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Chapter 1: System Overview CPC400 Series User’s Guide
4 Watlow Anafaze Doc. 0600-2900-2000
•
Keypad or Computer Operation:
Set up and run
the controller from the keypad or from a local or re-
mote computer. Use WATVIEW HMI software to set
up the controller, manage jobs (recipes), log data or
monitor system performance.
•
Modbus RTU Protocol, EIA/TIA-232 and 485
Communications:
Connect operator interface termi-
nals and third-party software packages using the
widely supported Modbus RTU protocol.
•
Multiple Job Storage:
Store up to eight jobs in the
controller’s battery-backed memory. Load a job
through the keypad, digital inputs or software. Each
job is a set of operating conditions, including set points
and alarm limits.
•
Nonlinear Output Curves:
Select either of two non-
linear output curves for each control output.
•
Pulse Input:
Use the pulse input for precise control of
motor or belt speed.
•
Low Power Shutdown:
The controller shuts down
and turns off all outputs when it detects the input volt-
age drop below the minimum safe operating level.
•
Process Variable Retransmit:
Scale a temperature
or process and convert it to an analog output for exter-
nal devices such as chart recorders.
•
Two-Zone Cascade Control:
Control thermal sys-
tems with long lag times, which cannot be accurately
controlled with a single loop.
•
Ratio or Offset Control:
Control one process as a ra-
tio or offset of another process.
•
Remote Analog Set Point:
Scale an external voltage
or current source to provide a set point for a loop.
CPC400 Parts List
You may have received one or more of the following compo-
nents. See
Figure 2.1 on page 12
for CPC400 configuration
information.
• CPC400 series controller
• Controller mounting kit
• TB50 with 50-pin SCSI cable
• EIA/TIA-232 or EIA/TIA-485 communications cable
• Power supply with mounting bracket and screws
• Serial DAC (digital-to-analog converter)
• Special input resistors (installed in CPC400)
• User’s guide
- CPC400 Series 1
- User’s Guide 1
- Warranty 2
- Table of Contents 3
- List of Figures 7
- 7 Specifications 165 9
- List of Tables 11
- Values for BCD Job Load 12
- System Overview 15
- Getting Started 16
- Product Features 16
- CPC400 Parts List 18
- 40 _ -1 _ _ _ _ _ _ 19
- Technical Description 20
- CPCSI _ _ - _ _ - _ _ 20
- Front Panel Description 21
- Figure 1.4 CPC400 Front Panel 21
- CPC400 Cabling 22
- External Safety Devices 23
- Power-Fail Protection 24
- Installation 25
- Typical Installation 26
- Recommended Tools 27
- Mounting the Controller 27
- Figure 2.3 Wiring Clearances 28
- Figure 2.4 Mounting Bracket 29
- Mounting the TB50 30
- Mounting with Standoffs 31
- Mounting the Power Supply 32
- Mounting 33
- System Wiring 34
- Noise Suppression 35
- Avoiding Noise 36
- Power Connections 37
- Wiring the Power Supply 38
- Testing the System 40
- Sensor Wiring 41
- Input Wiring Recommendations 42
- Thermocouple Connections 42
- RTD Input Connections 43
- Reference Voltage Terminals 44
- Voltage Input Connections 44
- Current Input Connections 44
- Pulse Input Connections 45
- Output Wiring Recommendations 46
- Cable Tie Wraps 46
- Digital Outputs 46
- Stored in the Controller 47
- Configuring Outputs 48
- Digital Inputs 50
- TB18 Connections 51
- TB50 Connections 52
- Wiring the Serial DAC 54
- Serial Communications 55
- EIA/TIA-485 Interface 57
- Cable Recommendations 58
- Connections 58
- Signal Common 59
- Termination 59
- Operation and Setup 61
- General Navigation Map 62
- Figure 3.2 Keypad Navigation 63
- Displays 64
- Alarm Displays 65
- How to Acknowledge an Alarm 66
- System Alarm Messages 66
- Job Display 67
- Changing the Set Point 68
- How to Access the Setup Menus 70
- How to Edit a Setup Parameter 70
- Feedback 71
- Control Algorithm 71
- TRU-TUNE+™ 71
- Control Output Signal Forms 71
- Heat and Cool Outputs 71
- Input Scaling 72
- Figure 3.6 Input Scaling 73
- Situation 73
- (dc) Sensor 74
- Table 3.7 Scaling Values 75
- Autotuning 76
- Setting Up Alarms 77
- Thermocouple Open Alarm 78
- Thermocouple Reversed Alarm 78
- Alarm High and Alarm Low 80
- Deviation Alarms 80
- Global Alarm 81
- Variable Retransmit 82
- Setting Up Cascade Control 83
- Loop Has Heat Output Only 84
- How To Set Up Cascade Control 85
- Setting Up Ratio Control 87
- How to Set Up Ratio Control 88
- Loop (Loop 2) in the Example 89
- Loop (Loop 2) for the Example 90
- Loop (Loop 1) in the Example 91
- Non-Numeric Settings 92
- Bit-Wise Values 92
- Tuning and Control 95
- On/Off Control 96
- Proportional Control (P) 96
- Proportional 97
- Manually Tuning PID Loops 99
- Derivative Settings 100
- Proportional Band Only (P) 101
- Control Outputs 102
- Output Filter 103
- Reverse and Direct Action 104
- Menu and Parameter Reference 105
- Operator Parameters 106
- Heat/Cool Output 107
- Process Variable 107
- Overview of the Setup Menus 108
- >< 109
- Global Setup Menu 110
- BCD Job Load 111
- BCD Job Load Logic 112
- Mode Override 113
- Logic Program 113
- Power Up Alarm Delay 114
- Power Up Loop Mode 114
- Power Up With Logic 114
- Keypad Lock 115
- Thermocouple Short Alarm 115
- Controller Address 115
- Communications Baud Rate 116
- Communications Parity 116
- AC Line Frequency 116
- Digital Output Alarm Polarity 117
- Model and Firmware Version 117
- Input Menu 118
- Input Units 119
- Input Pulse Sample 119
- Calibration Offset 119
- Display Format 120
- Input Range High 121
- Input High Signal 121
- Input Range Low 122
- Input Low Signal 122
- Channel Menu 123
- PV Source 124
- Control Menu 125
- Heat/Cool Integral 126
- Heat/Cool Derivative 126
- Heat/Cool Manual Reset 126
- Heat/Cool Filter 127
- Hysteresis 127
- Restore Automatic Mode 128
- Tune Band 128
- Tune Gain 128
- Overshoot Reduction 129
- Control Type 129
- Output Menu 130
- Heat/Cool Cycle Time 131
- Heat/Cool SDAC Signal 131
- Heat/Cool SDAC Low Signal 131
- Heat/Cool SDAC High Signal 132
- Heat/Cool Action 132
- Heat/Cool Power Limit 132
- Heat/Cool Power Limit Time 133
- Sensor Fail Heat/Cool Output 133
- Heat/Cool Output Curve 134
- Alarms Menu 135
- Alarm High Function 136
- Alarm High Output 136
- High Deviation Value 136
- High Deviation Function 137
- High Deviation Output 137
- Low Deviation Value 137
- Low Deviation Function 137
- Low Deviation Output 137
- Alarm Low Set Point 138
- Alarm Low Function 138
- Alarm Low Output 138
- Alarm Hysteresis 138
- Alarm Delay 139
- Heat/Cool Output Retransmit 140
- Cascade Menu 141
- Ratio Menu 142
- Ratio Low Set Point 143
- Ratio High Set Point 143
- Control Ratio 143
- Soft Integers Menu 144
- Soft Booleans Menu 145
- I/O Tests Menu 145
- Keypad Test 146
- Test Digital Output 1 to 35 146
- Alarm Acknowledge 146
- Alarm Enable 147
- Alarm Function 147
- Alarm Status 148
- Ambient Sensor Reading 148
- Analog Input 148
- Data Changed Register 149
- Firmware Identification 149
- Firmware Version 149
- System Status 150
- Full Scale Calibration 150
- Zero Calibration 151
- When There is a Problem 153
- Returning a Unit 154
- Process Alarms 155
- Failed Sensor Alarms 156
- System Alarms 157
- Other Behaviors 157
- Low Power 159
- Battery Dead 159
- Ambient Warning 160
- H/W Failure: Gain or Offset 160
- H/W Failure: Ambient 160
- Keys Do Not Work 161
- Checking Analog Inputs 162
- Earth Grounding 163
- Checking Control Outputs 164
- Testing the TB18 and TB50 164
- Testing Digital Inputs 165
- Computer Problems 166
- Communications 166
- Clearing the RAM 167
- CAUTION! 168
- Installing Scaling Resistors 171
- Input Circuit 172
- Current Inputs 173
- Voltage Inputs 174
- RTD Inputs 175
- SERIAL DAC 176
- Configuring Dual DAC Outputs 177
- DUAL DAC 177
- Specifications 179
- Table 7.3 Physical Dimensions 180
- SCSI Cable 181
- TB50 Physical Specifications 182
- Figure 7.4 TB50 Dimensions 183
- Table 7.8 TB50 Connections 183
- Table 7.11 Analog Inputs 186
- Table 7.12 Pulse Inputs 186
- Table 7.13 Programmable Logic 187
- Resolution 187
- Table 7.17 Digital Inputs 188
- Analog Outputs 188
- CPC400 Power Supply 190
- Dual DAC Specifications 192
- Dual DAC Inputs 193
- Serial DAC Specifications 194
- Serial DAC Inputs 195
- Serial DAC Analog Outputs 196
- Appendix A: Modbus Protocol 197
- Response 198
- Modbus ASCII and RTU Modes 199
- Message Framing 199
- Address Field 200
- Function Field 200
- Data Field 201
- Error Checking Field 201
- Error Checking Methods 202
- CRC Checking 203
- Function Codes 204
- Force Single Coil 05 205
- Preset Single Register 06 205
- Diagnostics 08 205
- Force Multiple Coils 15 206
- Examples 207
- Write Examples 208
- Glossary 209
- — A standard for interface 210
- — A power 213
- 53, 146 217
- Parameter Address Reference 223
- Input (page 104) 224
- Channel (page 109) 224
- Control (page 111) 224
- Output (page 116) 225
- Alarms (page 121) 226
- Firmware Version (page 135) 228
- Declaration of Conformity 229
- Menu Structure 230
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