FC SERIES COMPACT CONTROLLER™–Super (CC-S) (BASIC PID AND FREELY CONFIGURABLE, CONTINUOUS OUTPUT TYPE) DATA SHEET PNA3 The Compact Controller-S (Basic PID and freely configurable type) is a compact single-loop controller using a microprocessor. It receives proportional signals from e.g. thermocouples and RTD's etc., as input, and is equipped with abundant control and computation functions to allow configuring a flexible system with a high cost/performance, above all, as stated below: — FIELD CONFIGURABLE SLC — AUTO TUNING FUNCTIONS — RS-422A DATA LINKAGE as standard. FEATURES 1) Versatile functions • All closed loop control functions, such as cascade, ratio, time scheduling, Iogic control, etc. are performed in one controller. • 86 kinds of control functional blocks (Wafers). • Generic interface RS-422A availability for personal computer (e.g., IBM PC-AT) for supervision, operation, maintenance, configuration, etc. • Auto tuning capability. • Pass code security. 2) Simple and flexible • Basic PID control configuration can be programmed in less than 1 (one) minute from front panel. • No program loaders and accessories necessary. • No software programming knowledge necessary. • Application oriented control function is configurable by connecting the functional blocks. • Field configurable through front panel. • Front panel operation Operations such as parameter setting, auto/manual changeover, back-up manual operation etc. are all achieved from the front panel. 3) Highly reliable • Highly reliable with MTBF of 200,000 hr per MIL Standard 217D. • Hard manual back-up operation is available. At repair position (draw-out), control output is still working by "Hard manual back-up operation" (option). • LED's are used for bargraph and parameter indication. • Nonvolatile memory enables to retain parameters in case of power failure. 4) Update hardware technology • Custom LSI. • Surface mounting technology. SPECIFICATIONS 1. Control system configuration There are two methods of control system configuration for CC-S, one is configuration by basic PID and the other is by wafer connection. Various types of configuration examples are shown "Various configuration (page 5) examples" stated hereafter. (1) Configuration by basic PID (fixed configuration) Basic PID control function is fixedly defined as standard control function in the controller beforehand. Configuration of basic PID can be performed through simple operation on the front panel keys, where wafer connection mentioned below is unnecessary. Computation wafers such as square root, filter, Iimiter, non linear, etc. can be made valid or invalid by simple operation of front panel keys. EDS11-98f Date Nov. 18, 2002 PNA3 FUNCTIONAL DIAGRAM Personal computer PV Auxiliary analog input 1 (AI1) Auxiliary analog input 2 (AI2) Auxiliary analog input 3 (AI3) Process value input (PV) External set point input (CAS) 4 to 20mA thermocouple RTD conversion A/D converter SV Constant 1 Constant 32 SUB control block (cascade control, ratio control or time schedule control) Control wafer PV Auxiliary analog output 1 (A01) MAIn control block (basic control) Control wafer Compensated PV signal (KPV) D/A converter External input terminals Communication terminals Other controllers Bargraph indicator External output terminals Serial communication interface Set point transmit signal (SV) Control output (current) (MI+, MI–) MV SV Auxiliary digital input 1 (DI1) Auxiliary digital input 2 (DI2) Auxiliary digital input 3 (DI3) Pulse width input (PI+) Control output (voltage) (MV) Auxiliary digital output 1 (D01) Auxiliary digital output 2 (D02) High alarm (H) Low alarm (L) Manual mode output (M) Fault output (FLT) Computation wafer Manual Pulse width input (PI–) Manual mode command (SMV) Fault up to 24 or 48 wafers usable (2) Configuration by wafer connection (freely configurable) 1) Wafer The wafer is a functional block (software package) containing control and computation functions needed for measurement and control. Combination of these wafers, each having its own particular function, enables configuring a flexible system applicable to a wide range of control . . . from basic PID control up to sophisticated advanced control. The PNA3 can accommodate up to 24 or 48 wafers. The following kinds of wafers are prepared to allow selection according to the control purpose. ➀ For control ............... PID control, ratio control, time schedule control, gain schedule control, PID parameter setting ➁ For computation ...... Various computations performed by connecting wafers given in Table 1 2) Internal input/output terminals Various internal terminals are provided for external analog input/output, digital input/output and wafer connection. 2 FLT Indicator Alarm H Indicator L Indicator 3) Constants Various parameters used in computation and control can be freely defined (32 constants or 48 constants). The following control configuration are achieved. 4) Control functions By connecting wafers (functional blocks) Control examples: Cascade control, ratio control, time schedule control, gain schedule control, selective control, dead time compensation control etc. Alarm function: PV high/low alarm PV change rate alarm DV high/low alarm Configurable by wafer connection, front panel indicator lights up 2. Control performance • PID control: Proportional band (P); 1.0 to 3276.7% Integration time (I): 0.1 to 3276.7 sec. Derivative time (D): 0.0 to 900.0 sec. PID auto tuning function • Execution rate: Ten (10) times per second/basic PID control Five (5) times per second/others Table 1 List of computation wafers Kinds Wafer name Wafer name (2) Analog output signal: 4 points Kinds Compensated PV signal KPV SV Logical operation 6 Analog averaging 1 Set point transmit signal Arithmetic operation 5 Analog integration 1 MV Temperature/pressure compensation 1 Pulse generation 1 Manipulated output (Voltage) Aux. analog output AO1 Dead band 1 3/6 Pulse no. counter 1 Time schedule control 4 Pulse no. output 1 Flip-flop 1 Decoder 1 Pulse width integration 1 Moving average 2 Selector 1 Sample hold 1 Changeover 1 Dead time 6 Linearize Timer 1 ON-OFF 1 Absolute value/ sign inversion 1 Alarm 1 Square root extraction 1 Position type pulse width conversion 1 Lead, lag 1 Bargraph indication 21 Limiter 1 Gain schedule control 5 Ramp function 2 1 to 5V DC Output resistance 1Ω or less, allowable error ± 0.2%/FS* KPV, SV, and MV is usable as aux. analog output. (3) Digital output signal: 6 points Fault output FLT Manual mode output M High limit alarm output H Low limit alarm output L Aux. digital output DO1 Aux. digital output DO2 Open collector output (Photo-coupler isolation) Output rating 30V DC 0.1A max. H and L are usable as aux. digital output. 5. Internal data conversion (1) Analog data 3. Input signals Standard Minimum Maximum (1) Process value input signal: One input selectable from the following 0.00 to 100.00% –327.6% 327.67% Voltage input signal 1 to 5V DC Current input signal 4 to 20mA DC I+ I0 I– Thermocouple input Resistance bulb input Input resistance 1MΩ or more Allowable error ± 0.2%/FS* Allowable error ± 0.2%/FS* 24V ± 2V DC can be supplied to transmitter in case of AC power supply approx. 35mA max. 0.01% OFF (Contact open) 0.00% 6. Indication, setting, operation functions (1) Bargraph indication PV indicator SV indicator MV indicator Indication method LED (Red) LED (Green) LED (Red) No. of segments 101 + 2 101 + 2 51 + 2 Pt100Ω (0°C) –50 to 500°C 50°C span or more Allowable error ± 0.5%/FS* Range 0 to 100% linear 0 to 100% linear 0 to 100% linear Resolution 1%/FS* 1%/FS* 2%/FS* Scale length 100mm 100mm 50mm Indication mode 0 to 100% bargraph indication, 0 to 100% reverse bargraph indication, dot indication, –50 to +50% deviation indication CAS Aux. analog input AI1 Aux. analog input AI2 Aux. analog input AI3 four 1 to 5V DC inputs or two 4 to 20mA DC inputs plus two 1 to 5V DC inputs Input resistance 1MΩ or more, allowable error ± 0.2%/FS* Two transmitter power supply 24V ± 2V DC approx. 35mA max. CAS is usable as aux. analog input. (3) Digital input signal: 4 points Aux. digital input SMV Contact input (Photo-coupler isolation) DI1 Aux. digital input DI2 Aux. digital input DI3 ON 0V DC, OFF 24V DC (Input current approx. 11mA/24V DC) (4) Pulse width input signal: 1 set Pl+, PI– Data ON (Contact closed) 10mV DC span or more; cold junction compensation comprised Allowable error ± 0.5%/FS* External set point Pulse width input signal Signal status Types J : 0 to 600°C K : 0 to 1200°C E : 0 to 800°C R : 0 to 1600°C (2) Analog input signal: 4 points Manual mode command (2) Digital data Contact input (Photo-coupler isolation) ON 0V DC, OFF 24V DC (Input current approx. 11mA/24V DC) (2) Operation mode indication Indicating method: LED (red and green) Red; M, HM, SCC Green; A, R (3) Numerical indication, setting Indication method: LED (red), name in 3 digits + data in 5 digits (negative sign included) Indication contents: Process value (Industrial value), set point (Industrial value), alarm high/low limit values, PID parameters etc. Indication data are selectable by F/S , , keys on front panel. Setting method:By use of F/S , , , , ST keys on front panel. *Note: "FS" stands for "Full Scale". 4. Output signals (1) Control output signal: 1 point Current output MI+, MI– 4 to 20mA DC Allowable load resistance 600Ω or less, allowable error ± 0.2%/FS* 3 PNA3 (4) SV setting function Fixed value setting method: By , buttons on front panel. Setting speed; about 40 sec/FS Remote setting method: By external set point signal (Voltage or pulse width input) (5) MV operating function Manual operating method: By , , buttons on front panel. Setting speed; about 40 sec/FS About 8 sec/FS when pressed simultaneously. (6) Operation mode changeover By R/A/M pushbuttons and HM switch on front panel. R A changeover A R changeover Balanceless bumpless Voltage signal Balance bumpless Pulse width input Balanceless bumpless A or R M changeover Balanceless bumpless A or R HM changeover Balanceless bumpless A or R HM changeover Balance bumpless 7. Power failure and restart function Power failure detection: Control function interrupted at power failure detection. During power failure: Operating parameters backed up by capacitor when power failure within 5 minutes. Initial set point and control output values, PID parameters etc. are stored in nonvolatile memory (lasts for 10 years expected at ambient temperature of 50°C or less) Restart from power failure: Initial or continuous start is selectable for power failure within 5 minutes. Restart from power failure lasting longer than 5 minutes is made by initial automatically. Control mode at initial start is selectable from. R: Remote mode M: Manual mode A: Automatic mode SCC: SCC mode 9. Communication functions (1) Communication items Supervisory items: PNA host Process value, set point, control output, deviation, operation mode, alarm information, fault information. PID parameters, various limiter values, constants, etc. Setting items: Host PNA Set point, control output, operation mode, PID parameters, various limiter values, constants, etc. (2) Communication enable/inhibit: Data setting from the host can be enabled/inhibited by set keys on the front panel. (3) Communication interface (a) T-link: Private interface Transmission speed: 500Kbps No. of units connectable: 32 max. Transmission distance: 1km max. Transmission form: Multi-drop Control method: I/O transmission and message (b) RS-422A/485: Universal interface Transmission speed: 2400, 4800, 9600 or 19200bps configurable No. of units connectable: 31 max. Transmission distance: 1km max. Transmission form: Multi-drop Control method: Polling/selecting 10. Personal computer software packages Two software packages, running on IBM PC-AT, are provided for CC-S supervision, operation, maintenance and configuration. They are FIX/D MACS software package and CC-S configurator. FIX/D MACS is a user-configurable, menu-driven software packages for CC-S supervision, operation and maintenance, while CC-S configurator is another package to configure CC-S control system. E.g. Real time process display Process alarming Trending Control strategy configuration FIX/D MACS is a trade mark of Intellution Inc./U.S.A. Standard software packages for plant supervision, operation and maintenance are available under Fix: 11. Security functions 8. Self-diagnosis functions Computation/control function failure: FLT indicator lights up, FLT contact output closes, and computation and control function interrupted. Manipulated output can be controlled manually at FLT (Soft manual). Input signal and control output failure: FLT indicator lights up, FLT contact output closes, control stops, and control output is held, while other computation and control functions continue to be processed. Fault indication: Cause of fault is indicated numerically on digital indicator of front panel. 4 Data security function by means of pass code. 12. Back-up manual functions Hard manual back-up unit (HMV) Control output: 4 to 20mA DC Allowable load resistance: 600Ω or less 13. Operating conditions Supply voltage: 24V DC (20 to 30V DC), 110V AC (85 to 132V AC), 220V AC (187 to 264V AC) Power consumption: Approx. 13W (DC), 20VA (AC) Power factor: approx. 0.6 Dielectric strength: 1500V AC for 1 minute Insulation resistance: 100MΩ or more at 500V DC Ambient temperature: 0 to 50°C CODE SYMBOLS Ambient humidity: 90%RH or less Enclosure: Steel case Enclosure class: Front IP65 (IEC 529) Rating plate (Name plate): 10(H) x 70(W), white acrylic Dimensions: 144(H) x 72(W) x 407 (D)mm, IEC 668 (DIN) standards Mass{weight}: Approx. 2.9kg Mounting method: Flush with indoor panel; vertical mounting is standard. Mounting on tilted surface possible (Angle α) 1 2 3 4 5 6 7 8 9 10 11 12 5 - PNA 3 Description A Process variable input signal 1 to 5V DC 4 to 20mA DC J thermocouple 10mV DC span or K thermocouple more, with referE thermocouple ence junction comR thermocouple pensating function Resistance bulb Pt100Ω 3-wire type, 50°C span or more A B C D E F G Auxiliary analog input Four 1 to 5V DC inputs Two 4 to 20mA DC with 24V DC power supply plus two 1 to 5V DC inputs B C Supply voltage 24V DC (20 to 30V DC) 110V AC (85 to 132V AC) 50/60Hz 220V AC (187 to 264V AC) 50/60Hz Hard manual back-up unit Without With 1 2 3 α=0° to 90° 0 1 Finish color: Munsell N1.5 Scope of delivery: Controller and mounting bracket. Item to be ordered separately: Communication cable (Type PNZ) Terminal resistor (Type PNY) Comunication interface Without T-link RS-422A RS-485 Y T R S Available wafer numbers 24 wafers 48 wafers 0 2 A PID auto tuning function With Note: Front scale and temperature range are to be selected and specified from the "STANDARD FRONT SCALE" and "STANDARD TEMPERATURE RANGE" stated hereafter, when order being placed. VARIOUS CONFIGURATION EXAMPLES Basic PID control (fixed configuration) Basic PID control function is fixedly defined as standard control function in the controller beforehand. Configuration of basic PID can be performed through simple operation on the front panel keys, where wafer connection is unnecessary. Computation functions such as square root, filter, limiter, non linear, etc. can be made valid or invalid by simple operation of front panel keys. PID control PID control is carried out by using only the MAln control block. PID control by means of an external set point is also performed. Feed-forward input Feed-forward computation Process variable External set point Filter MH P I D R SH H SL ML R.A L A.M Non-linear PV tracking command External MV input External MV command Process variable Filter PH PL External set point R SH SL A.M MV output M DV H Non-linear MH P I D ML R.A M MV output L DV MAIn control block (MAIn PID) 5 PNA3 Cascade control Cascade control is carried out by combining two PID control blocks. Since the output of the SUB PID controller follow up the set point of the MAln PID controller, A and R can be changed over balancelessly. Process variable for MAIn PID SV Process variable for SUB PID Filter INT Filter Process variable for SUB PID Filter PV SV PV-B1 SH MAIn PID R.A R SH X M SL EXT MV output A.M SV+B3 SL Process variable for MAIn PID INT R B2 PV Filter MAIn PID SV R.A Time schedule pattern Output Stop command STOP M R 7 segments MV output A.M PRESET Preset command Time Process variable for MAIn PID PV SV Filter MAIn PID P External set point R SH SL Adaptability reference 6 A.M In auto or manual, SUB PID traces the set point of MAIn PID. X Gain schedule control Carries out PID control according to three (3) PID parameter patterns, which are stored in the form of 7 segmented lines. R SH EXT SH Process variable for MAIn PID External set point MV output SUB PID SL SL Time schedule control By combining a time schedule block and a PID control block, the set point is decided according to a time schedule pattern. A preset function is also provided for starting time schedule control from the present temperature in a furnace for control of heating or the like. MAIn PID M External set point Ratio control Ratio control is carried out by combining a ratio computation and a PID control block. R.A PV Filter A.M P I D I D R.A M MV output Feed forward control By applying a suitable gain to an external interfering signal and adding it to the PID computation output, the effect of external interference can be eliminated. External interference Filter PH Gain Process variable Filter H External set point R SH Non-linear SL Dead time compensating control (Smith method) When the process includes some dead time, a compensating function can be added to eliminate the effect of the dead time. The Smith method is effective when the process characteristics are clearly known. SL ML L PH PL CON R.A MH Process variable Filter H R SH Process variable 1 (A11) Non-linear P I D DV H P I D L H DV H MAIn SV M MV output P I D L DV Valve reverse characteristic Valve characteristic Filter H R R.A MH SL ML Filter SH MV output M A.M SUB SV Process variable SL ML L Filter Process variable 2 (PV) MV output M DV X External set point R.A MH e –LS SL PID with valve compensating function When the relation between the output signal (MV) for a valve and the valve opening is not linear, control can be made by compensating the valve characteristics. P I D A.M 1 1+Ts External set point Selective control (auto selector) PID control is carried out using the process variables at two measuring points. In this example, output of the larger one of the PID computation results is selected. X CON PL L P I D MH SL ML R.A M MV output DV SL A.M 7 PNA3 STANDARD TEMPERATURE RANGE STANDARD SCALE Followings are standard input temperature ranges to be selected and to be specified with the ordering code. Followings are standard scales to be selected and to be specified with the ordering code. On condition that PV and SV are of the same scale each other, following standard scale plates are prepared as standard. Detector Measurement range J type thermocouple 0 to 200, 0 to 300, 0 to 400, 0 to 500, 0 to 600, 200 to 400, 300 to 600 deg C K type thermocouple 0 to 300, 0 to 400, 0 to 500, 0 to 600, 0 to 800, 0 to 1000, 0 to 1200, 300 to 600, 400 to 800, 500 to 1000, 600 to 1200 deg C E type thermocouple 0 to 200, 0 to 300, 0 to 400, 0 to 500, 0 to 600, 0 to 800, 200 to 400, 300 to 600 deg C R type thermocouple 0 to 1000, 0 to1200, 0 to 1600, 400 to 1400, 600 to 1600, 800 to 1600 deg C Platinum resistor temperature detector 0 to 50, 0 to 100, 0 to 150, 0 to 200, 0 to 300, 0 to 400, 100 to 300, 200 to 400, –50 to 100, –50 to 500 deg C Note: The underlined temperature range will be selected and delivered, when input temperature range is not specified in the ordering code. OUTLINE DIAGRAM Detector PV and SV scale J type thermocouple 0 to200, 0 to300, 0 to 400, 0 to500, 0 to 600, 200 to 400, 300 to 600 deg C, 0 to 100% K type thermocouple 0 to 300, 0 to 400, 0 to 500, 0 to 600, 0 to 800, 0 to 1000, 0 to 1200, 300 to 600, 400 to 800, 500 to 1000, 600 to 1200 deg C, 0 to 100% E type thermocouple 0 to 200, 0 to 300, 0 to 400, 0 to 500, 0 to 600, 0 to 800, 200 to 400, 300 to 600 deg C 0 to 100% R type thermocouple O to l000, 0 to 1200, 0 to 1600, 400 to 1400, 600 to 1600, 800 to 1600 deg C, 0 to 100% Platinum resistor temperature detector 0 to 50, 0 to 100, 0 to 150, 0 to 200, 0 to 300, 0 to 400, 100 to 300, 200 to 400, –50 to 100, –50 to 500 deg C, 0 to 100% 1 to 5 VDC input 0 0 0 0 MV 0 to 100% to to to to 10, 0 to 20, 0 to 30, 0 to 40, 0 to 50, 60, 0 to 80, 0 to 100, 0 to 200, 0 to 300, 400, 0 to 500, 0 to 600, 0 to 800, 1000 unit. 0 to 100% (Unit:mm) Panel thickness 8mm or less 16 144 Terminals 52 Mounting bracket 200min. Supporting bracket 72 355 Panel cutout When mounting "n" units +1 0 138 138 +1 0 200min. 250min. When mounting one unit 68 +0.7 0 8 (72.2n – 4) +1 0 No. of units n 2 EXTERNAL CONNECTION DIAGRAM Compression terminal AI (External set point) AI (Aux. analog input) AI (Aux. analog input) AI (Aux. analog input) AO (Manipulated output) 01 CAS 1+ 31 02 AI1 Io 32 03 AI2 I– 33 04 AI3 KPV 34 05 MV SV 35 AO1 36 06 AI (Indicating input 2) AO (Compensated PV signal) AO (Set point transmit signal) AO (Aux. analog output) 07 SC SC 37 08 SC SC 38 09 SO1 SO2 39 10 IR1 IR2 40 11 IO1 IO2 41 12 MI+ SMV 42 – 13 MI– DI1 43 + 14 PI+ DI2 44 15 PI– DI3 45 16 H DO2 46 17 L DO1 47 AI, AO Common bus AI, AO Common bus 1 to 5VDC signal output – + DC power for Transmitter + AO (current) (Control output) DI (Pulse width input) DO (High-limit alarm output) DO (Low limit alarm output) DO (FLT output) 1 to 5VDC signal output – + 18 FLT M 48 24VDC power for DI, DO – 19 PCD VPO 49 24VDC power for DI, DO – 20 PCD VPD 50 + Instrument power (24VDC) – 21 PC* VP* 51 + G AC AC 71 72 DC power for Transmitter DO (Manual mode command) DI (Aux. digital output) DI (Aux. digital output) DI (Aux. digital output) DO (Aux. digital output) DO (Aux. digital output) DO (Manual mode) + 24VDC power for DI, DO Instrument power (24VDC) 73 Ground Power supply (AC) Power supply (AC) Note*: Incase of AC instrument power supply, approximately 24V DC (0.1A max.)is supplied as VPO and PCO for hard manual backup unit. Process value input terminals connections 1 to 5V DC + The 5th digit of code symbols: B 4 to 20mA DC with inner DC power supply of CC-S The 5th digit of code symbols: B The 5th digit of code symbols: C,D,E,F 32 The 5th digit of code symbols: A 4 to 20mA DC Thermocouple 31 + – 33 + 31 + 31 – – 33 + 31 – 33 32 Resistance bulb The 5th digit of code symbols: G 32 – + – 33 + 31 – 33 32 + – 32 PC 21 9 PNA3 COMMUNICATION CONNECTOR 1 6 SIG GND 2 SHLD(SD) 7 8 RXD+ 9 RXD– 3 INH 4 TXD+(T1) 1 6 SIG GND 2 SHLD(SD) Black 7 White 8 RXD+ 9 RXD– 5 TXD–(T2) 3 INH 4 TXD+(T1) 5 TXD–(T2) Note:Symbol in ( ): T-link terminal symbol Yellow Green Brown Red 6 7 8 RXD+ 9 RXD– LINE TERMINATION RESISTOR 1 SIG GND 2 SHLD(SD) 7 3 INH 4 TXD+(T1) 5 TXD–(T2) 1 6 8 RXD+ 9 RXD– SIG GND 2 SHLD(SD) Black 3 INH White 4 TXD+(T1) 5 TXD–(T2) Green Yellow Red Brown End station HOST e.g. IBM PC-AT First station Host e.g. IBM PC-AT Termination Resistor Communication cable PNA3 PNA3 PNA3 PNA3 Caution on Safety *Before using this product, be sure to read its instruction manual in advance. Head Office 6-17, Sanbancho, Chiyoda-ku, Tokyo 102-0075, Japan http://www.fesys.co.jp/eng Sales Div. International Sales Dept. No.1, Fuji-machi, Hino-city, Tokyo, 191-8502 Japan Phone: 81-42-585-6201, 6202 Fax: 81-42-585-6187 http: //www.fic-net.jp/eng Information in this catalog is subject to change without notice. Printed in Japan