FACTS Engineering Direct Logic 405 User manual

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D i r e c t L o g i c 4 0 5
F o u r L o o p T e m p e r a t u r e C o n t r o l l e r
F 4 - 4 L T C
Manual Order Number: F4-4LTC-M

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Last Issued Date: June 1999
Current Issued Date: September 1999

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installs or uses this equipment should read this publication (and any other relevant
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At a minimum, you should follow all applicable sections of the National Fire Code,
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WARNING

CHAPTER 1: INTRODUCTION .................................................... 1.1
GENERAL DESCRIPTION .................................................. 1.1
TEMPERATURE CONTROL ................................................. 1.1
CONTROLLER I/O ........................................................ 1.1
OPERATOR INTERFACE ................................................... 1.1
Users ............................................................ 1.1
OEMs ............................................................ 1.1
ALARMING AND DIAGNOSTICS ............................................. 1.2
LEDs ............................................................ 1.2
Alarms ........................................................... 1.2
Low Level Diagnostics ............................................... 1.2
High Level Diagnostics ............................................... 1.2
OPERATIONAL SPECIFICATIONS ........................................... 1.3
ALARM SPECIFICATIONS .................................................. 1.3
TEMPERATURE CONTROLLER HARDWARE SPECIFICATIONS ................... 1.4
General Specifications ............................................... 1.4
Environmental Specifications .......................................... 1.4
Voltage Input Specifications ........................................... 1.5
Thermocouple Input Specifications ...................................... 1.5
RTD Input Specifications ............................................. 1.5
CHAPTER 2: INSTALLATION AND WIRING .......................................... 2.1
STEPS FOR F4-4LTC INSTALLATION ........................................ 2.1
SET CONFIGURATION JUMPERS ........................................... 2.2
RTD Inputs ........................................................ 2.2
Voltage or Thermocouple Inputs ........................................ 2.2
UNUSED TEMPERATURE INPUTS ........................................... 2.2
INSTALL F4-4LTC IN CPU BASE ............................................. 2.3
LED STATUS INDICATORS .......................................... 2.3
RTD CONNECTION DIAGRAM .............................................. 2.4
THERMOCOUPLE CONNECTION DIAGRAM ................................... 2.5
GROUNDED VS UNGROUNDED THERMOCOUPLES ............................ 2.6
Grounded Thermocouple Assembly ..................................... 2.6
Ungrounded Thermocouple Assembly ................................... 2.6
Exposed Grounded Thermocouple ...................................... 2.6
MAXIMIZING THERMOCOUPLE MEASUREMENT PRECISION ..................... 2.7
Ambient Temperature Variations ....................................... 2.7
Thermocouple Wiring Distance Limitations ................................ 2.7
DEDICATED V-MEMORY MAP .............................................. 2.8
Table Beginning Address ............................................. 2.8
Operating Mode and Loops Enabled ..................................... 2.9
Operating Mode .............................................. 2.9
Loops Enabled ............................................... 2.9
Error Flag ........................................................ 2.10
Fatal Errors ................................................ 2.10
Warning Errors ............................................. 2.10
Version .......................................................... 2.10
TEMPERATURE CONTROLLER LOOP CONFIGURATION MEMORY ............... 2.11
TEMPERATURE CONTROLLER LOOP CONFIGURATION MEMORY MAP, 1 LOOP
......................................................... 2.12
TABLE OF CONTENTS

TEMPERATURE CONTROL PARAMETER DESCRIPTIONS ....................... 2.13
Bit Mapped Mode Word (V5000) ...................................... 2.13
Usage of Mode Bits .......................................... 2.14
Temperature Set point (V5001) ....................................... 2.14
Output Bias (V5002) ................................................ 2.15
Output (V5003) .................................................... 2.15
Bit Mapped Alarm Word (V5004) ...................................... 2.16
Process Temperature (V5005) ........................................ 2.16
Gain (V5006) ..................................................... 2.17
Reset (V5007) .................................................... 2.17
Rate (V5010) ..................................................... 2.17
Temperature Low Alarm (V5011) ...................................... 2.17
Temperature High Alarm (V5012) ...................................... 2.18
Temperature Deviation Alarm (V5013) .................................. 2.18
Alarm Deadband (V5014) ............................................ 2.18
Setpoint Low Limit (V5015) ........................................... 2.18
Setpoint High Limit (V5016) .......................................... 2.18
Input Type (V5017) ................................................. 2.19
PID Control Period (V5020) .......................................... 2.20
ON/OFF Hysteresis (V5021) .......................................... 2.20
Temperature Calibration Adjustment (V5022) ............................. 2.21
TEMPERATURE CONTROLLER MEMORY MAP, 4 LOOPS ....................... 2.21
CHAPTER 3: SUPPORTING LADDER LOGIC ......................................... 3.1
SLOT DEPENDENT CONFIGURATION ........................................ 3.1
RE-READ LOOP PARAMETERS ............................................. 3.1
ALARM WORD DECODING ................................................. 3.2
ALARM WORD ENCODING ................................................. 3.2
FORCE OUTPUT ON/OFF (MANUAL OVER-RIDE) ............................... 3.3
DISCRETE OUTPUT STATUS ............................................... 3.4
NEGATIVE TEMPERATURES ............................................... 3.4
POSITIONING ACTUATOR CONTROL LOOPS .................................. 3.5
SETPOINT RAMP AND SOAK ............................................... 3.6
SetPoint Ramp ..................................................... 3.6
SetPoint Soak ..................................................... 3.8
CHAPTER 4: LOOP TUNING ...................................................... 4.1
AUTO TUNE PROCEDURE ................................................. 4.1
AUTO TUNE SEQUENCE .................................................. 4.2
AUTO TUNE TROUBLESHOOTING ........................................... 4.2
AUTO TUNE OPTIMIZATION ................................................ 4.4
USE AUTO TUNE TO BUILD RECIPES ........................................ 4.4
MANUAL PID TUNING ..................................................... 4.5

APPENDIX A: PID FUNDAMENTALS ................................................ 5.1
PID CONTROL FUNDAMENTALS ............................................ 5.1
Proportional Control ................................................. 5.1
Integral Control ..................................................... 5.1
Derivative Control .................................................. 5.1
LOOP OPERATING MODES ................................................ 5.2
PID Control ....................................................... 5.2
ON/OFF Control .................................................... 5.2
LOOP ALGORITHM ....................................................... 5.2
Loop Variables ..................................................... 5.2
PID Control ....................................................... 5.2
PID equation ............................................................ 5.3
Reverse Acting Loop (Cooling) .............................................. 5.4
RESET WINDUP PROTECTION ............................................. 5.4
Freeze Bias ....................................................... 5.4
APPENDIX B: TROUBLESHOOTING ............................................... 6.1
Description of Normal Operation .............................................. 6.1
Common Loop Temperature Controller Problems and Solutions ...................... 6.1

1.1
GENERAL DESCRIPTION
The Direct Logic 405 Four Loop Temperature Controller CoProcessor integrates into one single slot
module, all the functions of four, single loop temperature controllers. Because the module uses the
DL405 high speed parallel dual port RAM interface, the effect on CPU scan time is minimal.
TEMPERATURE CONTROL
The module provides control outputs and temperature inputs so that precision temperature control is
maintained even while the PLC is in program mode.
Auto tuning of the Controller PID loops provides simple setup and maintenance. Auto tuning easily
adapts to changing process conditions. Because the floating point math intensive temperature
calculations are performed in the Controller, it has little effect on CPU scan time. In most applications,
no supporting ladder logic is required.
The power of the DL405 can be used to enable features beyond the capabilities of most single loop
temperature controllers. For example, minimal additional ladder logic is needed to ramp and soak
SetPoint changes or to change process recipes.
CONTROLLER I/O
The Controller is jumper selectable for direct connection to either RTD or Thermocouple temperature
sensors.
On board solid state outputs are used to cycle heater or cooler relays using either time proportioning
(pulse) PID or ON/OFF control logic. The controller output is also placed in the PLC for optional use with
DL405 4-20 mA or voltage linear analog output modules.
A current transformer is connected directly to the Temperature Controller to provide heater burn-out
detection.
User field wiring is made to a removable socket type terminal block on the controller's face plate. Thus
the temperature controller can be easily removed or changed without removing the field wiring.
OPERATOR INTERFACE
All Temperature Controller parameters are placed in V-Memory so that configuration, operation and
monitoring are easily adapted to the needs of every application. Temperature values are in engineering
units, either EC or EF.
Users An intelligent Operator Interface Terminal or industrial computer connected to either port
on a DL405 CPU can be used to change SetPoints and monitor operation.
A single OIT can service one or several DL405 systems using the 25 pin DirectNET
network port on 405 CPU.
OEMs The temperature SetPoint in V-Memory may be easily changed via a Hand Held
Programmer or an attached operator interface.
CHAPTER 1: INTRODUCTION

INTRODUCTION
1.2
ALARMING AND DIAGNOSTICS
LEDs
The 20 LEDs on the face of the module provide a quick indication of the operating status of all four
temperature loops. An LED is provided for each loop to indicate when an Output is ON, Auto Tune is
ON, an Alarm condition is present or when heater burn-out has been detected. In addition, there are
Missing Terminal Block (TB), No External Power (24V), RUN, and OK LED indicators.
Alarms
The Temperature Controller alarms include, Low Alarm, High Alarm, Deviation Alarm, No Heater Current
Alarm (heater burn-out), Shorted Heater Output and Broken RTD or Thermocouple Alarm.
Low Level Diagnostics
The module performs both high and low level self diagnostics. Possible low level diagnostic errors
include, CPU Error, Firmware Error (Watchdog time-out circuit), Incorrect ROM Checksum, RAM Error,
and Analog Circuit Error. These errors are reported to PLC CPU in a slot dependent V-Memory location.
High Level Diagnostics
High level diagnostics include Loose Terminal Block and External Power Supply Failure diagnostic
errors. These errors are reported to the PLC CPU and identified on the module by LED indicators.
Loose Terminal Block and External Power Supply Failure diagnostic errors are reported to the DL405
CPU. An operator may use AUX 42 to determine the error type. Either error will also turn ON special
purpose coil SP45. V-Memory location V7762 will contain 0201 if the terminal block is loose. V7762 will
contain 0206 if no external power supply is present. V7760 specifies the base and module of the error
(0102 = Base 1 module 2).

INTRODUCTION 1.3
OPERATIONAL SPECIFICATIONS
Installation Up to 8 Temperature Controllers may be used with a single 405 CPU. Temperature
Controllers must be installed in the CPU base.
V-Memory
Block A slot dependent V-Memory location specifies the starting address of the block of V-Memory to be used by the Temperature Controller.
Loops Up to 4 independent temperature loops can be controlled. A unique V-Memory
location specifies the number of loops which are enabled for each Temperature
Controller.
Algorithm PID control with auto tuning or ON/OFF control with hysteresis.
Limit SP Optionally, specify a high and low limit for allowable SetPoint changes.
Scaling Conversion of the temperature value to engineering units is automatically done by
the Controller.
Gain Specify proportional gain of 0.0 to 6553.5. Gain may be determined automatically by
using the Auto Tuning feature.
Reset Specify reset time of 0 to 65535 seconds. Reset may be determined automatically
by using the Auto Tuning feature.
Anti-windup The reset action is stopped when the PID output reaches 0 or 100%.
Rate Specify the derivative time, 0 to 65535 in units of seconds. Rate may be determined
automatically by using the Auto Tuning feature.
Auto Tune Auto Tune can be programmed to calculate either PID or PI controller settings.
ALARM SPECIFICATIONS
Deadband Specify the temperature deadband on all alarms. The alarm will remain active
while the temperature is outside the alarm limit minus the deadband.
Alarm deadband prevents alarm chatter when the temperature is near the alarm
limit.
Temperature High The Temperature High Alarm is turned on when the temperature rises above the
programmed limit.
Temperature Low The Temperature Low Alarm is turned on when temperature falls below the
programmed limit.
Deviation Specify an alarm for high or low temperature deviation from the SetPoint. When
the temperature is further from the SetPoint than the programmed deviation limit
the Temperature Deviation Limit Alarm is turned on.
Broken Sensor The Broken RTD or Thermocouple alarm is turned on when the a RTD or
Thermocouple is burned-out or missing. It also is turned on when a RTD input is
shorted.
In both cases the indicated temperature will be full scale positive, 3276.7 EC or
EF.

INTRODUCTION
1.4
TEMPERATURE CONTROLLER HARDWARE SPECIFICATIONS
General Specifications
Number of Loops 4
Input Type Differential
Common Mode Range ± 5 Vdc
Converter Type Charge Balancing, 24-bit
Controller Output Open collector, 5 to 50 Vdc at .15A.
Notch Filter > 100 db notches at 50 Hz and 60 Hz
f-3db = 13.1 Hz
Common-Mode Rejection 90 db minimum at DC
150 db minimum at 50 Hz and 60 Hz
Sampling Rate 800 msec per loop (Slow 10 Hz Filter)
160 msec per loop (Normal 50 Hz Filter)
Current Transformer 5 A to 50 A sense range
F4-CT or equal
(The F4-CT Current Transformer input to output current ratio is
approximately 400:1)
Minimum Output ON time 300 msec to sense heater current
Mounting Single slot in CPU base, up to eight modules per system
I/O Points Required None, uses high speed intelligent parallel dual port memory
interface
LED Status Indicators 20
User Wiring Removable Terminal Block
Input Type Combinations J,K,E,N or R,S,B,C or T or Pt100,jPt100 or Pt1000 or CU-10Sor
CU-25S.
Environmental Specifications
Operating Temperature 0 EC to 60 EC (32 EF to 140 EF)
Relative Humidity 5 to 95% (non-condensing)
Storage Temperature -20 EC to 70 EC (-4 EF to 160 EF)
Internal Power Required 280 mA at +5 V dc Maximum from base power supply
External Power Required 75 mA at 24 V dc, ± 10%
Power Supply Rejection 85 db typical

INTRODUCTION 1.5
Voltage Input Specifications
Voltage Ranges 0-5, ±5V, 0-156.25, ±156.25mV
Resolution 16-bit binary (1 in 65536)
Calibration Error ±13 counts typ., ±33 maximum full scale
±1 count maximum offset (0V input)
Maximum Inaccuracy ±.02% typ. ±.2% maximum
Thermocouple Input Specifications
Temperature Ranges Type J -190/760 EC (-310/1400 EF)
Type E -210/1000 EC (-346/1832 EF)
Type K -150/1372 EC (-238/2502 EF)
Type R +65/1768 EC (+149/3214 EF)
Type S +65/1768 EC (+149/3214 EF)
Type T -230/400 EC (-382/752 EF)
Type B 529/1820 EC (+984/3308 EF)
Type N -70/1300 EC ( -94/2372 EF)
Type C +65/2320 EC (+149/4208 EF)
Input Fault Protection 60 Vrms or 50 Vdc maximum
Cold Junction Compensation Automatic
Input Impedance 20 MS
Resolution ±0.1 EC (Relative accuracy)
Warm-Up Time 30 min. typ. for ±1 EC repeatability
Maximum Inaccuracy ±3 EC excluding error of thermocouple
(See page 2.7 for additional sources of inaccuracy)
RTD Input Specifications
RTD Types European, = .003850, (Pt100 & Pt1000)
American, = .003916, (jPt100)
Copper (CU-10S& CU-25S)
Temperature Ranges Pt100, -200.0/850.0 EC (-328/1562 EF)
Pt1000, -200.0/595.0 EC (-328/1103 EF)
jPt100, -38.0/450.0 EC (-36/842 EF)
CU-10/25S, -200.0/260.0 EC (-328/500 EF)
Input Fault Protection 50 Vdc maximum
RTD Excitation Current 200 µA
Resolution ±0.1 EC or EF
Maximum Inaccuracy ±1 EC

INTRODUCTION
1.6

2.1
STEPS FOR F4-4LTC INSTALLATION
The following steps should be used as guideline for installation of the F4-4LTC. All steps may not be
necessary in all applications.
1. Set Jumpers for RTD or Thermocouple
2. Install F4-4LTC in the CPU Base and Note the Slot Number
3. Connect Temperature Sensors to TEMP Inputs
4. Connect SSR Controller Outputs to SSRs
5. Connect CT Inputs to Current Transformers
6. Connect 24VDC Power Supply to F4-4LTC
7. Power Up PLC and Initialize Dedicated V-Memory
8. Initialize Loop Configuration V-Memory
9. Tune Loops
CHAPTER 2: INSTALLATION AND WIRING

INSTALLATION AND WIRING
2.2
SET CONFIGURATION JUMPERS
The module should be jumpered for the type of input device that it will be connected to. Use the
following diagrams to configure the jumpers on your module. The two configurations shown here are the
only valid settings, any other settings may cause unpredictable results.
RTD Inputs
Voltage or Thermocouple Inputs
UNUSED TEMPERATURE INPUTS
Unused temperature inputs should be shorted together and connected to 24V common. For example, if
only three temperature loops are required, then wire the TEMP 4 +, TEMP 4 -, and COM terminal block
positions together
WARNING A thermocouple or RTD temperature sensor can become shorted
to a high voltage potential. Because common terminals are
internally connected together on the F4-4LTC, whatever voltage
potential exists on one temperature sensor will exist on the other
three.

INSTALLATION AND WIRING 2.3
INSTALL F4-4LTC IN CPU BASE
There can be up to 8 Four Loop Temperature Controllers per system. The temperature controller must
be installed in the CPU base.
LED STATUS INDICATORS
TB On when I/O terminal block is loose or missing.
24V On if no external 24 VDC power or if analog circuit
failed.
RUN This LED toggles every second under normal
operation.
OK On after Controller completes self diagnostics.
OUT On when corresponding heater Output is on.
AT On when corresponding loop is Auto Tuning.
HB On when corresponding Heater Burn-out has been
detected. When a user supplied current
ttransformer is connected, both shorted (current
when output is off) and open (current does not flow
when output is on) heater loads are detected.
ALM On when corresponding loop has a temperature
Alarm condition. Possible alarms are temperature
high, temperature low and temperature has
exceeded the deviation limit from the programmed
temperature SetPoint.

INSTALLATION AND WIRING
2.4
RTD CONNECTION DIAGRAM
Notes: Accurate lead wire compensation requires that the three wires which connect an RTD to the
Controller be exactly the same resistance (a 3.7' difference in 26 AWG lead length will introduce
a .2 EF error).
If a four wire RTD is used, leave unconnected one of the positive side leads (only one wire
should be connected to TEMP+).
Ground the shield drain wire only at the sensor end.
Observe the warning on page 2.2.