CPC400 Series User’s Guide Chapter 2: Installation Ground Loops Ground loops occur when current passes from the process through the controller to ground. This can cause instrument errors or malfunctions. The best way to avoid ground loops is to minimize unnecessary connections to ground.
Chapter 2: Installation CPC400 Series User’s Guide Wiring the Power Supply WARNING! Use a power supply with a Class 2 rating only. UL approval requires a Class 2 power supply. Connect power to the controller before any other connections, This allows you to ensure that the controller is working before any time is taken installing inputs and outputs. Table 2.
CPC400 Series User’s Guide Chapter 2: Installation CAUTION! Without proper grounding, the CPC400 may not operate properly or may be damaged. CAUTION! To prevent damage from incorrect connections, do not turn on the ac power before testing the connections as explained in Testing the System on page 26. NOTE! Do not connect the controller’s dc common (COM) to earth ground . Doing so will defeat the noise protection circuitry, making measurements less stable.
Chapter 2: Installation CPC400 Series User’s Guide Connecting the TB50 to the CPC400 1. Connect the SCSI cable to the controller. 2. Connect the SCSI cable to the TB50. Testing the System This section explains how to test the controller after installation and prior to making field wiring connections. TB50 or TB18 Test Use this procedure to verify that the TB50 or TB18 is properly connected and supplied with power: 1. Turn on power to the CPC400.
CPC400 Series User’s Guide Chapter 2: Installation Digital Input Test Use the following procedure to test digital inputs before connecting to field devices: 1. Disconnect any system wiring from the input to be tested. 2. Go to the Digital inputs test in the I/O tests menu. This test shows whether the digital inputs are off (open) or on (closed). 3. Attach a wire to the terminal of the digital input you want to test. See Table 2.5 on page 37 for TB 18 connections or Table 2.
Chapter 2: Installation CPC400 Series User’s Guide Figure 2.14 CPC400 Connector Locations Input Wiring Recommendations Use multicolored stranded shielded cable for analog inputs. Watlow Anafaze recommends that you use 20 AWG wire (0.5 mm2). If the sensor manufacturer requires it, you can also use 24 or 22 AWG wiring (0.2 mm2). Most inputs use a shielded twisted pair; some require a three-wire input.
CPC400 Series User’s Guide Chapter 2: Installation Use 18 or 20 AWG (0.5 or 0.75 mm2) for all thermocouple inputs. Most thermocouple wire is solid, unshielded wire. When using shielded wire, ground one end only. CH IN+ CH IN- White Type J Thermocouple Red Shield (if present) Earth Ground at Process End Figure 2.15 Thermocouple Connections CAUTION! Connect the earth ground terminal on TB2 to a good earth ground, but do not connect the analog common to earth ground.
Chapter 2: Installation CPC400 Series User’s Guide Reference Voltage Terminals The +5V Ref and Ref Com terminals are provided to power external bridge circuits for special sensors. Do not connect any other type of device to these terminals. Voltage Input Connections Voltage input requires scaling resistors. Special input resistors installed at Watlow Anafaze divide analog input voltages such that the controller sees a -10 to 60 mV signal on the loop. CH IN+ CH IN- Device with Voltage Output Figure 2.
CPC400 Series User’s Guide Chapter 2: Installation Pulse Input Connections The CPC400 can accept a pulse input up to 2000 Hz from a device such as an encoder. The frequency of this input is scaled with user-configured parameters; see Setting Up a Process or Pulse Input on page 58. This scaled value is the process variable for loop 5 on a CPC404, or loop 9 on a CPC408.
Chapter 2: Installation CPC400 Series User’s Guide Wiring Control and Digital I/O This section describes how to wire and configure the control outputs for the CPC400 series controller. The CPC400 provides dual control outputs for each loop. These outputs can be enabled or disabled, and are connected through a TB50 or TB18. NOTE! Control outputs are connected to controller common when the control output is on.
CPC400 Series User’s Guide Chapter 2: Installation Table 2.3 State Digital Output States and Values Stored in the Controller Value1 Description Off 0 Open circuit On 1 Sinking current to controller common 1 Read and write these values through serial communications and LogicPro programs. All digital outputs sink current to controller common when on. The load may powered by the 5VÎ (dc) supplied by the controller at the TB50, or by an external power supply.
Chapter 2: Installation CPC400 Series User’s Guide Configuring Outputs As you choose outputs for control and alarms, bear in mind the following points: • • • • • • You can enable or disable the control outputs. By default, heat outputs are enabled and cool outputs are disabled. You can program each control output individually for on/off, time proportioning, distributed zero-crossing or Serial DAC control. You can individually program each control output for direct or reverse action.
CPC400 Series User’s Guide Chapter 2: Installation TB50 or TB18 Solid-State Relay Solid-State Relay - + - + Solid-State Relay - + Heat Output Cool Output Alarm Output +5VÅ (ac) Figure 2.22 Sample Heat, Cool and Alarm Output Connections TB50 or TB18 Heat Output Cool Output Alarm Output Common Solid-State Relay Solid-State Relay - - + + Solid-State Relay - + - PS + Figure 2.
Chapter 2: Installation CPC400 Series User’s Guide Digital Inputs All digital inputs are transistor-transistor logic (TTL) level inputs referenced to controller common and the internal +5V power supply of the CPC400. When an input is connected to the controller common, the input is considered on. Otherwise, the input is considered off. Most features that use the digital inputs can be userconfigured to activate when an input is either on or off.
CPC400 Series User’s Guide Chapter 2: Installation Functions Activated by Digital Inputs Use digital inputs to activate the following functions: • Load a job that is stored in controller memory. See BCD Job Load on page 97. Change all loops to manual mode at specified output levels. See Mode Override on page 99. Enable thermocouple short detection. See Thermocouple Short Alarm on page 101. Restore automatic control after a failed sensor has been repaired. See Restore Automatic Mode on page 114.
Chapter 2: Installation CPC400 Series User’s Guide TB50 Connections Table 2.
CPC400 Series User’s Guide Chapter 2: Installation Analog Outputs Analog outputs can be provided by using a Dual DAC or Serial DAC module to convert the open collector outputs from the controller. Use multicolored stranded shielded cable for analog outputs. Analog outputs generally use a twisted pair wiring. The following sections describe how to connect the Dual DAC and Serial DAC modules to power the controller outputs and the load. Wiring the Dual DAC A Dual DAC module includes two identical circuits.
Chapter 2: Installation CPC400 Series User’s Guide Dual DAC TB50 or TB18 +5V 1 1 +5V CTRL Supply PID Loop Output 2 DZC CTRL PID Output 3 +12/24VÎ (dc) External Power Supply 4 +VÎ (dc) Load Connection 5 -mAdc Load Connection 6 -External Power Supply/ VÎ (dc) Load Connection + Vdc Load - + - Î (dc) Power Supply 12 to 24VÎ Figure 2.28 Dual DAC with Voltage Output Wiring the Serial DAC The Serial DAC provides a robust analog output signal.
CPC400 Series User’s Guide Chapter 2: Installation Daisy chain up to Controller 16 Serial DACs Power Supply Serial DAC +5 V 1 +5V In 5 V Common 2 COM In 15 V Common 3 CLK In 4 Data In 5 + Out 6 - Out TB50 or TB18 Serial DAC Clock Control Output Load + Figure 2.29 Single/Multiple Serial DACs Serial Communications The CPC400 series controllers are factory-configured for EIA/TIA-232 communications unless otherwise specified when purchased.
Chapter 2: Installation CPC400 Series User’s Guide Table 2.
CPC400 Series User’s Guide Chapter 2: Installation EIA/TIA-485 Interface To communicate with more than one CPC400 series controller on a controller network, or to use communication cable lengths greater than 50 feet (15 m) from PC to controller, you must use EIA/TIA-485 communications. When using EIA/TIA-485 communications, you must attach a 232-to-485 converter to the computer. Figure 2.31 and Figure 2.32 show the recommended system wiring.
Chapter 2: Installation CPC400 Series User’s Guide Cable Recommendations Watlow Anafaze recommends Belden 9843 cable or its equivalent. This cable includes three 24 AWG (0.2 mm2), shielded twisted pairs. It should carry signals of up to 19200 baud with acceptable losses for up to 4000 feet (1220 m). EIA/TIA-485 Network Connections Watlow Anafaze recommends that you use a single daisy chain configuration rather than spurs.
CPC400 Series User’s Guide Chapter 2: Installation Signal Common For usual installations, do not connect the dc commons of the controllers together or to the converter or host device. Termination For EIA/TIA-485 signals to be transmitted properly, each pair must be properly terminated. The value of the termination resistor should be equal to the impedance of the communications cable used. Values are typically 150 to 200 Ω.
Chapter 2: Installation 46 CPC400 Series User’s Guide Watlow Anafaze Doc.
3 Operation and Setup This chapter explains how to use the keypad and display to operate the controller. This chapter also explains the basic concepts that you need to understand to set up and operate the controller. Doc.
Chapter 3: Operation and Setup CPC400 Series User’s Guide General Navigation Map The normal display on the CPC400 is the loop display. Figure 3.1 shows how to navigate from the loop display to other displays, menus and parameters. Loop Display 01 Hold p x 925 °C 1000auto100 Scanning Loop Display 01 925 °C 1000man100 02 1025°C 1000man100 03 1050°C 1050auto 0 Job Display (if a job is loaded) >< Hold x x Job 1 running Setup Menus lGlobal setup Other menus r b Operator Parameters .
CPC400 Series User’s Guide Chapter 3: Operation and Setup Keypad l01 Set point r b 1000˚C Key Description x Access the setup menus (press and hold for 3 seconds). Cancel a change without saving. Escape from a parameter to a top-level setup menu. Escape from a setup menu to the loop display or job display. Acknowledge an alarm. > Toggle between the loop display and job display (if a job is loaded). Edit a parameter value. Scroll through the top-level setup menus.
Chapter 3: Operation and Setup CPC400 Series User’s Guide Displays Loop Display The loop display shows detailed information about a loop. Scrolling Rectangle if Logic is Running Loop Name 01s Set Point Figure 3.3 Process Variable Engineering Units 925 ˚Cc 0 1000manh100 Cool and Heat Output Power Control Mode (see Table 3.1) Loop Display The control modes are described in Table 3.1. Table 3.
CPC400 Series User’s Guide Chapter 3: Operation and Setup NOTE! If the input type for a loop is set to “skip,” the loop display will be blank for that loop. The scanning loop display sequentially displays the information for each loop. The data for each loop displays for one second. To activate the scanning loop display, go to the loop display, then press and hold the + side of the p key for three seconds. To exit the scanning mode, press any key.
Chapter 3: Operation and Setup CPC400 Series User’s Guide Table 3.2 describes the alarm codes and messages for process alarms and failed sensor alarms. Table 3.2 Alarm Code Alarm Codes and Messages for Process and Failed Sensor Alarms Alarm Message Description AH (No message) Alarm high. See Alarm High and Alarm Low on page 66. AL (No message) Alarm low. See Alarm High and Alarm Low on page 66. HD (No message) High deviation alarm. See Deviation Alarms on page 66.
CPC400 Series User’s Guide Chapter 3: Operation and Setup Table 3.3 Message System Alarm Messages Description Low power The power supply has failed. See Low Power on page 145. Battery dead The RAM battery in the CPC400 is not functioning correctly, and stored data has been corrupted. See Battery Dead on page 145. H/W failure: Ambient The temperature around the controller is outside of the acceptable range of 0 to 50°C. See If the controller has failed, it may have been damaged by excessive voltage.
Chapter 3: Operation and Setup CPC400 Series User’s Guide Changing the Set Point How to Manually Change the Set Point Start at the loop display and follow these steps: 1. Press p to choose the appropriate loop. 2. Press .. The Set point parameter should appear. If nothing happens, the keypad may be locked; see Keypad Lock on page 101. Also, the Set point parameter is not available if cascade control or ratio control is enabled on the loop. 3. Press > or < to adjust the set point value. 4.
CPC400 Series User’s Guide Chapter 3: Operation and Setup Changing the Control Mode and Output Power The CPC400 has four control modes: • • • • Auto: The controller automatically adjusts the output power according to the set point, process variable and other control parameters. Manual: The operator sets the output power level. Tune: The controller calculates the best PID settings for optimum control. For more information, see Autotuning on page 62. This mode has no effect with on/off control.
Chapter 3: Operation and Setup CPC400 Series User’s Guide Accessing and Navigating the Setup Menus Use the setup menus to configure the controller. For a list of all setup menus and parameters, refer to Figure 5.2 on page 95. How to Access the Setup Menus To access the setup menus, press and hold x for three seconds, until the Global setup menu appears.
CPC400 Series User’s Guide Chapter 3: Operation and Setup Setting Up Closed-Loop Control Closed-loop control is used to control an output based on feedback from a sensor or other signal. Feedback The controller receives electrical signals, or feedback, from a sensor or other device. The input parameters determine how the controller interprets the signal. The controller interprets or scales the input signal in engineering units such as °C or °F.
Chapter 3: Operation and Setup CPC400 Series User’s Guide the PID parameters to determine when control switches between heating and cooling. How to Set Up Closed-Loop Control The following are the basic steps to set up closed-loop control for a typical control loop: 1. Use the Input menu to specify the type of input signal and, if necessary, how to scale that signal. 2. If using on/off or both heat and cool outputs, use the Control menu to specify the control hysteresis. 3.
Chapter 3: Operation and Setup 28 Process Variable Range for set points and alarms CPC400 Series User’s Guide 8 0% 20% 100% Input Signal Figure 3.6 Input Scaling The range for set points and alarms is bound by the process variables that correspond to the 0 percent and 100 percent input signals (or the 0 Hz and 2000 Hz signals for pulse inputs). Bear in mind that the range for set points and alarms is not bound by the low and high process variable ranges that you enter in the scaling parameters.
Chapter 3: Operation and Setup CPC400 Series User’s Guide • • Input signal high = 20 mA/20 mA = 1.0 = 100% For the Input range low and Input range high parameters, enter the process values that correspond to the low and high signals. In this case, a 20 percent (4 mA) signal represents 0.0 PSI. A 100 percent (20 mA) signal represents 50.0 PSI. Table 3.4 Input Readings Process Variable Displayed Sensor Input Reading in Percent of Full Scale 50.0 PSI 20 mA 100% .
CPC400 Series User’s Guide Chapter 3: Operation and Setup Table 3.6 Input Readings and Calculations Process Variable Displayed Sensor Input Reading in Percent of Full Scale 65 GPM 4.75 V (4.75 V / 5.00 V) x 100% = 95% 3 GPM 0.5 V (0.5 V / 5.00 V) x 100% = 10% Table 3.7 Scaling Values Parameter Value Input range high 65 GPM Input high signal 95.0% Input range low 3 GPM Input low signal 10.
Chapter 3: Operation and Setup CPC400 Series User’s Guide 2000 pulses 60 seconds 1 inch 1 foot --------------------------------x ------------------------------- x ----------------------------- x -------------------------- = 11.111 FPM 1 second 1 minute 900 pulses 12 inches Table 3.8 Scaling Values Parameter Value Input range high 11.111 FPM Input high signal 2000 Hz Input range low 0.
CPC400 Series User’s Guide Chapter 3: Operation and Setup • • Heat power limit (if the heat output is used and 100% power is not safe) Cool power limit (if the cool output is used and 100% power is not safe) How to Autotune a Loop 1. Go to the loop display (see Loop Display on page 50) and press p to choose the loop to tune. 2. Enter the desired set point or one that is in the middle of the expected range of set points that you want to tune for. (See page 54.) 3. Set the control mode to tune.
Chapter 3: Operation and Setup CPC400 Series User’s Guide What Happens if a Failed Sensor Alarm Occurs? If a failed sensor alarm occurs: • • • The controller switches to manual mode at the output power indicated by the Sensor fail heat output and Sensor fail cool output parameters in the Output menu. (The output power may be different for a thermocouple open alarm; see Thermocouple Open Alarm below.) The controller displays an alarm code and alarm message on the display. See Alarm Displays on page 51.
CPC400 Series User’s Guide Chapter 3: Operation and Setup RTD Open or RTD Shorted Alarm The RTD open alarm occurs if the controller detects that the positive or negative RTD lead is broken or disconnected. The RTD shorted alarm occurs if the controller detects that the positive and negative RTD leads are shorted. You do not have to set any parameters for the RTD alarms. Restore Automatic Control After a Sensor Failure This feature returns a loop to automatic control after a failed sensor is repaired.
Chapter 3: Operation and Setup CPC400 Series User’s Guide Alarm Function: Standard Alarm or Boost Output You can configure each process alarm as either a standard alarm or a boost alarm: • • A standard alarm provides traditional alarm functionality: The operator must acknowledge the alarm message on the controller display, a latching global alarm is activated, and the alarm can activate a user-specified non-latching alarm output. A boost alarm provides on/off control output using the alarm set points.
CPC400 Series User’s Guide Chapter 3: Operation and Setup Upon power up or when the set point changes, the behavior of the deviation alarms depends upon the alarm function: • • If the alarm function parameter is set to standard, then deviation alarms do not activate until the after the process variable has first come within the deviation alarm band. This prevents nuisance alarms.
Chapter 3: Operation and Setup CPC400 Series User’s Guide Any available heat or cool output may be used as a retransmit output. Any process variable may be retransmitted, including the input from the same loop. To get a 4 to 20 mA or 0 to 5VÎ (dc) signal, the controller output signal must be connected to a Serial DAC. How to Set Up Process Variable Retransmit 1. Configure all of the setup parameters for the primary loop (the loop whose input signal will be retransmitted). 2.
CPC400 Series User’s Guide Chapter 3: Operation and Setup Table 3.9 shows the parameter setup for this example. Table 3.9 Menu PV retrans PV retrans Parameter Ht output retrans Ht retrans LowPV Parameters Settings for Process Variable Retransmit Example Value Comment PV 1 Choose to retransmit the loop 1 process variable. 0˚F This is the input value represented by a 0 percent output signal.
Chapter 3: Operation and Setup CPC400 Series User’s Guide • If the primary loop has both heat and cool outputs, then the set point of the secondary loop is equal to the Cascade low SP parameter when the cool output is at 100 percent, and is equal to the Cascade high SP when the heat output is at 100 percent. See Figure 3.9.
CPC400 Series User’s Guide Chapter 3: Operation and Setup Proportional-Only Control on the Primary Loop The PID parameters of the primary loop must be tuned to produce the desired effect on the set point of the secondary loop. The primary loop typically uses proportional-only control. Disabling the integral and derivative components of PID makes the secondary set point a predictable function of the primary loop’s process variable.
Chapter 3: Operation and Setup CPC400 Series User’s Guide Loop 1: Primary Cascade Loop Loop 2: Secondary Cascade Loop Water Loop 1 Input Process Variable Outer Thermocouple Loop 2 PID Output Loop 2 Input Process Variable CPC400 Heater Inner Thermocouple Power Controller Figure 3.11 Example Application Using Cascade Control Table 3.
CPC400 Series User’s Guide Chapter 3: Operation and Setup As the temperature in the middle of the tank (loop 1) drops, the output goes up proportionally and the set point of loop 2 goes up proportionally. Thus heat is added to the system at the element even though the temperature near the element may have been at the desired temperature. With proportional control, when loop 1 is at set point, its output is 0 percent, and the set point of loop 2 is equal to the desired temperature 150°F.
Chapter 3: Operation and Setup CPC400 Series User’s Guide . High SP l Ratio Loop Set Point tia P S o+ ren iffe D ti l tro Ra on V rP *C te as Low SP M SP Differential Input Range Low Input Range High Master Loop Process Variable SP = Set Point PV = Process Variable Figure 3.13 Relationship Between the Process Variable on the Master Loop and the Set Point of the Ratio Loop NOTE! Ratio control cannot be used on the same control loop as cascade control. How to Set Up Ratio Control 1.
CPC400 Series User’s Guide Chapter 3: Operation and Setup KOH Input Water Input Loop 1: Water Flow Control Loop Loop 2: KOH Flow Control Loop Loop 1 Input Process Variable Flow Transducer Loop 1 PID Output CPC400 Loop 2 Input Process Variable Loop 2 PID Output Motorized Control Valve 2 Motorized Control Valve 1 Serial DAC Serial DAC Mixture Output Figure 3.14 Application Using Ratio Control Table 3.
Chapter 3: Operation and Setup CPC400 Series User’s Guide Differential Control Example: Thermoforming A thermal forming application requires that the outer heaters operate at temperature 50ºF hotter than the center heaters. The center heaters use infrared (IR) sensors for temperature feedback. The outer heaters use thermocouples for feedback. We can use differential control to control the outer heaters at a 50ºF differential to the central heaters.
CPC400 Series User’s Guide Chapter 3: Operation and Setup How to Set Up a Remote Analog Set Point 1. For the master loop (the loop that accepts the input signal from the external device), set the parameters in the Input menu. 2. For the ratio loop (the one whose set point is controlled by the external device), set the parameters in the Ratio menu. Specify the loop that accepts the input signal as the master loop.
Chapter 3: Operation and Setup Menu CPC400 Series User’s Guide Table 3.15 Parameter Settings for the Ratio Loop (Loop 2) in the Example Value Comment Parameter Loop 1 is the master loop (receives the input signal from the external device). Ratio Ratio master loop 01 Ratio Ratio low SP 0˚F Ratio Ratio high SP 300˚F Ratio Control ratio 1.0 For this example, we want to retain the original input value, so we will multiply it times 1.0.
CPC400 Series User’s Guide Chapter 3: Operation and Setup For example, the bit that indicates whether or not the high deviation alarm has been acknowledged is the forth bit in the alarm acknowledge word for each channel. To determine if the high deviation alarm has been acknowledged for a channel, extract the fourth bit from that channel’s alarm acknowledge parameter by ANDing it with a word that is all zeros except the fourth bit (0000 0000 0000 1000, or 8 in decimal).
Chapter 3: Operation and Setup CPC400 Series User’s Guide Decimal Placement for Numeric Values Numeric values that are in the loop’s engineering units are stored as integers. The number of decimal places that are assumed when a parameter value is stored in the controller depends upon the Input type and Disp format parameter values for the loop. See Table 3.16. Table 3.
4 Tuning and Control This chapter describes the different methods of control available with the CPC400. This chapter covers control algorithms, control methods, PID control, starting PID values and tuning instructions to help appropriately set control parameters in the CPC400 system. For more information about PID control, consult the Watlow Anafaze Practical Guide to PID. Control Algorithms This section explains the algorithms available for controlling a loop.
Chapter 4: Tuning and Control CPC400 Series User’s Guide On/Off Control On/off control is the simplest way to control a process. The controller turns an output on or off when the process variable reaches limits around the desired set point. This limit is adjustable. For example, if the set point is 1000°F and the control hysteresis is 20°F, the heat output switches on when the process variable drops below 980°F and off when the process rises above 1000°F.
CPC400 Series User’s Guide Chapter 4: Tuning and Control Set Point Offset Proportional Band Process Variable Figure 4.2 Proportional Control Proportional and Integral Control (PI) With proportional and integral control, the integral term corrects for offset by repeating the proportional band’s error correction until there is no error.
Chapter 4: Tuning and Control CPC400 Series User’s Guide Proportional, Integral and Derivative Control (PID) Derivative control corrects for overshoot by anticipating the behavior of the process variable and adjusting the output appropriately. For example, if the process variable is rapidly approaching the set point from below, derivative control reduces the output, anticipating that the process variable will reach set point.
CPC400 Series User’s Guide Chapter 4: Tuning and Control Manually Tuning PID Loops We recommend using the CPC400's advanced autotuning and TRU-TUNE+™ adaptive control capabilities to set up and maintain the PID control parameter settings. See Autotuning on page 62. It is, of course, possible to tune the controller manually. The information in this section is intended as a guide to that end. When tuning a loop, choose PID parameters that will best control the process.
Chapter 4: Tuning and Control CPC400 Series User’s Guide Table 4.2 Integral Term and Reset Settings Integral (Seconds/Repeat) Reset (Repeats/Minute) Integral (Seconds/Repeat) Reset (Repeats/Minute) 30 45 60 90 120 150 180 2.0 1.3 1.0 0.66 0.50 0.40 0.33 210 240 270 300 400 500 600 0.28 0.25 0.22 0.20 0.15 0.12 0.10 As a general rule, use 60, 120, 180 or 240 as a starting value for the integral. Derivative Settings The controller’s derivative parameter is programmed in seconds.
CPC400 Series User’s Guide Chapter 4: Tuning and Control General PID Constants by Application This section gives PID values for many applications. They are useful as control values or as starting points for PID tuning. Proportional Band Only (P) Set the proportional band to seven percent of the set point. (Example: Set point = 450, proportional band = 31). Proportional with Integral (PI) • Set the proportional band to ten percent of set point. (Example: Set point = 450, proportional band = 45).
Chapter 4: Tuning and Control CPC400 Series User’s Guide Control Outputs The controller provides open collector outputs for control. These outputs normally control the process using solidstate relays. Open collector outputs can be configured to drive a serial digital-to-analog converter (Serial DAC) which, in turn, can provide 0 to 5VÎ (dc), 0 to 10VÎ (dc) or 4 to 20 mA control signals to operate field output devices.
CPC400 Series User’s Guide Chapter 4: Tuning and Control Distributed Zero Crossing (DZC) With DZC outputs, the PID algorithm calculates an output between 0 and 100 percent, but the output is distributed on a variable time base. For each ac line cycle, the controller decides whether the power should be on or off. There is no fixed cycle time since the decision is made for each line cycle.
Chapter 4: Tuning and Control CPC400 Series User’s Guide Also, use the filter to reduce the process output swings and output noise when a large derivative is necessary, or to make badly tuned PID loops and poorly designed processes behave properly. Reverse and Direct Action With reverse action an increase in the process variable causes a decrease in the output. Conversely, with direct action an increase in the process variable causes an increase in the output.
5 Menu and Parameter Reference The CPC400 has operator and setup parameters that let you change the configuration of the controller. This section contains the following information for each operator and setup parameter: • • • • Description Values Default value Information for addressing controller parameters using serial communications and LogicPro programs. For information about how to access the operator and setup parameters, see the Operation and Setup chapter. Doc.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Operator Parameters Use the operator parameters to change the set point, control mode or output power level. . Access the operator parameters (from the loop display). Save a value and go to the next parameter. >< Edit parameter values. , p x Save a value and go to the previous parameter. Save a value and go to the next or previous loop. Cancel a change without saving. Escape to the loop display. Figure 5.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference Table 5.1 Display Value Control Mode Menu Options Modbus or LogicPro Value Description manual 0 The operator manually sets the output power for the loop. auto 1 The controller automatically controls the outputs. 2 The controller applies a step change and calculates initial PID parameters for the loop. After the initial tuning, the control mode changes to adapt to fine tune the loop. This mode has no effect with on/off control.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Overview of the Setup Menus The CPC400 has eleven setup menus. Table 5.2 provides a brief description of each menu. Figure 5.2 lists all of the menus and parameters in the same order that they appear in the controller. Table 5.2 Menu CPC400 Setup Menus Page Number Description Global setup Configure global settings, which affect all loops. 96 Input Configure the input for each loop.
CPC400 Series User’s Guide Global setup Load setup from job Save setup as job BCD job load BCD job load logic Mode override Mode override D/I active Logic program Power up alarm delay Power up loop mode Power up with logic Keypad lock TC short alarm Controller address Comm baud rate Comm parity AC line freq D/O alarm polarity CPC4xx Vx.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Global Setup Menu lGlobal setup r Other menus b Use the Global setup menu to set parameters that affect all loops. Load Setup From Job lLoad setup r from job bnone Load one of the jobs stored in battery-backed RAM. The following parameters are loaded for each loop as part of a job: • • • • PID constants, filter settings, set points and hysteresis.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference • • Alarm functions, set points, hysteresis and delay settings. Soft integers 81 to 100 and soft Booleans 237 to 256. If you have enabled remote job selection (see BCD Job Load on page 97), you will see the message below, and you will not be able to use the controller keypad to save a job. lSave setup as r not available Values: 1 to 8 (1 to 8) or none (0). Values in parentheses are for serial communications and LogicPro.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide BCD Job Load Logic lBCD job load r logic b1=true Choose which state is considered “true” for the digital inputs that are used for remote job selection. • • If 1=true is selected, then an input is true if connected to controller common, and false for an open circuit. If 0=true is selected, then an input is true for an open circuit, and false if connected to controller common. Table 5.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference Mode Override lMode override r bdisabled Choose the digital input to use for the mode override feature. When the input is activated, the controller sets all loops to manual mode at the output levels specified at the Sensor fail heat output and Sensor fail cool output parameters in the Output menu. Use the Mode override D/I active parameter to choose which signal state activates the mode override feature.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Power Up Alarm Delay Specify how long to delay high, low and deviation alarms on all loops during powerup. This feature does not delay failed sensor alarms. lPower up alarmr delay b 0 min Values: 0 to 60 minutes Default: 0 Modbus Address: 40409 Parameter Number: 24 LogicPro Driver: Database LogicPro Address: 24.1 Power Up Loop Mode Choose the power-up state of the control outputs. lPower up loop r modebmanual 0% Values: See Table 5.5.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference Keypad Lock lKeypad lock r boff Set this parameter to on to disable the . key on the keypad. This restricts access to the operator parameters from the controller keypad. Values: on (1) or off (0). Values in parentheses are for serial communications and LogicPro, and are stored as the second bit of the system command word, so set or read only that bit.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Communications Baud Rate lComm baud rater b 19200 Choose the baud rate for serial communications. Choose the same baud rate for both the controller and the HMI software or operator interface panel. Values: 2400 (1), 9600 (0) or 19200 (2). Values in parentheses are for serial communications and LogicPro. Default: 19200 (2) Modbus Address: 44844 Parameter Number: 119 LogicPro Driver: Database LogicPro Address: 119.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference Digital Output Alarm Polarity Choose the polarity of all digital outputs used for alarms. lD/O alarm polarity r bon This setting does not apply to the global alarm output or the CPU watchdog output. Values: See Table 5.6. For serial communications and LogicPro, this parameter is stored as the fifth bit of the system command word, so set or read only that bit.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Input Menu Use the Input menu to configure the process input: l01 Input Other menus r b • • • Input type Engineering units Scaling, calibration and filtering. Input Type Choose the type of sensor that is connected to the analog input. l01 Input type r bJ T/C Values: See Table 5.7. For the pulse loop (CPC404 loop 5 or CPC408 loop 9), the only choices are pulse (7) and skip (10).
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference Input Units l01 Input unitsr b ˚F For a thermocouple or RTD input, choose the temperature scale. For a process or pulse input, enter a three-character description of the engineering units. Values: For a process or pulse input, see Table 5.10. For a thermocouple or RTD input, ˚F or ˚C.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Table 5.8 Calibration Offset Ranges Offset Range Type of Sensor ˚F RTD ˚C -300.0 to 300.0 -300.0 to 300.0 J Thermocouple K Thermocouple T Thermocouple -300 to 300 -300 to 300 B Thermocouple S Thermocouple -300 to 76 -300 to 300 R Thermocouple -300 to 66 -300 to 300 Reversed Thermocouple Detection l01 Reversed r T/C detect b on Choose whether to enable polarity checking for thermocouples.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference Table 5.9 Display Value -999 to 3000 Display Formats Modbus or LogicPro Value Minimum Process Variable Maximum Process Variable 255 -999 3000 -9999 to 30000 0 -9999 30000 -999.9 to 3000.0 1 -999.9 3000.0 -99.99 to 300.00 2 -99.99 300.00 -9.999 to 30.000 3 -9.999 30.000 -.9999 to 3.0000 4 -0.9999 3.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Modbus Address (Loops 1 to 9): 40615 to 40623 Parameter Number: 38 LogicPro Driver: Database LogicPro Address (Loops 1 to 9): 38.1 to 38.9 Decimal Placement for Modbus or LogicPro: See Decimal Placement for Percentage Values on page 80. Input Range Low l01 Input ranger low b 0 For a process or pulse input, enter the low process variable for input scaling purposes.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference Input Filter l01 Input r filter b 3scans Choose the amount of filtering to apply to the process variable before the value is logged, displayed or used in the control calculation. The input filter simulates a resistorcapacitor (RC) filter. Use it to keep the process variable from varying unrealistically.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Table 5.10 Characters for the Loop Name and Input Units Parameters Character Display Values ASCII Values A to Z A to Z 65 to 90 0 to 9 0 to 9 48 to 57 Degree symbol ˚ 223 Percent sign % 37 Forward slash / 47 Space . 32 Pound sign # 35 PV Source l01 PV source u input r Select whether an analog input or a soft integer is used for the channel's feedback.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference Control Menu l01 Control Other menus r b Use the Control menu to adjust heat and cool control parameters, including: • • • Proportional band, integral and derivative Output filter Control hysteresis The controller has separate PID and filter settings for heat and cool outputs. In this section, only the heat screens are shown, but the explanations apply to both the heat and cool parameters.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Heat/Cool Integral l01 Heat inte- r gral b 180 sec/R Enter the integral constant. A larger value yields less integral action. Values: 0 (off) to 6000 seconds per repeat Default: For the Heat integral parameter, 180 (or 0 for a pulse input). For the Cool integral parameter, 60 (or 0 for a pulse input).
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference Heat/Cool Filter Use this parameter to dampen the response of the heat or cool output. The output responds to a change by going to approximately two-thirds of its final value within the specified number of scans. A larger value results in a slower response to changes in the process variable.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Restore Automatic Mode l01 RestoreAutor bdisabled Choose a digital input. If the input is connected to controller common, the loop returns to automatic control mode after a failed sensor is repaired (if it was in automatic mode and the digital input was on when the sensor failure occurred). Values: enabled by D/I1 to enabled by D/I8 (1 to 8) or disabled (0). Values in parentheses are for serial communications and LogicPro.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference Figure 5.3 The Effect of Tune Gain on Recovery from a Load Change Overshoot Reduction l01 Overshoot r reduction b 50% Enter the amount of overshoot reduction. A larger value yields less overshoot. Values: 0% (0) to 100% (100) Default: 50% (50) Modbus Address (Loops 1 to 9): 46576 to 46584 Parameter Number: 146 LogicPro Driver: Database LogicPro Address (Loops 1 to 9): 146.1 to 146.9 Control Type Choose a control algorithm.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Output Menu l01 Output Other menus r b Use the Output menu to enable and configure heat and cool outputs. Heat/Cool Output Type l01 Heat outputr type bTP Choose the output type, or disable the heat or cool output. For more information about each output type, see the Tuning and Control chapter. (If an output is used for process variable retransmit, the disabled option is not available.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference Heat/Cool Cycle Time l01 Heat cycle r time b 10sec For a time-proportioning output, enter the cycle time in seconds. For more information about cycle time, see Time Proportioning (TP) on page 88.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Heat/Cool SDAC High Signal l01 Ht SDAC hi r signal b10.00vdc For a Serial DAC output, enter the high output signal level for the Serial DAC. The Serial DAC converts 100 percent output from the controller to the value set here. Enter the high and low values that match the input range of the output device. For instance, if the output device has a 4 to 20 mA input range, then set SDAC hi signal to 20 mA and set SDAC low signal to 4 mA.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference 44188 to 44196 (cool) Parameter Number: 70 (heat) or 71 (cool) LogicPro Driver: Database LogicPro Address (Loops 1 to 9): 70.1 to 70.9 (heat) or 71.1 to 71.9 (cool) Decimal Placement for Modbus or LogicPro: See Decimal Placement for Percentage Values on page 80.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide WARNING! Do not rely solely on the failed sensor alarm to adjust the output in the event of a sensor failure. If the loop is in manual mode when a failed sensor alarm occurs, the output is not adjusted. Install independent external safety devices to shut down the system if a failure occurs.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference 100 90 80 80 79 Actual Output 70 62 60 60 Linear 40 40 50 48 Curve 1 36 30 20 20 10 3 19 8 2 4 44 Curve 2 29 27 13 66 19 12 7 0 PID Calculation Figure 5.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Alarm High Function l01 Alarm high r func boff Choose whether the high alarm functions as an alarm or as a boost output, or disable the alarm. Values: See Table 5.16. Default: off Modbus and LogicPro: See Alarm Acknowledge on page 132 and Alarm Function on page 133. Table 5.16 Alarm Functions Value off Description No alarm function. Alarm is indicated and logged. Latching global alarm is activated.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference High Deviation Function l01 HiDeviationr func boff Choose whether the alarm functions as an alarm or as a boost output, or disable the alarm. Values: See Table 5.16 on page 122. Default: off Modbus and LogicPro: See Alarm Acknowledge on page 132 and Alarm Function on page 133. High Deviation Output l01 HiDeviationr outputbnone Choose a digital output to activate when the high deviation alarm occurs.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Default: none (0) Modbus Address (Loops 1 to 9): 40477 to 40485 Parameter Number: 28 LogicPro Driver: Database LogicPro Address (Loops 1 to 9): 28.1 to 28.9 Alarm Low Set Point l01 Alarm low r SP b 0 ˚F Enter the set point at which the low alarm activates. The low alarm activates if the process variable drops below this value. For more information, see Process Alarms on page 65.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference vent repeated alarms as the process variable cycles around an alarm limit. Values: See Table 5.17 for values and decimal placement. Default: See Table 5.17. Modbus Address (Loops 1 to 9): 40375 to 40383 Parameter Number: 22 LogicPro Driver: Database LogicPro Address (Loops 1 to 9): 22.1 to 22.9 Table 5.17 Input Type Values for Alarm Hysteresis Display Format Values Default Thermocouple n/a 0 to 500 2 RTD n/a 0 to 500.0 2.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Heat/Cool Output Retransmit l01 Heat outputr retrans PV b 2 Choose the loop that provides the process variable to be retransmitted. For example, in the sample display at left, the heat output from loop 1 (01) will retransmit the process variable from loop 2. Values: none (0), or loop 1 to 5 (1 to 5) for a CPC404 or 1 to 9 (1 to 9) for a CPC408. Values in parentheses are for serial communications and LogicPro.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference Cascade Menu l01 Cascade Other menus r b Use the cascade menu to configure cascade control. Use cascade control to calculate the set point of the current loop (the secondary, or outer, loop) based upon the output of another loop (the primary, or inner, loop). For more information about cascade control, see Setting Up Cascade Control on page 69. Cascade Primary Loop l01 Cascade r prim loop bnone Choose the primary loop.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Cascade High Set Point l01 Cascade hi r SP b 25 ˚F Enter the set point to use for the current loop when the output of primary loop is at its maximum value. The set point will never exceed this value. • • If the primary loop has only the heat output enabled, or has the heat and cool outputs enabled, this value is the set point when the output of the primary loop is 100 percent.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference Ratio Low Set Point l01 Ratio low r SP b 25 ˚F Enter the lowest allowable set point for the current loop. The set point will never drop below this value, regardless of the result of the ratio calculation. Values: For a thermocouple or RTD input, any value within the input range (see Table 5.7 on page 104). For a process or pulse input, any value between the Input range low and Input range high parameters.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Ratio Set Point Differential l01 Ratio SP r diff b 0 ˚F Enter the value to add to the ratio calculation before using it as the set point. Values: -9999 to 9999. Decimal placement depends upon the Input type and Disp format values in the Input menu. Default: 0 Modbus Address (Loops 1 to 9): 44818 to 44826 Parameter Number: 109 LogicPro Driver: Database LogicPro Address (Loops 1 to 9): 109.1 to 109.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference Soft Booleans Menu lSoft Booleans r Other menus b The Soft Booleans menu contains 256 one-bit Boolean registers. Use these parameters to read and set Boolean (true or false) data. Read and write access are available through a logic program, WatView, the controller display or a third-party host. Soft Boolean Value Read or set a true or false value.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Keypad Test To test the keypad, press <. This screen will appear: lKeypad test r press d to begin uu Ends test key pressed= To test a key, press it. If the key is working properly, an icon for that key appears. When you are done testing the keypad, press >> to return to the Keypad test parameter. Test Digital Output 1 to 35 lTest D/O 1 r boff NOTE! Use the Test D/O parameter to manually toggle a digital output on and off.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference Values: Unacknowledged (1) or acknowledged (0) Modbus Address (Loops 1 to 9): 40511 to 40519 Parameter Number: 30 LogicPro Driver: Database LogicPro Address (Loops 1 to 9): 30.1 to 30.9 Alarm Enable Enable or disable an alarm. Table 5.18 shows the bit to set or read for each alarm. This parameter is available only for serial communications and LogicPro programs.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Alarm Status Indicates whether an alarm is active. Table 5.19 shows the bit to set or read for each alarm. This parameter is available only for serial communications and LogicPro programs. See Bit-Wise Values on page 78 for information on reading or setting this parameter. Values: Not active (0) or active (1) Modbus Address (Loops 1 to 9): 40392 to 40400 Parameter Number: 23 LogicPro Driver: Database LogicPro Address (Loops 1 to 9): 23.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference Values: For thermocouples and RTD inputs, same as the input range (see Table 5.7 on page 104). For process, soft integer, and pulse inputs, any value between the Input Range Low and Input Range High parameters in the Input menu. Modbus Address (Loops 1 to 9): 45375 to 45383 Parameter Number: 135 LogicPro Driver: Database LogicPro Address (Loops 1 to 9): 135.1 to 135.
Chapter 5: Menu and Parameter Reference CPC400 Series User’s Guide Major Part Indicates the firmware version number to the left of the decimal point, such as “1” for version 1.07A. Modbus Address: 40844 Parameter Number: 52 LogicPro Driver: Database LogicPro Address: 52.2 Minor Part Indicates the firmware version number in the hundredths place to the right of the decimal point, such as “7” for version 1.07A. Modbus Address: 40845 Parameter Number: 52 LogicPro Driver: Database LogicPro Address: 52.
CPC400 Series User’s Guide Chapter 5: Menu and Parameter Reference Values: See Table 5.20. Modbus Address: 40786 (first to eighth bit), 40787 (ninth to sixteenth bit) Parameter Number: 48 LogicPro Driver: Database LogicPro Address: 48.1 (first to eighth bit), 48.2 (ninth to sixteenth bit) Table 5.20 Parameter System Status Bits Description Values Bit Battery Status Indicates whether the values in RAM have been corrupted while the power has been off.
Chapter 5: Menu and Parameter Reference 138 CPC400 Series User’s Guide Watlow Anafaze Doc.
6 Troubleshooting and Reconfiguring This chapter explains how to troubleshoot and reconfigure the controller. When There is a Problem The controller is only one part of your control system. Often, what appears to be a problem with the controller is really a problem with other equipment, so check these things first: • • NOTE! The controller is installed correctly. (See the Installation chapter.) Sensors, such as thermocouples and RTDs, are installed correctly and working.
Chapter 6: Troubleshooting and Reconfiguring CAUTION! CPC400 Series User’s Guide Before trying to troubleshoot a problem by replacing your controller with another one, first check the installation. If you have shorted sensor inputs to high voltage lines or a transformer is shorted out, and you replace the controller, you will risk damage to the new controller. If you are certain the installation is correct, you can try replacing the controller.
CPC400 Series User’s Guide Chapter 6: Troubleshooting and Reconfiguring Process Alarms When a process alarm occurs, the controller switches to the single-loop display for the loop with the alarm and displays the alarm code (see Alarm Displays on page 51). WatView software displays a message on the alarm screen and logs the alarm in the event log.
Chapter 6: Troubleshooting and Reconfiguring CPC400 Series User’s Guide Responding to a Process Alarm Your response to an alarm depends upon the alarm function setting, as explained in Table 6.1. Table 6.1 Operator Response to Process Alarms Alarm Function Operator Response Boost The operator does not need to acknowledge the alarm. The alarm clears automatically when the process variable returns within limits. Standard Acknowledge the alarm by pressing x on the keypad or by using HMI software.
CPC400 Series User’s Guide Chapter 6: Troubleshooting and Reconfiguring System Alarms If the controller detects a hardware problem, it displays an alarm message. The message persists until the condition is corrected. The CPC400 displays the following system alarm messages: • • • • • Low power: See Low Power on page 145. Battery dead: See Battery Dead on page 145. H/W failure: Ambient: See H/W Failure: Ambient on page 146. H/W failure: Gain: See H/W Failure: Gain or Offset on page 146.
Chapter 6: Troubleshooting and Reconfiguring Symptom CPC400 Series User’s Guide Possible Causes Check the display or HMI software for a failed sensor message. Failed sensor Control mode of one or more loops changes from automatic to manual Recommended Action Check whether the new job was supposed to be loaded. If not, check the BCD job load setup: BCD job selection feature loaded a different job Check the settings of the BCD job load parameters in the Global setup menu.
CPC400 Series User’s Guide Chapter 6: Troubleshooting and Reconfiguring Corrective and Diagnostic Procedures The following sections detail procedures you may use to diagnose and correct problems with the controller. Low Power If the controller displays Low power or the display is not lit: 1. Turn the power to the controller off, then on again. 2. If the Low power alarm message returns, check that the power supplied to the controller is at least 12.0VÎ (dc) at 1 A.
Chapter 6: Troubleshooting and Reconfiguring CPC400 Series User’s Guide Ambient Warning The ambient warning alarm indicates that the ambient temperature of the controller is too hot or cold. Ambient warning occurs when the controller's temperature is in the range of 23 to 32°F or 122 to 131°F. The operating limits are 32 to 122°F. If the controller displays AW in the lower left corner of the display: 1. Acknowledge the alarm. 2.
CPC400 Series User’s Guide Chapter 6: Troubleshooting and Reconfiguring to 50°C. This alarm can also occur if there is a hardware failure. If the controller displays H/W failure: Ambient: NOTE! 1. Acknowledge the alarm. 2. If the error message remains, check the ambient air temperature near the controller. Adjust ventilation, cooling or heating so that the temperature around the controller is 0 to 50°C.
Chapter 6: Troubleshooting and Reconfiguring CPC400 Series User’s Guide Checking Analog Inputs Follow these steps to troubleshoot problems with the analog inputs to the CPC400 controller: WARNING! Shorts between heaters and sensors or wiring errors can cause potentially lethal voltages to be present in the CPC400 and associated wiring and devices. Only qualified personnel taking appropriate precautions should attempt to troubleshoot or service equipment. 1.
CPC400 Series User’s Guide Chapter 6: Troubleshooting and Reconfiguring 5. Verify the sensors: • • 6. For thermocouples, remove the thermocouple leads and use a digital voltmeter to measure the resistance between the positive and negative thermocouple leads. A value of 2 to 20 Ω is normal. Readings in excess of 200 Ω indicate a problem with the sensor. For RTDs, measure between the IN+ and IN- terminals of TB1. RTD inputs should read between 20 and 250 Ω.
Chapter 6: Troubleshooting and Reconfiguring CPC400 Series User’s Guide • For an RTD or process input, check that the correct input scaling resistors are installed (see Installing Scaling Resistors on page 157) and check the input scaling parameter settings (see Setting Up a Process or Pulse Input on page 58). If readings are erratic, look for sources of electrical noise. See Noise Suppression on page 21. Contact your supplier for further troubleshooting guidance.
CPC400 Series User’s Guide Chapter 6: Troubleshooting and Reconfiguring b) Connect the voltmeter’s positive lead to the TB18 or TB50 terminal 1. Testing Control and Digital Outputs 1. Switch off power to the controller. 2. Disconnect any output wiring on the output to be tested. 3. Connect a 500 Ω to 100 kΩ resistor between the +5V terminal (TB18 or TB50 terminal 1) and the output terminal you want to test. 4.
Chapter 6: Troubleshooting and Reconfiguring CPC400 Series User’s Guide Additional Troubleshooting for Computer Supervised Systems These four elements must work properly in a computer-supervised system: • • • • The controller The computer and its EIA/TIA-232 or EIA/TIA-485 serial interface The EIA/TIA-232 or EIA/TIA-485 communication lines The computer software For troubleshooting, disconnect the communications line from the computer and follow the troubleshooting steps in the first section of this chap
CPC400 Series User’s Guide Chapter 6: Troubleshooting and Reconfiguring • • • • • • Controller Address: Configure software to look for the controller at the correct address. In a multiple-controller installation, each controller must have a unique address. Baud Rate: Software and controller must be set the same. Parity: In the Modbus RTU protocol, the parity may be set to none, even or odd. For error-free communications to occur, the CPC400 and any other device must have the same parity setting.
Chapter 6: Troubleshooting and Reconfiguring 6. CPC400 Series User’s Guide Restore the controller settings. If you have a stand-alone system, you must manually reenter your original parameters. If you have a computer-supervised system with WatView software, you can save a copy of your parameters to a job file and then reload them into the controller. Replacing the Flash Memory Chip This procedure requires a Phillips screwdriver and an IC extraction tool or jeweler’s flathead screwdriver.
CPC400 Series User’s Guide Chapter 6: Troubleshooting and Reconfiguring 5. Remove the electronics assembly from the case, as shown in Figure 6.1. Figure 6.1 6. Unscrew the four screws at the corners of the top board and carefully unplug this board to access the bottom board. Figure 6.2 shows the screws to remove: Figure 6.2 Doc.
Chapter 6: Troubleshooting and Reconfiguring 7. CPC400 Series User’s Guide Locate the flash memory chip on the circuit board. The flash memory chip is a 32-pin socketed chip that is labeled with the model, version and checksum. Figure 6.3 8. Remove the existing flash memory chip from its socket with an IC extraction tool or a jeweler’s flathead screwdriver. Figure 6.4 9. Location of Flash Memory Chip Removal of Flash Memory Chip Carefully insert the new flash memory chip into the socket.
CPC400 Series User’s Guide Chapter 6: Troubleshooting and Reconfiguring Changing the Hardware Communications Protocol To switch between EIA/TIA-232 and EIA/TIA-485, change the jumpers as shown in Figure 6.5. JU1 JU2 JU3 JU4 JU5 A A B Configured for EIA/TIA-232 Figure 6.5 A B Configured for EIA/TIA-485 B Last controller in system configured for EIA/TIA-485 Jumper Configurations You will need tweezers and a Phillips head screwdriver to switch between EIA/TIA-232 and EIA/TIA-485: 1.
Chapter 6: Troubleshooting and Reconfiguring CAUTION! CPC400 Series User’s Guide Scaling resistors are soldered to the circuit board. Only qualified technicians should attempt to install or remove these components. Improper techniques, tools or materials can result in damage to the controller that is not covered by the warranty. Input Circuit The CPC400 can accept differential thermocouple, mVdc, Vdc, mAdc and RTD inputs.
CPC400 Series User’s Guide Chapter 6: Troubleshooting and Reconfiguring Current Inputs For each current input, you must install a resistor. The value of the resistor must be correct for the expected input range. Install the resistor in the listed resistor pack (RP) location. Note the resistor pack locations have three throughholes. Install the resistor as shown in the illustration below. Table 6.3 Resistor Values for Current Inputs Input Range Resistor Value RD 0 to 10 mA 6.0 Ω 0 to 20 mA 3.
Chapter 6: Troubleshooting and Reconfiguring CPC400 Series User’s Guide Voltage Inputs For each voltage input, you must install two resistors. The resistances must be correct for the expected input range. Note the resistor pack (RP) locations have three throughholes. Install the RD resistor as indicated in the illustration below. Table 6.5 Resistor Values for Voltage Inputs Resistor Values Input Range RC RD 0 to 100mVÎ (dc) 499 Ω 750 Ω 0 to 500mVÎ (dc) 5.49 kΩ 750 Ω 0 to 1VÎ (dc) 6.91 kΩ 442.
CPC400 Series User’s Guide Chapter 6: Troubleshooting and Reconfiguring RTD Inputs For each RTD input, you must install three resistors: RA, RB, and RC. The resistance must be correct for the expected input range. RA and RB are a matched pair of resistors. Install them in the resistor pack (RP) locations as shown in the illustration below. Resistor values: • • RA/RB: 25 kΩ RC: 18.2 Ω Resistor tolerances: • RA/RB: Matched to 0.02% (±5 ppm/˚C) with absolute tolerance of 0.
Chapter 6: Troubleshooting and Reconfiguring CPC400 Series User’s Guide Scaling and Calibration The controller provides offset calibration for thermocouple, RTD, and other fixed ranges, and offset and span (gain) calibration for process and pulse inputs. In order to scale the input signal, you must: 1. Install appropriate scaling resistors. (Contact the Customer Service Department at Watlow Anafaze for more information about installing scaling resistors.) 2.
CPC400 Series User’s Guide Chapter 6: Troubleshooting and Reconfiguring Configuring Dual DAC Outputs Dual DAC modules ship with both of the outputs configured for the signal type and span that were ordered. The module contains two independent circuits (DAC 1 and DAC 2). These circuits can be configured for different output types. Remove the board from the housing and set the jumpers. The odd-numbered jumpers determine the signal from DAC 1; the even-numbered jumpers determine the output from DAC 2.
Chapter 6: Troubleshooting and Reconfiguring CPC400 Series User’s Guide 1. Power down the system (if the Dual DAC is already installed and wired). 2. Ensure the DAC 1 and DAC 2 terminal blocks or associated wires are labeled such that you will know which terminal block connects to which side of the board if the module is already installed and wired. 3. Unplug the two terminal blocks. 4. Depending on the installation, you may need to unmount the Dual DAC module before proceeding.
7 Specifications This chapter contains specifications for the CPC400 series controllers, TB50 terminal board, Dual DAC module, Serial DAC module and the CPC400 power supply. CPC400 System Specifications This section contains CPC400 series controller specifications for environmental specifications and physical dimensions, inputs, outputs, the serial interface and system power requirements.
Chapter 7: Specifications CPC400 Series User’s Guide Table 7.3 Physical Dimensions Weight 1.98 lbs 0.9 kg Length* 8.0 inches 203 mm Width 3.78 inches 96 mm Height 1.96 inches 50 mm * Without SCSI connector or with TB18 option. 3.78 in. (96 mm) 1.96 in. (50 mm) 1.76 in. (45 mm) 6.12 in. (155 mm) 3.55 in. (90 mm) 8.0 in. (203 mm) 166 Figure 7.1 CPC400 Module Dimensions Table 7.4 CPC400 with Straight SCSI Length 9.6 inches 244 mm Width 3.78 inches 96 mm Height 1.
CPC400 Series User’s Guide Chapter 7: Specifications 1.0 in. (25 mm) 7.0 in. (178 mm) 1.6 in. (41 mm) 0.5 in. (13 mm) 1.96 in. (50 mm) Figure 7.2 CPC400 Clearances with Straight SCSI Cable Table 7.5 CPC400 with Right Angle SCSI Length 8.6 inches 218 mm Width 3.78 inches 96 mm Height 1.96 inches 50 mm 1.0 in. (25 mm) 7.0 in. (178 mm) 0.60 in. (15 mm) 0.5 in. (13 mm) 1.96 in. (50 mm) Figure 7.3 Doc.
Chapter 7: Specifications CPC400 Series User’s Guide Table 7.6 CPC400 Connections Power Terminals (TB2) Captive screw cage clamp Power Wire Gauge (TB2) 22 to 18 AWG (0.5 to 0.75 mm2) Power Terminal Torque (TB2) 4.4 to 5.3 in.-lb. (0.5 to 0.6 Nm) Sensor Terminals (TB1) Captive screw cage clamp Sensor Wire Gauge (TB1) Thermocouple: 20 AWG (0.5 mm2) Process: 22 to 20 AWG (0.5 mm2) Communications: 24 AWG (0.2 mm2) Sensor Terminal Torque (TB1) 4.4 to 5.3 in.-lb. (0.5 to 0.
CPC400 Series User’s Guide Chapter 7: Specifications 4.1 in. (104 mm) 4.0 in. (102 mm) Figure 7.4 TB50 Dimensions Table 7.8 TB50 Connections Screw Terminal Torque 4.4 to 5.3 in.-lb. (0.5 to 0.6 Nm) SCSI Connector on Board SCSI-2 female Output Terminals Captive screw cage clamp Output Wire Gauge Output Terminal Torque Table 7.9 Doc. 0600-2900-2000 1.5 in. (37 mm) Multiconductor cables: 24 AWG (0.2 mm2) Single-wire: 22 to 18 AWG (0.5 to 0.75 mm2) 4.4 to 5.3 in.-lb. (0.5 to 0.
Chapter 7: Specifications CPC400 Series User’s Guide 6.4 in. (163 mm) 4.0 in. (102 mm) 170 1.5 in. (37 mm) Figure 7.5 TB50 Dimensions with Straight SCSI Cable Table 7.10 TB50 with Right Angle SCSI Length 5.4 inches 137 mm Width 4.0 inches 102 mm Height 1.5 inches 37 mm Watlow Anafaze Doc.
CPC400 Series User’s Guide Chapter 7: Specifications 5.4 in. (137 mm) 4.0 in. (102 mm) Figure 7.6 1.5 in. (37 mm) TB50 Dimensions with Right-Angle SCSI Cable Inputs The controller accepts analog sensor inputs which are measured and may be used as feedback for control loops. It also accepts digital (TTL) inputs which may be used to trigger certain firmware features. Doc.
Chapter 7: Specifications CPC400 Series User’s Guide Table 7.11 Number of Control Loops Number of Analog Inputs Input Sampling Rate Analog Inputs CPC404: 5 CPC408: 9 CPC404: 4 with full range of input types, plus one pulse CPC408: 8 with full range of input types, plus one pulse CPC404: 6 Hz (167 ms) at 60 Hz; 5 Hz (200 ms) at 50 Hz CPC408: 3 Hz (333 ms) at 60 Hz; 2.
CPC400 Series User’s Guide Chapter 7: Specifications Table 7.
Chapter 7: Specifications CPC400 Series User’s Guide Table 7.16 Input Resistance for Voltage Inputs Range Input Resistance 0 to 12V 85 kΩ 0 to 10V 50 kΩ 0 to 5V 40 kΩ 0 to 1V 7.4 kΩ 0 to 500 mV 6.2 kΩ 0 to 100 mV 1.2 kΩ Table 7.17 Digital Inputs Number 8 Configuration 8 selectable for output override, remote job selection or programmable logic Input Voltage Protection Diodes to supply and common. Source must limit current to 10 mA for overvoltage conditions Voltage Levels <1.
CPC400 Series User’s Guide Chapter 7: Specifications The digital outputs may be used in conjunction with Dual DAC or Serial DAC modules to provide analog signals. See Dual DAC Specifications on page 178 and Serial DAC Specifications on page 180. Digital Outputs Table 7.18 Digital Outputs Control / Alarm Number 35 Operation Open collector output; ON state sinks to logic common Function 34 Outputs selectable as closed-loop control, alarms or programmable logic.
Chapter 7: Specifications CPC400 Series User’s Guide Table 7.21 CPC400 Serial Interface Type EIA/TIA-232 3-wire or EIA/TIA-485 4-wire Isolation 530VÅ (ac) Baud Rate 2400, 9600 or 19200, user selectable Error Check Cyclic redundancy check (CRC) Number of Controllers Protocol 1 with EIA/TIA-232 communications Up to 32 with EIA/TIA-485 communications Modbus RTU Table 7.
CPC400 Series User’s Guide Chapter 7: Specifications Table 7.25 Power Supply Physical Specifications Weight 1.2 lb. 0.6 kg Length 6.9 inches 175 mm Width 3.9 inches 99 mm Height 1.4 inches 36 mm Table 7.26 Power Supply with Mounting Bracket Length 8.1 inches 206 mm Width 3.9 inches 99 mm Height 1.4 inches 36 mm 0.7 inch (18 mm) 8.1 inches with mounting bracket (206 mm) 7.5 inches (191 mm) 3.9 inches (99 mm) 0.3 inch (8 mm) 1.4 in (36 mm) 6.9 inches (175 mm) 0.
Chapter 7: Specifications CPC400 Series User’s Guide Table 7.27 Power Supply Inputs and Outputs Input Voltage 120/240VÅ (ac) at 0.75 A, 50/60 Hz Output Voltage (V1) 5VÎ (dc) at 4 A Output Voltage (V2) 15VÎ (dc) at 1.2 A Dual DAC Specifications The Watlow Anafaze Dual DAC (digital-to-analog converter) is an optional module for the CPC400 series controller. The Dual DAC converts a distributed zero crossing (DZC) output signal to an analog process control signal.
CPC400 Series User’s Guide Chapter 7: Specifications +5V IN DZC IN +10-24V IN V OUT I SINK OUT COM ZE 1 C A D C A D L A U D FA A N A 0.162 in. diameter (4 mm) 1 C A D 2 3 6 2 5 1.8 in. 44 mm +5V IN DZC IN +10-24V IN V OUT I SINK OUT COM 4 1 2 3 4 5 6 3.7 in. 94 mm 3.0 in. 76 mm 4.4 in. 112 mm 3.6 in. 91 mm 0.3 in. 0.4 in. 8 mm 10 mm Figure 7.
Chapter 7: Specifications CPC400 Series User’s Guide Dual DAC Analog Outputs Table 7.30 Version Dual DAC Specifications by Output Range 4 to 20 mA 0 to 5V 0 to 10V Units ±6 ±6 ±6 percent ± 0.75 ± 0.75 ± 0.75 percent of full scale range 1.6 1.6 1.
CPC400 Series User’s Guide Chapter 7: Specifications +5 C V C OM IN D LK IN FL ATA IN =R AS IN U HI N N N G IN G 4 OU TP CU UT RR VO SE EN LT LE T AG CT E { { 1.8 in. 44 mm 5 + - OU O T U T 3 C A D 2 ZE FA A N A 1 L IA R PI N: SE 0.162 in. diameter 4 mm 6 4.7 in. 119 mm 3.0 in. 76 mm 3.6 in. 91 mm 5.4 in. 137 mm 0.3 in. 8 mm 0.4 in. 10 mm Figure 7.9 Serial DAC Dimensions Table 7.
Chapter 7: Specifications CPC400 Series User’s Guide Table 7.35 Serial DAC Power Requirements Voltage 4.75 to 5.25 VÎ (dc) @ 300 mA maximum Current 210 mA typical @ 20 VÎ (dc) out Serial DAC Analog Outputs Table 7.36 Serial DAC Analog Output Specifications Absolute Maximum Common Mode Voltage Measured between output terminals and controller common: 1000V Resolution 15 bits (plus polarity bit for voltage outputs) (0.305 mV for 10V output range) (0.
A Appendix A: Modbus Protocol The serial communications port on the CPC400 supports the Modbus RTU protocol. This protocol defines the message structure for all communication packets. The protocol is the same for both EIA/TIA-232 and EIA/TIA-485 serial interfaces. Modbus ASCII is not supported. Up to 32 CPC400 controllers may be connected on a network. Watlow Anafaze offers a Modbus driver for use with Windows-based software applications that communicate with the CPC400.
Appendix A: Modbus Protocol CPC400 Series User’s Guide curred in receipt of the message, or if the slave is unable to perform the requested action, the slave will construct an error message and send it as its response. Query Message from Master Device Address Device Address Function Code Function Code Eight-Bit Data Bytes Eight-Bit Data Bytes Error Check Error Check Response Message from Slave Figure A.
CPC400 Series User’s Guide Appendix A: Modbus Protocol Modbus ASCII and RTU Modes The Modbus protocol supports two distinct serial transmission modes: ASCII and RTU. The mode determines how messages are framed and coded. Typically, ASCII is used for simple communication tasks or diagnostics while RTU is used where a more robust and efficient protocol is required. The CPC400 supports Modbus RTU mode only.
Appendix A: Modbus Protocol Start T1-T2-T3-T4 Address 8 Bits CPC400 Series User’s Guide Function 8 Bits Data n X 8 Bits Figure A.2 CRC Check 16 Bits End T1-T2-T3-T4 Example Message Frame Address Field The address field of a message frame contains eight bits. Valid slave device addresses are in the range of 0 to 247 decimal. The individual slave devices are assigned addresses in the range of 1 to 247. Address 0 is reserved for broadcast messages.
CPC400 Series User’s Guide Appendix A: Modbus Protocol In addition to its modification of the function code for an exception response, the slave places a unique code into the data field of the response message. This tells the master what kind of error occurred, or the reason for the exception. The master device’s application program has the responsibility of handling exception responses.
Appendix A: Modbus Protocol CPC400 Series User’s Guide Field Format When messages are transmitted on standard Modbus serial networks, each character or byte is sent in this order (left to right): Least Significant Bit…Most Significant Bit The bit sequence is as follows: • With parity checking: Start • 1 2 3 4 5 6 7 8 Parity Stop 5 6 7 8 Stop Stop Without parity checking Start 1 2 3 4 Error Checking Methods Modbus RTU use two kinds of error checking: • • Parity checking Frame check
CPC400 Series User’s Guide Appendix A: Modbus Protocol For example, suppose these eight data bits are contained in an RTU character frame: 1100 0101 Four bits are set to 1. If even parity is used, the frame’s parity bit will be a 0, resulting in an even quantity of bits (four) set to 1. If odd parity is used, the parity bit will be set to 1, resulting in an odd quantity of bits (five) set to 1. When the message is transmitted, the parity bit is calculated and applied to the frame of each character.
Appendix A: Modbus Protocol CPC400 Series User’s Guide ORed with the register’s current value, and the process repeats for eight more shifts as described above. The final contents of the register, after all the bytes of the message have been applied, is the CRC value. Function Codes The listing below shows the function codes supported by the CPC400 controllers. Codes are listed in decimal. Table A.
CPC400 Series User’s Guide Appendix A: Modbus Protocol Force Single Coil 05 Forces a single coil (0X reference) to either on or off. When broadcast, the function forces the same coil reference in all attached slaves. Preset Single Register 06 Presets a value into a single holding register (4X reference). When broadcast, the function presets the same register reference in all attached slaves.
Appendix A: Modbus Protocol Subfunction CPC400 Series User’s Guide Data Field Description Query Response Force Listen-Only Mode (04): Forces the addressed slave to listen-only mode for Modbus communications. This isolates it from the other devices on the network, allowing them to continue communicating without interruption from the addressed slave. No response is returned. 00 04 00 00 No Response When the slave enters listen-only mode, all active communication controls are turned off.
CPC400 Series User’s Guide Appendix A: Modbus Protocol Preset Multiple Registers 16 Presets values into the sequence of holding registers (4X references). When broadcast, the function presets the same register references in all attached slaves. Examples Read Examples The data read must be sequentially located. Table A.3 on page 193 shows the query and Table A.4 on page 193 shows the response: Table A.
Appendix A: Modbus Protocol CPC400 Series User’s Guide Write Examples The data written is echoed back to the controller. The following examples show sample query and response packets. Example 1 The host query (Table A.5 on page 194) uses the multiplepoint write function to write a value of 20 to the proportional band for loop 1 in a controller with address 1. The slave responds (Table A.6 on page 194). Table A.
CPC400 Series User’s Guide Glossary Glossary Analog Output A continuously variable signal that is used to represent a value, such as the process value or set point value. Typical hardware configurations are 0 to 20mA, 4 to 20mA or 0 to 5VÎ (dc). A AC See Alternating Current. AC Line Frequency The frequency of the ac line power measured in Hertz (Hz), usually 50 or 60 Hz. Accuracy Closeness between the value indicated by a measuring instrument and a physical constant or known standards.
Glossary CPC400 Series User’s Guide Circuit Any closed path for electrical current. A configuration of electrically or electromagnetically-connected components or devices. Closed Loop A control system that uses a sensor to measure a process variable and makes decisions based on that feedback. Cold Junction Connection point between thermocouple metals and the electronic instrument.
CPC400 Series User’s Guide Glossary Heat/Cool Filter — A filter that slows the change in the response of the heat or cool output. The output responds to a step change by going to approximately 2/3 its final value within the numbers of scans that are set. cations over a short distance (50 feet [15 m] or less) and to a single device. EIA/TIA-485 — A standard for electrical characteristics of generators and receivers for use in balanced digital multipoint systems.
Glossary CPC400 Series User’s Guide portional band and below the cooling proportional band. Process Hysteresis — In heat/cool applications, the +/- difference between heat and cool. Also known as process deadband. I Input Analog Input — An input that accepts process variable information. Digital Input — An input that accepts on and off signals. Input Scaling The converting of input signals to the engineering units of the process variable.
CPC400 Series User’s Guide Glossary Optical Isolation Two electronic networks that are connected through an LED (Light Emitting Diode) and a photoelectric receiver. There is no electrical continuity between the two networks. Output Control signal action in response to the difference between set point and process variable. Output Type The form of control output, such as time proportioning, distributed zero crossing, Serial DAC or analog.
Glossary CPC400 Series User’s Guide S Serial Communications A method of transmitting information between devices by sending all bits serially over a single communication channel. Set Point (SP) The desired value of the process variable. For example, the temperature at which a system is to be maintained. Transmitter A device that transmits temperature data from either a thermocouple or RTD by way of a twowire loop. The loop has an external power supply.
CPC400 Series User’s Guide Index A AC line freq parameter 102 adaptive control 3, 50, 55, 57, 62, 93, 114–115 address field, Modbus 186 agency compliance controller 165 power supply 176 Serial DAC 181 AH alarm code 52 AL alarm code 52 Alarm Acknowledge parameter 132 Alarm delay parameter 125 Alarm Enable parameter 133 Alarm Function parameter 133 Alarm high func parameter 122 Alarm high output parameter 122 Alarm high SP parameter 66, 121 Alarm hysteresis parameter 124 Alarm low func parameter 124 Alarm lo
Index CPC400 Series User’s Guide parity 102 restarting 191 software problems 153 troubleshooting 152–153 wire sizes and lengths 21 see also EIA/TIA computer, see communications control algorithms 81–84 on/off 82 proportional (P) 82, 87 proportional with integral (PI) 83, 87 proportional, integral and derivative (PID) 84, 87 Control menu 111–115 control mode as shown on display 50 changing 55 unexpected switch from automatic to manual 144 control outputs 88–90 action 118 control algorithms, see control alg
CPC400 Series User’s Guide Index navigation 48 process variable not correct 143, 148 scanning loop 51 toggling between loop and job displays 53 distributed zero crossing 89, 116 droop 112 Dual DAC configuring outputs 163–164 dimensions 19, 178–179 environment 178 input specifications 179 jumper settings 163 mounting 19 output specifications 180 specifications 178–180 weight 178 wiring 39–40 dust 13 DZC, see distributed zero crossing thermocouple short 64, 101 field format, Modbus 188 filter output 89, 11
Index controller 165 Dual DAC 178 power supply 176 Serial DAC 180 hysteresis alarm 66 control 113 Hysteresis parameter 113 I I/O tests menu 131–132 Input filter parameter description 109 Input high signal parameter 107 Input low signal parameter 108 Input menu 104–109 input power, see power supply Input pulse sample parameter 105 Input range high parameter 107 Input range low parameter 108 input registers, reading contents of 190 Input type parameter 104 Input units parameter 105 inputs analog, see sensor
CPC400 Series User’s Guide loops autotuning, see autotuning closed-loop control 57–62 display information 50 number available 172 tuning 85–87 low deviation alarm, see process alarms Low power alarm 53, 145 M man message on loop display 50 manual mode during a failed sensor alarm 119 during a mode override 119 during a thermocouple open alarm 120 if ambient temperature is out of range 137 Mode parameter 92 setting 55 manual reset 112 manual tuning 85 menus accessing 56 Alarms 121–125 Cascade 127–128 Chann
Index CPC400 Series User’s Guide channels 109 control 111–115 editing through keypad 56 through LogicPro programs 78 through serial communications 78 global 96–103 I/O tests 131–132 input 104–109 map of 95, 216 navigating 56 output 116–121 process variable retransmit 125–126 ratio control 128–130 restoring all default settings 153 serial communications and LogicPro only 132–137 Serial DAC 117–118 soft Booleans 131 soft integers 130 parity 102, 188 parts list 4 personal computer, see communications PID aut
CPC400 Series User’s Guide repair, returning controller for 140 reset, integral: see integral response, Modbus 184 RestoreAuto parameter 65, 114 retransmit, see process variable retransmit returning the controller 140 reverse action, see control outputs Reversed T/C detect parameter 64, 106 RFI, see noise RMA number 140 RO alarm code 52 RS alarm code 52 RS-232, see EIA/TIA-232 RS-485, see EIA/TIA-485 RTD accuracy 173 alarm messages 52 calibration offset 105 range 173 recommended type 29 resolution 173 scal
Index for powering Serial DAC 40 mounting on DIN rail 16 mounting with standoffs 17 specifications 168–171 technical description 8 terminal specifications 169 testing after installation 26 to power encoders 31 troubleshooting 150 weight 168 TC short alarm parameter 64, 101 temperature incorrect on display 143, 148 operating 165, 176, 178, 180 storage 165, 176, 178, 180 temperature scale 105 terminal specifications TB50 169 Test D/O parameter 132 testing TB18 after installation 26 TB50 after installation 26
CPC400 Series User’s Guide Parameter Reference Parameter Address Reference Use this section to quickly locate addresses for interface software and logic programs. Parameter Modbus Address Parameter Number LogicPro Driver Size (bits) LogicPro Address Operator Parameters (page 92) Set point 40205 to 40213 12 Setpoint 16 1 to 9 Mode 40120 to 40128 7 Database 16 7.1 to 7.9 Heat Output 40273 to 40281 16 Database 16 16.1 to 16.9 Cool Output 40290 to 40298 17 Database 16 17.1 to 17.
Parameter Reference CPC400 Series User’s Guide Modbus Address Parameter Number LogicPro Driver Size (bits) LogicPro Address Input Type 40103 to 40111 6 Database 16 6.1 to 6.9 Loop Name 45309 and 45310 for loop 1, 45311 and 45312 for loop 2, and so on 16 132.1 and 132.2 for loop1, 132.3 and 132.4 for loop 2, and so on Input Units 40792, 40793 and 40794 for loop 1; 40795, 40796 and 40797 for loop 2; and so on 51 Database 16 51.1, 51.2 and 51.3 for loop1; 51.4, 51.5 and 51.
CPC400 Series User’s Guide Parameter Reference Modbus Address Parameter Number LogicPro Driver Size (bits) LogicPro Address Cool Filter 40256 to 40264 15 Database 16 15.1 to 15.9 Hysteresis 40856 to 40864 54 Database 16 54.1 to 54.9 Restore Automatic Mode 44460 to 44468 87 Database 16 87.1 to 87.9 Tune Band 46542 to 46550 144 Database 16 144.1 to 144.9 Tune Gain 46559 to 46567 145 Database 16 145.1 to 145.9 Overshoot Reduction 46576 to 46584 146 Database 16 146.
Parameter Reference CPC400 Series User’s Guide Modbus Address Parameter Number LogicPro Driver Size (bits) LogicPro Address Alarm High Set Point 40307 to 40315 18 Database 16 18.1 to 18.9 Alarm High Function See “Alarm Acknowledge” on page 132 and “Alarm Function” on page 133 Parameter Alarms (page 121) Alarm High Output 40426 to 40434 25 Database 16 25.1 to 25.9 High Deviation Value 40341 to 40349 20 Database 16 20.1 to 20.
CPC400 Series User’s Guide Parameter Reference Modbus Address Parameter Number LogicPro Driver Size (bits) LogicPro Address Cascade Primary Loop 44648 to 44654 99 Database 16 99.1 to 99.9 Cascade Low Set Point 44682 to 44690 101 Database 16 101.1 to 101.9 Cascade High Set Point 44699 to 44707 102 Database 16 102.1 to 102.9 Ratio Master Loop 44750 to 44758 105 Database 16 105.1 to 105.9 Ratio Low Set Point 44767 to 44775 106 Database 16 106.1 to 106.
Parameter Reference CPC400 Series User’s Guide Parameter Modbus Address Parameter Number LogicPro Driver Size (bits) LogicPro Address Data Changed Register 40791 50 Database 16 50.1 Firmware Identification 40847 52 Database 16 52.1 Firmware Version (page 135) Major Part 40844 52 Database 16 52.2 Minor Part 40845 52 Database 16 52.3 Revision Letter 40846 52 Database 16 52.4 Full Scale Calibration 40718 45 Database 16 45.
Declaration of Conformity CPC400 Series Erklärt, daß das folgende Produkt: WATLOW ANAFAZE 314 Westridge Drive Watsonville, California 95076 USA Declares that the following product: Designation: CPC400 Series Model Number(s): 40 (4, or 8) - (1) (0,1 or 2) (0 or 2) (0,1,2 or 3) (0,1,2 or 3) (0,1, or 2) (any letter or number) Classification: Installation Category II, Pollution Degree II Rated Voltage: 12 to 24VÎ (dc) Rated Current: 610mA maximum 1995 Limits for harmonic current EN 61000-3-3: 1995
Menu Structure CPC400 Series User’s Guide Menu Structure Global setup (page 96) Load setup from job Save setup as job BCD job load BCD job load logic Mode override Mode override D/I active Logic program Power up alarm delay Power up loop mode Power up with logic Keypad lock TC short alarm Controller address Comm baud rate Comm parity AC line freq D/O alarm polarity CPC4xx Vx.
