CALogix Programming and Installation Manual DM000M22 Page 1 of 44
Introduction Installation Mechanical Installation a) Base-unit b) Control module c) Mounting d) Removing a module e) Removing the base-unit from DIN-rail f) Cleaning g) Dimensions 4 4 4 4 5 5 5 6 Electrical Installation a) Output devices b) Supply Voltage c) Wiring a connector d) Replacing modules e) Inductive loads f) EN61010 g) EMC guidelines h) Supply and RS485 communications connections i) Input options (module) j) Output options (module) k) Example circuit l) Input sensor selection 7 7 7 7 7 7 7 8 9
m) Error messages n) PID module settings 20 20 Programmer a) Function overview b) Accessing the programmer interface c) Programmer interface d) Creating a program e) Program segment types f) Program properties g) Reading program data from a controller h) Creating an additional program i) Selecting a program j) Insert segments to a program k) Deleting segments l) Modifying a program m) Running Programs n) Stopping a program 25 25 25 25 25 26 28 28 29 29 29 29 29 29 30 Logic I/O module and Logic Programmi
CALogix Installation Instructions System Overview CALogix is a modular multi-loop PID controller with logic function capability. The controller consists of a DIN-rail mount base-unit that incorporates the power supply, RS485 communications ports and slots for up to 4 control modules. The control modules are available as PID or Logic I/O and can be selected then mounted into the base-unit as required for the application.
3. Ensuring the input terminals are facing downwards, add the control modules to base unit. Press the top and bottom tabs on the module lightly and ensuring module is kept straight, push to locate in base unit (see diagram below). Press 4. Pre-wire connectors and plug into the appropriate modules (we suggest wire markers for identification) REMOVING A MODULE 1. 2. 3. 4. Isolate supply to CALogix and all module input and output connectors. Unplug connectors to module requiring removal.
DIMENSIONS Note Ensure adequate clearance for connectors and wiring Page 6 of 44
Electrical Installation The system is designed to be installed in an enclosure which provides adequate protection against electrical shock. The enclosure should also be of a sufficient IP (NEMA) rating for protection against water and dust. CALogix should be mounted in an enclosure with minimum internal dimensions of 160 wide x 125 high x 85 mm deep. OUTPUT DEVICES Three types of output are available on an output module: relay, solid state relay drive (ssd) and analog.
EMC GUIDELINES We make a number of general recommendations that can reduce the possibility of EMC problems. 1) It is important to suppress CALogix relay contacts, this will reduce switching interference and also prolongs life of the contacts. RC Networks fitted across the relay contacts are recommended for resistive and larger inductive loads, values such as 0.1μF capacitor in series with a 100Ω resistor. For small inductive loads, a suitable rated VDR is recommended.
SUPPLY AND RS485 COMMUNICATIONS CONNECTIONS (BASE-UNIT) INPUT OPTIONS (MODULE) 7P---0A000 7P---0A000 7P---0B000 = 4-20mA 7P---0C000 = 0-5V 7P---0D000 = 0-10V 7P---0A000 7L---0E000 OUTPUT OPTIONS (MODULE) 7P111----7L111----- 7PB11----- = 4-20mA 7PC11----- = 0-5V 7PD11----- = 0-10V 7P211----7L211----- 7P221----7L221----- 7PB21 = 4-20mA 7PC21 = 0-5V 7PD21 = 0-10V Page 9 of 44
EXAMPLE CIRCUIT The circuit below shows an example applicaion which includes a base-unit that has one PID module and one logic module fitted. FS1 Fuse = 1A time lag type to IEC127. CSA/UL rating 250V FS2 Fuse = 2A time lag type to IEC127. CSA/UL rating 250V FS3 Fuse = High rupture capacity (HRC).
Configuring CALogix CALogix is configured using Windows-based CALogix-sw software. Before using CALogix–sw, connect CALogix to a PC as shown below: CALOGIX NETWORK To other CALogix controllers RS232/485 converter RS485 from PC <1200m <15m CALogix uses RS485 full duplex serial communications link which is the standard most commonly used for industrial applications due to high noise immunity and multi-drop capability.
For multiple instrument networks each transmission line must be properly terminated to prevent reflections. 120Ω termination resistors should be fitted between TX+ & TX- and RX+ & RX- at the connection to the PC in addition to the last instrument in the chain. See example below. When transmission lines are not transmitting, they remain in an intermediate state which can allow receivers to receive invalid data bits due to electrical noise on the cable.
4. 5. Click on ‘CALogix’ icon. CALogix program should now run. USING CALOGIX-SW 1. Refer to on-screen help or CALogix programming manual contained on CALogix-sw CD. Diagnostics Each control module has LEDs to indicate when each of the outputs are on (or relay closed). If an analogue output option is fitted the LED dims proportionately with the output level, e.g. a PID module with a 4-20mA output, the LED will be dim at 4mA and bright at 20mA.
CALogix-sw Configuration Software STARTING CALOGIX-SW 1. 2. 3. 4. 5. Click ‘start’ on Windows toolbar Mouse-over ‘all programs’ Mouse-over ‘CALogix folder’ in menu Click on ‘CALogix’ icon CALogix program should now run CONNECTING TO A CONTROLLER 1. Click on to add a new instrument 2. Click on browse 3. Select communications port, baud rate and Modbus address (default 1). Once settings are entered click on browse. 4. CALogix unit is then shown in device list when detected. Click on OK. . 5.
Open File Open controller application settings or logic program file. Note : when a saved application or logic file is loaded to a CALogix unit, the logic program will not be running. Save Save controller application settings or logic programs. Export Application Creates rich text file (.rtf) with application settings data Export device Creates rich text file (.rtf) with current device settings data Export program (only available when programmer interface is open) Creates rich text file (.
CONFIGURING A PID MODULE SETTINGS MENU To access settings for a PID module 5. Right-click on controller image. 6. 7. Mouse over properties, then left-click on the required PID module number, see diagram above. The settings menu will now open VIEWING PARAMETER SETTINGS 1.
4. Once these settings have been made click on apply to write to the controller. PARK MODE Once initial settings are written to the controller it will still be in park mode i.e outputs to the controller are disabled. To take the controller out of park, change mode (setpoint 1 settings) to control type required i.e P (proportional), PI (proportional integral), PID (proportional integral derivative), PD (proportional derivative) or ON/OFF control.
Cycle time recommendations − It is recommended that relay outputs should not have a cycle time of less than 10S. If a cycle time of less than 10s is required, solid state drive outputs are advised. SECOND AND THIRD SETPOINTS (SP2 and SP3) Primary Alarm Modes − Configure SP2 and SP3 outputs to operate as an alarm from setpoint 2 and 3 control sections in the ‘module settings menu’ The alarms will be individually triggered when the process value changes according to the options listed below.
Autotune sets PID terms for Heat and Cool with the same setting values. Band, integral time, derivative time, DAC and derivative sensitivity settings can all be modified independently for both heat (setpoint 1 settings) and cool (setpoint 2 settings). In some processes oscillations occur during cooling. If this occurs double the value of band (setpoint 2 settings).
− 0-5V Models with 0 to 5V input use an internal resistor to spread the signal across the input range 0 to 50 mV using a divider of 100. Where a transducer provides a smaller output, the input maximum and minimum values can be similarly calculated. − 0-10V Models with 0 to 10V input use an internal resistor to spread the signal across the input range 0 to 50 mV using a divider of 200. Where a transducer provides a smaller output, the input maximum and minimum values can be similarly calculated.
Resolution of PV and Setpoint on CALogix-sw can be set as 0.01, 0.1 or 1. This resolution is also the format used for the corresponding data register with CALogix unit to be read by an operator panel or for data acquisition. It is recommended that display setting of 0.01 is NOT used when a thermocouple or PT100 sensor is used as the displayed value will fluctuate. Setpoint 1 upper limit Sensor Max -9999 to 9999 step 0.
Derivative Sensitivity 0.5 0-1.5, step 0.1 Cycle time 10 secs 0.1 to 9.9, step 0.1 10 to 81, step 1 SP1 proportional cycle-time - Determines the cycle rate of the output device for proportional control. The choice of cycle-time is influenced by the external switching device or load. eg. contactor, SSR, valve. A setting that is too long for the process will cause oscillation and a setting that is too short will cause unnecessary wear to an electro-mechanical switching device.
Change setpoint 2 value Band 2 -9999 to 9999 step 0.01 SP2 proportional band or Hysteresis -* 100% sensor maximum, proportional control eliminates the cycling of on-off control. Output power is varied, by proportioning action, across the proportional band Integral time 5 mins 0 to 1000, step 0.1 SP2 integral time/reset - Auto-corrects proportional control offset error Derivative time 25 secs 0 to 200.
The current proportional output of SP3 shown as %. Manual Power Off Off, 0 to 100, step 1 Manual power overrides PID calculated power output. The proportional output for SP3 will remain constant at the entered value. To return to PID control set manual power to 0. Display Alarm No No, Yes When set to yes, alarm symbol is shown on controller image within CALogix-sw when an alarm output is switched.
PROGRAMMER FUNCTION OVERVIEW The Programmer function enables CALogix to control applications that require setpoint changes over time. Examples of this are ramp changes where setpoint is gradually increased at a specified rate until a target level is reached or step changes which are instantaneous. These can be separated by soak periods during which the process is held at a constant value.
6. 7. To add segments click on ramp/soak/step. Enter quantity of segments required then press OK. 8. 9. Click and drag segment points on the profile chart area to draw the required profile. Click to open data for each segment in segment property menu. 10. Adjust values for any parameters that require modification. (see section on segment parameters). 11. If you require to add additional segments (ramp/soak/step), call programs, event inputs, event outputs or loops, see notes below. 12.
Event outputs can be selected as an individual segment or after other segment types have completed such as ramps, soaks, steps and loop. Outputs must be assigned as event outputs in setpoint 2 and/or setpoint 3 control settings menu before EOP’s can be used. See section on PID Module settings. Once outputs are configured select the correct EOP status for program segment. None 2D 2E 3D 2E 2D 3D 2E 3D 2E 3E 2D 3E No event output. SP2 output de-energised to mark event. SP2 output energised to mark event.
PROGRAM PROPERTIES Program properties allows you to set parameters for a program displayed on the profile chart area. When a program is displayed on the user interface click on properties in the programmer menu. The program properties box should now open Current program tab Program Number Displays the number of the currently open program. Description A user defined label (name) can be set as a program name. Power Fail After a power failure one of three options can be chosen.
2. 3. Click on read program data in the programmer menu. Information from the controller is read and program 1 is displayed on the programmer interface. CREATING AN ADDITIONAL PROGRAM 1. Follow instructions in section on creating a program. SELECTING A PROGRAM 1. When the programmer interface is open click on the required module tab. 2. Click on select program in the programmer menu. 3. Select required program. 4. The selected program will now be displayed on the program interface.
STOPPING A PROGRAM 1. Right click on controller image. 2. 3. Mouse over properties select programmer and set-points. Expand (+) programmer menu. 4. 5. 6. 7. Scroll to required module. Set program run mode of required module to off. Apply settings to controller. The program will now stop.
Logic I/O Module and Logic Programming OVERVIEW CALogix has integrated logic function capability that can be used for controlling a system by linking associated inputs and outputs using logic, timer, counter and comparator functions. A logic programming utility is included within CALogix-sw that can be used to create logic function block diagrams when a CALogix system has logic I/O modules fitted.
Create input function block I/O module inputs, power up or output status can be used as logic input function blocks. Create output function block Function blocks for a switching a physical output, changing setpoint, selecting manual power, starting autotune, event input and running a program can be created. Function block linking tool Creates a link between two function blocks in a logic program.
Resize function blocks to same height and same width Resize all function blocks to the height and width of the blocks to that of the widest and highest blocks. Apply grid to desktop Apply grid to the logic desktop to assist with aligning and creating programs. PLACING A FUNCTION BLOCK ON THE LOGIC DESKTOP 1) 2) 3) 4) Left-Click on the icon for the logic function block type you require. Continuing to hold the mouse button, drag the mouse pointer into the logic desktop area.
II. Timers A number of timer functions are available with CALogix, these are: on-delay, off-delay, on-off delay, on-pulse, off-pulse, on-off pulse, delayed-pulse, symmetrical recycler pause, symmetrical recycler pulse, asymmetrical recycler pause and asymmetrical recycler-pulse. Timer charts showing the operation of these are shown in appendix The time settings are entered by clicking on the time required and entering the data in HHH.MM.SS.S format. Once entered click on OK to accept the settings change.
Comparators convert the input level to a percentage of full scale e.g On a logic I/O module input with range of 0 24V, an input voltage of 2.4V will be considered to have a value of 10.0 in a comparator block. The compare function allows a greater or a less than comparison with the input. If the comparison is true the block will have a high-state output (1). The block will require one input for comparing with a constant or two when comparing inputs.
Manual power can be selected to apply to SP1, SP2 or SP3 of a specified module and will operate when input to the block switches from low (0) to high (1) logic state. To return to PID control from manual power an additional block can be created within the logic program to set manual power value to 0. IV. Autotune A PID module can be tuned using an output logic block. Autotune@75%SP (75% setpoint) or Autotune@ATSP (at setpoint) can be selected for the required PID module.
When the input to the block is high (1), the chosen programmer function will be activated. INVERTING INPUTS Function block inputs can be inverted in the following way 1. 2. Right-click on function block Click on inputs 3. Click on invert boxes for the inputs that require inverting. 4. Click on OK to accept setting. VALIDATING A PROGRAM Once a logic program is complete click on icon on the logic toolbar. A check is then carried out for program validity and any errors are displayed see example below.
Click on the logic toolbar to start a program that is written to the controller, the Logic running LED on the base unit should be ON when a logic program is running. To stop a logic program running click logic running LED should switch off. on the logic toolbar and the TRACE MODE Trace mode allows a user to monitor a logic program as it is running. After a logic program is started click logic tool bar.
APPENDIX Boolean Functions AND INP1 0 0 1 1 INP2 0 1 0 1 OUT 0 0 0 1 INP1 0 0 1 1 INP2 0 1 0 1 OUT 1 1 1 0 INP1 0 0 1 1 INP2 0 1 0 1 OUT 0 1 1 1 INP1 0 0 1 1 INP2 0 1 0 1 OUT 1 0 0 0 INP1 0 0 1 1 INP2 0 1 0 1 OUT 0 1 1 0 INP1 0 0 1 1 INP2 0 1 0 1 OUT 1 0 0 1 INP1 0 0 1 1 INP2 0 1 0 1 OUT Latched 0 1 Latched NAND OR NOR XOR XNOR LATCH Page 39 of 44
Timer Functions On-Delay Timer Off-Delay Timer On-Off Delay Timer On-Pulse Timer Off Pulse Timer Page 40 of 44
On-Off Pulse Delayed Pulse T1 – Delay T2 – Pulse Symmetrical Recycler Pause Symmetrical Recycler Pulse Asymmetrical Recycler Pause T1 – Pause T2 – Pulse Page 41 of 44
Asymmetrical Recycler Pulse T1 – Pulse T2 – Pause Page 42 of 44
Specification PID MODULE : THERMOCOUPLE – 9 Types – B, E, J, K, L, N, R, S, T Standards CJC rejection External resistance IEC 584-1 30:1 typical 100Ω maximum RESISTANCE THERMOMETER – 2 or 3 Wire Standards IEC 751 (100Ω 0°/138.5Ω 100°C Pt) 0.2mA maximum Bulb Current LINEAR PROCESS INPUTS Linear Input 0-50mV Typical Accuracy ±0.1% 4-20mA 0-5V 0-10V ±0.1% ±0.1% ±0.1% Range ± 0.00 – 99.99, ±100.00 – 499.95, ±500 – 999.
Safety and Warranty Information Installation EN61010-1 / UL61010C-1 / CSA 22.2 No 1010 To offer a minimum of basic insulation only Suitable for measurement within category II and III and pollution degree 2 See Electrical installation It is the responsibility of the installing engineer to ensure this equipment is installed as specified in this manual and is in compliance with appropriate wiring regulations. Configuration The controller can only be configured using CALogix-sw or CALgrafix software.
