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PPC Manual Revision 1

Setup Procedure

The following flowchart shows the setup procedure for the PPC5 controller.

Install and wire a controller.

Monitoring and control of regular operations

Adjust PID using auto-tuning or manually in PID control.

Other setup

Operation

YES

Control mode: Single-loop control only

Set the other parameters as necessary.

PID tuning

Input setup

Output setup

Installation

and Wiring

Power ON

Control mode setup

Control type setup

Input/output setup

Use

Quick setting

function?

Main Page

default chapter3
- Table of Contents3
- Overview of this Publication11
- Safety Precautions11
- Who Should Read this Manual11
- Checking the Contents of the Package13
- Handling Precautions for the Controller13
- PPC5 Models and Description14
- Symbols Used in this Manual16
- Setup Procedure17
Chapter 1 - Installation and Wiring18
- Installation Location19
- Mounting Method21
- Mounting the Controller21
- External Dimensions and Panel Cutout Dimensions22
- Mounting the Controller22
- Wiring23
- Important Information on Wiring23
- PV Input Wiring25
- Remote Auxiliary Analog Input Wiring (PPC5-110X Models)26
- Control Output (Relay, Current and Voltage Pulse) Wiring27
- Contact Input Wiring29
- Alarm Contact Output Wiring31
- Retransmission Output Wiring32
- DC Loop Power Supply Wiring32
- Communication Interface Wiring (PPC5-1X01 Models)33
- Coordinated Operation Wiring (PPC5-1X01 Models)34
- Ethernet Communication Interface Wiring (PPC5-1X02 Models)35
- Power Supply Wiring37
- Attaching and Detaching Terminal Cover38
Chapter 2 - Introduction to Unit, Key, and Display Functions39
- Definition of Main Symbols and Terms40
- Input/Output Function41
- Display and Key Functions43
- Communication Functions44
- Names and Functions of Display Parts46
- Names and Functions of Keys48
- List of Display Symbols49
- Overview of Display Switch and Operation Keys51
- How to Set Parameters54
Chapter 3 - Quick Setting Function58
- Setting Using Quick Setting Function59
- Restarting Quick Setting Function64
Chapter 4: Operation Monitoring and Control65
- Monitoring and Control of Operation Displays66
- Operation Display Transitions in Single-Loop Control, Cascade Primary-Loop Control, Cascade Secondary-Loop Control, Loop Control for Backup, and Loop Control with PV-Hold Function66
- Operation Display Transitions in Loop Control with PV Switching and Loop Control with PV Auto-Selector67
- Operation Display Transitions in Loop Control with PV Switching and Loop Control with PV Auto- Selector67
- Operation Display Transitions in Cascade Control68
- Setting Target Setpoint74
- Performing and Canceling Auto-Tuning76
- Adjusting PID Manually79
- Setting Alarm Setpoint85
- Selecting Target Setpoint Number (SPNO)86
- Switching Operation Modes87
- Switching between AUTO and man87
- Switching between cas (Cascade), AUTO, and man89
- Switching between STOP and RUN91
- Switching between REM (Remote) and LCL (Local)93
- Manipulating Control Output During Manual Operation94
- Releasing On-State (Latch) of Alarm Output96
Chapter 5 - Input Setting Functions97
- Setting Functions of PV Input and Remote Auxiliary Analog Input98
- Setting Input Type, Unit, Range, Scale, and Decimal Point Position98
- Setting Burnout Detection for Input101
- Setting Reference Junction Compensation (RJC) or External Reference Junction Compensation (ERJC)102
- Correcting Input Value103
- Setting Ratio Bias/Filter108
- Setting Input Sampling Period (Control Period)109
- Using Larger, Smaller, Average, or Difference of Two Inputs as PV110
- Setting Remote Input Method111
- Adjusting PV Range for Loop Control with PV Switching or Loop Control with PV Auto-Selector112
- Setting PV Switching Methods of Loop Control with PV Switching113
Chapter 6 - Control Mode Settings117
- Setting Control Mode (CTLM)118
- Single-Loop Control118
- Cascade Primary-Loop Control120
- Cascade Secondary-Loop Control122
- Cascade Control124
- Loop Control for Backup126
- Loop Control with PV Switching128
- Loop Control with PV Auto-Selector130
- Loop Control with PV-Hold Function132
- Setting Control Type (CNT)134
- PID Control135
- ON/OFF Control (1 Point of Hysteresis / 2 Points of Hysteresis)136
- PD Control (Stable Control in Which a Setpoint Is Not Exceeded)138
- Sample PI Control (Controlling a Process with Long Dead Time)139
- Batch PID Control (Performing Control with Rapidly Settling Setpoints)141
- Setting PID Control Mode (ALG)143
- Switching PID145
- Switching PID According to Target Setpoint Number (SPNO)145
- Switching PID According to PV146
- Switching PID According to SP148
- Switching PID According to Target SP150
- Switching PID According to Deviation (Reference Deviation)152
- Setting Hysteresis at Time of PID Switch153
- Switching PID by Contact Input153
- Suppressing Overshoot (Super Function)154
- Suppressing Hunting (Super2 Function)156
- Suppressing Integral Action (Anti-Reset Wind-Up)158
- Performing Non-Linear PID Control159
- Adjusting Auto-Tuning Operation160
Chapter 7 - Setpoint Functions161
- Setting SP Limiter162
- Changing SP at a Fixed Rate (SP Ramp-Rate Setting Function)163
- Forcing SP to Track PV (PV Tracking)165
- Forcing SP to Track Remote Input (SP Tracking)166
Chapter 8 - Output Setting Functions167
- Setting Control Output Type168
- Setting Control Output Cycle Time170
- Setting Limiter to Control Output171
- Disabling Output Limiter in man Mode172
- Setting Velocity Limiter to Control Output173
- Reducing 4-20 Ma Current Output to 0 Ma (Tight Shut Function)174
- Setting ON/OFF Control Hysteresis175
- Canceling Offset of PV and SP (Manual Reset)177
- Setting Retransmission Output Terminal, Type, and Scales178
- Setting Preset Output Value180
- Setting Output Value in STOP Mode (Preset Output)180
- Setting Output Value When Switched to man Mode (Manual Preset Output)181
- Setting Output Value When Error Occurs (Input Error Preset Output)183
- Setting 10-Segment Linearizer for Output184
- Changing Current Output Range186
- Setting Split Computation Output Function187
- Using 15 V DC Loop Power Supply189
Chapter 9 - Alarm Functions191
- Setting Alarm Type192
- Setting Number of Alarm Groups to Use204
- Setting Hysteresis to Alarm Operation205
- Delaying Alarm Output (Alarm Delay Timer)206
- Setting Alarm Output to Control Relay Terminal207
- Setting Alarm Action According to Operation Mode208
Chapter 10: Contact Input and Output Functions209
- Setting Contact Input Function210
- Changing Contact Type of Contact Input220
- Setting Contact Output Function221
- Setting Function of Contact Output221
- Changing Contact Type of Contact Output226
Chapter 11 - Setting Display and Key Functions227
- Setting Display Functions228
- Setting Active Color PV Display Function228
- Masking Arbitrary Display Value in Operation Display231
- Registering SELECT Display (up to 5 Displays)232
- Changing Event Display233
- Registering SELECT Parameter Display (up to 10 Displays)235
- Setting Bar-Graph Display Function237
- Masking Least Significant Digit of PV Display239
- Changing Deviation Display Lamp Action240
- Setting Economy Mode241
- Selecting the Initial Operation Display that Appears at Power on242
- Setting Message Function243
- Switching Guide Display Language243
- Changing Guide Scroll Speed244
- Turning Guide Display ON/OFF244
- Setting Automatic Return to Operation Display244
- Assigning Function to User Function Key and A/M Key246
- Setting Security Functions249
- Setting or Clearing the Password249
- Setting Parameter Display Level249
- Locking (Hiding) Parameter Menu Display250
- Key Lock252
- Setting Display/Non-Display of Operation Display252
- Prohibiting Writing Via Communication253
- Confirmation of Key and I/O Condition and Version254
- Confirmation of Key and I/O Condition254
- Confirmation of Version257
Chapter 12 - Resetting Default Values258
- Initializing Parameter Settings to Factory Default Values259
- Registering and Initializing User Default Values260
- Registering User Settings as Default Values260
- Initializing to User Setting (Default) Values260
Chapter 13 - Power Failure Recovery261
- Remedies if Power Failure Occurs During Operations262
- Setting Time between Powering on Controller and Starting Control (Restart Timer)263
- Power Frequency Setting264
Chapter 14 - Troubleshooting266
- Troubleshooting266
- Troubleshooting Flowchart266
- Maintenance279
- Cleaning279
- Disposal279
Chapter 15 - Parameter Settings280
- Parameter Map281
- List of Parameters288
- Operation Parameters288
- Setup Parameters296
Chapter 16: Software Functional Overview321
- Functional Overview322
- Connecting the Controller to a PC and Setting Parameters324
Chapter 17: Software Setting Flow and Navigation330
- Setting Flow331
- Starting Up/Exiting the Parameter Setting Software332
- Window Names and Functions334
- Creating New Parameter File Using the Wizard Function337
- Setting the Parameter View Level343
- Setting System Data344
- Setting Parameters347
- Creating User File Information351
- Downloading Data352
- Uploading Data354
- Comparing Data with Controller's Data356
- Monitoring/Changing Data358
- Monitoring/Changing Tuning Data358
- Setting Data Read Cycle369
- Managing Files370
- Creating a New File370
- Opening a User File371
- Setting/Clearing a User File Password372
- Closing a File373
- Saving by Overwrite373
- Saving a File373
- Comparing with File Data374
- Saving Tuning Data375
- Saving a CSV File377
- Making Environmental Settings378
- Window Operations380
- Printing381
- Initializing the Controller382
- Checking Software Version384
- Viewing the List of Tables385
Chapter 18 - Communication Overview386
- PPC5 Controller Communication387
- Communication (PPC5-1X01 Models)388
- Communication Specifications388
- Ethernet Communication (PPC5-1X02 Models)389
- Communication Specifications389
- Coordinated Communication (PPC5-1X01 Models)391
- Communication Specifications391
Chapter 19 - Communication Settings392
- Setting Parameters393
- Setting RS-485 Communication (PPC5-1X01 Models)393
- Setting Ethernet Communication (PPC5-1X02 Models)395
- Setting Coordinated Operation (PPC5-1X01 Models)397
- Setting Communication Write Permit398
Chapter 20 - Modbus Communication399
- Modbus Communication (PPC5-1X01 Models)400
- Overview400
- Configuration of Messages402
- Configuration of Responses406
- Specifying Broadcast407
- Messages and Responses408
- Reading Multiple I Relays409
- Reading Multiple D Registers410
- Writing to an I Relay411
- Writing to a D Register411
- Loopback Test412
- Writing to Multiple I Relays413
- Writing to Multiple D Registers414
Chapter 21 - Modbus/Tcp Communication415
- Overview416
- Overview417
- TCP/IP-Based Communication (PPC5-1X02 Models)418
- Configuration of Network Frames419
- Configuration of MBAP Header419
- Configuration of PDU419
- Communication with Host Computer420
- List of Function Codes420
- Requests and Responses421
- Reading Multiple I Relays421
- Reading Multiple D Registers421
- Writing to an I Relay422
- Writing to a D Register422
- Loopback Test423
- Writing to Multiple I Relays424
- Writing to Multiple D Registers425
- Response Error Codes426
- Ethernet-Serial Gateway Function (PPC5-1X02 Models)427
- Overview427
- Communication with Serial Devices428
- Process Data High-Speed Response Function429
- Overview429
- How to Set the Function430
- Process Data for High-Speed Response430
- IP Access Restriction Function431
Chapter 22 - Coordinated Operation432
- Overview433
- Coordinated Items434
- Starting Coordinated Operation435
Chapter 23 - D Registers (Holding Registers)436
- Overview437
- Conventions Used in D Register Tables438
- Classification of D Registers439
- D Registers439
- Process Monitoring440
- 10-Segment Linearizer Setting Parameter (D4801 to D5000)440
- Input / Output Terminal Status Register (D7601 to D7700)440
- D Registers441
- Process Monitoring441
- Process Data Area443
- Process Data (D2001 to D2100)443
- Current SP Group and PID Group (D2101 to D2200)451
- Loop-1 Operation Parameter (D2501 to D3600)452
- Loop-1 SP and Alarm Setpoint Setting of Groups 1 to 8 (D2501 to D2700)459
- Loop-1 SP-Related Setting (D2701 to D2800)460
- Loop-1 Alarm Function Setting (D2801 to D2900)461
- Loop-1 PV-Related Setting (D2901 to D3000)462
- Loop-1 PID Setting of Groups 1 to 8 and R (D3001 to D3500)463
- Loop-1 Control Action-Related Setting (D3501 to D3600)465
- Loop-2 Operation Parameter (D3601 to D4700)466
- Loop-2 SP and Alarm Setpoint Setting of Groups 1 to 8 (D3601 to D3800)472
- Loop-2 SP-Related Setting (D3801 to D3900)473
- Loop-2 Alarm Function Setting (D3901 to D4000)474
- Loop-2 PV-Related Setting (D4001 to D4100)475
- Loop-2 PID Setting of Groups 1 to 8 and R (D4101 to D4600)476
- Loop-2 Control Action-Related Setting (D4601 to D4700)478
- P Parameter (D4701 to D4800)479
- 10-Segment Linearizer Setting Parameter (D4801 to D5000)479
- Setup Parameters (D5001 to D7000)482
- Control Function Setting (D5001 to D5100)491
- Input Setting (D5101 to D5300)492
- Output Setting (D5301 to D5400)495
- Communication Setting (D5501 to D5700)498
- Key Operation Setting, Display Function Setting, and SELECT Display Setting (D5701 to D5800)500
- Lock Setting (Key Lock/Menu Lock) (D5801 to D5900)505
- DI Function Setting (D5901 to D6200)507
- DO Function Setting (D6201 to D6300)509
- I/O Display (D6301 to D6400)511
- System Setting (D6401 to D6500)512
- Registers (D7001 to D7600)513
- For Input Calculation (D7001 to D7100)517
- For Output Calculation (D7101 to D7200)518
- Status Registers (D7201 to D7300)518
- Constant Register (D7301 to D7330)520
- Input Range / Scale (D7501 to D7600) (Read Only)520
- Input / Output Terminal Status Register (D7601 to D7700)522
- Writing Via Communication523
Chapter 24 - I Relays (Coil)524
- Overview525
- Classification of I Relays526
- System Error, Input Error, and Operation Mode (4001 to 4320)531
- Alarm, Alarm Latch (4321 to 4576)531
- SP Number and PID Number (4577 to 4704)532
- Key (4705 to 4768)532
- Display, PV Event Status and Time Event Status (4769 to 5024)532

Automationdirect.com prosense PPC5 Series - Setup Procedure

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