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PPC-2000 User’s Guide Chapter 2: Hardware Installation
Doc.# 30002-00 Rev 2.3 Watlow Anafaze 35
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CAUTION!
Power, input or output circuits with hazardous voltage
levels should not have any live accessible parts.
Wiring Recommendations
Keep the following guidelines in mind when selecting wires and
cables:
• Use stranded wire. (Solid wire can be used for fixed
service; but it makes intermittent connections when you
move it for maintenance.)
• Use #20 AWG TC extension wire. Larger or smaller sizes
may be difficult to install, may break easily, or may cause
intermittent connections.
• Use shielded wire. (The electrical shield protects the
signals and the PPC-2000 from electrical noise.) Connect
only one end of the shield to earth ground.
• Use copper wire for all connections other than
thermocouple sensor inputs.
See Table 2.9 for cable recommendations.
Table 2.9 Cable Recommendations
Noise Suppression
The PPC-2000’s outputs are designed to drive resistive loads.
Open collector outputs can drive solid state relays. These relays
may in turn operate more inductive types of loads such as
Function Mfr. P/N
No. of
Wires
AWG
Gauge
Max.
Length
Analog Inputs
Belden #9154
Belden #8451
2
2
20
22
RTD Inputs
Belden #8772
Belden #9770
3
3
20
22
TC Inputs TC Ext. Wire 2 20
Digital PID Outputs
and Digital I/O
Belden #9539
Belden #9542
9
20
24
24
Analog Outputs
Belden #9154
Belden #8451
2
2
20
22
Computer
Communication:
RS232, RS422,
RS485, or 20mA
Belden #9729
Belden #9730
Belden #9842
Belden #9843
Belden #9184
4
6
4
6
4
24
24
24
24
22
4000 ft.
4000 ft.
6000 ft.
- 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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