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14-7

PPC Manual Revision 1

Chapter 14: Troubleshooting

Errors during Operation (2)

The errors shown below may occur during operation.

PV display

(Operation

Display)

Setpoint display

(Operation

Display)

Status indicator

(Operation

Display)

Parameter

that

displays error

details

Error description

Cause and diagnosis

Remedy

Normal

indication

RSP B.OUT

–

Setup

parameter

(PV1.E/PV2.E)

Burnout error when RSP

input is used for control

(Loop 1, Loop 2)

Burnout error of analog

input connected to RSP

when RSP is used for

control computation

Check wiring and

sensor.

Error indication is

erased in normal

operation.

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

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