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

Please include the Manual Number and the Manual Issue, both shown below, when
communicating with Technical Support regarding this publication.
Manual Number: PPC5-USER-M
Issue: 1st Edition
Issue Date: 04/20
ProSense
Advanced Process
Controllers
Publication History
Issue Date Description of Changes
1st Edition 04/20 Original Issue

i
PPC Manual Revision 1
Preface
Contents
Overview of this Publication .............................................................................................................................. a
Who Should Read This Manual......................................................................................................................... a
Safety Precautions ............................................................................................................................................ a
Handling Precautions for the Controller............................................................................................................. c
Checking the Contents of the Package ............................................................................................................. c
PPC5 Models and Description........................................................................................................................... d
Symbols Used in This Manual ............................................................................................................................ f
Setup Procedure................................................................................................................................................ g
Chapter 1 - Installation and Wiring .........................................................................1-1
1.1 Installation Location........................................................................................................................... 1-2
1.2 Mounting Method............................................................................................................................... 1-4
Mounting the Controller ................................................................................................................................................1-4
1.3 External Dimensions and Panel Cutout Dimensions.......................................................................................1-5
Mounting the Controller ................................................................................................................................................1-5
1.4 Wiring ................................................................................................................................................ 1-6
1.4.1 Important Information on Wiring..........................................................................................................1-6
1.4.2 PV Input Wiring ...................................................................................................................................1-8
1.4.3 Remote Auxiliary Analog Input Wiring (PPC5-110x models)...............................................................1-9
1.4.4 Control Output (Relay, Current and Voltage Pulse) Wiring ...............................................................1-10
1.4.5 Contact Input Wiring .........................................................................................................................1-12
1.4.6 Alarm Contact Output Wiring ............................................................................................................1-14
1.4.7 Retransmission Output Wiring .........................................................................................................1-15
1.4.8 15 V DC Loop Power Supply Wiring .................................................................................................1-15
1.4.9 RS-485 Communication Interface Wiring (PPC5-1x01 Models) .......................................................1-16
1.4.10 Coordinated Operation Wiring (PPC5-1x01 Models) ........................................................................1-17
1.4.11 Ethernet Communication Interface Wiring (PPC5-1x02 Models)......................................................1-18
1.4.12 Power Supply Wiring.........................................................................................................................1-20
1.5 Attaching and Detaching Terminal Cover ........................................................................................ 1-21
Chapter 2 - Introduction to Unit, Key, and Display Functions ..............................2-1
2.1 Definition of Main Symbols and Terms .............................................................................................. 2-2
2.2 Input/Output Function........................................................................................................................ 2-3
2.3 Display and Key Functions................................................................................................................ 2-5
Preface

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Preface
2.4 Communication Functions................................................................................................................. 2-6
2.5 Names and Functions of Display Parts ............................................................................................. 2-8
2.6 Names and Functions of Keys ........................................................................................................ 2-10
2.7 List of Display Symbols ................................................................................................................... 2-11
2.8 Overview of Display Switch and Operation Keys ............................................................................ 2-13
2.9 How to Set Parameters ................................................................................................................... 2-16
Chapter 3 - Quick Setting Function.........................................................................3-1
3.1 Setting Using Quick Setting Function................................................................................................ 3-2
3.2 Restarting Quick Setting Function..................................................................................................... 3-7
Chapter 4 - Operation Monitoring and Control ......................................................4-1
4.1 Monitoring and Control of Operation Displays................................................................................... 4-2
4.1.1 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 Function.......................................................4-2
4.1.2 Operation Display Transitions in Loop Control with PV Switching and Loop Control with PV Auto-selector
4-3
4.1.3 Operation Display Transitions in Cascade Control .............................................................................4-4
4.2 Setting Target Setpoint .................................................................................................................... 4-10
4.3 Performing and Canceling Auto-tuning............................................................................................ 4-12
4.4 Adjusting PID Manually ................................................................................................................... 4-15
4.5 Setting Alarm Setpoint..................................................................................................................... 4-21
4.6 Selecting Target Setpoint Number (SPNO) ..................................................................................... 4-22
4.7 Switching Operation Modes ............................................................................................................ 4-23
4.7.1 Switching between AUTO and MAN .................................................................................................4-23
4.7.2 Switching between CAS (Cascade), AUTO, and MAN .....................................................................4-25
4.7.3 Switching between STOP and RUN..................................................................................................4-27
4.7.4 Switching between REM (Remote) and LCL (Local).........................................................................4-29
4.8 Manipulating Control Output during Manual Operation........................................................................................... 4-30
4.9 Releasing On-State (Latch) of Alarm Output................................................................................... 4-32
Chapter 5 - Input Setting Functions........................................................................5-1
5.1 Setting Functions of PV Input and Remote Auxiliary Analog Input.................................................... 5-2
5.1.1 Setting Input Type, Unit, Range, Scale, and Decimal Point Position ..................................................5-2
5.1.2 Setting Burnout Detection for Input.....................................................................................................5-5
5.1.3 Setting Reference Junction Compensation (RJC) or External Reference Junction Compensation (ERJC)
5-6
5.1.4 Correcting Input Value.........................................................................................................................5-7
5.1.5 Setting Ratio bias/filter ......................................................................................................................5-12
5.2 Setting Input Sampling Period (Control Period) .............................................................................. 5-13
5.3 Using Larger, Smaller, Average, or Difference of Two Inputs as PV .............................................. 5-14
5.4 Setting Remote Input Method.......................................................................................................... 5-15
5.5 Adjusting PV Range for Loop Control with PV Switching or Loop Control with PV Auto-selector ........5-16
5.6 Setting PV Switching Methods of Loop Control with PV Switching ................................................. 5-17
Chapter 6 - Control Mode Settings..........................................................................6-1
6.1 Setting Control Mode (CTLM) ........................................................................................................... 6-2
6.1.1 Single-loop Control .............................................................................................................................6-2
6.1.2 Cascade Primary-loop Control............................................................................................................6-4
6.1.3 Cascade Secondary-loop Control .......................................................................................................6-6

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PPC Manual Revision 1
Preface
6.1.4 Cascade Control .................................................................................................................................6-8
6.1.5 Loop Control for Backup ...................................................................................................................6-10
6.1.6 Loop Control with PV Switching........................................................................................................6-12
6.1.7 Loop Control with PV Auto-selector ..................................................................................................6-14
6.1.8 Loop Control with PV-hold Function..................................................................................................6-16
6.2 Setting Control Type (CNT) ............................................................................................................. 6-18
6.2.1 PID Control .......................................................................................................................................6-19
6.2.2 ON/OFF Control (1 point of hysteresis / 2 points of hysteresis)........................................................6-20
6.2.3 PD Control (Stable Control in Which a Setpoint is not Exceeded)....................................................6-22
6.2.4 Sample PI Control (Controlling a Process with Long Dead Time) ....................................................6-23
6.2.5 Batch PID Control (Performing Control with Rapidly Settling Setpoints) ..........................................6-25
6.3 Setting PID Control Mode (ALG) ..................................................................................................... 6-27
6.4 Switching PID .................................................................................................................................. 6-29
6.4.1 Switching PID According to Target Setpoint Number (SPNO) ..........................................................6-29
6.4.2 Switching PID According to PV .........................................................................................................6-30
6.4.3 Switching PID According to SP .........................................................................................................6-32
6.4.4 Switching PID According to Target SP ..............................................................................................6-34
6.4.5 Switching PID According to Deviation (Reference Deviation)...........................................................6-36
6.4.6 Setting Hysteresis at Time of PID Switch..........................................................................................6-37
6.4.7 Switching PID by Contact Input ........................................................................................................6-37
6.5 Suppressing Overshoot (Super Function) ....................................................................................... 6-38
6.6 Suppressing Hunting (Super2 Function) ......................................................................................... 6-40
6.7 Suppressing Integral Action (Anti-reset Wind-up) ....................................................................................6-42
6.8 Performing Non-linear PID Control.................................................................................................. 6-43
6.9 Adjusting Auto-tuning Operation ..................................................................................................... 6-44
Chapter 7 - Setpoint Functions ...............................................................................7-1
7.1 Setting SP Limiter.............................................................................................................................. 7-2
7.2 Changing SP at a Fixed Rate (SP Ramp-Rate Setting Function) ..................................................... 7-3
7.3 Forcing SP to Track PV (PV Tracking) .............................................................................................. 7-5
7.4 Forcing SP to Track Remote Input (SP Tracking) .................................................................................7-6
Chapter 8 - Output Setting Functions.....................................................................8-1
8.1 Setting Control Output Type .............................................................................................................. 8-2
8.2 Setting Control Output Cycle Time .................................................................................................... 8-4
8.3 Setting Limiter to Control Output ....................................................................................................... 8-5
8.4 Disabling Output Limiter in MAN mode ............................................................................................. 8-6
8.5 Setting Velocity Limiter to Control Output.......................................................................................... 8-7
8.6 Reducing 4-20 mA Current Output to 0 mA (Tight Shut Function) .................................................... 8-8
8.7 Setting ON/OFF Control Hysteresis .................................................................................................. 8-9
8.8 Canceling Offset of PV and SP (Manual Reset).............................................................................. 8-11
8.9 Setting Retransmission Output Terminal, Type, and Scales ........................................................... 8-12
8.10 Setting Preset Output Value ............................................................................................................ 8-14
8.10.1 Setting Output Value in STOP Mode (Preset Output).......................................................................8-14
8.10.2 Setting Output Value When Switched to MAN Mode (Manual Preset Output) ..............................................8-15
8.10.3 Setting Output Value When Error Occurs (Input Error Preset Output)..............................................8-17
8.11 Setting 10-segment Linearizer for Output ....................................................................................... 8-18
8.12 Changing Current Output Range..................................................................................................... 8-20
8.13 Setting Split Computation Output Function ..................................................................................... 8-21
8.14 Using 15 V DC Loop Power Supply ................................................................................................ 8-23

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Preface
Chapter 9 - Alarm Functions....................................................................................9-1
9.1 Setting Alarm Type ............................................................................................................................ 9-2
9.2 Setting Number of Alarm Groups to Use ......................................................................................... 9-14
9.3 Setting Hysteresis to Alarm Operation ............................................................................................ 9-15
9.4 Delaying Alarm Output (Alarm Delay Timer) ................................................................................... 9-16
9.5 Setting Alarm Output to Control Relay Terminal.............................................................................. 9-17
9.6 Setting Alarm Action According to Operation Mode......................................................................... 9-18
Chapter 10 - Contact Input and Output Functions ..............................................10-1
10.1 Setting Contact Input Function ........................................................................................................ 10-2
10.1.1 Setting Contact Input Function..........................................................................................................10-2
10.1.2 Changing Contact Type of Contact Input ........................................................................................10-12
10.2 Setting Contact Output Function ................................................................................................... 10-13
10.2.1 Setting Function of Contact Output.................................................................................................10-13
10.2.2 Changing Contact Type of Contact Output .....................................................................................10-18
Chapter 11 - Setting Display and Key Functions .................................................11-1
11.1 Setting Display Functions................................................................................................................ 11-2
11.1.1 Setting Active Color PV Display Function ......................................................................................... 11-2
11.1.2 Masking Arbitrary Display Value in Operation Display ...................................................................... 11-5
11.1.3 Registering SELECT Display (Up to 5 Displays)...............................................................................11-6
11.1.4 Changing Event Display.................................................................................................................... 11-7
11.1.5 Registering SELECT Parameter Display (Up to 10 Displays)........................................................... 11-9
11.1.6 Setting Bar-graph Display Function ................................................................................................ 11-11
11.1.7 Masking Least Significant Digit of PV Display ................................................................................ 11-13
11.1.8 Changing Deviation Display Lamp Action ....................................................................................... 11-14
11.1.9 Setting Economy Mode................................................................................................................... 11-15
11.1.10 Selecting the Initial Operation Display that Appears at Power ON ................................................. 11-16
11.1.11 Setting Message Function .............................................................................................................. 11-17
11.1.12 Switching Guide Display Language ................................................................................................ 11-17
11.1.13 Changing Guide Scroll Speed......................................................................................................... 11-18
11.1.14 Turning Guide Display ON/OFF ...................................................................................................... 11-18
11.1.15 Setting Automatic Return to Operation Display............................................................................... 11-18
11.1.16 Setting Brightness and Contrast Adjustment of LCD and Display Update Cycle............................ 11-19
11.2 Assigning Function to User Function Key and A/M Key ................................................................ 11-20
11.3 Setting Security Functions............................................................................................................. 11-23
11.3.1 Setting or Clearing the Password ................................................................................................... 11-23
11.3.2 Setting Parameter Display Level..................................................................................................... 11-23
11.3.3 Locking (Hiding) Parameter Menu Display ..................................................................................... 11-24
11.3.4 Key Lock ......................................................................................................................................... 11-26
11.3.5 Setting Display/Non-display of Operation Display .......................................................................... 11-26
11.3.6 Prohibiting Writing via Communication ........................................................................................... 11-27
11.4 Confirmation of Key and I/O Condition and Version...................................................................... 11-28
11.4.1 Confirmation of Key and I/O Condition ........................................................................................... 11-28
11.4.2 Confirmation of Version................................................................................................................... 11-31
Chapter 12 - Resetting Default Values ..................................................................12-1
12.1 Initializing Parameter Settings to Factory Default Values................................................................ 12-2
12.2 Registering and Initializing User Default Values.............................................................................. 12-3
12.2.1 Registering User Settings as Default Values ....................................................................................12-3
12.2.2 Initializing to User Setting (Default) Values .......................................................................................12-3
Chapter 13 - Power Failure Recovery ...................................................................13-1
13.1 Remedies if Power Failure Occurs during Operations .................................................................... 13-2
13.2 Setting Time between Powering on Controller and Starting Control (Restart Timer) ...................... 13-3
13.3 Power Frequency Setting ................................................................................................................ 13-4

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PPC Manual Revision 1
Preface
Chapter 14 - Troubleshooting................................................................................14-1
14.1 Troubleshooting............................................................................................................................... 14-2
14.1.1 Troubleshooting Flowchart................................................................................................................14-2
14.1.2 Errors at Power On ...........................................................................................................................14-3
14.1.3 Errors during Operation ....................................................................................................................14-5
14.2 Maintenance.................................................................................................................................. 14-15
14.2.1 Cleaning..........................................................................................................................................14-15
14.2.2 Disposal ..........................................................................................................................................14-15
Chapter 15 - Parameter Settings ...........................................................................15-1
15.1 Parameter Map................................................................................................................................ 15-2
15.2 List of Parameters ........................................................................................................................... 15-9
15.2.1 Operation Parameters.......................................................................................................................15-9
15.2.2 Setup Parameters ...........................................................................................................................15-17
Chapter 16 - Software Functional Overview.........................................................16-1
16.1 Functional Overview........................................................................................................................ 16-2
16.2 Connecting the Controller to a PC and Setting Parameters............................................................ 16-4
Chapter 17 - Software Setting Flow and Navigation............................................17-1
17.1 Setting Flow..................................................................................................................................... 17-2
17.2 Starting up/Exiting the Parameter Setting Software ........................................................................ 17-3
17.3 Window Names and Functions........................................................................................................ 17-5
17.4 Creating New Parameter File Using the Wizard Function............................................................... 17-8
17.5 Setting the Parameter View Level ................................................................................................. 17-14
17.6 Setting System Data...................................................................................................................... 17-15
17.7 Setting Parameters........................................................................................................................ 17-18
17.8 Creating User File Information ...................................................................................................... 17-22
17.9 Downloading Data ......................................................................................................................... 17-23
17.10 Uploading Data.............................................................................................................................. 17-25
17.11 Comparing Data with Controller’s Data......................................................................................... 17-27
17.12 Monitoring/Changing Data............................................................................................................. 17-29
17.12.1 Monitoring/Changing Tuning Data ..................................................................................................17-29
17.12.2 Setting Data Read Cycle.................................................................................................................17-40
17.13 Managing Files ............................................................................................................................. 17-41
17.13.1 Creating a New File ........................................................................................................................17-41
17.13.2 Opening a User File ........................................................................................................................17-42
17.13.3 Setting/Clearing a User File Password ...........................................................................................17-43
17.13.4 Closing a File ..................................................................................................................................17-44
17.13.5 Saving by Overwrite........................................................................................................................17-44
17.13.6 Saving a File ...................................................................................................................................17-44
17.13.7 Comparing with File Data................................................................................................................17-45
17.13.8 Saving Tuning Data.........................................................................................................................17-46
17.13.9 Saving a CSV File...........................................................................................................................17-48
17.13.10 Making Environmental Settings .............................................................................................................17-49
17.14 Window Operations ...................................................................................................................... 17-51
17.15 Printing ......................................................................................................................................... 17-52
17.16 Initializing the Controller ............................................................................................................... 17-53
17.17 Checking Software Version .......................................................................................................... 17-55
17.18 Viewing the List of Tables ............................................................................................................. 17-56
Chapter 18 - Communication Overview................................................................18-1
18.1 PPC5 Controller Communication .................................................................................................... 18-2
18.2 RS-485 Communication (PPC5-1x01 Models)................................................................................ 18-3
18.2.1 Communication Specifications..........................................................................................................18-3

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Preface
18.3 Ethernet Communication (PPC5-1x02 Models) .............................................................................. 18-4
18.3.1 Communication Specifications..........................................................................................................18-4
18.4 Coordinated Communication (PPC5-1x01 Models) ........................................................................ 18-6
18.4.1 Communication Specifications..........................................................................................................18-6
Chapter 19 - Communication Settings..................................................................19-1
19.1 Setting Parameters.......................................................................................................................... 19-2
19.1.1 Setting RS-485 Communication (PPC5-1x01 Models)....................................................................................... 19-2
19.1.2 Setting Ethernet Communication (PPC5-1x02 Models)....................................................................19-4
19.1.3 Setting Coordinated Operation (PPC5-1x01 Models) .......................................................................19-6
19.2 Setting Communication Write Permit .............................................................................................. 19-7
Chapter 20 - Modbus Communication ..................................................................20-1
20.1 Modbus Communication (PPC5-1x01 Models) ............................................................................... 20-2
20.1.1 Overview ...........................................................................................................................................20-2
20.1.2 Configuration of Messages ...............................................................................................................20-4
20.1.3 Configuration of Responses..............................................................................................................20-8
20.1.4 Specifying Broadcast ........................................................................................................................20-9
20.1.5 Messages and Responses..............................................................................................................20-10
01 Reading multiple I relays.................................................................................................................................. 20-11
03 Reading multiple D registers............................................................................................................................20-12
05 Writing to an I relay ..........................................................................................................................................20-13
06 Writing to a D register ......................................................................................................................................20-13
08 Loopback test...................................................................................................................................................20-14
15 Writing to multiple I relays................................................................................................................................20-15
16 Writing to multiple D registers ..........................................................................................................................20-16
Chapter 21 - Modbus/TCP Communication..........................................................21-1
21.1 Overview ......................................................................................................................................... 21-2
21.2 TCP/IP-based Communication
(PPC5-1x02 Models) .................................................................................................21-4
21.3 Configuration of Network Frames.................................................................................................... 21-5
21.3.1 Configuration of MBAP Header.........................................................................................................21-5
21.3.2 Configuration of PDU ........................................................................................................................21-5
21.4 Communication with Host Computer............................................................................................... 21-6
21.4.1 List of Function Codes ......................................................................................................................21-6
21.4.2 Requests and Responses.................................................................................................................21-7
01 Reading multiple I relays ...................................................................................................................................21-7
03 Reading multiple D registers .............................................................................................................................21-7
05 Writing to an I relay ............................................................................................................................................21-8
06 Writing to a D register ........................................................................................................................................21-8
08 Loopback test.....................................................................................................................................................21-9
15 Writing to multiple I relays................................................................................................................................21-10
16 Writing to multiple D registers .......................................................................................................................... 21-11
21.4.3 Response Error Codes ...................................................................................................................21-12
21.5 Ethernet-Serial Gateway Function
(PPC5-1x02 Models) ...............................................................................................21-13
21.5.1 Overview .........................................................................................................................................21-13
21.5.2 Communication with Serial Devices................................................................................................21-14
21.6 Process Data High-speed Response Function ............................................................................. 21-15
21.6.1 Overview .........................................................................................................................................21-15
21.6.2 How to Set the Function..................................................................................................................21-16
21.6.3 Process Data for High-speed Response.........................................................................................21-16
21.7 IP Access Restriction Function...................................................................................................... 21-17
Chapter 22 - Coordinated Operation.....................................................................22-1

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Preface
22.1 Overview ......................................................................................................................................... 22-2
22.2 Coordinated Items ........................................................................................................................... 22-3
22.3 Starting Coordinated Operation....................................................................................................... 22-4
Chapter 23 - D Registers (Holding Registers)......................................................23-1
23.1 Overview ......................................................................................................................................... 23-2
23.2 Conventions Used in D Register Tables.......................................................................................... 23-3
23.3 Classification of D Registers ........................................................................................................... 23-4
23.4 D Registers...................................................................................................................................... 23-6
23.4.1 Process Monitoring ...........................................................................................................................23-6
Process Data Area......................................................................................................................................................23-8
Process Data (D2001 to D2100).................................................................................................................................23-8
Current SP Group and PID Group (D2101 to D2200) ..............................................................................................23-16
23.4.2 Loop-1 Operation Parameter (D2501 to D3600).............................................................................23-17
Loop-1 SP and Alarm Setpoint Setting of Groups 1 to 8 (D2501 to D2700).............................................................23-24
Loop-1 SP-related Setting (D2701 to D2800)...........................................................................................................23-25
Loop-1 Alarm Function Setting (D2801 to D2900)....................................................................................................23-26
Loop-1 PV-related Setting (D2901 to D3000)...........................................................................................................23-27
Loop-1 PID Setting of Groups 1 to 8 and R (D3001 to D3500) ................................................................................23-28
Loop-1 Control Action-related Setting (D3501 to D3600) ........................................................................................23-30
23.4.3 Loop-2 Operation Parameter (D3601 to D4700).............................................................................23-31
Loop-2 SP and Alarm Setpoint Setting of Groups 1 to 8 (D3601 to D3800).............................................................23-37
Loop-2 SP-related Setting (D3801 to D3900)...........................................................................................................23-38
Loop-2 Alarm Function Setting (D3901 to D4000)....................................................................................................23-39
Loop-2 PV-related Setting (D4001 to D4100)...........................................................................................................23-40
Loop-2 PID Setting of Groups 1 to 8 and R (D4101 to D4600) ................................................................................23-41
Loop-2 Control Action-related Setting (D4601 to D4700) .........................................................................................23-43
23.4.4 P Parameter (D4701 to D4800) ......................................................................................................23-44
23.4.5 10-segment Linearizer Setting Parameter (D4801 to D5000).........................................................23-44
23.4.6 Setup Parameters (D5001 to D7000) .............................................................................................23-47
Control Function Setting (D5001 to D5100)..............................................................................................................23-56
Input Setting (D5101 to D5300) ................................................................................................................................23-57
Output Setting (D5301 to D5400) .............................................................................................................................23-60
Communication Setting (D5501 to D5700) ...............................................................................................................23-63
Key Operation Setting, Display Function Setting, and SELECT Display Setting (D5701 to D5800) ........................23-65
Lock Setting (Key Lock/Menu Lock) (D5801 to D5900)............................................................................................23-70
DI Function Setting (D5901 to D6200)......................................................................................................................23-72
DO Function Setting (D6201 to D6300)....................................................................................................................23-74
I/O Display (D6301 to D6400)...................................................................................................................................23-76
System Setting (D6401 to D6500) ............................................................................................................................23-77
23.4.7 Registers (D7001 to D7600) ...........................................................................................................23-78
For Input Calculation (D7001 to D7100) ...................................................................................................................23-82
For Output Calculation (D7101 to D7200) ................................................................................................................23-83
Status Registers (D7201 to D7300)..........................................................................................................................23-83
Constant Register (D7301 to D7330) ......................................................................................................................23-85
Input Range / Scale (D7501 to D7600) (Read only) ................................................................................................23-85
23.4.8 Input / Output Terminal Status Register (D7601 to D7700).............................................................23-87
23.5 Writing via Communication............................................................................................................ 23-88
Chapter 24 - I Relays (Coil) ....................................................................................24-1
24.1 Overview ......................................................................................................................................... 24-2
24.2 Classification of I Relays ................................................................................................................. 24-3
System Error, Input Error, and Operation Mode (4001 to 4320) .................................................................................24-8
Alarm, Alarm Latch (4321 to 4576).............................................................................................................................24-8
SP Number and PID Number (4577 to 4704) .............................................................................................................24-9
Key (4705 to 4768) .....................................................................................................................................................24-9
Display, PV Event Status and Time Event Status (4769 to 5024) ..............................................................................24-9

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Preface
Input (Status) Relay and Output (Status) Relay (5025 to 5280) ...............................................................................24-12
Control (Status) Relay (5281 to 5408) ......................................................................................................................24-12
Internal Relay (5537 to 5792) ...................................................................................................................................24-12
DI Terminals and DO Terminals (6305 to 6560)........................................................................................................24-12

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PPC Manual Revision 1
1st Edition : April 2020
All Rights Reserved, Copyright © 2020 AutomationDirect.com
Overview of this Publication
This User Manual describes the installation, configuration, and methods of operation of
the PPC5 series Prosense Advanced Process Controller.
Who Should Read This Manual
This manual contains important information for those who will install, maintain, and/or
operate any of the PPC5 series advanced process controllers.
Our technical support group is glad to work with you in answering your
questions. If you cannot find the solution to your particular application, or, if
for any reason you need additional technical assistance, please call technical
support at 770-844-4200. We are available weekdays Monday through Friday,
9:00 a.m.to 6:00 p.m. E.T.
We also encourage you to visit our web site where you can find technical and
non-technical information about our products and our company. Visit us at
www.automationdirect.com.
Safety Precautions
This instrument is a product of Installation Category II of IEC/EN/CSA/UL61010-1,
IEC/EN61010-2-201, IEC/EN61010-2-030 Safety Standards and Class A of EN61326-
1, EN55011 (EMC Standards). For use in Pollution Degree 2 environments.
CAUTION
This instrument is an EMC class A product. In a domestic environment, this
product may cause radio interference in which case the user needs to take
adequate measures.
The instrument is a product rated Measurement Category O (other).
* Measurement Category O (other)
This category applies to electric equipment that measures a circuit connected to a
low-voltage facility and receives power from stationary equipment such as electric
switchboards.

bPPC Manual Revision 1
To use the instrument properly and safely, observe the safety precautions described
in this user’ s manual when operating it. Use of the instrument in a manner not
prescribed herein may compromise protection features inherent in the device. We
assume no liability for or warranty on a fault caused by users’ failure to observe these
instructions.
This instrument is designed to be used within the scope of Measurement Category O
(other) and is dedicated for indoor use.
Notes on the User’ s Manual
• This user’ s manual should be readily accessible to the end users so it can be
referred to easily. It should be kept in a safe place.
• Read the information contained in this manual thoroughly before operating the
product.
• The purpose of this user’ s manual is not to warrant that the product is well suited
to any particular purpose, but rather to describe the functional details of the
product.
Safety, Protection, and Modification of the Product
The following symbols are used in the product and user’ s manuals to indicate safety
precautions:
AC
AC/DC
“Handle with Care” (This symbol is attached to the part(s) of the product to
indicate that the user’s manual should be referred to in order to protect the
operator and the instrument from harm.)
The equipment wholly protected by double insulation or reinforced insulation.
Functional grounding terminal (Do not use this terminal as a protective grounding terminal.)
• In order to protect the system controlled by this product and the product itself, and
to ensure safe operation, observe the safety precautions described in this user’ s
manual. Use of the instrument in a manner not prescribed herein may compromise
the product’ s functions and the protection features inherent in the device.
We assume no liability for safety, or responsibility for the product’ s quality,
performance or functionality should users fail to observe these instructions when
operating the product.
• Installation of protection and/or safety circuits with respect to a lightning
protector; protective equipment for the system controlled by the product and the
product itself; foolproof or failsafe design of a process or line using the system
controlled by the product or the product itself; and/or the design and installation
of other protective and safety circuits are to be appropriately implemented as the
customer deems necessary.
• This product is not designed or manufactured to be used in critical applications
that directly a󱐯ect or threaten human lives. Such applications include nuclear
power equipment, devices using radioactivity, railway facilities, aviation equipment,
air navigation facilities, aviation facilities, and medical equipment. If so used, it is
the user’ s responsibility to include in the system additional equipment and devices
that ensure personnel safety.
• Modication of the product is strictly prohibited.
• This product is intended to be handled by skilled/trained personnel for electric
devices.
• This product is UL Recognized Component. In order to comply with UL standards,
end-products are necessary to be designed by those who have knowledge of the
requirements.

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PPC Manual Revision 1
WARNING
● Power Supply
Ensure that the instrument’ s supply voltage matches the voltage of the
power supply before turning ON the power.
● Do Not Use in an Explosive Atmosphere
Do not operate the instrument in locations with combustible or explosive
gases or steam. Operation in such environments constitutes an extreme safety
hazard. Use of the instrument in environments with high concentrations of
corrosive gas (H2S, SOX, etc.) for extended periods of time may cause a failure.
● Do Not Remove Internal Unit
● Damage to the Protective Construction
Operation of the instrument in a manner not specified in this user’ s manual
may damage its protective construction.
Handling Precautions for the Controller
• The instrument comprises many plastic components. To clean it, wipe it with a soft,
dry cloth. Do not use organic solvents such as benzene or thinner for cleaning, as
discoloration or deformation may result.
• Keep electrically charged objects away from the signal terminals. Not doing so may
cause the instrument to fail.
• Do not apply volatile chemicals to the display area, operation keys, etc. Do not
leave the instrument in contact with rubber or PVC products for extended periods.
Doing so may result in failure.
• If the equipment emits smoke or abnormal smells or makes unusual noises, turn
OFF the instrument’ s power immediately and unplug the device. In such an event,
contact AutomationDirect Technical Support.
Checking the Contents of the Package
Unpack the box and check the contents before using the product. If the product is
different from that which you have ordered, if any parts or accessories are missing, or
if the product appears to be damaged, contact AutomationDirect.
PPC5 Controller
The PPC5 controllers have nameplates affixed to the side of the case.
Check the model inscribed on the nameplate to confirm that the product received is
that which was ordered.

dPPC Manual Revision 1
PPC5 Models and Description
Model Description
PPC5-1000
ProSense advanced process controller, 1/4 DIN, 2-line alpha-numeric LCD, bar
graph LCD, current, voltage, RTD, thermocouple, discrete input, current, voltage
pulse, relay, retransmission output, 100-240 VAC operating voltage.
PPC5-1001
ProSense advanced process controller, 1/4 DIN, 2-line alpha-numeric LCD, bar
graph LCD, current, voltage, RTD, thermocouple, discrete input, current, voltage
pulse, relay, retransmission output, 100-240 VAC operating voltage, RS-485.
PPC5-1002
ProSense advanced process controller, 1/4 DIN, 2-line alpha-numeric LCD, bar
graph LCD, current, voltage, RTD, thermocouple, discrete input, current, voltage
pulse, relay, retransmission output, 100-240 VAC operating voltage, Ethernet.
PPC5-1100
ProSense advanced process controller, 1/4 DIN, 2-line alpha-numeric LCD, bar
graph LCD, current, voltage, RTD, thermocouple, discrete, auxiliary analog input,
current, voltage pulse, relay, retransmission output, 100-240 VAC operating
voltage.
PPC5-1101
ProSense advanced process controller, 1/4 DIN, 2-line alpha-numeric LCD, bar
graph LCD, current, voltage, RTD, thermocouple, discrete, auxiliary analog input,
current, voltage pulse, relay, retransmission output, 100-240 VAC operating
voltage, RS-485.
PPC5-1102
ProSense advanced process controller, 1/4 DIN, 2-line alpha-numeric LCD, bar
graph LCD, current, voltage, RTD, thermocouple, discrete, auxiliary analog input,
current, voltage pulse, relay, retransmission output, 100-240 VAC operating
voltage, Ethernet.
Accessories
The product is provided with the following accessories. Check that none of them are
missing or damaged.
1 2
3
4

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PPC Manual Revision 1
No. Product Name Quantity
1 Brackets 2
2 Terminal cover 1
3 Unit label 1
4Installation Instructions
and User’ s Guide 1
How to use the unit label
• Affix the unit label to the front panel. If necessary, combine with unit prefixes. Affix it so
that the LCD area is not blocked.
• Maintenance port seals (two spares) are available. Use them if the seal affixed to the
controller loses its adhesiveness.

fPPC Manual Revision 1
Symbols Used in This Manual
This symbol is used on the instrument. It indicates the possibility of injury to the
user or damage to the instrument, and signifies that the user must refer to the user’
s manual for special instructions. The same symbol is used in the user’ s manual on
pages that the user needs to refer to, together with the term “WARNING” or “CAUTION.”
WARNING
Calls attention to actions or conditions that could cause serious or fatal injury to the
user, and indicates precautions that should be taken to prevent such occurrences.
CAUTION
Calls attention to actions or conditions that could cause injury to the user or damage
to the instrument or property and indicates precautions that should be taken to
prevent such occurrences.
Note
Identifies important information required to operate the instrument.
Indicates related operations or explanations for the user’ s reference.
[ ]
Indicates a character string displayed on the display.
Setting Display
Indicates a setting display and describes the keystrokes required to display the
relevant setting display.
Setting Details
Provides the descriptions of settings.
Description
Describes restrictions etc. regarding a relevant operation.

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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
NO
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
Control type setup
Input/output setup
Use
Quick setting
function?

1-1
PPC Manual Revision 1
Chapter 1: Installation and Wiring

1


Contents
  1-2
  1-4
 1-5
  1-6
 1-6
 1-8
 1-9
 
 1-12
 1-14
 1-15
 1-15
 1-16
 1-17
 1-18
 
 1-21
C  - I  W

1-2 PPC Manual Revision 1
Chapter 1: Installation and Wiring
1.1 Installation Location

 

 






 
 

 
 
Front panel
of controller Keep this angle
within 30°
Rear of
controller
30°
Note






1-3
PPC Manual Revision 1
Chapter 1: Installation and Wiring
Do not mount the instrument in the following locations:
 
 
  


 

  
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
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  
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


 
150 mm150 mm
150 mm
150 mm
 