Multifunction Programmable Controller Installation and User manual

Multifunction Programmable Controller Installation and User manual
Multifunction Programmable Controller
Installation and User manual of the
AC10 - AC20 - AC30 controller
USER MANUAL
M.I.U. ACMO – 11 / 00 - 03
Cod. J30 - 304 - 1AMIAC-ING
Installation and User manual of the AC10 - AC20 - AC30 controller
Copyright  1996 ASCON spa
All rights reserved
No part of this document may be stored in a retrieval system, or transmitted
in any form, electronic or mechanical, without prior written permission of
ASCON SpA.
ASCON has used the best care and efforts in preparing this book and
believes the information in this publication are accurate. The ASCON
Products are subjected to continuous improvement, in order to pursue the
technological leadership; these improvements could require changes to the
information of this book. ASCON reserves the right to change such
information without notice.
ASCON makes no warranty of any kind, expressed or implied, with regard to
the documentation contained in this book. ASCON shall not be liable in any
event - technical and publishing error or omissions - for any incidental and
consequential damages, in connection with, or arising out of the use of this
book.
AC STATION, AC PROGRAPH and AC EDIT, are trademarks of ASCON spa.
All the other tradenames or product name are trademark or registered
trademarks.
ASCON spa
20021 Ospiate di Bollate ( Milano ) Italy
Via Falzarego 9 / 11 - Tel. ++39-02-333371 - Fax ++39-02-3504243
http://www.ascon.it
[email protected]
2
Installation and User manual of the AC10 - AC20 - AC30 controller
TABLE OF CONTENTS
1.
GENERAL INFORMATION .................................................................................................................................. 7
1.1
MAIN DIFFERENCES BETWEEN AC10, AC20 AND AC30...................................................................................... 7
1.2
TECHNICAL SPECIFICATION .................................................................................................................................. 7
1.2.1
I/O maximum capabilities........................................................................................................................... 7
1.3
HARDWARE DESCRIPTION ................................................................................................................................... 9
1.4
RESIDENT STRATEGIES DESCRIPTION ................................................................................................................ 10
1.5
LIBRARY OF THE FUNCTIONAL MODULES OF THE AC10, AC20 AND AC30 CONTROLLERS ................................ 11
2.
INSTALLATION.................................................................................................................................................... 13
2.1
DIMENSIONS ...................................................................................................................................................... 13
2.2
PANEL MOUNTING ............................................................................................................................................. 13
2.3
CONNECTIONS AND TERMINATIONS ................................................................................................................... 14
2.4
ELECTRICAL CONNECTIONS ............................................................................................................................... 15
2.4.1
Passive Transmitter .................................................................................................................................. 15
2.4.2
Active transmitter...................................................................................................................................... 15
1.1.3
Analog output ........................................................................................................................................... 15
1.1.4
Digital Inputs and Outputs ....................................................................................................................... 16
1.1.5
Frequency Input........................................................................................................................................ 16
1.1.6
RS485 Serial Port Main Comm ................................................................................................................ 16
1.1.7
ARCNET Network ..................................................................................................................................... 16
1.1.8
Connection to a PC via the programming port ........................................................................................ 17
1.1.9
Connection to the Expansion Unit, via the RS485 port AUX Comm ........................................................ 17
1.1.10 RS485 Main Comm serial connection + expansion unit .......................................................................... 18
3.
STARTUP................................................................................................................................................................ 19
1.1
KEYBOARD ........................................................................................................................................................ 19
1.2
PUSHBUTTONS FUNCTIONALITY......................................................................................................................... 20
1.3
DISPLAY ............................................................................................................................................................ 21
1.3.1
1 Bar Panel............................................................................................................................................... 22
1.3.2
2 Bar Panel............................................................................................................................................... 23
1.3.3
4 Bar Panel............................................................................................................................................... 25
1.3.4
Trend Panel .............................................................................................................................................. 26
1.3.5
2 Trend Panel ........................................................................................................................................... 28
1.3.6
4 Trend Panel ........................................................................................................................................... 30
1.3.7
12 Analog Display Panel .......................................................................................................................... 31
1.3.8
4 Analog Display Panel ............................................................................................................................ 32
1.3.9
4 Writable Analog Display Panel ............................................................................................................. 32
1.3.10 Alarm Panel.............................................................................................................................................. 33
1.3.11 Selector Panel........................................................................................................................................... 34
1.4
MANAGEMENT OF THE ACTIVE PANELS .............................................................................................................. 35
1.5
SELECTION OF A RESIDENT CONFIGURATION ...................................................................................................... 35
4.
PID, TUNE AND COMMUNICATION ............................................................................................................... 37
4.1
TUNING.............................................................................................................................................................. 37
4.2
GAIN SCHEDULING ............................................................................................................................................ 38
4.3
PID WITH TWO DEGREE OF FREEDOM ................................................................................................................ 39
4.4
COMMUNICATIONS ............................................................................................................................................ 40
4.4.1
Handling the Programming port .............................................................................................................. 40
4.4.2
Handling the Main Comm Supervisory Computer.................................................................................... 40
1.1.3
Handling the Aux Comm........................................................................................................................... 42
1.1.4
Handling the LAN (ARCNET ).................................................................................................................. 43
1.5
PARAMETER CHANGE ........................................................................................................................................ 43
1.6
AC-PROGRAPH / AC_EDIT SOFTWARE .............................................................................................................. 44
1.7
SAMPLING TIME ................................................................................................................................................. 44
5.
MODULES.............................................................................................................................................................. 45
5.1
RULES USED THROUGHOUT THIS CHAPTER ......................................................................................................... 45
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Installation and User manual of the AC10 - AC20 - AC30 controller
5.2
I/O MODULES ....................................................................................................................................................46
5.2.1
Analog Input (AI) ......................................................................................................................................46
5.2.2
Frequency Input (FI).................................................................................................................................48
5.2.3
Digital Input (DI) ......................................................................................................................................49
5.2.4
Analog Output (AO) ..................................................................................................................................50
5.2.5
Digital Output (DO) ..................................................................................................................................51
5.3
DISPLAY PANEL ..................................................................................................................................................52
5.3.1
Single bargraph panel (1BP) ....................................................................................................................52
5.3.2
Double bargraph panel (2BP)...................................................................................................................54
5.3.3
Quadruple bargraph panel (4BP) .............................................................................................................56
5.3.4
Trend Panel (TRP) ....................................................................................................................................58
5.3.5
Dual Trend Panel (2TP)............................................................................................................................60
5.3.6
Four Trend Panel (4TP)............................................................................................................................62
5.3.7
Alarm TagList (ALP) .................................................................................................................................64
5.3.8
Multiswitch panel (16SW) .........................................................................................................................65
5.4
SELECTOR PANEL (SELP) ..................................................................................................................................67
5.4.1
Four Analog Display Panel (4ADP) .........................................................................................................68
5.4.2
4 Writable Analog values (4ADP).............................................................................................................69
5.4.3
Analog Display Panel (ADP) ....................................................................................................................70
5.4.4
System CLK ( Date and time display panel ).............................................................................................71
5.5
PROCESSING AND CONTROL FUNCTIONS ............................................................................................................72
5.5.1
Setpoint and Deviation Calculation ( SDV ) .............................................................................................72
5.5.2
PID Algorithm(PID)..................................................................................................................................75
5.5.3
Output Station (MV) ..................................................................................................................................76
5.5.4
Heat/Cool Output Station (HCMV) ...........................................................................................................79
5.5.5
Servomotor Output (SRV)..........................................................................................................................82
5.5.6
Time Proportioning Output (TPO)............................................................................................................83
5.5.7
Scale Changer (SCH) ................................................................................................................................84
5.5.8
Filter (FILT)..............................................................................................................................................85
5.5.9
Analog Delay (ADLY) ...............................................................................................................................86
5.5.10 Digital Delay (DDLY) ...............................................................................................................................86
5.5.11 Rate Limiter (MSL)....................................................................................................................................87
5.5.12 Linearizator (CHAR).................................................................................................................................88
5.5.13 Minimum and Maximum Selector (MAX)..................................................................................................89
5.5.14 Software Analog Multiplexer (AMUX)......................................................................................................90
5.5.15 Hardware Analog Multiplexer (AMX8).....................................................................................................91
5.5.16 Analog Hold (HLD)...................................................................................................................................92
5.5.17 Software Digital Multiplexer (DMUX)......................................................................................................93
5.5.18 Hardware Digital Multiplexer (DMX8) ....................................................................................................94
5.5.19 Mass Flow (MFL)......................................................................................................................................95
5.5.20 Analog Totalizer ( TOT ) ...........................................................................................................................96
5.5.21 Analog Limiter (LMT) ...............................................................................................................................98
5.5.22 Alarms ( ALM )..........................................................................................................................................99
5.5.23 Rate Alarm ( SALM )...............................................................................................................................101
5.5.24 Analog Software Demultiplexer ( ASEL )................................................................................................102
5.5.25 Analog Hardware Demultiplexer ( AS8 ) ................................................................................................103
5.5.26 Digital Software Demultiplexer ( DSEL )................................................................................................104
5.5.27 Hardware Digital Demultiplexer ( DS8 ) ................................................................................................105
5.5.28 Decoder ( DEC8 ) ...................................................................................................................................106
5.5.29 Set page block (SETP).............................................................................................................................107
5.5.30 Timer Block (TMR)..................................................................................................................................108
5.5.31 Servomotor in Open/Close loop Block (SRV2)........................................................................................109
5.6
SUPERVISORY I/O MODULES ...........................................................................................................................110
5.6.1
Analog I/O to Computer (CAIO) .............................................................................................................110
5.6.2
Digital I/O to Computer (CDIO).............................................................................................................110
5.7
SYSTEM MODULES ...........................................................................................................................................111
5.7.1
Computer Timeout ( CALM )...................................................................................................................111
5.7.2
LAN Timeout ( LALM )............................................................................................................................111
5.7.3
Expansion Unit Timeout ( AALM )..........................................................................................................112
5.7.4
System Configuration ( SYS ) ..................................................................................................................112
5.7.5
Key Selector ( KEY )................................................................................................................................113
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Installation and User manual of the AC10 - AC20 - AC30 controller
5.7.6
Failure Module ( FAIL ) ......................................................................................................................... 113
5.7.7
Power Failure AC Restart flag ( PWRF ) ............................................................................................... 113
5.7.8
Setpoint control key lock Block (SPKL).................................................................................................. 114
5.7.9
Output Change Key Lock Block (OPKL) ................................................................................................ 114
5.8
MATH AND LOGIC FUNCTION........................................................................................................................... 115
5.8.1
Expression ( EXP ).................................................................................................................................. 115
5.8.2
Arithmetic ( OPR ) .................................................................................................................................. 115
5.8.3
Function ( FN ) ....................................................................................................................................... 116
5.8.4
Analog Single Constant ( CNS ) ............................................................................................................. 117
5.8.5
AND ........................................................................................................................................................ 117
5.8.6
NOT ........................................................................................................................................................ 118
5.8.7
EOR (XOR) ............................................................................................................................................. 118
5.8.8
OR........................................................................................................................................................... 119
5.8.9
8 Inputs OR (OR8) .................................................................................................................................. 119
5.8.10 Flip-Flop J-K LATCH (JKF) .................................................................................................................. 120
5.8.11 D LATCH Flip-Flop ............................................................................................................................... 120
5.8.12 Monostable ( MST ) ................................................................................................................................ 121
5.8.13 Counter ( CNT ) ...................................................................................................................................... 122
5.8.14 Multiple Analog Constants ( MCNS ) ..................................................................................................... 122
5.8.15 Analog Single Constant ( CNS ) ............................................................................................................. 123
5.8.16 Multiple Digital Constant ( MDCN ) ...................................................................................................... 123
5.8.17 Analog To Digital converter ( A/D ) ....................................................................................................... 124
5.8.18 Digital To Analog Converter ( D/A ) ...................................................................................................... 124
5.8.19 AND_8 Block (AND8)............................................................................................................................. 125
5.8.20 Shift Block (SHFT).................................................................................................................................. 125
5.9
PROGRAMMER FUNCTIONS .............................................................................................................................. 127
5.9.1
Real Time Clock with 8 outputs ( R.T.C. ) .............................................................................................. 127
5.9.2
Setpoint Programmer (PRG) .................................................................................................................. 127
6.
PASSWORD AND ACCESS CONTROL .......................................................................................................... 135
6.1
SETTING ACCESS MODES................................................................................................................................. 135
6.2
PASSWORD CHANGE ........................................................................................................................................ 138
6.3
PASSWORD DELETE ......................................................................................................................................... 138
6.3.1
Don’t panic!............................................................................................................................................ 138
7.
MAINTENANCE AND DIAGNOSTIC.............................................................................................................. 139
7.1
ADJUSTMENT OF THE DISPLAY CONTRAST ....................................................................................................... 139
7.2
ERROR MESSAGES............................................................................................................................................ 139
7.3
MASTER RESET................................................................................................................................................ 140
7.4
DIAGNOSTIC TEST AND CALIBRATION ............................................................................................................. 140
7.4.1
Diagnostic Tests...................................................................................................................................... 141
7.4.2
Calibrations ............................................................................................................................................ 142
7.5
REPLACEMENT OF FAULTY COMPONENTS ....................................................................................................... 144
7.6
SPARE PARTS ................................................................................................................................................... 144
7.7
MANUALS ........................................................................................................................................................ 144
8.
EXPANSION UNIT.............................................................................................................................................. 145
8.1
GENERAL INFORMATIONS ................................................................................................................................ 145
8.2
TECHNICAL CHARACTERISTICS ........................................................................................................................ 145
8.3
INSTALLATION ................................................................................................................................................. 145
8.4
ELECTRICAL CONNECTIONS ............................................................................................................................. 146
8.4.1
RS-485 .................................................................................................................................................... 146
8.4.2
Power Supply.......................................................................................................................................... 147
8.4.3
Inputs and Outputs.................................................................................................................................. 147
8.5
AUXILIARY UNITS ADDRESSING ...................................................................................................................... 147
9.
ORDERING DATA .............................................................................................................................................. 148
9.1
9.2
10.
ORDERING CODE ............................................................................................................................................. 148
AUXILIARY UNITS ............................................................................................................................................ 148
ANNEX “A” RESIDENT CONFIGURATIONS ........................................................................................... 149
5
Installation and User manual of the AC10 - AC20 - AC30 controller
I
N
T
R
O
D
U
C
T
I
O
N
Congratulation for having chosen an ASCON instruments.
This instruction manual is dedicated to the Multifunction Controllers:
Model
AC 10 - with 4 loops, preconfigured, with simple functionality.
Model
AC 20 - with 4 loops, custom configurable by mean of a PC.
Model
AC 30 - Programmer, with Real Time Clock, 4 loops, custom
configurable by mean of a PC.
NOTE:
A) Be sure that this manual is available to the user of the instrument.
B) The manual refers to a family of multifunction controllers, suitable for
panel mounting and supplied with high innovative graphic display. This
effective user interface provides a huge amount of quality information, the
user
perceive
more
immediately
than
other
technologies.
C) The configuration software for the AC20 and AC30 controllers, is supplied
on floppy disks. You must keep the original disks in a safe place. Any
copy of this software for purposes different than the configuration of the
ASCON AC series controllers, is forbidden. The use of the software is
regulated by the licence agreement provided by the Supplier.
D) Package contents verification. When you open the package of an AC10,
AC20 o AC30 multifunction controller, check that all the items correspond
to the packing list below. If an item is missed or damaged, you must
contact the nearest ASCON sales office.
1) AC station
2) Mounting clamps
3) User and Installation manual (consisting of this book)
4) Communication manual
6
Chapter 1. - General Information
MULTIFUNCTION PROGRAMMABLE CONTROLLER
1.
General information
1.1
Main differences between AC10, AC20 and AC30
The AC series controllers are supplied in the following 3 versions:
1.2
AC10
4 control loops, 4 analog inputs, 4 analog outputs, 8 digital I/O, with
12 control strategies, stored in the instrument memory and executed
upon command from the front panel.
The parametrisation of the controller is performed through one of the
following 3 ways: directly from the instrument panel, through the
serial comm Main Com and by mean of the AC-Prograph/AC-Edit
running on Windows.
AC20
4 control loops, 8 analog inputs, 4 analog outputs, 8 digital I/O, with
12 control strategies, stored in the instrument memory and recalled
from the front panel.
The parametrisation of the controller is performed through one of the
following 3 ways: directly from the instrument panel, through the
serial comm Main Com and by mean of the AC-Prograph/AC-Edit
running on Windows. Beyond the AC10 characteristics, this version
offers the feature of custom defined strategies, defined by mean of
the AC_PROGRAPH software, running on a Windows PC.
AC30
4 control loops, 8 analog inputs, 4 analog outputs, 8 digital I/O and
Real Time Clock with 12 control strategies, stored in the instrument
memory and recalled from the front panel.
The parametrisation of the controller is performed through one of the
following 3 ways: directly from the instrument panel, through the
serial comm Main Com and by mean of the AC-Prograph/AC-Edit
running on Windows. Beyond the AC20 characteristics, this version
offers the feature of Setpoints Programmers, generating time
dependant setpoint profiles and time sequenced digital outputs.
Technical specification
1.2.1 I/O maximum capabilities
Analog Inputs(AI)
Analog Outputs (AO)
Logic Inputs (DI)
Frequency Input
Logic Outputs(DO)
Main Comm RS 485
Aux Comm RS 485
Serial port RS 232
ARCNET LAN
N° 8 ( N° 4 only for AC10 )
N° 4
N° 8
N° 1 ( AC20 and AC30 )
N° 8
N° 1
N° 1 ( only for AC20 and AC30 )
N° 1
N° 1 ( only for AC20 and AC30 )
Analog Inputs(AI)
Voltage input, with range 0-5 V or 1-5 V cc,
software selectable.
Current input, with range AI 0-20 mA or 4-20
mA, with external 250 Ω burden resistors. 16
bit A/D conversion resolution.
Input impedance (DC) > 1000 MΩ.
Frequency Input
This feature is provided on the D1 input of
the AC20 and AC30 controllers, only.
Minimum input signal amplitude: 8Vpp. Input
7
Installation and User manual of the AC10 - AC20 - AC30 controller
ranges: 0.01 - 200 Hz, 0.1 - 2000 Hz, 1 - 20
Khz.
When the range 0.01-200 Hz is selected, an
antibounce filter of 1.5 ms. is automatically
inserted on the input signal.
Analog Output (AO)
Ranges: 0-5 V, 1-5 V, 0- 20 mA, 4-20 mA,
software selectable.
Output load drive:
- 500 Ω minimum for voltage output.
- 500 Ω maximum for current output.
Resolution ≅ 13 bit.
Logic Inputs (DI)
Input range: 24 VDC ( min 8 VDC, max. 36
VDC, for logic “1” ).
Optoisolated , current sinking,
4700 Ω input impedance.
bidirectional (no polarity), driven both by
positive and negative voltages.
Logic Outputs (DO)
Output level: 24 V cc/ca, max. 36 V cc/ca,
Maximum current: 300 mA.
Normally open output.
Protection against surges and short circuits
through automatically armed fuses.
Serial Communication
RS485 port (Main Com) to a Supervisory
Computer.
Protocol supported: MODBUS RTU.
Line length: 1200 metres maximum.
Units per line: 32 controllers with twisted pair
cable and 120 Ω termination resistors.
Transmission rate:19200 baud.
RS485 Port (Aux Com) to Expansion Units
or to a computer for the backup of the data.
Galvanic isolated from the controller I/O
signal (AC20 and AC30 only).
RS232 Port (programming Port) to a
computer, running the AC-Prograph (AC20
and AC30), for the design and the test of
control strategies, or running AC_EDIT, for
saving of the strategy parameters (AC10,
AC20 and AC30).
8
Failure Digital Output (DO)
Configurable.
Accuracy Class
Inputs: 0 - 5 V ; 0,1 % of the span.
Outputs: 0 - 20 mA, 0 - 5 V; 0,1 % of the
span.
Temperature Drift
Inputs 0.005 % / °C maximum.
Outputs 0.01 % / °C maximum.
Display
LCD graphic display, backlighted by EL (cool
cathode) lamp.
128 x 320 pixel resolution.
Control of the contrast from the keyboard,
with automatic environmental temperature
compensation.
Duration of the lamp > 20.000 hours.
Chapter 1. - General Information
Keyboard
8 multifunction keys.
Supply
90 - 264 Vac, 48 - 63 Hz, optionally 24
Vac/VDC + 20 %.
Maximum Power consumption 20 VA.
1.3
Transmitter Power Supply
24 V cc + 5 % regulated, 300 mA maximum,
with short circuit protection.
Isolation
EN 61010
Electromagnetic compatibility
EN 55011, EN 50081-2, EN 50082-2
IEC801-2, 801-3, 801-4, 801-5 Level IV
Operating Conditions
KWF for DIN 40040
Environmental Conditions
Temperature 0 - 50 °C.
Relative Humidity 10 to 90 % (without
condensation).
Protection
IP30 for the case.
IP20 for the termination unit.
IP54 front panel protection
Material
Self-extinguishing 94VI.
Dimension
DIN standard 72 x 144 x 260 mm.
Panel mounting
Through adjustable mounting clamps, fitted
on the top and the bottom of the controller.
Weight
1,7 Kg approximately.
Hardware Description
The AC10, AC20 and AC30 controllers, consists of:
FRONT PANEL
• LCD graphic display with automatic and manual adjustment of the
contrast.
• Keyboard, for issuing commands and for changing parameters.
• Plug in connector for programming the controller.
ELECTRONIC BOARD
• CPU board with analog and digital inputs.
• LAN Board with the serial interface to the LAN (optional for AC20 and
AC30).
• Power supply board.
• Output board, with digital and analog outputs.
• Display board with intelligent graphic display controller.
• LCD supply board with the LCD lamp voltage booster circuit.
REAR UNIT
• Termination unit with M3 terminals and connectors.
• Transparent terminal cover with connections indication.
9
Installation and User manual of the AC10 - AC20 - AC30 controller
1.4
Resident Strategies Description
The multifunction AC controllers are supplied with the following resident
configurations, already stored in the memory:
1 Loop A
1 Loop B
1 Loop C
2 Loops A
(Simple loop with Remote Setpoint and Controlled Variable
retransmission)
(Loop with Remote Setpoint and predefined stored
Setpoints, Feedforward, PV retransmission)
( Typical Heat/Cool Loop)
2 Loops B
2 Loops C
(2 simple Loops with Remote Setpoint
retransmission)
( 2 Loops, one complex and the other simpler)
( Heat Cool Loop plus 1 simple Loop)
Ratio
( 1 Ratio Loop plus 1 simple Loop)
Cascade
(Cascade loop
retransmission)
Override
( 2 Loops interconnected as override controllers)
4 Loops
( 4 simple Loops independent each other)
4 Indicators
( 4 measure indication, with retransmission and alarms)
2 A/M Station
( 2 A/M stations, with alarms and retransmission)
with
Remote
Setpoint
and
PV
and
PV
More information about this strategies are illustrated in Annex A: Resident
configurations.
10
Chapter 1. - General Information
1.5
Library of the functional modules of the AC10, AC20 and
AC30 controllers
Input/Output and Display
Description
Mnemonic
Code
Information displayed
on the controller panel
Analog Input
AI
A. Inputs
Digital Input
DI
D. Inputs
Frequency Input
FI
Freq. Input
Analog Output
AO
A. Outputs
Digital Output
DO
D. Outputs
Time proport. Output
TPO
T. Prop. Out
Bargraph Display
1BP
1 Bar Panel
Bargraph Display
2BP
2 Bar Panel
Bargraph Display
4BP
4 Bar Panel
Trend Display
TRP
Trend Panel
Trend Display
2TP
2 Tr. Panel
Trend Display
4TP
4 Trend Panel
Alarms Display
ALP
-
Control Panel
SELP
Sel. Panel
Analog meas. display
ADP
12AD Panel
Analog meas. display
4ADP
4AD Panel
Analog values Setting
4WAD
4WAD Panel
Multiswitch
16SW
-
Control and Processing
Description
Mnemonic
Code
Information displayed
on the controller panel
Setpoint and Deviation calculation
SDV
Set & Deviation
PID algorithm
PID
PID Block
Output
MV
Outs Mgt.
Heat/Cool output
HCMV
Motor positioner
SRV
Servo Motor
Setpoint Programmer
PRG
Programmer
Time Clock
RTC
Clk Program
Range Change
SCH
Sc. Changer
Filter
FILT
Dig. Filter
Analog signal delay
ADLY
Analog Delay
Digital signal delay
DDLY
Dig. Delay
MSL
Slope Limit
Rate limiter
Characterisation
Minimum or Maximum
H&C Out Mgt.
CHAR
Linearizator.
MAX
Min or Max
Analog Soft. Multiplexer
AMUX
Analog Mux
Analog Hard. Multiplexer
AMX8
-
HLD
-
Sample and Hold
Digital Soft. Multiplexer
DMUX
Dig. Select
Digital Hard. Multiplexer
DMX8
-
Mass flow compensation
AGA
-
Flow compensation
MFL
-
Totaliser
TOT
Totalizers
Signal Limiter
LMT
Limit Block
Alarms
ALM
Alarm Block
SALM
Speed Alarm
Analog Software Demux
ASEL
Analog Demux
Set page
SETP
-
Timer
TMR
-
Servomotor Open/Closed Loop
SRV2
-
Rate alarm
11
Installation and User manual of the AC10 - AC20 - AC30 controller
Control and Processing
Description
Mnemonic
Code
Analog Hardw.Demux
AS8
Information displayed
on the controller panel
-
Digital Software Demux
DSEL
Digital Hardware Demux
DS8
-
DEC8
-
Digital decoder
Dig. DeSel
Math and Logic
Description
Mnemonic
Code
Information displayed
on the controller panel
Analog var. to Computer
CAIO
-
Digital var. to Computer
CDIO
-
Key activation
KEY
-
Failure of the controller
FAIL
-
DLY
Dig. Delay
Delay
Computer time out
CALM
Comp. Alarm
Aux. Units time out
AALM
Aux. U. Alarm
LAN time out
LALM
LAN Alarm
System Configuration
SYS
-
Setpoint Control Key Lock
SPKL
-
Output Control Key Lock
OPKL
-
Math and Logic Functions
12
Description
Mnemonic
Code
Information displayed
on the controller panel
Expression
EXP
-
Arithmetic operation
OPR
Math Operat.
Math operation
FN
Math Funct.
Single Constant
CNS
-
And
AND
-
Or
OR
-
Eor
EOR
-
Not
NOT
-
Flip-Flop J-K Latch
JKF
Monostable
MST
Monostable
Counter
CNT
-
OR 8 inputs
OR_8
-
Analog predefined constants
MCNS
Constants
Digital predefined constants
MDCN
D. Constants
AND_8
AND_8
-
Shift
SHIFT
-
Chapter 2. - Installation
2.
Installation
2.1
Dimensions
Overall dimensions of the controller (compliant to the DIN 43700 standard)
MIN. 100
1 1 +1
4 3 0
4 8
1
6
6
68 +0.7
0
72
34,5
44,5
MIN. 80
2.2
Spessore max.20mm
258,7
MIN. 310
2
0
0
M
I
N
Panel Mounting
1. Insert the instrument in the aperture on the panel. (fig. 2.1)
2. Fit the two mounting clamps, fixing them in the slots of the instrument
case, on the top and on the bottom of the instrument walls. To hook firmly
the clamps, slide them away from the panel, in the direction of the
termination unit. (fig. 2.2)
3. Rotate clockwise the clamps screws up to when the instrument front
panel sticks completely on the panel wall. Do not tight the screws too
strongly, to avoid panel distortion.
78
9
Screwdriver
Figure 2.1 Insertion into the panel aperture
Figure 2.2 Hooking the clamps and blocking with
the screws
13
Installation and User manual of the AC10 - AC20 - AC30 controller
2.3
Connections and terminations
The screw terminals, located at the rear of the controller, can be accessed by
removing the transparent protective terminal cover. This cover is secured in
position by two screws.
On the transparent cover all the terminals are labelled, together with some
functional information, as shown in figure 2.3.
Screw Terminals AC-10
Screw Terminals AC-20 / AC-30
Figure 2.3 Termination Units
To avoid misunderstanding, the input and output terminals are functionally
grouped. Therefore, the left side of the termination unit houses the input
signals, while the outputs are on the right side.
This organisation facilitates the installation of the signal cable, because
inputs and outputs have different cable paths. In the central part of the
termination unit, the following connectors, for the serial communication, are
located:
• in the upper part, the connector to the LAN network is located
• in the lower part, the RS485 Aux and Main Comm connector is located.
Through the controller has been designed to work in the worst conditions,
typical of the industrial environment, the following suggestions must be
followed:
• Keep separate the cable to the controller power supply from the other
power cables to the plant.
• Avoid to install the controller near to power switches, electromagnetic
contactors, high power motors and others power sources.
• Avoid to install the controller near static power units, especially if they are
based on phase angle control.
The terminals are build up according to the UL-CSA standard.
For proper connections, it is recommended to use cable with maximum size
2
of 12AWG (2.5 mm ), to remove the cable insulation cover for approximately
8mm and to insert it completely in the terminal hole, before tightening the
screw (Use an edge screwdriver 0.4 x 2.5 x 75 mm).
8
14
Chapter 2. - Installation
2.4
Electrical Connections
The following pages illustrate the most common examples of connection
between the instrument and the field.
2.4.1 Passive Transmitter
Note
Use the 24 VDC power supply, on the terminals 25 and 26 only for powering
the passive transmitter. Do not use this power supply for the digital inputs
and outputs of the AC controller.
2.4.2 Active transmitter
The shunt resistor, shown in the figure below, is not required if the output of
the transmitter is already in voltage. In case of trasmitter with output in
current ( 0-20mA or 4-20mA), a shunt resistor, of 250Ω 0,1% 3W must be
installed on the terminal unit of the AC controller
+
250 Ω 0,1%
3W
A
-
1
25
2
26
+
V
-
1
25
2
26
3
3
2.4.3 Analog output
The setting of the output type ( between 0-5 V or 1-5 V voltage and 0-20 mA
or 4-20 mA current ) is performed by the AO (Analog Output) module.
A
N
A
L
O
G
O
U
T
27
28
+
-
Load 1
Load 2
29
30
31
+
+
-
Load 3
Load 4
32
+
15
Installation and User manual of the AC10 - AC20 - AC30 controller
2.4.4 Digital Inputs and Outputs
The power is provided by an external power supply, with range 8-36 VDC.
13
14
+
-
15
Power
D
I
G
I
T
A
L
D
I
G
I
T
A
L
I
N
P
U
T
O
U
T
33
Load
34
-
35
+
Power
External
Supply (24 VDC)
External
Supply (24 VDC)
N
46
SUPPLY
90 - 264 V ac
47
L
48
2.4.5 Frequency Input
The frequency input signal must not exceed the range 8-36 V
+
Pulse T
D
I
G
I
T
A
L
13
- 14
I
N
P
U
T
15
2.4.6 RS485 Serial Port Main Comm
Connector AC
6
CN2
485
Connector Supervisory
C
4
5
+
-
Female Connector
D-SUB DIN 41652
6
4
5
Male Connector
D-SUB DIN 41652
2.4.7 ARCNET Network
Connector Supervisory
Connector AC
CN1
LAN
16
2
3
+
2
3
5
C
5
Female Connector
NFC 93425
Chapter 2. - Installation
2.4.8 Connection to a PC via the programming port
....
PROGRAMMER
Connector ASCON
Blocking screw
In the figure below, the details of the connection to a 9 and a 25 pole
connector, are shown.
RS232 Connection
25 pole connector
RS232 Connection
9 pole connector
blue
brown
2
3
brown
blue
black
Controller
Front Panel
2
3
black
7
5
PC connector
Controller
Front Panel
PC Connector
2.4.9 Connection to the Expansion Unit, via the RS485 port AUX Comm
Note:
The figure above illustrates a controller with the maximum number of
Expansion Units connected to it. If there is an Expansion Unit model AACEU/88/4 (the one supporting analog signals) it must have assigned the
address “0” while the others the addresses “1” and “2”. If there is only one
Expansion Unit, it must have assigned always the address “0”. Furthermore,
the last unit in the serial link must have a termination resistor of 120Ω 1/4W.
17
Installation and User manual of the AC10 - AC20 - AC30 controller
2.4.10 RS485 Main Comm serial connection + expansion unit
CN1 AC
18
SUPERVISOR
Chapter 3. - Commissioning and start up
3.
Startup
STARTUP PROCEDURE
The flowchart of Figure 3.1lists all the steps you must carry out to have your
AC10, AC 20 and AC30 controller, installed on the plant and properly
controlling the Customer process.
Unpack and check
the instrument
Install, connect
and wire
Switch the
power on
Standard or
custom
configuration ?
Standard
Pick up one of the
resident strategies
Custom
Design the Custom
strategy by mean of
AC - PROGRAPH
Download the
strategy
Set the parameter values
Startup the controller
and tune the P.I.D.
Check the whole
functionality
3.1
Fig. 3.1
Keyboard
7 8 3 .2
1 0 0 .0
1 0 0 .0
LO C
0 .0
0 .0
0=
32
Fig. 3.2
The keyboard is located on the right side of the front panel. It consists of 8
pushbuttons, whose functionality is described in the following pages.
19
Installation and User manual of the AC10 - AC20 - AC30 controller
3.2
Pushbuttons Functionality
Increases the value of the selected variable, i.e. the Local Setpoint.
Lowers the value of the selected variable, i.e. the Local Setpoint.
Changes the Setpoint operating mode.
Selects the next variable of the scrolled variable list and displays it in
the corresponding field in the upper part of the panel.
Forces the controller to present, on the display, the next display
panel configured in the strategy.
Selects the Out station, operating mode between AUTO and MAN.
When the controller is in MAN, it decreases the value of the output.
When the controller is in MAN, it increases the value of the output.
The usual functionality of these 8 pushbuttons is described above. In same
peculiar circumstances, they perform differently. This occurs with some panel
(i.e. Selector, System Clock, Dual Trend, etc.), where the operator has to set
specific parameters. In this case, in order to clearly flag that the functionality
of the key has been changed, an icon of a button, with the mnemonic of the
new functionality, is displayed on the display panel, close to the pushbutton.
When the display panel changes, the icon disappears and the pushbutton
returns back to its original functionality.
The following ones are these new buttons, as they appear on the various
panels.
Enter It allows to input a value in a variable or, simply, to proceed with
the next step in a parameter definition procedure.
Page It allows to go to the next page, when the values of parameters
are listed on more than one page.
Return or Reject It allows, in any step of a parameter definition
procedure, to abort the current entry and go back to the previous
display, without changing any value.
Scroll keys. They allow picking up a choice from a list of various
possibilities.
NOTE During the calibration procedure, the following buttons are displayed:
Input Calibration.
N -> Proceeds to the next step.
C -> Performs the calibration and stores the calibration coefficients.
Output Calibration.
S -> Select: Selects/Deselects the output.
R -> Return: Returns back to the previous display panel
20
Chapter 3. - Commissioning and start up
3.3
Display
The display panel consists of a graphic LCD display, backlighted, with high
resolution (128 x 320 pixels).
On the AC controller, there are several types of active panels, each one
corresponding to a functional module of the strategy. These panel displays
have a complete user interface, allowing you to have detailed informations
about process variables, to issue commands and to set parameters. The
definition of the types and the quantities of these display panels are set in the
selected or designed strategy.
When the pushbutton
is pressed, the panels will be displayed in the
order set in the Tools – Edit Modules menu of the AC Prograph / AC Edit
programme.
For the above refer to section 7.6.2. of the manual.
The active panels are the following:
• 1 Bar Panel: front panel of a control loop, with numeric indication of the
relevant variables, bargraph display for the main ones (process variable,
setpoint, output) and status display of logical signals or alarms.
• 2 Bar Panel: front panel of two control loops, usually connected in
cascade, with numeric and bargraph indication of the most relevant
variables and status display of logical signals or alarms.
• 4 Bar Panel: front panel of four control loops, with bargraph indication of
the process variable and setpoint, numeric indication of the relevant
variables and a cumulative alarms display, common to all the 4 loops.
This panel automatically omits the display of the signals not connected to
its functional module, in order to avoid meaningless information.
Therefore, it is a suitable display from 2 to 4 loops.
• Trend Panel: It is the front panel of a single loop. It provides all the
numeric and bargraph displays of the 1 Bar Panel, with the addition of a
trend chart, reporting, graphically, the recent trend of an analog signal,
like the Process Variable. The user selects the time span of the chart
between the following 8 choices: 1, 2, 5, 10, 30 minutes- 1, 2, 5 hours.
• 2 Trend Panel: It is the front panel of a Setpoint Programmer. It provides
a trend chart, with the recent trend of 2 variables (usually, the Setpoint
and the Process variable), together with the display of the status of 2
digital signals and the visualization and the command of the various
operating modes of the Programmer. It is available only on the AC30
controller, where the Programmer module is supported. The time span of
the chart is selected by the user, between the following 8 choices: 1, 2, 5,
10, 30 minutes- 1, 2, 5 hours.
• 4 Trend Panel: This panel provides 2 trend chart, with the recent trend of
2 variables each, the real time display of the values of the trended
variables and the visualization of the status of 4 digital signals. The time
span of the chart is selected by the user, between the following 8 choices:
1, 2, 5, 10, 30 minutes- 1, 2, 5 hours.
• Alarm Panel: Alarm annunciator, displaying the status of 12 alarm signals.
Each alarm is displayed with a message of 12 alphanumeric characters
maximum, in reverse or normal according to the status of the
corresponding digital input.
• Selector Panel: Control panel allowing the user to set the pattern of 4
digital outputs, by choosing from a list of predefined patterns. Each
pattern performs a predefined operation on the process and is labeled
with a symbolic name for an immediate understanding.
• 12 Analog Display: Indicator panel, displaying the value of up to 12 analog
signal inputs. Each input is identified by a 6-character label for an
immediate understanding.
• 4 Analog Display: Indicator panel displaying the value of up to 4 analog
inputs. Compared to the 12 Analog Display module, this module provides
more informations (longer tag and engineering units) and the visualization
of the variables with big size characters (apx 1 cm. high), that can be
seen far away.
21
Installation and User manual of the AC10 - AC20 - AC30 controller
• 4 Writable Analog Display: This display panel allows the display or
generation of 4 analog variables directly from the front panel. For each
generated variable it will be possible to define an identification tag with its
own engineering unit of measurement.
3.3.1 1 Bar Panel
1
TAG-0000-0
2
Kg/h
1207
LSP
4
1210
1600
7
3
5
Loc
Loc
6
13
TRK
8
AL1
AL2
9
AUT
10
0
11
14
12
7
Out= 43
1) Tag
This tag is the identifier of the panel and consists of up to 10
alphanumeric characters. It is assigned automatically when the
module is created and can be modified through AC_Edit/ACPrograph.
2) Engineering Units
Engineering units mnemonic, consisting of a string of 3 characters
maximum. It is entered and modified through AC_Edit/ACPrograph.
3) Main Variable Value
Numerical visualization of the main variable, consisting of 6
characters, including the sign and the decimal point.
4) Scrolled Variable Tag
This 3-character label, specified by the Customer, identifies the
scrolled variable displayed.
The following ones are some examples of tags, as already defined
in the resident configurations. In the custom strategies, these tags
are almost defined by the user, but the ones related to general
variables, like the Working Setpoint etc.:
TSP : Target Set Point; value of the Setpoint.
WSP : Working Set Point; value of the Set to the PID module.
RSP : Remote Set Point; value of the Setpoint input signal.
CSP : Computer Set Point; value set by the Computer.
PV1 : Process Variable 1; value of the main variable n°1.
PV2 : Process Variable 2; value of the main variable n.2.
WSR : Working Set Ratio; value of the ratio setpoint.
5) Scrolled Variable Value
Numerical display of the selected scrolled variable. The list of the
variables includes the Local Setpoint and other analog input signals
of the module. It consists of 6 characters, including the sign and the
decimal point.
6) Setpoint Operating Mode
This short mnemonic reports the current Setpoint operating mode
of the loop. The various modes are: Loc, Rem, Com.
22
Chapter 3. - Commissioning and start up
7) Scale high/low Limits
They define the values of upper and lower limits of the scale. Each
value consists of 6 characters, including the sign and the decimal
point.
8) Set point Slider
Graphic representation, through a moving slider, of the real time
value of the Setpoint. The slider is moved in steps of 0,5 %.
9) Bargraph
Bargraph indication of the process variable. The bargraph shows
the process variable value in 200 steps, providing a resolution of
0,5 %.
10) Output bargraph
Horizontal bargraph, showing the loop control output value in steps
of 1 %.
11) Output Value
Numerical display of the loop control output, in percentage.
12) Auto/Man
Display of the Out station operating mode. The possible modes are
AUT or MAN.
13) Loc/Rem/Com
Display of the Setpoint operating mode that the user has requested
from the controller keyboard. The mode is indicated by the
mnemonics Loc, Rem and Com.
14) Alarms and Digital
Display, by mean of user defined, 3 characters mnemonic, of the
status of the 3 digital inputs of the module. These inputs are used
for representing alarms or simple logic status.
3.3.2 2 Bar Panel
The main purpose of this display is to provide the front panel for a cascade
loop (Master and Slave).
In this case, the setpoint and the measured variable of the Master loop is on
the left (Loop1), while the ones of the Slave are on the right (Loop2). The
control output (manipulated variable) displayed belongs to the Slave, while
the output of the Master, that becomes the Setpoint of the Slave, is
displayed, in engineering units, as a Setpoint value. The only setpoint the
user can change, is the one of the Master, because the one of the Slave is
just displayed.
1
2
TAG-0000-0
Kg/h
127.3
SPL
4
2345.6
3
2340
123.45
6
5
Rem
Loc
16
11
10
TRK
9
AL1
15
8
AL2
7
AUT
13
14
0
0
12
6
Out= 43
23
Installation and User manual of the AC10 - AC20 - AC30 controller
1) Tag
This tag is the identifier of the panel and consists of up to 10
alphanumeric characters. It is assigned automatically when the
module is created and can be modified through AC_Edit/ACPrograph.
2) Engineering Units
Engineering units mnemonic, consisting of a string of 3 characters
maximum. It is entered and modified through AC_Edit/ACPrograph.
3) Main Variable Value
Numerical visualization of the Master controlled variable, consisting
of 6 characters, including the sign and the decimal point.
4) Scrolled Variable Tag
This 3 characters label, specified by the Customer, identifies the
scrolled variable displayed.
The following ones are some examples of tags, as already defined
in the resident configurations. In the custom strategies, these tags
are almost defined by the user, but the ones related to general
variables, like the Working Setpoint etc.:
TSP :Target Set Point; value of the Setpoint.
WSP :Working Set Point; value of the Set to the PID module.
RSP :Remote Set Point; value of the Setpoint input signal.
CSP :Computer Set Point; value set by the Computer.
PV1 :Process Variable 1; value of the main variable n°1.
PV2 :Process Variable 2; value of the main variable n.2.
WSR :Working Set Ratio; value of the ratio setpoint.
5)Scrolled Variable Value
Numerical display of the selected scrolled variable. The list of the
variables includes the Local Setpoint and other analog input signals
of the module. It consists of 6 characters, including the sign and the
decimal point.
6) Scale high/low Limits
They define the values of upper and lower limits of the scale. Each
value consists of 6 characters, including the sign and the decimal
point.
7) Variable 1 Bargraph
Bargraph indication of the process variable n° 1, controlled by the
Master loop. The bargraph shows the process variable value in 200
steps, providing a resolution of 0,5 %.
8) Variable 2 Bargraph
Bargraph indication of the process variable n° 2, controlled by the
Slave loop.
9) Set point Slider 1
Graphic representation, through a moving slider, of the real time
value of the Setpoint n°1, corresponding to the Master loop. The
slider is moved in steps of 0,5 %.
10) Set point Slider 2
Graphic representation, through a moving slider, of the real time
value of the Setpoint n°2, corresponding to the Slave loop. The
slider is moved in steps of 0,5 %.
11) Loc/Rem/Com
Display of the Setpoint operating mode, that the user has
requested from the controller keyboard. The Setpoint refers to loop
1 (Master). The mode is indicated by the mnemonics Loc, Rem and
Com.
12) Auto/Man
Display of the Out station operating mode. The possible modes are
AUT or MAN.
13) Output bargraph
Horizontal bargraph, showing the loop 2 (Slave) control output
value in steps of 1 %.
24
Chapter 3. - Commissioning and start up
14) Output Value
Numerical display of the loop 2 (Slave) control output, in
percentage.
15) Alarms and Digital
Display, by mean of user defined, 3 characters, mnemonics, of the
status of the 3 digital inputs of the module. These inputs are used
for representing alarms or simple logic status.
16) Setpoint Operating Mode
This short mnemonic reports the current Setpoint operating mode
of the loop.1 (Master) The various modes are: Loc, Rem, Com.
3.3.3 4 Bar Panel
This display type is less rich of informations than the previous ones; because
it lacks the output bargraph and the main variable engineering units, but,
surely, it is the most versatile; as soon as you connect the signals of a loop, it
adds the bargraph and the slider, related to it. This way to operate improves
dramatically the readability, because the panel is not always filled with 4
bargraphs, when you need just two.
Furthermore, for each bargraph, you can choose if you want the slider or not,
so that, if you want to display just a measure, you do not have a meaningless
slider around. And, you can mix, as you like, bargraphs with the slider, for
control loops, and without, for measures and A/M stations.
1
TAG-000-00
1048
13
3
6
LSP
1048 Loc
WSP
1048 Loc
TEM F A
FG
LEV
2
12
11
5
8
4
7
9
M
A
A
A
O=34 O=65 O=76 O=48
10
1) Tag
This tag is the identifier of the panel and consists of up to 10
alphanumeric characters. It is assigned automatically when the
module is created and can be modified through AC_Edit/ACPrograph.
2) Main Variable Value
Numerical visualization of the controlled variable of the selected
loop, consisting of 6 characters, including the sign and the decimal
point. Each loop is selected cyclically, and the one selected has its
tag displayed in reverse.
3) Setpoint Label
LSP (Local Set Point) Mnemonic label of the setpoint value (n°5).
WSP (Working Set Point) Mnemonic label of the setpoint value
(n°4).
4) Working Setpoint Value
Numerical display of the value of the Working Setpoint of the
selected loop
25
Installation and User manual of the AC10 - AC20 - AC30 controller
5) Local Setpoint Value
Numerical display of the value of the Local Setpoint of the selected
loop. The Local setpoint is entered by the user through the front
keyboard.
6) Loops tag
This 3 characters label, specified by the Customer, identifies the
tag of the loop. The loop selected has its tag displayed in reverse.
7) Bargraphs
Bargraph indication of the process variables 1, 2, 3, 4,of the loops.
8) Set point sliders
Graphic representation, through a moving slider, of the real time
value of the Setpoints of the loops 1, 2, 3 and 4.
9) Auto/Man
Display of the Out station operating mode. The possible modes are
A (Auto) or M (Manual).
10) Output Value
Numerical display of the loop control output, in percentage.
11) Setpoint Operating Mode
This short mnemonic reports the current Setpoint operating mode
of the loop 1 (Master). The various modes are: Loc, Rem, Com.
12) Loc/Rem/Com
Display of the Setpoint operating mode, that the user has
requested from the controller keyboard. The Setpoint refers to loop
1 (Master). The mode is indicated by the mnemonics Loc, Rem and
Com.
13) Alarms
Blinking box, usually flagging anomalous conditions, requiring the
operator attention. It is activated by a digital input signal.
The following are few examples of the types of display you can
achieve with this panel. The type of visualization is automatically
selected, according to the connections performed on the module
inputs, through AC_Edit/AC-Prograph.
2 LOOPS
3 LOOPS
1048
LOOPS
4 DISPLAY
1050
1048
ST1,2 ST3,4
1050
1049
LSP
1048 Loc
LSP
1048 Loc
LSP
1048 Loc
LSP
LSP
WSP
1048 Loc
WSP
1048 Loc
WSP
1048 Rem
WSP
WSP
LP2
LP1
TEM
FG
FA
M
A
M
A
A
O=34
O=76
O=34
O=65
O=76
2 Loops
3 Loops
L1
L2
L3
L4
M
A
A
A
PV1
PV2
PV3 PV4
4 Loops
1048
TEM F A
M
O=34 O=65 O=76 O=48
1048
A
FG
LEV
A
A
O=34 O=65 O=76 O=48
4 Indicators
A/M stations
3.3.4 Trend Panel
This display has almost the same functionality of the 1 Bar Panel module,
with the addition of a trend chart of an analog variable. Its main purpose is to
provide the front panel of a simple control loop. The trend indication gives the
operator a better understanding of the situation of the process, than just the
real time display of process data.
This display is provided in all the resident strategies of the AC controller.
26
Chapter 3. - Commissioning and start up
1
2
TAG-0000-0
l/h
LSP
573
550
1200
4
Rem
Loc
6
3
5
12
14
HLD
7
AL1
13
8
AL2
15
9
10
MAN
W=5 min
0
11
6
OUT= 63
1) Tag
This tag is the identifier of the panel and consists of up to 10
alphanumeric characters. It is assigned automatically when the
module is created and can be modified through AC_Edit/ACPrograph.
2) Engineering Units
Engineering units mnemonic, consisting of a string of 3 characters
maximum. It is entered and modified through AC_Edit/ACPrograph.
3) Main Variable Value
Numerical visualization of the main variable, consisting of 6
characters, including the sign and the decimal point.
4)Scrolled Variable Value
Numerical display of the selected scrolled variable. The list of the
variables includes the Local Setpoint and other analog input signals
of the module. It consists of 6 characters, including the sign and the
decimal point.
5) Setpoint Operating Mode
This short mnemonic reports the current Setpoint operating mode
of the loop. The various modes are: Loc, Rem, Com.
6) Scale high/low Limits
They define the values of upper and lower limits of the scale. Each
value consists of 6 characters, including the sign and the decimal
point.
7) Set point Slider
Graphic representation, through a moving slider, of the real time
value of the Setpoint. The slider is moved in steps of 0,5 %.
8) Bargraph
Bargraph indication of the process variable. The bargraph shows
the process variable value in 200 steps, providing a resolution of
0,5 %.
9) Output bargraph
Horizontal bargraph, showing the loop control output value in steps
of 1 %.
10) Output Value
Numerical display of the loop control output, in percentage.
11) Auto/Man
Display of the Out station operating mode. The possible modes are
AUT or MAN.
27
Installation and User manual of the AC10 - AC20 - AC30 controller
12) Loc/Rem/Com
Display of the Setpoint operating mode that the user has requested
from the controller keyboard. The mode is indicated by the
mnemonics Loc, Rem and Com.
13) Alarms and Digital
Display, by mean of, user defined, 3 characters mnemonics, of the
status of the 3 digital inputs of the module. These inputs are used
for representing alarms or simple logic status.
14) Trend Chart
Area dedicated to the graphic display of the recent trend curve of a
variable. The time width of the chart corresponds to 75 samples.
15) Time Scale
Numerical display of the time span of the trend chart. The user
defines this value by choosing between the following set: 1, 2, 5,
10, 30 min. - 1, 2, 5 hours.
3.3.5 2 Trend Panel
This display provides a suitable interface to the Setpoint programmer
module, available on the AC30 controller, only. It provides both the trend of 2
variables and the status displays and the user commands to the Setpoint
programmer. Furthermore, it represents the status of 2 general purpose
logic signals. The time span of the trend chart is defined by the user, by
choosing between the following set: 1, 2, 5, 10, 30 min. - 1, 2, 5 hours.
1
2
3
4
TAG-0000-0
l/h
367.8
LSP
356.9
500.0
5
6
7
8
9
W=5 min
10
NRM
11
0.0
NXT
21
20
Rem
19
Loc
18
HLD
16
AL1
17
16
RUN
15
E
RST
14
4
13
12
1) Tag
This tag is the identifier of the panel and consists of up to 10
alphanumeric characters. It is assigned automatically when the
module is created and can be modified through AC_Edit/ACPrograph.
2) Engineering Units
Engineering units mnemonic, consisting of a string of 3 characters
maximum. It is entered and modified through AC_Edit/ACPrograph.
3) Scrolled Variable Tag
This 3 characters label, specified by the Customer, identifies the
scrolled variable displayed.
28
Chapter 3. - Commissioning and start up
button, the tag, together with the corresponding
Pressing the
value, of each variable of a list, is displayed, one at a time and
sequentially. The list includes the LSP and the 5 analog input
signals of the module.
4) Trend chart high/low scale Limits
They define the values of upper and lower limits of the scale. Each
value consists of 6 characters, including the sign and the decimal
point.
5) Trend Chart
Area dedicated to the graphic display of the recent trend curve of
one or more variables.
6) Trend of BI1
Recent trend curve display of the analog input signal BI1.
7) Trend of CI1
Recent trend curve display of the analog input signal CI1.
8) Bargraph
Bargraph indication of the analog input signal BI1.
9) Time scale
Numerical display of the time span of the trend chart.
10) Normal/Fast Function
Display of the running mode of the Programmer. The running mode
can be changed, by mean of the two button
and
,
selecting, respectively, the Fast and the Normal mode. After
pressing the button, push the Enter key to confirm.
11) Selection Cursor
Highlighting of the selected command. From this panel you can
enter some commands to the Programmer. These are the ones
listed at the lower line of the display (Normal/Fast, Next, Reset). To
do it, you must first select the command, by moving the cursor with
the
button. The selected command is the one displayed in
reverse. Once you have selected the command, follow the
instruction related to it, to proceed.
12) Next Function
Next command mnemonic. To send a Next command, that forces
the Programmer to skip to the next segment, you must select this
field and confirm with Enter.
13) Reset Function
Reset command mnemonic. To send a Reset command you must
select this field and confirm with Enter.
14) Enter (OK function)
Icon of the Enter button, corresponding to the physical button
.
This button must be pressed to confirm the command that has
been selected, as described at Point 1. It causes the starting of its
execution.
15) Operating mode
Display of the operating mode of the Programmer (Run or Hld).
The user can change the operating mode, forcing the program to
run or holding it, by mean of the button A/M .
16) Digital
Display, by mean of user defined, 3 character mnemonics of the
status of 2 digital input signals. The user can define a mnemonic
for each state of the digital signal.
17) Setpoint slider
Graphic representation, through a moving slider, of the real time
value of the Setpoint., corresponding to the analog input signal CI1.
18) Loc/Rem/Com
Display of the Setpoint operating mode that the user has requested
from the controller keyboard, by mean of the L/R key. The choices
are:
29
Installation and User manual of the AC10 - AC20 - AC30 controller
LOC Local Setpoint
REM Remote Setpoint
COM Computer Setpoint
19) Setpoint Operating Mode
This short mnemonic reports the current Setpoint operating mode
of the loop.
20) Scrolled Variable Value
Numerical display of the selected scrolled variable, selected by
mean of the
key. The list of the variables includes the Local
Setpoint and other analog input signals of the module. It consists of
6 characters, including the sign and the decimal point.
21) PV Variable Value
Numerical visualization of the PV variable, consisting of 6
characters, including the sign and the decimal point. Usually, this
variable corresponds to the one at input BI1.
3.3.6 4 Trend Panel
This panel is intended for displaying on a single panel, up to 4 trended
analog variables. Furthermore, it display the numeric value of these 4 analog
input signals and the logic status of 4 digital input signals.
Available only on the AC30 controller, Its main purpose is to provide a
complete user interface for the Setpoint Programmer. The time span of each
trend chart is defined by the user, independently from the other, by choosing
between the following set: 1, 2, 5, 10, 30 min. - 1, 2, 5 hours.
1
TAG-0000-0
2
Stringa 1
3
840
4
835
25
24
23
24
22
8
1200
RUN
5
6
20
0
7
W=10 min
8
Stringa 2
9
0.85
10
11
0.87
19
18
17
24
16
8
1.55
RUN
12
13
21
OFF
OFF
0.00
W=5 min
15
14
1) Tag
This tag is the identifier of the panel and consists of up to 10
alphanumeric characters. It is assigned automatically when the
module is created and can be modified through AC_Edit/ACPrograph.
2/8) Chart title
String of up to 10 alphanumeric characters, with the name of the
trend chart below. The string can be entered or modified through
AC_Edit/AC-Prograph.
3/9) SP values
Numeric display of the values of the analog input signals SP1 and
SP2. These signals are trended in the chart, too.
4/10) Trend Chart
Area dedicated to the graphic display of the recent trend curve of
the variables.
30
Chapter 3. - Commissioning and start up
5/11) Trend of SP
Recent trend display of the SP1 and SP2 analog input signals.
6/12) Trend of PV
Recent Trend display of the PV1 and PV2 analog input signals.
7/13) Time Scale
Numerical display of the time span of the trend chart.
14/20) Trend Chart Low Limit
They define the values of the low limits of the scale. Each value
consists of 6 characters, including the sign and the decimal point.
15/21) Digital
Display, by mean of user defined, 3 characters mnemonics of the
status of 4 digital input signals. The user can define a mnemonic
for each state of the digital signal.
16/19/22/25) 4 Variables Values
Numerical display of the value of the 4 trended variables. The ones
with big size numbers, correspond to PV, while the others
correspond to SP. It consists of 3 characters, including the sign and
it doesn’t allow the decimal point.
17/23) Trend Chart High Limits
They define the values of the high limits of the scale. Each value
consists of 6 characters, including the sign and the decimal point.
18/24) PV Values
Numerical values of the analog input signals PV1 and PV2.
These signals are trended in the chart, too.
3.3.7 12 Analog Display Panel
This display provides the functionalities of a set of analog indicators. It
displays both the value and the 6 characters tag, of up to 12 analog
variables, connected to it, as analog inputs.
1
2
TAG-0000-0
PV1Lev
123456
PV2Lev
123456
TICTmp
123456
LIC008
123456
PICMax
123456
QIC003
123456
MaxLev
123456
MinLev
123456
LowLev
123456
HIG Lev
123456
FIC003
123456
FIC004
123456
4
3
1) Tag
This tag is the identifier of the panel and consists of up to 10
alphanumeric characters. It is assigned automatically when the
module is created and can be modified through AC_Edit/ACPrograph.
2) Indicators Area
Area for the display of the analog input variables. Each line of the
display offers both the tag and the value of one of the 12 analog
input signals.
31
Installation and User manual of the AC10 - AC20 - AC30 controller
3) Variable Tags
This 6 characters label, specified by the Customer, identifies the
displayed variable.
4) Variable Values
Numerical display of the analog input signal. It consists of 6
characters, including the sign and the decimal point.
3.3.8 4 Analog Display Panel
This display provides the functionalities of a set of analog indicators. It
displays the value, the 10 characters tag and the 3 characters engineering
units of up to 4 analog variables, connected to it, as analog inputs. The value
is shown either as a 6 digits number, without decimal point, or as a 5 digits
number, with decimal point.
1
TAG-0000-0
2
Input 1
3
mV
4
Input 2
5
%
6
Input 3
7
mA
8
Input 4
9
Bar
8.7654
13
65.3
12
12.037
11
12.345
10
1) Tag
This tag is the identifier of the panel and consists of up to 10
alphanumeric characters. It is assigned automatically when the
module is created and can be modified through AC_Edit/ACPrograph.
2/4/6/8) Variable Tags
This 10 alphanumeric characters label, specified by the Customer,
identifies the displayed variable.
3/5/7/9) Engineering Units
Engineering units mnemonic, consisting of a string of 3
alphanumeric characters maximum.
10/11/12/13) Variables Values
Numerical display of the analog input signal. It consists of 6
characters, including the sign and the decimal point.
3.3.9 4 Writable Analog Display Panel
This panel allows the contemporaneous display or generation of up to 4
analog-type variables. Each variable is characterized by a tag (max 10
characters) and an engineering unit (max. 3 characters)
32
Chapter 3. - Commissioning and start up
1
TAG-0000-0
2
Out 1
3
4
5
6
7
8
9
mV
8.765
13
Out 2
65.3
12
12.03
11
%
Out 3
mA
Out 4
Bar
65.3
10
14
1) Tag
This tag is the identifier of the panel and consists of up to 10
alphanumeric characters. It is assigned automatically when the
module is created and can be modified through AC_Edit/ACPrograph.
2/4/6/8) Variable Tags
This 10 alphanumeric character label, specified by the Customer,
identifies the displayed variable.
3/5/7/9) Engineering Units
Engineering units mnemonic, consisting of a string of 3
alphanumeric characters maximum.
10/11/12/13) Variables Values
Numerical display of the analog input signal. It consists of 6
characters, including the sign and the decimal point.
14) Cursor positioning
Through these keys, the user scrolls the cursors on all the
variables, to point to the variable to modify.
3.3.10 Alarm Panel
This module provides the functionalities of an alarm annunciator with 12
alarm messages. Each message is connected with a digital input, that
defines the visualization of the message. All the 12 messages are listed at a
predefined position on the display, with different visualization modes,
according to the status of the associated digital input; in reverse, if the input
is active, or in normal, if it is inactive. This display can be used not only for
alarms, but for listing digital status, too.
33
Installation and User manual of the AC10 - AC20 - AC30 controller
1
2
TAG 000-0
Alarm 1
Alarm 2
Alarm 3
Alarm 4
Alarm 5
3
Alarm 6
Alarm 8
Alarm 9
Alarm 10
Alarm 11
Alarm 12
1) Tag
This tag is the identifier of the alarm panel and consists of up to 10
alphanumeric characters. It is assigned automatically when the
module is created and can be modified through AC-Prograph / ACEdit.
2) Alarm Messages
The alarm message is a 12 alphanumeric character string
(including space and symbols) associated to a digital input signal. If
this signal is in the active state, the message is displayed in
reverse, otherwise in normal.
3) Message Area
This display is reserved for 12 alarm messages, each on a line of
the display.
3.3.11 Selector Panel
This display provides the functionality of a control panel for digital
commands. It has 4 outputs, that are driven all together, by the pattern
selected through one of the 3 supported selection modes: Keyboard,
Supervisory Computer and the 4 Digital Inputs. Through these modes, a
number from 0 to 15 is specified, that forces the 4 digital outputs to assume
a well defined pattern, corresponding to the binary coding of the number and
identified by an alphanumeric label, for immediate understanding.
1
2
3
SELECTOR
Prio : None
Req. : None
1
Remote SP
Hold Out
*
Min. Out
Max. Out
No Function
4
E
5
6
7
34
Chapter 3. - Commissioning and start up
1) Tag
This tag is the identifier of the panel and consists of up to 10
alphanumeric characters. It is assigned automatically when the
module is created and can be modified through AC-Prograph / ACEdit e.
2) Selection Priority
Display of the selection mode that currently has the highest priority
and that, as a consequence, is selecting the output pattern. The
priority is defined by the user, by mean of the AC_Prograph, to the
3 potential selection modes: Keyboard, Digital Inputs and
Computer.
3) Selection Request
Display of the selection mode, that has been requested by the user
and, should be granted. By mean of the L/R button, the user can
modify the priority scheme, defined through the AC_Prograph,
giving the highest priority to the keyboard. This mechanism allows
that the control of the Selector is, usually, performed by the strategy
and/or the Supervisory computer, leaving the possibility of
operators interventions, through the keyboard, when required. The
number at the right of this field, indicates the item number of the
last selected pattern.
4) Item Area
This area consists of 16 lines, each associated to a defined output
pattern (named item) and identified by an alphanumeric, custom
defined tag. In AC_Prograph the user configures the Item ( from 1
to 16). The star symbol on the right of the item name specifies the
last item selected, whose pattern has set the digital outputs.
5) Enter Key
Enter key, required to confirm the choice operated with the button 6
and 7, in order to proceed with the execution.
6 - 7) Item Selection Key
Through this key, the user scrolls the cursors on all the items, to
point to the item to select. This selection operation is possible only
if the highest priority has been assigned to the keyboard.
3.4
Management of the active panels
Each active panel can be set in the following way:
R/W:
Panel and keyboard enabled
Read:
Panel enabled and keyboard locked
NO:
Panel not displayed
To set the panel’s active modalities, do the following:
Forno 3A
Zona 1
840
Main
Menu
8
835
1200
Tune & Views
Par. & Comms
Prog & Test
Keyb. Perm.
24
RUN
Tuning (Auto)
Tuning (Man)
PID Param.
F. Panel View
LCD Contrast
E
OFF
0
R
W=10 min
Zona 2
0.85
Act. Panels
Tuning and
View
E
R
No
Forno 3A No
Zona 2
Yes
Zona 4
No
General Yes
E
E
R
E
8
0.87
1.55
24
R
R
R
RUN
OFF
0.00
W=5 min
3.5
Selection of a resident configuration
At power up, the controller can either show, on the display, the first panel of
the selected configuration or display the “NO Program Found” message,
when no configuration has been already selected. In both cases, you can
select a new configuration, as shown below.
35
Installation and User manual of the AC10 - AC20 - AC30 controller
A) The controller has already a configuration
TAG-0000-0
l/h
LSP
Main
Menu
573
550
1200
Tune & Views
Par. & Comms
Prog & Test
Keyb. Perm.
Loc
Loc
HLD
R
Program
Selection
Prog. Sel.
& I - O Test
Sampling T.
I - O Test
Prg. Select.
Calibration
E
E
1 Loop A
1 Loop B
1 Loop C
2 Loop A
2 Loop B
2 Loop C
R Ratio
Cascade
Override
4 Loops
4 Indicators
A/M STation
E
E
R
AL1
R
AL2
R
E
R
MAN
W=5 min
0
OUT= 63
B) The controller doesn’t have a configuration.
TAG-0000-0
Program
Selection
AC -- Series
NO
Program
1 Loop A
1 Loop B
1 Loop C
2 Loop A
2 Loop B
2 Loop C
Ratio
Cascade
Override
4 Loops
4 Indicators
A/M STation
l/h
LSP
573
550
1200
E
HLD
E
AL1
R
AL2
Found
MAN
W=5 min
Release ---
Loc
Loc
0
OUT= 63
In this case, the page with the standard resident configuration, stored in
ROM, is displayed.
36
Chapter 4. – PID Tune and Communications
4.
PID, Tune and Communication
4.1
Tuning
The Tuning method, used in the AC series controller, is an highly
sophisticated, new generation algorithm, that represents the state of the art
in this technology area. The basic principle, this method is based, is
illustrated below.
Hysteresis relay
W
G(s)
X
Fig. 4.1
-1
Tune active
Start of Tune
A= Variable PV
Fig. 4.2
B= MV control output
In the closed loop configuration, illustrated above, the hysteresis relay,
causes a continuous endless oscillation of the measured variable. These
oscillations are carefully examined, in term of amplitude and period, by the
Tune algorithm, that, on the basis of this analysis, determines the optimal
PID terms values.
The use of the Tune is very simple, because it works with every process,
either in steady conditions or during transients. Furthermore, the Tune
algorithm is automatically fitted to the type of PID (P, PI, PID) selected.
The first step of the Tune procedure is to check and, if necessary, to change
the type of PID, by carrying on the following steps:
TAG-0000-0
l/h
LSP
Main
Menu
573
550
1200
Tune & Views
Par. & Comms
Prog & Test
Keyb. Perm.
Loc
Loc
HLD
R
PID
Block
Tuning and
View
Tuning (Auto)
Tuning (Man)
PID Param.
F.Panel View
LCD Contrast
E
E
R
Rev
PID_LOOP 1
PID_LOOP 2
PID_LOOP 3
PID_LOOP 4
E
E
PID_LOOP 1
R
E
R
Action
Algo
P.B.
Int. T.
Der. T.
Min. Out
Max. Out
M. Reset
G. Sch.
Rev
PID
100.0
100
1.0
0
100
50
No
E
AL1
AL2
R
R
R
R
MAN
W=5 min
0
OUT= 63
37
Installation and User manual of the AC10 - AC20 - AC30 controller
Once terminated this configuration step, the Tune procedure is launched, by
carrying on the following steps, that allow you to specify the loop to be tuned.
TAG-0000-0
l/h
LSP
Main
Menu
573
550
1200
Tune & Views
Par. & Comms
Prog & Test
Keyb. Perm.
Loc
Loc
HLD
R
Tuning
Tuning and
View
Choice
Tuning (Auto)
Tuning (Man)
PID Param.
F.Panel View
LCD Contrast
E
E
E
R
PID_LOOP 1
PID_LOOP 2
PID_LOOP 3
PID_LOOP 4
E
Eo R
E
AL1
R
AL2
R
R
MAN
W=5 min
0
OUT= 63
During the Tuning process, the message “Tune PID LOOP...” appears in the
tag field, at the top of the display panel of the loop under tuning.
It is possible to abort the Tuning procedure, anytime before the completion,
forcing the loop to Manual or returning back to the Main Menu display.
The controllers recognizes the abort of the Tuning, by displaying the
message “Tuning Aborted”. This message disappears after the user has
acknowledge it, by stroking any key.
You can select between two operating modes of the Tune algorithm,
according to the way the computed PID terms values are used: an AUTO
mode, that, at the end of the processing, writes the computed PID terms
values in the loop parameters directly, and a MAN (Manual) one, that
presents the values on the display, asking the user to confirm or cancel,
before writing them in the loop.
Tuning PID 1
l/h
LSP
573
550
1200
Tuning Completed
Loc
Old Values
Loc
P.B. = 12.85
Int.T. = 21
Der.T. = 4.20
New Values
E
HLD
P.B. = 17.13
Int.T. = 20
Der.T. = 4.00
AL1
Display panel at the
end of the Tuning
procedure (Man)
Enter Key : Accept
AL2
Other Key : Reject
MAN
W=5 min
0
OUT= 63
4.2
Gain Scheduling
Gain scheduling is based on the technique of changing the value of the 3
terms parameters of the PID algorithm, according to the value of a variable,
like the setpoint, the manipulated variable, the controlled variable and other
process signals. The main purpose of this functionality is to adjust
automatically the 3 terms parameters when dynamic changes occur in the
process to control, as, for instance, a load change. The gain scheduling is a
very effective control technique with superb results, but its diffusion has been
limited by the high skills and the considerable development efforts required to
implement it.
38
Chapter 4. – PID Tune and Communications
The word Gain scheduling is the historical name, and it doesn’t mean
absolutely that only the Proportional band value can be changed, because
this technique is now extended to all the 3 terms, including the integral time
and the derivative time.
The PID module of the AC series controllers has 3 analog inputs, named KP,
KI, KD, whose values multiply the configured 3 terms parameters (Gain,
Integral Time and Derivative Time), to determine the coefficients values to
use in the PID formula, as explained below:
PBu =
PB p
TI u = TI p * KI
KP
TDu = TD p * KD
where PBu, TIu and TDu are the coefficients of the 3 terms, used in the PID
formula, while the PBp, TIp and TDp are the values set by the user.
For instance, let us guess to have calculated three sets of the 3 terms
parameters, each one related to well defined setpoint range. You can
imagine that each set has been computed automatically by the controller
Tuning facility, as described in the Chapter 4.1.
Setpoint Range
0-300
300-500
500-700
Optimal PB
10
13,3
20
The best result is achieved if the Gain parameter is set according to the
value of the setpoint. This can be implemented automatically, exploiting the
scheduling facility, as illustrated below. A linearizator module, whose input
variable is the PID Working Setpoint, selects the appropriate coefficient, that,
through the KP input, multiplies the predefined value of PB (that is 20),
achieving the Gain value in the table above.
2.0
1.5
1.0
300
700
500
Characterization curve of the Linearizator module
WSP
1
KI
1
KD
PID
LIN
KP
Block diagram of the strategy for implementing a variable gain PID.
4.3
PID with two degree of freedom
In order to provide very effective control capabilities, the AC controllers are
supplied with a PID algorithm with two degree of freedom.
This second degree corresponds to the Beta parameter, that provides a sort
of weighting of the setpoint that goes in the PID formula. The benefit of using
this parameter, is a consistent lowering of the overshoot and the undershoot,
during the setpoint changes.
39
Installation and User manual of the AC10 - AC20 - AC30 controller
This Beta parameter, also named Set Point Weighting, has the same
characteristics of the Set Point Filtering, that is used by other Vendors,
because it doesn’t change the response at steady conditions. It modifies the
position of some zeroes in the closed loop transfer function, and this causes
a more beneficial response to the overshoot. The following picture illustrates
the concept and the better response achieved with an optimal value of Beta.
Fig. 4.3
Various simulation studies have demonstrated that the Set Point Weighting
is more effective than the Set Point Filtering , because, in identical conditions
of dumping amplitude, it reaches the target setpoint in a shorter time.
4.4
Communications
The AC series controllers are supplied with 3 serial ports:
• RS232 serial port for instrument programming.
• RS485 serial port to the Supervisory Computer.
• RS485 serial port to auxiliary units (Expansion Units).
• LAN network (ARCNET type) for “peer to peer” communication and to the
Supervisory Computer.
4.4.1 Handling the Programming port
The programming port (named service port, too) is mainly used to download
and upload strategies in the AC controller, by mean of the AC_Prograph or to
modify the parameters of a strategy, by mean of the AC_Edit. This RS232
serial port is configured with the fixed settings 9600, E, 7, 2 (9600 baud, even
parity, 7 data bits, 2 stop bits) that cannot be changed by the user, because
its use is reserved to AC-Prograph / AC-Edit.
4.4.2 Handling the Main Comm Supervisory Computer
The AC controller communicates, through this port, with a Supervisory
Computer, with the MODBUS and JBUS protocols. The physical media is a
twisted pair and up to 31 devices can be connected on a cable. The setting
of this port is as follows:
40
Chapter 4. – PID Tune and Communications
TAG-0000-0
l/h
LSP
Main
Menu
573
550
1200
Tune & Views
Par. & Comms
Prog & Test
Keyb. Perm.
Loc
Loc
HLD
R
Comms Sup.
Parameters
& Comms
E
E
9600
Parameters
Main Comm
LAN Address
R
B. Rate
D. Bits
S. Bits
Parity
Address
Mode
E
E
R
9600
8
1
None
1
JBus
E
AL1
R
AL2
R
R
MAN
W=5 min
0
OUT= 63
Main Comm port Setting
B. Rate
D. Bits
S. Bits
Parity
Address
Mode
Baud rate setting. Allowed values: 110, 300, 600, 1200, 2400, 4800, 9600,
19200
Fixed value set to 8.
Stop bits, the choice is between 1 or 2.
The choice is None, Odd, Even.
MODBUS/JBUS address of the controller. It is a number from 1 to 247.
ModBus or Jbus protocol.
Fig. 4.4
Supervisory port specification.
Interface:
Baud Rate:
Type of connection:
Max n° of controllers on a cable:
RS485 differential (2 wires)
110 .. 19200 Bit per Seconds
Multidrop
31 plus the Supervisory computer
Note:
It is strongly suggested to insert the termination resistors of 120Ω at both
ends of the cable, where the Supervisory computer and the last instrument of
the multidrop chain are located. Furthermore, to improve the noise rejection
figures, it is possible to bias the two wires of the differential line with the
insertion of a pull up resistors on a wire and a pull down resistors on the
other. This is achieved by moving the on board switch S3 to position A and
S4 to position B. Obviously, the bias must be enabled on one instrument
only. If there are more than one controller, is preferable to apply the bias, by
setting the switches as described above, on the last one.
41
Installation and User manual of the AC10 - AC20 - AC30 controller
• Example 1: There is a Supervisory computer connected with a controller,
only. The termination resistors must be applied both on computer and the
controller.
• Example 2: There are “n” controllers on the line. The termination resistors
must be applied both on the Supervisory computer and the last controller
on the line. On the controller, the insertion of the termination resistors is
achieved by moving the on board switch S1 to position B.
The on board switches for the bias and the termination of the line, are
located inside the instrument, close to the gold dual edge connector of the
CPU card (Refer to Fig. 4.5 below).
Termination
B ias
Fig. 4.5 Detail of the CPU card with the switches for the termination and the
bias of the line.
For more information on the MODBUS and JBUS protocol, consult the
Communication manual Cod. J30 - 304 - 1ACSAC
4.4.3 Handling the Aux Comm
This serial port is provided on the AC20 and AC30 controllers only, and uses
the RS485 standard. Its purpose is the transfer of real time data between the
Controller and Expansion units mod AAC-EU/88/4 or AAC-EU/88 or the
safety station, currently under development.
To get this connection operating, the user has just to make the appropriate
cabling, because all the hardware and the firmware required is already on
board and doesn’t require any configuration. Refer to Chapter 2.4.9 for the
diagram of the connections.
Once the Expansion unit is connected, its I/O can be easily used in the
strategy, you are designing with the AC_Prograph, as any other signal from
the controller. For more detail, refer to the AC_Prograph User Manual cod.
J30-304-AACPROGRAPH.
42
Chapter 4. – PID Tune and Communications
4.4.4 Handling the LAN (ARCNET )
The interface card to this network is supplied, as an option, on the AC20 and
AC30 controllers only. The purpose of this network is to handle the peer to
peer communication between all the devices on the LAN (Local Area
Network).
This LAN offers two big advantages:
1) It allows the softwiring between up to 8 controllers, located on 120 mt. of
cable (maximum distance between the first and the last controller),
without any additional hardware or software. This easy to use
functionality, with the plug and play feature, provides the transmission of
real time signals among the controllers, required for developing global
control strategies, involving a cluster of AC controllers.
2) It provides a communication media (2.5 Mbit/s) to a Supervisory computer
faster than the RS485 serial line. This feature, that requires an
appropriate hardware and software interface on the computer side, is
particularly useful in high performing application.
For more details, refer to the Communication manual Cod. J30 - 304 1ACSAC. The setting of this port is carried on as follows:
TAG-0000-0
l/h
LSP
Main
Menu
573
550
1200
Tune & Views
Par. & Comms
Prog & Test
Keyb. Perm.
Loc
Loc
HLD
LAN Addr.
Parameters
& Comms
E
E
R
1
Parameters
Main Comm
LAN Address
LAN Addr
E
E
R
1
E
R
AL1
R
AL2
R
R
MAN
W=5 min
0
OUT= 63
4.5
Parameter change
You can modify the parameter values, assigned by AC_Prograph to the
modules of the strategy, by carrying on the following procedure:
TAG-0000-0
l/h
LSP
Main
Menu
573
550
1200
Tune & Views
Par. & Comms
Prog & Test
Keyb. Perm.
Loc
Loc
HLD
R
Menu of
All Blocks
Parameters
& Comms
Parameters
Main Comm
LAN Addr.
E
E
R
E
E
AL1
AL2
R
R
A. Outputs
D. Outputs
1 Bar Panel
Trend Panel
Set & Deviat
PID Block
R Outs Mgt.
Linearizat.
Totalizers
Alarm Block
Math Operat.
Dig. Filter
PID
Block
Rev
PID_LOOP 1
PID_LOOP 2
PID_LOOP 3
PID_LOOP 4
E
E
PID_LOOP 1
R
E
E
R
Action
Algo
P.B.
Int. T.
Der. T.
Min. Out
Max. Out
M. Reset
G. Sch.
Rev
PID
100.0
100
1.0
0
100
50
No
E
P
R
R
R
MAN
W=5 min
0
Page 1 of 2
OUT= 63
43
Installation and User manual of the AC10 - AC20 - AC30 controller
4.6
AC-Prograph / AC_Edit Software
AC-Edit/AC-Prograph run on a PC or a compatible PC, with Windows
operating system, version 3.x or later, for basic editing of the AC controller
strategies. It allows to analyze the strategy in a controller and to change the
parameters values of the various modules and other strings, like tags.
Furthermore. it allows to save the parameters on a disk file, display them
again and download them into the controller. For more information, refer to
the AC-Edit/AC-Prograph User Manual.
4.7
Sampling time
The resident configurations have a predefined sampling time of 300 msec.,
that is perfectly suitable for most of the processes. Anyway, you can change
this time, by mean of the SYS module, and set it to a new value, with range
0,1 to 10,0 seconds at steps of 0,1 seconds.
The sampling time must be carefully set, because a too large value slows the
response time of the control strategy, risking the incapability of the control of
the process, while, if the sampling time is too short, the response of the
control strategy tends to overreact to process variations.
The following picture illustrate the procedure to use in order to modify the
sampling time.
TAG-0000-0
l/h
LSP
Main
Menu
573
550
1200
Tune & Views
Par. & Comms
Prog & Test
Keyb. Perm.
Loc
Loc
HLD
R
Sampling T
Prog. Sel.
& I - O Test
E
E
0.3
Samp. T. 0.3
Sampling T.
I - O Test
Prg. Select.
Calibration
R
E
E
R
E
AL1
AL2
MAN
W=5 min
0
OUT= 63
44
R
R
R
Chapter 5 – Modules
5.
Modules
This chapter describes all the functional modules available in the AC
controllers, in order to provide you all the detailed informations, you need to
built up your control strategy.
5.1
Rules used throughout this chapter
The following rules have been used in this chapter to describe the modules:
The values in “engineering units” of parameters, input and output signals,
have, by default and unless differently specified, the allowed range:
-9999 to 999999.
The values in “percentage” of parameters, input and output signals, have, by
default and unless differently specified, an allowed range:
0.0 to +100.0.
The two status of a digital output are indicated by:
“H” or “Active” for the status = 1
“L” or “Inactive” for the status = 0
In the drawing of the module symbol, the input signals are always on the left,
while the output signals are on the right.
45
Installation and User manual of the AC10 - AC20 - AC30 controller
5.2
I/O Modules
5.2.1 Analog Input (AI)
Description
This module converts one of the four/eight analog input signals, connected to
the termination unit of the controller, into a number, in engineering units. The
hardware range of the signal is 0-5V or 1-5V.
Beyond the conversion process, this module provides conditioning, filtering,
percentage ranging, linearization and out of range detection, on the input
signal. The available linearization curves include the square root and the
most diffused thermocouple and resistance thermometer.
If the range of the signal is less than the standard hardware one (0-5V or 15V), you configure directly this not standard range, in order to transform the
measure in engineering units, avoiding any further interpolation calculation.
For, instance, if your signal is the output of a transmitter with an actual range
of 2 to 4 V, while the standard is 0 to 5 V, you select the 0 - 5V standard and
you enter, in the Input Scaling Parameter, the actual range of your signal
(40% and 80% of the standard scale), that corresponds to the specified
engineering units range.
It is strongly recommended that the hardware range of the signal is greater
than 1.5 Volt.
AI 1
1
AI 4
AI 8
OUT
AI
DOVR
12
I/O Connections
OUT
DOVR
Value, in engineering unit, of the input signal.
Out of range detector. Active ( 1 logic ) if the signal is out
of the configured range, like in the case of some failure
on the transmitter device (1)
Note:
1. The detection is operating only if the selected range is 1-5 V (4-20 mA). In
this case the out of range is detected when the signal is lower than 0.875
Volt ( or 3.5 mA)
Parameters
PV LOOP 1
No
Scaling
% Low
% High
Inp.Type
Linear.
SqrCtOff
Filter
Range Lo
Range Hi
Format
46
No
0.00
100.00
0-5V
Ident
0.0
0.0
0.0
100.0
XXXX.X
E
R
Chapter 5 – Modules
Displayed Parameters
Scaling
% Low
%High
Inp. Type
Linear.
SqrCtOff
Filter
Range Lo
Range Lo
Format
Enables/disables the selection of the actual hardware range of the
signal, when different from the standard hardware range. The choice is
Yes or No
Defines the low limit of the actual hardware range of the signal. It is
entered as a percentage (0 to 100%) of the standard hardware range
specified.
Defines the high limit of the actual hardware range of the signal. It is
entered as a percentage (0 to 100%) of the standard hardware range
specified.
Specifies the standard hardware range of the signal. The choices are:
0-5V / 1-5V
Defines the linearization curve to apply to the input signal (2)
Specifies the Cutoff value used with flow measurement (3)
Filter time constant ( if the value is 0, the filter is disabled )
Low range, in engineering units of the signal (4)
High range, in engineering units, of the signal (4)
Defines the number of digits (format) of the output value
Note (2)
IDENT.
Sqr
TCT
TCJ
TCK
TCS
TCR
TCB
TCN
TCP
TCL
PT100
NI100
No linearization is performed
Square Root
Thermocouple T Range -200..400 °C
Thermocouple J Range -40.. 760 °C
Thermocouple K Range -40..1200 °C
Thermocouple S Range -50..1650 °C
Thermocouple R Range -50..1650 °C
Thermocouple B Range 400..1800 °C
Thermocouple N Range 0..1300 °C
Thermocouple P (Platinel) Range -50..1250 °C
Thermocouple L Range -40..760 °C
Resistance thermometer PT100 Range -200..850 °C
Resistance thermometer NI100 Range -60..180 °C
Note:
(3) The Cutoff value that is continuously compared with the input signal. If the
input signal falls below this value, it is considered 0. This is particularly
useful with flow measurement, where the measure becomes meaningless
when too low.
(4) Any change of these two values automatically affects the values of the
Scale range of the display panel modules ( Bar panel e Trend ) and the
“SDV “ module ( Setpoint and Deviation calculation ), related to the analog
input.
47
Installation and User manual of the AC10 - AC20 - AC30 controller
5.2.2 Frequency Input (FI)
Description
This module converts a frequency signal input, with range 0 to 20.000 Hz, to
a number, in engineering unit. The signal is applied to the termination unit of
the digital input n°1 (D1) of the AC controller.
The range of the output signal doesn’t necessarily start from 0, while the
module provide a filtering of the output value, to properly process the signal.
OUT
FI
DI 1
DOVR
I/O Connections
Out
Value, in engineering unit, of the frequency input
signal.
Dovr
Out of range detector. Active ( 1 logic ) if the signal is out of the
configured range, like in the case of some failure on the
transmitter device.
Parameters
Hz INPUT
0.00
Freq Lo
Freq Hi
Scale
Range Lo
Range Hi
Format
Filter
0.00
200.00
200Hz
0.0
1000.0
XXXX.X
0.0
E
R
Displayed Parameters
Freq Lo
Freq Hi
Scale
Range Lo
Range Hi
Format
Filter
Low limit of the frequency range of the signal. Adjustable from 0 to
20.000 Hz (1)
High limit of the frequency range of the signal. Adjustable from 0 to
20.000 Hz (1)
Selects the hardware range of the signal (2)
Low range, in engineering units, of the signal (3)
High range, in engineering units of the signal (3)
Defines the number of digits (format) of the output value
Filter time constant ( if the value is 0, the filter is disabled )
Note1) If the entered value exceeds the high range of the signal, as specified
in the parameter “Scale”, after pressing the “E” enter button, the
value is automatically clamped to the range limit.
Note 2) The choice is between the following ranges:
Display
200 Hz
2.000 Hz
20 kHz
Range
0.01 ... 200 Hz
0.1 ... 2.000 Hz
1 ... 20 kHz
Sampling
10 msec / 100 sec
1 msec / 10 sec
1 sec
Note 3) Any change of these two values automatically affects the values of
the Scale range of the display panel modules( Bar panel e Trend )
and the “SDV “ module ( Setpoint and Deviation calculation ), related
to the analog input.
48
Chapter 5 – Modules
5.2.3 Digital Input (DI)
Description
This module acquires one digital input and output it to the control strategy.
Beyond the basic acquisition task, this module performs some processing on
the digital signal, like inversion and delay.
DI 1
DI 9
13
DI
DI 8
DIEX
DOUT
DOUT
DI 32
24
I/O Connections
DOUT
Output
Parameters
DI 1 DRSP
L
0
Delay T. 0
Inv.
No
E
R
Displayed Parameters
Delay T.
Inv.
Defines the time the input signal must be delayed, before being
retransmitted to the output. It is entered as a multiple of the
sampling time of the controller. If it is set to 0, then the signal is
not delayed. Range from 0 to 30.
When selected, the modules performs an inversion of the status of
the digital input. The output signal corresponds to the Boolean NOT
of the input signal.
DIN
DOUT
Delay (sec) = Delay T. * Sampling T.
49
Installation and User manual of the AC10 - AC20 - AC30 controller
5.2.4 Analog Output (AO)
Description
This module converts a percentage value (range 0 - 100%) of the IN input, in
a signal, generated on the termination unit of the instrument. Beyond the
conversion, this module provides the inversion of the signal (complement to
100), the filtering and the selection of the hardware characteristics of the
signal, between various choices.
27
IN
AO 1
AO
AO 5
AOEX
IN
32
AO 4
AO 8
I/O Connections
IN
Input signal with the percentage value of the
output.
Parameters
RT SP
L1
0-5V
Out Type
Filter
Inv.
0-5V
0.0
No
E
R
Displayed Parameters
Out Type
Filter
Inv.
50
Hardware range of the output signal. The choices are: 0-5 V, 1-5 V, 020 mA, 4-20 mA.
Time constant value of the filter applied to the IN value. The range is
between 0 and 30 seconds.
When selected, it “inverts” the value of the IN input. The math
expression for this “inversion” operation is: 100 - IN. The choices are:
No or Yes.
Chapter 5 – Modules
5.2.5 Digital Output (DO)
Description
This module transfers the status of a digital variable, IN, generated by the
strategy to a physical output of the controller. Beyond this basic output task,
this module performs the inversion and the delay of the output signal.
33
IN
DO1
DO
DO9
DOEX
IN
44
DO8
DO32
I/O connections
In
Digital Input
Parameters
DO1
ALARM
0
Delay T.
Inv.
0
No
E
R
Displayed Parameters
Delay T.
Inv.
Defines the time the IN signal must be delayed before being
retransmitted to the physical output. It is entered as a multiple of
the sampling time of the controller. If it is set to 0 then the signal
is not delayed. Range from 0 to 30 (1)
When selected, the modules performs an inversion of the status
of the DIN digital input. The physical output corresponds to the
Boolean NOT of the IN input signal.
(1)
DIN
DOUT
Delay (sec) = Delay T. * Sampling T.
51
Installation and User manual of the AC10 - AC20 - AC30 controller
5.3
Display panel
The maximum number of active panels is 12 (including the REAL TIME
CLOCK for AC30).
The display sequence of the front display panels can be set in the Tools –
Edit Modules menu of AC Prograph / AC Edit.
For the above refer to Section 7.6.2. of the manual.
5.3.1 Single bargraph panel (1BP)
Description
This module provides the display, both by bargraph and numerically, of a
analog variables, logic variables by symbolic names of the states and alarms
by messages.
Furthermore, this module is not just a display device: It’s a front panel,
providing all the functionalities to carry out all the basic operations required to
interact with the loop. In fact, it allows:
• the setting of the Local Setpoint
• the change of the Setpoint operating mode, between Local, Remote and
Computer
• the change of the Output operating mode between Auto and Local
Tag (10 char.)
Main Variable
in engin. units
(3 char.)
TAG-0000-0
1207
Kg/h
SPL
Scrolled Variables
Mnemonic (3 char)
2340
2345
Main Variable PV1
(6 char. with sign and dp)
Scrolled variables values
(6 chars.with sign and d.p)
AI 1, 2, 3, 4, 5 e LSP
Loc
Scale High range
(6 char. with sign and
dp)
Loc
Setpoint operating mode
MOD
TRK
Requested Setpoint Mode:
Loc, Rem, Com
AL1
Slider CI1
Bar-graph BI1
AL2
Scale Low range
AUT
Logic Variables display
(3 char. strings)
DI 1, 2, 3
Out station operating mode
AUT , MAN
DA/M
Output value
in %
0
Y%
O= 43
AI1
AI2
AI3
AI4
AI5
BI1
CI1
PV1
Y%
YC%
DI1
DI2
DI3
52
LSP
1BP
MODE
DA/M
Chapter 5 – Modules
I/O Connections
DI1, DI2, DI3
AI1 ÷ AI5
BI 1
CI 1
PV 1
Y%
Yc%
DA/M
LSP
MOD
Digital inputs, whose status is displayed through a 3 characters label.
The most common use is to flag alarms or other digital events.
Analog variables, displayed numerically in the scrolled list, with a short
3 characters mnemonic. The number of displayed inputs can be set
though the parameter “items” in the module “1-Bargraph-Edit” of
AC Prograph / AC Edit.
For the above refer to Section 9.10.1 of the manual.
Analog Input displayed, graphically, on a bargraph, with a decimal
scale.
Analog input, displayed, graphically, by mean of a slider, moving along
the decimal scale.
Main Variable, displayed numerically, with big digits, at the top of the
display.
Analog Input, displayed, in percentage, numerically and by an
horizontal bargraph at the bottom of the display. It is intended for the
control output of a loop.
Analog Input, displayed, together with Y%, at the lower part of the
display, both numerically and by an horizontal bargraph. While Y% is
intended for a normal loop or for the Heat output, this variable is
intended for displaying the Cool output of an Heat/Cool loop.
Operating mode of the Out station: Manual (active), Auto (inactive)
Local setpoint value, entered through the keyboard.
Special I/O signal handling the Setpoint operating mode change.
Parameters
LOOP 1
100
Pv1Lo
Pv1H
For. PV1
SetLo
SetHi
For. LSP
BaGrLo
BaGrHi
For. BGr
For. TSP
For. WSP
For. RSP
For. MSP
For. CSP
0
100
XXXXX
0
100
XXXXX
0
100
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
E
R
Displayed parameters
Pv1Lo
Pv1Hi
For. PV1
SetLo
SetHi
For. LSP
BaGrLo
BaGrHi
For. BGr
For. TSP
For. WSP
For. RSP
For. MSP
For. CSP
Main variable low range
Main variable high range
Format: defines the number of digits of the PV variable.
Minimum value of the Local Setpoint
Maximum value of the Local Setpoint
Format: defines the number of digits of the Local Setpoint
Low range of the bargraph variable
High range of the bargraph variable
Format: defines the number of digits of the Bargraph variable.
Format: defines the number of digits of the AI1 variable (note 1)
Format: defines the number of digits of the AI2 variable (note 1)
Format: defines the number of digits of the AI3 variable (note 1)
Format: defines the number of digits of the AI4 variable (note 1)
Format: defines the number of digits of the AI5 variable (note 1)
Note (1)
The 3 characters mnemonic of these 5 analog inputs is defined completely in
the configuration by the user.
53
Installation and User manual of the AC10 - AC20 - AC30 controller
5.3.2 Double bargraph panel (2BP)
Description
This module has the same functionalities of the previous one, the 1BP. The
only difference is that it accommodates a second bargraph with its slider,
and, therefore, it has additional inputs.
Its main purpose is to provide the front panel of a cascade loop. In this case,
the setpoint and the measured variable of the Master loop (the one
generating the setpoint for the Slave loop) are displayed on the left bargraph,
while the ones of the Slave are on the right. The control output of the Slave is
displayed in the lower part of the panel. Both the setpoints are displayed, but
only the one of the Master can be changed from the keyboard.
Tag (10 char.)
Main Variable
in engin. units
(3 char.)
Scrolled Variables
Mnemonic (3 char)
TAG-0000-0
127.3
Kg/h
SPL
2345.6
2340
123.45
Rem
Loc
Scale High range
(6 char. with sign and dp)
TRK
Bar-graph 2 BI2
AL1
Slider 2 CI2
AL2
Slider CI1
Bar-graph BI1
Scrolled variables values
(6 chars.with sign and d.p)
AI 1, 2, 3, 4, 5 e LSP
Setpoint operating mode
MOD
Requested Setpoint Mode:
Loc, Rem, Com
Logic Variables display
(3 char. strings)
DI 1, 2, 3
Out station operating mode
AUT , MAN
DA/M
AUT
0
Scale Low range
Output value
in %
0
O= 43
Y%
AI1
AI2
AI3
AI4
AI5
BI1
BI2
CI1
CI2
PV1
Y%
DI1
DI2
DI3
54
Main Variable PV1
(6 char. with sign and dp)
LSP
2BP
MODE
DA/M
Chapter 5 – Modules
I/O connections
DI1, DI2, DI3
AI1 ÷ AI5
BI 1
CI 1
BI 2
CI 2
PV 1
Y%
Yc%
DA/M
LSP
MOD
Digital inputs, whose status is displayed through a 3 characters label. The
most common use is to flag alarms or other digital events.
Analog variables, displayed numerically in the scrolled list, with a short 3
characters mnemonic. The number of displayed inputs can be set though
the parameter “items” in the module “2-Bargraph-Edit” of AC Prograph /
AC Edit.
For the above refer to Section 9.10.2 of the manual.
Analog Input displayed, graphically, on a bargraph 1, with a decimal scale.
Analog input, displayed, graphically, by mean of a slider 1, moving along
the decimal scale.
Analog Input displayed, graphically, on a bargraph 2, with a decimal scale.
Analog input, displayed, graphically, by mean of a slider 2, moving along
the decimal scale.
Main Variable, displayed numerically, with big digits, at the top of the
display.
Analog Input, displayed, in percentage, numerically and by an horizontal
bargraph at the bottom of the display. It is intended for the control output of
a loop.
Analog Input, displayed, together with Y%, at the lower part of the display,
both numerically and by an horizontal bargraph. While Y% is intended as
the output of either a normal or a Heat loop, this variable is intended for
displaying the Cool output of an Heat/Cool loop.
Operating mode of the Out station: Manual (active), Auto (inactive)
Local setpoint value, entered through the keyboard.
Special I/O signal handling the Setpoint operating mode change.
Parameters
MASTER-SLV
0
Pv1Lo
Pv1Hi
For. PV1
SetLo
SetHi
For.LSP
BGLo1-2
BGHi1-2
For. BGr
BGLo3-4
BGHi3-4
For. BGr
For. WSm
For. RSm
For. CSm
For. PVs
For. WSs
0
100
XXXXX
0
100
XXXXX
0
100
XXXXX
0
100
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
E
R
Displayed Parameters
Pv1Lo
Pv1Hi
For. PV1
SetLo
SetHi
For. LSP
BGLo1-2
BGHi1-2
For. BGr
BGLo3-4
BGHi3-4
For. BGr
For. WSm
For. RSm
For. CSm
For. PVs
For. WSs
Main variable low range
Main variable high range
Format: defines the number of digits of the PV variable.
Minimum value of the Local Setpoint
Maximum value of the Local Setpoint
Format: defines the number of digits of the Local Setpoint
Low range of the bargraph 1 variable
High range of the bargraph 1 variable
Format: defines the number of digits of the Bargraph 1 variable.
Low range of the bargraph 2 variable
High range of the bargraph 2 variable
Format: defines the number of digits of the Bargraph 2 variable.
Format: defines the number of digits of the AI1 variable (note 1)
Format: defines the number of digits of the AI2 variable (note 1)
Format: defines the number of digits of the AI3 variable (note 1)
Format: defines the number of digits of the AI4 variable (note 1)
Format: defines the number of digits of the AI5 variable (note 1)
Note (1)
The 3 characters mnemonic of these 5 analog inputs is defined in the
configuration by the user.
55
Installation and User manual of the AC10 - AC20 - AC30 controller
5.3.3 Quadruple bargraph panel (4BP)
Description
These module has the same basic functionalities of the 1BP panel module
and it is intended for displaying, on an unique panel, more than one loop,
together with some analog measures or outputs.
Obviously, it is less rich of information than 1BP; it lacks the output bargraph
and the main variable engineering units. But, surely, it is the most versatile;
as soon as you connect the signals of a loop, it adds the bargraph and the
slider, related to it.
Furthermore, for each bargraph you can choose if you want the slider or not,
so that, if you want to display just a measure, you do not have a meaningless
slider around. And, you can mix, as you like, bargraphs with the slider, for
“control loops”, and without, for “measures” and “A/M station”.
At last, an alarm display is available. This is connected to a digital inputs in
order to flag anomalous conditions, requiring the operator attention. When
the alarm occurs, a rectangle blinks at the top of the display panel.
The modules settles automatically the display, detecting which are the
signals connected to it. It checks, for each bargraph, that the signals B
(bargraph value), Y% (manipulated variable) and A/M (operating mode) are
connected and, according to the result, sets the display, as follows:
For each B signal connected, a bargraph is displayed.
If the Y% signal is connected, then the slider is displayed, too, because it is
assumed the presence of a “control loop”; otherwise the slider is not
displayed at all, because it is assumed the presence of a “measure”.
If the A/M signal is connected, then the operating mode is displayed. The
lack of this connection doesn’t affect the bargraph and the slider display; for
instance, the lack of A/M, with the presence of Y%, is recognized as the
presence of a loop without the Out station, with fixed Auto operating mode.
Tag (10 char.)
WSP 1234
TAG-000-00
1048
Alarm display ALM
Working Setpoint
WSP 1, 2, 3, 4
LSP
1048 Loc
WSP
1048 Loc
TEM F A
FG
LEV
Main variable of the
selected loop BI 1, 2, 3, 4
Requested Setepoint
mode
Current Setpoint
mode MOD 1, 2, 3, 4
Loop tags (3 char.)
Main variable bargraph
BI 1, 2, 3, 4
Out Station Operatind
Mode A/M 1, 2, 3, 4
When the loop is selected,
this dispaly is reverted
M
A
A
A
WSPO=48
1234
O=34 O=65 O=76
Output value in %
Y% 1, 2, 3, 4
56
Chapter 5 – Modules
BI1
BI2
BI3
BI4
LSP1
A/M1
WSP1
WSP2
WSP3
WSP4
Y1
Y2
Y3
Y4
LSP2
A/M2
4BP
LSP3
A/M3
LSP4
A/M4
MOD1
MOD2
MOD3
MOD4
ALM
I/O connections
BI1 ÷ BI4
WSP1 ÷ WSP4
Y1 ÷ Y4
MOD1 ÷ MOD4
ALM
A/M1 ÷ A/M4
LSP1 ÷ LSP4
Analog Inputs displayed, graphically, on a bargraphs, with a decimal scale.
Analog inputs, displayed, graphically, by mean of a sliders, moving along
the decimal scale.
Analog Input, displayed, numerically, in percentage, at the bottom of the
display. It is intended for the control output of a loop.
Special I/O signals handling the Setpoint operating mode change.
Alarm input, activating the corresponding flag on the display
Operating mode of the Out stations: Manual (active), Auto (inactive)
Local setpoint values, entered through the keyboard.
Parameters
MULTI LOOP
100
Pv1Lo
Pv1Hi
For. PV1
Pv2Lo
Pv2Hi
For. PV2
Pv3Lo
Pv3Hi
For. PV3
Pv4Lo
Pv4Hi
For. PV4
SetLo1
SetHi 1
SetLo2
SetHi 2
SetLo3
SetHi 3
SetLo 4
SetHi 4
0
100
XXXXX
0
100
XXXXX
0
100
XXXXX
0
100
XXXXX
0
100
0
100
0
100
0
100
E
R
Displayed Parameters
PV1Lo ÷ PV4Lo
PV1Hi ÷ PV4Hi
For. PV1Lo ÷ PV4Lo
SetLo1 ÷ SetLo4
SetHi1 ÷ SetHi4
Low range of the analog inputs PV1-PV4
High range of the analog inputs PV1-PV4
Format: defines the number of digits of the Local Setpoint
Minimum value of the Local Setpoint 1-4
Maximum value of the Local Setpoint 1-4
57
Installation and User manual of the AC10 - AC20 - AC30 controller
5.3.4 Trend Panel (TRP)
Description
This module has almost the same functionality of the 1BP panel module, with
the addition of a trend chart of an analog variable. Its main purpose is to
provide the front panel of a simple control loop.
The trend is referred to the most recent values of the variable, during the last
minutes. It is continuously scrolled on the left, as soon as new more recent
samples are acquired. On the right side, a bargraph, at the beginning of the
trend curve, shows the real time value of the trended variable.
Tag (10 char.)
Main Variable
in engin. units
(3 char.)
Scrolled Variables
Mnemonic (3 char)
TAG-0000-0
l/h
367.8
LSP 356.9
500.0
Main Variable PV1
(6 char. with sign and dp)
Scrolled variables values
(6 chars.with sign and d.p)
AI 1, 2, 3, 4, 5 e LSP
Rem
Loc
Setpoint operating mode
MOD
Requested Setpoint Mode:
Loc, Rem, Com
Scale High range
(6 char. with sign and dp)
Chart area with the
trend of BI1
(200 x 75 pixel)
HLD
Bargraph of the trended
variable B1
AL2
Time span of
the chart
MAN
Y%
AL1
Logic Variables display
(3 char. strings)
DI 1, 2, 3
Slider CI1
0.0
W=5 min
Out station operating mode
AUT , MAN
DA/M
Scale Low range
Output value
in %
O= 63
AI1
AI2
AI3
AI4
AI5
BI1
CI1
PV1
Y%
YC%
DI1
DI2
DI3
58
LSP
TRP
MODE
DA/M
Chapter 5 – Modules
I/O Connections
DI1, DI2, DI3
AI1 ÷ AI5
BI 1
CI 1
PV 1
Y%
Yc%
DA/M
LSP
MOD
Digital inputs, whose status is displayed through a 3 characters label. The
most common use is to flag alarms or other digital events.
Analog variables, displayed numerically in the scrolled list, with a short 3
characters mnemonic. The number of displayed inputs can be set though
the parameter “items” in the module “2-Trend Panel” of AC Prograph /
AC Edit.
For the above refer to Section 9.10.4 of the manual.
Analog Input displayed, graphically, on a bargraph, with a decimal scale
Analog input, displayed, graphically, by mean of a slider, moving along
the decimal scale.
Main Variable, displayed numerically, with big digits, at the top of the
display.
Analog Input, displayed, in percentage, numerically and by an horizontal
bargraph at the bottom of the display. It is intended for the control output
of a loop.
Analog Input, displayed, together with Y%, at the lower part of the display,
both numerically and by an horizontal bargraph. While Y% is intended for
a normal loop or for the Heat output, this variable is intended for
displaying the Cool output of an Heat/Cool loop.
Operating mode of the Out station: Manual (active), Auto (inactive)
Local setpoint value, entered through the keyboard.
Special I/O signal handling the Setpoint operating mode change.
Parameters
MASTER
100
Pv1Lo
Pv1Hi
For. PV1
SetLo
SetHi
For. LSP
BaGrLo
BarGrHi
For. BGr
For. TSP
For. WSP
For. RSP
For. MSP
For. CSP
Window
0
100
XXXXX
0
100
XXXXX
0
100
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
2 min
E
R
Displayed Parameters
Pv1Lo
Pv1Hi
For. PV1
SetLo
SetHi
For. LSP
BaGrLo
BaGrHi
For. BGr
For. TSP
For. WSP
For. RSP
For. MSP
For. CSP
Window
Main variable low range
Main variable high range
Format: defines the number of digits of the PV variable.
Minimum value of the Local Setpoint
Maximum value of the Local Setpoint
Format: defines the number of digits of the Local Setpoint
Low range of the bargraph variable
High range of the bargraph variable
Format: defines the number of digits of the Bargraph variable.
Format: defines the number of digits of the AI1 variable (note 1)
Format: defines the number of digits of the AI2 variable (note 1)
Format: defines the number of digits of the AI3 variable (note 1)
Format: defines the number of digits of the AI4 variable (note 1)
Format: defines the number of digits of the AI5 variable (note 1)
Time span of the trend chart. Possible choices: 1, 2, 5, 10, 30 minutes
or 1, 2, 5 hours
Note (1)
The 3 characters mnemonic of these 5 analog inputs is defined in the
configuration by the user.
59
Installation and User manual of the AC10 - AC20 - AC30 controller
5.3.5 Dual Trend Panel (2TP)
Description
This panel modules it’s almost identical to the TRP module, but it provides
both the trend on a second variable, CI1, and a suitable interface to the
Setpoint Programmer module PRG, available in the AC30 controller.
The second trend, on the variable CI1 (in the TRP module, CI1 was
dedicated to move, just, the slider) is intended for the setpoint output of the
Setpoint Programmer. In this way, you have on the same trend chart both the
setpoint and the process variable, situation particularly useful when you deal
with Setpoint profile.
This panel module is available only on the AC30 controller. When you add
this module in your strategy, you must be sure that the target is an AC30
controller.
Tag of the Panel (10
Char)
Main variable engineering
units (3 char)
Scrolled variables
mnemonic (3 char)
TAG-0000-0
l/h
367.8
LSP 356.9
500.0
Trend of the CI1 input
Chart area
(200x75 pixels)
Requested operating mode
AL1
Logic variables display
(3 char strings)
DI1 and DI2
Trend of the BI1 input
E
W=5 min
Selection of the running mode
of the program: NRM or FST
(Normal, Fast)
NRM
Slider CI1
Program operating mode
Enter key, to set FST,
NORM, NXT and RST
Scale Low range
0.0
NXT
Setpoint Operating mode
HLD
RUN
Time span of the
chart
Next segment Advance
Scrolled variable values:
AI1, 2, 3, 4, 5 and LSP
Rem
Loc
Scale High Range
(6char with sign and dp)
Main Variable BI1
RST
Program Reset
DI1
DI2
LSP
DRUN
DFST
AI1
AI2
AI3
AI4
AI5
BI1
CI1
60
MODE
2TP
R/H
RST
FST
NXT
Chapter 5 – Modules
I/O Connections
DI1, DI2
DRUN
DFST
AI1 ÷ AI5
BI1
CI1
LSP
MODE
R/H
RST
FST
NXT
Digital inputs, whose status is displayed through a 3 characters label. The
most common use is to flag alarms or other digital events.
Run digital input. When this input goes active, the digital output R/H goes
active, with the effect of running the program.
Fast digital input. When this input goes active, the digital output FST goes
active, forcing the programmer to run in Fast mode.
Analog variables, displayed numerically in the scrolled list, with a short 3
characters mnemonic. The number of displayed inputs can be set though
the parameter “items” in the module “Dual Trend Panel” of AC Prograph /
AC Edit.
For the above refer to Section 9.11.2 of the manual.
Analog Input displayed, graphically on a bargraph and trended in the
chart as the Process Variable
Analog Input displayed, graphically on a bargraph and trended in the
chart as the Setpoint value.
Local setpoint value, entered through the keyboard.
Special I/O signal handling the Setpoint operating mode change.
Run/Hold digital output. It must be connected to the R/H input of the PRG
module
Reset digital output. It must be connected to the RST input of the PRG
module.
Fast digital output. It must be connected to the FST input of the PRG
module.
Next digital output. It must be connected to the NXT input of the PRG
module.
Parameters
Program
100
SetLo
SetHi
For. LSP
BaGrLo
BaGrHi
For. BGr
For. AI1
For. AI2
For. AI3
For. AI4
For. AI5
Window
0
100
XXXXX
0
100
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
2
E
R
Displayed Parameters
SetLo
Seth
For. LSP
bagel
burgh
For. Bar
For. AI1
For. AI2
For. AI3
For. AI4
For. AI5
Window
Low range of the slider variable CI1
High range of the slider variable CI1
Format: defines the number of digits of the Local Setpoint
Low range of the bargraph variable BI1
High range of the bargraph variable BI1
Format: defines the number of digits of the Bargraph variable.
Format: defines the number of digits of the AI1 variable (note 1)
Format: defines the number of digits of the AI2 variable (note 1)
Format: defines the number of digits of the AI3 variable (note 1)
Format: defines the number of digits of the AI4 variable (note 1)
Format: defines the number of digits of the AI5 variable (note 1)
Time span of the trend chart. Possible choices: 1, 2, 5, 10, 30
minutes or 1, 2, 5 hours
Note (1)
The 3 characters mnemonic of these 5 analog inputs is defined in the
configuration by the user.
61
Installation and User manual of the AC10 - AC20 - AC30 controller
5.3.6 Four Trend Panel (4TP)
Description
This module has the same basic functionalities of the TRP module and is
intended for displaying on a single panel, up to 4 trended analog variables.
Its main purpose is to provide a complete user interface for the Setpoint
Programmer, providing graphically the trend of the Profile Setpoint and the
process variable, the display of the program and segment number in
execution, the visualisation of the status of digital outputs, controlled by the
program, and a 10 characters title of each chart.
Tag (10 characters)
Label 1 Max 10 characters
SP1
TAG-0000-0
Label 1
356.9
33
367.8
500.0
271
PV1
SP1
AL1
AL2
PGNA
PV1
High Range B.G. 1
SGNA
Digital Input 2
Digital Input 1
Low Range B.G. 1
Time span B.G. 1
Label 2 Max 10 characters
SP2
0.0
W=2 min
Label 2
PGNB
45
32
27
100
High Range B.G. 2
27
SP2
AL3
PV2
Time span B.G. 2
AL4
0
PV2
SGNB
Digital Input 4
Digital Input 3
Low Range B.G. 2
W=5 min
DI1
DI2
DI3
DI4
SGNA
SGNB
PGNA
PGNB
PV1
SP1
PV2
SP2
62
4TP
Chapter 5 – Modules
I/O connections
DI1 ÷ DI4
SGNA
SGNB
PGNA
PGNB
PV1
PV2
SP1
SP2
Digital inputs, whose status is displayed through a 3 characters labels.
They, usually, flag alarms, events and status.
Analog input providing the number of the segment, currently running on
the PRG module. It’s displayed in the upper chart.
Analog input providing the number of the segment, currently running on
the PRG module. It is displayed in the lower chart.
Analog input providing the number of the program, currently running on
the PRG module. It’s displayed in the upper chart.
Analog input providing the number of the program, currently running on
the PRG module. It is displayed in the lower chart.
Analog input providing one of the two trended variables in the upper chart.
Analog input providing one of the two trended variables in the lower chart.
Analog input providing one of the two trended variables in the upper chart.
Analog input providing one of the two trended variables in the lower chart.
Parameters
Program
100
BG1Lo
BG1Hi
For. BG1
BG2Lo
BaGrHi
For. BGr
Window1
Window2
0
100
XXXXX
0
100
XXXXX
2 min
5 min
E
R
Displayed parameters
BG1Lo
BG1Hi
For. BG1
BG2Lo
BG2Hi
For. BG2
Window 1
Window 2
Low limit of the scale of the upper chart
High limit of the scale of the upper chart
Format: defines the number of digits of the upper chart variables.
Low limit of the scale of the lower chart
High limit of the scale of the lower chart
Format: defines the number of digits of the lower chart variables.
Time span of the upper trend chart. Possible choices: 1, 2, 5, 10,
30 minutes or 1, 2, 5 hours.
Time span of the lower trend chart. Possible choices: 1, 2, 5, 10, 30
minutes or 1, 2, 5 hours.
63
Installation and User manual of the AC10 - AC20 - AC30 controller
5.3.7 Alarm TagList (ALP)
Description
This module provides the functionalities of an alarm annunciator with 12
alarm messages. Each message is connected with a digital input, that
defines the visualization of the message. All the 12 messages are listed on
the display at a predefined position on the display, in a different mode,
according to the status of the associated digital input; in reverse, if the input
is active, or in normal, if it is inactive. The messages are 14 characters
strings, configured by the user.
ALARMS
MAX LEVEL H2O
Tag of the panel
(max. 10 char.)
Max. Temp. Z1
Max. Temp. Z2
Alphanumeric message
associated to a digital input
Min. P. Air
Min. Level H2O
Min. P. H2O
DI1
DI2
DI3
DI4
DI5
DI6
DI7
DI8
DI9
DI10
DI11
DI12
Area for the visualisation of
up to 12 logic signals
ALP
I/O connections
DI1 ÷ DI12
64
Digital input controlling the display of the associated message string. The
string is displayed in reverse, if the input is active, or in normal, if it is
inactive. The string is configured by the user through the AC-Prograph or
AC-Edit program, only.
Chapter 5 – Modules
5.3.8 Multiswitch panel (16SW)
Description
With this active panel it is possible to activate up to 16 digital keyboard
commands.
Use the arrows to select the command and ENTER to confirm.
Upon activation, the corresponding output is put to ON and an asterisk
appears to the right of the message to identify the command.
To lock the command, press ENTER again.
1
2
3
Page name (max. 10 characters)
Command area (max. 16 commands)
Activated command
16SW
DO1
DO2
DO3
DO4
DO5
DO6
DO7
DO8
DO9
DO10
DO11
DO12
DO13
DO14
DO15
DO16
Description of connections
DO1 ÷ DO16
Digital outputs on which to generate the command
65
Installation and User manual of the AC10 - AC20 - AC30 controller
Parameters
Multiswitch panel
Item No
66
Command number to display on the panel.
Select a number using the arrows on the keyboard.
Chapter 5 – Modules
5.4
Selector Panel (SELP)
Description
This module provides the functionality of a control panel for digital
commands. It has 4 outputs, that are driven all together, by the pattern
selected through one of the 3 supported selection modes: Keyboard,
Supervisory Computer and the 4 Digital Inputs. Through these modes, a
number from 0 to 15 is specified, that forces the 4 digital outputs to assume
a well defined pattern (also named item), corresponding to the binary coding
of the number.
Each of these three different selection modes is enabled to select and has a
custom specified priority, as specified through the SELP module parameters;
the mode that has the highest priority, makes the selection first. In the case
the selection mode with the highest priority has the “no choice” status, the
selection is done by the one with the immediately lower priority, and so on.
The priority order can be changed further, directly from the controller front
panel, as described at Chapter 3.- Start up, assigning the highest priority to
the keyboard. This mechanism of overriding the priority scheme, defined in
the strategy configuration, allows the user to operate, when the process
condition requires his intervention, leaving the control in the hands of the
strategy, at the end of the user operations.
Each of the 16 states of the digital outputs is indicated, on the display,
through an alphanumeric string, called item name, intended to provide an
immediate perception of what that pattern does on the process. For instance,
one item name can be “Valve XX open”, flagging that, when selected, the
digital outputs will assume the status required by the strategy to open the
valve XX.
Selection Modes
The three selection modes supported are:
• Supervisory Computer. Through the serial communication line, a
computer selects the item (that is the pattern of the outputs) , by writing
into a particular register. Please, refers to the Communication manual, for
the details about the location and the format of the register to write.
• Through a four bit code, specified by the DI1-DI4 digital inputs of the
SELP module, providing the item number.
• Through the front panel keyboard of the AC controller by mean of the
Scroll keys. By pressing this key, you choose the item to select and,
after, you confirm the choice, by pressing Enter.
Tag of the Panel
(10 Characters)
SELP_1
Current priority
Prio: Keyb.
Req. : None
1
Choice 1
*
Requested priority
Choice 2
Choice 3
Item name ( 14 char )
Choice 4
Choice 5
Choice
Choice
Choice
Choice
6
7
8
9
Choice 10
Choice 11
Display area of the 16
items (patterns of the
outputs)
E
Choice 12
Choice 13
Choice 14
Choice 15
Choice 16
67
Installation and User manual of the AC10 - AC20 - AC30 controller
DI1
DI2
SELP
DI3
DI4
DO1
DO2
DO3
DO4
I/O Connections
DI1 - DI4
DO1 - DO4
Digital Inputs specifying a 4 bit number from 0 to 15 corresponding to the
output pattern. If the Digital Input mode is the selection mode with the
highest priority, the digital outputs DO1 - DO4 will assume the value of the
inputs. The item name, displayed on the panel, is configured through the
AC-Prograph or AC-Edit program, only.
Digital Outputs, set according to the item selected and the priority
arbitration result.
5.4.1 Four Analog Display Panel (4ADP)
Description
This module provides the functionalities of a set of analog indicators. It
displays the value, the 10 characters tag and the 3 characters engineering
units of up to 4 analog variables, connected to it, as analog inputs. The value
is shown as a 6 digits number, without decimal point, or as a 5 digits number,
with decimal point.
TAG-0000-0
Tag input 1
(10 char max )
Input 1
Engineering units
(3 char. max)
mV
Tag input 2
(10 char max )
Input 2
Engineering units
(3 char. max)
%
8.7654
Value 1
65.3
Value 2
12.037
Value 3
Tag input 3
(10 char max )
Input 3
Engineering units
(3 char. max)
mA
Tag input 4
(10 char max )
Input 4
Engineering units
(3 char. max)
Bar
AI1
AI2
AI3
AI4
Tag of the Panel
(10 char. max)
12.345
Value 4
4ADP
I/O Connections
AI1 ÷ AI4
68
Analog Inputs. Each of these inputs is associated with a position on the
panel, where its value and its tag is displayed.
Chapter 5 – Modules
Parameters
4 Display
4
Input 1
Input 2
Input 3
Input 4
No. Data
XXXXX
XXXXX
XXXXX
XXXXX
4
E
R
Displayed Parameters
Input 1 ÷ Input 4
No. Data
Format: defines the number of digits of the 4 measured variables. Both
the tag and the engineering units of each measure, are configured
through the AC-Prograph and AC-Edit, only.
Number of the variables displayed on the panel.
5.4.2 4 Writable Analog values (4ADP)
Description
This display panel allows to display or generate 4 analog-type variables
contemporaneously. Each variable is characterized by a tag (max 10
characters) and an engineering unit (max. 3 characters)
TAG-0000-0
Titolo uscita 1
10 caratteri max.
Unità di misura
3 caratteri max.
Titolo uscita 2
10 caratteri max.
Unità di misura
3 caratteri max.
Titolo uscita 3
10 caratteri max.
Unità di misura
3 caratteri max.
Titolo uscita 4
10 caratteri max.
Unità di misura
3 caratteri max.
Tag 10 caratteri max.
Out 1
Variabile impostata
8.765
mV
Out 2
Variabile impostata
65.3
%
Out 3
Variabile impostata
12.03
mA
Seleziona la variabile
Out 4
Bar
Variabile impostata
12.3
4WAD
AO1
AO2
AO3
AO4
I/O Connections
AO1 ÷ AO4
Analog values outputs.
69
Installation and User manual of the AC10 - AC20 - AC30 controller
5.4.3 Analog Display Panel (ADP)
Description
This module provides the functionalities of a set of analog indicators. It
displays both the value and the 6 characters tag, of up to 12 analog
variables, connected to it as analog inputs. The value is shown either as a 6
digits number, without decimal point, or as a 5 digits number, with decimal
point.
TAG-0000-0
Tag of the Panel
( 10 char max )
PV1Lev
123456
Value (max 6 digits)
PV2Lev
123456
Tag (max 6 char.)
TICTmp
123456
LIC008
123456
PICMax
123456
QIC003
123456
MaxLev
123456
MinLev
123456
LowLev
123456
HIG Lev
123456
FIC003
123456
FIC004
123456
Max 12 indicators
AI1
AI2
AI3
AI4
AI5
AI6
AI7
ADP
AI8
AI9
AI10
AI11
AI12
I/O Connections
AI1 ÷ AI12
70
Analog Inputs. Each of these inputs is associated with a
position on the panel, where its value and its tag is
displayed.
Chapter 5 – Modules
Parameters
12 Display
XXXXX
AIN1
AIN2
AIN3
AIN4
AIN5
AIN6
AIN7
AIN8
AIN9
AIN10
AIN11
AIN12
No. Data
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
XXXXX
12
E
R
Displayed Parameters
AIN1 ÷ AIN12
No. Data
Format: defines the number of digits of the 4 measured
variables. Both the tag and the engineering units of each
measure, are configured through the AC-Prograph and ACEdit, only.
Number of the variables displayed on the panel.
5.4.4 System CLK ( Date and time display panel )
Description
This display is automatically shown on the AC30 front panel and is not
associated with any module of the strategy. It’s a standard basic function of
the instrument, that is provided independently of the strategy.
The display of the panel can be disabled through the F.Panel View item of
the Tune & View menu.
When this display is shown, the only operations the user can do is to change
the date and time. These operations can be done either from the keyboard or
through the serial communication (Main Comm).
The clock is battery backed up; therefore, it works even if the instrument
supply is disconnected.
Tag of the panel
(fixed)
SYSTEM CLK
Increment/decrement
the selected value
Clock dial
Confirm the new setting
E
Remove the new setting
and restores the previous
ones
Real Time Clock
R
Digital clock
A/M
<
12 : 30
Select the digit to change
>
Day mnemonic
Date
Wed 4 Dec
96
Year
Month
71
Installation and User manual of the AC10 - AC20 - AC30 controller
5.5
Processing and Control Functions
5.5.1 Setpoint and Deviation Calculation ( SDV )
Description
This module generates some preliminary processing of the signals required
in a PID algorithm, consisting of the calculation of the internal Working
Setpoint of the loop, according to the operating mode, and the calculation of
the deviation variables.
The module receives 3 possible initial Setpoints: by the Operator (Local), by
the Computer (Computer) or by a Remote signal (Remote).
The selection of the Working Setpoint from the three setpoints above is done
by a selection strategy, consisting of three different modes to operate, with a
custom specified priority assigned to each of them. These modes are:
Keyboard, Supervisory Computer and Digital Inputs. The mode that has the
highest priority, makes the selection first. In the case the selection mode with
the highest priority has the “no choice” status, the selection is done by the
one at the immediately lower priority, and so on.
The priority, for each of the selection modes, is defined by the user, between
the choices: “low”, “medium” or “high”. But the user can also disable
completely a mode, if he/she doesn’t want to use it. To avoid conflicts, it is
strongly recommended that each selection mode has a different level of
priority.
The Selection mechanism provides a fourth choice, beyond the Local,
Computer and Remote Setpoint. This choice consists in not selecting any
setpoint and passing the responsibility of the selection to the immediately
lower priority mode.
SetPoint selection mechanism
L/R
L/R
Loc
L/R
Rem
Com
L/R
No Setpoint
selection
Example
In the example below, the properties are assigned as follows:
Type
Priority
TAG-0000-0
l/h
LSP
TAG-0000-0
573
l/h
550
1200
Loc
Loc
LSP
L/R
Rem
72
0
LSP
TAG-0000-0
573
l/h
550
1200
L/R
Com
Com
Supervisory
low
LSP
573
550
1200
L/R
TAG-0000-0
l/h
LSP
573
550
1200
Rem
Loc
HLD
HLD
HLD
HLD
HLD
AL1
AL1
AL1
AL1
AL1
AL2
AL2
AL2
AL2
AL2
MAN
W=5 min
l/h
550
Rem
Digital Inputs
medium
TAG-0000-0
573
1200
Keyboard
high
MAN
MAN
W=5 min
0
W=5 min
0
MAN
W=5 min
0
OUT= 63
OUT= 63
OUT= 63
OUT= 63
1
2
3
4
MAN
W=5 min
0
OUT= 63
5
Chapter 5 – Modules
Note:
1) The Local setpoint is selected, pressing the L/R key.
2) The Remote setpoint is selected, pressing the L/R key.
3) The Computer Setpoint is selected, pressing the L/R key.
4) Pressing again the L/R key, the “no selection” option is chosen for the
keyboard. Therefore, the highest priority mode after the keyboard, is the
one driving the output. This mode is the one based on the digital inputs,
whose status is selecting the Remote Setpoint.
5) Later on, the digital inputs are set to the “no selection” status. Therefore, it
is the Supervisory Computer that selects the Setpoint, choosing the Local
Setpoint.
DSSP
DLSP
PDEV
IDEV
DDEV
TSP
DRSP
DBIA
LSP
RSP
BIAS
SDV
SSP
PV1
PV2
WSP
CSP
PV1%
WSR
MOD
I/O Connections
DSSP
DLSP
DRSP
DBIA
RSP
BIAS
SSP
PV1
PV2
PV1%
PDEV
IDEV
DDEV
MOD
TSP
WSP
CSP
LSP
WSR
Digital Input forcing the Safety Setpoint as the loop setpoint.
Together with the DRSP digital input specifies a two bit code, that selects the
Setpoint, according to the table above. (2)
Together with the DLSP digital input specifies a two bit code, that selects the
Setpoint, according to the table above. (2)
Enables the sum of the BIAS input to the Local or Remote Setpoint, in order to
calculate the Working Setpoint
Remote Setpoint analog input
Analog input with the value of the bias to add to the Local or Remote Setpoint.
Analog input with the value of the Safety Setpoint.
Controlled variable analog input.
Secondary variable analog input. Valid only for ratio loop.
Retransmission of PV1 as a percentage of the span.
Error value for the computation of the proportional term.
Error value for the computation of the integral term.
Error value for the computation of the derivative term.
Special bidirectional signal controlling the operating mode of the Setpoint.
Target Setpoint value.
Working Setpoint value, in case of a standard loop. It corresponds to the Target
Setpoint after the rate limiting operation.
Computer Setpoint.
Local Setpoint.
Working Setpoint value, in case of a ratio loop. (1)
Note:
1) WSR is PV2 * WSP in case of a direct ratio loop;
of a inverse ratio loop.
PV2 / WSP in case
2)
DLSP
0
1
0
1
DRSP
0
0
1
1
Action
No Setpoint selection
Local Setpoint request
Remote Setpoint request
Computer Setpoint request
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Installation and User manual of the AC10 - AC20 - AC30 controller
Parameters
SDV 1
100
Pv1 Lo
Pv1 Hi
Format
Cnt Algo
Pv2 Lo
Pv2 Hi
Format
Slope Up
Slope D.
Format
Set Mode
KeyBPrio
SwtPrio
CompPrio
Beta
0
100
XXXXX
Stand.
0
100
XXXXX
0
10
XXXXX
Loc
High
None
None
1.00
E
R
Displayed Parameters
PV1 Lo
PV1 Hi
Format
CNT Ago
PV2 Lo
PV2 Hi
Format
Slope up
Slope D.
Format
Set Mode
KeyBPrio
SwtPrio
CompPrio
Beta
Low limit of the controlled variable.
High limit of the controlled variable.
Format: defines the number of digits of the controlled variable.
Selection of the type of PID loop: Stand.=standard PID, Rt.x=direct ratio,
Rt.1/x=inverse ratio.
Low limit of the secondary variable (reference) of a ratio loop.
High limit of the secondary variable (reference) of a ratio loop.
Format: defines the number of digits of the ratio loop secondary variable.
Rising rate limit on the Setpoint e.u / sec.
Falling rate limit on the Setpoint in e.u / sec.
Format: defines the number of digits of the rate limits.
Defines which of the three Setpoints must be considered in the Setpoint
selection process (1).
Priority assigned to the selection mode Keyboard (2).
Priority assigned to the selection mode Digital Inputs (2).
Priority assigned to the selection mode Computer (2).
Set Point Weighting: from 0.01 to 1.00 .
1) The possible choices are:
Loc = Local
Rem = Remote
LocRem = Local and Remote
LocSup = Local and Supervisory Computer
LoReSu = Local, Remote and Supervisory Computer
2) The choices for the priority level are:
None
Low
Medium
High.
It is strongly recommended to avoid that two selection modes have the
same level of priority.
74
Chapter 5 – Modules
5.5.2 PID Algorithm(PID)
Description
This module implements the PID algorithm and generates the control output,
starting from the deviation value between the Setpoint and the controlled
variable. The control output drives the external actuator, in order to keep the
controlled variable at the target Setpoint level.
The PID algorithm (with the derivative term on the process variable) is
illustrated in the following picture.
1
TI * S
+
SP
e = SP - PV
+
100
+
PB
PV
TD * S
1 + α * TD * S
The derivative term includes a filter, in order to reject as much as possible
noise ( α = 1/10 ). In lack of this filter, being this term computed as the
derivative of the process variable, the noise would be the major source of the
derivative term, with unsuccessful results in the process control capability.
PV1%
PDEV
IDEV
DDEV
FFW
ACTY
KP
KI
KD
DBMP
DIH
MV
PID
DSAT
DTUN
I/O connections
PV1%
PDEV
IDEV
DDEV
FFW
ACTY
DBMP
KP
KI
KD
DIH
MV
DSAT
DTUN
Retransmission of PV1 as a percentage of the span.
Error value for the computation of the proportional term.
Error value for the computation of the integral term.
Error value for the computation of the derivative term.
Feed - Forward input signal.
Actual Output value. This signal is generated by the Out station
module of the controller and it is fed to the actuator of the loop.
Digital Input, indicating, through its negative transition, when the
adjustment of the PID terms, for the BUMPLESS transition
functionality, must be performed.
Proportional Gain coefficient (1)
Integral t Gain coefficient (1)
Derivative Gain coefficient (1)
Integral term disable.
Control output, in percentage, also named manipulated variable.
Desaturation Output. When active, this signal flags that the PID is
in saturation.
Digital Output flagging that the Tune algorithm is active.
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Installation and User manual of the AC10 - AC20 - AC30 controller
Note:
1)
If the gain scheduling is enabled, the three terms of the PID
algorithm are computed according to the following formulas:
PB p
PB u =
TIu = TIp * KI TDu = TD p * KD
KP
where PBu, TIu and TDu are the coefficients of the 3 terms, used in
the PID formula, while the PBp, TIp and TDp are the values set by
the user.
Parameters
PID LEVEL
PID
Action
Algo
P.B.
Int. T.
Der.T.
Min. Out
Max. Out
M.Reset
G. Sch.
Rev
PID
100.0
100
20.0
0
100
50
No
E
R
Displayed Parameters
Action
Algo
P.B.
Int. T.
Der. T.
Min. Out
Max. Out
M. Reset
G. Sch.
Selection of the control output direction: direct or inverse.
Selection of the type of PID algorithm: P, PI, PID .
Value of the Proportional Band, in percentage, with range from 0,5 to
9999.
Value of the Integral time, in seconds, with range from 0 to 9999.
Value of the derivative time, with range from 0 to 9999.
Low limit of the control output, in percentage, with range from 0 to 100 %.
High limit of the control output, in percentage, with range from 0 to 100
%.
Manual Reset value, with range from 0 to 100 %.
Enable/disable of the “gain scheduling” functionality.
More information about the PID and the Tuning process are provided in
Chapter 4.
5.5.3 Output Station (MV)
Description
This module is an Auto-Man station, to be connected downstream a PID
module, providing the functionalities the operator needs, to interact with the
loop. The module provides auto/manual/track/hold/force operating mode,
output limits and the keys for incrementally set the output. The operating
modes are defined by a set of digital inputs, as listed above, ordered
according to their priority level:
1)
Auto_Manual
DA/M
2)
Hold
DHLD
3)
Force Ymax
DYMX
4)
Force Ymin
DYMN
5)
Tracking
DTRK
Depending on these digital inputs, the functionality of the module changes as
follows:
If none of these digital signals are active, the module doesn’t alter the control
output signal, that is led unchanged directly from the input MV (from the PID
module) to the output Y%.
If DTRK (Tracking) is active, the output Y% assumes the value of the analog
input TRK.
76
Chapter 5 – Modules
If DHLD (Hold) is active, the output is frozen.
If both DHLD(Hold)and DYMN (Force Min) are active, the output Y% is set to
the minimum forcing value.
If both DHLD (Hold) and DYMX (Force Max) are active, the output Y% is set
to the maximum forcing value.
If the DA/M input is active (Manual mode request), the current output Y% is
not changed any longer according to the MV input, but it is changed only
from the keyboard.
All these digital inputs are connected to an OR logic gate, whose output is
the signal DBMP. This signal, active when the module status is either
manual, or track, or hold, or forced, is connected with the PID block, to stop
the PID execution and to perform BUMPLESS transition, on the change from
the active to the inactive state.
Note: the modules MV N° 1 and 2 are alternative to the modules HCMV N° 1,
while the modules MV N° 3 and 4 are alternative to the module HCMV N° 2
DA/M
DHOLD
DYMX
DYMN
KEYBOARD
YMAX
DTRK
TRK
SER
DCAM
SER
CTRK
YMIN
Y%
MV
OR
DBUMP
DTRK
DHLD
DYMX
DYMN
DA/M
MV
Y%
MV
TRK
DBMP
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Installation and User manual of the AC10 - AC20 - AC30 controller
I/O Connections
MV
DTRK
TRK
DHLD
DYMX
DA/M
DYMN
DBMP
Y%
Controlled variable (also named manipulated variable). It is
generated by the PID module as a percentage value of the span.
Track input. It enables the Track functionality
Track value. Analog signal with the value to set the output Y% when
the Track is enabled
Hold input. When active, the output Y% is frozen.
Digital input enabling the forcing of the Y% to the Max Forcing
value.
Digital input selecting the Auto and Manual mode.
Digital input enabling the forcing of the Y% to the Min Forcing value.
Digital input, indicating through its negative transition, when the
adjustment of the PID terms for the BUMPLESS transition must be
performed.
Control output, in percentage
Parameters
OUT _ 1
100
Min Out
Max Out
0
100
E
R
Displayed Parameters
Min Out
Max Out
78
Minimum Forcing value of the control output, with
range from 0 to 50.
Maximum forcing value of the control output, with
range from 0 to 100.
Chapter 5 – Modules
5.5.4 Heat/Cool Output Station (HCMV)
Description
This module is an Output station for an Heat/Cool loop, providing the
functionalities the operator needs to interact with the loop. The loop is
controlled by two PIDs, connected downstream to this module; each one is
dedicated to one channel. The module provides auto/manual/track/hold/force
operating mode, output limits and the keys for incrementally set the output.
The operating modes, that are unique for both the Cool and the Heat output,
are defined by a set of digital inputs, as listed above, ordered according to
their priority level.
Auto_Manual
Hold
Force Ymin
Force Ymax
Tracking
DA/M
DHDL
DMIN
DMAX
DTRK
Depending on these digital inputs, the functionality of the module changes as
follows:
If none of these digital signals are active, the module doesn’t alter the control
output signals, that are led, unchanged, directly from the input MVC and
MVH to the output Y% and Yc%. The Deadband parameter defines how the
Cool and the Heat channel interact each other in the phase splitter. The
phase splitter is used when a single output value, like in Manual mode or
Track mode, needs to drive both the Heat and Cool output. When it is
positive, this parameter defines the deadband width, centered around a
value 0 of the output. It means that for each output value included in the
deadband both the Yc% and the Y% output are 0. When it is negative, the
opposite occurs; for each value included in the deadband (now named cross
band), both the Yc% and the Y% are different from 0.
If DTRK (Track) is active, the outputs are set according to the value of the
analog input TRK. This signal, that has a range from -100 to +100, drives,
through a phase splitter, both Y% and Yc%.
When its value is in the range -100 to 0, it means that a Cool action must be
taken; therefore, Y% is set to 0, while Yc% is set to the value of TRK, with
the sign inverted.
Inversely, when it is in the range 0 to 100, Yc% is set to 0, while Y% is set to
TRK.
These values are valid if the deadband of the phase splitter is set to 0,
otherwise they slightly change.
If DHLD (Hold) is active, both outputs are frozen.
If both DHLD(Hold)and DYMN (Force Min) are active, the output Yc% is set
to the maximum Cool Forcing value.
If both DHLD (Hold) and DYMX (Force Max) are active, the output Y% is set
to the maximum Heat Forcing value.
If the DA/M input is active (Manual mode request), the current outputs are
not driven any longer according to the MV inputs, but they are changed only
from the keyboard.
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Installation and User manual of the AC10 - AC20 - AC30 controller
MVC
Yc%
0 : 100
100 : 0
-100 : 0
-100 : 0
-100 : 0
YMIN
-100
D YMX
D A/M
D HLD
D YMN
KEYBOARD
D TRK
TRK
-100 : 100
SER
SER
D CAM
CTRK
-100 : 100
0 : 100
YMAX
100
0 : 100
0 : 100
MVH
Y%
0 : 100
0 : 100
OR
DBUMP
DTRK
DHLD
DYMX
DYMN
DA/M
MVC
HCMV
Yc%
Y%
MVH
TRK
80
DBMP
Chapter 5 – Modules
I/O Connections
MVH
MVC
DTRK
TRK
DHLD
DYMX
DA/M
DYMN
DBMP
Y%
Yc %
Analog input, corresponding to the control output (also named
manipulated output) of the Heat PID module. Value in percentage.
Analog input, corresponding to the control output (also named
manipulated output) of the Cool PID module. Value in percentage.
Track input. It enables the Track functionality.
Track value. Analog signal with the value to set the output s Y%
and Yc% when the Track is enabled.
Hold input. When active, the output Y% and Yc% are frozen.
Digital input enabling the forcing of the Y% to the Max Forcing
value.
Digital input selecting the Auto and Manual mode.
Digital input enabling the forcing of the Yc% to the Min Forcing
value.
Digital input, indicating through its negative transition, when the
adjustment of the PID terms for the BUMPLESS transition must be
performed.
Control output, in percentage, of the Heat channel
Control output, in percentage, of the Cool channel
Parameters
MCF _ 1
100
Max Heat
Mass Cool
Dead Band
100
100
0.0
E
R
Displayed Parameters
Max Heat
Max Cool
Dead Band
Maximum forcing value of the heat channel, with range from 0 to 100
%
Maximum forcing value of the cool channel, with range from 0 to 100
%
Deadband, with range from -10.0 to +10.0 %
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Installation and User manual of the AC10 - AC20 - AC30 controller
5.5.5 Servomotor Output (SRV)
Description
This module is a servo-positioner, like a valve positioner, that controls, by
mean of a raise and lower digital output, the movement of the actuator up to
the target position, specified by the IN analog input.
The IN analog input provides the position, in percentage units with range
from 0 to 100%, the actuator has to assume.
DO
IN
SRV
DC
I/O Connections
IN
DO
DC
Analog input, specifying the actuator position.
Digital Output, enabling the movement in the Open direction.
Digital Output, enabling the movement in the Close
direction.
Parameters
SRV _ 1
60
Travel T.
Dead Bnd
60
0.1
E
R
Displayed Parameters
Travel T.
Dead Band
Travel time, with range from 15 to 600 seconds, required by the
servomotor to go from the zero position to the full travel end.
Dead band of the actuator, with range from 0,1 to 5,0 (1)
(1) To assure a correct operation of this module, you must check that the
dead band value, you configure, satisfies the following relationship:
Dead Band >
100 * Ts
Travel T.
Where Ts = Sampling Time in seconds
82
Chapter 5 – Modules
5.5.6 Time Proportioning Output (TPO)
Descriptions
This modules converts an analog signal, IN, generated by the strategy, in a
rectangular wave digital signal, with variable mark/space ratio, proportional to
the input. The digital signal is generated on a physical digital output of the AC
controller only, with the exclusion of the outputs of the Auxiliary Units.
The cycle time of the rectangular wave is configured by the user, while the
duty cycle is controlled by IN.
The IN signal is in percentage, with range 0 to 100%.
The maximum number of blocks of this type in a strategy is limited to 8.
33
DO1
44
DO8
TPO
IN
I/O Connections
IN
DO1 .. DO8
Analog input, in percentage.
Time proportioning digital output.
Parameters
TPO _ 1
30
Cycle T.
30
E
R
Displayed Parameters
Cycle T.
Cycle time, in seconds, of the period of the rectangular wave
with variable mark/space ratio. The range is between 1 to
100 seconds. The mark part of the rectangular wave is
proportional to IN.
83
Installation and User manual of the AC10 - AC20 - AC30 controller
5.5.7 Scale Changer (SCH)
Descriptions
This modules re-ranges an analog signal, according to the new range limits,
set by the user. The applications of this modules are quite extensive; among
the many, the most important conversions are:
From an engineering unit to another.
From an engineering unit to a percentage unit.
From a percentage unit to an engineering unit.
IN
SCH
OUT
I/O Connections
IN
OUT
Input signal, in engineering units (1)
Analog output, in engineering units (1)
1) The relationship between IN and OUT, implementing the range
conversion, is as follows:
FSu - ISu
OUT =
where:
FS =
IS =
i=
u=
FSi - ISi
* ( IN − ISi ) + ISu
High range
Low range
Input
Output
Parameters
SCH RTX WS
0
ScInLo
ScInHi
Format
ScOutLo
ScOutHi
Format
0
100
XXXXX
0
100
XXXXX
E
R
Displayed Parameters
ScInLo
ScInHi
Format
ScOutLo
ScOutHi
Format
84
Low range of the input signal
High range of the input signal
Format: it defines the number of digits of the input signal
Low range of the output signal
High range of the output signal
Format: it defines the number of digits of the output signal
Chapter 5 – Modules
5.5.8 Filter (FILT)
Descriptions
This modules implements a first order RC filter, with the filter time constant
defined by the user.
IN
FILT
OUT
I/O Connections
IN
OUT
Input signal in engineering units
Output signal in engineering units
Parameters
FILT _ 1
1.0
Cst Time
1.0
E
R
Displayed Parameters
Cst Time
Time constant of the filter, in seconds, with range from 0 to 30 seconds. If
set to 0, the filter is disabled.
85
Installation and User manual of the AC10 - AC20 - AC30 controller
5.5.9 Analog Delay (ADLY)
Descriptions
This module is a delay line, reproducing, on the output OUT, the signal on
the input IN, delayed by a predefined time, named Delay Time.
IN
ADLY
OUT
I/O Connections
IN
OUT
Input signal in engineering units
Output signal in engineering units
Parameters
ADLY_1
0
Delay T.
0
E
R
Displayed Parameters
Delay T.
Delay time, to apply to the input signal, with range from 0 to 3.600 sec.
5.5.10 Digital Delay (DDLY)
Descriptions
This module reproduces, on the output DOUT, the digital signal on the input
DIN delayed by a predefined time, named Delay Time.
DIN
DDLY
DOUT
I/O Connections
DIN
DOUT
Digital input signal
Digital output signal
Parameters
DDLY_1
5
Delay T.
5
E
R
Displayed Parameters
Delay T.
86
Delay time, to apply to the input signal, with range from 0 to 3.600 sec.
Chapter 5 – Modules
5.5.11 Rate Limiter (MSL)
Descriptions
This module provides a rate limiting functionality. It retransmits the input IN to
the output OUT, by limiting it, to a predefined value the rate of change. The
effect is that OUT ramps continuously towards the signal IN, but limited to a
specified rate of change.
The formula below explains the module functionality. The module,
continuously, computes the derivative of the IN signal, by calculating the
difference of the value at one sample and at the next sample, and comparing
it with the slope limit:
dIN/Ts = IN(T + Ts) - IN(T) / Ts <= Slope
where Ts is the sampling time of the controller at runtime.
According to the result of the comparison, the module takes two different
actions:
If the increment of input signal IN, during the TS time, exceeds (Slope *Ts),
then OUT is set to (Slope * Ts).
If the increment of input signal IN, during the TS time, doesn’t exceed (Slope
*Ts), then OUT is set to the value of IN.
IN
MSL
OUT
I/O Connections
IN
OUT
Analog Input in engineering units
Analog output in engineering units
Parameters
MSL _ 1
1
Slope
Format
1
XXXXX
E
R
Displayed Parameters
Slope
Format
Slope Limit, corresponding to the maximum allowed rate of change
of the IN signal in the time Ts. Range from 0 to 9999
Format: it defines the number of digits of the Slope value
87
Installation and User manual of the AC10 - AC20 - AC30 controller
5.5.12 Linearizator (CHAR)
Description
This module, provides the same functionality of an analog characterizer, with
up to 12 breakpoints. Each breakpoint is defined by a coordinate pair (X,Y),
specifying the value of the IN input variable (X), and the corresponding value
of the OUT output variable (Y). The function OUT=F(IN), for all the values of
IN, is derived by the characterizer breakpoints list, by mean of simple linear
interpolation calculation. The minimum number of breakpoint is 2.
The output is set continuously to the value OUT = F(IN).
Out = F (In)
P (x1,y1)
P (x2,y2)
P (x3,y3)
P (x4,y4)
P (xn,yn)
Value (In)
IN
CHAR
OUT
I/O Connections
IN
OUT
Analog input in engineering units
Analog output in engineering units
Parameters
LIN _ 1
0
X Pnt 1
Y Pnt 1
X Pnt 2
Y Pnt 2
X Pnt 3
Y Pnt 3
X Pnt 4
Y Pnt 4
X Pnt 5
Y Pnt 5
X Pnt 6
Y Pnt 6
X Pnt 7
Y Pnt 7
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Format
No.Pts
XXXXX
7
E
R
Displayed Parameters
X Pnt 1....12
Y Pnt 1....12
Format
No. Pts
88
Value, in engineering units, of the coordinate IN for a breakpoint
Value, in engineering units, of the coordinate OUT for a breakpoint
Format: it defines the number of digits of the breakpoint coordinates
Number of breakpoints (X,Y), with range form 2 to 12
Chapter 5 – Modules
5.5.13 Minimum and Maximum Selector (MAX)
Description
This module has two inputs and can be configured to select the minimum or
the maximum of these two inputs. The input selected is retransmitted out
through the OUT output.
IN1
MAX
OUT
IN2
I/O Connections
IN 1
IN 2
OUT
Analog input signal n.1
Analog input signal n. 2
Output
Parameters
MIN _ 1
Min
Function
Min
E
R
Displayed Parameters
Function
Selection of the operation to perform on the two analog input
signals: “Min” for the minimum and “Max” for the maximum.
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Installation and User manual of the AC10 - AC20 - AC30 controller
5.5.14 Software Analog Multiplexer (AMUX)
Description
This module is a 6 to 1 multiplexer of analog signals. One of the 6 inputs is
retransmitted on the OUT output.
The Input to retransmit is selected by one of the two following modes:
a) Static mode, by mean of a parameter set during the configuration of the
strategy.
b) Dynamic mode, through a 3 bit code from the DS1÷DS3 inputs, specifying
the input number, according to the following table:
DS 3
0
0
0
0
1
1
DS 2
0
0
1
1
0
0
DS 1
0
1
0
1
0
1
Input transmitted to OUT
IN 1
IN 2
IN 3
IN 4
IN 5
IN 6
IN1
IN2
IN3
IN4
IN5
IN6
AMUX
OUT
DS1
DS2
DS3
I/O Connections
IN 1.....6
DS 1..3
OUT
Analog inputs to multiplex
Selection inputs
Output
Parameters
AMUX _ 1
Dig.
Sel Code
Dig.
E
R
Displayed parameters
Sel Code
90
Specification of the selection mode to use (dynamic or
static)
Chapter 5 – Modules
5.5.15 Hardware Analog Multiplexer (AMX8)
Description
This module is an 8 to 1 multiplexer. One of the 8 inputs IN1÷IN8, selected
by mean of the 3 bit code on the DS1÷DS3 inputs, is retransmitted on the
OUT output. Furthermore, the module can be selected or deselected through
an external input DSEL. Once the module is deselected, its OUT output will
hold the value it had before the deselection, until further selected.
The input to multiplex, is selected, with the DSEL signal in the active state, by
mean of the inputs DS1÷DS3, as in the following table:
DS1
0
1
0
1
0
1
0
1
DS2
0
0
1
1
0
0
1
1
DS3
0
0
0
0
1
1
1
1
Input transmitted to OUT
IN 1
IN 2
IN 3
IN 4
IN 5
IN 6
IN 7
IN 8
IN1
IN2
IN3
IN4
IN5
IN6
IN7
IN8
AMX8
OUT
DSEL
DS1
DS2
DS3
I/O Connections
IN 1.....8
DS 1..3
DSEL
OUT
Inputs to multiplex
Selection Inputs
Selection enable input
Output
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Installation and User manual of the AC10 - AC20 - AC30 controller
5.5.16 Analog Hold (HLD)
Description
This module has the functionality of a Sample and Hold circuit. It latches the
value of the analog input IN on the output OUT, in correspondence of the
rising edge of the latch digital input DHLD. When DHLD is inactive, the value
of the output OUT is identical with the signal at the input IN, that is OUT = IN.
When DHLD goes active, the OUT output is latched and this value is hold
until the DHLD signal goes inactive again.
IN
OUT
DSEL
IN
HLD
OUT
DHLD
I/O Connections
IN
DHLD
OUT
Input
Hold command input
Output
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
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Chapter 5 – Modules
5.5.17 Software Digital Multiplexer (DMUX)
Description
This module is a 6 to 1 multiplexer of digital signals. One of the 6 inputs is
retransmitted on the digital DOUT output. The Input to retransmit is selected
by one of the two following modes:
a) Static mode, by mean of a parameter set during the configuration of the
strategy, specifying which of the inputs DIN1 to DIN6 must be selected.
b) Dynamic mode, through a 3 bit code from the DS1÷DS3 inputs, specifying
the input number, according to the following table:
DS 3
0
0
0
0
1
1
DS 2
0
0
1
1
0
0
DIN1
DIN2
DIN3
DIN4
DIN5
DIN6
DS 1
0
1
0
1
0
1
Input transmitted to OUT
DIN 1
DIN 2
DIN 3
DIN 4
DIN 5
DIN 6
DMUX
DOUT
DS1
DS2
DS3
I/O Connections
DIN 1.....6
DS 1..3
OUT
Digital Inputs to the multiplexer
Selection inputs
Output
Parameters
DMUX _ 1
DIn 1
Sel Code
DIn1
E
R
Displayed Parameters
Sel Code
Specification of the selection mode to use (dynamic or static)
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Installation and User manual of the AC10 - AC20 - AC30 controller
5.5.18 Hardware Digital Multiplexer (DMX8)
Description
This module is an 8 to 1 multiplexer. One of the 8 inputs DIN1÷DIN8,
selected by mean of the 3 bit code on the DS1÷DS3 inputs, is retransmitted
on the OUT output. Furthermore, the module can be selected or deselected
through an external input DSEL. Once the module is deselected, its OUT
output will hold the value it had before the deselection, until further selected.
The input to multiplex, is selected, with the DSEL signal in the active state, by
mean of the inputs DS1÷DS3, as in the following table:
DS1
0
1
0
1
0
1
0
1
DS2
0
0
1
1
0
0
1
1
DS3
0
0
0
0
1
1
1
1
Input transmitted to OUT
DIN 1
DIN 2
DIN 3
DIN 4
DIN 5
DIN 6
DIN 7
DIN 8
DIN1
DIN2
DIN3
DIN4
DIN5
DIN6
DIN7
DMX8
DOUT
DIN8
DSEL
DS1
DS2
DS3
I/O Connections
DIN 1.....8
DS 1..3
DSEL
OUT
Inputs to multiplex
Selection Inputs
Selection enable input
Output
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
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Chapter 5 – Modules
5.5.19 Mass Flow (MFL)
Description
This modules converts a raw flow or a differential pressure measurement,
into a pressure and temperature-compensated flow measure, in order to
compute the exact mass flow of the fluid.
The compensated flow is retransmitted as an analog value (FOUT), to other
modules, like PID or totalizers.
QIN
TIN
MFL
FOUT
PIN
I/O Connections
QIN
TIN
PIN
OUT
Raw flow or differential pressure, in engineering units
Fluid temperature in Celsius degree
Relative pressure measure, in engineering units
Compensated flow output
The compensation formula is illustrated below; you can select if you want to
have temperature compensation or pressure compensation or both.
OUT = QIN *
PIN + PABS
PR + PABS
TR + 273.14
*
TIN + 273.14
Parameters
MFL _ 1
T&P
Compens.
Ref. T.
Ref. P.
Abs. P.
Format
T&P
0
0
0
XXXXX
E
R
Displayed parameters
Compens.
Ref. T.
Ref. P
Abs. P.
Format
Selection of the type of compensation (temperature, pressure or both)
Reference Temperature in °C, considered in the design of the primary
measuring device.
Reference Pressure , considered in the design of the primary measuring
device.
Absolute atmospheric Pressure, relative to vacuum.
Format: it defines the number of digits of the values above.
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Installation and User manual of the AC10 - AC20 - AC30 controller
5.5.20 Analog Totalizer ( TOT )
Description
This module performs the totalization of the analog input IN, retransmitting
the totalizer results on the output OUT. This modules includes other
functionalities, related to the flow totalization, like the generation of a pulse
output, for driving external counters, a cutoff threshold on the Input
(Dropout), that stops the totalization when the Input signal is below it, the
alarming when the counter reaches a predefined level (Pulse V. and
Rollover) and the scaling of the Input signal before the totalization, in order to
set the engineering units of the totalizer.
The totalization is carried on, every time sample, according to the following
formula:
Out new = Out old + In * SF * (
Ts
3600
)
where:
Out = Output with the current value of the totalizer (new = current one, old
= previous calculation)
In = Input with the value to totalize
Ts = Sampling time in seconds
SF = Scale Factor, for ranging the value to the totalization engineering
units
IN
OUT
TOT
DRES
DO
I/O Connections
IN
DRES
OUT
DO
Analog Input
Reset input of the totalizer
Analog output with the totalization value
Pulse output for external totalization(1)
Note:
The module generates a pulse, with time width equal to the controller
sampling time, every time the OUT totalization value reaches the threshold or
its multiple, specified by the value of the Pulse V. parameter. The DO pulse
output allows external counting device, like mechanical counters, to further
totalize, with a greater number of digits, the IN signal.
Example
Let us totalize the quantity, in liters, of a fluid during an entire year, guessing
that the average instantaneous flow rate is 30 l/h.
Considering that the maximum value the totalizer can reach before a rollover
is 99999, the Scale Factor (SF) should be set to the value computed in the
following formula, in order to prevent a rollover, before the end of the year:
SF =
99999
30 * 365 * 24
= 0.3805
Setting SF to the value above, the totalizer will be set to the value of 0.3805
after 1 hour, assuming for the flow a constant value of 1 l/h.
In order to have the totalizer engineering unit immediately understandable, it
is better to set SF to a lower value than above, and, precisely, to 0.1.
96
Chapter 5 – Modules
In this way we achieve that the totalizer doesn’t roll over in one year and that
its engineering unit are immediately related to the flow engineering unit.
Setting SF to 0.1, the totalization unit is tens liters and after one hour of
totalization, the value is, assuming a constant flow of 1 l/h:
0.1
SF =
= 0.1
1* 1
Parameters
TOT _ 1
1
Scale F.
Format
Dropout.
Format
Rollover.
Pulse V.
Format
1
XXXXX
10
XXXXX
100
100
XXXXX
E
R
Displayed Parameters
Scale F.
Format
Dropout
Format
Rollover
Pulse V.
Format
Scale factor, in engineering units, with range from 0 to 99999
Format: it defines the number of digits of the Scale Factor value
Minimum value of the input signal, for enabling the totalization. If IN is
below this value, the totalization is unchanged. Range from 0 to 99999.
Format: it defines the number of digits of the Dropout value.
Rollover value. When the totalization reaches this value, the totalizer
restart from 0. Range from 0 to 99999.
Value of totalization corresponding to one pulse. Every time the
totalization value reaches this threshold or its multiple, a pulse is sent out
on the Output DO.
Format: it defines the number of digits of the Rollover and Pulse V. value
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Installation and User manual of the AC10 - AC20 - AC30 controller
5.5.21 Analog Limiter (LMT)
Description
This modules retransmits the input signal to the output, limiting it to a
predefined range, set by the user.
You define the minimum and the maximum allowed value. When the signal
exceeds one of the two limits it is clamped to them.
IN
LMT
OUT
I/O Connections
IN
OUT
Input
Output
Parameters
LMT _ 1
0
Lo Limit.
Hi Limit.
Format
0
100
XXXXX
E
R
Displayed Parameters
Lo Limit
Hi Limit
Format
98
Value of the minimum limit to apply to the output
value of the maximum limit to apply to the output
Format: it defines the number of digits of the values above
Chapter 5 – Modules
5.5.22 Alarms ( ALM )
Description
This module is an alarm comparator, that can be configured to flag either
absolute or deviation alarms, with an hysteresis band, defined by the user.
Being structured internally as a comparator; its use is not limited to alarms; in
fact, it can be used, also, as a control element of the strategy, performing
real time comparisons on process variables. The status of the digital output
is fully programmable, in order to support all the various combinations of
high, low, deviation alarm.
The diagram below illustrates the operating principle of the ALM module,
valid for all the alarm configurations. When the module is configured as a
deviation alarm, with the band defined by the two thresholds, MIN VAL and
MAX VAL, if the signal DEV is inside the band, the alarm is off, otherwise is
on. The “off” status corresponds to the state “inactive” on the output DOUT.
outside -> alarm = On
Max Val.
Inside -> alarm = Off
Min Val.
outside -> alarm = On
In the next page, a few examples of alarm configurations are shown.
ABS
DEV
ALM
DOUT
I/O Connections
ABS
DEV
OUT
Absolute alarm analog input
Deviation alarm analog input
Digital output with the result of the alarm comparison
Parameters
ALM _ 1
0
Min Val.
Max Val.
Hyst.
Format
Input
0
100
100
XXXXX
Indip.
E
R
Displayed Parameters
Min Val.
Max Val.
Hyst.
Format
Input
Low alarm threshold
High alarm threshold
Alarm Hysteresis
Format: it defines the number of digits of the values above
Selection of the type of alarm: absolute (independent) or deviation
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Installation and User manual of the AC10 - AC20 - AC30 controller
Examples
1)
Absolute (independent) high alarm
VMAX = 300 °C
Active if ABS > 300 °C
ABS
ALM
DOUT =
Inactive if ABS < 300 °C
VMIN =Low range
2)
Absolute (independent) low alarm
VMAX=High range
Inactive if ABS > 300 °C
ABS
ALM
DOUT =
Active if ABS < 300 °C
VMIN = 300 °C
3)
Deviation alarm (active when out of the deviation band)
VMAX = 30.0 %
DEV
ALM
DOUT = Inactive if VMIN > DEV > VMAX
VMIN = 15.0 %
4)
Deviation alarm (active when in the deviation band).
This configuration requires an external module to perform a Boolean
NOT operation.
VMAX = 30.0 %
DEV
ALM
VMIN = 15.0 %
100
NOT
DOUT = Active if VMIN < DEV < VMAX
Chapter 5 – Modules
5.5.23 Rate Alarm ( SALM )
Description
This module is an alarm comparator that flags rate alarms, with an hysteresis
band defined by the user. This module computes the derivative of the signal
at the input IN and compares it with a low and high thresholds, defined by the
user. If the derivative of the signal is between the two threshold, the alarm is
off, otherwise is on. When the alarm is on the OUT digital output goes in the
active state.
IN
SALM
OUT
I/O Connections
IN
OUT
Input
Output
Parameters
SALM _ 1
0
Sl. Min
Sl. Max
Hyst.
Format
0
100
0
XXXXX
E
R
Displayed parameters
Sl. Min
Sl. Max
Hyst.
Format
High rate alarm threshold
Low rate alarm threshold
Alarm Hysteresis
Format: it defines the number of digits of the values above
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Installation and User manual of the AC10 - AC20 - AC30 controller
5.5.24 Analog Software Demultiplexer ( ASEL )
Description
This module is a 1 to 6 demultiplexer of analog signals. It retransmits its IN
analog input to one, of the 6 OUT1÷OUT6 analog outputs, that has been
selected. The other not selected outputs are set to 0. The output is selected
by one of the two following modes:
a) Static mode, by mean of a parameter set during the configuration of the
strategy, specifying the number of the output OUT1÷OUT6 to select.
b) Dynamic mode, through a 3 bit code from the DS1÷DS3 inputs, specifying
the output number, according to the following table:
DS 3
0
0
0
0
1
1
DS 2
0
0
1
1
0
0
DS 1
0
1
0
1
0
1
Selected Output (OUT)
OUT 1
OUT 2
OUT 3
OUT 4
OUT 5
OUT 6
OUT1
IN
OUT2
ASEL
OUT3
OUT4
OUT5
DS1
OUT6
DS2
DS3
I/O Connections
IN
DS 1..3
OUT 1.....6
Input to demultiplex
Selection inputs
Outputs
Parameters
ASEL _ 1
Dig.
Choice
Dig.
E
R
Displayed parameters
Sel Code
102
Specification of the selection mode to use (dynamic or static)
Chapter 5 – Modules
5.5.25 Analog Hardware Demultiplexer ( AS8 )
Description
This module is a 1 to 8 demultiplexer of analog signals. It retransmits its IN
analog input to one of the 8 OUT1÷OUT8 analog outputs. The output is
selected through the 3 bit code on the DS1÷DS3 inputs, as listed in the
following table. The other not selected outputs are set to 0.
Furthermore, the module can be selected or deselected through an external
input DSEL. Once the module is deselected, its OUT output will hold the
value it had before the deselection, until further selected.
DS1
0
1
0
1
0
1
0
1
DS2
0
0
1
1
0
0
1
1
DS3
0
0
0
0
1
1
1
1
Selected Output (OUT)
OUT 1
OUT 2
OUT 3
OUT 4
OUT 5
OUT 6
OUT 7
OUT 8
IN
OUT1
OUT2
DS1
DS2
DS3
OUT3
OUT4
OUT5
OUT6
OUT7
AS8
DSEL
OUT8
I/O Connections
IN
DS 1..3
DSEL
OUT 1.....8
Input to demultiplex
Selection inputs
Selection enable input
Outputs
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
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Installation and User manual of the AC10 - AC20 - AC30 controller
5.5.26 Digital Software Demultiplexer ( DSEL )
Description
This module is a 1 to 6 demultiplexer of digital signals. It retransmits its DIN
digital input to one of the 6 DO1÷DO6 digital outputs, that has been selected.
The other not selected outputs are set to 0. The output is selected by one of
the two following modes:
a) Static mode, by mean of a parameter set during the configuration of the
strategy, specifying the number of the output DO1÷DO6 to select.
b) Dynamic mode, through a 3 bit code from the DS1÷DS3 inputs, specifying
the output number, according to the following table:
DS 3
0
0
0
0
1
1
DS 2
0
0
1
1
0
0
DS 1
0
1
0
1
0
1
Selected Output (DO)
DO 1
DO 2
DO 3
DO 4
DO 5
DO 6
DO1
DIN
DO2
DSEL
DO3
DO4
DO5
DS1
DO6
DS2
DS3
I/O Connections
DIN
DS 1..3
DO 1.....6
Input to demultiplex
Selection enable inputs
Outputs
Parameters
DSEL _ 1
DOut 1
Choice
DOut1
E
R
Displayed Parameters
Sel Code
104
Specification of the selection mode to use (dynamic or static)
Chapter 5 – Modules
5.5.27 Hardware Digital Demultiplexer ( DS8 )
Description
This module is a 1 to 8 demultiplexer of digital signals. It retransmits its DIN
digital input to one of the 8 DO1÷DO8 digital outputs. The output is selected
through the 3 bit code on the DS1÷DS3 input, as listed in the following table.
The other not selected outputs are set to 0.
Furthermore, the module can be selected or deselected through an external
input DSEL. Once the module is deselected, its DOn output will hold the
value it had before the deselection, until further selected.
DS1
0
1
0
1
0
1
0
1
DS2
0
0
1
1
0
0
1
1
DS3
0
0
0
0
1
1
1
1
Selected Output (DO)
DO 1
DO 2
DO 3
DO 4
DO 5
DO 6
DO 7
DO 8
DO1
DIN1
DO2
DO3
DS1
DS2
DS8
DS3
DO4
DO5
DO6
DO7
DSEL
DO8
I/O Connections
DIN
DS 1..3
DSEL
DO 1.....8
Input to demultiplex
Selection inputs
Selection enable input
Outputs
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
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Installation and User manual of the AC10 - AC20 - AC30 controller
5.5.28 Decoder ( DEC8 )
Description
This modules is a 1 to 8 decoder. It selects, one of the 8 DO1÷DO8 digital
outputs, according to the 3 bit binary code specified on the DS1÷DS3 inputs,
as listed in the table below. The selected output is set to 1, while the others
are set to 0. The DSEL digital input, enables the module, when set to 1, and
disables it, when 0. Once the module is disabled, the output selected doesn’t
change, even if the 3 bit binary code value varies. Enabling again the
module, the output is selected according to the 3 bit binary code.
DS1
0
1
0
1
0
1
0
1
DS2
0
0
1
1
0
0
1
1
DS3
0
0
0
0
1
1
1
1
Selected Output(DO)
DO 1
DO 2
DO 3
DO 4
DO 5
DO 6
DO 7
DO 8
DO1
DO2
DS1
DS2
DS3
DO3
DEC8
DO4
DO5
DO6
DSEL
DO7
DO8
I/O Connections
DS 1..3
DSEL
DO 1.....8
106
Select inputs
Selection enable input
Decoder Outputs
Chapter 5 – Modules
5.5.29 Set page block (SETP)
Description
This module allows to set an active panel when DSEL (digital input) switches
from "0" to "1".
IN
SETP
DSEL
Description of connections
IN
DSEL
*
Analogue input for panel selection
Digital input for panel activation*
The multiswitch panel cannot be used to generate the DSEL digital
command.
Parameters
This block has no parameters, and is not present in the Controller’s menus.
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Installation and User manual of the AC10 - AC20 - AC30 controller
5.5.30 Timer Block (TMR)
Description
This module performs a Timer function, with the possibility of setting a preset value.
PRS
DRES
OUT
TMR
EN
DO
Description of connections
PRS
EN
DRES
OUT
DO
Analogue
input
for
second
preselection.
Digital input for Timer activation.
Digital input for Timer reset.
Analogue output for the Timer
instantaneous value in seconds
This output is reset with the DRES
command.
Digital output. This output is
activated when the Timer reaches
the pre-set value.
Parameters
This block has no parameters, and is not present in the Controller’s
configuration menu.
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Chapter 5 – Modules
5.5.31 Servomotor in Open/Close loop Block (SRV2)
Description
This module generates the valve open and close commands in relation to the
position required by the IN signal and to the present valve position as
detected by the APOS signal.
IN
OMIN
DOPN
CMIN
APOS
ITIM
SRV2
DCLS
OCDL
TRVL
DBND
O/C
Description of connections
IN
OMIN
CMIN
APOS
ITIM
OCDL
TRVL
DBND
O/C
Required position (0÷100)
Minimum
duration
of
open
command in seconds
Minimum
duration
of
close
command in seconds
Valve position
Integral time
Minimum time between an open
and a close command (and vice
versa)
Servomotor travel time in seconds
Dead band (in %)
Open/Close Loop selection
Parameters
This block has no parameters, and is not present in the Controller’s
configuration menu.
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Installation and User manual of the AC10 - AC20 - AC30 controller
5.6
Supervisory I/O Modules
5.6.1 Analog I/O to Computer (CAIO)
Description
This module consists of 8 analog values, corresponding to input or output
values of the strategy, that can be easily accessed, through the RS485 JBUS
serial port ( Main Comm ), by a Supervisory computer. The computer
accesses the variables, by writing in the input ones and reading the output
ones. A maximum of 4 modules of this type can be included in the strategy.
AIO1
AIO2
COMPUTER
AIO3
CAIO
AIO4
AIO5
AIO6
AIO7
AIO8
I/O Connections
AIO 1..8
Computer
Analog I/O
JBUS Addresses of the register with the I/O
values
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
5.6.2 Digital I/O to Computer (CDIO)
Description
This module consists of 8 digital values, corresponding to input or output
states of the strategy, that can be easily accessed, through the RS485 JBUS
serial port ( Main Comm ), by a Supervisory computer. The computer
accesses the variables, by writing in the input ones and reading the output
ones. A maximum of 4 modules of this type can be included in the strategy.
DIO1
DIO2
COMPUTER
DIO3
CDIO
DIO4
DIO5
DIO6
DIO7
DIO8
I/O Connections
DIO 1..8
Computer
Digital I/O
JBUS Addresses of the register with the I/O values
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
110
Chapter 5 – Modules
5.7
System Modules
5.7.1 Computer Timeout ( CALM )
Descriptions
This module monitors the communication activity with the Supervisory
Computer, activating the DOUT alarm output if the computer stops to
interrogate the instrument for a time greater than the specified timeout.
CALM
DOUT
I/O Connections
DOUT
Alarm output, flagging the lack of communication
Parameters
CALM _ 1
30
Time Out
30
E
R
Displayed Parameters
Time out.
Minimum lack of communication time : 0 to 600 seconds
5.7.2 LAN Timeout ( LALM )
Description
This module generates an alarm, activating the DOUT output if the controller
doesn’t receive, on the LAN, the values of “consumer” type variables, for a
time greater than the specified timeout.
LALM
DOUT
I/O Connections
DOUT
Alarm output flagging the lack of LAN communication
Parameters
LALM
30
Time Out
30
E
R
Displayed Parameters
Time out.
Minimum lack of LAN communication time : 0 to 600 seconds
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Installation and User manual of the AC10 - AC20 - AC30 controller
5.7.3 Expansion Unit Timeout ( AALM )
Description
This modules activates a digital alarm output when there is not
communication between the AC controller and its Expansion units for a time
greater than the specified timeout.
AALM
DOUT
I/O Connections
DOUT
Alarm output, flogging the lack of communication with the
Expansion Units
Parameters
AALM
5
Time Out
5
E
R
Displayed Parameters
Time out.
Minimum lack of communication time : 0 to 600 seconds
5.7.4 System Configuration ( SYS )
Description
This module, configurable through the AC-Prograph only, defines the
optional characteristics and the configurable behaviors of the AC30
controller. It specifies:
• the characteristics of the communication protocol of Main Comm.
• the characteristics and the addressing of the LAN.
• the sampling time.
• the levels of access of some operations and the password.
SYS
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
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Chapter 5 – Modules
5.7.5 Key Selector ( KEY )
Description
This module provides the functionality of the key pressing simulation,
allowing the strategy to “press” the keys on the AC30 controller. When its
DIN digital input goes active, the result will be the same than pressing the
corresponding key of the AC 30 8 buttons keyboard. The configuration of this
module is carried out through the AC-PROGRAPH only.
DIN
KEY
I/O Connections
DIN
Digital Input forcing the pressing of the key
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
5.7.6 Failure Module ( FAIL )
Description
This module, once the diagnostic of the AC controller has detected a failure,
activates a digital output, in order to trigger the safety logic external to the
instrument. The user chooses which of the 8 digital outputs of the controller
must be activated.
33
DO 1
44
DO 8
FAIL
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
5.7.7 Power Failure AC Restart flag ( PWRF )
Description
This module generates a pulse, on its output, every time a power up or a
strategy download occurs on the controller. The pulse duration corresponds
to 3 times the parameter T Sample (sampling time of the controller, specified
in the SYS module).
PWRF
DOUT
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
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Installation and User manual of the AC10 - AC20 - AC30 controller
5.7.8 Setpoint control key lock Block (SPKL)
Description
By switching DSEL from “OFF” to “ON”, the keys that control the Setpoints
(Increase/Decrease and L/R) on all active panels of the active strategy, are
locked.
SPKL
DSEL
Parameters
This block has no parameters, and is not present in the Controller’s
configuration menu.
5.7.9 Output Change Key Lock Block (OPKL)
Description
By switching DSEL from “OFF” to “ON", the keys that control the output
change (Increase/Decrease and A/M) on all active panels of the active
strategy, are locked.
OPKL
DSEL
Parameters
This block has no parameters, and is not present in the Controller’s
configuration menu.
114
Chapter 5 – Modules
5.8
Math and Logic Function
5.8.1 Expression ( EXP )
Description
This module allows the entry of an alphanumeric string, specifying a
mathematical expression, manipulating up to 4 input variables (Inputs A, B,
C, D) and involving arithmetic operators, math functions and parenthesis.
The result, is returned in the output R.
The arithmetic operators are: addition, subtraction, multiply, division and
Exponentiate.
The math functions are: Absolute value, Square root, Square, Sine, Cosine,
Arc Tangent (Radians), Natural Logarithm (base e), Logarithm (base 10),
Exponentiation e (2.71828).
A
B
C
EXP
R
D
I/O Connections
A
B
C
D
R
Input, corresponding to the variable A of the expression
Input, corresponding to the variable B of the expression
Input, corresponding to the variable C of the expression
Input, corresponding to the variable D of the expression
Result
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
5.8.2 Arithmetic ( OPR )
Description
This module executes a basic arithmetic operation on a couple of scaled
analog inputs, A and B, returning the result on the output R.
IN1
IN2
OPR
R
I/O Connections
A
B
R
Input, corresponding to the variable A of the expression
Input, corresponding to the variable B of the expression
Result
115
Installation and User manual of the AC10 - AC20 - AC30 controller
Parameters
OPR _ 1
Add
Function
Add
E
R
Displayed Parameters
Function
Specification of the Arithmetic operation. The choices are: Add,
Sub, Mul, Divide, Power
where:
Add
Sub
Mul
Divide
= addition
= subtraction
= multiply
= division
Power
= Exponentiate
(A+B = Y)
(A-B = Y)
(AxB = Y)
(A/B = Y) Note: Input B cannot be zero
B
(A = Y )
5.8.3 Function ( FN )
Description
This module executes the selected math
logarithmic or exponential) on an analog input.
FN
IN1
operation
RFN
I/O Connections
IN1
RFN
Input
Output with the result of the execution of the selected function
Parameters
FN _ 1
Abs
Function
Abs
E
R
116
(trigonometric,
Chapter 5 – Modules
Displayed Parameters
Function
where:
Abs
Sqrt
Sqr
Sin
Cos
Atan
Loge
Log10
Exp
Selection of the function to execute. The choices are:
Abs, Sqrt, Sqr, Sin, Cos, Atan, Loge, Log10, Exp, Deriv.
= Absolute value of the input signal
= Square root
= Square
= Sine (Radians)
= Cosine (Radians)
= Arc tangent (Radians)
= Natural logarithm (base e)
= Logarithm (base 10)
= Exponentiation of e(2.71828)
5.8.4 Analog Single Constant ( CNS )
Description
This module generates a fixed analog signal on the output Y1, whose value
is specified by the user through AC-Prograph / AC-Edit..
CNS
Y1
I/O Connections
Y1
Output with the constant value
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
5.8.5 AND
Description
This module performs the Boolean AND operation between two digital inputs
DIN1
AND
DOUT
DIN2
I/O Connections
DIN 1
DIN 2
DOUT
Digital Input 1
Digital Input 2
Output
Truth Table (AND)
DIN 1
0
0
1
1
DIN 2
0
1
0
1
DOUT
0
0
0
1
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
117
Installation and User manual of the AC10 - AC20 - AC30 controller
5.8.6 NOT
Description
This module perform the Boolean NOT of a digital input.
DIN1
NOT
DOUT
I/O Connections
DIN 1
DOUT
Digital input
Output
Truth
Table(NOT)
DIN 1
0
1
DOUT
1
0
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
5.8.7 EOR (XOR)
Description
This module performs the Boolean XOR (Exclusive OR) between two digital
inputs.
DIN1
EOR
DOUT
DIN2
I/O Connections
DIN 1
DIN 2
DOUT
Digital Input 1
Digital Input 2
Output
Truth Table(EOR)
DIN 1
0
0
1
1
DIN 2
0
1
0
1
DOUT
0
1
1
0
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
118
Chapter 5 – Modules
5.8.8 OR
Description
This module performs the Boolean OR between two digital inputs
DIN1
OR
DOUT
DIN2
I/O Connections
DIN 1
DIN 2
DOUT
Digital Input 1
Digital Input 2
Output
Truth
Table (OR)
DIN 1
0
0
1
1
DIN 2
0
1
0
1
DOUT
0
1
1
1
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
5.8.9 8 Inputs OR (OR8)
Description
This modules performs the Boolean OR between 8 digital inputs.
DIN1
DIN2
DIN3
DIN4
DIN5
DIN6
DIN7
DIN8
OR_8
DOUT
I/O Connections
DIN 1......8
OUT
Digital Inputs
Output with the result of the OR operation
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
119
Installation and User manual of the AC10 - AC20 - AC30 controller
5.8.10 Flip-Flop J-K LATCH (JKF)
Description
This module performs a J-K Latch Flip - Flop with two digital inputs.
DIN1
JKF
DOUT
DIN2
I/O Connections
DIN 1
DIN 2
DOUT
Digital Input 1
Digital Input 2
Output
State Table (JFK)
DIN 1
0
1
1
0
DIN 2
0
1
0
1
DOUT
No Toggle
Toggle
1
0
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
5.8.11 D LATCH Flip-Flop
Description
This module operates as the classical Flip-Flop D Latch, with 3 digital inputs,
setting the output, according to the timing chart below.
DT
CLK
DFF
DOUT
RST
I/O Connections
DT
CLK
RST
DOUT
Data digital input
Clock
Reset
The output is calculated on the basis of the DT, Clk and RST digital
inputs as illustrated below.
D T
C L K
R S T
D o u t
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
120
Chapter 5 – Modules
5.8.12 Monostable ( MST )
Description
This modules implements a monostable circuit, triggered by the digital inputs
and capable to generate pulses of variable delays. Through the Parameters
of this module, you choose between different operating mode (Mode) and
you enter the time values (Delay) for the generated pulses
DIN1
MST
DOUT
RES
I/O Connections
DIN 1
RES
DOUT
Monostable trigger digital input
Monostable reset (set the output to 0)
Digital Output of the monostable
Parameters
MST _ 1
1
Mode
Delay
1
0
E
R
Displayed Parameters
Mode
Delay
Selection of the operating mode. The choices are: 0, 1, 2, 3 (1)
Time delay value, entered as a number of sampling time. Range
from 0 to 300.
(1) The monostable is supporting 4 different operating modes, selected by
the codes 0, 1, 2, 3. Their behavior is listed in the following picture:
DIN 1
Positive
edge delay
DELAY
Negative
edge delay
Pulse
DELAY
DELAY
Shifted delay
DELAY
DELAY
TIME
Chart illustrating the different monostable operating modes
121
Installation and User manual of the AC10 - AC20 - AC30 controller
5.8.13 Counter ( CNT )
Description
This module counts the input pulses, defined by the positive edge of the
digital input DIN1. The counter total is returned on the analog output OUT. It
can be configured as either an up or a down counter and it is controlled by a
pair of digital inputs, defining the operating mode.
DIN1
U/D
CNT
CSEL
OUT
RES
I/O Connections
DIN 1
CSEL
RES
U/D
OUT
Counter input. Each positive edge increases the counter of one unit.
Counting enabling digital input.
Counter Reset digital Input.
Counting direction select input (Up or Down).
Output with the current value of the counter.
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
5.8.14 Multiple Analog Constants ( MCNS )
Description
This module generates a fixed analog signal on the 5 outputs CNS 1 - 5,
whose values are specified by the module parameters.
CNS1
CNS2
CNS3
CNS4
MCNS
CNS5
I/O Connections
CN 1...5
Analog Outputs
Parameters
MCNS _ 1
50
CNS1
Format
CNS2
Format
CNS3
Format
CNS4
Format
CNS5
Format
50
XXXXX
0
XXXXX
0
XXXXX
0
XXXXX
0
XXXXX
E
R
Displayed Parameters
CNS 1...5 (1)
Format
Values to set the analog outputs
Format: it defines the number of digits of the values above
(1) The tag of the 5 analog constants, as displayed on the controller panel, is
directly configured by the AC-Prograph.
122
Chapter 5 – Modules
5.8.15 Analog Single Constant ( CNS )
Description
This module generates a fixed analog signal on the output CNS, whose value
is specified by the Value parameter.
CNS
CNS
I/O Connections
CNS
Analog output set to the predefined value
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
5.8.16 Multiple Digital Constant ( MDCN )
Description
This modules generates a fixed digital signal on the 5 outputs DCN 1 - 5,
whose values are specified by the module parameters.
DCN1
DCN2
MDCN
DCN3
DCN4
DCN5
I/O Connections
DCN 1...5
Digital Outputs
Parameters
MDCN _ 1
0
CNS 1
CNS 2
CNS 3
CNS 4
CNS 5
0
0
0
0
0
E
R
Displayed Parameters
CNS 1...5 (1)
Status to set the digital outputs
(1) The tag of the 5 digital constants, as displayed on the controller panel, is
directly configured by the AC-Prograph.
123
Installation and User manual of the AC10 - AC20 - AC30 controller
5.8.17 Analog To Digital converter ( A/D )
Description
This module performs the conversion of a number, provided as an input
signal to the module, to a 16 bit binary number, specified through 16 digital
outputs. The range of the input number is 0 ÷ 65535. If the input number
exceeds this range, it is still converted in binary number, but the 16 digital
outputs corresponds to the status of the least significant bits. The Carry
output is not available, to flag the overrange: therefore, the strategy must
provide the actions to avoid or take care of this situation.
DO1
DO2
DO3
DO4
DO5
DO6
IN
A/D
DO7
DO8
DO9
DO10
DO11
DO12
DO13
DO14
DO15
DO16
I/O Connections
IN
DO1 - DO16
Analog Input
Digital Output
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
5.8.18 Digital To Analog Converter ( D/A )
Description
This module converts a 16 bit binary number, provided through 16 digital
inputs, into a number. The number is transferred out through the analog
output of the module, with range 0 to 65535. The Carry output is not
available.
DI1
DI2
DI3
DI4
DI5
DI6
DI7
DI8
DI9
D/A
OUT
DI10
DI11
DI12
DI13
DI14
DI15
DI16
I/O Connections
OUT
DI1 - DI16
Analog Output
Digital Input
Parameters
This module doesn’t have any parameter and, therefore, it is not displayed
on the instrument panel.
124
Chapter 5 – Modules
5.8.19 AND_8 Block (AND8)
Description
The block performs the AND logic function of the DIN1 ÷ DIN8 inputs.
The non-configured inputs are put to "ON"
DIN1
DIN2
DIN3
DIN4
DIN5
AND8
DOUT
DIN6
DIN7
DIN8
Description of connections
DIN 1
DIN 2
DIN 3
DIN 4
DIN 5
DIN 6
DIN 7
DIN 8
DOUT
Digital input 1
Digital input 2
Digital input 3
Digital input 4
Digital input 5
Digital input 6
Digital input 7
Digital input 8
Output
Parameters
This block has no parameters, and is not displayed on the Controller.
5.8.20 Shift Block (SHFT)
Description
The block performs the logic SHIFT function on 16 outputs.
By switching the UP input from “OFF” to “ON”, the output bits DO1÷D016 are
moved one position forward and the DO1 output is put to the value present
on DIN1 (SHIFT UP).
By switching the DN input from “OFF” to “ON”, the output bits D016÷D01 are
moved one position backward and the DO16 output is put to the value
present on DIN1 (SHIFT DOWN).
DO1
DO2
DIN1
UP
DN
RES
SHFT
DO3
DO4
DO5
DO6
DO7
DO8
DO9
DO10
DO11
DO12
DO13
DO14
DO15
DO16
125
Installation and User manual of the AC10 - AC20 - AC30 controller
Description of connections
DIN 1
UP
DN
RES
DO1 ÷ DO16
Shift register input
SHIFT UP Input
SHIFT DN Input
Input for DO1÷D016
output reset
Outputs as a result of the
SHIFT operation
Parameters
This block has no parameters, and is not displayed on the Controller.
126
Chapter 5 – Modules
5.9
Programmer Functions
5.9.1 Real Time Clock with 8 outputs ( R.T.C. )
Description
This modules, available on the AC30 controller only, provides the
functionalities of a weekly timer. It has 8 digital outputs that can be pulsed,
independently each other, once a day and for all the day of the week, at
predefined times. The generated pulse has a fixed time duration of 1 minute.
You configure the timer, specifying, for each output, the day of the week it
must be activated and if it must be enabled or disabled.
DO1
DO2
DO3
DO4
RTC
DO5
DO6
DO7
DO8
I/O Connections
DO1 ÷ DO8
Digital Outputs
Parameters
RTC
0:00
DO0
Active
DO1
Active
DO2
Active
DO3
Active
DO4
Active
DO5
Active
DO6
Active
DO7
Active
0:00
No
0:00
Yes
8:30
No
0:00
Yes
12:30
No
0:00
No
0:00
Yes
17:15
No
E
R
Displayed Parameters
DO0 ÷ DO7
Active
Digital output activated at predefined time and date
Enable/Disable of the activation
5.9.2 Setpoint Programmer (PRG)
Description
This module, available on the AC30 controller only, provides the
functionalities of a Setpoint Programmer generating the profile of an
analogue setpoint SP, organized as a series of segments, and setting the
status of 16, segments related, digital outputs DO1 - DO 16 and the level of
an auxiliary analog output AUX.
The module can store up to 100 segments and a maximum of 16 programs.
Each program has a variable number of segments but the overall number of
segments of all the programs cannot exceed the limit above. A strategy can
house up to 4 PRG modules. Therefore, the maximum capability of an AC30
controller is to house up to 64 programs, with an total number of segments of
up to 400 and driving up to 64 digital outputs.
127
Installation and User manual of the AC10 - AC20 - AC30 controller
Despite the sophisticated performance of this programmer, it is easily
programmed, both through the AC-Prograph or the controller keyboard, in a
friendly, simple and guided environment. The use of AC-Prograph is very
effective and strongly recommended.
A wide selection of strategies is offered by the PRG to recover the program
from anomalous situations of the process. For instance, you choose, among
several possibilities the actions to take after a power failure. Briefly, you can
chose if your Programmer must be Reset, Hold or Resumed on the basis of
the time the power has stayed off, on the basis of the deviation of the
process variable PV from the last Setpoint generated, or, simply, always.
R/H
SP
AUX
RST
FST
NXT
PV
SEL1
SEL2
SEL3
SEL4
DHLD
PRG
DO1
DO2
DO3
DO4
DO5
DO6
DO7
DO8
DO9
DO10
DO11
DO12
DO13
DO14
DO15
DO16
RUN
HLD
NPGM
NSGM
SRT
TCYC
ACYC
I/O Connections
R/H
RST
FST
NXT
PV
SEL1 ÷ SEL4
DHLD
SP
AUX
DO1 ÷ DO16
RUN
128
Run/Hold I/O. Bidirectional signals, specifying the operating status of
the Programmer. When in Hold mode, the Programmer doesn’t
progress and all the outputs are frozen. When in Run mode, the
Programmer executes the predefined program, stepping between the
segments, up to the end.
Reset. Digital input specifying that the Programmer must be reset,
forcing it to restart from the initial segment 0.
Fast Input. When inactive the program is executed on the basis of the
configured times values. Otherwise (Fast mode) all the times are
scaled by a predefined factor and the program segments are executed
very rapidly.
Next. Digital input forcing, on the rising edge (inactive to active) the
Programmer to go to the next segment .
Main Variable. This analog input is intended for acquiring the process
variable, that is, continuously, compared with the Setpoint output of
the Programmer, in order to detect an excessive deviation.
Select digital inputs. These 4 digital inputs specify a 4 bit code,
corresponding to the program to be selected.
Hold Input. This digital input, on the rising edge, (inactive to active)
forces the Programmer to the Hold mode, stopping the execution of the
current segment.
Analog output, with the Setpoint value generated by the module.
Auxiliary Setpoint output. This analog output is set, automatically, at the
beginning of each segment and it is kept constant for the entire
segment.
Digital outputs, set, at the beginning of the segment, to the pattern,
configured. These values are hold for the entire segment.
Run mode. This digital output is active when the program is running
and becomes inactive, when the Programmer enters in Hold mode.
Chapter 5 – Modules
HLD
Hold mode. This digital output is active when the Programmer is in Hold
mode, due either to an excessive deviation between SP and PV or
other causes.
NPGM
Program Number. Analog output, returning the number of the program
currently executed.
NSGM
Segment Number. Analog output, returning the number of the segment
currently executed.
SRT
Remaining time. This analog output returns the remaining time to
complete the segment, currently under execution.
TCYC
Total Cycles. This number returns the configured number of cycles of
the program currently running.
ACYC
Actual Cycles. This number returns the number of cycles, already
executed, since the beginning of the program, currently running.
Operativity
The following picture explains the procedure to follow in order to edit the
parameters of a program in a PRG module. First, you reach the panel with
the list of all the modules (Menu of All Block); here, you select the
Programmer module. Second, in the (Program Block) panel, you choose
which of the 4 PRG modules of the strategy, houses the program you want to
edit. Next, you continue by selecting the program to edit ( in the example the
program n°2 of the PRG module n°1 has been chosen). At this point you
reach the (Program No “n”) display panel, consisting in a menu of all the
operations you can do on the selected program.
TAG-0000-0
l/h
LSP
Main
Menu
573
550
1200
Tune & Views
Par. & Comms
Prog & Test
Keyb. Perm.
Loc
Loc
HLD
R
Menu of
All Blocks
Parameters
& Comms
Parameters
Main Comm
LAN Addr.
E
E
E
E
R
AL1
AL2
R
R
A. Outputs
D. Outputs
1 Bar Panel
Trend Panel
Set & Deviat
Programmer
R Outs Mgt.
Linearizat.
Totalizers
Alarm Block
Math Operat.
Dig. Filter
Program
Block
PRG_1
PRG_1
PRG_2
PRG_3
PRG_4
E
E
Program No
2
2
Prg. No.
2
E
E
E
R
E
R
R
Edit Program
New Program
Delete Prg.
Copy Program
Prg. LIst
Insert Seg.
Delete Seg.
E
P
R
R
R
R
MAN
W=5 min
0
Page 1 of 2
OUT= 63
In the following pages, all the various commands of the menu (Program No
“n”), allowing to operate with the PRG programs, are described in detail.
Program No “n” Edit Program
This command allows you to edit all the data of an existing program. The first
display (Prg No. “n”) presents the basic data of a program, while the second
one presents, one at a time, the data regarding one segment. The panel
(Edit Seg.) allows you to choose the segment to edit. Once the segment to
edit has been selected, its data are presented on the (PRG NO “n”) panel,
where they can be easily modified.
Program No
2
Prg No. 2
Edit Seg
m:s
Edit Program
New Program
Delete Prg.
Copy Program
Prg. LIst
Insert Seg.
Delete Seg.
E
E
R
m:s
Time
Fast
2
Cycles
12
Restart
Resume
Dev1
0
E
Dev2
0
R
Time1
0:00
Time2
0:00
Range Lo 0
Ramge Hi 1200 R
Format
XXXXX
PRG NO 2
Prog. No.
Seg. No.
S.P. Val.
Aux. V.
Time
00 0 0 0
00 0 0 0
Dev.
Last Sg.
0
Seg. No.
E
R
0
E
E
2
0
50
20
0:05
0 00
0 00
100 E
No
1200
E
R
R
R
0
==
0
1
129
Installation and User manual of the AC10 - AC20 - AC30 controller
Detailed view of the PRG NO “n” display panel
Selected Programmer
Selected Program
Selected Segment
Final Setpoint
Auxiliary Setpoint
Segment Execution Time
Digital Outputs pattern
Allowed Deviation
Last Segment Flag
Setpoint High Range
PRG NO 2
Prog. No.
Seg. No.
S.P. Val.
Aux. V.
Time
00 0 0 0
00 0 0 0
Dev.
Last Sg.
2
0
50
20
0:05
000
000
100 E
No
1200
Enter the modifications and
go back to the previous page
Profile Window
Increase the number of the
Segment to edit
Previous Segment
Decrease the number of the
Segment to edit
Currently Edited Segment
R
Next Segment
Programmed Setpoint
Profile
Move the cursor up
Setpoint Low Range
Previous Segment
Cancel the modifications and
go back to the previous page
0
==
0
1
Move the cursor down
Currently edited Segment number
Next Segment
Description of the Parameters
S.P. Val.
Aux. V.
Time
Digital Outputs
Dev.
Last Sg.
130
Value, in engineering units, specifying the target value of the SP
Setpoint output at the end of the segment.
Value, in engineering units, specifying the level the AUX analog output
(Auxiliary Setpoint value) will assume at the beginning of the segment
and will hold for the entire segment.
This is the time assigned for the execution of the entire segments. The
format of the time is hh:mm or mm:ss, according to the setting
operated in the display panel Prg No. “n”.
Pattern of the 16 digital outputs. 0= Off, 1=On. At the beginning of the
segment execution, the digital output will assume the specified pattern
and will hold it, for the entire segment. The upper row is for Outputs 1
to 8, while the lower one is for the Outputs 9 to 16.
This parameter specifies the maximum allowed deviation between the
SP Setpoint output and the PV Main variable input. This deviation is
continuously monitored during the execution of the segment. If the
deviation value exceeds the configured threshold, the program goes
automatically in Hold. It returns back to the Run mode when PV
reenters in the allowed range.
Setting Yes, you flag this segment as the last one of the Program,
while, setting No, you specify that another segment will follow the
current one.
Chapter 5 – Modules
Program No “n” New Program
This command allows you to enter a new program from scratch. The first
thing to do is to select, from the menu Program List the number of the
Program. This menu will list all the 16 programs of a PRG module, reporting
the status of each of them, the total number of segments used and the
quantity of available segments.
Program No
2
Edit Program
New Program
Delete Prg.
Copy Program
Prg. LIst
Insert Seg.
Delete Seg.
Prg List
Program 0
Program 1
Program 2
Program 3
Program 4
Program 5
Program 6
Program 7
Program 8
Program 9
Program 10
Program 11
Program 12
Program 13
Program 14
Program 15
E
E
R
R
Occupied
Void
Occupied
Void
Void
Occupied
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Free Segments 75
Press Any Key
After having set the program number, you proceed with the definition of the
new program by entering, first, the basic informations, and, after, the data of
all the segments of the Program, as illustrated in the picture below.
Program No
2
PRG_1
Prg No. 2
2
Edit Seg
m:s
Prg. No. 2
E
E
R
Edit Program
New Program
Delete Prg.
Copy Program
Prg. LIst
Insert Seg.
R Delete Seg.
E
E
R
m:s
Time
Fast
2
Cycles
12
Restart
Resume
Dev1
0
E
Dev2
0
R
Time1
0:00
Time2
0:00
Range Lo 0
Ramge Hi 1200 R
Format
XXXXX
PRG NO 2
Prog. No.
Seg. No.
S.P. Val.
Aux. V.
Time
00 0 0 0
00 0 0 0
Dev.
Last Sg.
0
Seg. No.
E
R
0
E
E
2
0
50
20
0:05
0 00
0 00
100 E
No
1200
E
R
R
R
0
==
0
1
Detail of the PRG No. “n”
Through this panel all the basic parameters of your program, are provided.
Prg No. 2
m:s
Selected Time units
Time factor for Fast mode
N°of program cycles.
Definition of the actions to
take after a "Power Fail"
Additional parameters
related to "Power Fail"
High range of the Setpoint
Low range of the Setpoint.
Format of the Setpoint
m:s
Time
Fast
2
Cycles
12
Restart Resume
Dev1
0
E
Dev2
0
Time1
0:00
Time2
0:00
Range Lo 0
Ramge Hi 1200 R
Format XXXXX
131
Installation and User manual of the AC10 - AC20 - AC30 controller
Description of the Parameters
Time
Fast
Cycle
Restart
Dev1
Dev2
Time1
Time2
Range Lo
Range Hi
Format
It specifies the time units for all the time values of the program . The choices are h:m
(hours:minutes) and m:s (minutes:seconds).
Acceleration factor. All the time values of the program are scaled by the value specified by
this parameter. The effect is that the program will be executed in a shorter time.
Cycles number. This number specifies how many times a program must be cycled, before
terminating it.
These parameters allow to define the recover strategy after a power failure, choosing
between a wide range of possibilities.
The 4 possible choices are:
1) Resume - Automatic restart of the program, at power on, from the same status, the
Programmer was, at power off.
2) SP = PV - Automatic restart of the program, at power on, after setting the SP output at
the measured value of PV. If the segment in execution at the power off time was a dwell,
the program restarts from the previous ramp segment.
3) Hold - The Programmer is forced in the Hold mode, at power on. The Programmer stays
in the Hold status until an operating or a running mode change occurs.
4) Reset - The Programmer is automatically reset, forcing it to segment 0, and in hold, until
an operating or a running mode change occurs.
Parameter of a recovery strategy, based on the deviation value between SP and PV at the
power on time. If the deviation exceeds the value set in this parameter, the SP output is set
equal to PV input and the program restarts from the point at power off.
Parameter of a recovery strategy, based on the deviation value between SP and PV at the
power on time. If the deviation exceeds the value set in this parameter, the programmer is
reset to segment 0 and put in hold, waiting for an operator intervention.
Parameter of a recovery strategy, based on the time the power has been off. If this
interruption time has been greater than the value set in this parameter, the SP output is set
equal to PV input and the program restarts from the point at power off.
Parameter of a recovery strategy, based on the time the power has been off. If this
interruption time has been greater than the value set in this parameter, the programmer is
reset to segment 0 and put in hold, waiting for an operator intervention.
Low range of the Setpoint output.
High range of the Setpoint output.
Format: it defines the number of digits of the Setpoint output
Program No “n” Delete Program
This command allows you to delete an existing program. First, you must
select the program to delete, from the panel PRG, specifying its number.
Next, you select the Delete Prg. item form the Program No “n” menu. At this
point, the alert message “If Sure Press Enter” is displayed. You must
E
confirm the delete command, by pressing the
button, in order to proceed
with the delete operation. Otherwise, you can abort the delete operation and
R
return back to the Program No “n” menu, by pressing the
button.
Program No
2
PRG_1
Program No
2
2
Prg. No.
2
E
E
Edit Program
New Program
Delete Prg.
Copy Program
Prg. LIst
Insert Seg.
R Delete Seg.
E
E
Edit Program
New Program
Delete
Prg.
If Sure
Copy Program
Press
Prg. LIst Enter
Insert Seg.
E Delete Seg.
E
R
R
132
R
R
Chapter 5 – Modules
Program No “n” Copy Program
This command allows you to duplicate a program, by copying an existing
program in an empty one.
First, you must select the program to copy, as illustrated above, and select
the Copy Program command from the Program No “n” menu. At this point, a
dialog box will be displayed, asking to specify the number of the destination
program. After entering these data, you must confirm the operation, by
E
pressing the
button, in order to progress. Two potential situations can
occur:
• The destination program is empty.
The message “All done it’s OK” is displayed, in order to confirm the
successful conclusion of the operation.
• The destination program is not empty.
The alert message “First delete program” is displayed, to flag that the
operation cannot be carried on. At this point, you must press a key to
return back to the Program No menu.
Program No
2
Cpy Prg 2
Cpy Prg 2
3
Edit Program
New Program
Delete Prg.
Copy Program
Prg. LIst
Insert Seg.
Delete Seg.
to Prg.
E
3
3
E
to Prg.
3
All Done
It's OK
E
R
R
E
E
R
R
Any key
Program No “n” Insert Segment
This command allows you to add to an existing program a new empty
segment, at a predefined program position. Once added, the segment is
parameterized by mean of the Edit Program command. After issuing the
command, you define the segment, which the new one should be inserted
E
afterward. You confirm the entry by pressing the
button. Two potential
situations can occur:
• The segment specified is one of the segment of the program.
The alert message “All Done” is displayed, in order to confirm the successful
operation. Next, you must press any key for the message to disappear
and return back to the Program No menu.
• The segment specified doesn’t exist, because its number is greater than
the total number of segments, the program consist of.
The message “Segment not Available” will be displayed, to flag that the
operation cannot be carried on. At this point, you must press a key to
return back to the Program No menu.
133
Installation and User manual of the AC10 - AC20 - AC30 controller
Program No
Insert Seg
Insert Seg
2
1
Edit Program
New Program
Delete Prg.
Seg. No.
E
Copy Program
Prg. LIst
Insert Seg.
Delete Seg.
E
1
1
E
R
R
Seg. No.
1
All Done
It's OK
E
E
R
R
Any key
After the insertion of the segment, all the other segments of the program
following the new one, have its numbers incremented by one. To enter the
data in the new segment, you must select the command Edit Program from
the Program No “n” selection menu and follow the instructions given above
for that command.
Program No “n” Delete Segment
This command allows you to delete an existing segment of a program. After
issuing the command, you define the segment which should be deleted, from
E
the Delete Seg. panel. You confirm the entry by pressing the
button. Two
potential situations can occur:
• The segment to delete is existing
The alert message “All Done” is displayed, in order to confirm the successful
operation. Next, you must press any key for the message to disappear
and return back to the Program No menu.
• The segment to delete doesn’t exist, because its number is greater than
the total number of segments, the program consists of.
The message “Segment not Available” will be displayed, to flag that the
operation cannot be carried on. At this point, you must press a key to
return back to the Program No menu.
Program No
2
Delete Seg
Delete Seg
7
Edit Program
New Program
Delete Prg.
Copy Program
Prg. LIst
Insert Seg.
Delete Seg.
Seg. No.
E
7
7
E
Seg. No.
7
All Done
It's OK
E
R
R
E
E
R
R
Any key
After the deletion of the segment all the other segments of the program
following the new one, have its numbers decremented by one.
134
Cap.6. - Password and Access Control
6.
Password and Access Control
Description
This chapter refers to an innovative feature of the AC Controller, consisting in
customizing the access mode for each display panel, in order to prevent
unauthorized intervention of the user. You can easily configure, for each
display panel, if the user can recall it on the screen and if he/she can change
the values and the parameters.
In order to facilitate the configuration of the access modes, most of the
operations, performed by the AC Controller, are classified in just 3 groups: A,
B, C.
Furthermore, two more operations, consisting in the typical operator front
panel setting and not included in these groups, are considered as two
separate groups; they are the Setpoint Management and the Auto/Manual
station, involving the Setpoint handling and the Out station.
For all these 5 groups, the picture below lists all the possible modes the user
can assign, separately, to each of them.
Description
Tuning procedure
Display
Tune & Views
Group
A
Parameters, Modules and
Communication
Par & Comms
B
Prog & Test
Set. Pnt
Manual
C
Configuration and Diagnostics
Setpoint modification from keyboard
Auto/Manual Station
Possible Modes
N.Visa, Visabl.
Vi&Mo
N.Visa, Visabl.
Vi&Mo
Prog.
Visabl., N.Visa
Lock - Unlock
Lock - Unlock
A brief explanation of the modes is as follows:
Not visible
Visible
means that the display panel is hidden to the user.
means that the display panel is presented on the
screen, but the user cannot enter any data or
command.
Visible and modifiable means that the display panel is presented on the
screen and the user can fully operate with it.
Blocked
means that the panel is displayed but the user
cannot enter any value or setting.
Unblocked
means that the panel is displayed and the user can
fully operate with it.
Prog.
allows to display/change the programmers’ (PRG)
parameters and to lock all the other parameters.
6.1
Setting Access Modes
The following drawing shows the basic menu structure on the AC Controller.
Starting from the Main Menu, 4 submenu are accessible:
Keyb Perm & Password
Program Select & I-O
Parameters & Comms
Tuning & Views
allowing password definitions and access mode
setting.
allowing diagnostic and calibrations.
allowing the setting of Comms parameters and
the access to modules data and parameters.
allowing the self tuning procedure and other
display setting.
135
Installation and User manual of the AC10 - AC20 - AC30 controller
The last 3 submenu correspond to the operations of groups A, B and C.
Main
Menu
Tune & Views
E
Par. & Comms
E
Progr & Test
E
Keyb. Perm.
E
Keyb. Perm
& Password
Prog. Sel.
& I-O Test
Parameters
& Comms
Tuning and
Views
Group Perm.
Sampling T.
Parameters
Tuning (Auto)
Change Passwd
I-O Test
Main Comm
Tuning (Man)
Prg. Select.
LAN Addr.
PID Param.
Calibration
F.Panel View
LCD Contrast
To set the access mode, you must select the Keyb Perm item from the Main
menu and reach the Permission display panel, where all the 5 groups are
listed, with their mode on the left side.
The modes can be easily changed with the scroll buttons, followed by a
E
confirmation, by mean of the
button, in order to permanently store the
modifications.
The setting choices, for each of the 5 groups, are listed in the column
Possible Modes of the table above.
For a better security of important features, like the access modes
customization, it is possible to insert an optional password, in order to allow
the modification of the setting to authorized people, only.
In this case, to reach the Keyb Perm menu, the user must enter the proper
password; if the password is not the correct one, the access to the menu is
denied.
The following pictures show the procedure for the access modes setting in
either in presence of password or without it.
With Password
Forno 3A
Zona 1
840
Main
Menu
8
835
1200
Enter the
Password
Tune & Views
Par. & Comms
Prog & Test
Keyb. Perm.
24
RUN
Permission
Keyb. Perm
& Password
E
Vi&Mo
Group Perm.
Change Passwd
E
Group A
Group B
Group C
Set Pnt
Manual
E
OFF
0
R
W=10 min
Zona 2
0.85
0.87
1.55
RUN
OFF
0.00
136
E
R
R
E
R
E
99999
8
24
W=5 min
E
Vi&Mo
Vi&Mo
Ulock
Ulock
Lock
R
R
R
R
Cap.6. - Password and Access Control
Without Password
Forno 3A
Zona 1
840
Main
Menu
8
835
1200
Tune & Views
Par. & Comms
Prog & Test
Keyb. Perm.
24
RUN
Permission
Keyb. Perm
& Password
Vi&Mo
Group Perm.
Change Passwd
E
Group A
Group B
Group C
Set Pnt
Manual
E
OFF
0
R
W=10 min
Zona 2
0.85
E
R
E
R
Vi&Mo
Vi&Mo
Ulock
Ulock
Lock
E
8
0.87
1.55
24
R
R
R
RUN
OFF
0.00
W=5 min
By default the AC controller doesn’t have the password protection. You can
easily add it by following the procedure below for Password Change.
Note
• The password consists of 5 alphanumeric characters
• The AC controller doesn’t have the password protection when shipped
• Once a password has been defined, it operates, unchanged, up to the
next modification or deletion.
137
Installation and User manual of the AC10 - AC20 - AC30 controller
6.2
Password Change
The following picture shows the steps required to insert the password for the
first time. You access the Key. Perm menu, select the Change Passwd
E
command, enter the password and confirm with the
button.
Forno 3A
Zona 1
840
Main
Menu
8
835
1200
Keyb. Perm
& Password
Tune & Views
Par. & Comms
Prog & Test
Keyb. Perm.
24
RUN
Enter new
Password
Group Perm.
Change Passwd
E
Enter new
Password
E
OFF
0
R
W=10 min
Zona 2
0.85
E
R
E
0.87
1.55
24
E
R
99999
8
R
R
R
R
Do you really
desire to
change the
E
password?
Press "E"
to confirm
or any other key
to teminate
the operation.
RUN
OFF
0.00
W=5 min
Any key
In the case of an already existing password, the procedure slightly changes.
To reach the Key. Perm menu, in order to modify the password, the user
must enter the old password, otherwise the procedure is aborted.
Anyway, in both cases, once the new password has been entered, a
confirmation is required to the user, in order to avoid to accept wrongly typed
passwords.
6.3
Password Delete
To delete the password, the user must change the existing password to the
new value of “00000”, as illustrated above.
Once this new value has been entered, the password won’t be asked any
further.
6.3.1 Don’t panic!
If you have forgotten the password, don’t panic, because you have not lost
your data. In fact, through the Supervisory Computer Comm line, you can
read at predefined addresses, the password value. Refer to the
Communication Manual, in order to get the proper informations. Once the
password is read, you must enter it from the AC controller panel and operate
as you like. Furthermore, the value of the password can be read from the
Programming port, by mean of the AC_Edit, too.
138
Cap.7. - Maintenance and Diagnostic
7.
Maintenance and Diagnostic
7.1
Adjustment of the display contrast
The contrast of the front panel LCD display can be adjusted in order to
perfectly match it with the light at the installation site. This operation is carried
out from the controller keyboard, carrying on the following steps.
Once reached the LCD Contrast panel, the contrast of the display is changed
pressing the
and the
button. The LCD display reflects automatically
E
the new setting. When the preferred contrast has been achieved, the
button must be pressed in order to store permanently the new setting.
After the setting, the contrast is automatically varied according to the
temperature changes, in order to compensate the drift caused by the
temperature and achieve an optimal readability over the entire temperature
range of 0 ÷ 50 °C.
TAG-0000-0
l/h
LSP
Main
Menu
573
550
1200
Tune & Views
Par. & Comms
Prog & Test
Keyb. Perm.
Loc
Loc
HLD
Tuning and
View
R
Tuning (Auto)
Tuning (Man)
PID Param.
F.Panel View
LCD Contrast
E
E
LCD
Contrast
R
E
E
AL1
AL2
Release 00A
E
E
R
R
R
R
MAN
W=5 min
0
OUT= 63
7.2
AC30-Series
Error messages
The AC controller is provided with a diagnostic system, capable to detect a
wide range of faults and automatically alert the operator. Most of this faults
are caused by wrong assignment of parameters or other mistakes in the
instrument configuration. When one of these anomalous situations arises,
the display is completely blanked and an error message appears, in order to
alert the user.
The operator must acknowledge the message, by pressing, at the same
time, the
and
keys. As a consequence, the message disappears
and the display returns to its previous conditions.
The following are the various error message that the AC controller handles:
• Net Ovrf
• Due to NET
This message flags anomalous situations on the network, usually due to
memory overflow, when receiving large amount of data, or a duplication of
the addresses of the LAN cards.
• Net Error
This message is, usually, caused by errors in the configuration data.
• Overflow
• Invalid Instruct.
• Divide By Zero
• Address Error
This error messages do not appear when the instrument hardware isn’t
properly working. Therefore, if they appears on the display, please refer to
the Technical Service.
139
Installation and User manual of the AC10 - AC20 - AC30 controller
7.3
Master Reset
This functionality is required when, due to a temporary failure of the
hardware, normally triggered by some anomalous external conditions, the
AC controller appears completely locked and doesn’t allow to operate from
the keyboard or the serial ports. In most of these cases, you can recover the
situation by “resetting “ the AC controller.
When a failure of the type described above, occurs, the first thing to do is to
switch off and on the AC Controller; operation that in a lot of cases, forces
the instrument to start to properly work.
If the AC controller doesn’t restart, you must proceed with the Reset
operation, by switching off the instrument and on, again, with the two keys
and
pressed.
After the power up, the following display panel is shown.
Your
Choice
Clear Config.
LCD Contrast.
Calibration
System Test
E
R
The 4 commands of this menu perform the following functions:
• Clear Config.
Deletion of the existing configuration
• LCD Contrast. Adjustment of the display contrast
• Calibration
Operations for the calibration of the controller
• System Test
Operations of system test
To Reset the instrument, you must select the command Clear Config. and
E
confirm by pressing the
key. The existing configuration will be completely
deleted; at the end the message “No program Found” will appear on the
display. Now, the instrument is fully operating and ready to accept a new
configuration, that will be downloaded as usual.
7.4
Diagnostic Test and Calibration
This Chapter describes how to perform the autodiagnostic and the calibration
procedures. It is recommended the use of a digital multimeter, for taking
precise measures of the signals generated by the AC controller during the
test phase, as well as a calibrator for testing the analog outputs, like the
ASCOCAL 10 series model or one with similar performances.
140
Cap.7. - Maintenance and Diagnostic
7.4.1 Diagnostic Tests
To execute the self test procedure, you have to access to the System Test
panel, carrying out the following steps:
TAG-0000-0
l/h
LSP
Main
Menu
573
550
1200
Tune & Views
Par. & Comms
Prog & Test
Keyb. Perm.
Loc
Loc
HLD
Prog. Sel.
& I - O Test
Sampling T.
I - O Test
Prg. Select.
Calibration
E
E
R
System
Test
N
KeyBoard
Display
Input
Out Volt
Out mA
E
E
R
I
E
.
E
R
T
E
AL1
R
AL2
R
R
S
T
MAN
W=5 min
3.015
2.015
4.072
1.356
4.875
2.500
3.085
1.785
0
OUT= 63
From the System Test you can select 5 test functions, capable to exercise
most of the hardware of the instruments. These functions are:
• Keyboard test (Keyboard). It tests the keyboard by lighting a rectangle on
the display when the corresponding key is pressed.
• Display test (Display). It tests the display, by switching on and off,
alternatively, contiguous pixels of the LCD panel.
• Input test (Input) It displays a panel with 8 (4 for the AC10) analog inputs,
in Volt, and 8 digital inputs. By exercising externally this inputs, by mean
of the calibrator, and checking the results on the display, the faulty inputs
are detected.
•
TAG-0000-0
l/h
LSP
Main
Menu
573
550
1200
Prog. Sel.
& I - O Test
Tune & Views
Par. & Comms
Prog & Test
Keyb. Perm.
Loc
Loc
HLD
Voltage output (Out V/Out mA): You access the test page of the analogue
and digital outputs. At the beginning of the test all the digital and analogue
outputs are locked on the last value calculated by the strategy.
The analogue outputs may be changed as V or mA depending on their
configuration. The non-configured outputs may be changed both as V and
as mA.
R
Sampling T.
I - O Test
Prg. Select.
Calibration
E
E
System
Test
R
O
KeyBoard
Display
Input
Out Volt
Out mA
E
E
A. Outs = V
R
E
T
E
AL1
AL2
MAN
W=5 min
0
OUT= 63
U
2.50
2.50
2.50
2.50
T
E
R
R
R
S
T
2.50
When the A Outs = V panel has been displayed, the analog output to
exercise is selected through the
and
buttons, followed by the
button, for confirming the operation. The voltage value, the output is set, is
shown in the lower right corner of the display.
141
Installation and User manual of the AC10 - AC20 - AC30 controller
Now you can drive the output at various level, by changing this value, in order
to take different measures with the external multimeter. This is done through
the
and
buttons, followed by the
confirmation button.
The procedure is quite the same for the digital outputs. Once the output has
been selected, pressing the
key causes its status to complement.
• Current Output test. (Out mA) It’s like the previous one, but related to the
current outputs only.
Note
To abort one of these test functions, press, at the same time, both the
and the
key.
7.4.2 Calibrations
The AC controller allow the on site calibration of the analog inputs and
outputs. As shown in the picture below, the first step consists in reaching the
Calibr. Page menu, with all the various calibration functions.
TAG-0000-0
l/h
LSP
Main
Menu
573
550
1200
Tune & Views
Par. & Comms
Prog & Test
Keyb. Perm.
Loc
Loc
HLD
Prog. Sel.
& I - O Test
R
Sampling T.
I - O Test
Prg. Select.
Calibration
E
E
Calibrat.
Page
R
Calib. Input
Calib. Out 1
Calib. Out 2
Calib. Out 3
Calib. Out 4
E
E
R
E
AL1
R
AL2
R
R
MAN
W=5 min
0
OUT= 63
Inputs calibration (Calib. Input).
This calibration procedure involves the analog input 1 and calibrates all the
analog inputs at the same time. To perform the procedure, you must connect
a calibrator to input 1 (terminals 1 and 2) and apply the voltages asked on
the display. You will be asked to apply 0 Volt. Once you have done it, press
the “N” (Next) key. You will be asked to apply 5 Volt. Once you have done it,
press “C” to compute the calibration coefficients and store them permanently.
N -> Next:
go to the next calibration value.
C -> Calib: store the calibration coefficients.
142
Cap.7. - Maintenance and Diagnostic
The following picture illustrate this procedure.
Calibrat.
Page
Inputs
Calibrat.
Calib. Input
Calib. Out 1
Calib. Out 2
Calib. Out 3
Calib. Out 4
Inputs
Calibrat.
Apply 0 volts
to Input #1
E
N
Apply 5 volts
to Input #1
C
E
-9999
R
N
-9999
C
N
C
N -> Next
C -> Calib.
N -> Next
C -> Calib.
Pressing the N or C key
Outputs N° 1, 2, 3, 4 (Calib. Out).
This procedure must be followed, for each of the 4 analog outputs separately
and works as follows.
The AC controller generates, on the selected output, a voltages that the user
must measure with the multimeter, entering the read value in the controller.
Four signal are generated by the AC controller to complete a calibration: two
voltages, one at 5% and the other at 95% of the span and two
corresponding currents.
The picture below illustrates the procedure. In the Calibrat. Out No. menu,
the list of the 4 calibration signals appears.
Pressing S (Select) the first signal is generated on the output.
At this point the user must measure the signal at the controller terminal and
enter the measured value in the controller, that is displayed with big size
digits in the lower part of the display.
Press again S (Select) to proceed to the next signal and carry out the
operations, as listed above for the first signal, up to completion. Do it for all
the four calibration signals. The calibration signal currently in use is marked
with an “*” in the Calibrat. Out No menu.
S -> Select:
The first time is pressed, it selects the first calibration signal;
next, it confirms the measured value, just entered.
R -> Return: Terminate the calibration procedure.
Calibrat.
Page
Calibrat.
Out No. 1
Calib. Input
Calib. Out 1
Calib. Out 2
Calib. Out 3
Calib. Out 4
Calibrat.
Out No. 1
5% volt
95% volt
5% mA
95% mA
E
E
S
S
R
R
R
S -> Select
R -> Return
5% volt *
95% volt
5% mA
95% mA
Read Volt
0.078
S
R
S -> Select
R -> Return
Pressing the R key
Display for the calibration of the analog outputs
143
Installation and User manual of the AC10 - AC20 - AC30 controller
7.5
Replacement of Faulty Components
Some components require continuous maintenance and they are, therefore,
designed to be easily replaced by the user. These components are: the cool
cathode backlight lamp and the supply fuse.
The lamp requires to be changed every 20.000 hours, because of the aging.
To replace the lamp, follow this simple and safe procedure:
• Switch the power of the AC controller off.
• Unscrew the blocking screw in the lower part of the instrument and pull it
out.
• Remove the front panel cover, sliding it in the direction of the arrow.
• Unplug the lamp connector and remove the lamp from the socket.
• Insert the new lamp and insert the connector.
• Adjust, if required, the LCD display contrast, following the procedure listed
at Chapter 7.1
The fuse, must be checked either every time the AC controller doesn’t light
up, when switched on, or in the case it simply switch off, when operating
regularly, with the power connected. The fuse is located into the controller on
the power supply card.
To replace the fuse, follow this simple and safe procedure:
• Disconnect the power supply from the instrument
• Unscrew the blocking screw in the lower part of the instrument and pull it
out.
• Remove the protective cover of the fuse.
• Plug the fuse out and check that is not an open circuit, by mean of a
simple tester or a digital multimeter. If it is broken, replace it with a glass
fuse of 5x20, 1A 250V delayed.
7.6
7.7
Spare Parts
Pos.
1
2
3
Description
9 poles female connector Kit (LAN)
Connection kit for inst. programming
CCFL lamp
Pos.
1
Description
User manual of the AC10 - AC20
- AC30 controllers
AC_PROGRAPH / AC-EDIT
software User Manual
Communication protocols of the
AC controllers
Introduction to the control of an
industrial process
Part number
H10-301-D09FD
H10-395-1A1D9
A61-259-7A0
Manuals
2
3
4
144
Note
Note
Part number
J30 - 304 - 1AMIAC
J30 - 304 - ACPROGRAPH
J30 - 304 - 1ACSAC
NT.1 / 95.05
Cap.8. - Expansion Units
8.
Expansion Unit
8.1
General Informations
The Expansion units AAC-EU/88/4 and AAC-EU/88 series, provide the AC
controller with an additional number of analog and digital I/O, up to a
maximum expansion of 8 analog outputs, 32 digital inputs and 32 digital
outputs. The analog inputs are not supported by the available Expansion
Units. The digital inputs can be, directly, connected to a free voltage contact
or can be driven by an open collector NPN transistor.
The digital outputs are provided with a normally open contact from a relay.
The relay can support resistive load of up to 220Vac/5A.The 4 analog
outputs, on the AAC-EU/88/4 Expansion Units, are of 4..20 mA type.
8.2
Technical Characteristics
The AAC-EU/88/4 and AAC-EU/88 Expansion Units have been designed for
properly working in harsh environment, typical of the industrial plants. These
units complies completely to the IEC 801-4 level 4 standard.
Max n° of units:
Digital Inputs:
Digital Outputs:
Analog Outputs 4 .. 20 mA:
Power supply:
Led:
Serial Line:
Noise Immunity:
Case unit AAC-EU/88:
Case unit AAC-EU/88/4:
8.3
One AAC-EU/88/4 unit and two AACEU/88 units or 3 AAC-EU/88 units
8 Optoisolated
8 relays type with N.A. contact 220 Vac
5A
4 on the AAC-EU/88/4 only
2 supplies for each unit, 11Vac 600mA
for the I/O section and 11Vac 200mA for
the CPU card.
8 led for the inputs, 8 led for the outputs,
1 led for Run and 1 led for Alarm (Failure)
RS-485 standard with ModBus protocol
Level IV° of the IEC 801-4 standard
DIN 6 modules (105 mm)
DIN 9 modules (157.5 mm)
Installation
The Expansion units are suitable to be installed into a cubicle, mounted on a
rail of type omega or Top Hat.
Dimension of the units and of the supply transformer:
145
Installation and User manual of the AC10 - AC20 - AC30 controller
8.4
Electrical Connections
8.4.1 RS-485
The Expansion Units are connected to the AC controller through a RS-485
serial communication bus. This communication has a Plug and Play
capability, because the setting of the baud rate and the other communication
parameters is embedded in the firmware of the controller and doesn’t require
any customization by the user. The user has, just, to set the address on the
expansion units, make the cabling and use the additional I/O in the strategy,
he/she is developing with the AC-Prograph.
It is important to remind that:
• the digital I/O from 1 to 8 and the 4 analog outputs from 1 to 4 are on the
AC controller,
• the digital I/O from 9 to 16 and, possibly, the analog outputs from 5 to 8,
are on the Expansion Unit with address 0
• the digital I/O from 17 to 24 are on the Expansion Unit with address 1
• the digital I/O from 25 to 32 are on the Expansion Unit with address 2.
The maximum distance between the AC Controller and the farthest
expansion unit is limited, by the RS-485 standard, to about 1.000 mt. When
the line is at the maximum limits of length the layout of the communication
cable and the choice of the cable type must be carried out carefully.
Note:
This drawing reports the configuration with the maximum number of
expansion units, an AC controller can support. If, among the Expansion
units, there is the AAC-EU/88/4 model, this latter one unit must be
compulsory set to the address “0”, setting the address of the others to “1”
and “2”. If only one Expansion Unit is connected, its address must be set to
“0”. Furthermore, don’t forget to add a termination resistor of 120Ω 1/4W to
the unit at the other end of the line, opposite to the AC controller.
146
Cap.8. - Expansion Units
8.4.2 Power Supply
The power supply of the Auxiliary Units must be provided through the
transformer with double secondary windings, mod. AAC-TA. The picture
below illustrates the connections.
8.4.3 Inputs and Outputs
8.5
Auxiliary Units Addressing
Each Auxiliary Unit has an address, with range from 0 to 2, set by the user,
generally at the installation time, by mean of 4 switches, located on the unit.
The address must be unique among the various Units connected to the line.
In setting the address the following simple rules must be complied:
• The first unit must always be set to address 0.
• If there is an AAC-EU/88/4 Unit, these one must be set to address 0.
• The only valid addresses are: 0, 1, 2 and are set according to the
following drawing:
ADDRESS = 0
ON
1
ADDRESS = 1
ON
2
3
4
1
ADDRESS = 2
ON
2
3
4
1
2
3
4
147
Installation and User manual of the AC10 - AC20 - AC30 controller
9.
Ordering Data
Multifunction, multi I/O Unit, ASCON AC10 - AC20 - AC30 series
9.1
Ordering Code
Model: AC10/
Supply
100 ... 240 V, 50/60 Hz
18 ... 28 V, 50/60 Hz o 20 ... 30 Vdc
Spare lamp (optional)
0000
3
5
Not supplied
0
Supplied
1
Model: AC20/
Supply
100 ... 240 V, 50/60 Hz
18 ... 28 V, 50/60 Hz o 20 ... 30 Vdc
00/0000
3
Code of
the Control
Strategy
5
Spare Lamp (optional)
0
1
Not supplied
Supplied
External Units Port (optional)
0
1
Not supplied
Supplied
LAN Port (optional)
0
Not supplied
Supplied (ARCNET type)
1
Modello: AC30/
Supply
100 ... 240 V, 50/60 Hz
18 ... 28 V, 50/60 Hz o 20 ... 30 Vdc
00/0000
3
5
Code of
the Control
Strategy
Spare Lamp (optional)
Not supplied
Supplied
0
1
External Unit Port (optional)
Not supplied
Supplied
LAN Port (optional)
Not supplied
Supplied (ARCNET type)
9.2
0
1
0
1
Auxiliary Units
Expansion Unit with 8 digital I/O
AAC-EU/88
Expansion Units with 8 digital I/O and 4 4..20 mA outputs
AAC-EU/88/4
Power supply for 1..3 Auxiliary Units mod. AAC-EU/88 and AAC-EU/88/4.
Supply: 220/240 Vac 50Hz.
AAC-TA
148
Annex A. - Resident Configurations
10. Annex “A” Resident Configurations
149
Installation and User manual of the AC10 - AC20 - AC30 controller
TABLE OF CONTENTS
10.
ANNEX “A” RESIDENT CONFIGURATIONS............................................................................................149
11.
HOW TO IMPLEMENT A PID CONTROLLER .........................................................................................153
12.
1 LOOP A ..........................................................................................................................................................155
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
12.9
12.10
13.
1LOOP B............................................................................................................................................................159
13.1
13.2
13.3
13.4
13.5
13.6
13.7
13.8
13.9
13.10
13.11
14.
16.1
16.2
16.3
150
DESCRIPTION....................................................................................................................................................164
BLOCK DIAGRAM .............................................................................................................................................164
CONTROL .........................................................................................................................................................165
REMOTE SETPOINT ...........................................................................................................................................165
FORCING OPERATIONS .....................................................................................................................................165
ALARMS ...........................................................................................................................................................165
VARIABLES RETRANSMISSIONS ........................................................................................................................166
GRAPHIC DISPLAYS ..........................................................................................................................................166
APPLICATIONS ..................................................................................................................................................167
ELECTRICAL CONNECTIONS ..........................................................................................................................167
2 LOOPS A ........................................................................................................................................................168
15.1
15.2
15.3
15.4
15.5
15.6
15.7
15.8
15.9
15.10
16.
DESCRIPTION....................................................................................................................................................159
BLOCK DIAGRAM .............................................................................................................................................159
CONTROL .........................................................................................................................................................159
REMOTE SETPOINT ...........................................................................................................................................160
FEED FORWARD ...............................................................................................................................................160
FORCING OPERATIONS .....................................................................................................................................160
ALARMS ...........................................................................................................................................................161
VARIABLES RETRANSMISSIONS ........................................................................................................................161
GRAPHIC DISPLAYS ..........................................................................................................................................161
APPLICATIONS ..............................................................................................................................................162
ELECTRICAL CONNECTIONS .........................................................................................................................163
1LOOP C ...........................................................................................................................................................164
14.1
14.2
14.3
14.4
14.5
14.6
14.7
14.8
14.9
14.10
15.
DESCRIPTION....................................................................................................................................................155
FUNCTIONAL BLOCK DIAGRAM ........................................................................................................................155
CONTROL .........................................................................................................................................................155
REMOTE SETPOINT ...........................................................................................................................................155
FORCING OPERATIONS .....................................................................................................................................156
ALARMS ...........................................................................................................................................................156
VARIABLES RETRANSMISSION ..........................................................................................................................156
GRAPHIC DISPLAYS ..........................................................................................................................................156
APPLICATIONS ..................................................................................................................................................157
ELECTRICAL CONNECTIONS .........................................................................................................................158
DESCRIPTION....................................................................................................................................................168
BLOCK DIAGRAM .............................................................................................................................................168
CONTROL .........................................................................................................................................................168
REMOTE SETPOINT ...........................................................................................................................................168
FORCING OPERATIONS .....................................................................................................................................169
ALARMS ...........................................................................................................................................................169
VARIABLES RETRANSMISSION ..........................................................................................................................169
GRAPHIC DISPLAY ............................................................................................................................................169
APPLICATIONS ..................................................................................................................................................171
ELECTRICAL CONNECTIONS .........................................................................................................................171
2 LOOPS B ........................................................................................................................................................172
DESCRIPTION....................................................................................................................................................172
BLOCK DIAGRAM .............................................................................................................................................172
CONTROL .........................................................................................................................................................173
Annex A. - Resident Configurations
16.4
16.5
16.6
16.7
16.8
16.9
16.10
16.11
17.
2 LOOPS C ........................................................................................................................................................177
17.1
17.2
17.3
17.4
17.5
17.6
17.7
17.8
17.9
17.10
18.
21.1
21.2
21.3
DESCRIPTION....................................................................................................................................................189
BLOCK DIAGRAM .............................................................................................................................................189
CONTROL .........................................................................................................................................................189
REMOTE SETPOINT ...........................................................................................................................................190
FORCING MODES ..............................................................................................................................................190
ALARMS ...........................................................................................................................................................190
VARIABLES RETRANSMISSION ..........................................................................................................................191
GRAPHIC DISPLAYS ..........................................................................................................................................191
APPLICATIONS ..................................................................................................................................................193
ELECTRICAL CONNECTIONS .........................................................................................................................194
OVERRIDE .......................................................................................................................................................195
20.1
20.2
20.3
20.4
20.5
20.6
20.7
20.8
20.9
20.10
21.
DESCRIPTION....................................................................................................................................................183
BLOCK DIAGRAM .............................................................................................................................................183
CONTROL .........................................................................................................................................................184
BIAS .................................................................................................................................................................184
REMOTE SETPOINT ...........................................................................................................................................184
FORCING MODES ..............................................................................................................................................184
ALARMS ...........................................................................................................................................................185
GRAPHIC DISPLAYS ..........................................................................................................................................186
APPLICATIONS ..................................................................................................................................................187
ELECTRICAL CONNECTIONS .........................................................................................................................188
CASCADE..........................................................................................................................................................189
19.1
19.2
19.3
19.4
19.5
19.6
19.7
19.8
19.9
19.10
20.
DESCRIPTION....................................................................................................................................................177
BLOCK DIAGRAM .............................................................................................................................................177
CONTROL .........................................................................................................................................................178
REMOTE SETPOINT ...........................................................................................................................................178
FORCING MODES ..............................................................................................................................................178
ALARMS ...........................................................................................................................................................179
VARIABLES RETRANSMISSION ..........................................................................................................................179
GRAPHIC DISPLAYS ..........................................................................................................................................180
APPLICATIONS ..................................................................................................................................................181
ELECTRICAL CONNECTIONS .........................................................................................................................182
RATIO................................................................................................................................................................183
18.1
18.2
18.3
18.4
18.5
18.6
18.7
18.8
18.9
18.10
19.
REMOTE SETPOINT ...........................................................................................................................................173
FEED-FORWARD ...............................................................................................................................................173
FORCING MODES ..............................................................................................................................................173
ALARMS ...........................................................................................................................................................174
VARIABLES RETRANSMISSION ..........................................................................................................................174
GRAPHIC DISPLAYS ..........................................................................................................................................174
APPLICATIONS ..............................................................................................................................................176
ELECTRICAL CONNECTIONS .........................................................................................................................176
DESCRIPTION....................................................................................................................................................195
BLOCK DIAGRAM .............................................................................................................................................195
CONTROL .........................................................................................................................................................195
REMOTE SETPOINT ...........................................................................................................................................196
FORCING MODES ..............................................................................................................................................196
ALARMS ...........................................................................................................................................................196
VARIABLE RETRANSMISSIONS ..........................................................................................................................197
GRAPHIC DISPLAY ............................................................................................................................................197
APPLICATIONS ..................................................................................................................................................198
ELECTRICAL CONNECTIONS ..........................................................................................................................199
4 LOOPS ............................................................................................................................................................200
DESCRIPTION....................................................................................................................................................200
BLOCK DIAGRAM .............................................................................................................................................200
CONTROL .........................................................................................................................................................200
151
Installation and User manual of the AC10 - AC20 - AC30 controller
21.4
21.5
21.6
21.7
21.8
22.
22.1
22.2
22.3
22.4
22.5
22.6
22.7
23.
23.1
23.2
23.3
23.4
23.5
23.6
23.7
23.8
152
FORCING MODES ..............................................................................................................................................201
ALARMS ...........................................................................................................................................................201
GRAPHIC DISPLAYS ..........................................................................................................................................201
APPLICATIONS ..................................................................................................................................................202
ELECTRICAL CONNECTIONS .............................................................................................................................203
4 INDICATORS ................................................................................................................................................204
DESCRIPTION....................................................................................................................................................204
BLOCK DIAGRAM .............................................................................................................................................204
ALARMS ...........................................................................................................................................................204
VARIABLES RETRANSMISSION ..........................................................................................................................204
GRAPHIC DISPLAYS ..........................................................................................................................................205
APPLICATIONS ..................................................................................................................................................206
ELECTRICAL CONNECTIONS .............................................................................................................................206
A/M STATION ..................................................................................................................................................207
DESCRIPTION....................................................................................................................................................207
BLOCK DIAGRAM .............................................................................................................................................207
FORCING MODES ..............................................................................................................................................207
ALARMS ...........................................................................................................................................................208
VARIABLES RETRANSMISSION ..........................................................................................................................208
GRAPHIC DISPLAY ............................................................................................................................................208
APPLICATIONS ..................................................................................................................................................209
ELECTRICAL CONNECTIONS .............................................................................................................................210
Annex A. - Resident Configurations
11. How to implement a PID controller
Process disturbances
Fig. 1
Manipulated
Variables
Process
Controlled
Variables
The purpose of a PID loop is to control a variable of an industrial process. The
purpose of an industrial process is to produce materials, products or energy,
using the minimum quantity of energy and providing the maximum level of
safety. To achieve this target with an high level of quality standard, each single
element of the process must work precisely. That means that each variable of
the process must be, finely, tuned and kept as much as possible close to the
predefined setpoint. The operation of keeping the variables close to the setpoint
is called regulation, and the PID is the PID is one of the tool that does it.
To understand how the regulation process works, we have to consider that the
process is a system, whose behaviour is determined by the 3 class of
magnitudes, as shown in fig. 1:
controlled variable, manipulated variable and disturbances.
The controlled variables are the chemical, physical and electrical magnitudes,
that must be controlled and kept at the setpoint, in order to produce efficiently
and with an high degree of quality. For instance, pressures, levels, flows,
temperature etc. are controlled variables. They are, usually, named with the
mnemonic PV (process value), while its setpoint is named SP.
The manipulated variables are the ones the regulation system moves
continuously, in order to carry out the control action and keep stable and close
the controlled variable to the setpoint. For instance, air, water, oil, gas, energies,
fuels etc. are manipulated variable.
The disturbances are transient situations, related to physical magnitudes, that
interfere, randomly and abruptly, with the process and have the effect of moving
"PV” far away from "SP". For instance, the simple change of the Setpoint can
be considered a disturbance.
Therefore, the purpose of controller is to carry out all the actions required to
satisfy the equation: PV-SP=0, generating a control output, that, driving
dedicated actuators, acts on the manipulated variables. This control output is
named M.V. (manipulated value) and, not having a well defined engineering unit,
is indicated in percentage.
SP
+
P.I.D.
MV
Actuator
+
PV
Fig. 2
Regulator
Sensor
Manipulated
Variables
Controlled
Variables
Process
Fig.2 shows the process, with the various magnitudes types and an elementary
PID regulator. Following the considerations above, a block diagram of this PID
loop can be easily determined. First of all, the PID must have an analog input
circuit capable to acquire, from the field, the PV signal, connected to the
termination unit of the loop. Second, the PV value is compared with the SP
Setpoint in the node at the PID input. The result of this comparison is named
error, or deviation and is fed into the PID algorithm.
153
Installation and User manual of the AC10 - AC20 - AC30 controller
The output of the PID algorithm is the signal MV, that, usually, is not connected
directly with the termination blocks of the controller, because the output signal
needs, in some cases, when operator interventions are required, to be
generated manually.
Therefore, a special module, named Auto/Manual Station is inserted between
the MV output and the instrument terminations blocks. The MV output of the PID
module is connected to the input of the Auto/Manual Station. The output of the
Auto/Manual Station is connected to the termination blocks, providing an
electrical signal capable to drive the external actuator.
Fig 3 shows the block diagrams of the complete loop.
AI
PV
SET
&
DEV
PV-SP
MV
PID
A/M
DB
Y%
OUTPUT
MANAGEMENT
Y%
AO
BUMPLESS
FIG. 3
This is a simple PID with an Auto/Manual station and consists of the following
modules.
The PV signal is applied to the AI module, that converts the signal in a number.
The module SET DEV computes the error between the SP and PV.
The PID module computes the control output on the basis of the error input.
The OUT MANAGEMENT module handles the manipulated variable, together
with others control signals (Aut/Man, Hold, Tracking, Bumpless etc.), supporting
various operating modes.
The AO modules converts the calculated value in an electric signal, available at
the termination blocks.
154
Annex A. - Resident Configurations
12. 1 Loop A
12.1
Description
The drawings below are providing the following informations:
Block Diagram.
User interface, consisting in a set of display panels.
Termination unit for the connection to the field.
12.2
Functional Block Diagram
In the following block diagram, corresponding to the configuration of a simple
loop, the interconnections between the various modules and the display panels
are not indicated, in order to improve the understanding of the functionality
performed.
UNDERFLOW
DI1
AI1
AI2
DI2
DI6
DI5
PV1
PV1
DRSP
WSP
SET
WSP-PV
ALM
ALM
3
2
1
1
RSP
DEV
ALM
MUX
PID
Y%
2
1
DB
MCNS
2
CONTROL
OUT
OR
A/M
TRK
DTRK
HOLD
VISU 1
SCH
VISU 2
VISU 3
DO4
12.3
DO3
DO2
DO1
AO1
AO2
Control
Control of the variable connected to the analog input AI1.
The AI module performs the A/D, the scaling and the conversion in engineering
unit of the controlled variable and detects the out of range of the signal,
presumably caused by a sensor failure. The output value of the AI module, PV1
is fed into the three modules which implement the core of the PID loop. The
output of the PID is connected to the terminal blocks of the instrument through
the output module AO1.
12.4
Remote Setpoint
Activating D1 (i. e., closing the contact as in the picture 2.4.4), the Remote
Setpoint is the one selected for the loop; otherwise, the Local Setpoint is
selected. In fact, the setpoint mode selection, as illustrated in the SDV module
description, is more complicated, because it is based on the arbitration of the
requests coming from various sources. The Remote Setpoint can be the signal
at the input AI2 (RSP), if the digital input DI2 is inactive, or the constant stored in
the MCNS module (MSP), if the digital input DI2 is active. The truth table below
lists all the various combinations of setpoint.
155
Installation and User manual of the AC10 - AC20 - AC30 controller
DI1
Off
Off
On
On
DI2
Off
On
Off
On
SP
LSP
LSP
RSP
MSP
.
12.5
Forcing Operations
These operations are related to the loop output and consist of the Hold and
Tracking mode. The Hold mode freezes the loop output, until the DI5 digital
input is active, while the Tracking mode sets the output to the value of the
constant n° 2 of the module MCNS, until DI6 is active.
12.6
Alarms
There are three alarms either on the controlled variable PV1 or the deviation,
according to the parameters selected in each of the ALM modules. The module
WSP-PV computes the deviation, in the same engineering units of the controlled
variable PV1. The status of each alarm is retransmitted out through the DO1,
DO2 and DO3 modules. A fourth alarm, the digital output DO4 flags the out of
range of the variable PV1.
12.7
Variables Retransmission
The controlled variable PV1 is retrasmitted out to the termination unit, through
the SCH and AO2 modules.
The module SCH allows the modification of the ranges of the retrasmitted
output, that are not, necessarily, the same of the PV1 input. This is achieved by
setting the input range parameters of the SCH module to different values than
the output range parameters. In this way, the retrasmitted PV1 can be limited to
a portion of the input signal scale, with the advantage of an improved resolution.
12.8
Graphic Displays
TSP
WSP
LOOP 1
85.3
mm
LSP
85.0
200
Loc
mm
LSP
85.3
85.0
200
Loc
MSP
CSP
LSP
Current operating mode
Requested
operating mode
Loc
Requested
operating mode
OR
OR of the forcing modes.
OR
OR of the forcing modes
ALH
Alarm 1
ALH
Alarm1
ALL
OR of all the alarms
ALL
OR of all the alarms
AUT
Aut/Man station
Low range of the scale.
W=1 min
-200
ALARMS
RSP
Loc
AUT
-200
RSP
MSP
CSP
LSP
Current operating mode
TSP
WSP
TREND 1
ALARM 1
ALARM 2
ALARM 3
UNDERFLOW
Aut/Man Station
Scale low range
TRAKING
HOLD
Out= 35
Out= 35
The pictures above show the different types of display panels, providing the
most effective interface for this strategy configuration.
The most used panels are the single bargraph display and the single pen trend,
that provides the same functionalities of the previous panel, with the addition of
a programmable time width chart, displaying the trend profile of the controlled
variables.
The main controlled variable is displayed both in the large size digits display and
through the bargraph, the Working Setpoint, WSP, is displayed by the slider and
the output by the horizontal bargraph and numerically.
156
Annex A. - Resident Configurations
The following variables, consisting of the entire set of Setpoints, are displayed,
one at a time, in the scrollable display area:
LSP
Local setpoint
TSP
Target setpoint
WSP Working setpoint
RSP
Remote setpoint
MSP Memorised setpoint
CSP
Computer setpoint
The squared digital indications, on the right side of the panel, are flagging the
status of the alarms and the forcing mode of the loop. More precisely, they
highlight the following general situations:
1
When an alarm is active, the label ALL is visible
2
When the Alarm 1 is active, the label AL1 is visible.
3
When a forcing mode is active the label FOR is displayed.
These are global flags: the detailed cause of the event, is shown in the ALARMS
panel, where the digital status of each alarm and forcing input is clearly shown.
These are:
ALL 1
Alarm 1
ALL 2
Alarm 2
ALL 3
Alarm 3
UNDERFL
Input AI1 out of range (for 1-5V or 4-20 mA signals,
only)
TRACKING
Force the control output to a predefined value
HOLD
Freeze the control output
12.9
Applications
This easy to use configuration is for simple applications, where the control
requirements need some additional functionalities than the basic classic PID
loop, like the availability of multiple setpoints, remote or predefined, selectable
through an external digital signal. Furthermore, this configuration offers the
possibility to acts on the control output, both by forcing it to a predefined value
and by freezing it, upon an external command.
The multiple alarm modules offer an effective tool for monitoring continuously
the controlled variable and for detecting anomalous changes.
The retransmission of the controlled variable, over a different range, improves
the resolution of the signal, because it is limited to the meaningful portion of the
original range (zoom effect)
157
Installation and User manual of the AC10 - AC20 - AC30 controller
12.10
Electrical Connections
The following picture provides a clear view of all the termination blocks, with the
associated functionality, and it is specific of this configuration. No signals must
be connected to the termination blocks not used by the strategy.
The termination blocks 25 and 26 are providing a 24V DC output, particularly
suitable to supply of the 2 wires transmitters.
PV1 measure
Remote SP
1
25 +24
26 +24
2
3
4
5
6
A
N
A
L
O
G
7
8
I
N
P
U
10
T
11
LAN
9
33
12
34
D
I 35
G
I 36
T
A 37
L
38
13
DRSP
Rem / Mem
Hold
Tracking
158
A 27
N
A 28
L
O 29
G
30
O
U 31
T
32
14
15 D
I
16 G
17 I
T
18 A
L
19
20
Actuator
Retransmitted PV1
Alarm 1 Pv1
Alarm 2 Pv1
Alarml 3 Pv1
Und.F. Pv1
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I
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U
22 T
23
44
24
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Annex A. - Resident Configurations
13. 1Loop B
13.1
Description
The drawings below are providing the following informations:
Block Diagram.
User interface, consisting in a set of display panels.
Termination unit for the connection to the field.
13.2
Block Diagram
In the following block diagram the interconnections between the various
modules and the display panels are not indicated, in order to improve the
understanding of the functionality performed. This configuration is a single loop
with enriched functionalities than the previous one, suitable for more demanding
process control applications.
UNDERFLOW
PV1
AI1
DI1
DI2
DI3
AI3
AI2
DI4
AI4
DI6
DI5
DI7
DI8
WSP
WSP - PV
SCH
AI4
PV1
DRSP
WSP
ALM
7
ALM
6
ALM
5
ALM
4
ALM
3
ALM
2
1
SET
ALM
1
2
RSP
DEV
1
3
MUXSP
2
3 MCNS
4
4
2
Y%
F.F.
PID
DB
VISU 2
OR
MUX FF
1
0
2
TRK
CONTROL
OUT
MUXTRK
1
SCH
TRK
DTRK
A/M
HOLD
YMAX
VISU 1
YMIN
SCH
WSP
VISU 3
DO4
13.3
DO8
DO7
DO6
DO5
DO3
DO2
DO1
AO3
AO1
SCH
AI4
SCH
PV1
AO4
AO2
Control
The AI module performs the A/D, the scaling and the conversion in engineering
unit of the controlled variable and detects the out of range of the signal,
presumably caused by a sensor failure. The output value of the AI module, PV1
is fed into the three modules which implement the core of the PID loop. The
output of the PID is connected to the terminal blocks of the instrument through
the output module AO1.
The control loop provides important additional functions than the basic
controlling ones, like, for instance, the remote setpoint, the forcing modes, the
feed forward, up to 7 alarm modules and the retransmission of the controlled
variable.
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Installation and User manual of the AC10 - AC20 - AC30 controller
13.4
Remote Setpoint
This configuration supports the Remote Setpoint, providing sophisticated
features, selectable through the external digital inputs DI1-DI3, as illustrated in
the table below. The features offered are:
a) The Remote Setpoint value is selected, among four different possibilities,
through the MUX SP module, by mean of the DI2 and DI3 inputs.
b) The Remote Setpoint is enabled, by activating the digital input DI1; in fact,
the setpoint mode selection, as illustrated in the SDV module description, is
more complicated, because it is based on the arbitration of the requests
coming from various sources.
c) When the DI2 and DI3 inputs are both inactive, the Remote Setpoint
corresponds to the signal at the analog input AI2.
d) The other three combinations of DI2 and DI3 selects three different
predefined values, stored in the MCNS analog constant module.
DI1
Off
On
On
On
On
DI2
x
Off
On
Off
On
DI3
x
Off
Off
On
On
SP
Loc
Remote from AI2
Mem 1
Mem 2
Mem 3
x= Don’t care
13.5
Feed Forward
This feature provides a lead action to the control algorithm, consisting in
anticipating the response of the loop to a change of the controlled variable. It is
enabled by a parameter of the multiplexer MUX FF module and it consists in
connecting the analog input AI3 to the Feed-Forward input of the PID module.
13.6
Forcing Operations
These operations are related to the loop output, that can be driven by other
sources than the straight PID algorithm. This configuration allows the following 4
modes:
Tracking
Hold
Hold + Y Max
Hold + Y Min
a) Tracking: it is enabled by the DI6 digital input and it consists in setting the
control output either to a predefined value or to the value of the analog input
AI4. The selection between these two choices is operated by the MUX TRK
multiplexer module, by mean of the DI4 digital input.
When DI4 is active, the control output value is provided by the analog
constant of the MCNS module, while, when the DI4 is inactive, it is provided
by AI4 signal, after being properly ranged to percentage units by the SCH
TRK module.
b) Hold: when DI5 is active, the control output is frozen at the value it had at the
time of the rising transition.
c) Hold+Ymax: When both DI5 (Hold) and DI7 are active, the control output is
forced to its maximum value, defined by the parameters of the CONTROL
OUT module.
d) Hold+Ymin: When both DI5 (Hold) and DI8 are active, the control output is
forced to its minimum value, defined by the parameters of the CONTROL
OUT module.
An important point to bear in mind is that, all these forcing modes are handled
by the module, according to the following priority: A/M; Ymin, Ymax, Hold and
Track.
160
Annex A. - Resident Configurations
13.7
Alarms
There are 5 alarms either on the controlled variable PV1 or the deviation,
according to the parameters selected in each of the ALM modules. The module
WSP-PV computes the deviation, in the same engineering units of the controlled
variable PV.
The other 2 alarms are related to the analog input AI4, that has multiple
functionalities.
The status of all these alarms is retransmitted out through the DO1 to DO8
digital output.
The DO4 digital output flags the out of range of the variable PV1.
13.8
Variables Retransmissions
The controlled variable PV1 is retrasmitted out to the termination unit, through
the SCH and AO2 modules.
The module SCH allows the modification of the ranges of the retrasmitted
output, that are not, necessarily, the same of the PV1 input. This is achieved by
setting the input range parameters of the SCH module to different values than
the output range parameters. In this way, the range of the variable can be
changed, in order to consider only a part of the original signal scale, with
sensible advantages on the resolution of the output.
The WSP, working set-point, is retransmitted out, though the analog output
AO3, properly reranged by the SCH WSP module, with the previously described
advantages in term of resolution.
The AI4 analog input, suitable for multiple functionalities (tracking/retransm./all),
can be retransmitted out to output AO4, after the rerange, operated by the SCH
AI4 module.
13.9
Graphic Displays
TSP
WSP
LOOP 1
85.3
mm
LSP
85.0
200
Loc
Loc
RSP
AI4
CSP
LSP
Current operating mode
TSP
WSP
TREND 1
mm
LSP
85.3
85.0
200
Loc
RSP
AI4
CSP
LSP
Current Operating Mode
Requested
Operating mode
Loc
OR
OR of the forcing modes.
OR
OR of the forcing modes
ALH
Alarm 1
ALH
Alarms 1
ALL
OR of all the alarms
ALL
OR of all the alarms
Required
Operating mode
ALARMS
ALARM 1
ALARM 2
ALARM 3
ALARM 4
ALARM 5
ALARM 6
ALARM 7
UNDERFLOW
TRAKING
HOLD
AUT
-200
AUT
Aut/Man Station
Scale low limit
W=1 min
-200
Aut/Man Station
Scale low limit
Y MAX
Y MIN
Out= 35
Out= 35
The pictures above show the different types of display panels, providing the
most effective interface for this strategy configuration.
The most used panels are the single bargraph display and the single pen trend,
that provides the same functionalities of the previous panel, with the addition of
a programmable time width chart, with the trend profile of the controlled
variables.
The main controlled variable is displayed, both in the large size digits display
and through the bargraph, the Working Setpoint, WSP, is displayed by the slider
and the output , by the horizontal bargraph and numerically.
The following variables, consisting of the entire set of Setpoints, are displayed,
one at a time, in the scrollable display area:
LSP
Local setpoint
TSP Target setpoint
WSP Working setpoint
RSP
Remote setpoint
CSP
Computer setpoint
AI4
Multifunction Analog input 4
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Installation and User manual of the AC10 - AC20 - AC30 controller
The squared digital indications, on the right side of the panel, are flagging the
status of the alarm and the forcing mode of the loop. More precisely, they
highlight the following general situations:
1
When an alarm is active, the label ALL is visible
2
When the Alarm 1 is active, the label AL1 is visible.
3
When a forcing mode is active the label FOR is displayed.
These are global flags: the detailed cause of the event, is shown in the ALARMS
panel, where the digital status of each alarm and forcing input is clearly shown.
These are:
ALL 1 PV
Alarm 1
ALL 2 PV
Alarm 2
ALL 3 PV
Alarm 3
ALL 4 PV
Alarm 4
ALL 5 PV
Alarm 5
ALL 6 RTX
Alarm 6 on the variable AI4
ALL 7 RTX
Alarm 7 on the variable AI4
UNDERFL
Input AI1 out of range (for 1-5V or 4-20 mA signals, only)
TRACKING
Force the control output to a predefined value
HOLD
Freeze the control output
Y MAX
Force the control output to the maximum value.
Y MIN
Force the control output to the minimum value.
13.10
Applications
This easy to use, single loop configuration, provides a wide set of additional
functionalities than the basic classic PID loop, like the availability of multiple
setpoints, chosen between 3 predefined values and a remote one, generated by
an analog input. This feature is strongly used in the discontinuous processes,
like the management of both solid and liquid materials.
The feed forward functionality is an useful feature, when the process provides a
variable that can anticipate the future changes of the controlled variable. The
following processes are suitable to benefit from this feature:
a) Control of the pressure of the steam in a boiler (master ), using the steam
flow as the feed-forward variable.
b) Control of the pressure of the combustion chamber, using the fuel flow as the
feed-forward variable.
c) Control of the level of the two elements boiler barrel of a steam generator,
using the steam flow as the feed-forward variable, considering that it
generates the major demand of water.
FT
FT
PT
LT
PV1
FF
PV1
FT
FF
PT
FF
PV1
water
These control applications can strongly benefit from the availability of the
Remote Setpoint and the forcing modes features, provided by the controller and
triggered by external signals. These features allow effective implementations of
automatic operation like the cleaning of the combustion chamber and the
automatic forcing to the minimum level during the idle times.
162
Annex A. - Resident Configurations
13.11
Electrical Connections
The following picture provides a clear view of all the termination blocks, with the
associated functionality, and it is specific of this configuration. No signals must
be connected to the termination blocks not used by the strategy.
The termination blocks 25 and 26 are providing a 24V DC output, particularly
suitable to supply of the 2 wires transmitters.
PV1measure
SP Remote
Feed Forward
Tracking Input
1
25 +24
26 +24
2
3
4
5
6
A
N
A
L
O
G
7
8
I
N
P
10 U
T
11
DRSP
Rem / Mem
SP Sel.
SP Sel.
Hold
Tracking
Mv Max
Mv Min
LAN
A 27
N
A 28
L
O 29
G
30
O
U 31
T
32
9
33
12
34
D
I 35
G
I 36
T
A 37
L
38
13
14
15 D
I
16 G
I
T
18 A
L
19
17
20
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24
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Actuator
Retrasm. PV1
Retrasm. WSP
Retransm. AI4
Alarm 1 Pv1
Alarm 2 Pv1
Alarm 3 Pv1
Und.F. Pv1
Alarm 4 Pv1
Alarm 5 Pv1
Alarm 6 AI4
Alarm 7 AI4
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Installation and User manual of the AC10 - AC20 - AC30 controller
14. 1Loop C
14.1
Description
The drawings below are providing the following informations:
Block Diagram.
User interface, consisting in a set of display panels.
Termination unit for the connection to the field.
14.2
Block Diagram
In the following block diagram the interconnections between the various
modules and the display panels are not indicated, in order to improve the
understanding of the functionality performed.
DI4
DI2
AI4
DI3
DI1
AI1
AI2
DI6
DI5
DI7
DI8
UNDERFLOW
WSP-PV
PV
WSP
SET
COST
ALM
ALM
ALM
4
1
2
DRSP
DEV
RSP
3
MUX
3
2
1
DB
Y%
PID
Y%
PID
DTune
DTune
Cool
Heat
0
MUX
0
Ok Cool
Ok Heat
OR 1
DTRK
DB
CONTROL
OUT H/C
TRK
DHOLD
YMAX
YMIN
A/M
VISU
ALM
ALM
4
5
SCH
PV
VISU
AO2
DO4
DO3
DO2
DO1
DO5
AO1
HEAT ACTUAT.
AO4
DO6
SCH
WSP
AO3
COOL ACTUAT.
This configuration is suitable for those processes which require two actuators in
order to control the process variable. For instance, a temperature control, that
needs both a heating function and a cooling function.
The configuration consists of a single “Set-Dev” module, generating an unique
setpoint both for the cool and the heat channel, two PID and an Heat/Cool
output module. It has the advantage of allowing a separate set of the three
terms parameters for the cool and the heat channel. This characteristic
improves abruptly the control capabilities, because of the compensation of the
mismatch of the two channel.
164
Annex A. - Resident Configurations
14.3
Control
The process variable PV is acquired by the AI1 module, providing the ranging,
the conversion in engineering units and the out of range detection. It is
transmitted to the SET DEV module that computes the deviation for the two PID
modules, controlling both the Heat channel, with inverse action, and the Cool
channel, with direct action.
The outputs of the two PID are connected to the single H/C output station,
through two MUX multiplexer modules, required for properly selftuning the
loops.
These two multiplexers interfere with the control output only when the Tune
operation has been started on one of the PID modules, as flagged out by the
Dtune signal.
The H/C Out station offers a wide range of forcing strategies and, first of all, a
phase slitter, providing a deadband or a crossover between the two outputs.
14.4
Remote Setpoint
This configuration supports Remote Setpoints, both from an analog input AI2
and a set of 3 predefined values. The Remote Setpoint functionality is enabled
by the DI1 digital input, while the DI2 and DI3 inputs select the source of the
Setpoint, as illustrated in the following table.
DI1
Off
On
On
On
On
14.5
DI2
x
Off
On
Off
On
DI3
x
Off
Off
On
On
Selected Value
Set Loc
Input AI2
Mem 1
Mem 2
Mem 3
Forcing Operations
These operations are related to the loop output, that can be driven by other
sources than the straight PID algorithm. This configuration allows the following 4
modes, selected through the DI5-6-7-8 digital inputs:
Tracking
Hold
Hold + Y Max
Hold + Y Min
a) Tracking: it is enabled by the DI6 digital input and it consists in setting the
control output either to a predefined value, from the CONST analog constant
module, or to the value of the analog input AI4. The selection between these
two choices is operated by the MUX multiplexer module, by mean of the DI4
digital input. The range of the track value is -100 to 100, with -100
corresponding to the maximum cool value.
b) Hold: when DI5 is active, the control output is frozen at the value it had at the
time of the rising transition.
c) Hold+Ymax: When both DI5 (Hold) and DI7 are active, the control output is
forced to its maximum value, defined by the parameters of the CONTROL
OUT H/C module.
d) Hold+Ymin: When both DI5 (Hold) and DI8 are active, the control output is
forced to its minimum value, defined by the parameters of the CONTROL
OUT H/C module.
An important point to bear in mind is that, all these forcing modes are handled
by the module, according to the following priority: A/M; Ymin, Ymax, Hold and
Track.
14.6
Alarms
There are 3 alarms either on the controlled variable PV or the deviation,
according to the parameters selected in each of the ALM modules. The module
WSP-PV computes the deviation, in the same engineering units of the controlled
variable PV. The status of all these alarms is retransmitted out, through the DO1
to DO3 digital output.
The DO4 digital output flags the out of range of the variable PV (underflow).
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Installation and User manual of the AC10 - AC20 - AC30 controller
Two alarms are related to the control outputs of the two actuators. Their status
is transmitted out to the DO5-6 digital outputs and are used to flag which of the
two channel is operating.
14.7
Variables Retransmissions
The controlled variable PV is transmitted out, after the reranging operated by the
SCH PV module, to the output AO2. The WSP, working set-point, is
retransmitted out, though the analog output AO3, properly reranged by the SCH
WSP module; the range of the variable can be changed, in order to consider
only a part of the original signal scale, with sensible advantages on the
resolution of the output.
14.8
Graphic Displays
Heat Cool
mm
LSP
LSP
WSP
85.3
RSP
85.0
MS2
MS3
Current operating mode
200
Loc
Loc
MS1
Heat Cool
mm
LSP
LSP
WSP
ALARMS
85.3
RSP
85.0
MS2
MS3
Current operating mode
ALARM 2
Requested
operating mode
ALARM 4
200
Loc
MS1
Requested
operating mode
Loc
OR
OR of the forcing modes.
OR
OR of the forcing modes
ALH
Alarm 1
ALH
Alarm 1
ALL
OR of the alarms
ALL
OR of the alarms
ALARM 1
ALARM 3
ALARM 5
TRAKING
HOLD
AUT
-200
AUT
Aut/Man station
W=1 min
-200
Aut/Man station
Y MAX
Y MIN
C= 0
H= 25
C= 0
H= 25
The pictures above show the different types of display panels, providing the
most effective interface for this strategy configuration.
The most used panels are the single bargraph display and the single pen trend,
that provides the same functionalities of the previous panel, with the addition of
a programmable time width chart, with the trend profile of the controlled
variables.
The main controlled variable is displayed both in the large size digits display and
through the bargraph, while the Working Setpoint, WSP, is displayed by the
slider.
The outputs are displayed both numerically and by the horizontal bargraph, with
the value of 0 in the central position, the output of the cool actuator on the left
and the output of the heat actuator on the right.
The following variables, consisting of the entire set of Setpoints (Local plus other
5 setpoints), are displayed, one at a time, in the scrollable display area:
LSP
Local setpoint
WSP Working setpoint
RSP
Remote setpoint
MS1
Memorised set 1
MS2 Memorised set 2
MS3 Memorised set 3
The squared digital indications, on the right side of the panel, are flagging the
status of the alarm and the forcing mode of the loop. More precisely, they
highlight the following general situations:
1
When an alarm is active, the label ALL is visible
2
When the Alarm 1 is active, the label AL1 is visible.
3
When a forcing mode is active the label FOR is displayed.
These are global flags: the detailed cause of the event, is shown in the ALARMS
panel, where the digital status of each alarm and forcing input is clearly shown.
166
Annex A. - Resident Configurations
14.9
Applications
The typical application of this configuration is in the temperature control area,
where both the heat and the cool actions are required, for keeping the
temperature at the setpoint, when there are material changes, line speed
variation and peculiar chemical reactions.
A few examples of the process using this configurations are the continuous heat
treatment furnaces and most of the chemical reactors.
TT
PV
TT
COOLING AIR
LOGIC
COMB. AIR
GAS
STEAM
COOLING
WATER
14.10
Electrical connections
The following picture provides a clear view of all the termination blocks, with the
associated functionality, and it is specific of this configuration. No signals must
be connected to the termination blocks not used by the strategy.
The termination blocks 25 and 26 are providing a 24V DC output, particularly
suitable to supply of the 2 wires transmitters.
PV
RSP
26 +24
2
3
4
Tracki ng
25 +24
1
5
6
A
N
A
L
O
G
7
8
I
N
P
10 U
T
11
LAN
9
Sel.
RSP/Mem
A.TRK / M.TRK
Hold
Tracki ng
Y max
Y mi n
13
14
15 D
I
16 G
17 I
T
18 A
L
19
20
I
N
21 P
22 U
T
23
24
Heat Actua tor
PV retra nsmission
WSP retra nsmission
Cool Actuator
33
34
D
I 35
G
I 36
T
A 37
L
38
12
RSP
RSP/Mem
A 27
N
A 28
L
O 29
G
30
O
U 31
T
32
Alarm 1
Alarm 2
Alarm 3
Unde rflow
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Alarm 5
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15. 2 Loops A
15.1
Description
This configuration consists of 2 separate basic PID loop, not interconnected
each other. Each loop provides the following functionality: Remote Setpoint,
Output Forcing modes, 3 alarms and the PV out of range (underflow) detection.
The description of the control functionalities is reported, in the following pages,
related to the loop1, only. The functionality of the loop 2 is perfectly identical but
with the index numbers of the modules different. To the get the proper index
numbers for loop 2, refer to the Block Diagram.
15.2
Block Diagram
In the following block diagram the interconnections between the various
modules and the display panels are not indicated, in order to improve the
understanding of the functionality performed.
UNDERFLOW
PV1
AI1
WSP - PV
DI1
DI3
DI2
DI4
UNDERFLOW
AI2
PV2
OR 1 DB1 DB2
WSP1
WSP - PV
DI6
DI5
AI4
DI7
DI8
AI3
WSP2
PV1
PV2
OR2
DRSP
DRSP
SET
ALM
ALM
ALM
3
2
1
SET
1
DEV
RSP
OR3
2
MUX
Y%
2
ALM
5
4
3
CONST
DB
4
7
4
8
OR 1
CONTROL
OUT
A/M
VISU 1
L 1 / L2
OR 1
TRK
HOLD
CONTROL
OUT
DTRK
A/M
SCH
PV L1
VISU 2
L1
TRK
HOLD
DTRK
SCH
PV L2
VISU 2
L2
VISU 3
L2
VISU 3
L1
DO4
15.3
2
3
PID
Y%
6
2
1
RSP
MUX
5
CONST
DB
ALM
6
VISU
FRL4
1
PID
1
ALM
DEV
DO3
DO2
DO1
AO1
AO2
DO8
DO7
DO6
DO5
AO4
AO3
Control
The AI1 module performs the A/D, the scaling and the conversion in engineering
unit of the controlled variable and detects the out of range of the signal,
presumably caused by a sensor failure. The output value of the AI1 module,
PV1 is fed into the three modules which implement the core of the PID loop 1
(SET DEV 1, PID 1 and CONTROL OUT 1). The output of the PID 1 is
connected to the terminal blocks of the instrument, through the output module
AO1, in order to drive the external actuator.
15.4
Remote Setpoint
This functionality is provided for both the loops. Referring to loop1, the following
description applies.
Activating DI1 (i. e., closing the contact as in the picture 2.4.4) the Remote
Setpoint is the one selected for the loop; otherwise the Local Setpoint is
selected. In fact, the setpoint mode selection, as illustrated in the SDV module
description, is more complicated, because it is based on the arbitration of the
requests coming from various sources. The Remote Setpoint can be the signal
at the input AI2 (RSP), if the digital input DI2 is inactive, or the constant stored in
168
Annex A. - Resident Configurations
the MCNS module (MSP), if the digital input DI2 is active. The truth table below
lists all the various combinations of setpoint.
DI1
Off
On
On
15.5
DI2
x
Off
On
Selected value
Set Loc
Input AI2
Set mem.
Forcing Operations
These operations are related to the loop output and consist of the Hold and
Tracking mode.
a) Tracking: the Tracking mode sets the output to the value of constant, named
Ysaft, until DI4 is active.
b) Hold: The Hold mode freezes the loop output, until the DI3 digital input is
active.
15.6
Alarms
There are three alarms either on the controlled variable PV1 or the deviation,
according to the parameters selected in each of the ALM modules. The module
WSP-PV computes the deviation, in the same engineering units of the controlled
variable PV. The status of each alarm is retransmitted out through the DO1,
DO2 and DO3 modules. A fourth alarm, the digital output DO4 flags the out of
range of the variable PV.
15.7
Variables Retransmission
The controlled variable PV1 is retrasmitted out to the termination unit, through
the SCH PV L1 and AO2 modules.
The module SCH PV L1 allows the modification of the ranges of the retrasmitted
output, that are not, necessarily, the same of the PV1 input. This is achieved by
setting the input range parameters of the SCH PV L1 module to different values
than the output range parameters. In this way, the range of the variable can be
changed, in order to consider only a part of the original signal scale, with
sensible advantages on the resolution of the output.
15.8
Graphic Display
PID1 PID2
71.2
OR of the alarms
LSP loop sel.
WSP loop sel.
Selected Loop
LSP
WSP
TEM
71.0 LOC
71.0 LOC
FG
PV of the
selected loop
WSP loop 1
PV loop 1
WSP loop 2
PV loop 2
Aut/Man Station
MV loop 1
A
O=23
A
O=47
ALLARME 1 L1
Requested
operating mode
ALLARME 2 L1
Current Operating mode
ALLARME 3 L1
TAG loops
Aut/Man Station
MV loop 2
TSP
WSP
LOOP1
ALL e FORZ
Alarm 1 L1
Alarm 2 L1
85.3
mm
LSP
85.0
200
RSP
CSP
MSP
LSP
Current operating mode
Alarm 3 L1
Loc
UNDERFL L1
Underflow L1
Loc
Requested
operating mode
ALLARME 4 L2
Alarm 4 L2
ALLARME 5 L2
Alarm 5 L2
AL
OR of the forcing modes
ALLARME 6 L2
Alarm 6 L2
UNDERFL L2
Underflow L2
ALH
Alarm 1
TRAKING L1
Tracking L1
ALL
OR of alarms
HOLD L1
Hold L1
TRAKING L2
Tracking L2
HOLD L2
Hold L2
AUT
Aut/Man Station
-200
Out 35
169
Installation and User manual of the AC10 - AC20 - AC30 controller
TSP
WSP
LOOP 1
mm
LSP
85.3
85.0
200
Loc
W=1 min
-200
Out 35
TSP
WSP
LOOP2
85.3
RSP
AI4
CSP
LSP
Current operating mode
mm
LSP
85.0
200
Loc
RSP
CSP
MSP
LSP
Current operating mode
TSP
WSP
LOOP 2
mm
LSP
85.3
85.0
200
Loc
RSP
AI4
CSP
LSP
Current operating mode
Loc
Requested
operating mode
Loc
Requested
operating mode
Loc
Requested
operating modes
AL
OR of the forcing modes
AL
ORof the forcing mode
AL
OR of the forcing modes.
ALH
Alarm 1
ALH
Alarm 1
ALH
Alarm 1
ALL
OR of Alarms
ALL
OR of Alarms
ALL
OR of Alarms
AUT
Aut/Man station
AUT
Aut/Man Station
AUT
Aut/Man station
-200
Out 35
W=1 min
-200
Out 35
The panel with the dual bargraph provides a complete view of both the loop, with
a fine level of details on the most important parameters.
The left bargraph relates to loop 1 while the right relates to loop2. If you want to
operate on a loop, first you have to select it, by pressing the
button.
The loop selected is highlighted by the fact that both the tag and the output
operating mode are displayed in reverse. Once the loop has been selected, it is
possible to change either the Setpoint or the A/M station operating mode.
Furthermore, the parameters shown in the upper part of the panel relates to the
selected loop.
The status of the alarms is flagged by the small box on the upper left part of the
panel. When an alarm or a forcing mode is activated, the box blinks
continuously, to alert the operator. Next, the operator can get a more detailed
view of the alarms, by looking at the ALL e FOR panel.
Furthermore, this configuration provides other 4 additional panels, 2 for each
loop, with the well know bargraph and trend displays, with the following
functionality.
The main controlled variable is displayed both in the large size digits display and
through the bargraph, the Working Setpoint, WSP, is displayed by the slider and
the output by the horizontal bargraph and numerically.
The following variables, consisting of the entire set of Setpoints, are displayed,
one at a time, in the scrollable display area:
LSP
Local setpoint
TSP
Target setpoint
WSP Working setpoint
RSP
Remote setpoint
MSP Memorised setpoint
CSP
Computer setpoint
The squared digital indications, on the right side of the panel, are flagging the
status of the alarm and the forcing mode of the loop. More precisely, they
highlight the following general situations:
1
When an alarm is active, the label ALL is visible
2
When the Alarm 1 is active, the label AL1 is visible.
3
When a forcing mode is active the label FOR is displayed.
A more detailed view of the alarms and the forcing status is presented on the
ALL e FOR display panel.
170
Annex A. - Resident Configurations
15.9
Applications
This easy to use configuration is for simple applications, where the control
requirements needs some additional functionalities than the basic classic PID
loop, like the availability of multiple setpoints, remote or predefined, selectable
through an external digital signal. Furthermore, this configuration offers the
possibility to acts on the control output, both by forcing it to a predefined value
and by freezing it, upon an external command.
The multiple alarm modules offer an effective tool for monitoring continuously
the controlled variable and detect anomalous changes.
The retransmission of the controlled variable, over a different range, improves
the resolution of the signal, because it is limited to the meaningful portion of the
original range (zoom effect).
Furthermore, this configuration has the advantage of providing 2 loops in a
single box, with perfectly identical characteristics, providing an attractive
price/performance solution.
15.10
Electrical Connections
The following picture provides a clear view of all the termination blocks, with the
associated functionality, and it is specific of this configuration. No signals must
be connected to the termination blocks not used by the strategy.
The termination blocks 25 and 26 are providing a 24V DC output, particularly
suitable to supply of the 2 wires transmitters.
LOOP 1
LOOP 2
PV1 measure
SP remote
SP remote
PV2 measure
1
25 +24
2
26 +24
3
4
5
6
A
N
A
L
O
G
7
8
I
9 N
P
10 U
T
11
LAN
LOOP 1
Hold
Track
Loc/Rem
Rem/Mem
LOOP 2
Hold
Track
13
14
15 D
I
16 G
I
T
18 A
L
19
17
20
I
N
21 P
U
22 T
33
34
D
I 35
G
I 36
T
A 37
L
38
12
Loc/Rem
Rem/Mem
A 27
N
A 28
L
O 29
G
30
O
U 31
T
32
39
CN2
485
O 40
U
T 41
42
43
44
Retrans. PV1
Retrans. PV2
Actuator 2
LOOP 1
LOOP 2
Al. 1 Pv1
Al. 2 Pv1
Al. 3 Pv1
LOOP 1
Und.F. Pv1
Al. 4 Pv2
Al. 5 Pv2
LOOP 2
Al 6 Pv2
Und.F.Pv2
46
Power Supply
23
24
Actuator 1
48
171
Installation and User manual of the AC10 - AC20 - AC30 controller
16. 2 Loops B
16.1
Description
This configuration provides two loops:
1 with basic characteristics
1 with additional performing features
The loop 1 is the main one, it is the more powerful and it supports the following
additional functionalities:
Remote Setpoint from an analog input
Remote Setpoint from stored constants
Feed-Forward
Forcing of the output
3 alarms on PV1
Out of range detection (underflow) of PV1
Retransmission of both PV1 and WSP
The loop 2 is the basic one and provides the following basic functionalities:
Remote Setpoint from stored constants
Forcing of the output
3 alarms on PV2
Out of range detection (underflow) of PV2
The description of the control functionalities is reported, in the following pages,
related to the loop1 only. The functionality of the second loop is perfectly
identical but with the index numbers of the modules different. To the get the
proper index numbers for the second loop, refer to the Block Diagram.
16.2
Block Diagram
In the following block diagram the interconnections between the various
modules and the display panels are not indicated, in order to improve the
understanding of the functionality performed.
UNDERFLOW
UNDERFLOW
DI1
AI1
PV1
DI2
DI3
DI4
DI5
1
2
DI6
AI4
PV2
OR 4
PV2
DRSP
DRSP
ALM
ALM
3
2
1
VISU
FRL4
SET
1
RSP
DEV
MUX
SET
2
ALM
ALM
ALM
6
5
4
RSP
DEV
3
WSP
COST
1
COST
2
1
2
3
PID
Y%
F.F.
MUX
DB
OR 1
CONTROL
OUT
A/M
VISU 1
L1 / L2
4
5
2
DB
4
Y%
6
PID
7
1
OR 1
TRK
CONTROL
OUT
HOLD
A/M
DTRK
SCH
WSP
SCH
PV1
AO3
AO2
VISU 3
L1
172
DO2
DO1
AO1
TRK
DTRK
HOLD
VISU 2
L2
YMIN
DO4 DO3
DB
8
0
YMAX
VISU 2
L1
DI7
WSP
WSP - PV
1
2
PV1
ALM
DI8
OR 1 DB1 DB2
DSEL
WSP
WSP - PV
AI3
AI2
VISU 3
L2
DO8
DO7
DO6
DO5
AO4
Annex A. - Resident Configurations
16.3
Control
Referring to loop 1, the process variable PV1 is acquired by the AI1 module,
providing the conversion in engineering units and the out of range detection. It is
transmitted to the SET DEV module, that with the PID and CONTROL OUT
modules, makes up the core PID block. The output is transmitted out on the
terminal blocks, through the AO1 module, for driving the external actuator.
16.4
Remote Setpoint
This feature is supported on both the loops but with the following different
performances.
Loop 1
a) The remote setpoint is enabled by mean of the DI1 input
b) The Remote Setpoint source (AI2 analog input or a stored constant) is
selected through the MUX RSP multiplexer, by mean of the DI2 input.
DI1
Off
On
On
DI2
x
Off
On
Selected Value
Set Loc
Input AI2
Set mem.1
Loop 2
a) The Remote Setpoint is enabled by mean of the DI6 input.
b) The source of the Setpoint can be a stored constant with label Setmem 2
DI6
Off
On
16.5
Selected Setpoint
Set Loc
Set mem.2
Feed-Forward
This features is provided on loop 1 only and it provides a lead action to the
control algorithm, consisting in anticipating the response of the loop to a future
change of the controlled variable. It is enabled by a parameter of the multiplexer
MUX module and it consists in connecting the analog input AI3 to the FeedForward input of the PID module.
16.6
Forcing Modes
These operations are related to the loop output, that can be driven by other
sources than the straight PID algorithm. The functionality provided by the two
loop are slight different, as described below.
Loop1
This configuration allows the following 4 modes:
Tracking
Hold
Hold + Y Max
Hold + Y Min
a) Tracking: it is enabled by the DI4 digital input and it consists in setting the
control output to a predefined constant value.
b) Hold: when DI3 is active, the control output is frozen at the value it had at the
time of the rising transition.
c) Hold+Ymax: When both DI3 (Hold) is active, the selector module DSEL is on
position 1 and DI5 is active, the control output is forced to its maximum value,
defined by the parameters of the CONTROL OUT module.
d) Hold+Ymin: When both DI3 (Hold) is active, the selector module DSEL is on
position 2 and DI5 is active, the control output is forced to its minimum value,
defined by the parameters of the CONTROL OUT module.
DI3
Off
On
On
On
DI5
x
Off
On
On
Dsel
x
x
1
2
Selected Value
A/M or TRK
Output frozen
Max Out
Min Out
173
Installation and User manual of the AC10 - AC20 - AC30 controller
Loop 2
This configuration allows only the following 2 modes: Tracking e Hold
a) Tracking: the Tracking mode set the output to the value of the constant n° 2,
named Trk L2, of the module MCNS, until DI8 is active
b) Hold: The Hold mode freezes the loop output, until the DI3 digital input is
active.
c) These 2 forcing modes are handled by the module, according to the following
priority: A/M; Hold and Track.
16.7
Alarms
Loop 1
There are three alarms either on the controlled variable PV1 or the deviation,
according to the parameters selected in each of the ALM modules. The module
WSP-PV computes the deviation, in the same engineering units of the controlled
variable PV1. The status of each alarm is retransmitted out through the DO1,
DO2 and DO3 modules. A fourth alarm, the digital output DO4, flags the out of
range of the variable PV1 (underflow).
Loop 2
There are three alarms either on the controlled variable PV2 or the deviation,
according to the parameters selected in each of the ALM modules. The module
WSP-PV computes the deviation, in the same engineering units of the controlled
variable PV2. The status of each alarm is retransmitted out through the DO5,
DO6 and DO7 modules. A fourth alarm, the digital output DO8 flags the out of
range of the variable PV2 (underflow).
16.8
Variables Retransmission
The controlled variable PV1 is retrasmitted out to the termination unit, through
the SCH PV1 and AO2 modules.
The module SCH allows the modification of the ranges of the retrasmitted
output, that are not, necessarily, the same of the PV1 input. This is achieved by
setting the input range parameters of the SCH module to different values than
the output range parameters. In this way, the range of the variable can be
changed, in order to consider only a part of the original signal scale, with
sensible advantages on the resolution of the output.
The WSP, working set-point, of loop 1is retransmitted out, though the analog
output AO3, properly reranged by the SCH WSP module, with the previously
described advantages in term of resolution.
16.9
Graphic Displays
PID1 PID2
71.2
ORof the alarms
LSP loop sel.
WSP loop sel.
Selected Loop
LSP
WSP
TEM
71.0 LOC
71.0 LOC
FG
PV of the
selected
Requested
operating mode
Current operating mode
TAG loops
ALL-FORZ L1
ALL-FORZ L2
ALLARME 1 L1
ALLARME 1 L2
ALLARME 2 L1
ALLARME 2 L2
ALLARME 3 L1
ALLARME 3 L2
UNDERFL L1
UNDERFL L2
TSP
WSP
LOOP1
85.3
mm
LSP
85.0
200
Loc
WSP loop 1
PV loop 1
WSP loop 2
PV loop 2
TRAKING L1
RSP
AI4
CSP
LSP
Current operating mode
Loc
Requested
operating mode
AL
OR of the forcing modes
ALH
Alarm 1
ALL
OR of the alarms
HOLD L1
Aut/Man Station
MV loop 1
174
A
O=23
A
O=47
Aut/Man Station
MV loop 2
Y MAX L1
TRAKING L2
Y MIN L1
HOLD L2
AUT
-200
Out 35
Aut/Man station
Annex A. - Resident Configurations
TSP
WSP
LOOP 1
q/h
LSP
35.3
85.0
200
Loc
-200
Out 35
45.3
RSP
AI4
CSP
LSP
Current operating mode
mm
LSP
85.0
200
Loc
RSP
AI4
CSP
LSP
Current operating mode
TSP
WSP
LOOP 2
q/h
LSP
75.3
85.0
200
Loc
RSP
AI4
CSP
LSP
Current operating mode
Loc
Requested
operating mode
Loc
Requested
operating mode
Loc
AL
OR of the Forcing modes
AL
OR of the Forcing modes
AL
OR of the Forcing modes
ALH
Alarm 1
ALH
Alarm 1
ALH
Alarm 1
ALL
OR of the Alarms
ALL
OR of the Alarms
ALL
OR of the Alarms
AUT
W=1 min
TSP
WSP
LOOP2
AUT
Aut/Man station
-200
Out 35
AUT
Aut/Man station
W=1 min
Requested
operating mode
Aut/Man station
-200
Out 35
The panel with the dual bargraph provides a complete view of both the loop, with
a fine level of details on the most important parameters.
The left bargraph relates to loop 1 while the right relates to loop2. If you want to
button.
operate on a loop, first you have to select it, by pressing the
The loop selected is highlighted by the fact that both the tag and the output
operating mode are displayed in reverse. Once the loop has been selected, it is
possible to change either the Setpoint or the A/M station operating mode.
Furthermore, the parameters shown in the upper part of the panel relates to the
selected loop.
The status of the alarms is flagged by the small box on the upper left part of the
panel. When an alarm or a forcing mode is activated, the box blinks
continuously, to alert the operator. Next, the operator can get a more detailed
view of the alarms of each loop, by looking at the ALL-FORZ L”n” panels.
Furthermore, this configuration provides other 4 additional panels, 2 for each
loop, with the well know bargraph and trend displays, with the following
functionality.
The main controlled variable is displayed both in the large size digits display and
through the bargraph, the Working Setpoint, WSP, is displayed by the slider and
the output by the horizontal bargraph and numerically.
The following variables, consisting of the entire set of Setpoints, are displayed,
one at a time, in the scrollable display area:
LSP
Local setpoint
TSP
Target setpoint
WSP Working setpoint
RSP
Remote setpoint
MSP Memorised setpoint
CSP
Computer setpoint
The squared digital indications, on the right side of the panel, are flagging the
status of the alarm and the forcing mode of the loop. More precisely, they
highlight the following general situations:
1
When an alarm is active, the label ALL is visible
2
When the Alarm 1 is active, the label AL1 is visible.
3
When a forcing mode is active the label FOR is displayed.
A more detailed view of the alarms and the forcing status is presented on the
ALL -FORZ L”n” display panels, each one is associated to a loop.
175
Installation and User manual of the AC10 - AC20 - AC30 controller
16.10
Applications
This two loops configuration is particularly suitable for controlling processes with
predictive variables, being the main loop equipped with the feed-forward.
For instance, in a boiler control system, this configuration is dedicated both to
the control of the 2 elements boiler barrel and to the more simple control of the
air pressure or to another basic loop.
In a preheating furnace, for instance, this configuration is dedicated both to the
control of the pressure of the furnace, using the global fuel flow as the predictive
feed forward magnitude, and to the more basic control of the fuel air pressure.
16.11
Electrical Connections
The following picture provides a clear view of all the termination blocks, with the
associated functionality, and it is specific of this configuration. No signals must
be connected to the termination blocks not used by the strategy.
The termination blocks 25 and 26 are providing a 24V DC output, particularly
suitable to supply of the 2 wires transmitters.
PV1 measure
LOOP 1
Remote SP
Feed Forw.
LOOP 2
PV2 measure
1
25 +24
2
26 +24
3
4
5
6
A
N
A
L
O
G
7
8
I
N
P
10 U
T
11
Loc/Rem
Rem/Mem
LOOP 1
Hold
Track
Y min/Max
Loc/Rem
LOOP 2
Hold
Track
176
LAN
A 27
N
A 28
L
O 29
G
30
O
U 31
T
32
9
33
12
34
D
I 35
G
I 36
T
A 37
L
38
13
14
15 D
16 I
G
17 I
T
18 A
L
19
20
I
N
21 P
U
22
T
23
24
39
CN2
485
O 40
U
T 41
42
43
44
Actuator 1
Retr. PV1
Actuator 2
LOOP 2
Al. 1 Pv1
Al. 2 Pv1
LOOP 1
Al. 3 Pv1
Und.F. Pv1
Al. 4 Pv2
Al. 5 Pv2
LOOP 2
Al. 6 Pv2
Und.F.Pv2
46
Power Supply
48
LOOP 1
Retr. WSP
Annex A. - Resident Configurations
17. 2 Loops C
17.1
Description
The drawings below are providing the following informations:
Block Diagram.
User interface, consisting in a set of display panels.
Termination unit for the connection to the field.
17.2
Block Diagram
In the following block diagram the interconnections between the various
modules and the display panels are not indicated, in order to improve the
understanding of the functionality performed.
AI3
AI2
AI1
DI2
DI4
DI1
DI3
DI5
AI4
DI6
UNDERFLOW
WSP - PV1
PV2
DRSP
WSP
WSP - PV1
DRSP
SET
SET
1
AL
2
AL
1
2
MUX
DI8
WSP
PV1
AL
3
DI7
AL
7
DEV
2
DEV
AL
6
RSP
RSP
1
COST
MUX
Y%
DB
PID
OR 1
PID
Y%
5
DTune
DTune
Heat
6
3
Cool
Y% PID
0
COST
VISU
0
4
DB
Ok Cool
Ok Heat
OR 1
1
CONTROL
OUT
2
3
DB
CONTROL
OUT H/C
TRK
4
TRK
DTRK
A/M
DHOLD
DTRK
Y MAX
Y MIN
A/M
VISU
SCH
PV
AL
4
AL
5
VISU
AO3
DO4
DO3
DO2
DO1
DO5
AO1
HEAT ACT.
AO2
DO6
DO8
DO7
AO4
COOL ACT.
This configuration is suitable for those processes requiring two actuators in
order to control the process variable. For instance, a temperature control, that
needs both a heating function and a cooling function.
The configuration consists of a single “Set-Dev” module, generating an unique
setpoint both for the cool and the heat channel, two PID and an Heat/Cool
output module. It has the advantage of allowing a separate set of the three
terms parameters for the cool and the heat channel; this feature improves
abruptly the control capabilities, because of the compensation of the mismatch
of the two channel.
Furthermore, a basic standard loop is available in the controller.
177
Installation and User manual of the AC10 - AC20 - AC30 controller
17.3
Control
Loop H/C
The process variable PV1 is acquired by the AI1 module, providing the ranging,
the conversion in engineering units and the out of range detection. It is
transmitted to the SET DEV module that computes the deviation for the two PID
modules, controlling both the Heat channel, with inverse action, and the Cool
channel, with direct action.
The outputs of the two PID are connected to the single H/C output station,
through two MUX multiplexer modules, required for properly selftuning the
loops.
These two multiplexers interfere with the control output, only when the Tune
operation has been started on one of the PID modules, as flagged out by the
Dtune signal.
The H/C Out station offers a wide range of forcing strategies and, first of all, a
phase slitter providing a deadband or a crossover between the two outputs.
Loop 2
The variable PV2 is acquired though the AI4 analog input module, providing the
conversion in engineering units and the out of range detection. It is transmitted
to the SET DEV module that, with the PID and CONTROL OUT modules,
makes up the core PID block. The output is transmitted out on the terminal
blocks, through the AO4 module, for driving the external actuator.
17.4
Remote Setpoint
This feature is supported on both the loop but with the following different
performances.
Loop H/C
a) The remote setpoint is enabled by mean of the DI1 input.
b) The Remote Setpoint source (AI2 analog input or a stored constant) is
selected through the MUX RSP multiplexer, by mean of the DI2 input.
DI1
Off
On
On
DI2
x
Off
On
Selected Value
Set Loc
Input AI2
Constant SPM H/C
Loop 2
a) The Remote Setpoint is enabled by mean of the DI7 input.
b) The source of the Setpoint can be a stored constant, named SPM L2
17.5
Forcing modes
These operations are related to the loop output, that can be driven by other
sources than the straight PID algorithm. The functionality provided by the two
loop are slight different, as described below.
Loop H/C
This configuration allows the following 4 modes, selected through the DI3, DI4,
DI5 and DI6:
Tracking
Hold
Hold + Y Max
Hold + Y Min
a) Tracking: it is enabled by the DI4 digital input and it consists in setting the
control output either to a predefined value, from the analog constant module,
or to the value of the analog input AI3. The selection between these two
choices is operated by the MUX multiplexer module, by mean of a
parameter. The range of the track value is -100 to 100, with -100
corresponding to the maximum cool value.
178
Annex A. - Resident Configurations
DI4
Off
On
On
Mux Trk
x
1
2
Selected Value
A/M -- Hold
Input AI3
Constant YSIC H/
b) Hold: when DI3 is active, the control output is frozen at the value it had at the
time of the rising transition.
c) Hold+Ymax: When both DI3 (Hold) and DI5 are active, the control output is
forced to its maximum value, defined by the parameters of the CONTROL
OUT H/C module.
d) Hold+Ymin: When both DI3 (Hold) and DI6 are active, the control output is
forced to its minimum value, defined by the parameters of the CONTROL
OUT H/C module.
DI3
Off
On
On
On
DI5
x
Off
On
Off
DI6
x
Off
Off
On
Selected Value
A/M TRK
Hold
(Ymax) Maximum Heat
(Ymin) Maximum Cool
Loop 2
Only the Tracking mode is supported by this loop. The tracking is enabled by the
digital input DI8 and set the output to the value specified by the constant,
labelled TRK L2.
An important point to bear in mind is that, all these 4 forcing modes are handled
by the module, according to the following priority: A/M; Ymin, Ymax, Hold and
Track
17.6
Alarms
Loop H/C
There are three alarms either on the controlled variable PV1 or the deviation,
according to the parameters selected in each of the ALM modules. The module
WSP-PV computes the deviation, in the same engineering units of the controlled
variable PV1.
The status of each alarm is retransmitted out through the DO1, DO2 and DO3
modules.
A fourth alarm, the digital output DO4 flags the out of range of the variable PV2
(underflow).
Two alarms are related to the control outputs of the two actuators. Their status
is transmitted out to the DO5-6 digital outputs and are used to flag which of the
two channel is operating.
Loop 2.
There are two alarms either on the controlled variable PV2 or the deviation,
according to the parameters selected in each of the ALM modules. The module
WSP-PV computes the deviation, in the same engineering units of the controlled
variable PV2.
The status of each alarm is retransmitted out through the DO7 and DO8
modules.
17.7
Variables Retransmission
Loop H/C
The controlled variable PV1 is retrasmitted out to the termination unit, through
the SCH PV and AO3 modules.
The module SCH allows the modification of the ranges of the retrasmitted
output, that are not, necessarily, the same of the PV1 input. This is achieved by
setting the input range parameters of the SCH module to different values than
the output range parameters. In this way, the range of the variable can be
changed, in order to consider only a part of the original signal scale, with
sensible advantages on the resolution of the output.
179
Installation and User manual of the AC10 - AC20 - AC30 controller
17.8
Graphic Displays
HEAT COOL
85.3
mm
LSP
85.0
200
Loc
Loc
AL
ALH
ALL
AUT
TSP
WSP
85.3
RSP
mm
SP1
SP2
SP3
Current operating mode
LSP
85.0
200
Loc
Loc
Requested
operating mode
AL
OR of Forcing modes
ALH
Alarm 1
AUT
Aut/Man station
ALARMS
RSP
CSP
MSP
LSP
Current operating mode
ALLARME 1 L1
Alarm 1 L1
ALLARME 2 L1
Alarm 2 L1
ALLARME 3 L1
Alarm 3 L1
Requested
operating modes
UNDERFL L1
Underflow L1
HEAT
Alarm 4 Heat
COOL
Alarm 5 Cool
TRAKING
Tracking
HOLD
Hold
Y MAX
Out Max
Y MIN
Out Min
ALLARME 6 L2
Alarm 6 L2
ALLARME 7 L2
Alarm 7 L2
OR of Forcing modes
Alarm 1
ALL
OR of the Alarms
-200
C= 0
TSP
WSP
LOOP2
OR of the Alarms
Aut/Man Station
-200
H= 35
Out 35
HEAT COOL
mm
LSP
85.3
85.0
200
Loc
W=1 min
C= 0
TSP
WSP
RSP
SP1
SP2
SP3
Current operating mode
TSP
WSP
LOOP 2
mm
LSP
85.3
85.0
200
Loc
RSP
AI4
CSP
LSP
Current Operating mode
Loc
Requested
operating mode
Loc
Requested
operating mode
AL
OR of Forcing modes
AL
OR of Forcing modes
ALH
Alarm 1
ALH
Alarm1
ALL
OR of the Alarms
ALL
OR of the Alarms
AUT
Aut/Man Station
-200
H= 35
AUT
W=1 min
Aut/Man Station
-200
Out 35
Loop H/C
The pictures above show the different types of display panels, providing the
most effective interface for this strategy configuration.
The most used panels are the single bargraph display and the single pen trend,
that provides the same functionalities of the previous panel but the addition of a
programmable time width chart, with the trend profile of the controlled variables.
The main controlled variable is displayed both in the large size digits display and
through the bargraph, the Working Setpoint, WSP, is displayed by the slider.
The outputs are displayed both numerically and by the horizontal bargraph, with
the value of 0 in the central position, the output of the cool actuator on the left
and the output of the heat actuator on the right.
The following variables, consisting of the Local Setpoint plus other 5 analog
variables, are displayed, one at a time, in the scrollable display area:
LSP
Local setpoint
WSP Working setpoint
RSP
Remote setpoint
MSP Memorised set
TRK Tracking value
PV2
Variable of loop 2
The squared digital indications, on the right side of the panel, are flagging the
status of the alarm and the forcing mode of the loop. More precisely, they
highlight the following general situations:
1
When an alarm is active, the label ALL is visible
2
When the Alarm 1 is active, the label AL1 is visible.
3
When a forcing mode is active the label FOR is displayed.
These are global flags: the detailed cause of the event, is shown in the ALARMS
panel, where the digital status of each alarm and forcing input is clearly shown.
180
Annex A. - Resident Configurations
Loop 2
The most used panels are the single bargraph display and the single pen trend,
that provides the same functionalities of the previous panel but the addition of a
programmable time width chart, with the trend profile of the controlled variables.
The main controlled variable is displayed both in the large size digits display and
through the bargraph, the Working Setpoint, WSP, is displayed by the slider and
the output by the horizontal bargraph and numerically.
The following variables, consisting of the Local Setpoints plus other 5 analog
variables, are displayed, one at a time, in the scrollable display area:
LSP
Local setpoint
WSP Working setpoint
MSP Memorised set
YS2
Tracking value
PV1
Process variable of the Loop H/C
WS1
Working set of the Loop H/C
The squared digital indications, on the right side of the panel, are flagging the
status of the alarm and the forcing mode of the loop. More precisely, they
highlight the following general situations:
1
When an alarm is active, the label ALL is visible
2
When the Alarm 1 is active, the label AL1 is visible.
3
When a forcing mode is active the label FOR is displayed.
These are global flags: the detailed cause of the event, is shown in the ALARMS
panel, where the digital status of each alarm and forcing input is clearly shown.
17.9
Applications
The typical application of this configuration is in the temperature control area,
where both the heat and the cool actions are required for keeping the
temperature at the setpoint. The availability, in the same box, of another basic
PID loop is an advantage, because of the better the price/performance figures.
181
Installation and User manual of the AC10 - AC20 - AC30 controller
17.10
Electrical Connections
The following picture provides a clear view of all the termination blocks, with the
associated functionality, and it is specific of this configuration. No signals must
be connected to the termination blocks not used by the strategy.
The termination blocks 25 and 26 are providing a 24V DC output, particularly
suitable to supply of the 2 wires transmitters.
PV1 Loop1
RSP Loop1
TRK Loop1
PV2 Loop2
1
25 +24
2
26 +24
3
4
5
6
A
N
A
L
O
G
7
8
I
N
P
10 U
T
11
RSP
RSP/Mem
Hold
Tracking
Y max
Y min
RSP Loop2
TRK Loop2
182
LAN
A 27
N
A 28
L
O 29
G
30
O
U 31
T
32
9
33
12
34
D
I 35
G
I 36
T
A 37
L
38
13
14
15 D
I
16 G
I
T
18 A
L
19
17
20
21
22
I
N
P
U
T
39
CN2
485
O 40
U
T 41
42
Cool Actuator
PV1 retransmission
Loop 2 Actuator
Alarm 1
Alarm l 2
Alarm l 3
Underflow
Alarm l 4
Alarm l 5
Alarm 6 Loop2
43
44
Alarm 7 Loop2
46
POWER SUPPLY
23
24
Heat Actuator
48
Annex A. - Resident Configurations
18. Ratio
18.1
Description
The drawings below are providing the following informations:
Block Diagram.
User interface, consisting in a set of display panels.
Termination unit for the connection to the field.
18.2
Block Diagram
In the following block diagram the interconnections between the various
modules and the display panels are not indicated, in order to improve the
understanding of the functionality performed.
Underflow PV1 (Controlled variable)
AI1
AI2
AI3
DI5
DI4
DI3
DI1
DI2
DI7
DI8
DI6
AI4
Underflow PV2 (Reference variable)
PV3
PV2
WSP
DMUX
WSP-PV
PV1
WSR-PV1
ALM
5
1
WSR
PV1
ALM
4
2
PV3
PV2
DRSP
BIAS
SP DEV
ALM
3
ALM
2
2
RSP
SP DEV
ALM
6
1
DBIAS
ALM
1
MUX
VISU FORZ
2
VISU FORZ L1
Y%
PID 1
1 MCNS
PID2
Y%
DB
D.B.
3
1 OR 1
3
2
4
5
6
7
TRK
CONTR
OUT
TRK
DTRK
HOLD
8
A/M
A/M
YMAX
HOLD
OR
VISU ALL
CONTR
OUT
DTRK
OR1
YMIN
VISU AL1
VISU FRL4
DO4
DO7
DO6
DO5
DO3
DO2
DO1
AO1
AO4
DO8
This configuration consists of:
1 Ratio Loop
1 Standard loop
The first loop is the main loop of the instrument, it implements fully the ratio
control algorithm, where the setpoint is derived, through a ration operation, from
the reference analog input signal (PV2), and it is equipped with the following list
of important functionalities:
Bias on the Local Setpoint
Output forcing modes
Alarms on PV1
Alarms on PV2
The second loop is a basic PID loop, with the following functionalities :
Memorised Setpoint
Remote setpoint (through AI3 if this signal is not used for the bias)
Output forcing modes
Alarm on the controlled variable PV3
183
Installation and User manual of the AC10 - AC20 - AC30 controller
18.3
Control
Ratio Loop
PV1, the controlled variable, is acquired through the AI1 module, providing the
conversion in engineering units and the out of range detection.
PV2, the reference variable of the ratio loop, is acquired through the AI2 module,
providing the conversion in engineering units and the out of range detection.
These two variables are transmitted to the SP DEV module, that computes the
Working Setpoint for the loop, on the basis of the selected type of ratio (direct or
reverse), as in the following formulas:
Direct ratio = PV2 x Ratio Setpoint = WSR
Inverse ratio = PV2 / Ratio Setpoint. = WSR
The Working Setpoint Ratio WSR is the target setpoint for the controlled
variable PV1; it is the setpoint considered in the calculation of the PID deviations
and in the visualisation of the display panel.
The output of the loop, suitable for driving the actuator, is transmitted out
through the AO1 module.
Standard Loop
The controlled variable PV3 is acquired though the AI4 module, providing the
conversion in engineering units and the out of range detection. It is transmitted
to the SET DEV module that, with the PID2 and CONTROL OUT modules,
makes up the core PID block. The output is transmitted out on the terminal
blocks, through the AO4 module, for driving the external actuator.
18.4
Bias
The bias feature consists in adding to the ratio setpoint, set in the SP DEV
module a value, provided through the BIAS input (AI3). The result of the sum of
these two values provides the resultant ratio setpoint, that, multiplied or divided
by the reference variable (PV2), gives the Setpoint of the controlled variable.
This feature is enabled when the digital input DI5 is in the active state.
18.5
Remote Setpoint
This feature is supported on the standard loop (Loop 2), only, and it is enabled
by the active state of the DI6 digital input. The Remote Setpoint is selected,
according to the parameter controlling the switch of the MUX module, between
the constant value, stored in the MCNS module, and the analog input AI3. The
latter choice is alternative to using AI3 as the Bias input of the Ratio loop.
18.6
Forcing modes
These operations are related to the loop output, that can be driven by other
sources than the straight PID algorithm. The functionality provided by the two
loops are slight different, as described below.
Ratio Loop
This configuration allows the following 4 modes, selected through the DI1, DI2,
DI3 and DI4:
Tracking
Hold
Hold + Y Max
Hold + Y Min
a) Tracking: it is enabled by the active state of the DI4 digital input and it
consists in setting the control output to the constant value stored in the
MCNS module.
b) Hold: when DI3 is active, the control output is frozen at the value it had at the
time of the rising transition.
184
Annex A. - Resident Configurations
c) Hold+Ymax: When both DI3 (Hold) and DI1 are active, the control output is
forced to its maximum value, defined by the parameters of the CONTROL
OUT module.
d) Hold+Ymin: When both DI3 (Hold) and DI2 are active, the control output is
forced to its minimum value, defined by the parameters of the CONTROL
OUT module.
DI3
Off
On
On
On
DI1
x
Off
On
Off
DI2
x
Off
Off
On
Selected Value
A/M -- TRK
Hold
Ymax
Ymin
An important point to bear in mind is that all these 4 forcing modes are handled
by the module, according to the following priority: A/M; Ymin, Ymax, Hold and
Track.
Standard Loop
Only the Hold and the Tracking mode are supported by this module.
The Hold mode freezes the loop output, until the DI7 digital input is active
The Tracking mode set the output to the value of the constant stored in the
MCNS module, until DI8 is active.
DI7
Off
On
Off
On
18.7
DI8
Off
Off
On
On
Selected Value
A/M
Hold
TRK Constant MV STBY
Hold (because of the higher priority than TRK)
Alarms
Ratio Loop
There are three alarms either on the controlled variable PV1 or the deviation,
according to the parameters selected in each of the ALM modules. The module
WSP-PV computes the deviation, in the same engineering units of the controlled
variable PV1. The status of each alarm is retransmitted out through the DO1,
DO2 and DO3 modules.
Two alarms are implemented by the additional ALM modules on the reference
variable PV2. Their status is retransmitted out through the DO6 and DO5 digital
outputs.
The out of range of, respectively, the variable PV1 (controlled variable) and the
variable PV2 (reference variable) is detected and retransmitted out through the
digital outputs DO4 and DO7.
Loop Standard
This loop is provided with an unique alarm either on the controlled variable PV3
or the deviation, according to the parameters selected in the ALM module. The
module WSP-PV computes the deviation, in the same engineering units of the
controlled variable PV3. The status of the alarm is retransmitted out through the
DO8 module.
185
Installation and User manual of the AC10 - AC20 - AC30 controller
18.8
Graphic Displays
ALARMS
RATIO LP2
71.2
OR of the alarms
LS Sel. Loop.
WSP loop sel.
Selected Loop
LSP
WSP
L1
71.0
71.0
L2
LOC
LOC
L3
PV of the select.
Loop
Requested
operating mode
Current operating mode
Loop TAG area
ALLARME 1
MV STBY RT
ALLARME 2
HOLD RT
ALLARME 3
Y MAX RT
ALLARME 4
Y MIN RT
TSP
WSP
RATIO
FORZAM.
85.3
mm
LSP
85.0
200
Loc
RSP
CSP
MSP
LSP
Current operating mode
Loc
Requested
operating mode
AL
OR of Forcing modes
ALH
Alarm 1
ALL
OR of the Alarms
ALLARME 5
WSP loop 1
PV loop 1
WSP loop 2
PV loop 2
WSP loop 3
PV loop 3
UNDERFL PV1
UNDERFL PV2
ALLARME 6 PV3
AUT
MV STBY L2
Aut/Man Station
MV loops
A
A
A
O=23
O=38
O=65
mm
LSP
38.3
85.0
200
Loc
Loc
-200
Out 35
TSP
WSP
LOOP2
85.3
RSP
AI4
CSP
LSP
Current operating mode
mm
LSP
85.0
200
Loc
TSP
WSP
LOOP 2
RSP
CSP
mm
MSP
LSP
LSP
Current operating mode
85.3
85.0
200
Loc
RSP
AI4
CSP
LSP
Current operating mode
Requested
operating mode
Loc
Requested
operating mode
Loc
Requested
operating mode
AL
OR of Forcing modes
AL
OR of Forcing modes
AL
OR of Forcing modes
ALH
Alarm 1
ALH
Alarm 1
ALH
Alarm1
ALL
ORof the Alarms
ALL
OR of the Alarms
ALL
OR of the Alarms
AUT
Aut/Man station
AUT
W=1 min
Out 35
TSP
WSP
RATIO
Aut/Man stations
-200
HOLD L2
AUT
Aut/Man station
-200
Out 35
Aut/Man station
W=1 min
-200
Out 35
The pictures above show the different types of display panels, providing the
most effective interface for this strategy configuration. The first 3 panel
consisting in the 3 bargraph display, the alarm list and the Forcing mode list,
provide, by themselves, a complete interface for this configuration.
Referring to the 3 bargraph display, the two bargraphs in the centre (reference
variable PV2) and on the left, with the RAT tag and related to the PV1 variable,
belong to the Ratio loop, while the one on the right, with the L2 tag, belongs to
Loop 2.
If you want to operate on a loop, first you have to select it, by pressing the
button. The loop selected is highlighted by the fact that both the tag and the
output operating mode are displayed in reverse. Once the loop has been
selected, it is possible to change either the Setpoint or the A/M station operating
mode. Furthermore, the parameters shown in the upper part of the panel relates
to the selected loop.
The status of the alarms is flagged by the small box on the upper left part of the
panel. When an alarm or a forcing mode is activated, the box blinks
continuously, to alert the operator. Next, the operator can get a more detailed
view of the alarms, by looking at the ALLARMS and FORZAM. panels.
Furthermore, this configuration provides other 4 additional panels, 2 for each
loop, with the well know bargraph and trend displays, as shown in the pictures
above.
186
Annex A. - Resident Configurations
18.9
Applications
The purpose of the ratio loop is to control processes where it is required to keep,
at a predefined set, the ratio between two controlled variables. There are plenty
of examples of processes of this type: for instance, the control of the blending
between two fluids and the control of the combustion (air and gas mix).
The second basic PID loop can be used to control an independent variable of
the process, where the ratio control is required
An example is shown in the picture below, related to the combustion control of a
steam generator. The steam pressure is controlled by the Loop2, whose output
defines the energy ( heat amount) to supply to the boiler, driving the gas valve.
The ratio loop controls the air flow rate, that, in order to optimise the
combustion, must be kept to a predefined ratio with the instantaneous gas flow
rate. The ratio loop receive the gas flow rate, as PV2, and its output drives the
air door. The control of combustion can be, further, improved by measuring the
oxygen in the fumes and correcting, according to the measure, the air/gas ratio
setpoint, by mean of the Bias input.
Furthermore, using the digital inputs, some additional functionalities, can be
implemented, like forcing the closure of the gas valve, tracking the valve at the
start up, and disabling the oxygen bias when the production is at the minimum
level.
O2
PV1
PV2
BIAS
AT
PV3
LOGIC
PT
FT
FT
Another application of the ratio loop is in controlling the dosing of an additive to a
fluid with variable flow. In this application, Loop 2 can be used for the control of
the level of the tank where the fluid enters.
PV1
PV2
PV3
LOGIC
LT
FT
FT
187
Installation and User manual of the AC10 - AC20 - AC30 controller
18.10
Electrical Connections
The following picture provides a clear view of all the termination blocks, with the
associated functionality, and it is specific of this configuration. No signals must
be connected to the termination blocks not used by the strategy.
The termination blocks 25 and 26 are providing a 24V DC output, particularly
suitable to supply of the 2 wires transmitters.
PV1 measure
RATIO
LOOP
PV2 measure
Bias/Rsp
LOOP 2
PV3 measure
1
25 +24
2
26 +24
3
4
5
6
A
N
A
L
O
G
7
8
I
N
P
10 U
T
11
Y Max
Y Min
RATIO
LOOP
Hold
Track.
Bias
Loc/Rem
LOOP 2
Hold
Track
188
LAN
A 27
N
A 28
L
O 29
G
30
O
U 31
T
32
9
33
12
34
D
I 35
G
I 36
T
A 37
L
38
13
14
15 D
I
16 G
17 I
T
18 A
L
19
20
I
N
21 P
U
22 T
23
24
39
CN2
485
O 40
U
T 41
42
43
44
Ratio Loop
Actuator
Loop 2 Actuator
Alarm 1 Pv1
Alarm 2 Pv1
Alarm 3 Pv1
Und.F. Pv1
Alarm 4 Pv2
Alarm 5 Pv2
Und.F. Pv2
Alarm 6
Loop 2
46
POWER SUPPLY
48
RATIO
LOOP
Annex A. - Resident Configurations
19. Cascade
19.1
Description
The drawings below are providing the following informations:
Block Diagram.
User interface, consisting in a set of display panels.
Termination unit for the connection to the field.
This configuration consists of two loops interconnected in a cascade
configurations.
The first loop is named Master, while the second loop is named Slave. The
control output of the Master becomes the setpoint of the Slave, entering as a
Remote Setpoint. The Slave loop is in the Remote Setpoint mode, during the
normal working conditions, and it is switched to Local mode during transient
situations, like start up, operator manoeuvre etc.
The displays, related to this configuration, include the usual single loop bargraph
and trend panel, one dual loop panel and an alarm list, global to both the loops.
19.2
Block Diagram
In the following block diagram the interconnections between the various
modules and the display panels are not indicated, in order to improve the
understanding of the functionality performed.
Underflow PV Master
DI1
AI1
AI2
DI2
AI4
DI8
DI7
PV MST
DRSP
WSP
WSP - PV
SET
DEV
Underflow PV Slave
1
RSP
MUX
2
PV
1
MCNS
WSP - PV
WSP
2
Y%
ALM
ALM
ALM
3
2
1
PID
DIH
DB
PV SLV
SCH
TRK MAST
CONTR
OUT
TRK
SET
DEV
RSP
A/M
1
2
ALM
ALM
ALM
4
5
6
DTRK
3
SAT
4
OR 1
D.B.
SCH
RSP SLAVE
PID
Y%
5
VISU 1
A/M
VISU 3
SCH
RTX PV M
AO2
19.3
VISU 2
DO4
DO3
DO2
DO1
8
6
CONTR
OUT
7
TRK
OR 1
D.TRK.
HOLD
SCH
RTX PV SL
AO3
AO4
DO5 DO6
DO7
DO8
Control
Loop Master
The master process variable PV MS1 is acquired by the AI1 module, providing
the conversion in engineering units and the out of range detection. It is
transmitted to the SET DEV module that, with the PID and CONTROL OUT
modules, makes up the core PID block. The output, after being adjusted to the
range of the PV SLV by the SCH RSP SLAVE modules, enters, as a Remote
Setpoint RSP, into the SLAVE module.
Loop Slave
189
Installation and User manual of the AC10 - AC20 - AC30 controller
The process variable PV SLV is acquired by the AI4 module, providing the
conversion in engineering units and the out of range detection. It is transmitted
to the SET DEV module that, with the PID and CONTROL OUT modules,
makes up the core PID block. The output is transmitted out on the terminal
blocks, through the AO4module, for driving the external actuator.
The controlled variable PV SLV, after being adjusted to the Master range, by the
SCH TRK MAST module, is connected to the Track input of the Master Loop.
Furthermore, the DB out of the Slave Loop is connected both to the Track
enable of the Master loop and to the Bumpless input of the Slave loop. These
two connections are required in order to perform bumpless transfers, in case of
Auto/Manual and forcing modes changes. Every time there is a change, the
output of the Master is aligned with the instantaneous value of the controlled
variable of the Slave.
The following important functionalities are added to the basic cascade control
feature:
Remote and Memorised Setpoint for the Master
Forcing modes on the Slave
Alarms on the variable and deviation, both on the Master and the Slave
Retransmission both of the PV MST and the PV SLV variable.
19.4
Remote Setpoint
This feature is supported in both the loops, but, while on the Slave the Remote
Setpoint is completely dedicated to the implementation of the Cascade
configuration and cannot be used for other purposes, on the Master, it available
for the user needs.
The Master Remote Setpoint feature is enabled both by the DI1 input active and
by the priority based arbitration logic, governing the operating mode change.
The Setpoint source is selected between an analog constant, stored in the
MCNS module and the Remote signal from the analog input AI2, by mean of the
DI2 digital input. As shown in the table below, when DI2 is active, the stored
constant is selected as the Remote Setpoint.
DI1
Off
On
On
19.5
DI2
x
Off
On
Selected value
Set Loc
Input AI2
Constant SP MEM
Forcing modes
These operations are related to the loop output, that can be driven by other
sources than the straight PID algorithm. This feature is provided on the Slave
loop, where the following 2 modes are supported:
Tracking
Hold
a) Tracking: it is enabled by the DI8 digital input and it consists in setting the
control output to a predefined constant value of the MCNS module
b) Hold: when DI7 is active, the control output is frozen at the value it had at the
time of the rising transition.
An important point to bear in mind is that all these 4 forcing modes are handled
by the module, according to the following priority: A/M; Ymin, Ymax, Hold and
Track
19.6
Alarms
There are three alarms, for each loop, either on the controlled variables PV SLV
and PV MST or the deviations, according to the parameters selected in each of
the ALM modules. The module WSP-PV computes the deviation, in the same
engineering units of the controlled variable PV1. The status of each alarm is
retransmitted out through the DO1, DO2 and DO3 modules, for the Master loop,
and DO5, DO6 and DO7, for the Slave loop. A fourth alarm, for each loop, flags
190
Annex A. - Resident Configurations
the out of range of the controlled variable (underflow, detected on 1-5V, 4-20mA
inputs) and it is transmitted out on the DO4 (Master) and DO8 (Slave) modules.
19.7
Variables Retransmission
The Master controlled variable PV MST is transmitted out, after a rerange,
operated by the SCH RTX PVM module, on the AO2 output.
The Slave controlled variable PV SLV is transmitted out, after the rerange,
operated by the SCH RTX PV SL module, on the AO3 output.
The SCH modules allow the modification of the ranges of the retrasmitted
output, that are not, necessarily, the same of the input variable. This is achieved
by setting the input range parameters of the SCH module to different values
than the output range parameters. In this way, the range of the variable can be
changed, in order to consider only a part of the original signal scale, with
sensible advantages on the resolution of the output.
19.8
Graphic Displays
MAST SLAVE
E.U. PV Master
PV Master
85.3
PV1
LSP 85.0
Master scale High limit
200.0
200.0
Rem
Rem
WSP Slave
WSP Master
PV Master
LSP
WSP
RSP
CSP
PVS
WSS
ALLARME 1 Mst
For
OR of Forcing modes
MIN
Alarm 1
AUT
Master scale Low Limit
0.0
0.0
200
Loc
ALLARME 3 Mst
UNDERFL Mst
85.3
85.0
200
Loc
-200
Out 35
Aut/Man station
Loc
Requested
operating mode
AL
OR of Forcing modes
ALH
ALL 1
ALL
OR of Alarms
AUT
Aut/Man Station
ALLARME 4 Slv
ALLARME 5 Slv
TRAKING
-200
HOLD
Valve position
TSP
WSP
MASTER
CSP
MSP
LSP
Current operating mode
OR of Alarms
Slave scale Low Limit
Out= 37
W=1 min
85.0
UNDERFL Slv
ALL
LSP
LSP
RSP
ALLARME 6 Slv
PV Slave
mm
85.3
mm
ALLARME 2 Mst
Slave scale High Limit
Current operating mode
Requested
operating mode
TSP
WSP
MASTER
ALARMS
Out 35
TSP
WSP
SLAVE
85.3
RSP
AI4
CSP
LSP
Current operating mode
mm
LSP
85.0
200
Loc
RSP
CSP
MSP
LSP
Current operating mode
TSP
WSP
SLAVE
mm
LSP
66.6
85.0
200
Loc
RSP
AI4
CSP
LSP
Current operating mode
Loc
Requested
operating mode
Loc
Requested
operating mode
Loc
Requested
operating mode
AL
OR of Forcing modes
AL
OR of Forcing modes
AL
OR of Forcing modes
ALH
Alarm 1
ALH
Alarm 1
ALH
Alarm 1
ALL
OR of Alarms
ALL
OR of Alarms
ALL
OR of Alarms
AUT
Aut/Man station
AUT
Aut/Man station
AUT
Aut/Man Station
-200
Out 35
W=1 min
-200
Out 35
The pictures above show the different types of display panels, providing the
most effective interface for this strategy configuration. The panel with the 2
bargraph, provides, by itself, a complete interface of both the loop.
Referring to the 2 bargraph display, the Master controlled variable is displayed
both at the top, with large size digits, and with the larger bargraph on the left,
while the Master Working Setpoint, WSPM, is displayed by the slider.
About the Slave loop, the controlled variable PV SL is displayed by the thinner
bargraph on the right and the setpoint WSP SL is displayed by the slider.
The Slave control output, driving the external actuator, is displayed by the
horizontal bargraph and numerically.
The following variables, consisting of the setpoints and process variables, are
displayed, one at a time, in the scrollable display area:
LSP
Local setpoint of the Master loop
191
Installation and User manual of the AC10 - AC20 - AC30 controller
WSm
Working setpoint of the Master loop
RSm
Remote setpoint of the Master loop
Csm
Computer setpoint of the Master loop
PVs
Process variable of the Slave loop
WSs
Working setpoint of the Slave loop
The displayed Setpoint operating mode is the one of the Master loop: its mode,
indicated by the Loc, Rem and Com mnemonic is displayed in reverse, on the
panel, at the same height of the L/R key, that is used to change the mode.
The squared digital indications, on the right side of the panel, are flagging the
status of the alarm and the forcing mode of the loop. More precisely, they
highlight the following general situations:
1
When an alarm is active, the label ALL is visible
2
When the Alarm 1 is active, the label AL1 is visible.
3
When a forcing mode is active the label FOR is displayed.
These are global flags: the detailed cause of the event, is shown in the ALARMS
panel, where the digital status of each alarm and forcing input is clearly shown.
The status of the digital signal is indicated by the type of display of the alarm
message: in reverse if active, normal if inactive.
On the ALARMS panel, the following alarms and forcing status are displayed:
ALM1 PV MAST
Alarm 1 loop Master
ALM2 PV MAST
Alarm 2 loop Master
ALM3 PV MAST
Alarm 3 loop Master
UNDERFL, MAST
Out of range of the AI1 input (only for 1-5V or 4-20 mA
input signals)
ALM4 PV SLAV
Alarm 4 loop Slave
ALM5 PV SLAV
Alarm 5 loop Slave
ALM6 PV SLAV
Alarm 6 loop Slave
UNDERFL. SLAV
Out of range of the AI4 input (only for 1-5V or 4-20 mA
input signals)
TRACKING
Output forced to a predefined value
HOLD
Output frozen at the value of activation of the forcing
condition
Furthermore, this configuration provides the well known single bargraph display
and the single pen trend, that provides the same functionalities of the previous
panel, but the addition of a programmable time width chart, with the trend profile
of the controlled variables.
The picture provides details about the displayed variables.
192
Annex A. - Resident Configurations
19.9
Applications
A typical case, where the cascade control provides excellent results is when the
manipulated variable influences the process variable indirectly, through other
process variables, dynamically mismatched, whose stability is influenced by
external events.
An example is shown in the picture below.
Loop Master
Loop Slave
SET
SET
+
PID
+
PID
FLOW
The target is to control the tank temperature, by controlling the flow rate of hot
fluid to the heat exchanger.
This can be achieved, using just one loop, by measuring the temperature of the
tank and controlling the valve regulating the flow rate of hot fluid. Such a
solution, in most cases, is unsatisfactory, because it generates continuous
unstability on the controlled variable. This is due to the fact that, when the
pressure of the fluid increases, the flow rate increases, but it takes a lot of time
for the temperature to raise, in order to have a response on the control output to
the valve. The effect is a big accumulation of heat in the tank, that creates the
unstability.
The Cascade control provides a perfect solution, because the Temperature
loop, with its slow inertia is controlled by a separate loop, whose output defines
the target flow rate of the fluid. This target flow rate is the set of the Slave loop
controlling the flow rate, that having as measured variable the instantaneous
flow rate, is capable to compensate immediately the changes of pressure of the
fluid.
193
Installation and User manual of the AC10 - AC20 - AC30 controller
19.10
Electrical Connections
The following picture provides a clear view of all the termination blocks, with the
associated functionality, and it is specific of this configuration. No signals must
be connected to the termination blocks not used by the strategy.
The termination blocks 25 and 26 are providing a 24V DC output, particularly
suitable to supply of the 2 wires transmitters.
Master PV measure
Master Remote SP
1
25 +24
2
26 +24
3
4
Slave PV measure
5
6
A
N
A
L
O
G
7
8
I
N
P
U
10
T
11
LAN
A 27
N
A 28
L
O 29
G
30
O
U 31
T
32
33
9
D
I
G
I
T
A
L
12
Master
Loc/Rem
Rem/Mem
13
14
15 D
I
16 G
I
T
18 A
L
19
17
20
Slave
194
Hold
MV Stby
I
N
21 P
U
22 T
34
35
36
37
38
39
CN2
485
O 40
U
T 41
42
43
44
Slave PV retrans.
Actuator
Alarm 1 Pv
Alarm 2 Pv
Master
Alarm 3 Pv
Und.F. Pv
Alarm 4 Pv
Alarm 5 Pv
Slave
Alarm 6 Pv
Und.F. Pv
46
POWER SUPPLY
23
24
Master PV retrans.
48
Annex A. - Resident Configurations
20. Override
20.1
Description
The drawings below are providing the following informations:
Block Diagram.
User interface, consisting in a set of display panels.
Termination unit for the connection to the field.
The override control is the right solution for controlling processes, where more
than one variable must be controlled at the same time. For instance, the
process consists of a Main variable, that must be kept at the setpoint and a Limit
one, that must not exceed a predefined threshold, during normal operations,
start up or when abruptly changes occurs.
This configuration controls two variables in override. It is based on 2 PID loops,
each one controlling a process variable but only one output to the external
actuator. The output to the actuator is computed as the minimum or the
maximum of the two control output of the loops.
The two loops are dedicated to the Main variable and the Limit one.
20.2
Block Diagram
In the following block diagram the interconnections between the various
modules and the display panels are not indicated, in order to improve the
understanding of the functionality performed.
UNDERFLOW
AI1
DI1 DI2
AI2
AI3
DI7 DI8
AI4
DI4 DI3 DI5 DI6
UNDERFLOW
PV1
PV2
PV1
DRSP
WSP
WSP-PV
SP DEV
DRSP
1
RSP
MUX
2
2
2
1
2
COST
RSP
WSP
SP DEV
MUX
WSP-PV
3
ALM ALM ALM
3
1
1
Y%
Y%
D.B.
D.B.
PID1
PID2
(main)
(limit)
ALM
ALM
4
5
1
OR 1
2
3
MIN
MAX
4
OR 1
5
VISU
M-L
D.B.
VISU
VISU
CONTR
OUT
TRK
6
7
DTRK
A/M
ALM
HOLD
6
Y MAX
VISU
Y MIN
VISU
SCH
PV1
AO2
20.3
SCH
PV2
DO4
DO3 DO2 DO1
DO8
AO1
DO5 DO6
DO7
AO3
Control
The main variable PV1 is acquired by the AI1 module, providing the conversion
in engineering units and the out of range detection. It is transmitted to the loop 1,
consisting of the SET DEV and PID module.
The limit variable is acquired by the AI4 modules and it is transmitted to the loop
2.
195
Installation and User manual of the AC10 - AC20 - AC30 controller
The outputs of the two PID modules are connected to a Selector module that,
according to the selection criteria configured, chooses one of the two outputs
and transmits them to the CONTR OUT module, common to both the loops. The
output of this module, through the AO1 module, drives the actuator.
All the forcing modes are acting on the unique CONTROL OUT module and,
therefore, common to both the loops.
The Bumpless transfer output is common to both the loops, in order to keep the
two PID aligned.
20.4
Remote Setpoint
This feature is supported identically by both the loops. It is enabled both by the
DI1 (Main) or DI8 (Limit) and by the priority based arbitration logic, governing the
Setpoint mode change. The Remote setpoint is selected between an analog
constant, stored in the CONST module, and the remote signal from the analog
input AI2 (Main) or AI3 (Limit).
The selection between these two Setpoint sources is operated by the inputs DI2
(Main) or DI7 (Limit), as shown in the table below.
DI1/DI8
Off
On
On
20.5
DI2/DI7
x
Off
On
Selected value
Set Loc
InputAI2/Input AI3
Constant MSP Main/MSP LMT
Forcing modes
These operations are related to the loop output, that can be driven by other
sources than the straight PID algorithm, by mean of the DI3-4-5-6 digital inputs.
These modes are related to the CONTR OUT module and, therefore, are
common and influence both the loops.
a) Tracking: it is enabled by the DI4 digital input and it consists in setting the
control output to a predefined constant value of the MCNS module.
b) Hold: when DI3 is active, the control output is frozen at the value it had at the
time of the rising transition.
c) Hold+Ymax: When both DI3 (Hold) and DI5 are active, the control output is
forced to its maximum value, defined by the parameters of the CONTROL
OUT module.
d) Hold+Ymin: When both DI3 (Hold) and DI6 are active, the control output is
forced to its minimum value, defined by the parameters of the CONTROL
OUT module.
An important point to bear in mind is that all these 4 forcing modes are handled
by the module, according to the following priority: A/M; Ymin, Ymax, Hold and
Track
DI3
Off
On
On
On
20.6
DI5
x
Off
On
Off
DI6
x
Off
Off
On
Selected Value
A/M
Hold
YMax
YMin
Alarms
Main Loop
There are three alarms either on the controlled variable PV1 or the deviation,
according to the parameters selected in each of the ALM modules. The module
WSP-PV computes the deviation, in the same engineering units of the controlled
variable PV1.
The status of each alarm is retransmitted out through the DO1, DO2 and DO3
modules.
The out of range of, the variable PV1 is detected and retransmitted out through
the digital output DO4.
196
Annex A. - Resident Configurations
Limit Loop
There are two alarms either on the controlled variable PV2 or the deviation,
according to the parameters selected in each of the ALM modules. The module
WSP-PV computes the deviation, in the same engineering units of the controlled
variable PV2.
The status of each alarm is retransmitted out through the DO5 and DO6
modules.
An additional alarm performs the comparison between the outputs of the Main
loop and the Limit one, determining which of the two loop is driving the output
and flagging it out, through the DO8 output.
The out of range of the PV2 variable is detected and retransmitted out through
the digital output DO7.
20.7
Variable retransmissions
The Main variable PV1 is retrasmitted out to the termination unit, through the
SCH PV1 Main and AO2 modules.
The Main variable PV2 is retrasmitted out to the termination unit, through the
SCH PV2 Main and AO3 modules.
The module SCH allows the modification of the ranges of the retrasmitted
output, that are not, necessarily, the same of the input. This is achieved by
setting the input range parameters of the SCH module to different values than
the output range parameters. In this way, the range of the variable can be
changed, in order to consider only a part of the original signal scale, with
sensible advantages on the resolution of the output.
20.8
Graphic Display
OVERRIDE
E.U. PV Master
PV Master
85.3
PV1
LSP 85.0
Master scale High Limit
200.0
200.0
PV Master
ALLARME 1 Mst
ALLARME 2 Mst
Rem
Rem
Slave scale High Limit
Current operating mode
Requested
operating mode
For
OR of Forcing modes
MIN
Alarm 1
ALL
OR of Alarms
AUT
Aut/Man station
WSP Slave
WSP Master
ALARMS
LSP
WSm
RSm
PVL
CSL
ALLARME 3 Mst
UNDERFL Mst
ALLARME 4 Lmt
ALLARME 5 Lmt
UNDERFL Lmt
PV Slave
Master scale Low Limit
0.0
0.0
Out= 37
mm
LSP
HOLD
85.3
85.0
-200
Out 35
Y MIN
Valve position
RSP
CSP
M-L
LSP
WSP
LIMIT
mm
LSP
200
W=1 min
Y MAX
Slave scale Low Limit
LSP
WSP
MAIN
TRAKING
85.3
85.0
RSP
CSP
M-L
200
Loc
Current operating mode
Loc
Current operating mode
Loc
Requested
operating mode
Loc
Requested
operating mode
AL
OR of Forcing modes
AL
OR of Forcing modes
ALH
Alarm 1
ALH
Alarm 1
ALL
OR of Alarms
ALL
OR of Alarms
AUT
Aut/Man station
AUT
Aut/Man Station
W=1 min
-200
Out 35
The pictures above show the different types of display panels, providing the
most effective interface for this strategy configuration.
The panel with the two bargraph gives a complete overview of the main
variables, involved in this configuration. The PVMain controlled variable is
197
Installation and User manual of the AC10 - AC20 - AC30 controller
displayed both in the large size digits display and through the larger bargraph on
the left, while the Working Setpoint, WSPMain, is displayed by the slider.
The PVLimit limit variable is displayed on the thinner bargraph on the right, while
the Working Setpoint, WSPLim is displayed by the slider.
The control output is displayed both numerically and by horizontal bargraph.
The following variables, consisting of the Local Setpoint and other 5 analog
variables, are displayed, one at a time, in the scrollable display area:
LSP
Local setpoint of the Main loop
WSM Working setpoint of the Main loop
RSM Remote setpoint of the Main loop
CSM Computer setpoint of the Main loop
PVL
Limit Process variable
WSL Limit Working setpoint
The displayed Setpoint operating mode is the one of the Main loop: its mode,
indicated by the Loc, Rem and Com mnemonic is displayed in reverse, on the
panel at the same height of the L/R key, that is used to change the mode.
The Setpoint and its operating mode of the Limit loop are displayed and can be
changed from the display panel LIMIT.
The squared digital indications, on the right side of the panel, are flagging the
status of the alarm and the forcing mode of the loop. More precisely, they
highlight the following general situations:
1
When an alarm is active, the label ALL is visible
2
When the Alarm 1 is active, the label AL1 is visible.
3
When a forcing mode is active the label FOR is displayed.
These are global flags: the detailed cause of the event, is shown in the ALARMS
panel, where the digital status of each alarm and forcing input is clearly shown.
This configuration support two trend panels, one for each loop, with the trend
profile of the controlled variable.
20.9
Applications
The override control is the right solution for controlling processes where more
than one variable must be controlled at the same time. For instance, the
process consists of a Main variable, that must be kept at the setpoint and a Limit
one, that must not exceed a predefined threshold, during normal operations,
start up or when abruptly changes occurs.
A few examples of a process requiring the override are:
- Flow control with a maximum limit on the pressure.
- Control of the pressure with a limit on the flow.
- Control of the temperature of an object with limit on the maximum temperature
of the heating elements.
PV1
PV2
LOGIC
PT
FT
198
Annex A. - Resident Configurations
PV2
PV1
LOGIC
20.10
Electrical connections
The following picture provides a clear view of all the termination blocks, with the
associated functionality, and it is specific of this configuration. No signals must
be connected to the termination blocks not used by the strategy.
The termination blocks 25 and 26 are providing a 24V DC output, particularly
suitable to supply of the 2 wires transmitters.
LOOP 1
(main)
LOOP 2
(limit)
PV1 measure
SP. Rem
SP. Rem
PV2 measure
1
25 +24
2
26 +24
3
4
5
6
A
N
A
L
O
G
7
8
I
N
P
10 U
T
11
Loc/Rem
Rem/Mem
LOOP 1
(main)
Hold
Tracking
Y Max
Y Min
LOOP 2
(limit)
Loc/Rem
Rem/Mem
LAN
A 27
N
A 28
L
O 29
G
30
O
U 31
T
32
9
33
12
34
D
I 35
G
I 36
T
A 37
L
38
13
14
15 D
I
16 G
I
T
18 A
L
19
17
20
I
N
21 P
U
22 T
23
24
39
CN2
485
O 40
U
T 41
42
43
44
Actuator
PV1 retransmission
PV2 retransmission
Alarm 1 Pv1
Alarm 2 Pv1
Alarm 3 Pv1
LOOP 1
(main)
Und.F. Pv1
Alarm 4 Pv2
Alarm 5 Pv2
LOOP 2
(limit)
Und.F. Pv2
Alarm 6 (main-limit)
46
Power Supply
48
199
Installation and User manual of the AC10 - AC20 - AC30 controller
21. 4 Loops
21.1
Description
The drawings below are providing the following informations:
Block Diagram.
User interface, consisting in a set of display panels.
Termination unit for the connection to the field.
This configuration provides 4 basic independent PID loops, equipped with
forcing modes on the output and 2 absolute or deviation alarms, each.
The description of the control functionalities is reported, in the following pages,
related to the loop1, only. The functionality of the other loops is perfectly
identical, but with the index numbers of the modules different. To the get the
proper index numbers for the other loops, refer to the Block Diagram.
21.2
Block Diagram
In the following block diagram the interconnections between the various
modules and the display panels are not indicated, in order to improve the
understanding of the functionality performed.
DI1
AI1
DI2
DI3
AI2
DI5
AI3
DI4
DI6
DI7
AI4
DI8
1/8
WSP
WSP - PV
WSP
WSP
WSP - PV
PV
WSP - PV
PV
WSP
WSP - PV
PV
PV
OR 8
ALL
PV1
ALM
ALM
1
2
PV3
PV2
SET
DEV1
ALM
ALM
3
4
SET
VISU
DEV2
ALM
ALM
5
6
PV4
SET
DEV3
ALM
ALM
7
8
SET
DEV4
1/8
VISU 3
Y%
Y%
PID1
PID2
HOLD
CONTROL
OUT
VISU 3
Y%
COST
PID3
VISU 3
CONTROL
HOLD
A/M
DTRK
CONTROL
OUT
COST
TRK
DTRK
PID4
ALL
VISU 3
DB
HOLD
OUT
COST
COST
3
2
TRK
Y%
DB
HOLD
CONTROL
OUT
1
A/M
OR 8
FORZAM
DB
DB
A/M
OR
ALL
4
A/M
TRK
DTRK
TRK
DTRK
FORZAM
DO1
21.3
DO2
AO1
DO3
DO4
AO2
VISU
DO5
DO6
AO3
DO7
DO8
AO4
Control
The AI1 module performs the A/D, the scaling and the conversion in engineering
unit of the controlled variable and detects the out of range of the signal,
presumably caused by a sensor failure. The output value of the AI1 module,
PV1 is fed into the three modules which implement the core of the PID loop 1
(SET DEV 1, PID 1 and CONTROL OUT 1). The output of the PID 1 is
connected to the terminal blocks of the instrument, through the output module
AO1, in order to drive the external actuator.
200
Annex A. - Resident Configurations
21.4
Forcing modes
These operations are related to the loop output and consist of the Hold and
Tracking mode.
a) Tracking: the Tracking mode sets the output to the value of constant until DI2
is active.
b) Hold: The Hold mode freezes the loop output, until the DI1 digital input is
active.
When the forcing mode cease, the transfer to the normal operating mode is
bumpless.
21.5
Alarms
There are two alarms either on the controlled variable PV1 or the deviation,
according to the parameters selected in each of the ALM modules. The module
WSP-PV computes the deviation, in the same engineering units of the controlled
variable PV. The status of each alarm is retransmitted out through the DO1 and
DO2 modules.
21.6
TAG of the panel
Graphic Displays
MULTI LOOPS
71.2
OR ALL
LSP loop sel.
WSP loop sel.
Selected loop
LSP
WSP
L1
71.0
71.0
L2
L3
LOC
LOC
L4
ALARMS
ALL1 PV1
WSP loop 1
PV loop 1
WSP loop 2
PV loop 2
WSP loop 3
PV loop 3
WSP loop 4
PV loop 4
mm
Y SIC L1
Requested
operating mode
ALL2 PV1
Current operating mode
ALL3PV2
TAG area
LSP
HOLD L1
66.6
85.0
200
Loc
Y SIC L2
ALL4 PV2
HOLD L2
ALL5 PV3
Y SIC L3
ALL6 PV3
HOLD L3
ALL7 PV4
Y SIC L4
ALL8 PV4
HOLD L4
Loc
A
A
M
O=23 O=34
O=45
26.6
LSP
85.0
200
Loc
W=1 min
-200
Out 35
DEV
YSA
LSP
Current operating mode
Requested
operating mode
AL
OR of Forcing modes
ALH
ALL1
ALL
OR of Alarms
AUT
Aut/Man station
Aut/Man station
O=23
Out 35
TSP
WSP
LOOP 2
l/h
A
CSP
-200
W=1 min
Output value
TSP
WSP
LOOP 1
FORZAM
TSP
WSP
LOOP 3
CSP
DEV
m3h
YSA
LSP
LSP
Current operating mode
43.6
85.0
200
Loc
CSP
DEV
YSA
LSP
TSP
WSP
LOOP 4
A/h
LSP
66.6
85.0
200
Loc
CSP
DEV
YSA
LSP
Current operating mode
Requested
operating mode
Requested
operating mode
Loc
Current operating mode
Requested
operating mode
AL
OR of Forcing modes
AL
OR of Forcing modes
AL
OR of Forcing modes
ALH
ALL1
ALH
ALL1
ALH
ALL1
ALL
OR of Alarms
ALL
OR of Alarms
ALL
OR of Alarms
AUT
Aut/Man station
AUT
Aut/Man station
AUT
Aut/Man station
Loc
W=1 min
-200
Out 35
Loc
W=1 min
-200
Out 35
The panel with the 4 bargraphs provides a complete view of all the 4 loops, with
a fine level of details on the most important parameters.
For each loop, the PV is represented by the bargraph and the Working Setpoint
by the slider. The left bargraph relates to loop 1 while the right relates to loop4. If
you want to operate on a loop, first you have to select it, by pressing the
button.
The loop selected is highlighted by the fact that both the tag and the output
operating mode are displayed in reverse. Once the loop has been selected, it is
201
Installation and User manual of the AC10 - AC20 - AC30 controller
possible to change either the Setpoint or the A/M station operating mode.
Furthermore, the parameters shown in the upper part of the panel relates to the
selected loop.
The numeric indication with large size digits at the top of the panel, is always
displaying the controlled variable value of the selected loop.
The status of the alarms is flagged by the small box on the upper left part of the
panel. When an alarm or a forcing mode is activated, the box blinks
continuously, to alert the operator. Next, the operator can get a more detailed
view of the alarms, by looking at the ALLARMS and FORZAM panels.
Furthermore, this configuration provides other 4 additional panels with the well
know bargraph and trend displays, one for each loop.
The picture above list all the parameters accessible from the various panel.
21.7
Applications
This easy to use configuration is for simple applications, where standard PIDs
are required to control up to 4 independent variables It has the big advantage
of providing 4 loops in just one box, with perfectly identical characteristics,
providing an attractive price/performance solution.
Furthermore, the loops have some additional functionality, like alarms and
forcing modes, for implementing a more advanced control than the basic PID.
A typical example of a process where this configuration is targeted, is the control
of the combustion of a reheating furnace, where the 4 loops are controlling:
Air pressure
Air temperature
Furnace pressure
Fumes temperature at the recuperator
AIR TEMPERATURE
AIR PRESSURE
FUMES TEMPERATURE
LOGICA
&
BLOCCHI
FURNACE PRESSURE
PT
TT
FUMES
ACT. AIR FOR FUMES DILUTION - FUMES TEMPERATURE CONTROL
ACTUATOR TO FAN - AIR PRESSURE CONTROL
ACT. AIR OUTLET - AIR TEMPERATURE CONTROL
FUMES VALVE ACTUATOR -
202
FURNACE PRESSURE CONTROL
PT
TT
Annex A. - Resident Configurations
21.8
Electrical Connections
The following picture provides a clear view of all the termination blocks, with the
associated functionality, and it is specific of this configuration. No signals must
be connected to the termination blocks not used by the strategy.
The termination blocks 25 and 26 are providing a 24V DC output, particularly
suitable to supply of the 2 wires transmitters.
PV1 Loop1
PV2 Loop2
PV3 Loop3
PV4 Loop4
1
25 +24
2
26 +24
3
4
5
6
A
N
A
L
O
G
7
8
I
N
P
U
10
T
11
Loop 1
Loop 2
Hold
Track
Hold
Track
Loop 3
Hold
Track
Hold
Loop 4
Track
LAN
A 27
N
A 28
L
O 29
G
30
O
U 31
T
32
9
33
12
34
D
I 35
G
I 36
T
A 37
L
38
13
14
15 D
I
16 G
I
T
18 A
L
19
17
20
I
N
21 P
U
22 T
23
24
39
CN2
485
O 40
U
T 41
42
43
44
Actuator 1
Actuator 2
Actuator 3
Actuator 4
Al. 1
Al. 2
Al. 3
Loop 1
Loop 2
Al. 4
Al. 5
Al. 6
Al. 7
Loop 3
Loop 4
Al. 8
46
POWER SUPPLY
48
203
Installation and User manual of the AC10 - AC20 - AC30 controller
22. 4 Indicators
22.1
Description
The drawings below are providing the following informations:
Block Diagram.
User interface, consisting in a set of display panels.
Termination unit for the connection to the field.
This configuration provides the monitoring of 4 analog inputs with 2 associated
alarms and retransmission of the variable, after an optional reranging operation.
The alarms are fully configurable, but, usually, they are programmed one as a
low alarm and the other as an high alarm. For this reason, this common high/low
configuration has been used in the picture below.
22.2
Block Diagram
In the following block diagram the interconnections between the various
modules and the display panels are not indicated, in order to improve the
understanding of the functionality performed.
AI1
AI2
AI4
AI3
ALM
ALM
ALM
ALM
ALM
ALM
ALM
1
2
3
4
5
6
7
ALM
8
OR
VISU
SCH
PV2
SCH
PV1
DO1
22.3
AO1
DO2
DO3
AO2
SCH
PV3
DO4
DO5
AO3
SCH
PV4
DO6
DO7
AO4
DO8
Alarms
Each analog input is connected to 2 alarms modules, with absolute
programmable threshold. The status of the alarm is retransmitted out of the
digital outputs.
22.4
Variables Retransmission
All the 4 analog inputs are retransmitted out, after a reranging operated by the
SCH PV modules. This SCH PV modules allow the modification of the ranges of
the retrasmitted outputs, that are not, necessarily, the same of the inputs. This is
achieved by setting the input range parameters of the SCH module to different
values than the output range parameters. In this way, the retrasmitted variable
can be limited to a portion of the input signal scale, with the advantage of an
improved resolution.
204
Annex A. - Resident Configurations
22.5
Graphic Displays
4 DISPLAY
Panel TAG
71.2
OR of Alarms
LSP Sel. Loop
LSP
WSP Sel Loop
WSP
Selected Indicator L1
71.0
71.0
L2
L3
VARIABLE 1
ALARMS
LSP
ALL2 PV1
L4
66.6
mm
ALL1 PV1
85.0
200
Loc
Indicator tag area
ALL3 PV2
PV1
PV2
PV3
PV4
AO1
LSP
Current operating mode
Loc
Requested
operating mode
AL
OR of Forcing modes
ALH
Alarm 1
ALL
OR of Alarms
AUT
Aut/Man Station
ALL4 PV2
PV loop 1
ALL5 PV3
PV loop 2
ALL6 PV3
PV loop 3
PV loop 4
ALL7 PV4
ALL8 PV4
W=1 min
-200
Out 35
VARIABLE 2
mm
LSP
66.6
85.0
200
Loc
W=1 min
-200
Out 35
PV1
PV2
VARIABLE 3
PV3
PV4
AO2
LSP
Current operating mode
mm
LSP
66.6
85.0
200
Loc
Loc
Requested
operating mode
Loc
AL
OR of Forcing modes
AL
ALH
Alarm 1
ALL
OR of Alarms
AUT
Aut/Man Station
W=1 min
-200
PV1
PV2
VARIABLE 4
PV3
PV4
AO3
LSP
mm
LSP
66.6
85.0
200
Loc
Current operating mode
PV1
PV2
PV3
PV4
AO4
LSP
Current operating mode
Loc
Requested
operating mode
OR of Forcing modes
AL
OR of Forcing modes
ALH
Alarm 1
ALH
Alarm 1
ALL
OR of Alarms
ALL
OR of Alarms
AUT
Aut/Man Station
AUT
Aut/Man Station
Requested
operating mode
W=1 min
Out 35
-200
Out 35
This configuration offers 6 display panels.
The panel with the four bargraphs gives a complete view of all the 4 input
measures. It provides the bargraph indication of all the variables, plus the
numeric indication, with large size digits, of the selected variable.
You select the variable, by pressing the
, as you do when you operate with
the configurations with multiple loops. The measure that has been selected is
highlighted by the fact that the tag is displayed in reverse.
The span of the bargraph can be different to the original one of the analog input.
For instance, you can display only a portion of the full span, in order to have a
better resolution. This “Zoom” effect applies only to the bargraph, while the
numeric indication, always reflects the full value of the variable.
The status of the alarms is flagged by the small box on the upper left part of the
panel. When an alarm or a forcing mode is activated, the box blinks
continuously, to alert the operator. Next, the operator can get a more detailed
view of the alarms, by looking at the ALLARMS panel.
Furthermore, a trend panel is available, for each of the analog input. This page,
similar to the one used for loops, has a trend chart, with programmable time
width, that presents the recent trend profile of the variable. At the top of the
panel the numeric indication, with large size digits, of the variable is displayed.
The squared digital indications, on the right side of the panel, reports, in the
order from the top: the global alarms flag, the status of the first alarm of the
variable and the status of the second alarm of the variable.
By pressing
the values of the 5 variables, shown in the picture, are
displayed, one at a time, in the scrollable display area.
205
Installation and User manual of the AC10 - AC20 - AC30 controller
Furthermore, on the trend chart, the range of the trended profile can be a portion
of the full range of the variable in order to enhance the resolution on the
interesting part of the span.
22.6
Applications
Monitoring of 4 variables, with alarms and retransmission.
22.7
Electrical Connections
The following picture provides a clear view of all the termination blocks, with the
associated functionality, and it is specific of this configuration. No signals must
be connected to the termination blocks not used by the strategy.
The termination blocks 25 and 26 are providing a 24V DC output, particularly
suitable to supply of the 2 wires transmitters.
Variable 1
Variable 2
Variable 3
Variable 4
1
25 +24
2
26 +24
3
4
5
6
A
N
A
L
O
G
7
8
I
9 N
P
10 U
T
11
LAN
13
14
20
I
N
21 P
U
22 T
23
24
206
33
34
D
I 35
G
I 36
T
A 37
L
38
12
15 D
I
16 G
17 I
T
18 A
L
19
A 27
N
A 28
L
O 29
G
30
O
U 31
T
32
39
CN2
485
O 40
U
T 41
42
43
44
Var. Retr. 1
Var. Retr. 2
Var. Retr. 3
Var. Retr. 4
Al. 1
Al. 2
Al. 3
Al. 4
Al. 5
Al. 6
Var. 1
Var. 2
Var. 3
Al. 7
Al. 8
Var. 4
46
Power Supply
48
Annex A. - Resident Configurations
23. A/M Station
23.1
Description
The drawings below are providing the following informations:
Block Diagram.
User interface, consisting in a set of display panels.
Termination unit for the connection to the field.
The description of the control functionalities is reported, in the following pages,
related to the AM station 1, only. The functionality of the AM station 2 is perfectly
identical but with the index numbers of the modules different. To the get the
proper index numbers for AM station 2, refer to the Block Diagram.
23.2
Block Diagram
In the following block diagram the interconnections between the various
modules and the display panels are not indicated, in order to improve the
understanding of the functionality performed.
DI1
AI1
AI2
DI3
DI2
DI4
AI3
AI4
PV1
PV2
ALM
ALM
ALM
ALM
1
2
3
4
PV4
2 MUX K
1
+-x:
2
3
4
OUT
1
2
A/M
TRK
ALM
ALM
ALM
5
6
7
8
DI8
+-x:
1
2
MUX
AM
3
COST
4
DHOLD
DTRK
OR1
5
6
7
8
Y MAX
Y MIN
MUX TRK
VISU
ALM
MUX
AM
CONTROL
OR1
1
DI7
MUX K
2
1
2
1
1
COST
2
DI5 DI6
PV3
DB1
CONTROL
OUT
DHOLD
A/M
Y MAX
DTRK
1
2
TRK
Y MIN
MUX TRK
VISU
DB2
DB2 OR1
SCH
PV2
SCH
PV4
OR
MSL
MSL
OR
DO1
DO2
DO3
DO4
AO1
AO2
VISU
DO5
DO6
DO7
DO8
AO4
AO3
This configuration offers 2 A/M station, for driving two actuators.
The features of each A/M station include, the Auto and the Manual operating
mode, 4 Forcing modes, 4 alarms modules and a ratio calculation on the input
variable.
When in MAN mode, the output of the A/M station is directly driven by the front
panel of the instrument, while, when in Auto, the output corresponds to the
analog input AI1, optionally divided by a ratio value. This ratio value can be
either the AI2 analog input or a constant value store in a module.
The Forcing modes are: Tracking, Hold, Ymax and Y min.
The alarms are on the input variables and of absolute type.
23.3
Forcing Modes
These operations are related to the A/M station output, that can be driven by
other sources than the keyboard or the input variable.
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Installation and User manual of the AC10 - AC20 - AC30 controller
The A/M station allows the following 4 forcing modes, selected through the DI1,
DI2, DI3 and DI4, when the operating mode is AUTO:
Tracking
Hold
Hold+Ymax
Hold+Ymin
23.4
It is enabled by the DI2 digital input and it consists in setting
the output to a predefined constant value or to the AI2 value
When DI1 is active, the control output is frozen at the value it
had at the time of the rising transition.
When both DI1 (Hold) is active and DI3 is active, the output is
forced to its maximum value, defined by the parameters of the
CONTROL OUT module.
When both DI1 (Hold) is active and DI4 is active, the control is
forced to its minimum value, defined by the parameters of the
CONTROL OUT module.
Alarms
Four alarm modules are provided, two for the AI1 and two for the AI2 analog
input. The status of the alarms is transmitted out through the DO1-2-3-4 digital
inputs.
23.5
Variables Retransmission
Both the input variable AI1 and AI2 are retrasmitted out to the termination unit,
through the SCH PV module. The SCH PV module allows the modification of the
ranges of the retrasmitted output, that are not, necessarily, the same of the
original input. This is achieved by setting the input range parameters of the SCH
module to different values than the output range parameters. In this way, the
retrasmitted variable can be limited to a portion of the input signal scale, with the
advantage of an improved resolution.
23.6
Graphic Display
ST1 ST2
71.2
OR of Alarms
Var. Sel. Stat.
Var. Sel. Stat.
Selected Station
ALARMS
PV of the
Selected Station
Requested
operating mode
Current operating modes
Station TAG
71.0 LOC
71.0 LOC
PV2
LSP
WSP
PV1
FORZAM
ALLARME 1 PV1
TRAKING ST1
ALLARME 2 PV1
HOLD ST1
ALLARME 3 PV2
YMAX ST1
ALLARME 4 PV2
YMIN ST1
ALLARME 5 PV3
TRAKING ST2
MV Station 1
PV1 Station 1
MV Station 2
PV1 Station 2
Aut/Man Station
MV Station 1
A
A
O=23
Aut/Man Station
O=47
LSP
HOLD ST2
ALLARME 7 PV4
YMAX ST2
ALLARME 8 PV4
YMIN ST2
MV STation 2
PV1
PV2
ST A-M 1
PV1
ALLARME 6 PV3
85.3
85.0
PV3
PV4
MV
PV1
LSP
200
W=1 min
-200
Out 35
208
PV1
PV2
ST A-M 2
85.3
85.0
PV3
PV4
MV
200
AL
OR of Forcing modes
AL
OR of Forcing modes
ALH
Alarm 1
ALH
Alarm 1
ALL
OR of Alarms
ALL
OR of Alarms
AUT
Aut/Man Station
AUT
Aut/Man Station
W=1 min
-200
Out 35
Annex A. - Resident Configurations
This configuration offers 5 display panels, providing a complete and optimal
operator interface.
The two bargraph panel provides a complete view of both the A/M stations, with
a fine level of details on the most important parameters. It provides the bargraph
indication of the outputs, plus the numeric indication, with large size digits, of the
variable of the selected A/M station.
You select the station by pressing the
key, as you do when you operate
with the configurations with multiple loops. The A/M station that has been
selected is highlighted by the fact that the tag is displayed in reverse.
The status of the alarms is flagged by the small box on the upper left part of the
panel. When an alarm or a forcing mode is activated, the box blinks
continuously, to alert the operator. Next, the operator can get a more detailed
view of the alarms, by looking at the ALLARMS panel.
Furthermore, a trend panel is available, for each of the A/M station. This page,
similar to the one used for loops, has a trend chart, with programmable time
width, that presents the recent trend profile of the MV output variable. At the top
of the panel the numeric indication, with large size digits, of the variable is
displayed, together with all the variables of the scroll list, related to the A/M
station.
23.7
Applications
The most common application of A/M station is when an actuator must be
driven, directly or in ratio, either of an input signal or the signal from another
actuator, leaving the possibility of performing manual or automatic forcing
operations.
One example is the control of the lower heating zone of a furnace, that must be
proportional to the heat demand of the upper zone. In this case, the PV1 input to
the A/M station is the control output of the actuator of the upper zone, that,
probably, is driven by a temperature PID loop. A ratio coefficient can be set in
the Constant module of the A/M station, in order to define the ratio value
between the level of outputs of the two actuators.
The Tracking forcing mode, that allows to bypass the normal way to control the
actuator from the upper one, by driving it directly from the external signal AI2, is
particularly useful for handling emergencies and start-ups.
ST
LOGIC
&
SHUTDOWN
TIC
TT
PT
TT
FUMES
209
Installation and User manual of the AC10 - AC20 - AC30 controller
23.8
Electrical Connections
The following picture provides a clear view of all the termination blocks, with the
associated functionality, and it is specific of this configuration. No signals must
be connected to the termination blocks not used by the strategy.
The termination blocks 25 and 26 are providing a 24V DC output, particularly
suitable to supply of the 2 wires transmitters.
PV1 input
A/M 1
Station
A/M 2
Station
PV2 / TRK
PV3 input
PV4 / TRK
1
25 +24
26 +24
2
3
4
5
6
A
N
A
L
O
G
7
8
I
9 N
P
10 U
T
11
LAN
A/M 1
Station
A/M 2
Station
210
Y Max
Y Min
HOLD
TRK
Y Max
Y Min
13
14
15 D
16 GI
17 I
T
18 A
L
19
20
Actuator 1
Station
Retra. PV2
A/M 1
Actuator 2
Station
Retra. PV4
A/M 2
33
34
D
I 35
G
I 36
T
A 37
L
38
12
HOLD
TRK
A 27
N
A 28
L
O 29
G
30
O
U 31
T
32
Al. 1
PV 1
Al. 2
Al. 3
PV 2
Al. 4
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Al. 5
PV 3
Al. 6
42
43
I
N
21 P
U
22 T
23
44
24
48
Al. 7
PV 4
Al. 8
46
POWER
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