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

Thank you for purchasing automation equipment from FACTS Engineering. We want
your new FACTS Engineering automation equipment to operate safely. Anyone who
installs or uses this equipment should read this publication (and any other relevant
publications) before installing or operating the equipment.
To minimize the risk of potential safety problems, you should follow all applicable local
and national codes that regulate the installation and operation of your equipment.
These codes vary from area to area and usually change with time. It is your
responsibility to determine which codes should be followed, and to verify that the
equipment, installation, and operation is in compliance with the latest revision of these
codes.
At a minimum, you should follow all applicable sections of the National Fire Code,
National Electrical Code, and the codes of the National Electrical Manufacturers
Association (NEMA). There may be local regulatory or government offices that can
help determine which codes and standards are necessary for safe installation and
operation.
Equipment damage or serious injury to personnel can result from the failure to follow all
applicable codes and standards. We do not guarantee the products described in this
publication are suitable for your particular application, nor do we assume any
responsibility for your product design, installation, or operation.
If you have any questions concerning the installation or operation of this equipment, or
if you need additional information, please call us at 1-800-783-3225.
This document is based on information available at the time of its publication. While
efforts have been made to be accurate, the information contained herein does not
purport to cover all details or variations in hardware and software, nor to provide for
every possible contingency in connection with installation, operation, and maintenance.
Features may be described herein which are not present in all hardware and software
systems. FACTS Engineering assumes no obligation of notice to holders of this
document with respect to changes subsequently made. FACTS Engineering retains the
right to make changes to hardware and software at any time, without notice. FACTS
Engineering makes no representation or warranty, expressed, implied, or statutory with
respect to, and assumes no responsibility for the accuracy, completeness, sufficiency,
or usefulness of the information contained herein. No warranties of merchantability of
fitness for purpose shall apply.
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