Automationdirect.com prosense PPC5 Series User Manual

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PS A
P C
PPC S
Models:
PPC5-1000
PPC5-1001
PPC5-1002
PPC5-1100
PPC5-1101
PPC5-1102

Automationdirect.com prosense PPC5 Series Specifications

General

Display Size	5.7 inch
Display Type	TFT LCD
Resolution	320 x 240 pixels
Touchscreen	Yes
Power Supply	24 VDC
Operating Voltage	24 VDC
Digital Inputs	8
Communication Ports	Ethernet
Operating Temperature	0°C to 50°C
Enclosure Rating	IP65

Summary

Preface

Overview of this Publication

Describes the installation, configuration, and methods of operation of the PPC5 series Prosense Advanced Process Controller.

Who Should Read This Manual

Provides important information for those who will install, maintain, and/or operate PPC5 series advanced process controllers.

Safety Precautions

Details safety standards and EMC standards compliance, and use in Pollution Degree 2 environments.

Handling Precautions for the Controller

Provides guidance on cleaning, avoiding static discharge, and precautions for plastic components and chemicals.

Checking the Contents of the Package

Instructions for unpacking and verifying all product contents are present and undamaged.

PPC5 Models and Description

Lists and describes the different PPC5 series advanced process controller models.

Symbols Used in This Manual

Explains symbols used in the manual to indicate safety precautions and references.

Setup Procedure

Outlines the flowchart for setting up the PPC5 controller.

Chapter 1: Installation and Wiring

1.1 Installation Location

Specifies conditions for installing the instrument in indoor locations and instrument panels.

1.2 Mounting Method

Details the procedure for mounting the controller onto an instrumented panel.

1.3 External Dimensions and Panel Cutout Dimensions

Provides detailed dimensions for the controller and panel cutout for mounting.

1.4 Wiring

Covers important information, procedures, and diagrams for wiring the controller's terminals.

1.5 Attaching and Detaching Terminal Cover

Explains the method for attaching and detaching the terminal cover of the controller unit.

Chapter 2: Introduction to Unit, Key, and Display Functions

2.1 Definition of Main Symbols and Terms

Defines main symbols and terms used in the manual and controller.

2.2 Input/Output Function

Explains the PV input, control output, and remote auxiliary analog input functions.

2.3 Display and Key Functions

Describes the active color PV display, guide display, multilingual guide, and parameter display levels.

2.4 Communication Functions

Details the RS-485 and Ethernet communication capabilities of the PPC5 series.

2.5 Names and Functions of Display Parts

Identifies and explains the functions of various display parts on the controller.

2.6 Names and Functions of Keys

Identifies and explains the functions of the control keys on the controller panel.

2.7 List of Display Symbols

Provides a list of symbols used in the PV display, symbol display, and group display.

2.8 Overview of Display Switch and Operation Keys

Illustrates the transitions between Operation Display, Operation Parameter Setting Display, and Setup Parameter Setting Display.

2.9 How to Set Parameters

Provides an example operating procedure for setting alarm setpoints and other parameters.

Chapter 3: Quick Setting Function

3.1 Setting Using Quick Setting Function

Explains the Quick Setting function for easily setting basic controller functions like control type, input, and output.

3.2 Restarting Quick Setting Function

Describes methods to restart the Quick Setting function if it does not start automatically.

Chapter 4: Operation Monitoring and Control

4.1 Monitoring and Control of Operation Displays

Details the transitions between different operation displays based on control modes.

4.2 Setting Target Setpoint

Explains how to set the target setpoint (SP) in the Operation Display and Parameter Setting Display.

4.3 Performing and Canceling Auto-tuning

Describes how to perform and cancel the auto-tuning function for PID parameter optimization.

4.4 Adjusting PID Manually

Explains how to manually adjust PID parameters such as Proportional band (P), Integral time (I), and Derivative time (D).

4.5 Setting Alarm Setpoint

Details how to set alarm setpoints for different alarm types like PV, SP, deviation, and output.

4.6 Selecting Target Setpoint Number (SPNO)

Explains how to select the target setpoint number (SPNO) for zone PID selection.

4.7 Switching Operation Modes

Describes how to switch between operation modes like AUTO, MAN, CAS, STOP, RUN, REM, and LCL.

4.8 Manipulating Control Output during Manual Operation

Explains how to control the output value using direct key or SET/ENTER key methods in manual mode.

4.9 Releasing On-State (Latch) of Alarm Output

Describes how to release the alarm latch function using user function keys, communication, or contact input.

Chapter 5: Input Setting Functions

5.1 Setting Functions of PV Input and Remote Auxiliary Analog Input

Covers setting input type, unit, range, scale, and decimal point position for PV and remote analog inputs.

5.2 Setting Input Sampling Period (Control Period)

Explains how to set the input sampling period, also known as the control period.

5.3 Using Larger, Smaller, Average, or Difference of Two Inputs as PV

Describes how to use PV auto-selector to select or calculate larger, smaller, average, or difference of two PV inputs.

5.4 Setting Remote Input Method

Explains the two methods for remote input: analog input and communication.

5.5 Adjusting PV Range for Loop Control with PV Switching or Loop Control with PV Auto-selector

Details how to adjust PV range for control when measurement ranges of two input signals differ.

5.6 Setting PV Switching Methods of Loop Control with PV Switching

Explains how to set PV switching methods for Loop control with PV switching.

Chapter 6: Control Mode Settings

6.1 Setting Control Mode (CTLM)

Details the different control modes available, such as Single-loop, Cascade, and Loop controls.

6.2 Setting Control Type (CNT)

Describes various control types including PID, ON/OFF, PD, Sample PI, and Batch PID.

6.3 Setting PID Control Mode (ALG)

Explains the selection between standard PID and fixed-point PID control modes.

6.4 Switching PID

Covers methods for switching PID parameters based on target setpoint number, PV, SP, deviation, or contact input.

6.5 Suppressing Overshoot (Super Function)

Explains the Super function for monitoring overshoot danger and temporarily adjusting the setpoint.

6.6 Suppressing Hunting (Super2 Function)

Describes the Super2 function for suppressing controller hunting without re-tuning PID parameters.

6.7 Suppressing Integral Action (Anti-reset Wind-up)

Explains the anti-reset wind-up function for preventing extreme integral output by stopping PID computations.

6.8 Performing Non-linear PID Control

Details how to perform non-linear PID control by adding proportional gain based on deviation.

6.9 Adjusting Auto-tuning Operation

Describes the adjustment of auto-tuning operation, including auto-tuning type and output limiter settings.

Chapter 7: Setpoint Functions

7.1 Setting SP Limiter

Explains how to set SP high and low limits to restrict the SP range, applicable to all SP groups and loops.

7.2 Changing SP at a Fixed Rate (SP Ramp-Rate Setting Function)

Describes the SP ramp-rate setting function to force SP change at a fixed rate, preventing abrupt changes.

7.3 Forcing SP to Track PV (PV Tracking)

Explains the PV tracking function to align SP with PV and then change to original SP at the SP ramp rate.

7.4 Forcing SP to Track Remote Input (SP Tracking)

Describes the SP tracking function to force local SP to track remote SP when switching from REM to LCL mode.

Chapter 8: Output Setting Functions

8.1 Setting Control Output Type

Explains how to select the output type as relay output, voltage pulse output, or current output.

8.2 Setting Control Output Cycle Time

Details setting the cycle time for relay or voltage pulse output for faster cycling and finer control.

8.3 Setting Limiter to Control Output

Explains how to set control output high and low limits to restrict the output to a specific range.

8.4 Disabling Output Limiter in MAN mode

Describes how to release the output limiter when the operation mode is changed from MAN to AUTO.

8.5 Setting Velocity Limiter to Control Output

Explains the output velocity limiter to prevent sudden changes in control output signal.

8.6 Reducing 4-20 mA Current Output to 0 mA (Tight Shut Function)

Describes the tight shut function to fully close the control valve beyond its positioner dead band.

8.7 Setting ON/OFF Control Hysteresis

Explains how to set hysteresis for ON/OFF control to prevent frequent relay output cycling (chattering).

8.8 Canceling Offset of PV and SP (Manual Reset)

Describes how manual reset can be used to cancel the offset when integral action is disabled.

8.10 Setting Preset Output Value

Details setting preset output values for STOP mode and manual preset output.

8.11 Setting 10-segment Linearizer for Output

Explains the function for correcting control output by adding bias values to 11 points or using approximation.

8.12 Changing Current Output Range

Describes how to select the analog output type from 4-20 mA, 0-20 mA, 20-4 mA, or 20-0 mA.

8.13 Setting Split Computation Output Function

Explains the V-mode and Parallel-mode characteristics of split computations for current output.

8.14 Using 15 V DC Loop Power Supply

Describes the function to supply DC power (14.5 to 18.0 V DC) to a 2-wire transmitter.

Chapter 9: Alarm Functions

9.1 Setting Alarm Type

Covers alarm parameters including type, stand-by action, energized/de-energized, latch function, and setpoints.

9.2 Setting Number of Alarm Groups to Use

Explains how to set the number of alarm groups, with options to hide unused parameters.

9.3 Setting Hysteresis to Alarm Operation

Describes how to prevent frequent alarm switching by increasing the alarm hysteresis.

9.4 Delaying Alarm Output (Alarm Delay Timer)

Explains the on-delay and off-delay timers for delaying alarm output when an alarm condition occurs or is removed.

9.5 Setting Alarm Output to Control Relay Terminal

Details how to use the control relay terminal for alarm output when it is not used for control output.

9.6 Setting Alarm Action According to Operation Mode

Explains how to set the alarm mode to disable alarm action in STOP or MAN modes.

Chapter 10: Contact Input and Output Functions

10.1 Setting Contact Input Function

Describes how the contact input function works by setting internal relay numbers for functions like AUTO/MAN and REMOTE/LOCAL.

10.2 Setting Contact Output Function

Explains how the contact output function works by setting a status such as an alarm to the contact output.

Chapter 11: Setting Display and Key Functions

11.1 Setting Display Functions

Covers functions related to display settings like active color PV, masking values, SELECT displays, and bar-graphs.

11.2 Assigning Function to User Function Key and A/M Key

Explains how to assign various functions to the user function keys and A/M key on the front panel.

11.3 Setting Security Functions

Details setting password protection, parameter display levels, locking menus, and key locks.

11.4 Confirmation of Key and I/O Condition and Version

Describes how to confirm key status, I/O conditions, and software versions.

Chapter 12: Resetting Default Values

12.1 Initializing Parameter Settings to Factory Default Values

Explains how to initialize all parameter settings back to their factory default values.

12.2 Registering and Initializing User Default Values

Covers registering user settings as default values and initializing the controller to user default values.

Chapter 13: Power Failure Recovery

13.1 Remedies if Power Failure Occurs during Operations

Details the controller's status and remedies after power failures of different durations.

13.2 Setting Time between Powering on Controller and Starting Control (Restart Timer)

Explains how to set the time delay between powering on the controller and starting control computation.

13.3 Power Frequency Setting

Describes how to set the power frequency by automatic detection or manually to match the installation location.

Chapter 14: Troubleshooting

14.1 Troubleshooting

Provides a flowchart and details for troubleshooting common issues like display, key, I/O, and communication failures.

14.2 Maintenance

Covers maintenance procedures including cleaning the instrument and proper disposal.

Chapter 15: Parameter Settings

15.1 Parameter Map

Provides a brief description of the parameter map, group display, loop-2 display, and parameter display levels.

15.2 List of Parameters

Lists parameters by menu symbol, name, display level, setting range, and initial value.

Chapter 16: Software Functional Overview

16.1 Functional Overview

Describes the main functional overview of the Parameter Setting Software, including parameter setting and monitoring functions.

16.2 Connecting the Controller to a PC and Setting Parameters

Explains how to connect the controller to a PC using IR Adapter or Maintenance Port Communication.

Chapter 17: Software Setting Flow and Navigation

17.1 Setting Flow

Provides a flowchart for setting parameters on the controller using the software.

17.2 Starting up/Exiting the Parameter Setting Software

Details the procedure for starting up and exiting the Parameter Setting Software, including the Startup Guide window.

17.3 Window Names and Functions

Explains the names and functions of the Basic window, File window, Register window, and Parameter Setting window.

17.4 Creating New Parameter File Using the Wizard Function

Guides through creating a new parameter file using the Wizard function, including system data and parameter settings.

17.5 Setting the Parameter View Level

Explains how to set the parameter view level in the software (Easy, Standard, Professional).

17.6 Setting System Data

Describes how to set system data such as model, control mode, and input/output settings.

17.7 Setting Parameters

Details the procedure for setting parameters, including entering set values and registering register symbols.

17.8 Creating User File Information

Explains how to create user file information for data sheets submitted to customers.

17.9 Downloading Data

Provides the procedure for downloading parameter data to the controller, including communication conditions.

17.10 Uploading Data

Details the procedure for uploading data such as user file name, system data, and parameter data from the controller.

17.11 Comparing Data with Controller’s Data

Explains how to compare file data with controller data to identify any mismatches.

17.12 Monitoring/Changing Data

Describes how to monitor and change tuning data, including trend display and data read cycle settings.

17.13 Managing Files

Covers file management operations such as creating, opening, saving, comparing, and managing environmental settings.

17.14 Window Operations

Explains how to perform window operations like cascading, tiling, arranging icons, and making toolbars visible/invisible.

17.15 Printing

Details the procedure for printing data, including selecting the print range and previewing the image.

17.16 Initializing the Controller

Explains how to initialize the controller to factory default values or user default values.

17.17 Checking Software Version

Describes how to check the software version information of the Parameter Setting Tool.

17.18 Viewing the List of Tables

Explains how to view the list of .dll and .xml files contained in the Table folder.

Chapter 18: Communication Overview

18.1 PPC5 Controller Communication

Provides an overview of the PPC5 controller's communication capabilities, including RS-485 and Ethernet.

18.2 RS-485 Communication (PPC5-1x01 Models)

Details the RS-485 communication protocols, specifications, and connection methods.

18.3 Ethernet Communication (PPC5-1x02 Models)

Explains Ethernet communication capabilities for PPC5-1x02 models, including Modbus/TCP protocol.

18.4 Coordinated Communication (PPC5-1x01 Models)

Describes the coordinated operation function where PPC5 controllers act as master and slave.

Chapter 19: Communication Settings

19.1 Setting Parameters

Covers setting parameters for RS-485, Ethernet, and Coordinated Operation.

19.2 Setting Communication Write Permit

Explains how to permit or prohibit writing to registers via communication protocols.

Chapter 20: Modbus Communication

20.1 Modbus Communication (PPC5-1x01 Models)

Provides an overview of Modbus communication, including parameter placement, configuration, and message structures.

Chapter 21: Modbus/TCP Communication

21.1 Overview

Introduces Modbus/TCP communication protocol for PPC5-1x02 models via Ethernet or other networks.

21.2 TCP/IP-based Communication (PPC5-1x02 Models)

Explains the Modbus/TCP transaction procedure on the TCP/IP socket interface.

21.3 Configuration of Network Frames

Details the configuration of Modbus/TCP frames, including MBAP Header and PDU.

21.4 Communication with Host Computer

Lists Modbus function codes and explains requests, responses, and error codes for host communication.

21.5 Ethernet-Serial Gateway Function (PPC5-1x02 Models)

Describes the Ethernet-serial gateway function allowing access to RS-485 devices via Ethernet.

21.6 Process Data High-speed Response Function

Explains the function to read process data from PPC5 and serial devices at high speed.

21.7 IP Access Restriction Function

Details the IP access control function to permit access from registered IP addresses and reject others.

Chapter 22: Coordinated Operation

22.1 Overview

Introduces coordinated operation with a master controller and multiple slave PPC5 controllers.

22.2 Coordinated Items

Lists items that controllers operate in coordination with, such as Super function start-up and operation mode switching.

22.3 Starting Coordinated Operation

Provides steps for starting coordinated operation after wiring and communication setup.

Chapter 23: D Registers (Holding Registers)

23.1 Overview

Describes the functions and applications of D registers used in Modbus and Ethernet communications.

23.2 Conventions Used in D Register Tables

Explains conventions used in D register map tables, including register numbers, symbols, and read/write attributes.

23.3 Classification of D Registers

Outlines how D registers are classified by their numbers in the D register map tables.

23.4 D Registers

Details D registers for process monitoring, loop operation parameters, setup parameters, and terminal status.

23.5 Writing via Communication

Explains how to write data to registers via communication, including setting target setpoints and control output values.