EDS11-118C

FC SERIES COMPACT CONTROLLER™–Super (CC-S) (BASIC PID AND FREELY CONFIGURABLE, STEP OUTPUT TYPE) DATA SHEET The Compact Controller-S (Basic PID and freely configurable type) is a compact single-loop controller using a microprocessor. It receives proportional signals from e.g. thermocouples and RTD's etc., as input, and is equipped with abundant control and computation functions to allow configuring a flexible system with a high cost/performance, above all, as stated below: — FIELD CONFIGURABLE SLC — AUTO TUNING FUNCTIONS — RS-422 DATA LINKAGE as standard. PNC3 FEATURES 1) Versatile functions • All closed loop control functions, such as cascade, ratio, time scheduling, Iogic control, etc. are performed in one controller. • 86 kinds of control functional blocks (Wafers). • Generic interface RS-422 availability for personal computer (e.g., IBM PC-AT) for supervision, operation, maintenance, configuration, etc. • Auto tuning capability. • Pass code security. 2) Simple and flexible • Basic PID control configuration can be programmed in less than 1 (one) minute from front panel. • No program loaders and accessories necessary. • No software programming knowledge necessary. • Application oriented control function is configurable by connecting the functional blocks. • Field Configurable through front panel. • Front panel operation Operations such as parameter setting, auto/manual changeover, etc. are all achieved from the front panel. 3) Highly reliable • Highly reliable with MTBF of 200,000 Hr per MIL Standard 217D. • LED's are used for bargraph and parameter indication. • Nonvolatile memory enables to retain parameters in case of power failure. 4) Update hardware technology • Custom LSI. • Surface Mounting Technology. SPECIFICATIONS 1. Control system configuration There are two methods of control system configuration for CC-S, one is configuration by Basic PID and the other is by wafer connection. Various types of configuration examples are shown "VARIOUS CONTROL EXAMPLES" stated hereafter. (1) Configuration by basic PID (fixed configuration) Basic PID control function is fixedly defined as standard control function in the controller beforehand. Configuration of basic PID can be performed through simple operation on the front panel keys, where wafer connection mentioned below is unnecessary. Computation wafers such as square root, filter, Iimiter, non linear, etc. can be made valid or invalid by simple operation of front panel keys. EDS11-118c Date Jan. 27, 1999 P NC3 FUNCTIONAL DIAGRAM Personal computer Other controllers External output terminals Auxiliary analog output 1 (AO1) D/A converter Compensated PV signal (KPV) Set point transmit signal (SV) Valve position input Serial communication interface Communication terminals External input terminals Constant 1 Constant 32 Bargraph indicator SUB control block (cascade control, ratio control or time schedule control) SV Control wafer PV A/D converter Valve position input (W+, WO, W-) Auxiliary analog input 1 (AI1) Auxiliary analog input 2 (AI2) Process value input (PV) External set point input (CAS) Auxiliary digital input 1 (DI1) Auxiliary digital input 2 (DI2) Auxiliary digital input 3 (DI3) Pulse width input (PI+) Pulse width input (PI-) Manual mode command (SMV) 4 to 20mA, thermocouple RTD conversion PV SV MAIn control block (basic control) Control wafer MV Manipulated output (pulse width) (PO+, PO-) Computation wafer Manual Fault up to 24 wafers usable Alarm Auxiliary digital output 1 (DO1) Auxiliary digital output 2 (DO2) High alarm (H) Low alarm (L) Manual mode output (M) Fault output (FLT) FLT Indictor H Indictor L Indictor (2) Configuration by wafer connection (Freely configurable) 1) Wafer The wafer is a functional block (software package) containing control and computation functions needed for measurement and control. Combination of these wafers, each having its own particular function, enables configuring a flexible system applicable to a wide range of control . . . from basic PID control up to sophisticated advanced control. The PNC3 can accommodate up to 24 wafers. The following kinds of wafers are prepared to allow selection according to the control purpose. x For control ............... PID control, ratio control, time schedule control, gain schedule control, PID parameter setting ➁ For computation ...... Various computations performed by connecting wafers given in Table 1 2) Internal input/output terminals Various internal terminals are provided for external analog input/output, digital input/output and wafer connection. 3) Constants Various parameters used in computation and control can be freely defined (32 constants). The following control configuration are achieved. 4) Control functions By connecting wafers (functional blocks) Control examples: Cascade control, ratio control, time schedule control, gain schedule control, etc. Alarm function: PV high/low alarm PV change rate alarm DV high/low alarm Configurable by wafer connection, front panel indicator lights up 2. Control performance • PID control: Proportional band (P); 1.0 to 3276.7% Integration time (I): 0.1 to 3276.7 sec. Derivative time (D): 0.0 to 900.0 sec. PID auto tuning function • Execution rate: Ten (10) times per second/Basic PID control Five (5) times per second/others 2 Table 1 List of computation wafers Wafer name Logical operation Arithmetic operation Temperature/pressure compensation Linearize Time schedule control Flip-flop Pulse width integration Selector Changeover Timer Absolute value/ sign inversion Square root extraction Lead, lag Limiter Ramp function Kinds 6 5 1 3 4 1 1 1 1 1 1 1 1 1 2 Wafer name Analog averaging Analog integration Pulse generation Dead band Pulse no. counter Pulse no. output Decoder Moving average Sample hold Dead time ON-OFF Alarm Position type pulse width conversion Bargraph indication Gain schedule control Kinds 1 1 1 1 1 1 1 2 1 6 1 1 1 21 5 4. Output signals (1) Manipulated output signal: 1 point Pulse width output PO+ PO– Open collector output (Photocoupler isolation) Output rating 30V DC 0.1A max. (2) Analog output signal: 3 points Compensated PV signal Set point transmit signal Aux. analog output KPV SV AO1 1 to 5V DC Output resistance 0.5Ω or less, allowable error ± 0.2%/FS* KPV and SV are usable as aux. analog output. (3) Digital output signal: 6 points Fault output Manual mode output High alarm output Low alarm output Aux. digital output Aux. digital output FLT M H L DO1 DO2 Open collector output (Photocoupler isolation) Output rating 30V DC 0.1A max. 3. Input signals (1) Process value input signal: One input selectable from the following Voltage input signal 1 to 5V DC Input resistance 1MΩ or more Allowable error ± 0.2%/FS* Allowable error ± 0.2%/FS* Transmitter power supply 24V ± 2V DC approx. 35mA max. 10mV DC span or more; reference junction compensating function built in Allowable error ± 0.5%/FS* 50°C span or more Allowable error ± 0.5%/FS* H and L are usable as aux. digital output. 5. Internal data conversion (1) Analog data Standard 0.00 to 100.00% Minimum –327.6% Maximum 327.67% Current input signal 4 to 20mA DC (2) Digital data Signal status ON (Contact closed) OFF (Contact open) Data 0.01% 0.00% Thermocouple input I+ I0 I– Types J : 0 to 600°C K : 0 to 1200°C E : 0 to 800°C R : 0 to 1600°C Pt100Ω (0°C) –50 to 500°C 6. Indication, setting, operation functions (1) Bargraph indication PV indicator Indication method No. of segments LED (Red) 101 + 2 0 to 100% linear 1%/FS* 100mm SV indicator LED (Green) 101 + 2 0 to 100% linear 1%/FS* 100mm MV indicator LED (Red) 51 + 2 0 to 100% linear 2%/FS* 50mm Resistance bulb input (2) Analog input signal: 3 points External set point CAS three 1 to 5V DC inputs or two 4 to 20mA DC inputs plus two 1 to 5V DC inputs Input resistance 1MΩ or more, allowable error ± 0.2%/FS* Two transmitter power supply 24V ± 2V DC approx. 35mA max. Range Resolution Scale length Indication mode Aux. analog input AI1 Aux. analog input AI2 0 to 100% bargraph indication, 0 to 100% reverse bargraph indication, dot indication, –50 to +50% deviation indication CAS is usable as aux. analog input. (3) Digital input signal: 4 points Manual mode command Aux. digital input Aux. digital input Aux. digital input SMV Contact input (Photocoupler isolation) DI1 DI2 DI3 ON 0V DC, OFF 24V DC (Input current approx. 11mA/24V DC) (4) Pulse width input signal: 1 set Pulse width input signal Pl+ PI– Contact input (Photocoupler isolation) ON 0V DC, OFF 24V DC (Input current approx. 11mA/24V DC) (5) Valve position input signal Voltage input Potentiometer input WO W+ WO W– 1 to 5V DC 50Ω to 1.5MΩ width Input resistance 1MΩ or more Allowable error ± 0.5%/FS 3-wire potentiometer Allowable error ± 0.5%/FS (2) Operation mode indication Indicating method: LED (Red and green) Red; M, HM, SCC Green; A, R (3) Numerical indication, setting Indication method: LED (Red), name in 3 digits + data in 5 digits (Negative sign included) Indication contents: Process variable (Industrial value), set point (Industrial value), high/low alarm values, PID parameters, etc. Indication data are selectable by F/S , , keys on front panel. Setting method:By use of F/S , , , , ST keys on front panel. *Note: "FS" stands for "Full Scale". Potentiometer input is 10-100-10Ω standard. 3 P NC3 (4) SV setting function Fixed value setting method: , buttons on front panel. By Setting speed; about 40 sec/FS* Remote setting method: By external set point signal (Voltage or pulse width input) (5) MV operating function Manual operating method: By , buttons on front panel. digital indicator of front panel. 9. Communication functions (1) Communication items Supervisory items: From CC-S to host Process variable, set point, manipulated out-put, deviation, operation mode, alarm in-formation, fault information, PID parameters, various limiter values, constants, segmented line, analog input/output, digital input/output, configuration program (Wafer connection) etc. Setting items: From host to CC-S Set point, manipulated output, operation mode, PID parameters, various limiter values, constants, segmented line, configuration program (Wafer connection) etc. (2) Communication enable/inhibit: Data setting from the host can be enabled/inhibited by F/S , , , , ST keys on the front panel. (3) Communication interface RS-422: Universal interface Transmission speed: 2400, 4800, 9600 or 19200 BPS selectable No. of units connectable: 31 max. Code format: One or two stop bits, parity EVEN/ODD/ NONE selectable. Transmission distance: 1 km max. (6) Operation mode changeover By R/A/M pushbuttons on front panel. R A A changeover R changeover Voltage signal Pulse width input A or R M changeover Balanceless bumpless Balance bumpless Balanceless bumpless Balanceless bumpless 7. Power failure and restart function Power failure detection: Control function interrupted at power failure detection. During power failure: Operating parameters backed up by capacitor when power failure within 5 minutes. Initial set point and control output values, PID parameters etc. are stored in nonvolatile memory (lasts for 10 years or longer at ambient temperature of 50°C or less) Restart from power failure: Initial or continuous start is selectable for power failure within 5 minutes. Restart from power failure lasting longer than 5 minutes is made by initial automatically. Control mode at initial start is selectable from. R: Remote mode M: Manual mode A: Automatic mode SCC: SCC mode 10. Personal computer software packages Two software packages, running on IBM PC-AT, are provided for CC-S supervision, operation, maintenance and configuration. They are Fix software packages and CC-S configurator. Fix is a user-configurable, menu-driven software packages for CC-S supervision, operation and maintenance, while CC-S configurator is another package to configure CC-S control system. E.g. Real time process display Process Alarming Trending Control Strategy Configuration Fix is a trade mark of Intellution Inc./U.S.A. Standard software packages for plant supervision, operation and maintenance are available under Fix: 8. Self-diagnosis functions Computation/control function failure: FLT indicator lights up, FLT contact output closes, and computation and control function interrupted. Manipulated output can be controlled manually at FLT (Soft manual). Input signal and control output failure: FLT indicator lights up, FLT contact output closes, control stops, and manipulated output is held, while other computation and control functions continue to be processed. Fault indication: Cause of fault is indicated numerically on 11. Security functions Data security function by means of pass code. 12. Operating conditions Supply voltage: 24V DC (20 to 30V DC), 110V AC (85 to 132V AC), 220V AC (187 to 264V AC) Power consumption: Approx. 13W (DC), 20VA (AC) Power factor: approx. 0.6 Dielectric strength: 4 1500V AC for 1 minute Insulation resistance: 100MΩ or more at 500V DC Ambient temperature: 0 to 50°C Ambient humidity: 90%RH or less Enclosure: Steel case Enclosure class: Front IP65 (IEC 529) Nameplate: 10(H) x 70(W), white acrylic Dimensions: 144(H) x 72(W) x 407 (D)mm, IEC 668 (DIN) standards Mass{weight}: Approx. 2.9kg Mounting method: Flush on indoor panel vertical mounting is standard. Mounting on tilted surface possible (Angle α) CODE SYMBOLS 12345678 9 10 11 12 PNC3 A B C D E F G 5- R0A Description Process variable input signal 1 to 5V DC 4 to 20mA DC with 24V DC power supply 10mV DC span or J thermocouple K thermocouple more, with reference E thermocouple junction compensating R thermocouple function RTD Pt100Ω (0°C) 3-wire type, 50°C span or more B C Auxiliary analog input Four 1 to 5V DC inputs Two 4 to 20mA DC with 24V DC power supply plus two 1 to 5V DC inputs 1 2 3 1 2 Supply voltage 24V DC (20 to 30V DC) 110V AC (85 to 132V AC), 50/60Hz 220V AC (187 to 264V AC), 50/60Hz Valve position input signal Voltage input (1 to 5V DC) Potentiometer input (10-100-10Ω) R 0 A Comunication interface RS-422 Wafer connection Without PID auto tuning function With α=0° to 90° Finish color: Munsell N1.5 Scope of delivery: Controller and mounting bracket. Item to be ordered separately: Communication cable (Type PNZ) Terminal resistor (Type PNY) Note: Front scale and temperature range are to be selected and specified from the "STANDARD FRONT SCALE" and "STANDARD TEMPERATURE RANGE" stated hereafter, when order being placed. VARIOUS CONFIGURATION EXAMPLES Basic PID control (Fixed configuration) Basic PID control function is fixedly defined as standard control function in the controller beforehand. Configuration of basic PID can be performed through simple operation on the front panel keys, where wafer connection is unnecessary. Computation functions such as square root, filter, limiter, non linear, etc. can be made valid or invalid by simple operation of front panel keys. Process variable Filter P I D L External set point SH SL R H A.M Non-linear R.A M MV output (PO) PV tracking command DV PID control PID control is carried out by using only the MAln control block. PID control by means of an external set point is also performed. Process variable Filter PH PL P I D L MAIn control block (MAIn PID) R.A M MV output (PO) External set point SH SL R A.M Non-linear H DV 5 P NC3 Cascade control Cascade control is carried out by combining two PID control blocks. Since the output of the SUB PID controller follow up the set point of the MAln PID controller, A and R can be changed over balancelessly. Process variable for MAIn PID PV Filter SV MAIn PID R.A M MV output (PO) Process variable for SUB PID Filter SH SUB PID SL R A.M External set point SH SL EXT INT In auto or manual, SUB PID traces the set point of MAIn PID. Ratio control Ratio control is carried out by combining a ratio computation and a PID control block. Process variable PV Filter SV MAIn PID Process variable for ratio control External set point SH SL Filter PV-B1 X X SH SL SV+B3 R R.A M A.M MV output (PO) EXT INT R B2 Time schedule control By combining a time schedule block and a PID control block, the set point is decided according to a time schedule pattern. A preset function is also provided for starting time schedule control from the present temperature in a furnace for control of heating or the like. Process variable PV Filter Program patterm SV Output STOP 7 segments R A.M MAIn PID R.A M MV output (PO) Stop command Preset command PRESET Time Gain schedule control Carries out PID control according to three (3) PID parameter patterns, which are stored in the form of 7 segmented lines. Process variable Filter PV SV P MAIn PID I D R.A M MV output (PO) External set point SH SL R A.M Adaptability reference P I D 6 STANDARD TEMPERATURE RANGE Followings are standard input temperature ranges to be selected and to be specified with the ordering code. Detector J type thermocouple K type thermocouple E type thermocouple R type thermocouple Platinum resistor temperature detector Measurement range 0 to 200, 0 to 300, 0 to 400, 0 to 500, 0 to 600, 200 to 400, 300 to 600 deg C 0 to 300, 0 to 400, 0 to 500, 0 to 600, 0 to 800, 0 to 1000, 0 to 1200, 300 to 600, 400 to 800, 500 to 1000, 600 to 1200 deg C 0 to 200, 0 to 300, 0 to 400, 0 to 500, 0 to 600, 0 to 800, 200 to 400, 300 to 600 deg C 0 to 1000, 0 to 1200, 0 to 1600, 400 to 1400, 600 to 1600, 800 to 1600 deg C 0 to 50, 0 to 100, 0 to 150, 0 to 200, 0 to 300, 0 to 400, 100 to 300, 200 to 400, –50 to 100, –50 to 500 deg C STANDARD SCALE Followings are standard scales to be selected and to be specified with the ordering code. On condition that PV and SV are of the same scale each other, following standard scale plates are prepared as standard. Detector J type thermocouple K type thermocouple E type thermocouple R type thermocouple Platinum resistor temperature detector 1 to 5 VDC input PV and SV scale 0 to200, 0 to 300, 0 to 400, 0 to 500, 0 to 600, 200 to 400, 300 to 600 deg C, 0 to 100% 0 to 300, 0 to 400, 0 to 500, 0 to 600, 0 to 800, 0 to 1000, 0 to 1200, 300 to 600, 400 to 800, 500 to 1000, 600 to 1200 deg C, 0 to 100% 0 to 200, 0 to 300, 0 to 400, 0 to 500, 0 to 600, 0 to 800, 200 to 400, 300 to 600 deg C 0 to 100% O to l000, 0 to 1200, 0 to 1600, 400 to 1400, 600 to 1600, 800 to 1600 deg C, 0 to 100% 0 to 50, 0 to 100, 0 to 150, 0 to 200, 0 to 300, 0 to 400, 100 to 300, 200 to 400, –50 to 100, –50 to 500 deg C, 0 to 100% 0 0 0 0 to to to to 10, 0 to 20, 0 to 30, 0 to 40, 0 to 50, 60, 0 to 80, 0 to 100, 0 to 200, 0 to 300, 400, 0 to 500, 0 to 600, 0 to 800, 1000 unit. 0 to 100% Note: The underlined temperature range will be selected and delivered, when input temperature range is not specified in the ordering code. MV 0 to 100% OUTLINE DIAGRAM Terminals (Unit:mm) Panel thickness 8mm or less 16 52 Supporting bracket 355 200min. Mounting bracket 144 72 Panel cutout When mounting one unit When mounting "n" units +1 0 250min. 200min. +1 0 68 +0.7 0 (72.2n – 4) +1 0 138 No. of units n2 138 7 P NC3 CONNECTION DIAGRAM Compression terminal Al (External set point) Al (Aux. analog input) Al (Aux. analog input) 01 02 03 04 Valve position input 05 06 Al, AO Common bus 07 08 1 to 5VDC signal output DC power for Transmitter PO (Pulse width) (Manipulated output) DI (Pulse width input) DO (High-limit alarm output) DO (Low limit alarm output) DO (FLT output) – 24VDC power for Dl, DO – 24VDC power for Dl, DO – Instrument power (24VDC) – + + – 09 10 11 12 13 14 15 16 17 18 19 20 21 CAS AI1 AI2 W+ WO W– SC SC SO1 IR1 IO1 PO+ PO– PI+ PI– H L FLT PCD PCD PC* I+ Io I– KPV SV AO1 SC SC SO2 IR2 IO2 SMV DI1 DI2 DI3 DO2 DO1 M VPD VPD VP* 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 + + + DO (Manual mode command) Dl (Aux. digital input) Dl (Aux. digital input) Dl (Aux. digital input) DO (Aux. digital output) DO (Aux. digital output) DO (Manual mode) 24VDC power for Dl, DO Instrument power (24V DC) 1 to 5VDC signal output – + DC power for Transmitter AO (Compensated PV signal) AO (Set point transmit signal) AO (Aux. analog output) Al, AO Common bus Process value input G 71 AC 72 AC 73 Ground Instrument power (AC) Instrument power (AC) Note: * Symbols for AC instrument power are VPO, PCO. Output: approx. 24V DC (0.1A, max.) Process value input terminals connections 1 to 5V DC The 5th digit of code symbols: A 4 to 20mA DC The 5th digit of code symbols: B 4 to 20mA DC with inner DC power supply of CC-S The 5th digit of code symbols: B + + – Thermocouple 31 32 33 + – + – 31 32 33 The 5th digit of code symbols: C,D,E,F Resistance bulb + – 31 32 33 – + The 5th digit of code symbols: G + – 31 32 33 – + – 31 32 33 PC 21 8 COMMUNICATION CONNECTOR 6 7 8 RXD + 9 RXD – 1 SIG GND 2 SHLD 3 INH 4 TXD + 5 TXD – Green Red Yellow Brown Black White 6 7 8 RXD + 9 RXD – 1 SIG GND 2 SHLD 3 INH 4 TXD + 5 TXD – 6 7 8 RXD + 9 RXD – LINE TERMINATION RESISTOR 1 SIG GND 2 SHLD 3 INH 4 TXD + 5 TXD – 6 7 8 RXD + 9 RXD – 1 SIG GND 2 SHLD 3 INH 4 TXD + 5 TXD – Green Red Yellow Brown HOST e.g. IBM PC-AT Black White Terminal station First station Host e.g. IBM PC-AT Termination Resistor Communication cable CC-S CC-S CC-S CC-S 9 P NC3 Caution on Safety *Before using this product, be sure to read its instruction manual in advance. Head Office 6-17, Sanbancho, Chiyoda-ku, Tokyo 102-0075, Japan http://www.fesys.co.jp/eng Sales Div. International Sales Dept. No.1, Fuji-machi, Hino-city, Tokyo, 191-8502 Japan Phone: 81-42-585-6201, 6202 Fax: 81-42-585-6187 http: //www.fic-net.jp/eng Information in this catalog is subject to change without notice. Printed in Japan