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Doc.# 30002-00 Rev 2.3 Watlow Anafaze 141
4
Troubleshooting
This chapter describes troubleshooting methods and fault
indicators that may be useful if you experience difficulties with
your PPC-2000 system. Appropriate remedial procedures are
detailed below.
General Description
The following LEDs light for status or diagnostic purposes:
• Green: Function operational, communications status (tx)
• Red: Fault
• Yellow: Communication status (rx)
• Orange: Processor reset due to low power condition or
watchdog timeout
PPC-2010 Processor
The processor provides a System OK circuit for monitoring
program and microcontroller integrity. The output of the
watchdog timer is available through the 50 pin I/O header on
the processor board. This is an open collector type output (up to
100mA) and will sink current to common when the processor is
operating properly. An open circuit indicates a processor
failure and remains open until proper operation is established.
- PPC-2000 1
- User’s Guide 1
- PPC-2000 Adaptive Control 3
- Addendum 3
- Adaptive Mode 4
- Plant Delay 4
- Using Adaptive Control 5
- PPC-2000 User's Guide 7
- Warranty 8
- Table of Contents 9
- Operating with AnaWin3 89 11
- Troubleshooting 141 12
- List of Figures 15
- List of Tables 19
- Tuning and Control 219 21
- Specifications 229 21
- Overview 25
- Getting Started 26
- Product Features 27
- System Components 27
- Figure 1.1 System Diagram 28
- Peripheral Modules 29
- PPC-2000 Modules 30
- PPC-2000 Terminal Boards 32
- Additional Components 33
- External Safety Devices 34
- External Switch Disconnect 35
- Battery Safety 35
- Hardware Installation 37
- Requirements at 12Vdc 38
- Mounting the Power Supply 39
- Dimensions 40
- Hardware Configuration 41
- PPC-2010 Jumper Settings 42
- Figure 2.4 PPC-2010 Jumpers 43
- PPC-2030 Jumper Settings 44
- PPC-2040 Jumper Settings 45
- PPC-205x Jumper Settings 46
- Figure 2.7 PPC-205x Jumpers 47
- Module Assembly 48
- Module Disassembly 50
- Mounting Modules 50
- DIN Rail Mounting 51
- Mounting Terminal Boards 52
- 5.756" 53
- (146 mm) 53
- DIN Rail Removal 56
- Panel Mounting 57
- Mounting an SDAC Module 58
- System Wiring 58
- Wiring Recommendations 59
- Noise Suppression 59
- Symptoms of RFI/EMI 60
- Avoiding Noise Problems 60
- Avoiding Ground Loops 61
- TB50 Connections 62
- Module I/O Number 63
- TB-50 63
- Terminal 63
- (Dig I/O Spreadsheet) 63
- Connecting Digital Inputs 64
- SDAC Connections 67
- Multiple SDAC Systems 68
- PPC-2021 — 2025 69
- Sensor Keys 70
- AITB Connections 71
- Connecting Thermocouples 73
- Connecting RTDs 74
- 1A and 1B. See Figure 2.34 75
- Differential Inputs 1 and 2 76
- Single-ended Inputs 1 and 2 77
- Differential Input Module: 77
- Input 1, 2, and 3 Shown 77
- Single-ended Analog Input 78
- Module: Input 1 and 2 Shown 78
- J4 J3 J2 J1 79
- EITB Connections 80
- Encoder Wiring 81
- 2 (input 1 phase 1+) 82
- 4 (input 1 phase 2+) 82
- 8 (input 2 phase 1+) 82
- 10 (input 2 phase 2+) 82
- 12 (COM) 82
- Analog Output Connections 84
- P PC-2030 85
- 4-20mAdc 85
- 1 (input 1 phase 1+) 89
- 2 (input 1 phase 2+) 89
- 3 (input 2 phase 1+) 89
- 4 (input 2 phase 2+) 89
- 37 (COM) 89
- PPC supply 90
- Supplies 90
- Analog Out Module 91
- Outputs 1 and 2 Shown 92
- PPC-206x 94
- (bottom view) 98
- Input 1 Shown 100
- PPC-207x Modules 100
- Connecting Power 101
- Communication Ports 102
- Communication Cables 103
- Connections 104
- Connectors 104
- Computer Using RS-232 105
- Computer Using RS-485 105
- Figure 2.71 RS-485 Wiring 106
- 485 Terminal Block 106
- Cable Recommendations 107
- RS-485 Network Connections 107
- Cable Runs 108
- Signal Common 109
- Termination 109
- Modbus Network Address 110
- WARNING! 111
- Operating with AnaWin3 113
- Feedback 114
- Control Algorithm 114
- Heat and Cool Outputs 114
- Setting up Control Channels 116
- Autotuning 117
- Tuning Method 118
- Using 118
- to Tune 118
- Failed Sensor Alarms 119
- Global Alarm 119
- Process Alarms 119
- Alarm Delay 120
- Setting Engineering Units 123
- Setting PV Lo and PV Hi 123
- Setting Decimal Places 124
- Linear Input Example 125
- Input Example 125
- Process Variable Retransmit 126
- Variable Retransmit 128
- Settings 128
- Cascade Control 129
- Setting up Cascade Control 130
- Cascade Control Example 130
- Cascade Control 131
- Ratio Control 133
- Setting up Ratio Control 134
- Ratio Control Example 135
- Differential Control 136
- Remote Set Point 136
- Logic Programs 136
- CAUTION! 138
- Controller Parameters 139
- Control Type Description 142
- Alarms 149
- Inputs 153
- PPC1:AI 1.3 153
- PPC1:Proc 154
- PPC1:Soft Input1 154
- PPC1:Channel 1 Output 155
- Table 3.15 Input Types 156
- Table 3.16 Units 157
- Digital I/O 158
- PPC1:Proc 0.0.2 159
- PPC1: DO 41.2 159
- Digital I/O Spreadsheet 160
- Table 3.18 Function Values 160
- Outputs 161
- PPC1:EIAO. 11. 3. 2 161
- Soft Integer 162
- Soft Boolean 163
- PPC Globals 164
- Table 3.20 System Status 165
- Table 3.21 Global Settings 165
- Troubleshooting 167
- Flash Memory 170
- Chip (firmware) 170
- Processor Module LEDs 173
- PPC-2040 Digital I/O 177
- PPC-2050 Analog Out 178
- PPC-206x Digital Out 179
- PPC-207x Digital In 179
- Digital Inputs and Outputs 180
- Process Variable 180
- Communications 181
- Disabling Control 183
- LogicPro and Modbus Reference 185
- The PPC-2000 Database 186
- Data Table Organization 187
- Database 189
- PPC-202x Modules 190
- Table 5.8 on page 168 191
- Inputs on page 127 191
- Encoder_Analog_2030 191
- IO Driver 191
- Database IO Driver 191
- PPC-2010 Processor Module 192
- Channel Outputs 192
- PPC-2040 Digital I/O Modules 193
- Table 5.8 Input Parameters 194
- Table 5.9 Input Status 195
- Table 5.10 Input Types 196
- Value Temperature Scale 197
- LogicPro 199
- Table 5.12 Channel Parameters 200
- Table 5.28 on page 190 201
- PPC-2030 Modules 203
- PPC-2040 Modules 205
- Table 5.18 Control Mode 206
- Table 5.19 Control Types 207
- Table 5.20 Output Types 209
- Table 5.21 Heat/Cool Curve 210
- (AnaWin3 Dig I/O Spreadsheet) 214
- Boolean and Soft Integers 218
- Table 5.28 Alarm Status 218
- Table 5.31 Alarm Acknowledge 220
- Alarm Deadband 221
- State and Logic 223
- PPC-206x Digital Out Modules 226
- PPC-207x Digital In Modules 227
- Digital I/O Uses 227
- Digital I/O Parameters 228
- Table 5.39 State and Logic 229
- Table 5.40 Direction 229
- Table 5.41 Logic 229
- Outputs on page 231
- Database IO Driver 231
- Analog Output Value 232
- Table 5.50 Baud Rate 236
- Table 5.52 237
- Table 5.54 237
- Zero Reference 238
- Table 5.56 Modules Present 239
- Table 5.57 Module Types 240
- Table 5.58 System Commands 241
- Table 5.59 System Status 242
- Table 5.60 System Status Bits 242
- Database Offset Description 243
- Table 5.62 System Error Log 245
- Description Range 246
- Tuning and Control 247
- Control Algorithms 248
- Proportional Control 249
- Derivative Control 251
- Control Outputs 252
- Output Filter 253
- Integral Settings 254
- Derivative Settings 255
- Proportional Band Only (P) 256
- PI with Derivative (PID) 256
- Specifications 257
- Physical Specifications 258
- Power Specifications 258
- Table 7.3 Model Number 260
- Table 7.6 Connections 261
- Table 7.13 Serial Interface 263
- Isolation Specifications 264
- Table 7.14 Model Numbers 265
- Table 7.17 Connections 265
- *Not applicable to PPC-2022 266
- PPC-2030 268
- Table 7.22 Model Number 269
- Table 7.25 Connections 270
- Table 7.30 Model Number 272
- Table 7.33 Connections 273
- Table 7.38 Model Number 276
- Table 7.41 Connections 277
- Table 7.45 Model Number 279
- Table 7.47 Connections 279
- 24Vac or 24Vdc signals 281
- Table 7.51 Model Number 282
- Table 7.54 Connections 283
- Table 7.55 Power 283
- Table 7.59 Connections 285
- SCSI Cable 285
- Watlow Anafaze 1997 286
- PPC-EITB Component Side 286
- Table 7.64 Connections 287
- Table 7.69 Connections 290
- Straight SCSI Cable 290
- Right-Angle SCSI Cable 291
- Figure 7.22 PPC-IPS-2 292
- SDAC Specifications 293
- Analog Outputs 295
- Appendix A: Modbus Protocol 297
- Response 298
- Modbus ASCII and RTU Modes 299
- Message Framing 299
- Address Field 300
- Function Field 300
- Data Field 301
- Error Checking Field 301
- Field Format 301
- Error Checking Methods 302
- CRC Checking 303
- Function Codes 304
- Diagnostics (08) 305
- 11 (0B Hex) 306
- Examples 308
- Write Examples 309
- Declaration of Conformity 312
- Glossary 313
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