SIMATIC S5 and S7 IP244 Temperature Controller with Function Block FB 162 Manual Notes for the Reader 1 IP 244 (-3AA22) Temperature Controller Instructions 2 IP 244 B (-3AB31) Temperature Controller Instructions 3 IP 244 Programming Instructions 4 FB 162 (64 Messages) Programming Instructions 5 Test Program with FB 162 Utilization in S5 6 IP 244 Utilization in S7-400 7 IP 244 Checklist for Start-Up 8 Glossary 9 Index C79000-G8576-C858-02 10 SIMATIC and SINEC are registered trademarks of SIEMENS AG. Safety guidelines This manual contains notices which you should observe to ensure your own personal safety, as well as to protect the product and connected equipment. These notices are highlighted in the manual by a warning triangle and are marked as follows according to the level of danger: ! Gefahr ! Warnung ! Vorsicht indicates that death, severe personal injury or substantial property damage will result if proper precautions are not taken. indicates that death, severe personal injury or substantial property damage can result if proper precautions are not taken. indicates that minor personal injury or property damage can result if proper precautions are not taken. Hinweis draws your attention to particularly important information on the product, handling the product or to a particular part of the documentation. Qualified personnel Only qualified personnel should be allowed to install and work on this equipment. Qualified persons are defined as persons who are authorized to commission, to ground and to tag equipment, systems and circuits in accordance with established safety practices and standards. Correct usage Note the following: ! Warnung This device may only be used for the applications described in the catalog or technical description, and only in connection with devices or components from other manufacturers which have been approved or recommended by Siemens. This product can only function correctly and safely if it is transported, stored and set up carefully and correctly, and operated and maintained as recommended. Copyright Siemens AG 1995 All Rights Reserved Disclaimer of Liability The reproduction, transmission, or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved. We have checked the contents of this manual for agreement with the hardware and software described. Since deviations cannot be precluded entirely, we cannot guarantee full agreement. However, the data in this manual are reviewed regularly and any necessary corrections included in subsequent editions. Suggestions for improvement are welcomed. Siemens AG 1995 Technical data subject to change. 6ES5998-2AB24 SIMATIC S5 IP 244 Temperature Controller 6ES52443AA22, 6ES52443AB31 Notes for the Reader C79000D8576C85802 Notes for the Reader 1-2 IP244 C79000-D8576-C858-02 Notes for the Reader Notes for the Reader This manual describes the SIMATIC S5 temperature controller module IP 244 the software package FB 162 and the test program for the temperature controller module The software is on the accompanying diskette and comprises the following parts: - organization blocks - function block - data blocks OB 1, 20, 21, 22 FB 62, 63, 162 DB 162, 163, 164, 172, 173 The software package and IP 244 module combine to form a unit for machine controls in process control applications. To familiarize you with the application of the temperature controller and to make information as accessible as possible, the manual has been divided into several separate functional sections. Definitions of process control terms used in the manual can be found in the glossary. Part 2 Instructions for the IP 244 describes the hardware requirements. This part describes the environment in which the module can be used and explains the required connections. Part 3 Programming Instructions for the IP 244 describes the function of the firmware on the module and how to program the module. Using this desription, you can calculate the required parameters and structure them for the data exchange between the programmable controller and the module. Part 4 Programming Instructions for the Function Block FB 162 (64 messages) describes the program package with which you can operate the IP 244 temperature controller module. Part 5 You can use the Test Program for the IP 244 Temperature Controller Module (FB 62, 63) to test the complete operation of the IP 244. Part 6 Checklist for Start-Up provides notes about the step-by-step installation and start-up of the hardware and software for the IP 244 temperature controller. Part 7 In the Glossary you can find definitions of process control terms used in the manual. Part 8 The Index helps you to find the section in the manual you need quickly and easily by means of key words. Part 9 The Pocket Guide "IP 244 Temperature Controller with Function Block FB 162" provides you with an overview of all messages and the assignment of the data blocks DB-A, DB-B and DB-C. It serves as a practical guide to help you create and enter parameters. IP244 C79000-D8576-C858-02 1-3 Notes for the Reader The following procedure is recommended for problem-free installation and start-up: Load the contents of the supplied diskette into the CPU of the programmable controller using the programmer. Then enter a parameter set. The function block can then be used to transfer the parameters to the tempera ture controller module. You can now test individual functions and start control functions by connecting analog signals. Using FB 162, communication and data exchange is now possible with the temperature controller module. Temperature control is of course only possible when the module has been completely wired up. Once the module has been successfully installed, you can transfer programs from blocks OB 1, 20, 21, 22 and FB 62, 63 to your user program. You are then also in a position to modify data blocks DB 162, 163 and 164 to suit the requirements of your system. The following figure shows possible combinations between the IP 244 and the function block FB 162 in all versions delivered so far: Versions of the IP 244 6ES5 244- 3AA13 1-4 Versions of the FB 162 FB 162 32 messages 6ES5 244- 3AA21 FB 162 64 messages version I 6ES5 244- 6ES5 244- 3AA22 3AA22 FB 162 64 messages version II 6ES5 244- 3AB31 FC 162 for S7-400 IP244 C79000-D8576-C858-02 SIMATIC S5 IP 244 Temperature Controller 6ES52443AA22 Instructions C79000B8576C85902 Contents Contents Page 1 Technical Description 2-3 1.1 Application 2-3 1.2 Design 2-3 1.3 Mode of Operation 2-5 1.4 Technical Data 2-7 2 Installation and Operation 2-11 2.1 Inserting and Removing the Module 2-11 2.2 Connecting Signal Lines and the Power Supply 2-11 2.2.1 Analog Inputs (Plug Connector X3) 2-11 2.2.2 Digital Outputs and One Digital Input (Socket Connector X4) 2-12 2.3 Slots 2-14 2.4 Wiring between the PLC and the Plant 2-15 3 Operation 2-19 3.1 Configuring and Connecting the Analog Inputs 2-19 3.1.1 Wiring the Inputs for Channels 0 to 12 when Connecting Thermocouples 2-19 3.1.2 Wiring the Inputs for Channels 13 and 14 to Connect Transducers 2-21 3.1.3 Wiring the Inputs for Channel 15 (Compensation Channel) 2-22 3.1.4 Using the Module for Resistance-Type Sensors (Pt 100) 2-24 3.1.5 Configuring Analog Inputs 0 to 6 2-25 3.1.6 Configuring Analog Inputs 7 to 14 (15) 2-25 3.1.7 Line Break Monitoring 2-26 3.2 Digital Outputs and Comparator Channel 2-26 3.2.1 Digital Outputs 2-26 3.2.2 Comparator Channel 2-26 3.3 Interface to the CPU 2-27 3.4 Jumpers, Switches and Resistors RS and RP 2-28 3.4.1 Setting the Module Address 2-32 3.4.2 Setting the Conversion Time Per Channel 2-33 3.4.3 Setting the Clock 2-34 3.4.4 BASP Evaluation 2-34 3.5 Pin Assignment 2-35 3.6 Pin Assignment of Connecting Cables 2-35 4 Spare Parts 2-37 2-2 IP244 C79000-B8576-C859-02 Technical Description 1 Technical Description 1.1 Application The IP 244 temperature controller can be used in SIMATIC S5-115U, S5-135U and S5-155U programmable controllers and expansion units as an intelligent I/O module for automatic control of machines. When used in the S5-115U, an adapter casing is required (order number: 6ES5 491-0LA11). The IP 244 module is used in S5 systems not only for temperature control but also for measured value acquisition and limit value monitoring of analog transmitter signals. The manipulated variables output by the controller are digital. One special application of the module is in the temperature control of plastic injection molding machines and monitoring the injection pressure and mold clamping force. The module is configured as follows: either: - 15 analog input channels to connect voltage sensors directly. When delivered, channels 0 to 12 are prepared for thermocouples (0 to 51.2 mV) Channels 13 and 14 are used to acquire transducer signals (0 to 20.48 V) Channel 15 is used as a compensation channel for thermocouples and is suitable for the direct connection of a Pt 100 resistance thermometer or: - 8 analog input channels for connecting resistance-type sensors directly using a 4-wire connection (0 to 512 mV) - A comparator output and 17 digital output channels to output the manipulated variable of the controller (pulse-duration modulated). Actuators can be operated directly (rated output current). - Automatic controller for up to 13 control loops. - Control function independent of the status of the CPU of the PLC. 1.2 Design The IP 244 temperature controller module is a compact module in a double-height Eurocard format belonging to the ES 902 packaging system with a 48-pin backplane connector. The backplane connector is the interface to the SIMATIC S5 bus. The front panel contains a 37-pin socket connector for the analog inputs (X3) L+ (24 V load voltage) is supplied via a tab connector on the front panel, L- is connected to the reference potential of the controller (central grounding point in the cabinet). L- is supplied to the module via the Mext pin (external chassis). 20 green LEDs on the front panel indicate the operating status of the temperature controller module, the input and outputs. A red LED indicates that one or more digital outputs are short-circuited. IP244 C79000-B8576-C859-02 2-3 Technical Description Controller Operation K 16 14 R= run LED lit when module is in operation E= on LED lit when controller is in operation i.e. signal 1 at input K= comparator LED lit when input voltage on channel 13 is greater than the preset threshold voltage (see Section 3.2.2) 12 10 8 6 4 2 Short circuit indicator (red) U L+ DA Socket connector with 1 digital input (DI) and 17 digital outputs (DQ) and 1 comparator output X4 AE Plug connector with 15 analog inputs (AI) (13 thermocouple inputs, 2 transducer inputs) and 1 compensation channel X3 Fig 1.2/1 Front panel 2-4 IP244 C79000-B8576-C859-02 Technical Description 1.3 Mode of Operation As shown in the block diagram (Fig. 1.3/1), the analog input signals are switched to an analog to digital converter (ADC) by a multiplexer. With a maximum conversion time of 80 ms, the ADC digitalizes the input voltage using the dual slope technique. The 13 control loops (8 with Pt 100 sensors) are processed cyclically. Before the voltage is digitalized, the signal lines are checked for line breaks and any detected faults are signalled. A line break is recognized when the total line resistance is greater than 1 kohm or when the transmitter (thermocouple or resistance-type sensor) has a contact resistance greater than 1 kohm compared with the reference potential. If voltage dividers or shunt resistors are used to adapt the measuring range, no line break can be signalled. When delivered, no line break signal is possible for channels 13 and 14. The parameters and control commands transferred from the CPU via the data bus are stored in a 2048 byte RAM area which is divided into 64 messages each 32 bytes long. The module occupies 32 bytes in the address area of the PLC. A microprocessor controls the functions of the controller module according to the firmware which is stored in a 64 Kbyte EPROM. The calculated manipulated variables are output in digital form (pulse-duration modulated) to output drivers via an output register. If the 5 V power supply fails, the module is reset. If the 24 V load voltage fails, the module continues to operate; the digital outputs can, however, no longer be activated. The NAU (power failure) signal is not evaluated by the module. The digital outputs can be disabled with the BASP signal, the content of the registers is retained (see Section 3.4.4 BASP Evaluation). The controller's integrator values are buffered if the IP 244 controller module is inserted in a slot with battery back-up (UBATT). The presence of battery back-up is detected by the module automatically. IP244 C79000-B8576-C859-02 2-5 Technical Description The various functions of the controller module are processed by the microprocessor: - measured value acquisition via multiplexer and ADC - measured value processing according to the control algorithm, (system error formation, manipulated variable calculation, self-optimization) - monitoring limit values of measured values and generation of interrupts - output of manipulated variables via registers and output drivers - calculation of the temperature compensation value according to the reference junction temperature (Pt 100) - comparison of an analog input value with a digital value (limit value monitoring disabled) - controlling the interface to the S5 system bus L+ Digital input Control ON/OFF S5 bus Channel no. LED (E) 0 Semiconductor multiplexer 1 . . RAM EPROM Data/address selection 7 Address 8 . . D Pt 100 14 D DAU M1 M13Differential amplifier ..... LED red (U) LED (R) R/W BASP Collision control Register 17 Bit A 15 mP internal data bus Analog signal distribution Wire break detecton 5bit subaddresses Interface logic A 13 8bit data 8/12bit address +PESP Module address Comparator L+ L- LED (K) LED 1 DQ 18 (K) Output drivers ...... LED 17 DA 1 DA17 Fig. 1.3/1 Block diagram of the temperature controller 244-3AA22 The module can be operated as a switching two or three step controller with percentage output according to the control algorithm stored in the EPROM. The controller action (P, PI, PD, PID) is selected by inputting the appropriate parameters. Data (setpoints and parameters) is exchanged between the CPU and the temperature control module by means of 64 messages each with a length of 32 bytes. 2-6 IP244 C79000-B8576-C859-02 Technical Description 1.4 Technical Data Analog inputs Number of input channels and input voltages: as delivered - 0 to 51.2 mV = 2048 units for thermocouples - 0 to 20.48 V = 2048 E - for Pt 100 resistance thermometer in 3-wire connection to compensate the reference junction temperature configurable - 0 to 512 mV = 2048 units for resistance-type sensor in 4-wire connection or 0 to 999 mV = 3997 units for voltage sensors - selectable current/voltage ranges by means of soldered divider/shunt resistors Temperature ranges: FE-constantan (type L and type J) NiCr-Ni (type K) Pt 10 % Rh-Pt (type S) Pt 13 % Rh-Pt (type R) Pt 100 reference junction via Pt 100 Auxiliary current for resistance measurement Isolated Permissible potential difference between sensor and reference potential of the controller (UCM) Max. permissible input voltage without damage Input resistance - for 0 to 51.2 mV or 512 mV - for 0 to 20 V Errors, related to rated value (internal) linearity digitalization error polarity reversal error Interference suppression for 50/60 Hz - mains frequency with common mode interference - with series mode interference IP244 C79000-B8576-C859-02 13 (channels 0 to 12) 2 (channels 13 and 14) 1 (channel 15) 8 channels 15 channels 9 (channels 7 to 15) 0 to 700 C 0 to 1200 C 0 to 1600 C 0 to 1600 C 0 to 830 C -20 to +60C 2.56 mA no < 1 V pp 18 V for channels without series and shunt resistors 60 V for channels 13 and 14 as supplied 0 V for channel 15 (only for passive sensors) as supplied > 10 Mohm > 50 kohm 1 unit 1 unit 1 unit -86 dB, max. 1 Vpp 40 dB, max. 100 % of the measuring range, relative to the peak value 2-7 Technical Description Additional error caused by voltage divider (e.g. channels 13 and 14) Temperature influence (range 0 to 50 mV) Additional error caused by temperature influence in channels with voltage dividers (temperature coefficient of the voltage divider) Error message when tolerance exceeded, overflow or line break Line break detection Measuring principle Measured value resolution (internal) Encoding time per channel Integration time - for 50 Hz power supply frequency - for 60 Hz power supply frequency Max. permissible length of lines for thermocouples (50 mV) for Pt 100 and linear sensors (> 500 mV) Comparator channel Rated input voltage Resolution Max. permissible potential difference (UCM) Time constant Error Comparator output (K) 2-8 0.25 % 1 o/oo / 10 Kelvin (2 units / 10 Kelvin) 0.5 o/oo / 10 Kelvin (1 unit / 10 Kelvin) yes yes for sensors with Ri < 1 kohm integrating 11 bits + sign (value plus sign); 2048 units; for Pt 100 0 to 4096 units typically 50 ms 40 ms for 0 60 ms for 2048 units 80 ms for 4096 units 20 ms 16 2/3ms 50 m, shielded 200 m, shielded (the recommended maximum line length; can be exceeded if suitable measures are taken to prevent parasitic voltages) (fixed wiring on channel 13) 10.24 V 1024 units (1 unit = 10 mV) < 1 Vpp typically 0.2 ms < 0.5 % digital ouptut 18 (technical data as for digital outputs 1 to 17) IP244 C79000-B8576-C859-02 Technical Description Digital input (heating switch) Input voltage - for signal 0 (control off) - for signal 1 (control on) Input current (rated value for 24 V) Time delay Digital outputs Number of outputs Isolated Supply voltage (rated value) Max. permissible range of supply voltage Ripple Vpp Circuit interruption voltage (inductive) Switching current Switching capacity for lamps Residual current at signal 0 Max. permissible line length Power supply Supply voltage Consumption from 5 V supply UBatt from S5 Bus Current consumption IP244 C79000-B8576-C859-02 -2 to + 4.5 V +13 to + 35 V 5 mA max. 5 ms current sourcing 18 no 24 V DC 20 to 30 V DC max. 3.6 V limited to -1 V 120 mA; (0.2 to 120 mA) short-circuit proof, current limitation at approx. 500 mA max. 2.4 W max. 20 mA 400 m, unshielded; 1000 m, shielded (Recommended maximum length of lines, this may be exceeded if appropriate measures are taken to prevent parasitic voltages.) +5V5% approx. 650 mA (550 to 700 mA) required for self-adjustment function and to buffer the controller's integrator values IP in operation approx. 10 mA IP not in operation approx. 15 mA 2-9 Technical Description Controller action Control algorithm Cascaded control Proportional band Heating Cooling Derivative action time TD Integral action time TN ON duration of controller outputs Sampling time Setpoints 1 and 2 Tolerance evaluation PID with structuring switches (P, PI, PID) as two or three step controllers; zone controllers with configurable self-adjustment function possible, controller 0 is then master controller 0 to 100 % 0 to 100 % 0 to 512 x sampling time TA 0 to 512 x sampling time TA 0 to 100 % min. 800/960 ms at 50/60 ms channel conversion time min 350/700 ms for hot channel control 0 to 1600 C depending on sensor 0 to 255 C above and below setpoint Error messages are generated if faults occur in the sensors or in the controller. Mechanical Data Dimensions Module width Weight Environmental conditions Operating temperature Storage and transportation temperature Relative humidity Operating altitude 2-10 double Eurocard format 1 1/3 standard slots (20 mm) approx. 0.3 kg 0 to 55 C -40 to +70 C max. 95 % at 25 C, no condensation max. 3500 m above sea level IP244 C79000-B8576-C859-02 Installation 2 Installation and Operation Please pay particular attention to the warnings in this section! 2.1 Inserting and Removing the Module The module must only be inserted or removed when the central controller, the expansion unit and the transmitters are switched off. Data buffered on the module is lost. 2.2 Connecting Signal Lines and the Power Supply The signal lines are connected via the connectors on the front panel of the module. If you use screened cables, the braided screen must be connected to the metallized part of the connector cap. The screen must make large area contact with the screen bar in the cabinet. For preassembled connecting cables for analog inputs and digital outputs, refer to the spare parts. The 24 V supply is connected by means of a push-on sleeve B2.8 - 1 DIN 46247. 2.2.1 Analog Inputs (Plug Connector X3) Input channel no. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Connection M+ M M M M M M M M M M M M M M M 0+ 1+ 2+ 3+ 4+ 5+ 6+ 7+ 8 +/S0 + 9 +/S1 + 10 +/S2 + 11 +/S3 + 12 +/S4 + 13 +/S5 + 14 +/S6 + 15 or 15 M15+ / S7+ U M15- / S7- not connected Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Connection MM M M M M M M M M M M M M M M 012345678- /S0 9- /S110- /S211- /S312- /S413- /S515- /S6- Pin no. 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 16 17 35 16 35 17 The assignment of inputs to outputs is made according to the selected controller structure beginning at digital output 17. IP244 C79000-B8576-C859-02 2-11 Installation 2.2.2 Digital Outputs and One Digital Input (Socket Connector X4) Function Digital input I (Heating switch) DQ 18(K) DQ DQ DQ DQ DQ DQ DQ DQ DQ DQ DQ DQ DQ DQ DQ DQ DQ 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Remarks Pin no. L = Low controller off L+ = High controller on Comparator output Controller outputs Controller outputs Controller outputs Controller outputs Controller outputs Controller outputs Controller outputs Controller outputs Controller outputs Controller outputs Controller outputs Controller outputs Controller outputs Controller outputs Controller outputs Controller outputs Controller outputs K = Comparator output I = Digital input Function 1 L+ (only to supply the input I) 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 LLLLLLLLLLLLLLLLL- Remarks No load must be connected here. Pin 21 supplies the contact on pin 1. Pin no. 20 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 Switching example for digital input I (heating switch): 1 Heating switch 20 Switch in position "Heating switch = OFF" 2-12 IP244 C79000-B8576-C859-02 Installation No load supply must be connected to pin number 20. The connection is used to supply the contact on pin 1. The lines from pins 21 to 37 of the S5115 must be connected to 0V (Mbar) i.e. reference potential, using the appropriate adapter casing. Depending on the configuration of the controller as a 2 or 3-step controller, the 17 digital outputs are assigned consecutively. The maximum number of controllers is determined by the required number of digital outputs (maximum 17). Example of controller configuration You require cascaded control with controllers 1, 2 and 3 as 3-step controllers and controllers 4, 5 and 6 as 2-step controllers, all other controllers are disabled. The assignments of inputs and outputs is shown in the following diagram: Controller 0 is master controller Analog input AI 0 controller 0 AI 1 AI 2 AI 3 AI 4 AI 5 AI 6 controller 1 DQ 16 Heating DQ 15 Cooling controller 2 DQ 14 Heating DQ 13 Cooling controller 3 DQ 12 Heating DQ 11 Cooling controller 4 DQ 10 Heating controller 5 DQ 9 Heating controller 6 DQ 8 Heating The remaining analog inputs are used only for measured value acquisition, the remaining digital outputs are not used. IP244 C79000-B8576-C859-02 2-13 Installation 2.3 Slots Warning ! The temperature controller modules 6ES5 2443AA13, 3AA21 and 3AA22 must only be used in slots with battery backup. If the module is inserted in slots without battery backup, undefined statuses may occur. When using the module in the S5-115U, the following versions of the power supply must be used: 6ES5 951-7LB14 6ES5 951-7LD12 6ES5 951-7NB13 6ES5 951-7ND12 6ES5 951-7ND21 6ES5 951-7ND31 from version 6 from version 2 from version 3 from version 4 from version 3 from version 2 It is also recommended to use an adapter casing (for ordering data see catalog). When using the module in the S5-115U, the following versions of the power supply must be used: S5-115U and Expansion Units: CR700-OLA PS CPU 0 1 2 CR700-OLB PS CPU 00 00 1 2 CR700-1 PS CPU 0 0 1 2 3 4 5 6 IM CR700-2 PS CPU 0 1 2 3 3 4 4 5 6 IM CR700-3 PS CPU 3 4 5 ER701-1 ER701-2 0 PS 1 0 3 4 5 6 7 8 IM 1 2 3 4 5 6 7 IM ER701-3 PS 0 1 2 3 4 5 6 7 IM 0 2-14 0 0 0 1 1 2 2 00 00 11 11 22 22 2 1 2 3 3 3 IM 3 3 4 IM 4 5 5 5 6 6 6 IM Can be used IP244 C79000-B8576-C859-02 Installation S5-135U, S5-155U and Expansion Units: Slots 3 11 19 27 35 43 51 59 67 75 83 91 99 107 115 123 131 139 147 155 163 CC 135U CC 155U EU 183U EU 184U EU 185U EU 186U EU 187U Can be used Can only be used after modifying the jumper settings on the bus board Using the IP in the expansion unit when you are also using the interface module IM 307/317 is not permitted. 2.4 Wiring between the PLC and the Plant When wiring the plant, i.e. the wiring between the PLC and the plant or control system, proceed as described in the following figures. The figures are based on the example of a plastic injection molding machine. IP244 C79000-B8576-C859-02 2-15 Installation C P U PLC cabinet Equalizing cable, cross sectional area > 16 mm2 Pt 100 I P 2 4 4 AA AA AA AA AA AA AA AA AA AA AA AA AA Metal connector (the screen must make large area contact with the connector) Ground bar, e.g.: Cu A AAA AA A AA AAA A AA AAA EE AA A AAA AA EEAAA AA A A EEE E EE EEE A E AA AA A EEAAA AA Thermal contact between the terminals Thermal wires Fig. 2.4/1 Wiring between the PLC and the plant, example 1 The transition from thermal wires to non-thermal wires takes place outside the PLC cabinet. 2-16 IP244 C79000-B8576-C859-02 Installation C P U Pt 100 PLC cabinet I P 2 4 4 A A A A A A A A AA A AA A AA A AA A AA A AA A AA A AA AAA A AA A AA A AA A AAA EEAAAA AA A AAA EEE E EE AA A EE EEE AAAA E AA A EEAAAA A Metal connector (the screen must make large area contact with the connector) Ground bar, e.g.: Cu Thermal contact between the terminals Thermal wires Thermal wires Equalizing cable, cross sectional area > 16 mm2 Fig. 2.4/2 Wiring between the PLC and the plant, example 2 The transition from thermal wires to non-thermal wires takes place inside the PLC cabinet. IP244 C79000-B8576-C859-02 2-17 Installation 2-18 IP244 C79000-B8576-C859-02 Operation 3 Operation 3.1 Configuring and Connecting the Analog Inputs The analog signals are connected via front connector X3. There are 16 differential inputs available with protection against overvoltage. The input sensitivity of the analog inputs can be selected with jumpers: 0 to 51.2 mV for thermal e.m.f. (as supplied) 0 to 512 mV for general voltage input values All the analog inputs are affected. Unused analog inputs must be shortcircuited and connected to M (reference potential) to prevent unwanted interference coupling. 3.1.1 Wiring the Inputs for Channels 0 to 12 when Connecting Thermocouples (0 to 51.2 mV = 2048 Units Resolution) If the thermocouple is not isolated, the potential difference UCM must not exceed a maximum of 1 VPP. Machine + Multiplexer M+ Thermocouple, not isolated + + M- - EEEEEEEEEEEEE - Equalizing cable > 16 mm2 0 V, Mbar in cabinet (reference potential) UCM Fig. 3.1.1/1 Input wiring for a non-isolated thermocouple IP244 C79000-B8576-C859-02 2-19 Operation If the thermocouple is floating, the negative pole on the module must be connected over as short a distance as possible with the M-bar in the cabinet (reference potential) Machine + Insulator Multiplexer + Thermocouple, floating M+ + M- - - UCM 1 VPP - 0 V, Mbar in cabinet (reference potential) Fig. 3.1.1/2 Input wiring for a floating thermocouple 2-20 IP244 C79000-B8576-C859-02 Operation 3.1.2 Wiring the Inputs for Channels 13 and 14 to Connect Transducers (0 to 20.48 V = 2048 Units Resolution) The inputs have resistors RS and RP connected as voltage dividers (400:1). This allows a signal range of 0 to 20.48 V. Other voltage ranges require other voltage dividers. Channel 13: RS= R83 RP = R84 + Multiplexer M+ RS + + Transmitter 0 to 20.48 V = - Channel 14: RS= R85 RP = R86 RP M- - UCM 1 VPP to Mbar 0 V, Mbar in cabinet (reference potential) Fig. 3.1.2/1 Connecting floating transmitters from 0 to 20.48 V IP244 C79000-B8576-C859-02 2-21 Operation 3.1.3 Wiring the Input for Channel 15 (Compensation Channel) A Pt 100 resistance thermometer can be connected to channel 15 using a 3-wire connection. The Pt 100 can detect the reference junction temperature. The Pt 100 resistance thermometer must make thermal contact with the terminals used for the transition from thermal wires to copper wires. The temperature values detected via the thermocouples of channels 0 to 12 are corrected by the microprocessor using the reference junction temperature and form the actual values for the process control. Terminal box Thermocouples with equalizing cables PLC/EU Terminal block e.g.. Fe Channel 0 Ko . . . . . Potential equalizing cable Grounding bar in the cabinet EEE EEEEE Cabinet housing Channel n Pt 100 in thermal contact with the terminals of the thermocouple Connecting cable 6ES5 7215xxx0 Connect 9 wires Connect 2 wires Connect 1 wires Grounding clamp see pin assignment for connecting cables (Section 3.6) Fig. 3.1.3/1 Arrangement of thermocouples and Pt100 for compensation When you connect the Pt 100 compensator, make sure that the cable cross section is adequate for connection at contact 16, i.e. 1 mm2 (or connect 9 wires when using connecting cable 6ES5 7215xx0). 2-22 IP244 C79000-B8576-C859-02 Operation The bridge circuit is balanced in the factory to 0 C = 0 mV. When using a 3-core shielded connecting cable with 3 x 1.5 mm2 cross sectional area, the balancing error over 50 m of cable is < 1.5 C. IP 244 Uref + Multiplexer 35 + M+ 17 - MPt 100 16 0V 0 V, Mbar in cabinet (reference potential) Fig. 3.1.3/2 Connecting a resistance thermometer for reference junction temperature compensation The cable from the Pt 100 to pin 16 must be connected and must not be grounded (otherwise this results in a ground loop, falsifying results). IP244 C79000-B8576-C859-02 2-23 Operation 3.1.4 Using the Module for Resistance-Type Sensors (Pt 100) When using Pt 100s, the temperature controller module can only be operated with a maximum of 8 channels. The sensors are supplied by the module via S+ and S-. A 4-wire connection is required. Mixed operation with thermocouples, or a combination of heating current measurement and the special function is not possible. To acquire values from resistance-type sensors, follow the procedure outlined below: - switch over the input sensitivity to 512 mV/1024 mV (at X8 and X9) - remove the voltage dividers for channels 13 and 14 and solder in jumpers for the series resistor (R83 to R86, jumpers for R83 and R85) - switch over channel 15 from the compensation mode to a normal input (at X8 and X9). The necessary module configuration is described in Section 3.4. The wiring for a resistance-type sensor can be seen in the following diagram. + M+ Multiplexer + - Pt 100 M- + - + S+ Iconst + + S- UCM 1 VPP to Mbar 0 V, Mbar in cabinet (reference potential) Fig. 3.1.4/1 Wiring for resistance-type sensors The connection from S- to the M-bar is necessary to remain below the maximum potential difference UCM of 1 VPP. When operating with Pt 100s, the comparator LED flashes, as channel 13 is converted to a current output. 2-24 IP244 C79000-B8576-C859-02 Operation 3.1.5 Configuring Analog Inputs 0 to 6 Sensors with an output voltage range of 51.2 mV for thermal e.m.f.s or 512 mV for general applications, can be connected to channels 0 to 6. 3.1.6 Configuring Analog Inputs 7 to 14 (15) The input channels 7 to 14 (15) have solder lugs on the board to allow shunt resistors for current measurement or voltage dividers for voltage measurement to be fitted. (When supplied, a voltage divider 1:400 is fitted for channels 13 and 14, providing an input voltage of 20.48 V at the ADC sensitivity of 51.2 mV.) If you wish to change the input range from the factory setting, follow the procedure outlined below. Remember that the ADC sensitivity can only be selected for the whole module and that the sensitivity required for channels 0 to 6 also determines the sensitivity of channels 7 to 14 (15). To fit the required resistors, the jumpers for RS of channels 7 to 12 must be removed. To obtain the required input voltage (UI), the divider ratio of the resistors is calculated as follows: UI [ mV] ADCsens. [ mV] = RS + RP Rp RP R S + RP 5 kohms 100 kohms = = Example: UI = 10.24 V : ADCsens. = 512 mV : Rp = 2.5 kohms R S = RP x UI ADCsens. - RP RS = 2.5 x 20 - 2.5 = 47.5 kohms Use metal foil resistors with 0.25 W, tolerance 0.1% and a temperature compensation value (t.c. value) of 50 x 10-6 or better. For input currents (e.g. transducer connection with 0 to 20 mA) a jumper must be fitted for RS. The required resistor RP is calculated as follows: RP = ADCsens. [ V] IN [ A] RP = 25 ohms Example: IN = 20.48 mA; ADCsens. = 512 mV RP = 0.512 0.02048 = 25 ohms Metal foil resistor 0.25 W, tolerance 0.1 %, t.c. value= 50 x 10 IP244 C79000-B8576-C859-02 -6 (or better). 2-25 Operation A mixture of current and voltage inputs is only feasible with an ADC sensitivity of 512 mV. Modifying the Pt 100 input (channel 15) By removing the jumpers X8/9-X9/9 and X8/10-X9/10, the Pt 100 input can be converted to a voltage or current input. The calculation of RS (R226) and RP (R227) is as described above (see also Section 3.4). 3.1.7 Line Break Monitoring / Wire Break Monitoring When using thermocouples, analog inputs 0 to 12 and 15 are monitored for line breaks. This is achieved by briefly applying a test current to the measurement loop. To ensure that the monitoring functions correctly, the source resistors of the sensors must be less than 1 kohm. The sensors must be grounded at one end (see Section 3.1). Depending on the parameter assignment, an emergency program can then be activated to switch to a substitute thermocouple or substitute Pt 100 or a sensor. When switching off the characteristics linearization the line break monitoring is switched off automatically. 3.2 Digital Outputs and Comparator Channel 3.2.1 Digital Outputs 17 outputs protected against interference voltage and short-circuit proof are available for the output of manipulated variables. The status of the output stages is displayed by LEDs on the front panel (for the assignment of socket connector X4: see Section 2.2.2). When the 5 V voltage is supplied, the controller outputs respond briefly once. Owing to the slow reactions of the heating circuits or contactors, the flickering of the indicators is tolerable. If one or more output stages are operating with a short circuit, a red group short circuit display (LED) on the front panel lights up (see Fig. 1.2/1). 3.2.2 Comparator Channel To allow limit value monitoring, a comparator channel is connected to digital output DQ 18 (K) in parallel with the analog input channel 13. The signal present at analog input 13 is amplified by a differential amplifier and compared by a comparator with the signal set as the limit value by the microprocessor via a digital-to-analog converter. If the input voltage of channel 13 exceeds the limit value set by the microprocessor (resolution of 10 bits) digital output DQ 18 (K) is energized. When operating with Pt 100s, the comparator channel has no effect. 2-26 IP244 C79000-B8576-C859-02 Operation mP 0 to 10.24 V 2 1024 units = 10.24 V Channel 13 Multiplexer D A Comparator Limit value = 0 to 25 mV Output K Actual value Differential amplifier Fig. 3.2.2/1 Function diagram of the comparator channel 3.3 Interface to the CPU Data is exchanged with the CPU according to the bus specifications for SIMATIC S5 systems. The temperature controller module occupies 32 bytes in the address area of the CPU. By writing a message number (0 to 63), 64 different data block messages each 31 bytes long can be transferred from or to the CPU (see message structure). There are therefore 2048 bytes available in the transfer RAM on the module for transferring parameters or measured values. Function block FB 162 is available for assigning parameters and operating the module. The address coding can be switched over from the S5 bus (PESP' + 8 address lines) to PESP + 12 address lines (addressing jumper base A77). The data transfer with S5 can be in the form of byte or word commands. There is no particular sequence necessary for the high and low byte. ADB 0 to ADB 7 (ADB 11) PESP' RDY CPU DB 0 to DB 7 Temperature controller 244 MEMWR MEMRD Fig. 3.3/1 Signal transfer IP244 C79000-B8576-C859-02 2-27 Operation 3.4 Jumpers, Switches and Resistors RS and RP Bus connector X1 1 2 3 4 5 6 7 8 off on off A 76 A on A 77 12 1 X6 12 1 X7 X9 X8 1 12 1 12 59K 148 59K 148 F2 X5 L+ B X4 DQ X3 AI = Jumper inserted = Jumper not inserted Fig. 3.4/1 Settings as supplied (thermal e.m.f. measurement, 51.2 mV) 2-28 IP244 C79000-B8576-C859-02 Operation Bus connector X1 1 2 3 4 5 6 7 8 off on off A 76 A on A 77 12 1 12 1 X9 X8 B X6 X7 1 12 1 12 F2 X5 L+ X4 DQ X3 AI = Jumper inserted = Jumper not inserted Fig. 3.4/2 Settings for resistance thermometer Pt 100 X1 X3 X4 X5 F2 A76 A77 A27 X6/7 X8/9 A-B Backplane connector Front connector for analog inputs Front connector for digital outputs Connections for load voltage L+ Fuse for DQ (load voltage L+) Module address, ADB 8-11 (DIL switch); see Section 3.4.1 Module address, ADB 5-7 (DIL switch); see Section 3.4.1 Interrupt setting switch (DIL); not fitted Jumpers; see top of next page Jumpers; see bottom of next page Jumper must be soldered in (only for test purposes) IP244 C79000-B8576-C859-02 2-29 Operation Significance of the jumpers Open X6 /X7 Inserted Jumper C Jumper D 1 1 2 2 3 3 4 4 5 5 (*) Test points (must be inserted) 6 6 (*) Test points (inserted = 64 messages) 7 7 (*) Test points (must be inserted) 8 8 (*) Test points (must be inserted) 9 9 10 10 (*) Standard setting 2443AA22 11 11 (*) Standard setting 2443AA22 12 12 See Section 3.4.2 50 Hz (*) Not used Inserted As delivered 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 Not used 12 12 Not used (*) 2-30 Selection of the integration time 20 ms/ 16 2/3 ms see Section 3.4.3 60 Hz Standard setting 2443AA22 (*) Open X8 /X9 Not used 51.2 mV input sensitivity User configuration 51.2 mV input sensitivity No BASP evaluation when jumper inserted Thermal e.m.f. Voltage Current Measurement Channel 15 for compensation with Pt 100 3wire Pt 100 Resistance sensor 4wire connection Channel 15 for general measurement time acquisition This setting is required for the module to function perfectly and must not be changed (the test points are required to test the module). Jumper A-B (for test purposes) must be soldered in. (Fig. 3.4/1 and Fig. 3.4/2). IP244 C79000-B8576-C859-02 Operation Positon of resistors RS und RP X9 X8 R216 R217 R218 R219 R220 R221 R222 R223 R224 R225 R83 R84 R85 R215 R86 R226 R227 R214 X3 AI Value of resistors RS und RP Corresponding channel RS RP State on delivery: Required for Required for 4wire thermocouple Pt 100 operation operation with 3wire compensation Pt 100 RS RP RS RP 7 R214 R215 0W n.f. 0W n.f. 8 11 R216 R217 0W n.f. 0W n.f. 12 9 R218 R219 0W n.f. 0W n.f. 10 R220 R221 0W n.f. 0W n.f. 11 R222 R223 0W n.f. 0W n.f. 12 R224 R225 0W n.f. 0W n.f. 13 R83 R84 59kW 148W 0W n.f. 14 R85 R86 59kW 148W 0W n.f. 15 R226 R227 n.f. n.f. 0W n.f. Required for general application RS RP Selected as required for particular application (see Section 3.1.6) n.f. = not fitted IP244 C79000-B8576-C859-02 2-31 Operation 3.4.1 Setting the Module Address Each IP 244 temperature controller module requires 32 addresses for transferring the required parameters. You only need to set the start address of the module. The following 31 addresses are then automatically occupied and no longer available for other modules. The addresses can be set in steps of 32. 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 P E S Gap PESP P 28 29 210 211 256 DIL switch A 76 for ADB 8 to 11 Gap 28 to 211 25 26 27 32 64 128 DIL switch A 77 for ADB 5 to 7 Switch A 77 No. EU CC EU Q area S5135 U S5155 U S5115U (CPU 945) only in EU 5 7 8 off on on on on on 28 to 211 28 =on uber = off 29 to A 211 77 = off at A 77 0..2240 to 224 0 P area all PLCs 5 7 8 off on on on on on 28.to 211 28 to uber 211 = off = off A 77 at A 77 128..224 128 to 224 1 ABS area S5115 U 5 7 8 on on off on on off 28 to 211 28 to 211 = off = off uber A 77 at A 77 0 to 224 0..224 2 Process area Switch A 76 Baugruppenadresse Module address CC Einstellen SetBereich Range Address parameter for FB 162 Example: you wish to assign the start address n = 160 in the normal I/O area P of the central controller. The switches must then be set as shown below: off on off on 1 2 3 4 5 6 7 8 The next module can then be assigned the start address 192 (160 + 32). A 76 2-32 A 77 IP244 C79000-B8576-C859-02 Operation 3.4.2 Setting the Conversion Time Per Channel Thermocouples, resistance-type sensors and other sensors for general applications can be connected to the analog inputs. Setting the conversion time of the analog-to-digital converter fixes the resolution of the analog input signals in encoding units. The conversion time per channel is selected with jumper D on the plug connectors X6/X7. With Pt 100s, jumper D is not effective. In this case, the conversion time is fixed to 80 ms (0 to 1024 mV = 4096 units). Jumper D (X6/X7, 2-2) X6 12 1 Inserted 60 ms = 0 to 51. 2 mV (Channel 0 to 12) or 0 to 512 mV = 0 to 20.48 V (Channel 13/14) depending on = 0 to 2048 units configuration Open 50 ms = 0 to 25. 6 mV (Channel 0 to 12) or 0 to 256 mV = 0 to 10.24 V (Channel 13/14) depending on = 0 to 1024 units configuration Jumper D X7 12 1 Conversion time and resolution With the special function "measured value acquisition on channel 13 and 14" the conversion time is fixed at 55 ms. The permissible thermocouples and resistance-type sensors allow the following maximum setpoint temperatures for the selectable conversion times from the sensor voltage: Sensor type 50 ms 55 ms 60 ms Jumper D open Special function Jumper D inserted C F C F C F Type L Type J Type K Type S Type R Pt 100 450 450 600 1600 1740 Conversion time IP244 C79000-B8576-C859-02 842 675 842 675 1112 900 2912 1600 3100 1740 1247 700 842 700 1652 1200 2912 1600 3100 1740 1292 1292 2192 2912 3100 80 ms Pt 100 operation C F 830 1526 2-33 Operation The following table shows the maximum actual values which can be read in. Conversion time Sensor Type 50 ms 55 ms 60 ms Jumper D open Special function Jumper D inserted C F C F C F Type L Type J Type K Type S Type R Pt 100 460 467 616 3063 2100 861 678 874 688 1141 926 5547 3063 3812 2100 1254 878 1270 889 1700 1265 5547 3063 3812 2100 1612 1632 2310 5547 3812 80 ms Pt 100 operation C F 850 1562 The characteristics of the thermocouples can be found in DIN 43710 or IEC 584. The characteristic curve of the Pt 100 can be found in DIN 43760. The characteristics of the permitted sensors are linearized internally by the firmware. The selection of sensors is made in the parameter assignment (see Part 3 of this manual). The maximum actual values which can be read in are indicated if there is a line break. 3.4.3 Setting the Clock To allow maximum interference suppression at main frequencies of 50 Hz or 60 Hz, the integration time can be selected. X6/X7 3-3 4-4 12 X6 1 x Integration time 50 Hz mains interference suppression (20 ms) =50 Hz x X7 12 1 60 Hz mains interference suppression (16 2/3 ms) 3.4.4 BASP Evaluation It is possible to evaluate the BASP signal or to disable the evaluation using jumper X8/4-X9/4. When BASP = 1, the outputs are disabled. If there is no BASP evaluation, you must use external measures to make certain that the machine will be forced into a safe operating state in case of error (see also IEC 204-1). If the S5-CPU is in STOP, it can no longer react to error messages from the IP (e.g. actual value too large, watchdog, ...). 2-34 IP244 C79000-B8576-C859-02 Operation 3.5 Pin Assignment Backplane connector 1: d 2 4 3.6 UBAT z 0V +5V PESP 6 ADB 0 CPKL 8 ADB 1 MR 10 ADB 2 MW 12 ADB 3 RDY 14 ADB 4 DB 0 16 ADB 5 DB 1 18 ADB 6 DB 2 20 ADB 7 DB 3 22 ADB 8 DB 4 24 ADB 9 DB 5 26 ADB 10 DB 6 28 ADB 11 DB 7 30 BASP 32 0V Pin Assignment of Connecting Cables 6ES5 721 4xxx0 6ES5 721 5xxx0 + 1 + + 37 19 37 19 + + 20 1 + + + 20 b Fig. 3.6/1 Connecting cable IP244 C79000-B8576-C859-02 2-35 Operation Connecting cable for temp. controller 6ES5 7214 . . . Pin assignment table Pin of Bundle/ Core 37pin sleeve color connector color wt 1 br 20 gn 2 ye 21 1 gr 3 rd pi 22 bl 4 rd 23 wt 5 br 24 gn 6 ye 25 2 gr 7 gn pi 26 bl 8 rd 27 wt 9 br 28 gn 10 ye 29 3 gr 11 ye pi 30 bl 12 rd 31 wt 13 br 32 gn 14 ye 33 4 gr 15 br pi 34 bl 16 rd 35 wt 17 br 36 gn 37 ye 18 5 gr 19 bk pi bl rd wt br gn 6 ye bl gr pi Shield Connecting cable for temp. controller 6ES5 7215 . . . bk Pin assignment table Bundle/ sleeve color Casing For digital signals (plug connector) Pt 100 connection to channel 15 Chassis connection Core color wt br gn ye gr pi bl rd wt br gn ye gr pi bl rd wt br gn ye gr pi bl rd wt br gn ye gr pi bl rd wt br gn ye gr pi bl rd wt br gn ye gr pi 1 rd 2 gn 3 ye 4 br 5 bk 6 bl Shield Pin of 37pin connector 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 37 18 19 16 16 16 17 16 16 16 16 16 Casing rd 5 1 rd wt 6 4 rd wt bl 2 gn gn 3 br wt ye Cable structure with core and sleeve colors Cable type: LIYCY/R3x2x0,09 Length key and order numbers: Order no. also rating plate labelling 6ES5 7215 . . . 0 6ES5 7214 . . . 0 AG0 AJ0 BB0 BB2 BB5 BC0 BC5 BD2 BE0 BF0 BG3 BJ0 CB0 CB2 CB5 CC0 CC5 CD2 CE0 CF0 CG3 CJ0 DB0 DB2 DB5 DC0 DC5 DD2 DE0 DF0 DG3 DJ0 EB0 Length L in meters 0.6 0.8 1.0 1.2 1.5 2.0 2.5 3.2 4.0 5.0 6.3 8.0 10 12 15 20 25 32 40 50 63 80 100 120 150 200 250 320 400 500 630 800 1000 For analog signals (socket connector) / connect core 17 twice } see / connect core 16 nine times Fig. 3.1.3/1 Fig. 3.6/2 Connecting cable (accessories) 2-36 IP244 C79000-B8576-C859-02 Spare Parts 4 Spare Parts Minijumper Connecting cable for digital outputs Connecting cable for analog inputs W79070G2601N2 6ES5 7214xxx0 6ES5 7215xxx0 For length key see page 36 When configuring the analog inputs with voltage dividers or shunt resistors (RP and RS), use metal foil resistors with a tolerance of 0.1% and a temperature coefficient 50ppm. Using poor quality resistors increases module errors! IP244 C79000-B8576-C859-02 2-37 Spare Parts 2-38 IP244 C79000-B8576-C859-02 SIMATIC S5 IP 244 B Temperature Controller 6ES52443AB31 Operating Instructions C79000B8576C86501 Contents Seite Inhalt 1 Technical Description 3-3 1.1 Application 3-3 1.2 Structure 3-3 1.3 Method of Operation 3-5 1.4 Specifications 3-7 2 Installation and Handling 3-11 2.1 Removing or Installing the Module 3-11 2.2 Connecting Signal Lines and Power Supply 3-11 2.2.1 Analog Inputs (X3 Male Connector Strip) 3-11 2.2.2 Digital Outputs and One Digital Input (X4 Female Connector Strip) 3-12 2.3 Slots 3-14 2.4 Wiring Between PLC and System 3-15 3 Operation 3-19 3.1 Configuring and Wiring Analog Inputs 3-19 3.1.1 Input Wiring for Connecting Thermocouples to Channels 0 through 12 3-19 3.1.2 Input Wiring for Connecting Transducers to Channels 13 and 14 3-20 3.1.3 Input Wiring of Channel 15 (Compensation Channel) 3-21 3.1.4 Using the Module for Resistance-Type Sensors (Pt 100) 3-23 3.1.5 Open Wire Diagnostics 3-24 3.2 Digital Outputs 3-24 3.3 Interface to the CPU 3-24 3.4 Switches and Jumpers 3-25 3.4.1 Setting the Module Address 3-27 3.4.2 Selecting the Conversion Time of each Channel 3-28 3.4.3 Clock Selection 3-29 3.4.4 BASP Interpretation 3-29 3.4.5 Comparison of the Jumper Assignments of 6ES5244-3AA22/-3AB31 3-30 3.5 Pin Assignment 3-31 3.6 Pin Assignment of Connecting Cables 3-31 4 Spare Parts 3-33 3-2 IP244B C79000-B8576-C865-01 Technical Description 1 Technical Description 1.1 Application In SIMATIC S5-115 U, S5-135 U, or S5-155U programmable logic controllers and extension units, the IP IP 244 B temperature control module can be used as an intelligent I/O module for closed-loop control tasks in machine controllers. An additional adapter casing (order no. 6ES5 491-0LA11) is required for installing the module in an AG 115 U PLC. In S5 systems, the module is used for temperature control and for measuring analog sensor signals. The manipulated variable is output as a digital value. Temperature control at plastic injection moulding machines and monitoring injection pressure and closing force are special applications of this module. The module offers the following features: either: - 15 analog input channel for direct sensor connection Channels 0...12 have been prepared for thermocouple connection (0...51.2 mV) when the module is delivered. Channels 13 and 14 are used for measuring sensor signals (0...20.48 V) Channel 15 is used as compensation channel for thermocouples and is suitable for direct connection of a Pt100 resistance thermometer. or: - 8 analog input channels for direct connection of 4-wire resistance thermometers (0...512 mV) - 17 digital output channels for outputting the manipulated variable of the closed-loop controller (pulse width modulation). Actuators can directly be connected (120 mA nominal output current). - Autonomous closed-loop controller for up to 13 control loops. - The closed-loop control function is independent of the mode of the PLC CLU. 1.2 Structure The IP 244 B temperature control module is a compact module in double-height Europa format in ES 902 packaging system with 48-way backplane connector. The backplane connector forms the interface to the SIMATIC S5 bus. The analog input signals connect to a 37-way male connector type "D" (X3), and the digital I/O signals connect to a 37-way female connector (X4). Both connectors are located on the front panel. Two connecting cables (one end with a matching connector, the other end loose) are available (see Chapter 4, "Spare Parts"). L+ (24-V load voltage) is connected to a push-on blade connector on the front panel. L- is connected to the reference potential of the controller (central grounding point in the cabinet). The module is grounded via the Mext spring (external ground). 19 green LEDs on the front panel indicate the operating states of the temperature controller module, the input, and the outputs. IP244B C79000-B8576-C865-01 3-3 Technical Description R E K 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 Controller Operation R= Run LED in ON when the module is in operating E= ON LED is ON, when the controller is operating; i.e. "1" signal applied to the input K= without function U= blank U L+ DA Female connector strip with 1 digital input (DI) and 17 digital outputs (DQ) X4 AE Male connector strip with 15 analog inputs (AI) (13 thermocouple inputs, 2 sensor inputs) and 1 compensation channel X3 Fig. 1.2/1 Front panel 3-4 IP244B C79000-B8576-C865-01 Technical Description 1.3 Method of Operation As shown in the block diagram (Fig. 1.3/1), an analog multiplexer connects the analog input signals to an analog/digital converter (ADC). At a maximum conversion time of 80 ms, the ADC converts the input voltage using the dual-slope method. The 13 control loops (8 with Pt100 sensors) are processed cyclically. Open wire diagnostics are performed before digitizing is started; faults are reported. An open wire condition can only be detected if the entire line resistance (including the sensor resistance) is greater than 1 kW. The default state of channels 13 and 14 is no open wire detection. The parameters and control commands that are transferred from the CPU via the data bus are stored in a RAM area that is subdivided into 64 message frames of 32 bytes each. The module occupies 32 bytes in the PLC address space. A microprocessor controls the functional sequence of the controller module according to the operation program (firmware) in an EPROM. The computed manipulated variable is output as a (pulse-width-modulated) digital value via an output register. The module is reset when the 5-V power supply fails. The BASP signal can be used for disabling the digital outputs; the register contents is reset in this case (see Section 3.4.4, BASP Interpretation). Provided that the IP 244 B controller module has been installed in a battery-backed (UBATT) slot (the module is able to recognize this condition), the controller's integral-action values are buffered. IP244B C79000-B8576-C865-01 3-5 Technical Description The microprocessor (mP) processes the different functions of the controller module: - Measuring values at a high common-mode range - Measuring values via multiplexer and ADC - Processing measured values according to the control algorithm (calculating system deviation and manipulated variable, self-optimization) - Monitoring values for alarm limits and generating alarms - Outputting manipulated variables via registers and output driver stages - Computing the temperature compensation values according to the reference junction temperature (Pt 100) - Controlling the interface to the S5 system bus L+ Digital input Contzrol ON/OFF S5 bus Channel no. LED (E) 0 Optocoupled multiplexer 1 . . RAM EPROM Data/address selection 7 Address 8 . . D Pt 100 Analog signal routing; open wire detecton 14 5bit subaddresses Interface logic A 13 8bit data mP R/W BASP internal data bus Collision control Register 17 Bit 15 ..... LED (R) 8/12bit address +PESP Module address - 0 + DC +5V DC Output drivers ...... 0V LED 1 LED 17 DA 1 DA17 Fig. 1.3/1 Block diagram of the temperature controller (IP 244 B-3AB31) The module can be used as a switching two- or three-step controller with percentage output according to the control algorithm in the EPROM. The controller's response (P, PI, PD, PID) is defined by parameters. 64 message frames of 32 bytes each are used for communication (setpoint values and parameters) between the CPU and the temperature controller module. 3-6 IP244B C79000-B8576-C865-01 Technical Description 1.4 Specifications Analog inputs Number of input channels and input voltages: upon delivery - 0 to 51.2 mV = 2048 units for thermocouples - 0 to 20,48 V = 2048 E - for reference junction compensation of 3-wire Pt100 resistance thermometers configurable - 0 to 512 mV = 2048 units for 4-wire RTD or 0 to 999 mV = 3997 units for voltage sensors Temperature ranges: Fe-Constantan (type L and type J) NiCr-Ni (type K) Pt 10 % Rh-Pt (type S) Pt 13 % Rh-Pt (type R) Pt 100 Reference junction via Pt 100 Auxiliary current for resistance measurement Isolation Permissible potential difference between any two sensors and the reference potential of the controller (UCM) Test voltage sensor/controller Test voltage sensor/sensor Max. input voltage without destruction Input resistance - for 0 to 51.2 mV or 512 mV - for 0 to 20 V Error, related to the nominal value (internal) Linearity Digitizing error Polarity reversal error Noise suppression for 50/60 Hz - Mains frequency with common mode interference - with series-mode interference IP244B C79000-B8576-C865-01 13 (channels 0...12) 2 (channels 13 and 14) 1 (channel 15) 8 channels 15 channels 0... 700 C 0... 1200 C 0... 1600 C 0... 1600 C 0... 830 C -20... +60 C 2.56 mA No AC 25 V/DC 60 V AC 500 V AC 120 V 18 V for channels 0 ... 12 60 V for channels 13 and 14 upon delivery 0 V for channel 15 (passive sensors only) upon delivery > 10 MW > 50 kW 1 unit 1 unit 1 unit -100 dB -40 dB, max. 100 % of range, related to the peak value 3-7 Technical Description Additional error by voltage divider (channels 13 and 14) Temperature influence (0 to 50 mV range) Additional error by temperature influence in channels with voltage divider (voltage divider temperature coefficient) Error message for out-of-tolerance, overrange and open wire conditions Open wire detection Measurement principle Resolution of measured value (internal) Conversion time per channel Integration time - 50 Hz mains frequency - 60 Hz mains frequency Max. cable length for thermocouples (50 mV) for Pt 100 and linear sensors (> 500 mV) Operation with ungrounded thermocouples 3-8 0.25 % 1 o/oo / 10 Kelvin (2 E / 10 Kelvin) 0,5 o/oo / 10 Kelvin (1 E / 10 Kelvin) Yes Yes for sensors with Ri <1 kW integrating 11 bits + sign (value + sign); 2048 units; with Pt 100 0...4096 units typ. 50 ms 40 ms with 0 60 ms with 2048 units 80 ms with 4096 units 20 ms 16 2/3ms 50 m, screened 200 m, screened (recommended max. cable length that may be exceeded if appropriate noise suppression measures have been taken) possible if the max. commonmode voltage is not exceeded. IP244B C79000-B8576-C865-01 Technical Description Digital input (heating switch) Input voltage - with signal 0 (closed-loop control OFF) - with signal 1 (closed-loop control ON) Input current (nominal value at 24 V) Time delay Digital outputs Number of outputs Isolation Module power (nominal value) max. range of module power Ripples Upp Shut-down voltage (inductive) Switching current Switching capacity for lamps Leakage current at signal 0 Max. cable length Power supply Input voltage Current consumption from 5-V supply UBatt from S5 bus Current consumption IP244B C79000-B8576-C865-01 - 2 ... + 4.5 V + 13 ...+ 35 V 5 mA max. 5 ms source 18 No DC 24 V DC 20 to 30 V max. 3.6 V limited to -1 V 120 mA; (0.2 to 120 mA) short-circuit-proof max. 2.4 W max. 20 mA 400 m, unscreened; 1000 m, screened (recommended max. cable length that may be exceeded if appropriate noise suppression measures have been taken) +5V5% ca. 400 mA (300... 500 mA) required for auto calibration and backup of the controller's integrator values IP in operation ca. 10 mA IP shut down ca. 15 mA 3-9 Technical Description Control response Control algorithm Cascaded control Proportional range Heating Cooling Derivative action time TD Integral action time TN Duty cycle of the controller outputs Sampling time Setpoint values 1 and 2 Tolerance interpretation Error messages in the event of a malfunction at the sensor side or controller malfunction Mechanical specifications Size Installation width Weight Ambient conditions Operating temperature Storage and transport temperature Relative humidity Operating altitude 3-10 PID with structure switches (P, PI, PID) as two- or threestep controller; zone controller with configurable auto adjustment possible; controller 0 is master controller 0...100 % 0...100 % 0...512 x sampling time TA 0...512 x sampling time TA 0...100 % min. 800/960ms at 50ms/60ms channel conversion time min. 350/700ms for hot channel control 0...1600 C depends on sensor 0...255 C around setpoint Double Europa format 1 1/3 SEP (20 mm) ca. 0.3 kg 0...55 C -40... +70 C max. 95 % at 25 C, no condensation max. 3500 m above sea level IP244B C79000-B8576-C865-01 Installation 2 Installation and Handling Caution: Observe the WARNINGs in this Chapter 2.1 Removing or Installing the Module Switch off the power to the central unit, the extension units, and the sensors before you install or remove a module. The data stored on the module will be lost. 2.2 Connecting Signal Lines and Power Supply The signal lines connect to the connectors on the front panel. Cable screens are connected to the metallic parts of the connector hood. In the cabinet, connect a large area of the screen to the screen connector bar. Chapter "Spare Parts" lists the cable assemblies that are available for analog and digital inputs and outputs. Use a B 2,8 - 1 DIN 46247 jack for the 24-V connection. 2.2.1 Analog Inputs (X3 Male Connector Strip) M+ conn. Input channel no. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 M M M M M M M M M M M M M M M 0+ 1+ 2+ 3+ 4+ 5+ 6+ 7+ 8 +/S0 + 9 +/S1 + 10 +/S2 + 11 +/S3 + 12 +/S4 + 13 +/S5 + 14 +/S6 + 15 or 15 M15+ / S7+ U M15- / S7- nor connected M- conn. Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 M M M M M M M M M M M M M M M 012345678- /S0 9- /S110- /S211- /S312- /S413- /S515- /S6- Pin no. 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 16 17 35 16 35 17 Starting from digital output 17, the selected controller configuration allocates the inputs to the outputs. IP244B C79000-B8576-C865-01 3-11 Installation 2.2.2 Digital Outputs and One Digital Input (X4 Female Connector Strip) Function Comments Digital input L "E" (heating L+ switch) DA DA DA DA DA DA DA DA DA DA DA DA DA DA DA DA DA 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 = = Low controller OFF High controller ON Controller Controller Controller Controller Controller Controller Controller Controller Controller Controller Controller Controller Controller Controller Controller Controller Controller outputs outputs outputs outputs outputs outputs outputs outputs outputs outputs outputs outputs outputs outputs outputs outputs outputs Pin no. Function Comments Pin no. 1 L+ (power supply to input E only) Do not connect a load here. Pin 20 powers contact at pin 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 LLLLLLLLLLLLLLLLL- 20 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 E = Digital input Typical wiring of digital input E (heating switch): 1 Heating switch 20 24 V (short-circuit-proof) Switch in position "Heating switch = OFF" 3-12 IP244B C79000-B8576-C865-01 Installation Do not connect a load power supply to pin 20. The connection provides a shortcircuit proof power supply of the contact at pin 1. In S5115, use the adapter casing and con nect the lines at pins 21 through 37 0 V (M bar), i.e. reference potential. Without leaving a gap, the 17 digital outputs are assigned consecutively as two- or three-step controllers according to the configuration. The number of controllers is limited by the digital outputs required (maximum 17). Typical controller assignment Required: Cascaded control with closed-loop controllers 1, 2, and 3 as three-step controllers and closed-loop controllers 4, 5, and 6 as two-step controllers. All other controllers are disabled. The diagram below shows the controller assignments: Controller 0 is the master controller Analog input AE 0 Controller 0 DA 16 Heating 1 DA 15 Cooling Controller DA 14 Heating DA 13 Cooling DA 12 Heating DA 11 Cooling Controller DA 10 Heating Controller DA 9 Heating Controller DA 8 Heating Controller AE 1 AE 2 2 Controller AE 3 AE 4 AE 5 AE 6 3 4 5 6 The other analog inputs are used for measuring. The remaining digital outputs are not used. IP244B C79000-B8576-C865-01 3-13 Installation 2.3 Slots Warning ! The 6ES5 2443AB31 temperature controller module must be installed in a bat terybacked slot. Failure to do so may result in an undefined state of the module. The following power supply versions are required if the module is used on an S5-115U system: 6ES5 951-7LB14 6ES5 951-7LD12 6ES5 951-7NB13 6ES5 951-7ND12 6ES5 951-7ND21 6ES5 951-7ND31 from version 6 onwards from version 2 onwards from version 3 onwards from version 4 onwards from version 3 onwards from version 2 onwards An adapter casing must be used in this case (see Catalogue for ordering information). Please refer to the Operating Instructions and to the two tables below (version May 1990) for a list of the PLC and EU slots in which the module may be installed. S5-115U and extension units CR700-OLA PS CPU 0 1 2 CR700-OLB PS CPU 00 00 1 2 CR700-1 PS CPU 0 0 1 2 3 4 5 6 IM CR700-2 PS CPU 0 1 2 3 3 4 4 5 6 IM CR700-3 PS CPU 3 4 5 ER701-1 ER701-2 0 PS 1 0 ER701-3 PS 0 3-14 0 0 0 1 1 2 2 00 00 11 11 22 22 2 3 3 IM 3 3 IM 4 5 5 6 6 IM 3 4 5 6 7 8 IM 1 2 3 4 5 6 7 IM 1 2 3 4 5 6 7 IM 1 2 3 4 5 6 installation possible IP244B C79000-B8576-C865-01 Installation S5-135U, S5-155U and extension units: Slots 3 11 19 27 35 43 51 59 67 75 83 91 99 107 115 123 131 139 147 155 163 ZG 135U ZG 155U EG 183U EG 184U EG 185U EG 186U EG 187U Installation possible Installation possible after jumpers have been altered on the module In the extension unit, the IP module may not be used together with the IM 307/317 interface unit. 2.4 Wiring Between PLC and System Follow the illustrations on the next two pages when you install the system wiring, i.e. the wiring between PLC and machine and/or controlled system. The figures show a plastic injection moulding machine. IP244B C79000-B8576-C865-01 3-15 Installation PLC cabinet Equipotential connection, > 16 mm2 Pt 100 C P U I P 2 4 4 B AA AA AA AA AA AA AA AA AA AA AA AA Metallic connector (connect a large area of the screen to the connector) Grounding bar, e.g.: Cu A AAA A AA AAA A AA AAA EE AA AAA EEAAA AAA AA A EEE E A AA EE EEE E AA A EEAAA AA A Thermal contact between the terminals Thermo wires Fig. 2.4/1 Wiring between PLC and system; example 1 The interface between thermo wires and non-thermo wires is outside the PLC cabinet. 3-16 IP244B C79000-B8576-C865-01 Installation C P U Pt 100 PLC cabinet I P 2 4 4 B AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA AA EEAAAA AA A AA AA EEE E EE AA A EE EEE AAAA E AA A EEAAAA A Metall ic connector (connect a large area of the screen to the connector) Grounding bar, e.g.: Cu Thermal contact between the terminals Thermo wires Thermo wires Equipotential connection, > 16 mm2 Fig. 2.4/2 Wiring between PLC and system; example 2 The interface between thermo wires and non-thermo wires is inside the PLC cabinet. IP244B C79000-B8576-C865-01 3-17 Installation 3-18 IP244B C79000-B8576-C865-01 Operation 3 Operation 3.1 Configuring and Wiring Analog Inputs The analog signals are connected via the X3 front connector. There are 16 differential inputs on a module. The sensitivity of the analog inputs is selected by configuring plug-in jumpers: 0 ... 51.2 mV for thermal e.m.f. (selection upon delivery) 0 ... 512 mV for general input voltage values The selection is valid for all analog inputs. Unused analog inputs should be shorted to avoid interference. 3.1.1 Input Wiring for Connecting Thermocouples to Channels 0 through 12 (0 ... 51,2 mV = 2048 units resolution) The voltage difference UCM may not exceed 25 VAC (120 VAC test voltage). Ungrounded thermocouples may be used as long as the maximum voltage difference is not exceeded (grounding thermocouples is recommended, though). Machine + Multiplexer M+ Thermocouple + + M- - - 0 V, M bar in cabinet (reference potential) UCM Fig. 3.1.1/1 Input wiring of thermocouple IP244B C79000-B8576-C865-01 3-19 Operation 3.1.2 Input Wiring for Connecting Transducers to Channels 13 and 14 (0 ... 20.48 V = 2048 units resolution) The resistors RS and RP are connected in series to the inputs, providing a voltage divider (400:1). This yields a signal range of 0 ... 20.48 V. + Multiplexer M+ RS + + Transducer 0 ... 20.48 V = - RP M- - UCM - Ungrounded transducers may be used as long as the maximum potential difference UCM is not exceeded. Fig. 3.1.2/1 Connecting floating transducers from 0 to 20.48 V 3-20 IP244B C79000-B8576-C865-01 Operation 3.1.3 Input Wiring of Channel 15 (Compensation Channel) A three-wire Pt 100 resistance thermometer can be connected to channel 15 that measures the reference junction temperature. The Pt 100 must be in thermal contact with the terminals that form the interface between the thermal wires and the copper wires. The microprocessor corrects the temperature values measured by the thermocouples that are connected to channels 0 ... 12 by the value of the reference junction temperature. The results are the actual values for the closed-loop process. Terminal box Thermocouples with compensation wres AG/EG Termianl block e.g. Fe Ch. 0 Ko . . . . . Equipotential conductor Grounding bar in the cabinet EEEEEE Cabinet enclosure Ch. n Pt 100 in thermal contact with the thermocouple terminals Connecting cable 6ES5 721-5xxx0 connect 9 wires connect 2 wires connect 1 wire Grounding clamp see cable configuration (Section 3.6) Fig. 3.1.3/1 Arrangement of thermocouples and Pt 100 for compensation Connecting a Pt 100 comparator requires the cross section of the cable to contact 16 to be at least 1 mm2. (Or connect 9 wires when you use the 6ES5 7215xx0 connecting cable. IP244B C79000-B8576-C865-01 3-21 Operation Upon delivery, the bridge circuit is adjusted to 0 C = 0 mV. The resulting calibration error of 50 m of a screened three-conductor cable of 3 x 1,5 mm2 cross section is < 1,5 C. IP 244 B Uref + Multiplexer 17 + M+ 35 - MPt 100 16 0V 0 V, M bar in cabinet (reference potential) Fig. 3.1.3/2 Connecting a resistance thermometer for reference junction temperature compensation The line between Pt 100 and pin 16 must be hardwired and must not be grounden (otherwise there will be a ground loop and invalid measured values). 3-22 IP244B C79000-B8576-C865-01 Operation 3.1.4 Using the Module for Resistance-Type Sensors (Pt 100) Only 8 channels are available if the temperature control module is used in Pt 100 mode. The sensors are fed from the module via S+ / S- . The sensors are connected via 4 wires. Mixed configurations with thermocouples, or a combination with heater current measurement and special function are not possible. To perform measurements with resistance-type sensors, use the following procedure: - Select an input sensitivity of 512 mV/1024 mV (X8) - Remove the voltage dividers from channels 13 and 14 (X9, X10) - Switch channel 15 from compensation mode to normal input (X11) The required module assignments and configuration is described in Chapter 3.4. The figure below shows the connection of resistance-type sensors: M+ + Multiplexer + - Pt 100 M- + - S+ + Iconst + S- + - Bild 3-1 Fig. 3.1.4/1 Connection of resistance-type sensors IP244B C79000-B8576-C865-01 3-23 Operation 3.1.5 Open Wire Diagnostics With thermocouples, the module performs open wire diagnostics for the analog inputs 0...12 and 15. To do this, a brief test current is sent to the measuring loop and measured. Safe functioning requires the sensor source resistance to be less than 1 kW. One side of the sensor must be grounded (see Chapter 3.1). Depending on the configuration, the diagnostics can activate an emergency and switch over to an alternate thermocouple, an alternate Pt 100, or a sensor. Open wire diagnostics are automatically disabled when the characteristic curve linearization is de-activated. 3.2 Digital Outputs There are 17 outputs available for outputting the manipulated variables. The outputs are shortcircuit-proof and protected against interference voltage. LEDs on the front panel indicate the states of the output stages (see Chapter 2.2.2 for connector pin assignments of the X4 connector). 3.3 Interface to the CPU Communications with the CPU is performed according to the bus specifications that are valid for SIMATIC S5 systems. The temperature controller occupies 32 bytes of the CPU address space. Writing a message frame number (0 ... 63) permits 64 different data block message frames of 31 bytes each to be transferred to or from the CPU module (see message frame structure). Thus, 2048 bytes are available in the transfer RAM on the module for transferring parameters or measured values. The FB 162 function block is available for configuring and handling the module. The address code can be selected as S5 bus (PESP' + 8 address lines) or PESP + 12 address lines (addressing socket J77). In S5, data transfer can be done using byte or word commands. The sequence of high byte and low byte is irrelevant. ADB 0...ADB 7 (ADB 11) PESP' RDY CPU module DB 0 ... DB 7 Temperature controller 244 MEMWR MEMRD Fig. 3.3/1 Signal transfer 3-24 IP244B C79000-B8576-C865-01 Operation 3.4 Switches and Jumpers X1 bus connector 1 2 3 4 5 6 7 8 off on off on 2 4 X12 2 4 6 8 1 3 X6 1 3 5 7 A 76 A 77 2 4 6 8 101214 16 X8 1 3 5 7 9 111315 2 4 2 4 X2 1 3 X5 L+ 2 4 X9 2 4 6 X10 1 3 X4 DA 1 3 X11 1 3 5 X3 AE = Jumper inserted = Jumper not inserted Fig. 3.4 Jumper settings upon delivery (thermal voltage measurement 51.2 mV) X1 X3 X4 X5 A76 A77 Backplane connector Front connector for analog inputs Front connector for digital outputs Connector for L+ load voltage Module address ADB 8-11 (DIL switch); see Chapter 3.4.1 Module address ADB 5-7 and PESP (DIL switch); see Chapter 3.4.1 X6 X8 X12 Jumpers; see next page X2 X9 X10 X11 Thermocouple/ Pt 100 selection; see next page Mode channel 13 Mode channel 14 Mode channel 15 IP244B C79000-B8576-C865-01 3-25 Operation Pt 100 mode Thermocouple mode (delivery state) X2 1 2 3 4 X8 1 3 5 7 9 11 13 15 2 4 6 8 10 12 14 16 X9 1 2 3 4 X10 1 2 3 4 1 3 5 X11 2 4 6 Thermal e.m.f. measurement with reference junction via channel 15 1-2, 3-4, 5-6: 51,2 mV input sensitivity 7-8: not used 9-10, 11-12, 13-14, 15-16: Thermal e.m.f. measurement Channel 13: 1:400 voltage divider active X2 1 2 3 4 X8 1 3 5 7 9 11 13 15 2 4 6 8 10 12 14 16 X9 4-wire Pt 100 measurement 1-2, 3-4, 5-6: 512 mV input sensitivity 7-8: not used 9-10, 11-12, 13-14, 15-16: Pt 100 resistance-type sensor 4-wire circuit Channel 13: X8 selects sensitivity 1 2 3 4 (1:400 divider inactive) Channel 14: Same sensitivity as selected by X8. (1:400 divider inactive) X10 Channel 14: 1:400 voltage divider active 1 2 3 4 Channel 15: Reference junction temperature measurement with Pt 100 in 3-wire circuit 1 3 5 X11 2 4 6 Channel 15: Normal input channel; same sensitivity as selected by X8 General selections 1 3 5 7 1 X6 X12 3 3-26 2 4 6 8 1-2: not used 3-4: jumper D 5-6: inserted 7-8: not inserted 2 BASP not effective for test purposes only, must remain open 4 = jumper inserted = jumper not inserted 50 Hz Netzunterdruckung 2 4 6 8 1-2: not used 3-4: jumper D (see Programming Instructions) 60 Hz Netzun5-6: inserted terdruckung 7-8: not inserted 1 2 3 4 BASP has an effect on digital outputs for test purposes only must remain open 1 3 5 7 X6 X12 IP244B C79000-B8576-C865-01 Operation 3.4.1 Setting the Module Address Each temperature controller module 244 requires 32 addresses for transferring the necessary parameters. Only the start address of each module must be set. The next 31 addresses are assigned by internal decoding and are no longer available to other modules. The addresses can be selected in multiples of 32. 8 7 6 5 4 3 2 1 8 P E 7 6 PESP break S 5 4 2 1 Break 28... 211 P 28 29 210 211 256 DIL switch A 76 for ADB 8 ... 11 3 25 26 27 32 64 128 DIL switch A 77 for ADB 5 ... 7 Switch A 77 No. EU CU Proces range Q area AG 135 U AG 155 U AG 115U (CPU 945) only in EU EU Switch A 76Baugruppenadresse Module address CU Einstellen SetBereich Range 5 7 8 off on on on on on 28..211 = off uber 28 =on A 77 29..211 = off by A 77 P area all PLCs 5 7 8 off on on on on on 28..211 = off uber 28..211 = off A 77 by A 77 ABS area AG 115 U 5 7 8 on on off on on off 28..211 = off 28..211 = off uber by A 77 0..224 0..224 128..224 128..224 0..224 0..224 Address parameter with FB 162 0 1 2 A 77 Example: The start address of the temperature controller module is n = 160 in the P area of the CU. Set the switches as follows: off on off on 1 2 3 4 5 6 7 8 The next module may then be aasigned from address 192 (160 + 32) onwards. A 76 A 77 IP244B C79000-B8576-C865-01 3-27 Operation 3.4.2 Selecting the Conversion Time of each Channel Thermocouples, resistance-type sensors and other general-purpose sensors may be connected to the analog inputs. The selected conversion time of the analog-digital converter defines the resolution in counts of the analog input signals. The plug-in jumper D defines the conversion time of the individual channels. Jumper D does not have an effect in Pt 100 mode. Here, a fixed conversion time of 80 ms has been selected. Jumper D (X6/3-4) Jumper D inserted 60 ms = 0...51, 2 mV (channels 0...12) = 0...20.48 V (channel 13/14) = 0...2048 units or 0...512 mV depends on configuration open 50 ms = 0...25, 6 mV (channel 0...12) = 0...10,24 V (channel 13/14) = 0...1024 units or 0...256 mV depends on configuration 2 4 6 8 X6 1 3 5 7 Conversion time and resolution In the special function "measuring via channels 13 and 14", a fixed conversion time of 55 ms has been selected. With the possible thermocouples or resistance-type sensors, the following maximum temperature values for setpoint definition result from the sensor voltage and the selectable conversion times: Conversion time Sensor type 50 ms 55 ms 60 ms Jumper D open Special function Jumper D inserted C F C F C F 80 ms Pt 100 mode C F Type L Type J Type K Type S Type R Pt 100 450 450 600 1600 1740 830 3-28 842 675 842 675 1112 900 2912 1600 3100 1740 1247 700 842 700 1652 1200 2912 1600 3100 1740 1292 1292 2192 2912 3100 1526 IP244B C79000-B8576-C865-01 Operation The following table specifies the maximum actual values that can be read: Conversion time Sensor type Jumper D open 50 ms Type L Type J Type K Type S Type R Pt 100 460 467 616 3063 2100 C F 55 ms Special function C F 861 678 874 688 1141 926 5547 3063 3812 2100 60 ms Jumper D inserted C F 1254 878 1270 889 1700 1265 5547 3063 3812 2100 1612 1632 2310 5547 3812 80 ms Pt 100 mode C F 850 1562 Please refer to DIN 43710 or IEC 584 for the characteristic curves of the thermocouples. The Pt 100 curve has been taken from DIN 43760. The characteristic curves of the valid sensors are linearized internally by the firmware. The sensors are selected by configuration (see Section 3 of this Manual). The maximum actual values that can be read are indicated in an openwire situation. 3.4.3 Clock Selection The integration time can be selected to obtain maximum noise suppression at 50 Hz or 60 Hz mains frequency. X6 5-6 X6 7-8 x Integration time 50-Hz mains noise suppression (20 ms) 2 4 6 8 X6 1 3 5 7 x 60-Hz mains noise suppression (162/3 ms) 3.4.4 BASP Interpretation The BASP signal can either be interpreted or interpretation can be disabled by the X12/1-2 jumper. BASP = 1 resets the output registers. X12/1-2 open: BASP signal is not interpreted X12/1-2 inserted: BASP signal is interpreted If BASP is not interpreted, additional external measures or devices must ensure that the machine is forced to a safe operating state in the event of a malfunction (cf IEC 204-1). In STOP mode, the S5 CPU is unable to respond to error messages from the IP (e.g. actual value too high; watchdog, ...). IP244B C79000-B8576-C865-01 3-29 Operation 3.4.5 Comparison of the Jumper Assignments of 6ES5244-3AA22/-3AB31 Thermocouple mode (delivery state) 6ES5244-3AB31 1 X2 3 1 3 5 7 9 11 13 15 1 X8 X9 2 4 6 8 10 12 14 16 2 4 X10 3 1 3 5 Thermal e.m.f. measurement with reference junction via channel 15 4 3 1 2 6ES5244-3AA22 2 1-2, 3-4, 5-6: 51,2 mV input sensitivity 7-8: not used 1-1, 2-2, 3-3: 9-10, 11-12, 13-14, 15-16: Thermal e.m.f measurement 5-5, 6-6, 7-7, 8-8: 2 4 6 1 2 3 5 6 7 8 5 6 7 8 Channel 13: 1:400 voltage divider active R83 and R84 in delivery state Channel 14: 1:400 voltage divider active R85 and R86 in delivery state 4 X11 X8 X9 1 2 3 Channel 15: Reference point temperature measurement with Pt 100 in 3-wire circuit 9 10 X8 X9 9 10 Pt 100 mode 6ES5244-3AB31 1 X2 3 1 3 5 7 9 11 13 15 1 4 X8 X9 3 1 X8 X9 1-2, 3-4, 5-6: 512 mV input sensitivity 7-8: not used 9-10, 11-12, 13-14, 15-16: Pt 100 resistance-type sensor 4-wire circuit 2 Channel 13: Same sensitivity as selected at X8 (1:400 divider inactive) R83 shorted, R84 removed Channel 14: Same sensitivity as selected at X8 (1:400 divider inactive) R85 shorted R86 removed 2 4 X11 Pt 100 measurement in 4-wire circuit 2 4 6 8 10 12 14 16 4 X10 3 1 3 5 2 6ES5244-3AA22 2 4 6 Channel 15: normal input channel Same sensitivity as selected at X8 1 2 3 1 2 3 5 6 7 8 5 6 7 8 9 10 X8 X9 9 10 General selections 6ES5244-3AB31 1 3 5 7 1 3 5 7 1 X6 X6 X12 3 1 3 3-30 2 4 6 8 1-2: not used 3-4: jumper D 5-6: inserted 7-8: not inserted 2 4 6 8 1-2: not used 3-4: jumper D (see Programming Instructions) 5-6: not inserted 60 Hz Netzunterdruckung 7-8: inserted 2 1-2: BASP not effective 3-4: for test purposes only, must remain open 4 X12 6ES5244-3AA22 2 4 50 Hz Netzunterdruckung 1-2: BASP has an effect on digital outputs 3-4: for test purposes only, must remain open 1-1 2-2 inserted 3-3 not inserted 4-4 1 2 3 4 1-1 2-2 not inserted 3-3 inserted 4-4 1 2 3 4 4-4 4 4 X6 X7 X6 X7 X8 X9 X8 X9 1 2 3 4 1 2 3 4 4 4 IP244B C79000-B8576-C865-01 Operation 3.5 Pin Assignment Backplane connector 1: d 2 4 3.6 UBAT z 0V +5V PESP 6 ADB 0 CPKL 8 ADB 1 MR 10 ADB 2 MW 12 ADB 3 RDY 14 ADB 4 DB 0 16 ADB 5 DB 1 18 ADB 6 DB 2 20 ADB 7 DB 3 22 ADB 8 DB 4 24 ADB 9 DB 5 26 ADB 10 DB 6 28 ADB 11 DB 7 30 BASP 32 0V Pin Assignment of Connecting Cables 6ES5 721 4xxx0 6ES5 721 5xxx0 + 1 + + 37 19 37 19 + + 20 1 + + + 20 b Fig. 3.6/1 Connecting cable IP244B C79000-B8576-C865-01 3-31 Operation Connecting cable for temp. controller 6ES5 7214 . . . Pin assignment table Pin of Bundle/ Core 37pin sleeve color connector color wt 1 br 20 gn 2 ye 21 1 gr 3 rd pi 22 bl 4 rd 23 wt 5 br 24 gn 6 ye 25 2 gr 7 gn pi 26 bl 8 rd 27 wt 9 br 28 gn 10 ye 29 3 gr 11 ye pi 30 bl 12 rd 31 wt 13 br 32 gn 14 ye 33 4 gr 15 br pi 34 bl 16 rd 35 wt 17 br 36 gn 37 ye 18 5 gr 19 bk pi bl rd wt br gn 6 ye bl gr pi Shield Connecting cable for temp. controller 6ES5 7215 . . . bk Pin assignment table Bundle/ sleeve color Casing For digital signals (plug connector) Pt 100 connection to channel 15 Chassis connection Core color wt br gn ye gr pi bl rd wt br gn ye gr pi bl rd wt br gn ye gr pi bl rd wt br gn ye gr pi bl rd wt br gn ye gr pi bl rd wt br gn ye gr pi 1 rd 2 gn 3 ye 4 br 5 bk 6 bl Shield Pin of 37pin connector 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 37 18 19 16 16 16 17 16 16 16 16 16 Casing rd 5 1 rd wt 6 4 rd wt bl 2 gn gn 3 br wt ye Cable structure with core and sleeve colors Cable type: LIYCY/R3x2x0,09 Length key and order numbers: Order no. also rating plate labelling 6ES5 7215 . . . 0 6ES5 7214 . . . 0 AG0 AJ0 BB0 BB2 BB5 BC0 BC5 BD2 BE0 BF0 BG3 BJ0 CB0 CB2 CB5 CC0 CC5 CD2 CE0 CF0 CG3 CJ0 DB0 DB2 DB5 DC0 DC5 DD2 DE0 DF0 DG3 DJ0 EB0 Length L in meters 0.6 0.8 1.0 1.2 1.5 2.0 2.5 3.2 4.0 5.0 6.3 8.0 10 12 15 20 25 32 40 50 63 80 100 120 150 200 250 320 400 500 630 800 1000 For analog signals (socket connector) / connect core 17 twice } see / connect core 16 nine times Fig. 3.1.3/1 Fig. 3.6/2 Connecting cable (accessories) 3-32 IP244B C79000-B8576-C865-01 Operation 4 Spare Parts Plugin jumper (Mini-Jump) Connecting cable for digital outputs Connecting cable for analog inputs W79070-G2601-N2 6ES5 721-4xxx0 6ES5 721-5xxx0 See page 36 for length code IP244B C79000-B8576-C865-01 3-33 Operation 3-34 IP244B C79000-B8576-C865-01 SIMATIC S5 IP 244 Temperature Controller 6ES52443AA22 and 3AB31 Programming Instructions C79000B8576C86002 Contents Contents Page 1 1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9 1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 Description of the Firmware Functional Description of Temperature Control Closed-Loop Control Actual Value Processing Manipulated Variable Processing, Outputs-Heating Switch Setpoint Processing, Closed-Loop Control Monitoring Functions and Error Messages 20.48 V Channels (for Special Function) Comparator Software Release Module Number Self-Tuning Temperature Controller Introduction Mode of Operation Calculated Parameters Which Controlled Systems Can the Self-Tuning Function be Used With? Assigning Parameters for the Self-Tuning Function 4-5 4-5 4-6 4-7 4-8 4-10 4-11 4-15 4-15 4-15 4-15 4-16 4-16 4-17 4-20 4-21 4-21 2 2.1 2.2 2.3 2.4 2.5 2.6 Data Exchange with the Central Controller Messages 0 to 12 (Controller Parameters) Messages 13 and 14 Message 15 Message 16 Messages 17 to 21 Messages 22 to 63 4-23 4-25 4-38 4-39 4-55 4-61 4-66 3 3.1 3.1.1 3.1.2 3.1.3 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 Special Functions for Plastic Machines Hot Channel Control Introduction Approach Phase Controller Sampling Time for Hot Channel Control Cascaded Control Introduction: Example Plastic Processing Machines Description of the Controller Structure Selecting Cascaded Control Parameter Assignment for Cascaded Control Changes/Additions to the Messages Notes on Operation with Cascaded Control 4-73 4-73 4-73 4-73 4-74 4-75 4-75 4-75 4-75 4-76 4-76 4-77 4-2 IP244 C79000-B8576-C860-02 Contents 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.5 Heating Current Monitoring Selecting the Heating Current Monitoring Distribution of the Controller Channels Input of Parameters for Heating Current Monitoring Actual Current Value Monitoring Indication and Signalling Concept of the Heating Current Monitoring Special Function, Measured Value Acquisition at Channels 13 and 14 Selecting the Special Function Stipulating the ADC Conversion Time Processing Sequence of the Analog Inputs Converting Voltage Values to Physical Values Processing the Special Function Miscellaneous Extensions to the Message Exchange 4-83 4-83 4-83 4-85 4-85 4-88 4-103 4-103 4-103 4-103 4-104 4-105 4-106 4-107 4 4.1 4.2 4.3 4.4 4.5 4.6 Notes on Controller Settings Characteristics of the Controlled System Controller Type (2-Step, 3-Step Controllers) Control Action with Different Feedback Structures Selecting the Controller Structure for a Given System Setting the Controller Characteristics (Tuning) Determining the System Parameters for 2/3-Step Controllers (when Main Control Byte 1, Bit 2 = 0) Determining the System Parameters for Purely Cooling Controllers (when Control Byte 1, Bit 0 = 0 and Bit 2 = 1) 4-123 4-123 4-124 4-127 4-134 4-135 4.7 IP244 C79000-B8576-C860-02 4-137 4-139 4-3 Contents 4-4 IP244 C79000-B8576-C860-02 Description of the Firmware 1 Description of the Firmware 1.1 Functional Description of Temperature Control Central controller (CC) Actual values Duration of monitoring We1 Min. values Max. values We2 Cumulative setpoints Parameters HD Setpoint ramping Manipulated variables Sampling time AI 0 W . . Error messages Input circuit . Linearization . . Compensation AI 12 AI 13 A - Xd XKorr K0 TD 0 + +100% D action Kp Tolerance monitoring Averaging -100% TN 0 I action AI 14 AI 15 HCR Measured value acquisition A 2 step Pulse shaping stage 2step output 3step output 3 step A AI 0 to 14 AI 15 HCR HD KP TD Off switch for controllers (heating switch) Analog inputs (channels 0 to 14) Compensation input (channel 15) Heating-cooling ratio Manual manipulated variable Controller gain Derivative action time TN W We1 We2 Xd Xkorr Integral action time Smoothed setpoint Temperature setpoint Lower setpoint System deviation Corrected analog value Fig. 1.1/1 Function diagram of the controller The controllers are stored in the form of an algorithm in an EPROM as continuous controllers with pulse output (pulse-duration modulated). The controllers are switching 2-step or 3-step controllers with percentage output. The 13 control loops are processed cyclically in the processor section of the module. The module is configurable within certain restrictions. The firmware contains a set of functions from which the required functions can be selected. This selection is made by setting bits in control bytes and main control bytes. The parameters for the controllers are transferred to the module for each controller separately in one or two messages. IP244 C79000-B8576-C860-02 4-5 Description of the Firmware 1.1.1 Closed-Loop Control The following equation of a PID controller for manipulated variable y (t) as a function of the system deviation x (t) applies: 1 YPID(t) = Kp { x(t) + ---- TN dx(t) x(t)dt + TD ---------- } dt Implementation as a sampling controller allows the representation in the parallel arrangement shown below: Actual value Actual value processing Controlled system Manipulated variable Output Manual i wk I Setpoint P Setpoint processing Swk + ik pK ek System deviation D Manipulated variable generation dK Sk + Kp Fig. 1.1.1/1 Basic structure of the controller The system deviation at instant k * TA is processed in the three parallel branches: P-branch: pk = ek I-branch: TA ik = ik-1 + ------ (ek + ek-1) 2TN 2TD TA - 2TZ D-branch: dk = --------------- (ek - ek-1) - ----------------- dk-1 TA + 2TZ TA + 2TZ Where: TA = TN = TD = TZ = 4-6 sampling time integral action time derivative action time filter time constant for damping the derivative influence, selected: TZ = 2TA IP244 C79000-B8576-C860-02 Description of the Firmware The manipulated variable (Sk) is obtained as follows Sk = KP (pk + ik + dk), converted to a value as a percentage of the sampling time. The individual branches can be disabled by setting the appropriate parameters TN, TD to 0. If you do not require the P-branch, the gain KR must be entered as 0; KP is then internally set to 1. To avoid the wind-up effect, the integration is interrupted when the manipulated variable reaches 100 % or when the manipulated variable of a 2-step controller is less than -12% (this only applies to a purely heating controller). For a purely heating controller, the I-action can never be negative. For a purely cooling controller, the same applies in reverse: +12% and the I-action is always negative. The derivative branch contains a first order filter to damp the control action. The calculated manipulated variable is converted to a heating or cooling time in multiples of 50 or 60 ms depending on the heating-cooling ratio. In Pt 100 operation, this is converted to a multiple of 80 ms (if the special function is selected, the time base is then a multiple of 55 ms). 1.1.2 Actual Value Processing The analog inputs (controller inputs) are read in cyclically and checked for line breaks. Depending on the selected type of sensor, the signal is linearized according to a stored characteristic curve and a temperature value is calculated (exception: linear sensors). In the case of thermocouples, a reference junction compensation is carried out on the module. Thermocouples supply a voltage proportional to the temperature difference (T1-T2) across the thermocouple. To determine the absolute temperature, the temperature of the reference junction must be compensated. Fe Cu UTh IP 244 Cu Measuring junction temperature T1 Reference junction with temperature T2 The following equation applies for the thermal e.m.f.: UTh = k * (T1 - T2 ) [V] (k = constant dependent upon type of thermocouple). IP244 C79000-B8576-C860-02 4-7 Description of the Firmware To obtain a temperature related to 0 C, the reference junction is acquired as UTH 2= K T 2 and is included in UTh. The temperature compensation is performed via a Pt 100 resistance thermometer with which the reference junction temperature is read in at the beginning of each cycle. The Pt 100 at channel 15 is also checked for line break. If a line break or a temperature > 60 C is detected, an error bit is set (message 16, byte 2). In this case, the value of the ambient temperature before the error was detected is used for further calculation. If the error occurs immediately after parameter assignment, the ambient temperature 0 C (= 32 F) is used. To indicate the actual value, a filter can be looped into the signal path. If this is required, appropriate parameters must be assigned. The actual value is displayed with a time delay after averaging eight values. If more than 1024 or 2048 encoding units (or 3997 encoding units in pure Pt 100 operation and 1536 encoding units with the special function) are read in, the actual value is limited to the maximum value. The actual values can be represented either as binary or BCD coded values as required. The actual values are stored in message 17. If BCD coding is required, the values are stored as follows: S5 format Address n: thousands hundreds Address n + 1: tens units 1.1.3 Manipulated Variable Processing, Outputs-Heating Switch The module has 17 digital control outputs for the 13 controllers. This means that nine 2-step controllers and four 3-step controllers or a maximum of eight 3-step controllers and one 2-step controller can be configured (control byte 1). Depending on the configuration, the outputs of 2 or 3-step controllers are assigned to the inputs internally by the firmware. If, for example, three controllers are configured as 2-step controllers with input channels 0, 1 and 2, the manipulated variables are output at outputs 17, 16 and 15 respectively. If a 3-step controller is configured as the fourth controller with input channel 3, the manipulated variable (e.g. heating, cooling) will then be output at outputs 14 and 13. The manipulated variable calculated from the control algorithm forms a 2 or 3-step signal depending on the configuration. With the pulse-duration modulation (percentage output), the manipulated variable (heating or cooling) is only output for the part of the sampling time (TA) which corresponds to the calculated value of the controller output signal. The smallest ON interval is 50, 55, 60 or 80 ms depending on the parameter assignment (see Operating Instructions in this manual, Section 3.4.2). At a sampling time of 10 s, for example, a resolution of maximum 0.5% is achieved at an ON interval of 50 ms. To suppress short ON or OFF times, a response threshold can also be input. 4-8 IP244 C79000-B8576-C860-02 Description of the Firmware The calculated analog manipulated variables as percentages are output in message 18 for channels 0 to 12. In the programmable controller, they can be passed on to an analog output. On Average > 50% Off On Average < 50% Off On 50% Off TA 2TA 3TA t TA sampling time Fig. 1.1.3/1 Percentage output With percentage output, the average of the manipulated variable is controlled by the pulse duration modulation at a constant frequency (= 1/TA). The stronger or weaker control action of cooling compared with heating (e.g. water cooling) can be taken into account with 3-step controllers by setting a heating-cooling ratio (as a percentage). If manual operation is intended, the manual manipulated variable to be set as a percentage is calculated as the corresponding proportion of the sampling time according to the pulse duration modulation. Heating switch (digital input) The heating switch (socket connector X4, pin 1) can be used to disable the controller outputs, if this was set for each controller individually. Pin 1, X4 connected to L+ Pin 1 open DQs enabled; DQs disabled. The disabling effect of the heating switch can be cancelled for each controller by setting bit 2 in control byte 2 of the controller messages. When the DQs are switched off, the controllers are stopped, the control algorithm is interrupted and error messages cleared. This allows a "bumpless" restart. IP244 C79000-B8576-C860-02 4-9 Description of the Firmware 1.1.4 Setpoint Processing, Closed-Loop Control For each controller, two setpoints and two positive and two negative tolerances can be set. If these values are violated, an error bit is set. Zone upper limits or lower limits can be preset for each individual controller. The control operates within these zones (zone control). It is also possible to specify a response threshold for the output manipulated variable. If, for example, a response threshold of 10% is specified, the calculated values will only be output in the range from 10 to 90%; under 10% the output is disabled, above 90% it is always enabled. To smooth sudden setpoint changes, a ramp can be planned with a slope in C/h. Fig. 1.1.4/1 shows an example of the curve of the actual setpoint value (setpoint ramping). The ramp begins at the current actual value and continues until the required setpoint is reached. If the setpoint is changed before the old value is reached (as at t4 in Fig. 1.1.4/1) the ramp is restarted with a negative slope. The output for the setpoint ramping is indicated in message 21. If no setpoint ramping is used, the setpoint you have selected is indicated in message 21. This does not apply to cascaded control. T Selected setpoint Actual setpoint value Actual (measured) value 0 t1 t2 t3 t4 t Fig. 1.1.4/1 Actual curve of the setpoint with setpoint ramping Temperature setpoints and actual values can be input or output in degrees Celsius or degrees Fahrenheit. Degrees Celsius are converted to degrees Fahrenheit by the following formula: T [F] = (T [C] x1.8 + 32); The parameters are written to the transfer RAM of the module by the CPU at system start up using function block FB 162. 4-10 IP244 C79000-B8576-C860-02 Description of the Firmware 1.1.5 Monitoring Functions and Error Messages Setpoints Two setpoints can be entered for each controller. The setpoint must not exceed the maximum value. - If a higher setpoint is entered, an error bit is set and the value is limited to the maximum value. - If the second setpoint (lower setpoint) is greater than the first setpoint, it is limited to the first setpoint and an error bit is set. Actual values, tolerances Two upper and two lower tolerances can be set for each controller. The following states can be monitored: - Actual value is greater/less than setpoint plus first positive tolerance or setpoint minus first negative tolerance corresponding error bit is set. - Actual value remains within the second tolerance band and returns to the first tolerance band the most extreme value reached is stored. This can be read by the CPU (in message 19 and 20). - Actual value violates the second tolerance band depending on the parameter assignment (in message 15) the affected controller may be disabled. T w1+2nd pos. tolerance w1+1st pos. tolerance Temperature setpoint w1 w1-1st neg. tolerance Lower setpoint w2 w1-2nd neg. tolerance w2-1st neg. tolerance w2-2nd neg. tolerance Switchover to 2nd setpoint t Fig. 1.1.5/1 Tolerance bands IP244 C79000-B8576-C860-02 4-11 Description of the Firmware T W+2nd pos. tolerance Store maximum value c b a Store maximum value d a b W+1st pos. tolerance 2nd tolerance band Setpoint W 1st tolerance band Actual value W-1st neg. tolerance e W-2nd neg. tolerance h g f Store minimum value t If the appropriate parameters are set in main control byte 4, the controller is disabled when the actual value was within the first tolerance band at least following a setpoint change. Fig. 1.1.5/2 Response at the tolerance limits a b c d e f g h Error bit "1st pos. tolerance exceeded" is set. Error bit "1st pos. tolerance exceeded" is reset. Error bit "2nd pos. tolerance exceeded" is set and controller disabled, if programmed. Error bit "2nd pos. tolerance exceeded" is reset, controller resumes operation. Error bit "below 1st neg. tolerance" is set. Error bit "below 2nd neg. tolerance" is set and the controller disabled, if programmed. Error bit "below 2nd neg. tolerance" is reset. If the controller was disabled, it only resumes operation if the commands "KS", "AE", "PA" or "AS" are executed in FB 162. Error bit "below 1st neg. tolerance" is reset. The extreme value acquisition is active whenever the actual value is outside the 1st tolerance band. If the actual value returns to the 1st tolerance band, the extreme value acquisition is reset and only restarted when the value once again leaves the tolerance band. Old extreme values are retained until new values are detected. The table below shows how the displays and tolerance evaluations are combined (not applicable when heating current acquisition is selected): Function Standard controller Special function selected " Channel No. Display of neg. actual values Tolerance evaluation With neg. setpoints With setpoint = 0 With heating switch= Off 0 to 12 no *) - no no 13, 14 yes no yes - 0 to 12 no *) - no no 13 14 no *) no *) - no yes - *) IP internal, the actual value is set to "0". 4-12 IP244 C79000-B8576-C860-02 Description of the Firmware Line break All analog inputs with sensors directly connected (thermocouples, Pt 100s) are checked for line break. If voltage dividers or shunt resistors are connected on channels 7 to 15 or if transducers are being used, no wire break check is possible. If a line break is detected (no actual value present), the following reactions are triggered depending on the configuration: control is disabled and a manipulated variable averaged over a selectable period of time is output until the line break is dealt with (emergency program, see Section 2.3). or the manipulated variable is disabled until a percentage value for the manipulated variable is entered manually (manual manipulated variable). or the module switches automatically to a substitute sensor (or analog input) connected to a different input, if inputs are still free. The substitute sensor bit is set and error identifiers are set (line break message A and B) and the maximum value (460 to 3063 C) is indicated as the actual value. If no actual value is present (line break), there is no evaluation of the tolerances. Summary of the messages Individual error bits are set separately for each controller (0 to 12) in the following situations: - - - - - - - - - - 1st positive tolerance exceeded, value below 1st negative tolerance, 2nd positive tolerance exceeded, value below 2nd negative tolerance, temperature setpoint too high, lower setpoint higher than temperature setpoint or too high, line break in thermocouple or Pt 100, switch over to substitute thermocouple, short circuit at the Pt 100, short circuit identified with thermocouple. IP244 C79000-B8576-C860-02 4-13 Description of the Firmware The following errors are indicated for channels 13 and 14: - positive tolerance exceeded, - value below the negative tolerance. A channel group error bit is generated for each individual controller or channel and a general group error bit is generated in the function block for the module. If the setpoint is zero or the heating switch is off, there are no signals for the corresponding controller. You have easy access to the following error messages via the function block: Program monitoring (watchdog) To monitor the correct execution of the program, the CPU interrogates a monitoring bit. This bit changes its state once per second when the program is correctly executed (firmware watchdog). If an error is present, it is indicated by the CPU in the user program via the function block (FB 162). If the CPU accesses the module too often and interferes with the internal timing, this is signalled via the function block. Voltage monitoring (reset) A monitoring circuit monitors the module for voltage failures and dips in the 5 V supply. It generates a defined reset pulse of < 10 ms for the microprocessor and the output registers of the digital outputs when the power supply returns. Following this, the module must be re-supplied with data and parameters. [v] +5V UB UTH t UB Reset UTh = threshold voltage Operation Reset Operation t Fig. 1.1.5/3 Reset pulse diagram 4-14 IP244 C79000-B8576-C860-02 Description of the Firmware 1.1.6 20.48-V-Channels (for Special Function) If jumper D (see jumper settings in C79000-B8576-C659) is inserted, 0 to 20.48 V can be connected to channels 13 and 14 (2048 units). If a measured value is outside a tolerance band above and below the setpoint, an error bit is set. The actual values for the two channels are stored in message 17, along with the actual temperature values of the controller. (The resolution is 10 mV.) The sampling time for the two transducer inputs 13 and 14 is as follows: jumper D inserted: jumper D not inserted: 960 ms 0 to 20.48 V ---------------------- 800 ms 0 to 10.24 V Channels 13 and 14 are only processed if the appropriate parameters are set. They are not processed with hot channel control, heating current monitoring or Pt 100 operation. 1.1.7 Comparator (Variant -3AA22 only) The comparator supplies a 24 V signal at digital output K, when the voltage applied to channel 13 reaches or exceeds a preset value in the range from 0 to 1024 = 0 to 10.24 V. The comparator cannot be switched over to channel 14. 1.1.8 Software Release The software release is stored at address 7FFFH in the firmware. It can be read by the PLC from byte 15 in message 16. 1.1.9 Module Number The module number can be read from byte 14 in message frame 16 (see table below). This byte contains the last two figures of the module's MLBF number.. Module Byte 14 in message frame 16 (module number) 6ES5 244-3AA22 22 6ES5 244-3AB31 31 IP244 C79000-B8576-C860-02 4-15 Description of the Firmware 1.2 Self-Tuning Temperature Controller 1.2.1 Introduction When correctly tuned, PID controllers achieve good control results with a wide variety of thermal processes. However, the selection of the control parameters can be relatively time-consuming. The self-tuning function implemented in the temperature controller module (EPROM) executes an automatic process identification during the heating procedure and determines the optimum controller parameters. The self-tuning is suitable for slow changing processes with connected heating control loops as found, for example, in plastic processing. The controller self-tuning function is particularly advantageous when the controlled system reacts differently at different operating points in the process, since the controller parameters for the particular operating point can be optimized. The selftuning function is not available for 2step controllers which are only used for cooling. This also applies to hot channel control and the master controller of a cascaded control system. The parameters determined by the selftuning function can be transferred to the programmable controller in messages by function block FB 162. This means that you can store or modify the parameters and, if necessary, reassign them to the IP. Parameter monitoring Oscillation detector KR Setpoint + TN Rugged Controlled PID controller system Actual value KR,TN,TD,Zo,TA,H/K Selftuning function Fig. 1.2.1/1 Structure of the temperature controller with self-tuning function 4-16 IP244 C79000-B8576-C860-02 Description of the Firmware 1.2.2 Mode of Operation Fig. 1.2.1/1 shows the structure of the temperature controller with self-tuning function. In addition to the PID controller as described in Chapter 1, the following functions are also included: - self-tuning, - parameter monitoring, - PID controller in rugged design. - The "self-tuning function" performs a process identification and determines the optimum controller parameters. It also controls the process during the self-tuning phase. On completion of the self-tuning, the rugged PID controller takes over process control. - The "parameter monitoring" function checks whether the controlled system has changed its characteristics, if necessary reduces the controller gain and increases the integral action time. - A rugged PID controller is obtained from the conventional PID control algorithm, which is not sensitive to small control system changes as caused, for example, by plastic-granulate change. IP244 C79000-B8576-C860-02 4-17 Description of the Firmware Fig. 1.2.2/1 shows a typical temperature curve during a heating process with a 2-step controller, for which the self-tuning function performs a process identification. From the data of the process identification, the self-tuning function determines the optimum controller parameters. During this heating procedure, overshoot up to 8 C can occur. Fig. 1.2.2/2 shows a heating process with the same controlled system as shown in Fig. 1.2.2/1. The controller operates with the parameters determined by the self-tuning function for this system. Fig. 1.2.2/3 shows a temperature curve during a heating process with a 3-step controller in which the self-tuning function performs the process identification. During the heating process, the self-tuning function switches the cooling on in addition to the heating to determine the ratio of the heating and cooling actions. It is possible at times for the cooling function to operate alone. Tem pera ture Selftuning with process identification and determination of the controller parameters Control with selftuned parameters 190 C 10 20 30 min Time Fig. 1.2.2/1 Heating process with self-tuning function (2-step controller) while determining parameters 4-18 IP244 C79000-B8576-C860-02 Description of the Firmware Tem pera ture 190 C 10 20 30 min Time Fig. 1.2.2/2 Heating process with self-tuned controller following determination of parameters Tem pera ture Selftuning with process identification and determination of the controller parameters Control with selftuned parameters 190 C Heating and cooling switched on simultaneously 10 20 30 min Time Fig. 1.2.2/3 Heating process with self-tuning (3-step controller) while determining parameters IP244 C79000-B8576-C860-02 4-19 Description of the Firmware 1.2.3 Calculated Parameters Following the process identification, the self-tuning function calculates the controller parameters sampling time (TA), controller gain (KP), integral action time (TN), derivative action time (TD) upper and lower control zone (ZONOB, ZONUN) and with 3-step controller, the heating-cooling ratio (HCR) or a separate parameter set for cooling. In 3-step controllers, the self-tuning function calculates the lower limit of the control zone while heating and the upper zone limit while cooling. The zones can therefore be asymmetrical. In 2-step controllers, the upper limit is set to match the lower limit and the control zones are therefore symmetrical. After they have been calculated, the parameters are entered in messages. During the selftuning, it is possible that the phase "heating and cooling simultaneously" is followed by an additional phase "only cooling". Criteria for calculating the parameters: TA: longest sampling time at which a control quality less than 1 is achieved KP, TN, TD: for good disturbance response at the operating point ZONOB, ZONUN: for good response when large setpoint changes occur HKV: for an operating point in the range from 100 C (only in 3-step controllers) Since individual parameters are optimized for the operating point, it is advisable to execute the heating procedure until the temperature approaches the operating point. 4-20 IP244 C79000-B8576-C860-02 Description of the Firmware 1.2.4 Which Controlled Systems Can the Self-Tuning Function be Used With? The self-tuning function can be used with systems which meet the following conditions: The system must display a low pass response. This condition is generally met by temperature processes. The control system must allow for the following temperature jump: at least 37 C with 2step controllers, at least 37 C up to 110 C with 2step controllers. The maximum rate of rise of the actual value must not exceed 60 C/min with full heating power or with simultaneous full heating and cooling power. The maximum rise of the actual value must be 0.05 C/min with full heating power. The heating procedure must not require more than 12 hours. With pure Pt 100 operation only 11.6 h is permitted. With mixed operation and one standard controller - and ADC conversion time = 50 ms, only 7.2 h permitted - and ADC conversion time = 60 ms, only 8.7 h permitted. If only the cooling is active, you must guarantee that the actual value falls. A further condition for calculating the cooling parameters is that the actual value must not fall faster than 60 C/min while the selftuning function is heating and cooling simultaneously. Suitable for systems in which no large steplike disturbances (in the automation control sense) occur. To convert to degrees Fahrenheit T [ F] = (T C] x1.8 + 32). 1.2.5 Assigning Parameters for the Self-Tuning Function Each of the 13 temperature controllers can be assigned parameters to operate as a standard or self-tuning temperature controller. This allows mixed controlled systems, some meeting the required conditions and some not meeting the required conditions, to be operated with one temperature controller module. The self-tuning function is specified in messages 0 to 12 in the "self-tuning" byte (byte 22). The self-tuning function and the end of the self-tuning phase are indicated in a separate bit for heating and cooling. If only heating parameters and no cooling parameters have been calculated for a 3-step controller, this is also indicated and a value for the required temperature jump is calculated and indicated to the user. While a controller is running with selftuning function and determines parameters, it can only be accessed by reading (if you try to assign parameters to the controller, the message "parameter error" is output at the FB 162). IP244 C79000-B8576-C860-02 4-21 Description of the Firmware 4-22 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller 2 Data Exchange with the Central Controller The module has a RAM area with a length of 2048 bytes which can be addressed by the central controller. This area is divided into 64 x 32 bytes. The message length and therefore the address area required by the module is 32 bytes. The message number has the highest module address. Example of use in SIMATIC S5: If the module is coded for peripheral address PY 160, the message number must be written to peripheral (I/O) byte PY 191. The information contained in the messages can be written to peripheral bytes PY 160 to PY 190 or read from here. The message number address cannot be read back. Caution! There must be no gaps between the controllers. If parameters are not assigned for a controller, i.e. the parameters are 0, actual values will nevertheless be acquired for this channel and the digital outputs assigned, i.e. the outputs cannot be used for other controllers. If the data (integration values, self-tuning parameters etc.) are to be buffered when using the IP 244 controller module for temperature control, the following points should be noted: a) The module must be inserted in a batterybacked slot. b) The data is lost when the module is inserted or removed. c) When assigning parameters to the module for the first time, function block FB 162 must be called once with the command "KS". d) Following a power failure, the IP 244 requests parameters from the PLC. After the parameters have been assigned with FB 162, the request is cleared. ! Caution Take great care when selecting parameters to ensure that all aspects of safety have been considered. Free data areas within data blocks must always remain unused and have 0 preassigned. IP244 C79000-B8576-C860-02 4-23 Data Exchange with the Central Controller List of messages: Message no. 0 Message no. 1 Message no. 2 Message no. 3 Message no. 4 Message no. 5 Message no. 6 Message no. 7 Message no. 8 Message no. 9 Message no. 10 Message no. 11 Message no. 12 Message no. 13 Message no. 14 Message no. 15 Message no. 16 Message no. 17 Message no. 18 Message no. 19 Message no. 20 Message no. 21 Message no. 22 Message no. 23 Message no. 24 Message no. 25 Message no. 26 Message no. 27 Message no. 28 Message no. 29 Message no. 30 Message no. 31 Message no. 32 Message no. 33 Message no. 34. Message no. 35 Message no. 36 Message no. 37 Message no. 38 Message no. 39 Message no. 40 Message no. 41 Message no. 42 Message no. 43 Message no. 44 Message no. 45 Message no. 46 Controller parameters Controller number 0 Controller number 1 Controller number 2 Controller number 3 Controller number 4 Controller number 5 Controller number 6 Controller number 7 Controller number 8 Controller number 9 Controller number 10 Controller number 11 Controller number 12 Parameter channel 13 Parameter channel 14 General parameters and main control bytes Status and error bytes Actual values Channels 0 to 14 Manipulated variable Channels 0 to 12 Minimum values Channels 0 to 12 Maximum values Channels 0 to 12 Cumulative setpoints for cascaded control Measured values 1 to 15 for special function Measured values 16 to 30 for special function Measured values 31 to 45 for special function Measured values 46 to 60 for special function Free Free Free Free Additional parameter, cooling controller parameters controller 0 Additional parameter, cooling controller parameters controller 1 Additional parameter, cooling controller parameters controller 2 Additional parameter, cooling controller parameters controller 3 Additional parameter, cooling controller parameters controller 4 Additional parameter, cooling controller parameters controller 5 Additional parameter, cooling controller parameters controller 6 Additional parameter, cooling controller parameters controller 7 Additional parameter, cooling controller parameters controller 8 Additional parameter, cooling controller parameters controller 9 Additional parameter, cooling controller parameters controller 10 Additional parameter, cooling controller parameters controller 11 Additional parameter, cooling controller parameters controller 12 Free Free Free Additional error messages dependent upon the parameter assignment. Message no. 47 to 63 free 4-24 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller 2.1 Messages 0 to 12 (Controller Parameters) Each message contains the setpoints and the parameters for the individual controller. (The second parameters sets are stored in messages 30 to 42.) 0 1 Temperature setpoint 0 to 1600 C in 1Csteps 2 1st positive tolerance 1 to 255 C in 1Csteps 3 1st negative tolerance 1 to 255 C in 1Csteps 4 5 Lower setpoint 0 to 1599 C in 1Csteps 6 2nd positive tolerance 1 to 255 C in 1Csteps 7 2nd negative tolerance 1 to 255 C in 1Csteps 8 Control byte 1 9 Control byte 2 10 Manual manipulated variable 11 Limit value (C) 0 to 255 , 1 unit =1 12 Evaluation factor (C) 0 to 255 %, 1 unit = 1 % 13 Free 14 15 Sampling time TA (ST) 350 to 65535 ms, 1 unit = 1ms if main control byte 1, Bit 2=0 /or for cooling only 350 to 392700 ms, 1 unit = 10 ms if main control byte 1, Bit 2=1 and no cooling controller is selected 16 17 Gain KR (ST) 1 to 25599, 18 19 Integral action time TN (ST) 0 or (TATN512 TA), 1 unit = 4 s 20 21 Derivative action time TD (ST) 0 or (TA TD 512 TA), 1 unit = 1 s 2 22 Selftuning parameters 23 If temperature values are specified in F: T [ F]=T [ C]*1.8+32 0 to 100 % or 128 to 228 % for negative numbers, 1 unit = 1 % Heatingcooling parameters only for cascaded control 1 unit = KR = 0.01 Checkback signal for selftuning function 25 Upper limit of control zone (ST) or setpoint ramping 0 to 1600 C/h, 0 to 3000 C/h or 0 to 2047 F/h (= 1137 C/h) (ramp slope) With 3step controllers and main control byte 1, bit 2 = 1 the upper limit of the control zone is relative to 200 C (see pages 34 and 35) 26 27 Lower limit of control zone (ST) 0 to 1600 C 28 Heatingcooling ratio (ST) 0 to 255 %, 1 unit = 1 % only if main control byte 1, bit 2=0, otherwise free 29 Response value 0 to 50 %, 1 unit = 1 % 24 30 31 Minimum jump for 3step controllers Message number Parameters marked with (ST) need not be specified for controllers with selftuning 1 unit = 10 C Checkback signal for selftuning function 0 to 12 Parameters marked with (C) are only valid for cascaded control Fig. 2.1/1 Structure of messages 0 to 12 IP244 C79000-B8576-C860-02 4-25 Data Exchange with the Central Controller Byte 0/1 Temperature setpoint If the value 0 C or 32 F (if specified in Fahrenheit) is entered, no control takes place and only the actual value is indicated. A check is made to establish whether the entered setpoint is between 0 and a maximum value dependent on the connected thermocouple. Maximum value for Without jumper D FeConstantan FeConstantan NiCrNi (K) Pt 10% RhPt Pt 13% RhPt Pt 100 450 450 600 1600 1740 830 ( J) (L) (S) (R) C C C C C C With jumper D (842 F) (842 F) (1112 F) (2912 F) (3100 F) (1526 F) 700 700 1200 1600 1740 830 C C C C C C (1292 F) (1292 F) (2192 F) (2912 F) (3100 F) (1526 F) The setpoints of the special function are described in Section 3.4. The maximum values listed above are valid for the linearization of the characteristic curve stored in the firmware. If the linearization of the characteristic curve is disabled ( bit 3 in control byte 2 set to 1) and if a normalization value is specified in messages 30 to 42, the maximum selectable temperature setpoint can be calculated as shown below. Maximum value M for selectable character istic curve Without jumper D M=[Actual value normalization x 25,6]-10C 25 (or 10 F) With jumper D M=[Actual value normalization x 51,2] 10C (or 10 F) 25 If the maximum value is exceeded, an error identifier is set (bit 4 in the corresponding error byte) and the setpoint is limited to the maximum value. Byte 2 1st positive tolerance If the actual temperature is above the setpoint plus the first positive tolerance, an error identifier is set (bit 0 in the appropriate error byte). If the value 0 is entered, the tolerance is not effective. Byte 3 1st negative tolerance If the actual temperature is below the setpoint minus the first negative tolerance, an error identifier is set (bit 1 in the appropriate error byte). If the value 0 is entered, the tolerance is not effective. Byte 4/5 Lower setpoint If bit 5 is set in main control byte 4, the lower setpoint is used as the setpoint provided it is lower than the temperature setpoint. The plausibility check is performed as for the temperature setpoint. 4-26 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Byte 6 2nd positive tolerance If the actual temperature is above the setpoint plus the second positive tolerance, an error identifier is set (bit 2 in the appropriate error byte) and the controller is switched off, if this has been selected in main control byte 4, bit 7. If the value 0 is entered, the tolerance is not effective. Byte 7 2nd negative tolerance If the actual temperature is below the setpoint minus the second negative tolerance, an error identifier is set (bit 3 in the appropriate error byte) and the controller is switched off, if this has been selected in main control byte 4, bit 7. If the value 0 is entered, the tolerance is not effective. The four tolerances must be within the range from 0 to 255 C (1 byte). Byte 8/9 Control bytes 1 and 2 The functions to be carried out are fixed in control byte 1 and 2 (bytes 8 and 9) in the message for the controller channel whose number is written in byte 31. Byte 8 Control byte 1 Value of control bits 2n Logical state Required function 20 1 0 3step controller 2step controller 21 1 0 Switch S0S12 Cascade 22 1 0 2step controller is to 23 1 0 With substitute thermocouple/Pt 100 Without substitute thermocouple/Pt 100 24 25 26 27 IP244 C79000-B8576-C860-02 0/1 0/1 0/1 0/1 = = = = 20 21 22 23 On Off cool heat Number of the input channel for the substitute thermocouple/Pt 100 (binary coded) 4-27 Data Exchange with the Central Controller Byte 9 Control byte 2 Value of control bits 2n 20 21 Logical state 1 0 Manual operation (command "HB" in FB 162) Automatic operation (command "AB" in FB 162) 1 Setpoint ramping * (not possible with selftuning or cascaded control) Zone control 0 22 23 24 25 26 27 Required function 0 1 Heating switch effective with this controller Heating switch not effective 1 No 0 Yes Linearization of characteristic curve and line break monitoring 1/0 1/0 1/0 1/0 Free * (only possible with 2-step controllers with a heating function) Bit 20 When switching over to manual operation the manual manipulated variable which is entered in byte 10 is output. Bit 23 If linear sensors (e.g. pyrosensors) are to be connected to the module, the linearization of the characteristic curve stored in the firmware must be disabled. Values must be entered in messages 30 to 42, bytes 0 and 1 for actual value normalization. If linearization is switched off, line break monitoring is also disabled. Example 1 Required function 3step controller with substitute thermocouple/Pt 100 Channel 7 Required Function function Manual operation and zone control Heating switch effective with the controller Control byte 1 0|1|1|1 1|0|0|1 7 9 binary hexadecimal Control byte 2 0|0|0|0 0|0|0|1 0 1 binary hexadecimal The dual or hexadecimal representation of control bytes 1 and 2 according to the structure table for examples 2 and 3 is as in example 1. 4-28 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Example 2 2-step controller (heating controller) without substitute thermocouple/Pt 100 with manual operation and zone control, heating switch not effective. Control byte 1 = 00H; control byte 2 = 05H Example 3 Example 3-step controller with substitute thermocouple/Pt 100 connected to channel 7 with setpoint ramping, without manual operation, heating switch effective. Control byte 1 = 79H, control byte 2 = 02H Byte 10 Manual manipulated variable If the controller is to be operated manually, bit 0 in control byte 2 must be set (1). Instead of the manipulated variable calculated by the controller, the manipulated variable entered by the operator as a percentage is used for the pulse-duration output. If the output for cooling is to be addressed with 3-step controllers, 128 must be added to the required percentage. Example: control byte 1 = 01 Hex (3-step controller) control byte 2 = 01 Hex (manual operation) manual manipulated variable = 60 (heating at 60 %) manual manipulated variable = 168 (cooling at 40 %) (40 + 128 entered) If a sensor fails, it is possible to avoid switching off the process by changing to manual operation. By updating the controller integrator, the switchover to automatically controlled operation after replacing the defect sensor is bumpless. Bit 0 in control byte 2 must be reset. At the FB 162 the command "HB" is used to enable manual operation, the command "AB" to disable manual operation. Warning! ! Please note: If, in manual operation, the controllers are switched off outside the second tolerance band, this has no effect on the manipulated variable, i.e. the system can continue to heat outside the second tolerance! Incorrect parameters are determined, if, before selftuning, manual operation was selected. Depending on the manual manipulated variable, the system may overheat! Byte 11/12 For explanation see "cascaded control" (Section 3.2) Byte 13 Free Byte 14/15 Sampling time The time base for the controller sampling time depends on the ADC conversion time and the number of analog inputs to be converted. These inputs must also be counted when controllers are disabled by entering setpoint = 0. The following tables show the time base: a) In normal operation including cascaded control Set conversion time Time base IP244 C79000-B8576-C860-02 50 ms 55 ms 60 ms 80 ms 800 ms 1540 ms 960 ms 640 ms 4-29 Data Exchange with the Central Controller b) For hot channel control Conversion time 50 ms (fixed for hot channel control) Number of controllers 1 to 6 Time base 350 ms without heating current monitoring 7 to 13 700 ms no heating current monitoring possible 1 to 6 400 ms with heating current monitoring The sampling time can be calculated according to the notes on settings in Chapter 4. The calculated numerical value is rounded up to match the time base by the IP 244. Bytes 16 to 21 Controller parameters By setting one or more parameters to zero, different types of controllers can be obtained. Controller type KR Byte 16/17 TN Byte18/19 TD Byte 20/21 P V 0 0 PI V V 0 PD V 0 V PID V V V 0 = parameter in message 0 to 12 set to zero V = required value entered in parameter in message 0 to 12 The controller parameters are restricted to the following ranges (all values binary coded): 1 KR 25599 (input in steps of 0.01) TA TN 512 TA (input in multiples of 4 s) 1/ 2 TA TD 512 TA (in seconds) TA is the sampling time in milliseconds (or in a multiple of 10 ms depending on main control byte 1, bit 2), as specified in message 0 to 12, bytes 14 and 15. If a 2-step controller is to be used for cooling, KR must be related to the operating point 200 C. 4-30 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Byte 22 Self-tuning parameters If no self-tuning is required for a particular controller, all the bits in the "self-tuning" bytes must be set to 0, otherwise bit 1 must be set. Bit 27 starts and stops the self-tuning function which refers to the individual controller. If the bit is set in the start-up OB of the user program, a configured self-tuning function starts up when the module is switched on. If the module has aborted a running self-tuning function, e.g. if marginal conditions have not been met, bit 27 is reset and the bit with the meaning "self-tuning aborted" is set in byte 23. Byte 23 also indicates the characteristics if parameters have been determined successfully or not. After the voltage has returned the firmware-internal edge flag is set to 0, i.e. when switching on or plugged in the module for the first time, it must not be set to zero (i.e. stop) by the user before he initially starts the system. The user can only stop the self-tuning function by means of the commands "KS" or "SE". The system must always be stopped before a new self-tuning function is activated. Value of bits 2n Logical state 20 0 Must be set to zero 21 1 0 Selftuning controller Standard PID controller 22 0 Must be set to zero 23 0 Must be set to zero 24 1 0 Selftuning 25 0 Must be set to zero 26 0 1 Must be set to zero for 3step controllers Asymmetrical controlled system with 2step controllers Symmetrical controlled system with 2step controllers 0 0 27 Bit 27 Bit 24 Required function 1 " once repeated Start of the selftuning function at edge change 0 1 Stop of the selftuning function at edge change 1 0 Is only evaluated by the new FB 162 with 64 messages. Is only evaluated by the old FB 162 with 32 messages. IP244 C79000-B8576-C860-02 4-31 Data Exchange with the Central Controller As long as the bit 27 is set, a new parameter set for the respective controller channel is determined every time the control system is heated up. Byte 23 Self-tuning: heating-cooling parameters If the heating parameters calculated by the self-tuning function are available for the controller, bit 4 is set and if cooling parameters are present, bit 0 is set. Assignment of bits to the controllers: Bit 7 6 5 4 3 2 1 0 "1" Cooling parameters were determined "1" Heating parameters were determined "1" Selftuning function was aborted Once the self-tuning function has calculated the parameters for heating, bit 4 in byte 23 is set for each controller. If the self-tuning function is reactivated, the bit is cleared. This can be checked simply with FB 162 using the "LE" command. The same applies to bit 0 for cooling with 3-step controllers. This allows you to check whether the parameters calculated by the self-tuning function exist or not. If the self-tuning function of a 3-step controller has calculated heating parameters but no cooling parameters, the system deviation-temperature jump is not high enough. In byte 30 of messages 0 to 12 you can see how high the temperature jump must be to allow the self-tuning function to calculate parameters for cooling. Another possible reason is that the actual temperature value has fallen by more than 60 C/min while simultaneously heating and cooling. Bit 7 is set if the self-tuning function was aborted externally or internally from the module and if no parameters or incomplete parameters were determined. If, after the parameters have been determined, the actual value is greater than the setpoint value and the heating is still in operation, the self-tuning function is automatically aborted. If no parameters can be calculated, the IP 244 continues to operate with the values which existed before the self-tuning function was activated. 4-32 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Byte 24/25 Upper control zone (ZONOB)/ramp slope For zone control, bit 1 in control byte 2 = 0. Upper control zone ZONOB: see Fig. 2.1/2. If setpoint ramping is required; bit 1 in control byte 2 = 1. The current setpoint is indicated in message 21 and the error messages in message 16 relate to the setpoint in message 21. Setpoint ramping is not possible with selftuning controllers, with cooling 2step controllers, with 3step controllers, cascaded and hot channel control. Byte 26/27 Lower control zone ZONUN (see Fig. 2.1/2) The upper and lower control zones are limited by the software to the maximum possible temperature value if the value entered exceeds the control range. Control zones (zone upper limit, zone lower limit) Among other things, temperature controllers should meet the following two general requirements: a) shortest possible heating time with minimum overshoot b) compensation of temperature disturbances as quickly as possible Requirement b) means that a relatively short integral action time is required of the PID controller. With larger setpoint jumps (e.g. heating) this leads, however, to a fast '"saturation" of the I-branch. The result is overshoot way beyond the setpoint. Remedy: The PID controller is only active within a certain temperature range. Outside this control zone the PID algorithm is interrupted. Depending on the system deviation, the process is then heated at 100% or cooled at 100%. Calculation of the control zone: The control zone is determined by the characteristics of the controlled system. The important parameters are the dead time and the maximum temperature curve of the system (see "Notes on Settings", Chapter 4). In general, it is sufficient to enter the control zone symmetrically, i.e. the upper limit of the control zone = the lower limit of the control zone. IP244 C79000-B8576-C860-02 4-33 Data Exchange with the Central Controller Approximate values (very general): Upper limit of the control zone = lower limit of the control zone Minimum Usual Extreme 5 C 10 to 30 C 40 to 60 C Notes: If the control zone is too restricted (0 to 4 C) the control action is similar to that of a purely switching controller (bimetallic controller). The control zone has nothing to do with the previously described tolerances. The tolerances are simply for monitoring, whereas the upper and lower limits of the control zone are controller parameters. T Cooling at 100% with 3step controllers or cooling 2step controllers Manipulated variable 0% with heating 2step controllers Setpoint plus upper control zone Upper control zone Control zone (here normal controller operation) Setpoint Lower control zone Setpoint minus lower control zone Heating at 100% with 3step controllers or heating 2step controllers Manipulated variable 0% with cooling 2step controllers 0 t Fig. 2.1/2 Upper and lower control zones Examples a) With zone control, bit 1 in control byte 2 = 0 ZONOB = 20 C ZONUN = 30 C Setpoint = 200 C Control zone = 170 C to 220 C b) No zone control active, bit 1 in control byte 2 = 1 ZONOB = 1600 C/h ZONUN = 1600 C Setpoint = 220 C Control zone = 0 to maximum value (in C) c) Setpoint ramp, bit 1 in control byte 2 = 1 ZONOB = 200 C/h ZONUN = irrelevant Setpoint = 300 C Control zone = 0 to maximum value (in C) The setpoint is reached in 1.5 hours following the ramp slope if the previous actual value was 0 C. 4-34 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Byte 28 Heating-cooling ratio as a percentage (0 to 255%) The difference in effectiveness of the cooling and heating functions of 3-step controllers can lead to oscillations with a normal controller action. The heating-cooling ratio, specified as a percentage, can help prevent this, as well as separate parameter sets for heating and cooling. Example 1: water cooling 10 s heating raises the temperature by 2 C. 10 s cooling lowers the temperature by 4 C. The cooling function is approximately twice as effective as the heating function. If 50% is entered as the heating-cooling ratio, the cooling is only activated for half as long as the heating, i.e. only 5 s instead of 10 s. Example 2: air cooling 10 s heating increases the temperature by 2 C. 10 s cooling lowers the temperature by 1 C. The cooling is approximately half as effective as the heating heating-cooling ratio 200%. Byte 29 Response value as a percentage (0 to 50%) If the calculated percentage manipulated variable is less than the response value, 0 is output; if it is greater than 100% minus the response value, 100% (= sampling time) is output (see Fig. 2.1/3). Setting time output as percentage 100% 100% minus response value Response value 0 Response value 100% minus response value 100% Calculated manipulated variable as % Fig. 2.1/3 Response value IP244 C79000-B8576-C860-02 4-35 Data Exchange with the Central Controller The pulse duration modulation of the controller output signal (manipulated variable) allows the use of switching control elements (contactor, triac etc.). With manipulated variables close to 0%, very short ON times occur which reduce the working life of mechanical actuators. The same applies to manipulated variables close to 100%. In this case short OFF times occur. Example: sampling time manipulated variable ON time = 3 100 16 s 3% x 16 s = 0.48 s Such repeated and unnecessary switching can be prevented by using a response value. The module then reacts as follows: Manipulated variable = Manipulated variable + recorded residual manipulated variable Manipulated variable < response value? No Yes No manipulated variable output, record manipulated variable Output manipulated variable Manipulated variable > (100% - response value)? Yes Output 100% record (manipulated variable - 100 %) No Output manipulated variable The "residual value processing" means that a good control action is achieved despite suppression of very short switching times. 4-36 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Calculation of the response value: Response value Example: minimum switching duration = sampling time sampling time minimum switching duration Response value = = = x 100 % 16 s 1 s (required) 1s 16 s x 100 % = 6.25 % Note: despite "residual value processing" the response value should not be more than 10%. If a greater value is used, unwanted temperature fluctuations can occur, depending on the controlled system. Guide values for the response value: - when using solid state switching devices (triac etc.): response value = 0% - when using mechanical switching devices: response value 3 to 6% - with 3-step controllers and air cooling (even when using solid state switching devices): response value 3 to 10% (to reduce wear on the fans) Byte 30 Minimum jump for 3-step controllers In this byte, you can read the minimum jump for the temperature setpoint if no cooling parameters could be calculated during the self-tuning phase of 3-step controllers (see byte 23). Byte 31 Message number IP244 C79000-B8576-C860-02 4-37 6 Data Exchange with the Central Controller 2.2 Messages 13 and 14 Messages 13 and 14 contain the setpoints and monitoring tolerances for the two voltage channels 13 and 14. 0 1 Setpoint 0 to 2048, 1 unit = 10 mV 2 Positive tolerance 0 to 255, 1 unit = 10 mV Negative tolerance 0 to 255, 1 unit = 10 mV 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Reserved for heating current acquisition 0 1 Setpoint 2 Positive tolerance 3 Negative tolerance 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Free Message number (13) 31 Free Reserved: must be 0 Free Message number (14) Fig. 2.2/1 Structure of message 13 and structure of message 14 Byte 0/1 Setpoint channels 13 and 14 The actual values read in via channels 13 and 14 are compared with the setpoint and checked for tolerance violations. Input: 0 to 1024 units = 10.24 V or 0 to 2048 units = 20.48 V. Byte 2 Positive tolerance channels 13 and 14 If the actual value is higher than the setpoint plus the positive tolerance, an error identifier is set (bit 0 in the corresponding error byte). By entering value 0, the tolerance processing is disabled. Byte 3 Negative tolerance channels 13 and 14 If the actual value is below the setpoint minus the negative tolerance, an error identifier is set (bit 1 in the corresponding error byte). By entering value 0, the tolerance processing is disabled. 4-38 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller 2.3 Message 15 Message 15 contains general parameters and the main control bytes. 0 Switchover value for comparator (channel 13) 1 0 to 1024, 1 unit = 10 mV (jumper D open) 1 unit = 20 mV (jumper D inserted) (not used in variant 3AB31) 2 0 to 3600 s, 1 unit = 1 s 3 4 5 Monitoring time (emergency program) Normalization factor for channel 14 6 Acquisition duration (channel 13) 7 Approach time (hot channel) 8 Approach manipulated variable (hot channel) 9 Approach zone (hot channel) 10 11 Approach setpoint (hot channel) 12 Max. temperature difference (ST) 13 Free 14 15 Normalization factor for channel 13 16 Free 17 Coolant temperature 18 19 Free 20 Main control byte 7 21 Main control byte 6 22 Main control byte 5 23 Main control byte 4a 24 Main control byte 4b 25 Main control byte 4c 26 Main control byte 4d 27 Main control byte 1 28 Main control byte 2 29 Main control byte 3 30 Main control byte 4 31 Message number (15) (ST) min. 3.3 s/30 values, 6.6 s/60 values, max. =255 s 0 to 60 min, 1 unit = 1 min 0 to 100 % 0 to 255 C 0 to 1600 C C/min (1 to 255) 0 to 100, 1 unit = 1 C or 32 to 212, 1 unit = 1 F Need not be specified with the selftuning function Fig. 2.3/1 Structure of message 15 Byte 0/1 Switchover setpoint for the comparator (not used in variant -3AB31) The value entered at channel 13 is supplied to a comparator along with the switchover setpoint specified in units and converted to an analog value. A maximum of 1024 units can be specified. The comparator output is set to 1 when the switchover setpoint is reached. If jumper D is inserted, the selected value (maximum 1024 units) corresponds to an input value of maximum 20.48 V (corresponding to 2048 units). IP244 C79000-B8576-C860-02 4-39 Data Exchange with the Central Controller If jumper D is open, the selected value (maximum 1024 units) corresponds directly to the value of maximum 10.24 V (maximum 1024 units) from the analog-to-digital converter. Byte 2/3 Monitoring time If owing to the failure of a thermocouple, the manipulated variable averaged over a selected time is to be output, bit 4 in main control byte 4 must be set and the monitoring time entered in seconds (maximum 3600 seconds). If 0 s is entered, the IP sets the value internally to 3600 s. Byte 4/5 Normalization factor for channel 14 (see Special Functions, Section 3.4.4) Byte 6 Acquisition duration (channel 13) (see Special Functions, Section 3.4) The value to be input is rounded off in steps to 3 or 6 seconds. Using T as the calculated acquisition duration, the following rounding off values result: Z 4 3; Z 8 6; Z 8 12; Z 5 Z 9 Z 15 6 (only for 30 curve values) 12 18 etc. Measured values are read via the direct functions in FB 162. Byte 7 Approach time, see "Hot Channel Control", Section 3.1 Byte 8 Approach manipulated variable, see "Hot Channel Control", Section 3.1 Byte 9 Approach zone, see "Hot Channel Control", Section 3.1 Byte 10/11 Approach setpoint, see "Hot Channel Control", Section 3.1 Byte 12 Maximum temperature difference To be able to recognize disturbances in the actual temperature values, a maximum actual value difference per minute is specified. If, for example, the maximum temperature increase with the heating power applied is 5 C and the sampling time is 10 s, all actual values greater than 5 C compared with the previous sample are considered as disturbances. Such a disturbance is suppressed. Instead an actual value is assumed which is obtained from the last actual value plus the maximum increase. The same applies if the temperature falls. The value you enter is rounded up to a multiple of the following units: Sampling time in ms depending on mode 350 400 640 700 800 960 1540 Numerical base in C/min 79 69 44 40 35 29 19 Byte 13 Byte 14/15 Byte 16 Byte 17 Byte 18,19 Byte 20 4-40 Free Normalization factor for channel 13 (see Special Functions, Section 3.4.4) Free Coolant temperature (see main control byte 3 bit 4) Free Main control byte 7, facilitates communication between function block and IP 244. IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Byte 21 Main control byte 6 Value of control bits 2n Logical state Required function 20 1 0 21 1 0 22 1 0 23 1 0 Free 24 1 0 Yes No 25 1 0 Free 26 1 0 Free 27 1 0 Free Number of standard controllers (see below) Mixed operation Recommended data format in DB: KH Byte 21 can be transferred to the IP with the FB 162 commands "KS", "PA" or "AE message 15". Bit 2 1 0 Number of standard controllers 0 0 0 0 1 1 1 1 0 0 1 1 0 0 1 1 0 1 0 1 0 1 0 1 One One Two Three Four Five Six Seven IP244 C79000-B8576-C860-02 4-41 Data Exchange with the Central Controller Byte 21 Main control byte 6 Number of standard controllers One Two Three Four Five Six Seven 0 to 5 0 to 5 0 to 5 0 to 5 0 to 5 0 to 5 0 to 5 6 6 and 7 6 to 8 6 to 9 6 to 10 6 to 11 6 to 12 Minimum possible sampling times for hot channel controller for ADC conversion time 50 ms 400 ms 400 ms 400 ms 400 ms 400 ms 400 ms 400 ms Minimum possible sampling times for standard controller for ADC conversion time 50 ms 480 ms 800 ms 1200 ms 1600 ms 2000 ms 2400 ms 2800 ms Minimum possible sampling times for hot channel controller for ADC conversion time 60 ms 480 ms 480 ms 480 ms 480 ms 480 ms 480 ms 480 ms Minimum possible sampling times for standard controller for ADC conversion time 60 ms 480 ms 960 ms 1440 ms 1920 ms 2400 ms 2880 ms 3360 ms Maximum value of temperature increase (C/min) permitted during selftuning of the standard controllers at an ADC conversion time of 50 ms 273 136 91 68 54 45 39 Maximum value of temperature increase (C/min) permitted during selftuning of the standard controllers at an ADC conversion time of 60 ms 227 113 75 56 45 37 32 Hot channel zones Standard controller zones If mixed operation has been selected, the IP cannot execute the following functions simultaneously: - - - - - - - special function heating current monitoring Pt 100 operation processing of channels 13 and 14 comparator pure hot channel control and cascaded control. 4-42 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Byte 22 Main control byte 5 Value of control bits 2n Logical state Required function 20 21 22 Message number (for data transfer IP PLC with FB 162) 23 24 25 26 27 IP244 C79000-B8576-C860-02 New setpoints if Bit 27 =0 (important for FB162) 4-43 Data Exchange with the Central Controller Main control byte 5 is used to check the data exchange: Sequence: Yes FB 162 checks whether main control byte 5, Bit 7=0? No FB 162 transfers bytes 0 ... 13 of the selected message to the IP and sets main control byte 5, bit 7 = 1 IP 244 checks main control byte 5, bit 7 = 1? No IP 244 operates in normal control mode IP 244 operating Yes IP 244 fetches all data from this message IP 244 sets main control byte 5, bit 7= 0 4-44 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Byte 23 Main control byte 4a Value of the control bits 2n Logical state 20 1 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 IP244 C79000-B8576-C860-02 Required function Start reading in measured values at channel 13, only if special function selected. Free 4-45 Data Exchange with the Central Controller Byte 24 4-46 Main control byte 4b Value of the control bits 2n Logical state 20 1 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 Required function Yes No Cold restart (PLC sets; IP resets) Free IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Byte 25 Main control byte 4c Value of the control bits 2n Logical state 20 1 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 IP244 C79000-B8576-C860-02 Required function Yes No Parameter transfer finished (PLC sets; IP resets) Free 4-47 Data Exchange with the Central Controller Byte 26 Main control byte 4d Value of the control bits 2n Logical state 20 1 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 4-48 Required function Read in channel 14 once instead of channel 13, only if special function selected Free IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Byte 27 Main control byte 1 Value of the control bits 2n Logical state 20 1 0 Filter for actual value indication off Filter for actual value indication on 21 1 0 Yes No Heating current monitoring 22 1 0 Yes No Reading in and out of the control parameters also with selftuning and separate parameter sets for heating and cooling 23 1 0 Yes No Reading in of 30/60 measured values via channel 13, measured value acquisition and monitoring at channel 14 (special function) 24 1 0 Yes No Hot channel control 25 1 0 Yes No Cascaded control 26 1 0 Actual value 27 0 Must be 0 Required function in BCD binary Bit 0 If the actual value indication is unsteady, a filter can be looped into the indication processing. Bit 0 = 0 filter on (damped display) Bit 1 Heating current monitoring (see Section 3.3) Bit 2 If this bit is set, two parameter sets can be used for each controller, e.g. separate parameters can be set for cooling. and: The controller parameters can be read in and out by the function block; i.e. the parameters calculated by the self-tuning function can also be read into the CPU and saved. If Bit 22 = 0, the self-tuning function is started and stopped via byte 22, Bit 21 (self-tuning parameter). This corresponds to the functionality of the IP 244 version -3AA13 with the old FB 162 (32 messages). If Bit 22 = 1, the self-tuning function is started and stopped via byte 22, Bit 27 using upward and downward edges. These edges are generated by the new FB 162 (64 messages) for each controller separately via the command "SE". Bit 3 Selection of the special function for reading in measured values. The special function can only be selected when hot channel control or Pt 100 operation or heating current monitoring have not been selected. Bit 4 If this bit is set, the hot channel control (see Section 3.1) is activated. Bit 5 Enables cascaded control (see Section 3.2). IP244 C79000-B8576-C860-02 4-49 Data Exchange with the Central Controller Bit 6 Numerical representation in BCD (1) or binary (0). Only for the 16-bit values which can be read from the IP (messages 17 to 25). Bit 7 Numerical representation of the setpoints, actual values and controller parameters (16-bit) in S5 format. Format Numerical representation Binary Byte n Byte n + 1 S5 BCD High byte Thousands Hundreds Low byte Tens Units Priorities set by the IP when parameter assignments contradict 1. If pure Pt 100 operation is selected, special function, heating current monitoring, hot channel control and mixed operation are deleted. 2. If mixed operation is selected, special function, heating current monitoring, hot channel control and cascaded control are deleted. 3. If hot channel control is selected, special function and main control byte 1 bit 2 are deleted. 4. If heating current monitoring is selected, special function is deleted. 4-50 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Byte 28 Main control byte 2 Value of the control bits 2n Logical state 1 0 20 Bit 7: Bit 3 2 1 0 0 0 0 0 1 0 21 *) Required function Thermocouple type 0 0 0 1 Feconstantanthermocouple type L to DIN 43710 Feconstantanthermocouple type L to DIN 43710 0 0 0 0 0 NiCrNithermocouple, type K to IEC 584 Pt10% RhPtthermocouple type S to IEC 584 Feconstantanthermocouple type J to IEC 584 Pt 100 to DIN 43760 *) Pt13% RhPtthermocouple type R to IEC 584 0 0 1 1 1 1 1 0 0 1 0 1 0 1 0 22 1 0 23 1 0 24 1 0 Yes No Read channel 13 + Error processing 25 1 0 Yes No Read channel 13 + Error processing 26 1 0 In F In C Temperature value 27 1 0 OFF ON Parameter monitoring All other codings are not used and must not be selected. Not possible with hot channel control, heating current monitoring or with pure Pt 100 operation In Pt 100 operation, only channels 0 to 7 are processed. Selection of heating current monitoring, hot channel control and the special function is no longer possible. The comparator can no longer be used (irrelevant in variant 3AB31). This function applies for all controllers, for which self-tuning is possible (even if it is not activated), when main control byte 1, bit 2 = "1" and for all controllers where a self-tuning function was run successfully, when main control byte 1, bit 2 = "0". Bit 7 can be transferred to the IP with the FB 162 commands "KS", "PA" or "AE message 15": If bit 7 = 1, bit 1 of the error bytes 0a to 12a is not set. IP244 C79000-B8576-C860-02 4-51 Data Exchange with the Central Controller Byte 29 Main control byte 3 Value of the control bits 2n Logical state Required function 20 1 0 Must be set by the PLC as a trigger bit at the end of a machine cycle (only for cascaded control). The IP 244 resets bit 20. 21 1 0 30 curve values acquired via channel 13 60 curve values acquired via channel 13 22 0 Free 23 0 Free 1 Coolant temperature can be set 0 Coolant temperature from compensationPt 100 temperature 25 1 0 Continuous process batch process 26 1 0 24 27 1 0 Bit 7 6 0 0 1 1 0 1 0 1 ON times of switching devices (only if heating current monitoring) maximum maximum maximum maximum 100 100 150 200 ms ms ms ms Bit 1: You can inform the IP 244 whether you want it to read 30 or 60 values each via channel 13 (only when special function is selected). Tno. 15, byte 6 (duration of acquisition) presets the total time of the readin procedure. The following applies for bit 21 = 1 in the main control byte 3: the minimum duration of acquisition is 3 seconds, otherwise (bit 21 = 0) 6 seconds. Bit 4: Valid for all controllers with cooling outputs: the controller parameters are adapted internally to the temperature of the coolant (e.g. air, oil water). If bit 4=1 the IP takes message 15 byte 17 as the coolant temperature, otherwise the temperature measured by the compensationPt 100 or operation without thermocouples 0 C (32 F) is selected. Bit 5: Continuous processes are those involving, for example, sheet extrusion or blow molding machines. Batch processes, for example, include injection molding machines. The IP only evaluates this bit if main control byte 1, bit 2 = 1, or with selftuning controllers. In these cases 3step controllers operate with temporary IP internal controller parameter modifications matched to the different machine types described above. In this way, 3step controllers react ideally to the different temperature disturbances occurring with the different machine types. The IP has therefore an optimized disturbance response. If bits 4 to 7 are transferred to the IP with FB 162, the commands KS, PA or AE (message 15) must be used. 4-52 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Byte 30 Main control byte 4 Value of the control bits 2n Logical state Required function 20 1 0 Yes No Start reading in measured values at channel 13. Only if special function selected. 21 1 0 Yes No Cold restart (PLC sets: IP resets) 22 1 0 Yes No Parameter transfer complete (PLC sets: IP resets) 23 1 0 Yes No Read in once from channel 14 instead of channel 13. Only if special function selected. 24 1 0 Yes No Output averaged manipulated variable (line break) 25 1 0 Yes No Switch over to lower setpoint 26 0 Free 27 1 0 Yes No Controller disabled if 2nd tolerances are violated Main control byte 4 Bit 0 Start bit for measured value acquisition on channel 13. Acknowledgement is by clearing bit 22 in status byte 1, message 16 (see Direct Functions: FB 162). Bit 1 Causes a cold restart. This clears certain memory areas in the IP (e.g. "integrator values or self-tuned values") (see command "KS": FB 162). This bit must be set when: a) the PLC is switched on for the very first time; b) the PLC has detected a battery power failure while the power supply was off (with S5-115U/135U). In addition to this, the whole IP is re-initialized according to the values in messages 0 to 15 and 30 to 42. The bit is reset by the IP. IP244 C79000-B8576-C860-02 4-53 Data Exchange with the Central Controller Bit 2 The whole module is re-initialized with the values stored in messages 0 to 15 and 30 to 42 (requires FB 162 for the data exchange with the commands "PA" and "PZ"). Bit 3 Trigger bit for measured value acquisition once at channel 14, resets acknowledgement bit 23 in status byte 1, message 16 (see Direct Functions: FB 162). Bit 4 Must be set if the manipulated variable averaged over the monitoring time (byte 2/3 in message 15) is to be output while a thermocouple is out of action. This is common to all controllers. (See commands "G1", "G2": FB 162). Bit 5 When this bit is set, the lower setpoint is used instead of the temperature setpoint (lower "night" temperature). (See commands "S1", "S2": FB 162). Bit 6 Free Bit 7 If the actual value of a controller is outside the second tolerance and bit 7 is set, the affected controller is disabled if the actual value had been within the first tolerance band at least once following a setpoint change. Bit 7 is set or reset in the FB 162 using the commands "T2" or "T1". When the actual value returns to the second positive tolerance band, the controller automatically resumes operation. To simplify operation with function block FB 162, bits 0, 1, 2 and 3 are stored individually a second time in the main control bytes 4a, 4b, 4c and 4d. You do not need to set or reset bits 0 to 3. This is performed automatically by the function block. 4-54 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller 2.4 Message 16 Message 16 serves as a signalling message. It contains general status information and the error bytes of the controllers or voltage channels. It can only be read. Message 46 contains further error bytes. Channel no. 0 Status byte 1 1 Free 2 Controller group error/channel group error 8 to 12/13,14 and 15 3 Controller group error/channel group error 0 to 7 4 Selftuning status 8 to 12 5 Selftuning status 6 7 8 9 10 11 12 13 14 15 Approach phase 0 to 7 8 to 12 Approach phase 0 to 7 16 Error byte 0 17 18 Error byte 1 19 20 Error byte 3 21 Error byte 5 22 23 Error byte 6 24 Error byte 8 25 26 Error byte 9 27 Error byte 11 28 29 30 31 Free Module number Software release Error byte 2 Error byte 4 Error byte 7 Error byte 10 Error byte 12 Error byte 13 Error byte 14 Message number (16) Fig. 2.4/1 Structure of message 16 IP244 C79000-B8576-C860-02 4-55 Data Exchange with the Central Controller Byte 0 Status byte 1 Value of the control bits 2n Logical state Required function 20 1 0 Yes No 21 0 Free 22 1 0 Acknowledgement bit for reading in measured values at channel 13 (special function) 23 1 0 Acknowledgement bit for reading in measured values at channel 14 (special function) 24 0 Free 25 1 0 Yes Yes No No Sampling time overflow 26 1 0 Yes No Parameter request (IP sets and clears) 27 1 0 Yes No Watchdog Group error Byte 0 Status byte 1 Bit 0 The group error bit is always set when a bit is set in one of the error bytes 0 to 14 or 0a to 12a in message 46, or if the Pt 100 has a fault. Bit 1 Free Bit 2 Acknowledgement bit for measured value acquisition at channel 13. The start of this function clears the bit, the end of the function sets the bit. Bit 3 Acknowledgement bit for single measurement at channel 14. The start of the function clears this bit, the end of the function sets this bit. Bit 4 Free (always 0) Bit 5 When the PLC accesses the IP, the IP processor is blocked. If the access takes too long, a sampling time overflow may occur. An "access rate" of one message per 100 ms is acceptable. 4-56 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Bit 6 Following a power failure, the IP sets the "parameter request" bit when the power returns. The PLC must then transfer messages 0 to 15 and 30 to 42 and on completion of the transfer set bit "parameter transfer complete" (in main control byte 4). This resets the request from the IP 244. If this does not happen, the IP is placed in a queue. The digital outputs are OFF, the IP does not read any actual values and the controllers are not processed. Bit 7 This bit changes its state at least once every one second. 1 0 max. 1 s max. 1 s This allows the user program in the PLC to recognize a "program crash" on the IP. Byte 1 Free Byte 2/3 Controller group error/channel group error The bit assigned to the controller/channel is set if an error bit is set in the corresponding error bytes in message 16 and 46. Assignment of the bits to the controllers: Byte 2 Bit Controller/ channel Byte 3 1 0 7 6 5 4 3 2 1 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 7 6 5 4 3 2 Fault in Pt 100: line break or temperature > 60 C or short circuit *) *) With the variant -3AB31, the error message is also set when the 24 V supply is missing. This error can also occur if the external wiring is missing or if the fuse on the module fails. Byte 4/5 Self-tuning status If the module performs a self-tuning run for one or more controllers, the bit assigned to the controller is set. Once the self-tuning function is complete, the corresponding bit is reset (see also Section 1.2). If parameters were successfully calculated, this is indicated in message 0 to 12, byte 23. IP244 C79000-B8576-C860-02 4-57 Data Exchange with the Central Controller Assignment of the bits in the controllers: Byte 4 7 Bit 6 5 4 3 Byte 5 2 1 Controller 15 14 13 12 11 10 9 0 8 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 Always 0, not used Selftuning see Section 1.2.5 Byte 6/7 Approach phase If a hot channel controller is in the approach phase, the bit belonging to the controller is set (see Section 3.1.2). Assignment of the bits in the controllers: Byte 6 1 0 7 6 5 4 3 2 1 0 Controller 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Bit 7 6 5 4 3 Byte 7 2 Always 0, not used The corresponding bit is 0 if: - setpoint = 0 or - heating switch off and effective for this controller Byte 8 to 13 Free Byte 14 This byte contains the two last numbers of the MLFB number: - for variant -3AA22: 22 - for variant -3AB31: 31 Byte 15 This byte contains the software release entered in the EPROM. 4-58 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Byte 16 to 28 Error bytes 0 to 12 Value of the control bits 2n Logical state Required function 20 1 0 Yes No 1st positive tolerance exceeded 21 1 0 Yes No Value below 1st negative tolerance 22 1 0 Yes No 2nd positive tolerance exceeded 23 1 0 Yes No Value below 2nd negative tolerance 24 1 0 Yes No Temperature setpoint too high 25 1 0 Yes No Lower setpoint greater than temperature setpoint or too high 26 1 0 Line break identifier A 27 1 0 Line break identifier B Explanation of the line break identifier A, B (for Pt 100 and thermocouples): Bit 7 (B) 6 (A) Required function 0 0 0 1 No line break Original sensor defective, no substitute sensor specified 1 1 0 1 Original sensor defective, substitute sensor active Original and substitute sensors defective If linearization of the characteristic curve was disabled (bit 3, control byte 2 = 1), the sensors are not checked for defects (external sensor modules are then connected). It is only possible to check thermocouples indirectly for short circuits. With the Pt 100, direct and indirect short circuit monitoring is possible (indirect short circuit monitoring by means of an entry in messages 30 to 42 and signalling via message 46). IP244 C79000-B8576-C860-02 4-59 Data Exchange with the Central Controller Byte 29/30 Error bytes 13, 14 Value of the error bits 2n 4-60 Logical state Required function 20 1 0 Yes No 1st positive tolerance exceeded 21 1 0 Yes No Value below 1st negative tolerance 22 0 Free 23 0 Free 24 0 Free 25 0 Free 26 0 Free 27 0 Free IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller 2.5 Messages 17 to 21 The numerical representation of messages 17 to 21 is determined by the main control byte 1, bit 6 (BCD/binary). Messages 17 to 21 can only be read. Message 17 This message contains the actual temperatures of sensors 0 to 12 in degrees Celsius or in degrees Fahrenheit (bytes 0 to 25) and the actual values of the voltage channels 13 and 14 (2048 units = 20.48 V) (bytes 26 to 29). Note the special function. 0 1 Actual value temperature controller 0 2 3 Actual value temperature controller 1 4 5 Actual value temperature controller 2 6 7 Actual value temperature controller 3 8 9 Actual value temperature controller 4 10 11 Actual value temperature controller 5 12 13 Actual value temperature controller 6 14 15 Actual value temperature controller 7 16 17 Actual value temperature controller 8 18 19 Actual value temperature controller 9 20 21 Actual value temperature controller 10 22 23 Actual value temperature controller 11 24 25 Actual value temperature controller 12 26 27 Actual value channel 13 28 29 Actual value channel 13 30 Free 31 Message number (17) Fig. 2.5/1 Structure of message 17 (actual values) IP244 C79000-B8576-C860-02 4-61 Data Exchange with the Central Controller Message 18 This message contains the manipulated variables of controllers 0 to 12. The output is in the form of a percentage. The following assignments apply: Range Range Range Range 0 x 100 101 x 127 128 x 228 229 x 65535 0 1 Manipulated variable controller 0 2 3 Manipulated variable controller 1 4 5 Manipulated variable controller 2 6 7 Manipulated variable controller 3 8 9 Manipulated variable controller 4 10 11 Manipulated variable controller 5 12 13 Manipulated variable controller 6 14 15 Manipulated variable controller 7 16 17 Manipulated variable controller 8 18 19 Manipulated variable controller 9 20 21 Manipulated variable controller 10 22 23 Manipulated variable controller 11 24 25 Manipulated variable controller 12 26 27 Free (00H) (00H) 28 29 Free (00H) (00H) 30 Free (00H) 31 Message number (18) => heating at x% => range not permitted (does not occur) => cooling at x - 128% => range not permitted (does not occur) Fig. 2.5/2 Structure of message 18 (manipulated variables) 4-62 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Message 19 Message 19 contains the minimum values detected when the actual value falls below the first negative tolerance (see Section 1.1.5). The values are in degrees Celsius or degrees Fahrenheit. The status of the digital outputs can also be read back. 0 1 Minimum value controller 0 2 3 Minimum value controller 0 4 5 Minimum value controller 0 6 7 Minimum value controller 0 8 9 Minimum value controller 0 10 11 Minimum value controller 0 12 13 Minimum value controller 0 14 15 Minimum value controller 0 16 17 Minimum value controller 0 18 19 Minimum value controller 0 20 21 Minimum value controller 0 22 23 Minimum value controller 0 24 25 Minimum value controller 0 26 27 Free (00H) (00H) 28 Digital outputs image DQ 1 29 Digital outputs image DQ 2 to 9 30 Digital outputs image DQ 10 to 17 31 Message number (19) Fig. 2.5/3 Message 19 (minimum values) (see Section 1.1.5) IP244 C79000-B8576-C860-02 4-63 Data Exchange with the Central Controller Digital outputs of the IP 244 Bit 7 6 5 4 3 2 1 0 Byte 28 0 0 0 0 0 0 0 DQ 1 Byte 29 DQ 2 DQ 3 DQ 4 DQ 5 DQ 6 DQ 7 DQ 8 DQ 9 Byte 30 DQ 10 DQ 11 DQ 12 DQ 13 DQ 14 DQ 15 DQ 16 DQ 17 The bits in bytes 28 to 30 can change their state every 50 to 80 ms, so that they must be read often enough by the PLC to obtain a meaningful evaluation. 4-64 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Message 20 Similar to message 19, message 20 contains the maximum values reached when the first positive tolerance is exceeded. 0 1 Maximum value controller 0 2 3 Maximum value controller 1 4 5 Maximum value controller 2 6 7 Maximum value controller 3 8 9 Maximum value controller 4 10 11 Maximum value controller 5 12 13 Maximum value controller 6 14 15 Maximum value controller 7 16 17 Maximum value controller 8 18 19 Maximum value controller 9 20 21 Maximum value controller 10 22 23 Maximum value controller 11 24 25 Maximum value controller 12 26 27 Maximum value controller 13 (only if special function selected) 28 29 Free 00H 00H 30 Free 00H 31 Message number (20) Fig. 2.5/4 Message 20 (maximum values) (see Section 1.1.5) IP244 C79000-B8576-C860-02 4-65 Data Exchange with the Central Controller Message 21 This message contains the "cumulative setpoints", formed under the influence of the master controller in cascaded control (see Section 3.2). 2.6 Messages 22 to 63 The messages described here perform the functions of the previous module 6ES5 244-3AA13 and include certain extra functions. If still more additional functions are activated or required, the following messages must have parameters set and must be evaluated. Messages 22 to 25 These messages contain 60 measured values read in by the special function at channel 13 (see Section 3.4). Messages 26 to 29 Free Messages 30 to 42 If bit 2 is set to 1 in main control byte 1, the further parameters for controllers 0 to 12 are contained in messages 30 to 42 in bytes 6, 7 and 14 to 25. Bytes 14 to 25 must only be entered for 3-step controllers. If a 2-step controller is only required for cooling, the parameters are in messages 0 to 12. Only 2step controllers can perform as purely cooling controllers. Selftuning for purely cooling controllers is not possible. 4-66 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Messages 30 to 42 0 1 Actual value normalization 1 unit= 1 C or -1 F 2 Minimum temperature difference 1 unit= 1 C/min or 1 F/min +Short circuit detection 3 Free 4 5 6 7 Maximum rate of rise when heating STH (ST) 1 unit= 0.1 C/min or 0.1 F/min 8 9 Delay time when heating TUH (ST) 1 unit= 1 s 10 11 Free 12 13 14 15 Sampling time when cooling TAK (200 C) (ST) 1 unit= 10 ms 16 17 Gain for cooling KRK (200 C) (ST) 1 unit= 0.01 18 19 Integral action time for cooling TNK (200 C) (ST) 20 21 Derivative action time for cooling TDK (200 C) (ST) 1 unit= 1 s 22 23 Value of slope when cooling STK (200 C) (ST) 1 unit= 0.1 C/min or 0.1 F/min 24 25 Delay time for cooling TUK (ST) 1 unit= 1 s 1 unit= 4 s 26 27 Free 28 29 30 31 Message number Fig. 2.6/1 Messages 30 to 42 for controllers 0 to 12 (ST) (200 C) You do not need to enter parameters for self-tuning controllers The parameters are related to the operating point 200 C minus the temperature of the coolant (see also main control byte 3 bit 4) IP244 C79000-B8576-C860-02 4-67 Data Exchange with the Central Controller Byte 0/1 Actual value normalization If the linearization of the characteristic curve is disabled for any controller in control byte 2, bit 3 and if no Pt 100 operation has been selected, the normalization between the input voltage and temperature value can be selected by entering a value. The value to be entered is the temperature which corresponds to 25 mV at the module input (or 250 mV if the ADC sensitivity has been changed with jumpers X8/X9 1, 2 and 3). As an example, 25 mV corresponds to 317 C, therefore value 317 should be entered (or 250 mV corresponds to 183 C enter 183). The sensors are not checked for line breaks. Byte 2 If a value is entered here, the temperature difference between two measurements compared with the preset value can be used to detect a short circuit at the input. The error messages are then written to error bytes 0a to 12a for the respective controller. This value depends on the system/machine and must be determined by the user. The following can be used as a guide for the input: minimum temperature difference < 50% of the maximum rate when heating Under these conditions, short circuit detection is possible, providing that the controlled system heats up uniformly and that actual value acquisition is free of disturbances. The value specified for the minimum temperature difference should be as small as possible. Byte 3,4,5 Free Byte 6,7,8,9 These values are determined by the heating curve of the system. See Chapter 4 at the end of these programming instructions. Bytes 10 to 13 Free Byte Byte Byte Byte 14/15 16/17 18/19 20/21 Sampling time Gain Integral action time Derivative action time For description see messages 0 to 12 Byte 22/23 These values are determined by the heating curve of the system. Byte 24/25 See Chapter 4 at the end of these programming instructions. Bytes 26 to 30 Free Messages 43, 44, 45 4-68 Free IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Message 46 Message 46 contains error bytes of controllers 0 ...12 (see also message 16). The message can only be read. 0 1 2 3 4 5 Free Reserved 6 7 8 9 10 11 Free 12 13 14 15 Reserved 16 17 Error byte 0a 18 19 Error byte 2a 20 21 Error byte 4a 22 23 Error byte 6a 24 25 Error byte 8a 26 27 Error byte 10a 28 29 Error byte 12a Error byte 1a Error byte 3a Error byte 5a Error byte 7a Error byte 9a Error byte 11a 30 31 Message number (46) Fig. 2.6/2 Message 46 Error bytes 0a to 12a, for controllers 0 to 12 IP244 C79000-B8576-C860-02 4-69 Data Exchange with the Central Controller Bytes 16 to 28 Value of the error bits 2n Logical state Required function 20 1 0 Yes No System parameter assignment error 21 1 0 Yes No Parameter monitoring has responded 22 0 23 0 24 0 25 0 26 1 0 Short circuit identifier A 27 1 0 Short circuit identifier B Free Error bytes 0a to 12a Bit 0 Parameter assignment error (system parameters): The bit is set if in control byte 1, bit 2 is 1, the self-tuning function is not currently active and you have entered zero in the messages for the parameters "slope" or "delay time". Bit 1 Parameter monitoring: This bit is set if main control byte 1, bit 2 is 1 and the parameter monitoring (oscillation detector, see Section 1.2.1) is not active. If the oscillation detector has changed the controller gain and the integral action time by a factor totalling 2.9, the oscillation detector switches itself off for this controller. In this case, the oscillation detector has either reacted to two weak oscillations, or one strong oscillation, or one weak and one strong oscillation.. The bit is not set if the setpoint is zero or the heating switch is OFF. The oscillation detector is reactivated as soon as the self-tuning function has been called again for the controller and the function has calculated parameters, or when main control byte 1, bit 2 is 1 following a cold restart. If the oscillation detector changes the parameters, the parameters stored in the message remain unchanged. If bit 7 in main control byte 2 is set, the parameter monitoring bit is not set. 4-70 IP244 C79000-B8576-C860-02 Data Exchange with the Central Controller Bits 6 and 7: Short circuit identifiers A, B: Short-circuit detection is only active when: - a value for minimum temperature difference is entered in byte 2 in messages 30 to 42 - the manipulated variable is 100% or the hot channel control is in the open-loop mode in the approach phase - the setpoint of a controller is not zero and the heating switch is not having an effect, or having an effect and is on. - A check is made only after o o 20 x Ta (sampling time) with non-self-tuned controllers 3 x Tu (delay time) with self-tuned controllers Short-circuit detection is not active when: - cooling controllers have been selected - self-tuning is currently active - zero is entered for minimum temperature difference in messages 30 to 42. Bit 7 (B) Bit 6 (A) Explanation 0 0 0 1 1 1 0 1 No short circuit Original sensor defective, no substitute sensor active Original sensor defective, substitute sensor active Original sensor and substitute sensor defective The following rules apply: - If one of these bits is set, the appropriate controller group error bit and the group error bit are set simultaneously. - If bit 6 = 1, the output of the controller is disabled. - The error messages can only be cleared by the commands "PA", "KS" and "AE" of function block FB 162. Messages 47 to 63 IP244 C79000-B8576-C860-02 Free 4-71 Data Exchange with the Central Controller 4-72 IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines 3 Special Functions for Plastic Machines 3.1 Hot Channel Control 3.1.1 Introduction The heating cartridges used in hot channel control are extremely sensitive to fast temperature changes. To handle this characteristic, an "approach phase" was developed. The system time constants involved when using these heating cartridges are small compared with those encountered using heating collars. The sampling time must therefore be kept as short as possible. 3.1.2 Approach Phase Until the actual value (actual value = approach setpoint (SWA) - start-up zone (ZA)) is reached, a uniform manipulated variable S is set for all controllers, e.g. 25% (no closed-loop control). Once the value reaches the approach zone, the approach time tAZ is started and the approach setpoint is used during this time. When the start-up time tAZ has elapsed, the temperature setpoint then becomes valid. If, during operation, the actual value sinks below the value = approach setpoint (SWA) minus zone (ZA) the approach procedure is restarted. T Operating setpoint SWB Approach setpoint SWA Approach zone ZA Actual temperature value Openloop control with approach manipulated variable S Approach time tAZ Closedloop control with approach setpoint SWA From this point, the end of the approach phase is indicated in message 16, bytes 6 and 7. Closedloop control with SWB Fig. 3.1.2/1 Approach phase for hot channel control Hot channel controllers may only be configured as 2step controllers. Selftuning is not possible! IP244 C79000-B8576-C860-02 4-73 Special Functions for Plastic Machines The parameters required for the approach are entered in message 15. Approach time tAZ in byte 7 (0 to 60 min) Approach manipulated variable S in byte 8 (0 to 100 %) Approach zone ZA in byte 9 (0 to 255 C) Approach setpoint SWA in bytes 10/11 (0 to 1600 C) 3.1.3 Controller Sampling Time for Hot Channel Control The sampling time can be shortened by switching off individual controllers (setpoint=0). The processing of the two voltage channels and the comparator is also dropped. No Pt 100 operation and no special function is possible with hot channel control. Only heating 2-step controllers are allowed. The self-tuning function cannot be used with hot channel control. Main control byte 1, bit 2 is set to 0 by the IP internally. When using hot channel control, the conversion time is 50 ms (regardless of jumper D). The following minimum sampling times are then obtained: 1 to 6 controllers: TA min = (6+1) tc= 350 ms without heating current monitoring 1 to 6 controllers: TA min = (6+1+1) tc= 400 ms with heating current monitoring 1 to 13 controllers: TA min = (13+1) tc= 700 ms no heating current monitoring possible tc = conversion time 4-74 IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines 3.2 Cascaded Control 3.2.1 Introduction: Example Plastic Processing Machines The conventional zone wall control with the extruders of plastic processing machines has the disadvantage that the temperature of the mass of plastic discharged is only constant in one operating status. Changes, for example in the screw speed, always mean changes in the temperature of the material. To compensate for this, the setpoints of the control zones on the extruder must be adjusted. With cascaded control, this adjustment is made by measuring the temperature of the material output by the extruder and by adjusting the setpoints of the individual zones if a deviation is recognized. 3.2.2 Description of the Controller Structure The controller structure for cascaded control is shown in Fig. 3.2.6/1. The extruder is divided into individual heating zones. The temperature of these zones can be controlled by up to 12 zone controllers, all subordinate to the master controller. The structure of the zone controllers is identical to that of the previously described temperature controllers. The temperature of the material is averaged over one machine cycle. This averaging is performed since temperature fluctuations occur when the reservoir head is output (see Fig. 3.2.6/2). The deviation of the actual value from the setpoint is fed back to a PI controller (master controller). The calculation of the manipulated variable of this master controller is always made on completion of a machine cycle. The master controller outputs its manipulated variable in degrees Celsius or in degrees Fahrenheit. The master controller output can be disabled totally with switch S0 and for each individual zone controller individually with switches S1 to S12 (control byte 1). When cascaded control is switched on, the master controller (controller 0) does not have a fixed digital output assigned. The digital outputs are assigned to the active controllers in the following order: DQ16; DQ15 ... DQ1; DQ17 If the switch of a controller is set to "OFF", this controller can be used as an independent temperature controller (S0 to S12). The setpoint correction can be influenced by the evaluation factors F1 to F12 to set a correction profile. The limiters B1 to B12 prevent a zone setpoint from being over-adjusted. A temperature profile can be set with the individual zone setpoints. 3.2.3 Selecting Cascaded Control Cascaded control is selected by setting bit 5 in main control byte 1. Once selected, a start-up must be executed (set bit 2 in main control byte 4). IP244 C79000-B8576-C860-02 4-75 Special Functions for Plastic Machines 3.2.4 Parameter Assignment for Cascaded Control If cascaded control is selected, the information in the messages 0 to 12 changes. Message 0 and therefore controller 0 is always assigned to the master controller. The 12 subordinate zone controllers are assigned messages 1 to 12. The structure of these changed messages can be found in Figs. 3.2.6/3 and 3.2.6/4. 3.2.5 Changes/Additions to the Messages Message 0 for the master controller: Bytes 0/1 (material temperature setpoint) and bytes 2 and 3 (positive and negative tolerance) are the same as for conventional controllers. A second setpoint and the corresponding tolerances (bytes 4 to 7) are omitted. Control byte 1 must be set as follows: Bit 0: always 0 Bit 1: switch S0 Bits 2 to 7: always 0 (2-step controller) "OFF" (0) or "ON" (1) Control byte 2 must be set as follows: Bit 0: always 0 Bit 1: always 0 Bits 2 to 7: always 0 (no manual operation) (no setpoint ramping possible) The controller gain (bytes 16/17), the integral action time (bytes 18/19) and the control zones (bytes 24 to 27) are the same as for standard controllers. The values for the derivative action time (bytes 20/21), heating/cooling ratio (byte 28) and response value (byte 29) are omitted. The selftuning function is not possible for the master controller. Main control byte 1, bit 2 is set to 0 internally for the master controller. Messages 1 to 12 for the secondary controllers: Messages 1 to 12 for the secondary controllers have a form identical to that of the messages described in the operating instructions. The following special features must be noted. SBn is the active setpoint of the individual controller. Bit 1 of control byte 1 corresponds to switches S1 to S12 in Fig. 3.2.6/1. If bit 1 is set, the controller is influenced by the master controller. If bit 1 = 0, the controller operates independently of the master and can therefore be used for other purposes. The evaluation factor and limitation value (see below) are then irrelevant. Setpoint ramping is not possible. The limitation value (byte 11) specifies how many per mil of the entered setpoint (bytes 0/1) of the controller the setpoint correction can be after evaluation. The value must be in the range from 0 to 255 per mil. 4-76 IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines The evaluation factor (byte 12) specifies how many percent of the correction factor of the master controller should be added to the setpoint. Positive evaluation factors from 0 to 127 and negative evaluation factors from 128 to 255 as a negative evaluation factor of 0 - 127% can be selected. The master controller can therefore be weighted zone by zone. The evaluation is limited internally to 100%. Main control bytes (message 15): Bit 5 must be set to 1 (cascaded control on) in main control byte 1 (byte 27). Following each complete machine cycle, bit 0 must be set to 1 in main control byte 3 (byte 29). Setting this bit triggers the actual value averaging and the processing of the master controller. The bit is automatically reset by the module. Message 21 (cumulative setpoints SZn): Bytes 0/1 contain the setpoint of the master controller. Bytes 2 to 25 contain the corrected setpoints (cumulative setpoints) of the secondary zone controllers 1 to 12. If cascaded control is not being used (switch S0 off), the setpoint is at the appropriate location (Fig. 3.2.6/5). 3.2.6 Notes on Operation with Cascaded Control The master controller should only be switched on (S0 on) when the actual values of the secondary controllers are within the first tolerance band (interrogation of the error bytes) and the extruder is switched on. If the master controller is enabled too early, the integrator can cause a large overshoot in the material temperature. The gain of the master controller must not be selected too high, since the system oscillates easily. If a limiter (B1 to B12) is activated, the integrator is slowed down. The correction of the material temperature then requires more time. This should be taken into account when selecting the limitation values. The correction of the zone values is limited by the evaluation factor and the limitation value which can be calculated as follows for each zone: K1 = K2 = 460 C x evaluation factor (in %) 100 x manipulated value from master controller (in %) 100 setpoint individual controller SBn x limitation value (in ) 1000 The two correction values K1 and K2 are calculated internally. The smaller of the two values produces the correction setpoint SFn directly. The effective setpoint for the individual controllers (cumulative setpoint SZn) is calculated as follows: SZn - SFn + SBn If the temperature of the material is not corrected after a longer period of time, you should check whether the limit of correction has been reached. IP244 C79000-B8576-C860-02 4-77 Special Functions for Plastic Machines Setpoint temperature of material Cascade "ON" Cycle triggering - PI Switch: . . Evaluation factor: *F1 Switch: Master controller S0 . S1 SF1 SF2 SZ (cumulative setpoint) Zone controller: Bn SBn SFn SB12 SF12 SZ12 - - - PID PID B12 SZn SZ2 - S12 *F12 B2 SB2 . Sn *Fn B1 Setpoint: . S2 *F2 Limiter: SB1 Actual value smoothing (1 cycle) PID PID Machine Zone heating: Zone wall temperature: S0 *F1 B1 SB1 SZ1 to to to to to . . Extruder S12 *F12 B12 SB12 SZ12 . Temperature of material: .. Software switches Evaluation factors Limiters Active setpoints of the individual controllers Cumulative setpoints Fig. 3.2.6/1 Cascaded control for an extruder 4-78 IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines Temperature of the material Setpoint minus lower control zone 1 machine cycle t Fig. 3.2.6/2 Temperature curve of the material with reservoir head blow-molding machines IP244 C79000-B8576-C860-02 4-79 Special Functions for Plastic Machines Master controller: 0 Setpoint temperature of material 0 to 1600 C in 1 C steps 2 1st positive tolerance 1 to 255 C in 1 C steps 3 1st negative tolerance 1 to 255 C in 1 C steps 1 4 in corresponding F x 5 6 x 7 x 8 Control byte 1 Setting for cascaded control: Control byte 1 : 0 0 0 0 0 0 0/1 0 9 Control byte 2 Control byte 2 : 0 0 H 10 x 11 x 12 x 13 x S0 off/on 14 x 15 16 17 18 19 Gain KR As for normal controller 1 to 25599 1 unit = 0.01 Integral action time TN 0 or (TA TN 512 TA) 1 unit = 4 s 20 21 x 22 23 x 24 25 Upper limit of the control zone in corresponding F 26 27 0 to 1600 C Lower limit of the control zone 28 x 29 x 30 x 31 0 0 to 1600 C x = irrelevant Fig. 3.2.6/3 Message 0 for cascaded control 4-80 IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines Secondary controllers: 0 1 Temperature setpoint (SBn) 0 to 1600 C in 1 C steps 2 1st positive tolerance 1 to 255 C in 1 C steps 1st negative tolerance 1 to 255 C in 1 C steps 5 Lower setpoint (SBn) 0 to 1599 C in 1 C steps 6 2nd positive tolerance 1 to 255 C in 1 C steps 7 2nd negative tolerance 1 to 255 C in 1 C steps 8 Control byte 1 9 Control byte 2 3 4 n = 1 to 12 n = 1 to 12 Settings as for normal control: 10 Manual manipulated variable 0 to 200 %, 1 unit =1 % 11 Limitation value (C) 0 to 255 , 1 unit = 1 12 Evaluation factor (C) 0 to 127 % for positive influence, 1 unit = 1 % 13 Free 14 15 Sampling time TA (ST) 800 to 65535 ms, 1 unit = 1 ms, if main control byte 1, bit 2 = 0 or with purely cooling controller 800 to 24480 ms, 1 unit = 10 ms, if main control byte 1, bit 2 = 1 or with purely cooling controller Gain KR (ST) 1 to 25599, Integral action time TN (ST) 0 or (TA TN 512 TA), 1 unit = 4 s 16 17 18 19 20 128 to 255 % for negative influence Derivative action time TD (ST) 21 0 or (TA 1 unit = 0.01 TD 512 TA), 1 unit = 1 s 2 22 Selftuning parameters 23 Heatingcooling parameters Checkback for selftuning function 24 25 Upper limit of the control zone (ST) or setpoint ramping 0 ... 1600 C/0...3000 C/h, 1 unit = 1 C or 0...2047 F/h (=1119 C/h) For 3step controllers and when main control byte 1, bit 2 = 1, the upper limit is relative to 200C 26 27 28 29 30 31 Lower limit of the control zone (ST) 0 to 1600 C Heatingcooling ratio (ST) 0 to 100 %, 1 unit = 1 % Response value 0 to 50 %, 1 unit = 1 % Minimum jump 1 unit = 10 C checkback for selftuning function Message number 1 to 12 Fig. 3.2.6/4 Messages 1 to 12 IP244 C79000-B8576-C860-02 (Parameters with (C) only valid for cascaded control) (Parameters with (ST) only apply to controllers without selftuning function) 4-81 Special Functions for Plastic Machines 0 1 Setpoint controller 0 2 3 Cumulative setpoint controller 1 (SZ1) 4 5 Cumulative setpoint controller 2 (SZ2) 6 7 Cumulative setpoint controller 3 (SZ3) 8 9 Cumulative setpoint controller 4 (SZ4) 10 11 Cumulative setpoint controller 5 (SZ5) 12 13 Cumulative setpoint controller 6 (SZ6) 14 15 Cumulative setpoint controller 7 (SZ7) 16 17 Cumulative setpoint controller 8 (SZ8) 18 19 Cumulative setpoint controller 9 (SZ9) 20 21 Cumulative setpoint controller 10 (SZ10) 22 23 Cumulative setpoint controller 11 (SZ11) 24 25 Cumulative setpoint controller 12 (SZ12) Conroller 0 is master controller 26 27 28 29 Free 30 31 Message number (21) Fig. 3.2.6/5 Message 21 (cumulative setpoints) 4-82 IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines 3.3 Heating Current Monitoring The heating current monitoring is a function specifically intended for plastic. This function detects whether the heating bands are supplied with the correct current at the correct time. This allows errors/faults in the power supply of the heating bands to be detected. Such faults include line breaks, short circuits, defect switching devices (relays, contactors) or failure of the power supply to the heating bands. If a fault develops, the IP 244 generates a message to the S5 CPU, which can then react accordingly. The hardware required to measure the heating currents and the power supply must be implemented in external devices. This hardware is available as heating current measurement module 904, which generates voltage values for the IP 244 proportional to the heating current or power supply voltage. The heating current measurement module measures the heating currents via its six current transformers and generates signals from the detected values for the IP 244. Thermocouples, power supply voltage and Pt 100s are connected to the module and do not need to be connected to the IP 244. The 904 module is connected to the IP 244 by means of the connecting cable supplied with the 904 (length 2 m). For monitoring 3-phase heating systems, three heating current measurement modules are required per IP 244 (three current conducting cables per control loop). 3.3.1 Selecting the Heating Current Monitoring If bit 1 of main control byte 1 is set to 1, the "heating current monitoring" mode of the IP is selected. The module can then operate a maximum of six controllers with heating current monitoring. For hot channel control, there is a fixed sampling time of 400 ms. In standard operation, the sampling time depends on the time constants of the controlled system. For an ADC conversion time of 50 ms, this is a multiple of 800 ms, for an ADC conversion time of 60 ms, it is a multiple of 960 ms. The sampling time is entered manually or calculated by the self-tuning function. If heating current monitoring is selected, the monitoring of the currents of each channel can be activated or deactivated individually. If the heating current monitoring function has been selected, bits 4 and 5 in main control byte 2 (read channel 13 or channel 14) are ignored, the special version can also not be selected. With Pt 100 operation, no heating current monitoring is possible. 3.3.2 Distribution of the Controller Channels Channels 0 to 5 are used for temperature control as if no heating current monitoring had been selected (see Figs. 3.3.2/1 and 3.3.2/2). Channels 6 to 11 are used for the heating current monitoring of channels 0 to 5. Channel 13 is used for power supply voltage measurement. Channel 15 is the compensation channel. All unused analog inputs must be short-circuited and grounded. IP244 C79000-B8576-C860-02 4-83 Special Functions for Plastic Machines 6 0 904 Thermocouples 5 11 Actual current IP 244 . . . . . . . . 6 6 . . . . . . . . 11 11 12 13 Power supply voltage 14 15 Pt 100 Fig. 3.3.2/1 Heating current monitoring module Assignment of the channel numbers Controller number Actual temperature value Actual current value 0 0 6 1 1 7 2 2 8 3 3 9 4 4 10 5 5 11 13 = Actual power supply voltage value 15 = Pt 100 for reference junction temperature measurement Jumpers 12 und 14 must be short circuited and connected to reference potential. Fig. 3.3.2/2 Assignment of the channel numbers 4-84 IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines 3.3.3 Input of Parameters for Heating Current Monitoring - Heating current monitoring The setpoint for current is entered in messages 6 to 11, bytes 0 and 1. Byte 2 is for the positive tolerance and byte 3 for the negative tolerance. The tolerances must be entered relative to the setpoint. If the setpoint for current is selected as zero, the corresponding current monitoring is disabled, error messages are cleared and the actual value indication for current is set to 0. The IP is to be informed about the current calibration value entered in bytes 4 and 5. Formula to calculate the current calibration value Ical : 25.6 mV I cal = nominal current [A] peak output voltage of current converter [mV] Example of how to determine the current calibration value: The nominal current consumption of the monitored system part is 15 Aeff. The current converter outputs a pulsating direct voltage of 21.2 mV at a 15 Aeff input current. The current calibration value Ical is then: I cal = 15[A] 25.6 [mV] 21.1 [mV] = 18.2 A The number to enter the calibration value for the current is then 182 (unit = 0.1 A) The current monitoring remains active if a controller is switched off by a temperature setpoint equal to zero or when the heating switch is OFF. - Actual current value monitoring The setpoint for the power supply voltage is entered in message 13, bytes 0 and 1. Byte 2 is for the positive tolerance of the power supply voltage actual value and byte 3 for the negative tolerance. The tolerances must be entered relative to the setpoint. If the setpoint is set to zero, the power supply voltage is not monitored and the heating current is not weighted with the actual power supply voltage value. In addition to this, the error messages are cleared and the power supply voltage actual value indication is set to 0. A voltage calibration value must be transferred to the IP with message 13, bytes 4 and 5. Here, the power supply voltage value corresponding to a sinusoidal half-wave signal with a peak voltage of 10.24 V at the module input (see Fig. 3.3.4/1) must be entered. Formula to calculate the voltage calibration value Ucal : 10.24 mV U cal = nominal voltage of the power supply [V] voltage at the output of the voltage converter [V] Example of how to determine the voltage caibration value Ucal : The nominal voltage of the power supply is: Ueff = 220 V Peak value of the nominal voltage is: Upeak = 220 V. 2 = 311 V The voltage converter is a 50:1 voltage divider: this means for the IP 244 that: UE = 311 [V] / 50 = 6.22 V. The voltage calibration value is then: Ucal = 220 [V] 10.24 [V] 6.22 [V] = 362 V The number to enter as the calibration value for the voltage is then 362 (unit = 1V). IP244 C79000-B8576-C860-02 4-85 Special Functions for Plastic Machines 3.3.4 Actual Current Value Monitoring An actual current value is measured per controlled temperature system. If heating bands are connected in parallel (heating cartridges) the total current is measured. For the actual current value measurement, a bridge-connected rectifier must be included so that both current half-waves can be measured (see Fig. 3.3.4/1). The advantage of this compared with an actual current value measurement in which only one half-wave is evaluated is that with inverse-parallel connected thyristors it is possible to check whether the current flow in the negative direction is also OK. The integration time of the ADC inputs must be set to 20 ms for a power supply frequency of 50 Hz and to 16 2/3 ms at a frequency of 60 Hz. Frequency fluctuations are ignored, since they are not detected by the module. Heating current I Heating band Actual current value measure ment IP 244 RS Voltage t Peak voltage Fig. 3.3.4/1 Heating current monitoring 4-86 IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines Channel 13 is intended to monitor power supply voltage fluctuations. With heating current monitoring, the heating current is monitored for 2 and 3-step controllers both when it is on and off. Either solid state relays or contactors are permitted as the switching devices for heating bands. Switching devices with switching times up to 50 ms can be used for hot channel control. This means that when the heating current is on, currents can only be monitored when the ON time per sampling period is at least 100 ms. The same applies for monitoring currents in the OFF state. For standard temperature control, switching devices with make times of maximum 100 ms, maximum 150 ms or maximum 200 ms can be used (see Fig. 3.3.4/1). Using main control byte 3, bits 6 and 7, you can inform the IP of the maximum make times of your switching devices. The break times of the switching devices must be a maximum of 50 ms. Currents can only be measured in the ON state when the heating is switched on for at least 150 ms (make time 100 ms) or 200 ms or 250 ms (for make times of 150 ms or 200 ms) during a sampling period. To monitor currents in the off state, the OFF time per sampling period must be at least 100 ms. For measuring the actual value of the currents and power supply voltage, a software filter minimizes the influence of disturbances. Switching KW 4 5.5 7.5 11 15 ms 20 to 170 20 to 170 35 to 180 35 to 180 35 to 190 On delay Fig. 3.3.4/2 Typical make times of contactors of different capacities IP244 C79000-B8576-C860-02 4-87 Special Functions for Plastic Machines 3.3.5 Indication and Signalling Concept of the Heating Current Monitoring The measured and averaged actual voltage value is indicated in message 17. If the actual voltage value exceeds the positive (negative) tolerance, bit 0 (bit 1) is set in error byte 13. The measured and averaged actual current values corrected by the amount of the actual voltage for the ON state are written to message 17 and for the OFF state to message 18. The measured, unfiltered and uncorrected actual current values for the ON state are written to message 19 and for the OFF state to message 20. If the corrected actual current value exceeds the positive (negative) tolerance in the ON state, bit 0 (bit 1) is set in the corresponding error bit. In the OFF state, bit 2 is set if the positive tolerance is exceeded (see Fig. 3.3.5/1). The error messages are continuously updated. The reaction to an error message (example: switching off the heating) must be contained in the S5 program. The time between the occurrence of an error until it is detected by the heating current monitoring, is up to 19.2 s for hot channel control. With standard temperature control, this time depends on the sampling time. At a sampling time of 800 ms, it is 6.4 s. A hardware adapter module for heating current measurement must supply the IP with a measurement signal, which provides positive sinusoidal half-waves with a maximum peak voltage of 25.6 V for the actual current values and 10.24 V for the actual power supply voltage value. Positive sinusoidal half-waves with an amplitude of 25.6 mV or 10.24 V correspond to a d.c. voltage of 16.3 mV or 6.52 V. If you set a power supply voltage or current setpoint which converts to a value greater than 16.3 mV or 6.52 V, bit 4 is set in the error bytes and the setpoint is limited to a value corresponding to 16.3 mV or 6.52 V. If the actual power supply voltage or actual current value exceeds 16.3 mV or 6.52 V, bit 6 of the error byte is set to 1 and the actual value read in is set to 16.3 mV or 6.52 V. Current + Tolerance - Tolerance Heating ON Heating OFF + Tolerance Time Fig. 3.3.5/1 Tolerance monitoring If heating current monitoring is selected, some of the messages and error bytes explained in Chapter 2 must be replaced by the messages and error bytes shown on the following pages. 4-88 IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines Messages 6 to 11 for heating current monitoring 0 1 Heating current setpoint 1 unit = 0.1 A 2 Positive tolerance 1 unit = 0.1 A 3 Negative tolerance 1 unit = 0.1 A Current calibration value 1 unit = 0.1 A 4 5 6 Referring to nominal current consumption and the transmission ratio of the current converter (see page 85). 7 8 9 10 11 12 13 14 15 16 17 Free 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Message number (....) IP244 C79000-B8576-C860-02 4-89 Special Functions for Plastic Machines Message 12 for heating current monitoring 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Free 18 19 20 21 22 23 24 25 26 27 28 29 30 31 4-90 Message number (12) IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines Message 13 for heating current monitoring 0 1 Power supply voltage setpoint 1 unit = 1 V 2 Positive tolerance 1 unit = 1 V 3 Negative tolerance 1 unit = 1 V Voltage calibration value 1 unit = 1 V 4 5 6 Referring to the power supply voltage and the transmission ratio of the voltage converter (see page 85). 7 8 9 10 11 12 13 14 15 16 17 Free 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Message number (13) IP244 C79000-B8576-C860-02 4-91 Special Functions for Plastic Machines Message 14 for heating current monitoring 0 1 2 3 Free 4 5 6 7 8 9 10 11 12 Reserved: must be 0 13 14 15 16 17 18 19 20 21 Free 22 23 24 25 26 27 28 29 30 31 4-92 Message number (14) IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines Messages 15 and 16 remain as described for the standard controller, only the significance of some of the error bytes/bits changes. Value of the error bits 2n Logical state 20 1 0 Yes No Positive tolerance exceeded in ON state 21 1 0 Yes No Negative tolerance exceeded in ON state 22 1 0 Yes No Positive tolerance exceeded in OFF state 23 0 Free 24 1 0 Yes No 25 0 Free 26 1 0 Yes No 27 0 Free Required function Current setpoint too high Actual current value too high Byte 22 ... 27 in message 16 Error bytes 6 ... 11 IP244 C79000-B8576-C860-02 4-93 Special Functions for Plastic Machines Value of the error bits 2n Logical state 20 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 Required function Free Byte 28 in message 16 Error byte 12 4-94 IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines Value of the error bits 2n Logical state Required function 20 1 0 Yes No Positive tolerance exceeded 21 1 0 Yes No Negative tolerance exceeded 22 0 Free 23 0 24 1 0 25 0 26 1 0 27 0 Yes No Voltage setpoint too high Yes No Actual voltage value too high Byte 29 in message 16 Error byte 13 IP244 C79000-B8576-C860-02 4-95 Special Functions for Plastic Machines Value of the error bits 2n Logical state 20 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 Required function Free Byte 30 in message 16 Error byte 14 4-96 IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines Message 17 for heating current monitoring 0 1 Actual temperature value controller 0 2 3 Actual temperature value controller 1 4 5 Actual temperature value controller 2 6 7 Actual temperature value controller 3 8 9 Actual temperature value controller 4 10 11 Actual temperature value controller 5 12 13 Weighted actual current value in ON state controller 0 1 unit = 0.1 A 14 15 Weighted actual current value in ON state controller 1 1 unit = 0.1 A 16 17 Weighted actual current value in ON state controller 2 1 unit = 0.1 A 18 19 Weighted actual current value in ON state controller 3 1 unit = 0.1 A 20 21 Weighted actual current value in ON state controller 4 1 unit = 0.1 A 22 23 Weighted actual current value in ON state controller 5 1 unit = 0.1 A 24 25 26 27 28 29 Free Actual power supply voltage value 1 unit = 1 V Free 30 31 Message number (17) IP244 C79000-B8576-C860-02 4-97 Special Functions for Plastic Machines Message 18 for heating current monitoring 0 1 Manipulated variable controller 0 2 3 Manipulated variable controller 1 4 5 Manipulated variable controller 2 6 7 Manipulated variable controller 3 8 9 Manipulated variable controller 4 10 11 Manipulated variable controller 5 12 13 Weighted actual current value in OFF state controller 0 1 unit = 0.1 A 14 15 Weighted actual current value in OFF state controller 1 1 unit = 0.1 A 16 17 Weighted actual current value in OFF state controller 2 1 unit = 0.1 A 18 19 Weighted actual current value in OFF state controller 3 1 unit = 0.1 A 20 21 Weighted actual current value in OFF state controller 4 1 unit = 0.1 A 22 23 Weighted actual current value in OFF state controller 5 1 unit = 0.1 A 24 25 26 27 Free 28 29 30 31 4-98 Message number (18) IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines Message 19 for heating current monitoring 0 1 Minimum value controller 0 2 3 Minimum value controller 1 4 5 Minimum value controller 2 6 7 Minimum value controller 3 8 9 Minimum value controller 4 10 11 Minimum value controller 5 12 13 Measured actual current value in ON state controller 0 1 unit = 0.1 A 14 15 Measured actual current value in ON state controller 1 1 unit = 0.1 A 16 17 Measured actual current value in ON state controller 2 1 unit = 0.1 A 18 19 Measured actual current value in ON state controller 3 1 unit = 0.1 A 20 21 Measured actual current value in ON state controller 4 1 unit = 0.1 A 22 23 Measured actual current value in ON state controller 5 1 unit = 0.1 A 24 25 26 27 28 29 30 31 Free Digital outputs image DQ 1 1 Digital outputs image DQ 2 ... 9 2 to 9 Digital outputs image DQ 10 ... 17 10 to 17 Message number (19) IP244 C79000-B8576-C860-02 4-99 Special Functions for Plastic Machines Message 20 for heating current monitoring 0 1 Maximum value controller 0 2 3 Maximum value controller 1 4 5 Maximum value controller 2 6 7 Maximum value controller 3 8 9 Maximum value controller 4 10 11 Maximum value controller 5 12 13 Measured actual current value in OFF state controller 0 1 unit = 0.1 A 14 15 Measured actual current value in OFF state controller 1 1 unit = 0.1 A 16 17 Measured actual current value in OFF state controller 2 1 unit = 0.1 A 18 19 Measured actual current value in OFF state controller 3 1 unit = 0.1 A 20 21 Measured actual current value in OFF state controller 4 1 unit = 0.1 A 22 23 Measured actual current value in OFF state controller 5 1 unit = 0.1 A 24 25 26 27 Free 28 29 30 31 4-100 Message number (20) IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines Message 21 for Messages 36 to 42 for heating current monitoring heating current monitoring 0 1 Setpoint controller 0 0 1 2 3 Setpoint controller 0 2 3 4 5 Setpoint controller 0 4 5 6 7 Setpoint controller 0 6 7 8 9 Setpoint controller 0 8 9 10 11 Setpoint controller 0 10 11 12 13 Heating current setpoint controller 0 12 13 14 15 Heating current setpoint controller 0 14 15 16 17 Heating current setpoint controller 0 16 17 18 19 Heating current setpoint controller 0 18 19 20 21 Heating current setpoint controller 0 20 21 22 23 Heating current setpoint controller 0 22 23 24 25 Free 24 25 26 27 Power supply voltage setpoint 26 27 28 29 Free 28 29 30 30 31 Free Message number (21) IP244 C79000-B8576-C860-02 31 Message number 4-101 Special Functions for Plastic Machines Value of the error bits 2n Logical state 20 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 Required function Free Bytes 22 to 28 in message 46 Error bytes 6a to12a 4-102 IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines 3.4 Special Function, Measured Value Acquisition at Channels 13 and 14 3.4.1 Selecting the Special Function You select the special function by setting the main control byte 1 bit 3. With this bit set, there are several changes compared with operation without the special function. The special function cannot be selected for Pt 100 operation, hot channel control and heating current monitoring! 3.4.2 Stipulating the ADC Conversion Time The conversion time of the ADC is fixed at 55 ms (jumper "D" on jumper base X6/X7 is not evaluated). The following limit values apply: Thermocouples (channels 0 ... 13) Fe-Constantan (L and J) NiCr-Ni (K) Pt 10%Rh-Pt (S) Pt 13%Rh-Pt (R) 675 C 900 C 1600 C 1740 C Voltage channels 13/14 max. 15 V 3.4.3 Processing Sequence of the Analog Inputs The order in which the individual channels are processed changes so that a voltage channel always follows a controller channel. The sampling time of channel 13 is therefore 110 ms. The minimum sampling time of a controller is then 1540 ms. Channel 13 is normally used. If, however, "read channel 14 once" is requested (main control byte 4, bit 3), channel 14 is read once instead of channel 13. Channel no. 0 1 13 2 13 3 13 4 13 5 13 6 13 7 13 8 13 9 10 13 13 11 13 12 13 15 13 0 13 1 13 (14) (14) (14) (14) (14) (14) (14) (14) (14) (14) (14) (14) (14) (14 ) (14) t/55ms 1 1 2 3 4 5 6 7 8 9 0 1 5 2 0 2 5 2 8 3 0 (28 55ms=1540ms) Fig. 3.4.3/1 Processing sequence of the analog inputs IP244 C79000-B8576-C860-02 4-103 Special Functions for Plastic Machines 3.4.4 Converting Voltage Values to Physical Values Channel 13 and comparator Channel 13 is used to measure transducer signals. As standard, the input is equipped with a voltage divider 400:1. For other applications, this divider can be changed (see C79000-B8576-C859 in Part 2 of this manual). The permitted input voltage with the 400:1 divider and 51.2 mV ADC sensitivity is 0 to 15.36 V (= 1536 units on the ADC). To take into account the transducer-specific data from measured value acquisition in the actual value indication in message 17, a normalization factor and a matching value are required. The normalization is performed by selecting bits A and B. The normalization factor and matching value are entered in message 15, bytes 14/15. 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Byte 14 B A Byte 15 Matching value (binary coded) Bits A,B: position of the decimal point B A 0 0 1 1 0 1 0 1 Corresponds to normalization factor 1 10 100 1000 Numerical range 0 0.0 0.00 0.000 < < < < x 16383 x 1638.3 x 163.83 x 16.383 The actual value appears in message 17, bytes 26/27 and is calculated according to the following formula: Actual value (in required unit) = voltage in mV normalization factor matching value Example for the normalization and adaption of the actual value display for channel 13: The connected voltage is 5200 mV, the desired display is 250. This results in: 5200/250 = 20.8. To represent the digit after the decimal point, you must multiply with 10 or 100 as the normalization factor. It is not possible to use 1000 as the normalization factor, as the accompanying number range is too small to represent 28.8 1000. Then the normalization factor is 10 : A = 1, B = 0, matching value = 208 (D0hex) The setpoint for the comparator in message 15, bytes 0 and 1 is calculated as follows: Setpoint for comparator = conversion value (in units) (in the unit of the actual value at channel 13) 4-104 matching value normalization factor IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines Channel 14 The same conditions apply to channel 14 as to channel 13. The actual value is calculated as follows: Actual value (channel 14) = voltage in mV Conversion value 10000 The conversion value is entered in message 15, bytes 4 and 5. The actual value is output in message 17, bytes 28 and 29 in the units of the conversion value. 3.4.5 Processing the Special Function Reading in measured values (channel 13) By setting main control byte 4, bit 0 "start reading pressure curve", 60 actual values are read into an internal table at equidistant instants via channel 13. The start bit resets the acknowledgement bit "reading measured values complete" in status byte 1, bit 2 (the start bit is also reset by the IP). After reading in the 60 values, the acknowledgement bit is set to 1. After this, the 60 values can be read out in messages 22 to 25. The total time of the reading in function is set by message 15, byte 6 (duration of acquisition) (max. 255 seconds, min. 6.6 seconds). The duration of acquisition is rounded up or down to multiples of 3 or 6 seconds. (Values 8s are rounded down to 6s, values 9s are rounded up to 12s values 14s are rounded down to 12s, values 15s are rounded up to 18s or values 4s are rounded down to 3s, values 5s are rounded up to 6s.) If only 30 values are input, the values 31 to 60 are not defined. In addition to this, the module records the maximum value which occurred on channel 13 during this time. The maximum value is entered in message 20, bytes 26/27 and compared with the setpoint of message 13, bytes 0/1 and its tolerances in bytes 2 and 3. If the tolerance is exceeded, the appropriate error bits are set. Note: If the module recognizes the signal "read measured value at channel 14 once" during the measured value acquisition on channel 13, a measured value is assigned the value 0 if the acquisition times are 8 s. IP244 C79000-B8576-C860-02 4-105 Special Functions for Plastic Machines Read measured value at channel 14 once If bit 3 of main control byte 4 is set, channel 14 is read once instead of channel 13. The request bit and the acknowledgement bit (status byte 1, bit 3) are reset by the IP. After entering the actual value and the error byte, the acknowledgement bit is set to 1. The reaction time from setting the request to setting the acknowledgement bit is as follows: - outside the pressure curve 55 - 110 ms - within the pressure curve 55 - 220 ms Note on tolerance monitoring: The entry of the setpoint is in the units of the conversion factor specified in message 14, bytes 0/1. The setpoint is limited to the conversion value internally. Tolerances cannot be selected. The tolerances are calculated as follows: - positive tolerance = 1.5 % conversion value, but minimum 2 units - negative tolerance always 2 units. 3.4.6 Miscellaneous The functions - self-tuning - cascaded control can still be used. The control bits "read channel 13" and "read channel 14" are irrelevant. 4-106 IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines 3.5 Extensions to the Message Exchange The extensions for the special function are marked with " * ". General functions of messages 0 to 31: Message number 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Controller parameter controller no. 0 1 2 3 4 5 6 7 8 9 10 11 12 Setpoint and tolerances for channel 13 * Setpoint for channel 14 * General parameters and main control bytes * Status and error bytes * Actual values 0 to 14 * Manipulated variables 0 to 12 Minimum values 0 to 12 Maximum values 0 to 13 * Cumulative setpoints Measured values from channel 13 1 to 15 * 16 to 30 * 31 to 45 * 46 to 60 * Free Free Free Free Free Free Messages 0 to 12 Messages 0 to 12 remain unchanged. IP244 C79000-B8576-C860-02 4-107 Special Functions for Plastic Machines Message 13 0 1 Setpoint of measured values * 1 unit = 1bar 2 Positive tolerance * 1 unit = 1bar 3 Negative tolerance * 1 unit = 1bar 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 4-108 Message number (13) IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines Message 14 0 1 Setpoint for channel 14 2 No tolerance selection 3 No tolerance selection * 1 unit = 1 metric ton 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Message number (14) IP244 C79000-B8576-C860-02 4-109 Special Functions for Plastic Machines Message 15 0 1 Conversion value for comparator 2 3 Monitoring time (emergency program) 4 5 Normalization factor for channel 14 * (40-4000 units) 6 Duration of acquisition of measured values on channel 13 * (6-255s) 1 unit = 1 s 7 8 9 10 11 The hot channel parameters are irrelevant with special function 12 Maximum temperature difference 13 Free 14 15 Normalization factor and matching value for channel 13 * 27 Main control byte 1 * 28 Main control byte 1 29 Main control byte 1 30 Main control byte 1 31 Message number (15) * 1 unit = 1 physical unit (0-3600s) 1 unit = 1 s * C/min 16 17 18 19 20 21 22 23 24 25 26 4-110 * IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines Byte 27 Main control byte 1 Value of the control bits 2n Logical state Required function 20 1 0 Yes No Free 21 1 0 Yes No Free 22 1 0 Yes No Free 23 1 0 Yes No Special function 24 1 0 Yes No Hot channel control 25 1 0 Yes No Cascaded control 26 1 0 27 0 IP244 C79000-B8576-C860-02 Actual values in BCD binary Must be 0 4-111 Special Functions for Plastic Machines Byte 28 Main control byte 2 Value of the control bits 2n 4-112 Logical state 20 1 0 21 1 0 Required function Type of thermocouple 22 1 0 23 1 0 24 1 0 Yes No Read channel 13 25 1 0 Yes No Read channel 14 26 1 0 Yes No Free 27 1 0 Yes No Free IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines Byte 29 Main control byte 3 Value of the control bits 2n Logical state Required function 20 1 0 21 1 0 Yes No Free 22 1 0 Yes No Free 23 1 0 Yes No Free 24 1 0 Yes No Free 25 1 0 Yes No Free 26 1 0 Yes No Free 27 1 0 Yes No Free IP244 C79000-B8576-C860-02 End of cycle (cascaded control) 4-113 Special Functions for Plastic Machines Byte 30 Main control byte 4 Value of the control bits 2n 4-114 Logical state Required function 20 1 0 21 1 0 Yes No Cold restart 22 1 0 Yes No Parameter transfer complete 23 1 0 Yes No Read channel 14 once instead of channel 13, only if special function selected 24 1 0 Yes No Output averaged manipulated variable (line break) 25 1 0 Yes No Switch over to 2nd setpoint 26 1 0 Reserved 27 1 0 Yes No * * Start reading measured values on channels 13 Use the 2nd tolerances IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines Message 16 0 Status byte 1 1 Reserved 2 Controller group error/channel group error Controller 8-12 / 13 & 14 3 Controller group error/channel group error Controller 0-7 4 Selftuning status Controller 8-12 5 Selftuning status Controller 0-7 * 6 7 8 9 10 11 12 13 14 Free 15 Software release 16 Error byte 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Message number (16) IP244 C79000-B8576-C860-02 4-115 Special Functions for Plastic Machines Byte 0 Main control byte 1 Value of the control bits 2n 4-116 Logical state Required function 20 1 0 Yes No 21 1 0 Reserved 22 1 0 Yes No Reading measured values on channel 13 complete 23 1 0 Yes No Reading measured values on channel 14 complete 24 0 Free 25 1 0 Yes No Sampling time overflow 26 1 0 Yes No Parameter request 27 1 0 Group error Watchdog IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines Message 17 0 1 Actual temperature value controller 0 2 3 1 4 5 2 6 7 3 8 9 4 10 11 5 12 13 6 14 15 7 16 17 8 18 19 9 20 21 10 22 23 11 24 25 12 1 unit = 1 C 26 27 Actual value (channel 13) * 28 29 Actual value (channel 14) * 30 Free 31 Message number (17) 1 unit = 1 physical unit Message 18 (Manipulated variables) unchanged Message 19 (Minimum values) unchanged IP244 C79000-B8576-C860-02 4-117 Special Functions for Plastic Machines Message 20 0 1 Max. temperature value controller 0 2 3 1 4 5 2 6 7 3 8 9 4 10 11 5 12 13 6 14 15 7 16 17 8 18 19 9 20 21 10 22 23 11 24 25 12 26 27 Maximum value of measured values on channel 13 28 29 Free 30 Free 31 Message number (20) 1 unit = 1 C * 1 unit = 1 bar Message 21 (Cumulative setpoints) unchanged 4-118 IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines Message 22 0 1 Measured values channel 13 Value 1 2 3 Value 2 4 5 Value 3 6 7 Value 4 8 9 Value 5 10 11 Value 6 12 13 Value 7 14 15 Value 8 16 17 Value 9 18 19 Value 10 20 21 Value 11 22 23 Value 12 24 25 Value 13 26 27 Value 14 28 29 Value 15 30 Free 31 Message number (22) IP244 C79000-B8576-C860-02 4-119 Special Functions for Plastic Machines Message 23 0 1 Measured values channel 13 Value 16 2 3 Value 17 4 5 Value 18 6 7 Value 19 8 9 Value 20 10 11 Value 21 12 13 Value 22 14 15 Value 23 16 17 Value 24 18 19 Value 25 20 21 Value 26 22 23 Value 27 24 25 Value 28 26 27 Value 29 28 29 Value 30 30 Free 31 Message number (23) 4-120 IP244 C79000-B8576-C860-02 Special Functions for Plastic Machines Message 24 0 1 Measured values channel 13 Value 31 2 3 Value 32 4 5 Value 33 6 7 Value 34 8 9 Value 35 10 11 Value 36 12 13 Value 37 14 15 Value 38 16 17 Value 39 18 19 Value 40 20 21 Value 41 22 23 Value 42 24 25 Value 43 26 27 Value 44 28 29 Value 45 30 Free 31 Message number (24) IP244 C79000-B8576-C860-02 4-121 Special Functions for Plastic Machines Message 25 0 1 Measured values channel 13 Value 46 2 3 Value 47 4 5 Value 48 6 7 Value 49 8 9 Value 50 10 11 Value 51 12 13 Value 52 14 15 Value 53 16 17 Value 54 18 19 Value 55 20 21 Value 56 22 23 Value 57 24 25 Value 58 26 27 Value 59 28 29 Value 60 30 Free 31 Message number (24) 4-122 IP244 C79000-B8576-C860-02 Notes on Controller Settings 4 Notes on Controller Settings (for non-self-tuning controllers) The following sections contain notes on settings (controller tuning) based on previous experience (in plastics) of the standard PID zone controller with pulse duration modulated output. 4.1 Characteristics of the Controlled System The dynamic behavior of the controlled system can be determined by the curve of the controlled variable x after a step change in the manipulated variable y from 0 to 100%. y 100 % ON Yh y Yh Tu Tg Ks = = = = = manipulated variable range of manipulated variable delay time response time transfer coefficient of the controlled system Ks 0 % OFF = Xmax Yh t x Tg Xmax Xh Dx Ks Dt Tu vmax = maximum rate of rise of the controlled variable Xmax = maximum value of the controlled system Xh = setting controller t vmax = Xmax Tg = Dx Dt Fig. 4.1/1 Response curve of a controlled system IP244 C79000-B8576-C860-02 4-123 Notes on Controller Settings Most controller systems are so-called self-regulating systems (see Fig. 4.1/1). The dynamic response can be approximated by the variables delay time Tu, response time Tg and maximum value Xmax. These values are determined by placing a tangent to the response curve which intersects the maximum and minimum values. The transient response must in many cases not be allowed to reach the maximum value, since the controlled variable must not exceed certain values. The rate of rise vmax is therefore used to define the controlled system. Tu From the ratio Tg or Tu vmax Xmax the controllability of the system can be estimated. The following applies: Tu Tg < 0.1 0.1 to 0.3 > 0.3 can be controlled well is controllable difficult to control Systems can be evaluated according to the following values: Tu < 0.5 min, Tg < 5 min = fast controlled system Tu > 0.5 min, Tg > 5 min = slow controlled system Characteristic values of important temperature-controlled systems Controlled variable Type of controlled system Temperature Small, electrically heated oven/kiln Large, electrically heated annealing furnace Large, gas heated annealing furnace Autoclave system High pressure autoclave system Injection molding machines Extruders Packaging machines 4.2 Delay time Tu Response time Tg Rate of rise Vmax 0.5 to 1 min 5 to 15 min to 60 K/min 1 5 min 10 to 20 min to 20 K/min 3 10 200 3 5 3 to 60 min to 20 min to 300 min to 30 min to 60 min to 40 min to 0.2 to 5 min 0.5 to 0.7 min 12 to 15 min 0.5 to 3 min 1 to 6 min 0.5 to 4 min 1 K /min to 30 K/min 5 K /min to 20 K/min 2 K /min to 35 K/min Controller Type (2-step, 3-step controllers) 2-step controller without feedback 2-step controllers have the switching states "ON" and "OFF". This corresponds to 100% or 0% power. This action produces a continuous oscillation of the controlled variable x round the setpoint w. The amplitude and the period of oscillation increases with the ratio of delay time (Tu) to response time Tg of the controlled system and with the hysteresis XSd of the controller. These controllers are mainly used for simple temperature controls, e.g. electric directly heated ovens or as limit value detectors. 4-124 IP244 C79000-B8576-C860-02 Notes on Controller Settings y w ON Yh = range of manipulated variable w = reference variable XSd = hysteresis Yh OFF XSd x Fig. 4.2/1 Characteristics of a 2step controller x Tg Transient response without controller Tu = delay time Tg = response time XSd = hysteresis w XSd Tu t y 100 % 0% Fig. 4.2/2 Control function of a 2step controller without feedback IP244 C79000-B8576-C860-02 t 4-125 Notes on Controller Settings 2-step controller with feedback The action of 2-step controllers on controlled systems with long delay times, e.g. furnaces in which the chamber is separate from the heating, can be improved by electronic feedback. With the aid of the feedback, the operating frequency of the controller is increased reducing the amplitude of the controlled variable. In addition to this, the control results in dynamic operation can be greatly improved. The limit for the operating frequency is set by the output stage. Mechanical actuations such as relays and contactors should not be switched more than 1 to 5 times per minute. For binary voltage and current outputs connected to thyristor or triac actuators, operating frequencies can be selected far higher than the limit frequency of the controlled system. Since the switching pulses at the output of the controlled system can no longer be detected, the results obtained are similar to those with continuous controllers. In contrast to a continuous controller in which the amplitude of the output signal represents the manipulated variable, the output variable of a 2-step controller with feedback is formed by pulse duration modulation. 2-step controllers with feedback are used, for example, for temperature control in furnaces and ovens in the plastic, textile, paper, rubber and foodstuff industries and for heating and cooling devices. 3-step controller 3-step controllers are used for heating/cooling. These controllers have two switching points. By means of electronic feedback structures, the controller results are optimized. Areas of application for such controllers are heating, refrigeration and climatic chambers and tool heating systems for plastic processing machines. . y w y11 y 12 = y21 y22 xSd1 xSd2 x xSh y = manipulated variable e.g. y11 = 100 % heating y12 = 0 % heating y21 = 0 % cooling y22 = 100 % cooling x = controlled variable e.g. temperature in C w = setpoint xSd1 = hysteresis, switching point 1 xSd2 = hysteresis, switching point 2 xSh = distance between switching point 1 and switching point 2 Fig. 4.2/3 Characteristics of a 3step controller 4-126 IP244 C79000-B8576-C860-02 Notes on Controller Settings 4.3 Control Action with Different Feedback Structures To achieve accurate control and optimum correction of the disturbance variable, the controller must be tuned to the dynamic response of the controlled system. To do this, feedback structures are used which have a proportional action (P), proportional plus derivative action (PD), proportional pus integral action (PI) or proportional plus integral plus derivative action (PID), depending on the structure of the feedback circuit. If there is a sudden step at the controller input, the response is also in the form of a step as shown in the following diagrams, assuming that the delay times of the controller are negligible and that the controller reacts very quickly. P controller x Step at the controller input Input variable t y Step response of the continuous controller Output variable t y 100 % Step response of the discontinuous controller 0% Output variable t Fig. 4.3/1 Step response of a P controller IP244 C79000-B8576-C860-02 4-127 Notes on Controller Settings The characteristic values of the P controller are the proportional band Xp or the proportional coefficient Kp and the operating point yo. Xp x w Xp 2 Xp 2 yo Symmetrical position of the proportional band Xp Input variable y y Output response of the continuous controller within the proportional band Xp Output variable t y Output response of the discontinuous controller within the proportional band Xp 100 % 0% Output variable t Fig. 4.3/2 Step response of a P controller 4-128 IP244 C79000-B8576-C860-02 Notes on Controller Settings The operating point yo is the value of the output signal at which the signal deviation becomes zero. The proportional band Xp and the proportional coefficient Kp have the following relationship: Kp = 1 100 % Xp Within the Xp band, the output variable and input variable are directly proportional, i.e. the change in the output variable = proportional coefficient x change in input variable; as a formula: y = Kp xw From the formula, it is clear that a change in the input variable , e.g. by a disturbance variable, causes a change in the output variable by a factor of Kp. In a static state, a change in the input variable means that the controller controls the system to a different value than before the occurance of the disturbance variable. This characteristic is common to all proportional controllers. This deviation is known as the proportional offset or proportional error. The proportional error cannot exceed the proportional band Xp. IP244 C79000-B8576-C860-02 4-129 Notes on Controller Settings PD controller D control elements alone are unsuitable for control, since they no longer output an actuating signal when the input variable returns to a static value. x Step at the controller input Input variable t y Tv Output variable Step response of the continuous controller t y 100 % 0% Step response of the discontinuous controller Output variable t Fig. 4.3/3 Step response of a PD controller In conjunction with P control elements, the D action is used to generate an actuating pulse dependent on the speed of change of the controlled variable. If a disturbance variable z influences the control system, the PD controller sets itself for a different system deviation as a result of the changed degree of correction. Disturbances are not completely corrected. The advantage is the good dynamic response. During start-up and when changes occur in the reference variable, a well-damped and oscillation-free transition is achieved. A controller with a D action is, however, not suitable for controlled systems with pulsating measured values, e.g. pressure or flow controls. 4-130 IP244 C79000-B8576-C860-02 Notes on Controller Settings PI controller x Step at the controller input Input variable t y Step response of the continuous controller Output variable t y 100 % Step response of the discontinuous controller 0% Output variable t Fig. 4.3/4 Step response of a PI controller IP244 C79000-B8576-C860-02 4-131 Notes on Controller Settings The output variable of I control elements is the integral of the input variable, i.e. the controller totals the deviation from the setpoint over time. This means that the controller continues to correct until there is no deviation from the setpoint. In practice, a combination of the various time elements is ideal, depending on the requirements of the control action. The dynamic response of the individual elements can be described using the controller parameters proportional band Xp, integral action time Tn (I action) and derivative action time Tv (D action). PID controller x Step at the controller input Input variable t y Tv Output variable Step response of the continuous controller t Tn y Step response of the discontinuous controller Output variable t Fig. 4.3/5 Step response of a PID controller 4-132 IP244 C79000-B8576-C860-02 Notes on Controller Settings Most controls required in process engineering can be performed with a controller with PI action. With slower controlled systems with a longer delay time, e.g. temperature controls, the control can be better implemented by a controller with a PID action. x 100 % Transient response wihout controller PID PD / PID w PD 0% t Fig. 4.3/6 Step response with different controller actions Controllers with PI and PID actions have the advantage that following the transient condition, the controlled variable does not deviate from the setpoint. The disadvantage is that the controlled variable overshoots the setpoint before it settles. If the controller parameters are well matched, combinations of PD and PID structures provide a good control action and good response to disturbances, approach the setpoint without overshoot and control without system deviation once the control point has been reached. IP244 C79000-B8576-C860-02 4-133 Notes on Controller Settings 4.4 Selecting the Controller Structure for a Given System The controlled systems are particularly important for selecting the control loop elements. Their characteristics are determined by the process control applications and cannot be changed afterwards. An optimum control action can only be achieved by selecting a suitable controller, whose action can be matched to the system data within certain limits. Selection of suitable controller structures Controller structure System P PD PI PID Useless Useless Control + disturbance Useless Dead time + 1st order delay Useless Useless Slightly worse than PID Control + disturbance Dead time + 2nd order delay Unsuitable Poor Worse than PID Control + disturbance 1st order + very small dead time (delay) Control Control with delay time Disturbance Disturbance with delay time Unsuitable Unsuitable Slightly worse than PID Control + disturbance Control (without delay) Control Disturbance (without delay) Disturbance Pure dead time Higher order Not self regulating with delay Suitable controllers for the most important controlled systems Controller: Controlled P PD variable: Steady state deviation Temperature For limited requirements and P systems where Tu Tv PID No steady state deviation Suitable <0.1 Pressure Suitable if no significant delay time Unsuitable Flow Less suitable, since required Xp band usually too great Unsuitable 4-134 PI The most suitable controller types for more sophisticated requirements (apart from specially adapted controllers) The most suitable controller types for more sophisticated requirements (apart from specially adapted controllers) Possible, but I controller alone usually better Hardly required for these controlled variables IP244 C79000-B8576-C860-02 Notes on Controller Settings 4.5 Setting the Controller Characteristics (Tuning) The setting range of the most common controllers for temperature and pressure are listed below. Once you have selected the suitable controller, the controller characteristics must be adapted to the controller system. Controller setting ranges for the most important controlled variables in process engineering Controlled variable Controller XP Temperature PD PI PID 0 ... 20 % 0 ... 20 % 0 ... 100 % Pressure PI 0 ... 500 % Tn 0.2 ... 0.2 ... 12 Tv 75 s 50 min 50 min 0.05 ... 10 min ... 120 min If the controlled system parameters Tu and Tg and the rate of rise vmax are known, the required controller parameters Xp, Tn und Tv can be approximately predicted. Rule of thumb for parameter settings Controller structure Setting P Xp vmax Tu [ C ] PI Xp 1.2 vmax Tu [ C ] PD Xp 0.83 vmax Tu [ C ] Tv 0.25 vmax Tu [ min ] Xp 0.83 vmax Tu [ C ] Tn 2 Tu [ min ] Tv 0.4 Tn [ min ] Xp 0.4 vmax Tu [ C ] Tn 2 Tu [ min ] Tv 0.4 Tu [ min ] PID PD / PID Instead of vmax = Dx Dt use Xmax Tg For controllers with a PID and PD/PID structure, the setting of the integral action time and the derivative action time are connected. The ratio Tn Tv is between 4 and 5 and is ideal for most controlled systems. With PD controllers, the derivative action time Tv is not critical.With PI or PID controllers, however, oscillations occur if the integral action time Tn is selected more than 50% too low. Too high an integral action slows down the correction of disturbances. No-one can expect that control loops function perfectly after the first parameter assignment. Generally, re-adjustments are necessary if the system is difficult to control, i.e. Tu/Tg > 0.3. IP244 C79000-B8576-C860-02 4-135 Notes on Controller Settings Influence of the proportional band on the control action XP Band Control action Breadth of fluctuation Switching frequency Larger More stable, slower Smaller Greater Smaller Less stable to unstable Larger Lower Type of controlled system Tu or Tt 1) Tg or Ts 2) Vmax. = Dx Dt Small electrically heated oven 0.5 to 1 min 5 to 15 min 1 C/s Larger electrically heated annealing furnace 1 to 5 min 10 to 60 min 0.3 C/s Large gas heated annealing furnace 0.2 to 5 min 3 to 60 min Distillation tower 1 to 7 min 40 to 60 min Autoclave (2.5m3) 0.5 to 0.7 min 10 to 20 min Highpressure autoclave (1000 C, 40 bar) 12 to 15 min 200 to 230 min Super heater 30 s to 2.5 min 1 to 4 min 2 C/s Room heating 1 to 5 min 10 to 60 min 1 C/min Flow Pipeline (gas) (liquid) 0 to 5s 0 0.2 to 10s 0 - Pressure Gas pipeline 0 0.1s - Boiler gas or oil heating 0 150s - Boiler with beater mills 1 to 2 min 2 to 5 min - Container level Boiler 0.6 to 1 min - 0.1 to 0.3 cm/s rpm Small electric drive 0 0.2 to 10s - Large electric drive 0 5 to 40s Steam turbine 0 - 50 min-1 Small generators Large generators 0 0 1 to 5s 5 to 10s - Feedback and controlled systems Controlled variable Temperature Electrical voltage 1) Tt= Dead time 4-136 0.1 to 0.5 C/s - 2) System constant IP244 C79000-B8576-C860-02 Notes on Controller Settings 4.6 Determining the System Parameters for 2/3-Step Controllers (when Main Control Byte 1, Bit 2 = 0) The heating and cooling curves of temperature-controlled systems are plotted with a recorder (see Fig. 4.6/1). The procedure is as follows: - main control byte 1, bit 2 = 0 - entry of non-critical control parameters TA KR TN, TD =5s =1 =0 (numerical value 5000) (numerical value 100) Upper limit of the control zone = 30 C Lower limit of the control zone = 30 C HKV = 100 % (for 3-step controllers) - Enter the setpoint temperature . The module switches the heating on. - Wait until the actual value has "settled" . Note: the actual value does not need to have reached the setpoint. - Enter setpoint temperature = 1 C . The module switches the cooling on. Note: and only required with 3-step controllers. The parameters are then obtained from the curve: TU SK SH = delay time (in s) = maximum slope of the cooling curve (in C/s) = maximum slope of the heating curve (in C/s) 2 Temperature SK 3 Setpoint temperature TU SH 1 Initial temperature TU 0 Heating curve Cooling curve Time Fig. 4.6/1 Recorded heating and cooling curves IP244 C79000-B8576-C860-02 4-137 Notes on Controller Settings Determining the Controller Parameters (Numerical Values for the IP 244) (see Section 2.1) (a) TA [ms] = 3000 SH (b) TN [4s] Value in ms; round up the calculated value according to the time base C s 23000 [0.01 C] KR [0.01] = SH (c) C ms s C s TD [s] TA [ms ] = TU [ s ] + ms s TA [ms ] = TU [ s ] + 1000 (e) ms s 2000 1000 (d) TA [ms ] TU [ s ] + Upper limit of the control zone [C] = Lower limit of the control zone [C] 1.665 4s s 0.6 ms s TA [ms ] = TU [ s ] + 1000 ms s SH C s In addition for 3step controllers: (f) SH C s SK C s HCR [%] = 4-138 100 [ % ] IP244 C79000-B8576-C860-02 Notes on Controller Settings 4.7 Determining the System Parameters for Purely Cooling Controllers (when Control Byte 1, Bit 0 = 0 and Bit 2 = 1) The cooling response of the temperature-controlled system is plotted with a recorder (see also Fig. 4.8/1). The procedure is as follows: enter non-critical control parameters: TA KR TN, TD = 0.8 s = 1 = 0 (numerical value 800) (numerical value 100) Upper limit of the control zone = 30 C Lower limit of the control zone = 30 C - Enter setpoint temperature = 0 C - Allow the temperature to settle to the operating temperature, dependent on external heating energy supply (e.g. by neighboring heating zones). - Enter setpoint temperature = 1 C . - The module switches the cooling on. Caution: during the cooling process the external supply of heating energy must remain constant (i.e. neighboring heating zones must heat with a constant manipulated variable). 1 Temperature SK 1 Tsta TU TU SK Cooling curve Time Fig. 4.8/1 Recorded cooling curve The parameters can then be determined from the curve: TU SK Tsta = = = delay time (in s) maximum slope of the cooling curve (in C/s) start temperature (in C). - The temperature TCOOL (in C) of the cooling medium must also be determined. IP244 C79000-B8576-C860-02 4-139 Notes on Controller Settings Determining the Controller Parameters (a) TA [ms] = 3000 C ms s SK (b) C s KR [0.01] of 200 C = 23000 [0.01 C] SK (c) TN [4s] = C s 200 C - TCOOL[C] Tsta[C] - TCOOL[C] TU [ s ] + TD [s] = 4s s 1.665 TU [ s ] + ms s 0.6 Upper limit of the control zone [C]= lower limit of the control zone [C] = TA [ms ] TU [ s ] + 1000 ms s TA [ms ] 1000 (e) ms s TA [ms ] 2000 TA [ms ] 1000 (d) TU [ s ]+ ms s SK C s Parameters The calculated values can be entered directly in the messages or in the data blocks A and B. As an alternative to calculating the parameter, the controller parameters can be determined by systematic trial and error. A suggested procedure can be found in Fig. 4.9/1. 4-140 IP244 C79000-B8576-C860-02 Notes on Controller Settings Starting point: KR small; TD TN 0 or small 0 or large TN, TD = 0 means: path is off Stimulation: by step in setpoint KR yes Poor damping? no TD yes Damping too good? no yes Has increasing TD several times not noticeably improved the damping? no Reduce KR and TD until the transfer function shows 5 % overshoot TN TN Overshoot > 5 % ? yes no Overshoot 5%? yes Objective reached no Fig. 4.9/1 Setting the controller by systematic trial and error IP244 C79000-B8576-C860-02 4-141 Notes on Controller Settings Optimum ! KR=8, TN=1000 s, TD=80 s, T=10 s TD=0,5 TD opt KR=8, TN=1000 s, TD=40 s, T=10 s TN= 0,5 TN opt KR=8, TN=500 s, TD=80 s, T=10 s TKR=0,5 KR opt KR=4, TN=1000 s, TD=80 s, T=10 s TD=2 TD opt KR=8, TN=1000 s, TD=160 s, T=10 s TN= 2 TN opt KR=8, TN=2000 s, TD=80 s, T=10 s TKR=2 KR opt KR=16, TN=1000 s, TD=80 s, T=10 s Fig. 4.9/2 Sensitivity of optimum controller setting compared with changes in the controller parameters 4-142 IP244 C79000-B8576-C860-02 SIMATIC S5 IP 244 Temperature Controller Function Block FB 162 (64 Messages) 6ES52443AA22 and 3AB31 Programming Instructions C79000B8576C86102 Contents Contents Page 1 Summary 5-3 2 Functional Description 5-5 3 Function 5-7 3.1 Calling the Function Block 5-7 3.2 Explanation of the Parameters 5-7 3.3 Assignment of the Parameters 5-8 3.4 Assignment of the Data Area 5-15 4 Technical Data 5-45 5 Application of the Function Block 5-48 Appendix A Notes on Operating the IP 244 with the Self-Tuning Function 5-59 A.1 Requirements 5-59 A.2 Recommended Procedure for Single Self-Tuning Function 5-59 A.3 Procedure for Self-Tuning with Repetition 5-61 5-2 IP244 C79000-B8576-C861-02 Summary 1 Summary These programming instructions describe the function block FB 162 (PER:TREG) "parameter assignment and control of temperature controller" Each of the following programmable controllers has its own function block with the name FB 162 PER:TREG: - S5-115U - S5-115U - S5-135U - S5-155U (CPU 941 to CPU 944 and CPU 941B to CPU 944B) (CPU 945) (CPU 922 from version A09, CPU 928 and CPU 928B) (CPU 946/947 and CPU 948) The appropriate function block is used in conjunction with the temperature controller module 6ES5 244-3AA22 and -3AB31. These programming instructions assume that you are familiar with the operating instructions for the temperature controller module and the programmable controller. An example in Part 5 of the manual illustrates the application of the function block. The function blocks and example are on the S5-DOS diskette in the following files: S5-115U S5-115U S5-135U S5-155U (CPU 941 to CPU 944 and CPU 941B to CPU 944B) (CPU 945) (CPU 922 from version A09, CPU 928 and CPU 928B) (CPU 946/947 and CPU 948) : : : : S5NA50ST.S5D S5NA55ST.S5D S5NB22ST.S5D S5NA60ST.S5D When using the CPU 922, CPU 928 or CPU 928B in the S5-155U, the file S5NB22ST.S5D should be used. IP244 C79000-B8576-C861-02 5-3 Summary 5-4 IP244 C79000-B8576-C861-02 Functional Description 2 Functional Description The function block "control temperature controller module" transfers the user data, which must already be stored in three data blocks before the module is called, to the module and allows controller-specific data to be read back. The function block can assign parameters both to the whole module or to a single controller. The controller data can either be read back automatically immediately following the self-tuning function or by means of a command. The data exchange between the CPU and IP 244 takes place in 64 messages each with a length of 16 data words (corresponds to 32 I/O bytes). The function block must be called for each module once in the cyclic program. Each time it is processed, only one or two messages are read or written, except for the function blocks "cold restart" and "parameter assignment"; in this case, messages 0 to 15 and 30 to 42 are transferred in one FB call. The function block cannot be called in interrupt OBs. A module cannot be addressed in the cyclic program (OB 1) and in the timedriven interrupt program (OB 13), nor is it possible to change the type of parameter assignment indirect via DB, direct via actual operands. Inhibiting and enabling interrupts when accessing the temperature control module is not necessary. IP244 C79000-B8576-C861-02 5-5 Functional Description 5-6 IP244 C79000-B8576-C861-02 Function 3 Function Controlling the IP 244 temperature controller module. 3.1 Calling the Function Block in STL (Statement list) : : JU FB162 : PER:TREG : : : : : : : : : : : : : Name ADRA BGAD DBNR BEF TNR ANST NEUA PAFE AFEH BFEH SFEH KANR FMLD 3.2 in LAD/CSF (Ladder Diagram or Control System Flowchart): FB162 ADRA BGAD DBNR BEF TNR ANST PER:TREG NEUA PAFE AFEH BFEH SFEH KANR FMLD Explanation of the Parameters Name Type of para. Type of data Meaning ADRA D KF Type of addressing BGAD D KF Module address DBNR D KY Specification of the first data block BEF D KC Specification of the command to be executed TNR D KF Message number ANST I BI Trigger with direct parameter assignment NEUA Q BI Cold restart - request from the module PAFE Q BI Parameter assignment error AFEH Q BI Sampling error (sampling time exceeded) BFEH Q BI Module error (watchdog) SFEH Q BI Group error (all channels) KANR Q BY Number of channel with error FMLD Q W Error bytes of channel with error IP244 C79000-B8576-C861-02 5-7 Function 3.3 ADRA: BGAD: Assignment of the Parameters KF = x KF = y Type of addressing x=0 Module is addressed in the extended I/O area (O area) (S5-115U with CPU 945 (only in the expansion unit), S5-135U and S5-155U). x=1 Module is addressed in normal I/O area (P area). x=2 Module is addressed with absolute address (only for S5-115U). Module address 0 y 224 Extended I/O area (O area) 128 y 224 Normal I/O area (P area) 0 y 224 DBNR: D, KY = x,y Absolute addressing x = data block type x=0 x=1 data block type = DB data block type = DX (in S5-115U only valid for CPU 945) y= Number of first data block (DB-A / DX-A) 10 y 253 if x = 0 10 y 253 if x = 1 direct parameter assignment via the block parameters y = 0 Indirect parameter assignment The input parameters are read from the currently open data block. y 0 Direct parameter assignment The data block specified in the parameter DB is valid. The function block operates with the values specified for the formal operands: ADRA (addressing type), BGAD (module address), BEF (command) and T-NR (message number). 5-8 IP244 C79000-B8576-C861-02 Function Specification of the command BEF: The following commands are valid without a message number being specified: KS = KS Cold restart Messages 0 to 15 and 30 to 42 are transferred. The module recalculates all the control parameters. The module identification and the software version are re-evaluated. This command must only be executed in organization blocks OB 20, OB 31 and OB 22. KS = PA Assign parameters Messages 0 to 15 and 30 to 42 are transferred. The module calculates the control parameters taking into account the previous values. This command can be executed for all PLCs in the start-up OBs (OB 20, OB 21, OB 22) and for the S5-115U, S5-135U and S5-155U also in the cyclic program. The module identification and the software version are re-evaluated. KS = S1 Switch over setpoint to temperature setpoint KS = S2 Switch over setpoint to lower setpoint KS = T1 The controller is not disabled if the second tolerances are violated. KS = T2 The controller is disabled if the second tolerances are violated KS = G1 Do not output the averaged manipulated variable. If a thermocouple fails, a 0% manipulated variable is output instead of an averaged manipulated variable. KS = G2 Output the averaged manipulated variable With the command "G2", you can decide whether a manipulated variable averaged over a specified monitoring time should be output if a thermocouple fails. IP244 C79000-B8576-C861-02 5-9 Function The following commands are only valid in conjunction with a message number: KS = AS Change setpoints Parameter T-NR: KF +0 to +15 If a change is made in data words DWn to DWn + 6 in messages 0 to 15, it is sufficient to transfer the message (T-NR) to the module with the command AS. KS = AE Change the parameters of a controller Parameter T-NR: KF +0 to +15 If the parameters of a controller are changed, the appropriate message must be transferred with the command AE. The parameters of the selected controller are recalculated on the module. (Two messages per controller are transferred.) KS = AB Switch over to automatic operation Parameter T-NR: KF +0 to +12 With the AB command (automatic operation) the function block resets bit 0 of control byte 2 in the specified controller message (parameter T-NR) and transfers control byte 2 to the module. KS = HB Switch over to manual operation Parameter T-NR: KF +0 to +12 With the HB command (manual operation) the function block sets bit 0 of control byte 2 in the specified controller message (parameter T-NR) and transfers control byte 2 to the module. KS = IW Read actual value, read current values Parameter T-NR: KF + 17 to + 21 (e.g. actual values, manipulated variables, minimum values etc.) The actual values are only read when this is requested with the command IW. The message number in which the required actual values are located must be specified. The structure in the actual value messages is described in the Instructions (C79000-B8576-C859). 5-10 IP244 C79000-B8576-C861-02 Function The actual values of channels 13 and 14 are only updated if bit 12 (read channel 13) and bit 13 (read channel 14) are set to "1" in data word DW 30 of data block DB-B. These values are only updated if no hot channel control, no heating current monitoring and no pure Pt 100 operation has been selected. With the special function, the bits are irrelevant. KS = LE Read the controller-specific data Parameter T-NR: KF +0 to +12 All the data of a controller (two messages) are read from the module. KS = SE Start/stop self-tuning function Parameter T-NR:KF + 0 to + 12 In cyclic operation the self-tuning function can be started or aborted. Before executing the command the byte "Self-tuning parameter" (DL n + 11) must be preassigned accordingly in the controller message. T-NR: D, KF = x Specification of the message number The message number depends on the command specified for parameter BEF: BEF: BEF: BEF: BEF: BEF: BEF: BEF: AS AE LE AB HB SE IW T-NR: T-NR: T-NR: T-NR: T-NR: T-NR: T-NR: + 0 + 0 + 0 + 0 + 0 + 0 +17 to to to to to to to +15 +15 +12 +12 +12 +12 +21 ANST: I, BI If the parameter ANST is set to "1", the execution of the command is triggered if direct parameter assignment has been selected. The parameter is reset by the function block with direct parameter assignment once the command has been executed or if a parameter assignment error occurs. If parameters are assigned indirectly, the parameter ANST is irrelevant. NEUA: Q, BI Cold restart request from the module After switching on the power supply, the module signals that it requires parameters. The parameter NEUA then has signal state "1". If the module is assigned parameters with the command KS (cold restart) or PA (parameter assignment), the module resets the "cold restart request" bit and the parameter NEUA is also reset. PAFE: Q, BI IP244 C79000-B8576-C861-02 If a non-permissible parameter is assigned, the parameter PAFE is set to "1". The error can then be found as an error number in flag byte FY255. 5-11 Function Error number indicated in KF format 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 AFEH: Wrong firmware Type of addressing not permitted Module address not permitted Module address not in increments of 32 DB no. (DB-A) or DB type not allowed DB-A does not exist or too short DB-B does not exist or too short DB-C does not exist or too short Command not permitted Message number (T-NR) not permitted DB no. (DB-A') or DB type not allowed DB-A' does not exist or too short DB-C' does not exist or too short Command "LE" or "automatic reading after self-tuning" is selected in FB 162, but not released on the IP 244, i.e. main control byte 1, bit 2 is at present 0 Module cannot be addressed at present because self-tuning function active Timeout during cold restart Acknowledgement delay (timeout) IP 244 (not valid with the S5-115U, CPU 941 to CPU 944 and CPU 941B to CPU 944B) 23 24 25 DBB DBC DBC' 26 -128 Wrong CPU (only with the S5-115U, CPU 945) Acknowledgement delay (timeout) (only with the S5-115U, CPU 941 to CPU 944 and CPU 941B to CPU 944B) (indicated in ISTACK:FB162 condition code QVZ; status FY255 = KF -128) Q, BI Sampling error, sampling time exceeded DB no. or DB type not permitted The parameter AFEH is set if the bit "sampling time overflow" (message 16, byte 0, bit 5) is set. The set parameter does not influence the processing in the function block. The bit "sampling time overflow" can be reset by switching off the power supply or by transferring message number 15 once with the command AE (change the parameters of a controller). BFEH: Q, BI Module error The parameter BFEH is set when the signal state of the watchdog bit does not change within 1 second. (Data block DB-B, data word 32, bit 15.) If the function block operating an IP 244 is called at intervals greater than 1 second, the correct evaluation of the watchdog bit is no longer possible. 5-12 IP244 C79000-B8576-C861-02 Function For this reason, parameter BFEH is set although the module is operating correctly. The evaluation of this signal no longer serves a purpose. The processing of function block FB 162 is not interrupted by the signal BFEH. The parameter BFEH is reset if the power supply to the programmable controller is switched off or if the commands KS (cold restart) or PA (assign parameters) are sent. Note that the command KS must only be used in the organization blocks OB 20, OB 21 and OB 22. SFEH: Q, BI Group error If an error occurs on one of the controller and measurement channels of the module, the parameter SFEH is set. The parameters KANR and FMLD provide more information about the error. Once all the errors have been dealt with, the parameter SFEH is reset automatically. KANR: Q, BY Channel number The channel number specifies which controller or which channel has signalled an error (0 KANR 15). If the parameter KANR has the value 15, this indicates that the error or fault concerns the resistance thermometer Pt 100 on channel 15 (compensation channel). The parameter FMLD then has the value 0. FMLD: Q, W Error signal byte If the IP 244 signals a group error, the parameter KANR contains the number of the channel on which the error has occurred. The parameter FMLD contains information about the cause of the problem. If several channels have problems at the same time, the parameter FMLD contains the error bytes of the channel with the lowest number. Exception: if an error occurs on channel 15 (KANR = 15) the parameter FMLD has the value zero (corresponds to: problem with Pt100 on channel 15). As long as a group error is present, the error messages are updated in every fifth cycle of FB 162. The function block automatically resets the parameter SFEH and clears the error bytes when there are no further errors. IP244 C79000-B8576-C861-02 5-13 Function Bit assignment of parameter FMLD: 15 14 13 12 Bits 0 to 7: Bits 8 to 15: 11 10 9 8 7 6 5 4 3 2 1 0 error byte from message 16 error byte from message 46 Notes on processing errors If the error byte (FY255) is to be evaluated, it must be saved on the rising edge of the parameter PAFE in a different data area after FB 162 has been called. Reason: scratchpad flag area of flag byte FY200 to FY255 when PAFE ----> FY255 parameter assignment error Notes on specifying the actual operands The identifiers ANST (I,BI) and NEUA, PAFE, AFEH, BFEH and SFEH (Q,BI) must not have the scratchpad flags written to them. The identifiers KANR (Q,BI) and FMLD (Q,W) must also not have the scratchpad flags of the function block FB162 written to them. 5-14 IP244 C79000-B8576-C861-02 Function 3.4 Assignment of the Data Area The three data blocks DB-A, DB-B and DB-C occupy space in the data area. Whereas, previously, the data blocks DB-A, DB-B and DB-C, as well as the alternative data blocks DB-A' and DB-C' had to have subsequent DB numbers, all data block numbers can now be allocated freely. In the programmable controllers S5-115U, CPU 945, S5-135U and S5-155U the DB types (DB/DX) of the individual data blocks can also differ from each other. In the following, however, we generally use the term DB number. When assigning parameters to the DB numbers (and DB types) you must differentiate between the parameter assignment types of the function block FB 162: Calling the FB 162 with direct parameter assignment: The DB number for the data block DB-A is indicated at the block parameter DBNR. All the other DB numbers have to be entered in the operating range of the function block in the data block DB-A. Calling the FB 162 with indirect parameter assignment: Before calling the FB 162 the data block DB-A must be selected. All DB numbers must be entered in the operating range of the function block in the data block DB-A. Data block DB-A contains the controller messages 0 to 12 and the messages 13 and 14 according to the assignment in the previous function block FB 162 for the module 6ES5 244-3AA13. Data block DB-B contains message 15 and the data read from the module (messages 16 to 25 and 46). Data block DB-C contains the second sets of data for controllers 0 to 12 in messages 30 to 42. If the self-tuning parameters are to be read from the module, this data can be stored in data blocks DB-A and DB-C or in the next two blocks DB-A' and DB-C' as required. The assignment in data blocks DB-A' and DB-C' is identical to that in DB-A and DB-C. Exception: since messages 13 and 14 cannot be read from the temperature controller module, they are not included in data block DB-A'. Data block DB-A' must only be set up as far as DW 223. Further values which can be read from the module (actual values, manipulated variables, minimum values, maximum values, cumulative setpoints and curve values of channel 13) are stored in data block DB-B. This also contains messages 15, 16 and 46. The function block FB 162 can have parameters assigned indirectly. The actual operand of the parameter DBNR must be assigned KY = 0,0 and data block DBA must be opened before calling function block FB 162. The parameters BEF, TNR, BGAD, DBNR and ADRA must first be entered in data words DW1 to DW5 by the user. The function block FB 162 for 64 messages can only operate the new IP 244 (6ES52443AA22). The block recognizes this automatically when transferring data between programmable controller and module. IP244 C79000-B8576-C861-02 5-15 Function Assignment in the data blocks DB-A or DB-A' _________________________________________________________ from DW Assignment _________________________________________________________ 0 16 32 48 64 80 96 112 144 160 176 192 208 224 240 Parameter assignment and working area of the function block Message Message Message Message Message Message Message Message Message Message Message Message Message Message 0: 1: 2: 3: 4: 5: 6: 8: 9: 10: 11: 12: 13: 14: data for controller 0 data for controller 1 data for controller 2 data for controller 3 data for controller 4 data for controller 5 data for controller 7 data for controller 8 data for controller 9 data for controller 10 data for controller 11 data for controller 12 data for controller 13 data for controller 14 _________________________________________________________ Messages 13 and 14 do not exist in data block DB-A'. The area free for the user begins from data word 244. DB-B _________________________________________________________ from DW Assignment _________________________________________________________ 0 Working area of the function block (reserved) 16 32 48 64 80 96 112 128 143 158 173 188 Message Message Message Message Message Message Message Message Message Message Message Message 15: 16: 17: 18: 19: 20: 21: 22: 23: 24: 25: 46: 204 - free for the user - main control bytes, general parameters status information, error messages actual values manipulated variables minimum values maximum values cumulative setpoints (for cascaded control) (curve values 1 - 15 channel 13) (curve values 16 - 30 channel 13) (curve values 31 - 45 channel 13) (curve values 46 - 60 channel 13) error messages controllers 0 - 12 _________________________________________________________ 5-16 IP244 C79000-B8576-C861-02 Function DB-C or DB-C' __________________________________________________________ from DW Assignment __________________________________________________________ 0 Working area of the function block (reserved) 16 32 48 64 80 96 112 128 144 160 176 192 208 Message Message Message Message Message Message Message Message Message Message Message Message Message 30: 31: 32: 33: 34: 35: 36: 37 38: 39: 40: 41: 42: 224 - free for the user - data for controller 0 data for controller 1 data for controller 2 data for controller 3 data for controller 4 data for controller 5 data for controller 6 data for controller 7 data for controller 8 data for controller 9 data for controller 10 data for controller 11 data for controller 12 __________________________________________________________ __________________________________________________________ Controller-specific data can either be read back to data blocks DB-A or DB-C or to blocks DB-A' and DB-C' (parameter assignment in DR6 in data block DB-A). DB-A' and DB-C' have the same structure as DB-A and DB-C. IP244 C79000-B8576-C861-02 5-17 Function Assignment within a message (numbers 0 to 12) in data block DB-A For changes in the data words DW n to DW n + 6, it is sufficient to transfer the changes with the command AS. Changes in data words DW n + 7 to DW n + 15 must be transferred with the command AE (or KS/PA). Data words DWn to DW n + 6 are also transferred. When changing the following: - bit 2, control byte 1 - bits 3 to 7, control byte 1 in pure Pt100 operation or - bits 1 and 3, control byte 2 the command AE (or KS/PA) should be used. Recommended data format Command AS AE DW n Temperature setpoint DW n+1 1st positive tolerance DW n+2 Lower setpoint DW n+3 2nd positive tolerance 2nd negative tolerance KY DW n+4 Control byte 1 Control byte 2 KM DW n+5 Manual manipulated variable Limitation value (C) KY DW n+6 Evaluation factor (C) - KY DW n+7 Sampling time (ST) KF to TA = +32767 **) KH to TA > +32767 DW n+8 Gain KR (St) KF DW n+9 Integral action time TN (ST) KF DW n+10 Derivative action time TD (ST) KF DW n+11 Selftuning parameters DW n+12 Zone upper limit (ST) /setpoint ramping KF DW n+13 Zone lower limit (ST) KF DW n+14 Heating/cooling ratio (ST) Response value KY DW n+15 Minimum jump (Message number) *) KY KF 1st negative tolerance KY KF Heating/cooling parameters KM *) The message number (data byte DR n + 15) must be entered in the data block by the user **) If the value for sampling time TA is greater than +32767, it must be converted to a hexadecimal number and given in the format KH. (C) Only required for cascaded control (ST) Parameter need not be entered for selftuning controllers Checkback signal for the selftuning function 5-18 IP244 C79000-B8576-C861-02 Function Assignment in message 0 for cascaded control in data block DB-A Recommended data format DW 16 Temperature setpoint (master controller) KF DW 17 1st positive tolerance 1st negative tolerance KY DW 18 - - DW 19 - - DW 20 Control byte 1 Control byte 2 DW 21 - - DW 22 - - DW 23 - - DW 24 Gain KR KF DW 25 Integral action time TN KF DW 26 - - DW 27 - - DW 28 Zone upper limit KF DW 29 Zone lower limit KF DW 30 - - DW 31 - (Message number) *) KM KY *) The message number must be entered by the user IP244 C79000-B8576-C861-02 5-19 Function Assignment in message 13 of data block DB-A Recommended data format DW 224 Setpoint DW 225 Positive tolerance DW 226 Reserved for heating current monitoring DW 227 - DW 228 - DW 229 - DW 230 - DW 231 - DW 232 - DW 233 - DW 234 - DW 235 - DW 236 - DW 237 - DW 238 - DW 239 - KF Negative tolerance (Message number) *) KY KF KY *) The message number must be entered by the user 5-20 IP244 C79000-B8576-C861-02 Function Assignment in message 14 of data block DB-A Recommended data format DW 240 Setpoint DW 241 Positive tolerance DW 242 - DW 243 - DW 244 - DW 245 - DW 246 Reserved: must be 0 DW 247 - DW 248 - DW 249 - DW 250 - DW 251 - DW 252 - DW 253 - DW 254 - DW 255 - KF Negative tolerance Reserved: must be 0 KY KY KH (Message number) *) KY *) The message number must be entered by the user IP244 C79000-B8576-C861-02 5-21 Function Assignment in message 15 of data block DB-B Recommended data format DW 16 Switchover value for the comparator (channel 13) KF DW 17 Monitoring time for emergency programs KF DW 18 Normalization factor for channel 14 (RA) KF DW 19 Acquisition time (RC) Approach time **) KY DW 20 Approach manipulated variable **) Approach zone **) DW 21 Approach setpoint DW 22 Max. temperature difference DW 23 Normalization factor for channel 13 (RC) KF DW 24 - Coolant temperature KY DW 25 - DW 26 Main control byte 7 Main control byte 6 KM DW 27 Main control byte 5 Main control byte 4a KM DW 28 Main control byte 4b Main control byte 4c KM DW 29 Main control byte 4d Main control byte 1 KM DW 30 Main control byte 2 Main control byte 3 KM DW 31 Main control byte 4 (Message number) *) KM *) **) (RC) (RA) The message number must be entered by the user Only for hot channel control Required for read curve value function channel 13 Required for read curve value function channel 13 1) KY KF - KY The entries in the main control bytes 4, 4a to 4d, 5 and 7 are made by the function block; these bytes should not be written to by the user. The very first entry in the main control byte must be KM 0000 0000. The main control bytes 1, 2, 3 and 6 are written to by the user. 1) The comparator function does not exist in the 6ES52443AB31 temerpatrue controller module. The parameter in DW 16 does not have an effect. 5-22 IP244 C79000-B8576-C861-02 Function Assignment in message 16 of data block DB-B Recommended data format DW 32 Status byte DW 33 Controller group error/channel group error KM DW 34 Status selftuning KM DW 35 Approach phase KM DW 36 - DW 37 - DW 38 - DW 39 Module number Software release KY DW 40 Error byte 0 Error byte 1 KM DW 41 Error byte 2 Error byte 3 KM DW 42 Error byte 4 Error byte 5 KM DW 43 Error byte 6 Error byte 7 KM DW 44 Error byte 8 Error byte 9 KM DW 45 Error byte 10 Error byte 11 KM DW 46 Error byte 12 Error byte 13 KM DW 47 Error byte 14 (Message number) *) *) 1 - KY KM The message number must be entered by the user With heating current monitoring, the significance of some bits in error bytes 6 to 14 is different (see Part 3, Section 3.3, Heating Current Monitoring). IP244 C79000-B8576-C861-02 5-23 Function Assignment in message 17 of data block DB-B Recommended data format DW 48 Actual value temperature controller 0 KF DW 49 Actual value temperature controller 1 KF DW 50 Actual value temperature controller 2 KF DW 51 Actual value temperature controller 3 KF DW 52 Actual value temperature controller 4 KF DW 53 Actual value temperature controller 5 KF DW 54 Actual value temperature controller 6 KF DW 55 Actual value temperature controller 7 KF DW 56 Actual value temperature controller 8 KF DW 57 Actual value temperature controller 9 KF DW 58 Actual value temperature controller 10 KF DW 59 Actual value temperature controller 11 KF DW 60 Actual value temperature controller 12 KF DW 61 Actual value channel 13 KF DW 62 Actual value channel 14 KF DW 63 - *) (Message number) *) KY The message number must be entered by the user 5-24 IP244 C79000-B8576-C861-02 Function Assignment in message 18 of data block DB-B Recommended data format DW 64 Manipulated variable controller 0 KF DW 65 Manipulated variable controller 1 KF DW 66 Manipulated variable controller 2 KF DW 67 Manipulated variable controller 3 KF DW 68 Manipulated variable controller 4 KF DW 69 Manipulated variable controller 5 KF DW 70 Manipulated variable controller 6 KF DW 71 Manipulated variable controller 7 KF DW 72 Manipulated variable controller 8 KF DW 73 Manipulated variable controller 9 KF DW 74 Manipulated variable controller 10 KF DW 75 Manipulated variable controller 11 KF DW 76 Manipulated variable controller 12 KF DW 77 - DW 78 - DW 79 - *) (Message number) *) KY The message number must be entered by the user IP244 C79000-B8576-C861-02 5-25 Function Assignment in message 19 of data block DB-B Recommended data format DW 80 Minimum value controller 0 KF DW 81 Minimum value controller 1 KF DW 82 Minimum value controller 2 KF DW 83 Minimum value controller 3 KF DW 84 Minimum value controller 4 KF DW 85 Minimum value controller 5 KF DW 86 Minimum value controller 6 KF DW 87 Minimum value controller 7 KF DW 88 Minimum value controller 8 KF DW 89 Minimum value controller 9 KF DW 90 Minimum value controller 10 KF DW 91 Minimum value controller 11 KF DW 92 Minimum value controller 12 KF DW 93 - DW 94 Digital outputs image (DQ 1 to 9) DW 95 Digital outputs image (DQ 10 to 17) KM (Message number *) KM *) The message number must be entered by the user 5-26 IP244 C79000-B8576-C861-02 Function Assignment in message 20 of data block DB-B Recommended data format DW 96 Maximum value controller 0 KF DW 97 Maximum value controller 1 KF DW 98 Maximum value controller 2 KF DW 99 Maximum value controller 3 KF DW 100 Maximum value controller 4 KF DW 101 Maximum value controller 5 KF DW 102 Maximum value controller 6 KF DW 103 Maximum value controller 7 KF DW 104 Maximum value controller 8 KF DW 105 Maximum value controller 9 KF DW 106 Maximum value controller 10 KF DW 107 Maximum value controller 11 KF DW 108 Maximum value controller 12 KF DW 109 Maximum value controller 13 (special function) KF DW 110 - DW 111 - (Message number) *) KY *) The message number must be entered by the user IP244 C79000-B8576-C861-02 5-27 Function Assignment in message 21 of data block DB-B Recommended data format DW 112 Setpoint controller 0 (master controller 1) KF DW 113 Cumulative setpoint controller 1 KF DW 114 Cumulative setpoint controller 2 KF DW 115 Cumulative setpoint controller 3 KF DW 116 Cumulative setpoint controller 4 KF DW 117 Cumulative setpoint controller 5 KF DW 118 Cumulative setpoint controller 6 KF DW 119 Cumulative setpoint controller 7 KF DW 120 Cumulative setpoint controller 8 KF DW 121 Cumulative setpoint controller 9 KF DW 122 Cumulative setpoint controller 10 KF DW 123 Cumulative setpoint controller 11 KF DW 124 Cumulative setpoint controller 12 KF DW 125 - DW 126 - DW 127 - (Message number) *) KY *) The message number must be entered by the user 5-28 IP244 C79000-B8576-C861-02 Function Assignment in message 22 of data block DB-B Recommended data format DW 128 Curve value 1 Channel 13 KF DW 129 Curve value 2 Channel 13 KF DW 130 Curve value 3 Channel 13 KF DW 131 Curve value 4 Channel 13 KF DW 132 Curve value 5 Channel 13 KF DW 133 Curve value 6 Channel 13 KF DW 134 Curve value 7 Channel 13 KF DW 135 Curve value 8 Channel 13 KF DW 136 Curve value 9 Channel 13 KF DW 137 Curve value 10 Channel 13 KF DW 138 Curve value 11 Channel 13 KF DW 139 Curve value 12 Channel 13 KF DW 140 Curve value 13 Channel 13 KF DW 141 Curve value 14 Channel 13 KF DW 142 Curve value 15 Channel 13 KF IP244 C79000-B8576-C861-02 5-29 Function Assignment in message 23 of data block DB-B Recommended data format DW 143 Curve value 16 Channel 13 KF DW 144 Curve value 17 Channel 13 KF DW 145 Curve value 18 Channel 13 KF DW 146 Curve value 19 Channel 13 KF DW 147 Curve value 20 Channel 13 KF DW 148 Curve value 21 Channel 13 KF DW 149 Curve value 22 Channel 13 KF DW 150 Curve value 23 Channel 13 KF DW 151 Curve value 24 Channel 13 KF DW 152 Curve value 25 Channel 13 KF DW 153 Curve value 26 Channel 13 KF DW 154 Curve value 27 Channel 13 KF DW 155 Curve value 28 Channel 13 KF DW 156 Curve value 29 Channel 13 KF DW 157 Curve value 30 Channel 13 KF 5-30 IP244 C79000-B8576-C861-02 Function Assignment in message 24 of data block DB-B Recommended data format DW 158 Curve value 31 Channel 13 KF DW 159 Curve value 32 Channel 13 KF DW 160 Curve value 33 Channel 13 KF DW 161 Curve value 34 Channel 13 KF DW 162 Curve value 35 Channel 13 KF DW 163 Curve value 36 Channel 13 KF DW 164 Curve value 37 Channel 13 KF DW 165 Curve value 38 Channel 13 KF DW 166 Curve value 39 Channel 13 KF DW 167 Curve value 40 Channel 13 KF DW 168 Curve value 41 Channel 13 KF DW 169 Curve value 42 Channel 13 KF DW 170 Curve value 43 Channel 13 KF DW 171 Curve value 44 Channel 13 KF DW 172 Curve value 45 Channel 13 KF IP244 C79000-B8576-C861-02 5-31 Function Assignment in message 25 of data block DB-B Recommended data format DW 173 Curve value 46 Channel 13 KF DW 174 Curve value 47 Channel 13 KF DW 175 Curve value 48 Channel 13 KF DW 176 Curve value 49 Channel 13 KF DW 177 Curve value 50 Channel 13 KF DW 178 Curve value 51 Channel 13 KF DW 179 Curve value 52 Channel 13 KF DW 180 Curve value 53 Channel 13 KF DW 181 Curve value 54 Channel 13 KF DW 182 Curve value 55 Channel 13 KF DW 183 Curve value 56 Channel 13 KF DW 184 Curve value 57 Channel 13 KF DW 185 Curve value 58 Channel 13 KF DW 186 Curve value 59 Channel 13 KF DW 187 Curve value 60 Channel 13 KF 5-32 IP244 C79000-B8576-C861-02 Function Assignment in message 46 of data block DB-B Recommended data format DW 188 - DW 189 - DW 190 Status selftuning DW 191 - DW 192 - DW 193 - DW 194 - DW 195 Module number Software release KY DW 196 Error byte 0a Error byte 1a KM DW 197 Error byte 2a Error byte 3a KM DW 198 Error byte 4a Error byte 5a KM DW 199 Error byte 6a Fehlerbyte 7a KM DW 200 Error byte 8a Error byte 9a KM DW 201 Error byte 10a Error byte 11a KM DW 202 Error byte 12a - KM DW 203 - (Message number) *) KM KM *) The message number must be entered in the data block by the user IP244 C79000-B8576-C861-02 5-33 Function Assignment in messages 30 to 42 of data block DB-C Recommended data format DW n Actual value normalization KF DW n + 1 Minimum temperature difference KY DW n + 2 - DW n + 3 Maximum slope when heating STH (ST) KF DW n + 4 Dead time when heating TUH (ST) KF DW n + 5 - DW n + 6 - DW n + 7 Sampling time for cooling TAK (200 C/392 F) (ST) KF DW n + 8 Gain for cooling KRK (200 C/392 F) (ST) KF DW n + 9 Integral action time TNK (200 C/392 F) (ST) KF DW n +10 Derivative action time TDK (200 C/392 F) (ST) KF DW n +11 Value of slope for cooling STK (200 C/392 F) (ST) KF DW n +12 Dead time for cooling TUK (ST) KF DW n+13 - DW n +14 - DW n +15 - *) (ST) (200 C/392 F) 5-34 (Message number) *) KY The message number must be entered in the data block by the user The parameter does not need to be entered for self-tuning controllers The parameters relate to an operating point of 200 C/392 F IP244 C79000-B8576-C861-02 Function Notes on heating current monitoring When operating the module with heating current monitoring, the following points should be noted: - a maximum of 6 controllers with heating current monitoring are possible, - the heating currents for each channel are monitored when the monitoring is selected and the hardware is available (channels 6 to 11), - the power supply voltage is measured via channel 13. This results in a different assignment in some of the messages when heating current monitoring is required: The assignment in messages 0 to 5 remains unchanged. The assignment in messages 6 to 11 of data block DB-A for heating current monitoring Changes in data words DWn to DWn + 6 are transferred with the command AS. Recommended data format Command AS AE DW n Heating current setpoint DW n + 1 Positive tolerance DW n + 2 Calibration value DW n + 3 - DW n + 4 - DW n + 5 - DW n + 6 - DW n + 7 - DW n + 8 - DW n + 9 - DW n +10 - DW n +11 - DW n +12 - DW n +13 - DW n +14 - DW n +15 - KF Negative tolerance KY KF (Message number) *) KY *) The message number (data byte DR n + 15) must be entered in the data block by the user IP244 C79000-B8576-C861-02 5-35 Function Assignment in message 12 of data block DB-A with heating current monitoring Changes in the data words DW n to DWn + 6 are transferred with the command AS. Command AS AE Recommended data format DW n - DW n + 1 - DW n + 2 - DW n + 3 - DW n + 4 - DW n + 5 - DW n + 6 - DW n + 7 - DW n + 8 - DW n + 9 - DW n +10 - DW n +11 - DW n +12 - DW n +13 - DW n +14 - DW n +15 - (Message number) *) KY *) The message number (data byte DR n + 15) must be entered in the data block by the user 5-36 IP244 C79000-B8576-C861-02 Function Assignment in message 13 of data block DB-A with heating current monitoring Recommended data format DW 224 Power supply voltage setpoint DW 225 Positive tolerance DW 226 Calibration value DW 227 - DW 228 - DW 229 - DW 230 - DW 231 - DW 232 - DW 233 - DW 234 - DW 235 - DW 236 - DW 237 - DW 238 - DW 239 - KF Negative tolerance KY KF (Message number) *) KY *) The message number must be entered by the user IP244 C79000-B8576-C861-02 5-37 Function Assignment in message 14 of data block DB-A with heating current monitoring Recommended data format DW 240 - DW 241 - DW 242 - DW 243 - DW 244 - DW 245 - DW 246 Reserved: must be 0 DW 247 - DW 248 - DW 249 - DW 250 - DW 251 - DW 252 - DW 253 - DW 254 - DW 255 - Reserved: must be 0 KY KH (Message number) *) KY *) The message number must be entered by the user The assignment in messages 15 and 16 is identical to that for standard controllers. The significance of individual bits in the error bytes is, however, changed (see Part 3, Section 3.3, Heating Current Monitoring). 5-38 IP244 C79000-B8576-C861-02 Function Assignment in message 17 of data block DB-B with heating current monitoring Recommended data format DW 48 Actual value temperature controller 0 KF DW 49 Actual value temperature controller 1 KF DW 50 Actual value temperature controller 2 KF DW 51 Actual value temperature controller 3 KF DW 52 Actual value temperature controller 4 KF DW 53 Actual value temperature controller 5 KF DW 54 Weighted actual current value in ON state controller 0 KF DW 55 Weighted actual current value in ON state controller 1 KF DW 56 Weighted actual current value in ON state controller 2 KF DW 57 Weighted actual current value in ON state controller 3 KF DW 58 Weighted actual current value in ON state controller 4 KF DW 59 Weighted actual current value in ON state controller 5 KF DW 60 - DW 61 Power supply voltage actual value DW 62 - DW 63 - KF (Message number) *) KY *) The message number must be entered by the user IP244 C79000-B8576-C861-02 5-39 Function Assignment in message 18 of data block DB-B with heating current monitoring Recommended data format DW 64 Manipulated variable controller 0 KF DW 65 Manipulated variable controller 1 KF DW 66 Manipulated variable controller 2 KF DW 67 Manipulated variable controller 3 KF DW 68 Manipulated variable controller 4 KF DW 69 Manipulated variable controller 5 KF DW 70 Weighted actual current value in OFF state controller 0 KF DW 71 Weighted actual current value in OFF state controller 1 KF DW 72 Weighted actual current value in OFF state controller 2 KF DW 73 Weighted actual current value in OFF state controller 3 KF DW 74 Weighted actual current value in OFF state controller 4 KF DW 75 Weighted actual current value in OFF state controller 5 KF DW 76 - DW 77 - DW 78 - DW 79 - (Message number) *) KY *) The message number must be entered by the user 5-40 IP244 C79000-B8576-C861-02 Function Assignment in message 19 of data block DB-B with heating current monitoring Recommended data format DW 80 Minimum value controller 0 KF DW 81 Minimum value controller 1 KF DW 82 Minimum value controller 2 KF DW 83 Minimum value controller 3 KF DW 84 Minimum value controller 4 KF DW 85 Minimum value controller 5 KF DW 86 Measured actual current value in ON state controller 0 KF DW 87 Measured actual current value in ON state controller 1 KF DW 88 Measured actual current value in ON state controller 2 KF DW 89 Measured actual current value in ON state controller 3 KF DW 90 Measured actual current value in ON state controller 4 KF DW 91 Measured actual current value in ON state controller 5 KF DW 92 - DW 93 - DW 94 Digital outputs image (DQ 1 to 9) DW 95 Digital outputs image (DQ 10 to 17) KM (Message number) *) KM *) The message number must be entered by the user IP244 C79000-B8576-C861-02 5-41 Function Assignment in message 20 of data block DB-B with heating current monitoring Recommended data format DW 96 Maximum value controller 0 KF DW 97 Maximum value controller 1 KF DW 98 Maximum value controller 2 KF DW 99 Maximum value controller 3 KF DW 100 Maximum value controller 4 KF DW 101 Maximum value controller 5 KF DW 102 Measured actual current value in ON state controller 0 KF DW 103 Measured actual current value in ON state controller 1 KF DW 104 Measured actual current value in ON state controller 2 KF DW 105 Measured actual current value in ON state controller 3 KF DW 106 Measured actual current value in ON state controller 4 KF DW 107 Measured actual current value in ON state controller 5 KF DW 108 - DW 109 - DW 110 - DW 111 - (Message number) *) KY *) The message number must be entered in the data block by the user The assignment in messages 21 to 35 and 46 is identical to that for standard controllers. 5-42 IP244 C79000-B8576-C861-02 Function Assignment in messages 36 to 42 of data block DB-C with heating current monitoring Recommended data format DW n - DW n + 1 - DW n + 2 - DW n + 3 - DW n + 4 - DW n + 5 - DW n + 6 - DW n + 7 - DW n + 8 - DW n + 9 - DW n +10 - DW n +11 - DW n +12 - DW n +13 - DW n +14 - DW n +15 - (Message number) *) KY *) The message number must be entered in the data block by the user IP244 C79000-B8576-C861-02 5-43 Function 5-44 IP244 C79000-B8576-C861-02 Application of the Function Block 4 Technical Data Programmable controller S5-115U all CPUs except 945 S5-115U CPU 945 S5-135U 922, 928, 928B S5-155U 946/947, 948 Block number FB 162 FB 162 FB 162 FB 162 Block name PER:TREG PER:TREG PER:TREG PER:TREG Library number (P71200-S...) -5162-D-3 -3162-A-2 -9162-D-3 -6162-D-3 Call length (words) 15 15 15 15 Block length (words) 1746 1788 1504 1637 Nesting depth 0 1 (1) 0 (1) Assignment in data area DB-A: DB-B: DB-C: up to DW255 up to DW203 up to DW223 inclusive inclusive inclusive Alternative DBs DB-A': DB-C': up to DW223 up to DW223 inclusive inclusive Assignment in flag area (2) From FY 208 From FY 208 to FY 255 to FY 255 From FY 208 From FY 208 to FY 255 to FY 255 Assignment in system data area (3) - - From RS 60 to RS 61 - (4) - (4) (4) Other: (1) Special operating system functions are called which are counted as normal block calls. (2) The flags are only used as buffers. Outside the function block they are freely available. (3) The system data are only used as buffers. Outside the function block they are freely available. (4) In the function block, interrupts and timed interrupts are at times blocked by the commands AS/AF or by PLC special functions. This means that a user programmed "interrupt inhibit" may be cancelled again. IP244 C79000-B8576-C861-02 5-45 Application of the Function Block Processing times The table lists the runtimes for FB 162 (PER:TREG) when indirect parameter assignment is selected. Command Programmable controller: S5 ... 115U CPU 941 115U CPU 941 B 115U CPU 942 115U CPU 942 B 115U CPU 943 115U 115U CPU CPU 943 B 944 115U 115U CPU CPU 944 B 945 PA 1st call 2nd call 173.6 33.6 74.4 6.3 100.8 11.6 74.4 6.3 80.8 6.6 72.8 5.9 10.0 1.8 5.9 1.0 3.7 0.6 AE 1st call 2nd call 57.4 33.2 13.0 6.0 23.8 11.1 13.0 6.0 7.9 7.5 12.6 5.6 2.7 1.3 1.3 0.7 0.4 0.2 S1/S2, T1/T2 G1/G2 38.0 6.9 12.8 6.9 7.7 6.5 1.3 0.8 0.2 AS AB, HB, SE 44.0 9.3 17.0 9.3 7.8 8.1 1.3 0.9 0.2 LE 91.2 11.9 34.0 11.9 15.4 11.5 1.6 1.1 0.4 IW 42.1 10.2 14.7 10.2 11.3 9.0 1.9 0.9 0.3 +45.0 +6.6 +21.0 +6.6 +6.0 +4.0 +0.8 +1.5 +0.1 40.6 7.6 13.2 7.6 7.5 7.1 1.2 0.8 0.2 0.62 1.7 0.62 1.7 0.61 0.07 0.015 None 135U CPU 922 135U CPU 928 135U CPU 928 B 155U 155U CPU CPU 946/947 948 PA 1st call 2nd call 5.7 4.7 4.3 2.1 12.6 1.9 1.7 1.2 3.4 0.7 AE 1st call 2nd call 8.8 5.6 6.2 3.3 2.5 1.4 1.3 0.9 0.6 0.3 S1/S2, T1/T2 G1/G2 AS AB, HB, SE 5.7 4.4 1.6 1.6 0.8 0.4 6.9 4.7 1.6 1.2 0.4 LE 5.8 4.2 1.4 1.5 0.6 IW 6.9 4.9 1.5 1.1 0.9 +6.5 +2.7 +1.0 +0.6 +0.2 5.2 4.2 1.4 0.4 0.3 Ext. runtime with 0.3 direct param. ass. 0.1 None 0.03 None With "read errors" (1) Idling Ext. runtime with 2.2 direct param. ass. With "read errors" Idling 5-46 (1) IP244 C79000-B8576-C861-02 Application of the Function Block (1) The maximum runtime is required when a job is being carried out, e.g. AS1 - change setpoint controller 1 - and the error messages must also be read. This would be the case in each fifth S5 cycle if errors have occurred. The total processing time consists of the time to execute the command and the time required for "read errors". Example with S5-135U, CPU 922: AS = 6.9 ms without "read errors", AS = 6.9 ms + 6.5 ms = 13.4 ms with "read errors". The commands grouped together above have similar execution times. The time shown in the table is the maximum time. The commands PA and AE require that the function block FB 162 is called twice (two S5 cycles). The others require only one FB 162 call. IP244 C79000-B8576-C861-02 5-47 Application of the Function Block 5 Application of the Function Block To control the temperature controller by means of the function block, at least three data blocks are required. The number of the first data block (DB-A) is specified in the parameter DBNR; for the other two data blocks (DB-B and DB-C) the numbers are entered in the data words DW12 and DW13 of the data block DB-A. Function block FB 162 allows the set controller parameters to be read from the module. The controller parameters can either be transferred to the data blocks DB-A and DB-C described above, or to two further data blocks DB-A' and DB-C'. The numbers and DB type of data block DB-A' and DB-C' are entered in data word DW 7 (DB-A) or DW 8 (DB-C') and can be selected freely. The setting of data byte DR 6 in data block DB-A decides the pair of blocks to which the values are transferred. If parameter DBNR is assigned KY = 0,0 (indirect parameter assignment), the number and DB type of the first data block (DB-A) must be entered in data word DW 4. In this case, the data block DB-A must be opened before the function block is called. The data blocks must be set up with the following lengths before the function block is called: DB-A: DB-B: DB-C: up to DW255 up to DW203 up to DW223 DB-A': up to DW223 DB-C': up to DW223 To assign parameters to the module, the controller parameters must be entered in messages 0 to 15 and 30 to 42 before the function block is called. The entry of values marked (ST) can be omitted if the controller self-tuning function is active. The assignments in the individual messages can be found in the Programming Instructions in Part 3 of this manual (C79000-B8576-C860). 5-48 IP244 C79000-B8576-C861-02 Application of the Function Block Calling the function block The function block can be called absolutely in the cyclic program. Exception: the command KS can only be specified in the startup OBs. In this case, it is advisable to use indirect parameter assignment. For this, the parameter DBNR must be assigned the value KY = 0.0 and the required parameters written to data block DB-A, DW1 to DW8 and DW12 to DW 13. The function block may only be called once per temperature controller module per cycle. When calling FB162, you can decide whether to use direct or indirect parameter assignment. Once the mode of parameter assignment has been selected, this must be adhered to for all further FB calls for the same IP module. In cyclic operation it is not permitted to address a module both with indirect and direct parameter assignment Indirect parameter assignment uses the working area of DB-A (DW0 to DW15): Application with indirect parameter assignment Recommended data format DW 0 Reserved KH DW 1 Command KC DW 2 Message number DW 3 Address of the module DW 4 DB/DX selection (*) DB no: DBA KY DW 5 - Addressing type KY DW 6 - Software switch KY DW 7 DB/DX selection (*) Alternative DB no: DBA' KY DW 8 DB/DX selection (*) Alternative DB no: DBC' DW 9 Reserved KH DW 10 Reserved KY DW 11 reserviert Reserved KH DW 12 DB/DX selection (*) DB no: DBB KY DW 13 DB/DX selection (*) DB no: DBC KY DW 14 DW 15 (*) Direct function KY KF KH Reserved KH Reserved KM omitted with S5115U (CPU 941 to CPU 944 and CPU 941B to CPU 944B) You will find the explanation of the data words under the parameters of the FB in direct parameter assignment (Sections 3.2 and 3.3) and on the following pages in this Chapter. IP244 C79000-B8576-C861-02 5-49 Application of the Function Block The DB type and DB number entered in data word DW4 must agree with the DB type and DB number of the data block opened when FB 162 is called. The number of DB-A' can be between 10 and 254. DB-A' and DB-C' must not overlap with DB-A, DB-B and DB-C. E.g. data block DB 170 DW 0 DW 1 DW 2 DW 3 DW 4 : : : : : or KH0000 KS KY KF KY 0,170 DX 170 DW 0 DW 1 DW 2 DW 3 DW 4 : : : : : KH0000 KS KY KF KY 1,170 If function block FB 162 is called with indirect parameter assignment, the data areas shown in bold face must be assigned before calling the FB. Data word DW1 is then cleared by FB 162 as soon as the entered command has been executed (DW 1 = KH0000). If a parameter assignment error occurs while the command is being processed, the command in DW 1 is once again cleared. A new command can now be entered (acknowledgement to the user program) Indirect parameter assignment Call data block DBA Data word DW1=KH0000 ? Yes A new command can be entered No / Call function block FB 162 5-50 IP244 C79000-B8576-C861-02 Application of the Function Block Select software switch: Assignment of the right data byte DR 6 DBA: 7 6 5 4 3 2 1 0 Automatic reading after selftuning complete Read out to alternative data block DBA' and DBC' Free Free Free Free Free Free Bit 0: if this bit is set, the parameters calculated after completion of the selftuning function (controllerspecific, e.g. controller 0: message 0 and message 30) are read by the module and stored in the data block (evaluation of the selftuning status bit). Bit 1: if this bit is set, the controller messages are stored in the alternative data blocks DBA' and DBC' either automatically or with the command "LE". Bits 2 to 7 are not assigned. IP244 C79000-B8576-C861-02 5-51 Application of the Function Block Byte for direct functions With direct access by the user program to the IP 244 temperature controller module, a byte (right data byte DR2) in data block DB-A, stipulates that the execution of certain commands has priority. The commands of this byte are known as direct functions. They are executed with priority over the commands in DW 1 or commands started by the parameters BEF and ANST. By setting a bit in this byte, you can transfer a command word as a direct function. If one of the commands S1, S2, T1, T2, G1 or G2 is set and a direct function is triggered in the same FB 162 call, both commands are transferred to the module in one message. In this case, data word DW 1 (DB-A) is also set to KH0000, or the parameter ANST is reset. Select direct functions: Assignment of the right data byte DR 2 in DBA 7 6 5 4 3 2 1 0 Start bit: read curve values channel 13 Acknowledgement bit: read curve values channel 13 Start bit: read actual value channel 14 Acknowledgement bit: read actual value channel 14 Free Free Free End of machine cycle (*) Only D 2.0: (*) for cascaded control start bit, read curve values channel 13 You set this bit to trigger the reading of 60 curve values on the module. FB 162 resets the bit immediately after the command has been transferred to the module. You can set the bit again at any time, even if the last job is not yet complete. Only the last job triggered is valid. D 2.1: acknowledgement bit, read curve values channel 13 This bit is set by FB 162 when the read function is complete and the values have been stored in data block DB-B. This bit remains set until a new job is started. 5-52 IP244 C79000-B8576-C861-02 Application of the Function Block D 2.2: start bit, read actual value channel 14. By setting this bit, you trigger the reading of the actual value on channel 14. FB 162 resets the bit immediately after the command has been transferred to the module. You can set the bit again at any time, even if the last job is not yet complete. The last job triggered is always valid. D 2.3: acknowledgement bit, read actual value channel 14. This bit is set by FB 162 when the read function is complete and the value is stored in DB-B: the bit remains set until a new read job is triggered. D 2.4: free D 2.5: free D 2.5: free D 2.7: end of the machine cycle (only for cascaded control). By setting this bit, you indicate the end of a machine cycle. The bit is reset by the function block. IP244 C79000-B8576-C861-02 5-53 Application of the Function Block Reading the image of the digital outputs without FB 162: The status indication of the image of the digital outputs is normally updated by reading message 19. The function block FB 162 must have the command IW (read actual value) and message number 19 assigned. To update the image quickly, it is possible to read only these three bytes of the image. To do this, certain requirements must be fulfilled. The function "Read the image of the digital outputs" is only allowed in cyclic operation, OB 1. The following diagrams describe ways of updating the image of the digital outputs (DB-B, DW 94 and DL 95) for specific PLCs. S5-115U: FB x = UPD.DQI Call data block DBB IA Block interrupts L T KF PY +19 n +31 Load message number in accumulator 1 where n corresponds to the base address of the IP 244 L T L T PW DW PY DL n +28 94 n +30 95 Read bytes 28 and 29 from the IP 244 Store DQ1 to DQ9 in the data block Read byte 30 from the IP 244 Store DQ10 to DQ17 in the data block RA Release interrupts Block end S5-135U CPU 922 and CPU 928 when interrupts are possible at the block boundaries and S5-155U in the 150U mode. FB x = UPD.DQ1 Call data block DBB L T KF PY +19 n +31 Load message number in accumulator 1 where n corresponds to the base address of the IP 244 L T L T PW DW PY DL n +28 94 n +30 95 Read bytes 28 and 29 from the IP 244 Store DQ1 to DQ9 in the data block Read byte 30 from the IP 244 Store DQ10 to DQ17 in the data block Block end 5-54 IP244 C79000-B8576-C861-02 Application of the Function Block S5-135U CPU 922 and CPU 928 when interrupts are allowed at the command boundaries. FB x = UPD.DQ1 Call data block DBB Block interrupts: L KB2 L KB5 JU OB122 Special function L T KF PY +19 n +31 Load message number in accumulator 1 where n corresponds to the base address of the IP 244 L T L T PW DW PY DL n +28 94 n +30 95 Read bytes 28 and 29 from the IP 244 Store DQ1 to DQ9 in the data block Read byte 30 from the IP 244 Store DQ10 to DQ17 in the data block Release interrupts: L KB3 L KB5 JU OB122 Special function Block end S5-155U when the PLC is operated in the 155U mode. FB x = UPD.DQ1 Call data block DBB Block interrupts: LIM T FD200 L KB0 SIM save interrupt mask block all interrupts L T KF PY +19 n +31 Load message number in accumulator 1 where n corresponds to the base address of the IP 244 L T L T PW DW PY DL n +28 94 n +30 95 Read bytes 28 and 29 from the IP 244 Store DQ1 to DQ9 in the data block Read byte 30 from the IP 244 Store DQ10 to DQ17 in the data block Release interrupts: L FD200 SIM restore interrupt mask Block end IP244 C79000-B8576-C861-02 5-55 Application of the Function Block Using the temperature controller module in multiprocessor operation (relevant for the S5-135U and S5-155U) If the temperature controller module is operated in a PLC with several CPU modules, you must ensure that the module can only be addressed by one CPU module. Access by more than one CPU module to the same temperature controller module is not permitted and would lead to program errors. Interrupting the user program by event and time-driven interrupts in the S5-115U The user program is always interrupted at command boundaries. If interrupt OBs are programmed in the user program, in which the scratchpad flag area (flag bytes FY200 to FY255) is used, make sure that this flag area is saved and reloaded before exiting the interrupt OB. The function block FB 162 must not be called in the interrupt OBs. Start-up procedure with the S5-115U Cyclic program execution following "cold restart" (OB 21) and "automatic warm restart" (OB 22) begins at the start of OB 1. The function block is normally called with the command KS (cold restart) following a cold restart and with the command PA (assign parameters) following an automatic warm restart. If neither "PA" or "KS" are executed following an automatic cold restart, the IP is placed in a queue. Interrupting the user program by event and time-driven interrupts with the S5-135U The user program is interrupted at block boundaries or at command boundaries if data block DX0 has suitable parameters assigned. If interrupt OBs are programmed in the user program in which the scratchpad flag area (flag bytes FY200 to FY255) is used, make sure the flag area is saved and reloaded before exiting the interrupt OB. The same applies to the operating system data RS60 and RS61. Function block FB162 must not be called in the interrupt OBs. 5-56 IP244 C79000-B8576-C861-02 Application of the Function Block Start-up procedure with the S5-135U Following a cold restart (OB 20) cyclic program execution begins at the start of OB 1. With the warm restarts OB 21 (manual warm restart) or OB 22 (automatic warm restart) program execution is continued from the point of interruption after the start-up OBs have been run through. When using the IP 244 temperature controller module in the S5 135U, neither manual nor automatic warm restart is permitted. The function "automatic warm restart" must be set in the function "automatic cold restart following power up" with the aid of DX0 (block identifier KH02xx, parameter KH1001, where xx corresponds to the block length). OB 20 is called both for a cold restart and automatic cold restart. The type of start-up which will be executed can be seen by evaluating operating system data RS 5 (for more detailed information, refer to the S5-135U manual). The command "STP" (STOP) must be programmed in OB 21 and OB 22. If neither "PA" or "KS" are executed following an automatic cold restart, the IP is placed in a queue. Interrupting the user program by event and time-driven interrupts with the S5-155U The user program is interrupted at the block boundaries or at the command boundaries if data block DX0 has suitable parameters assigned. If interrupt OBs are programmed in the user program in which the scratchpad flag area (flag byte FY200 to FY255) is used, make sure that this flag area is saved and reloaded before the interrupt OBs are exited. (Function blocks FB 38 and FB 39). Start-up procedure of the S5-150U Cyclic program execution following cold restart (OB 20) begins at the start of OB 1. With the warm restarts OB 21 (manual restart) or OB 22 (automatic warm restart), the program execution is resumed at the point of interruption after the start-up OBs have been run through. To save and load the scratchpad flag area, the standard function blocks FB 38 and FB 39 must be used. The function blocks operate in conjunction with a data block (in the example DB 255). This must be set up as far as DW 820. The function blocks must be used in pairs, i.e. the interrupt OBs must not be exited prematurely with the BEC instruction. If neither "PA" or "KS" are executed following an automatic cold restart, the IP is placed in a queue. Power up - first operation The temperature controller module must first have parameters assigned using the command KS (cold restart). The function block checks the version of the temperature controller module. The firmware release (message 16, byte 14) must be greater than 20. With older releases, the function block FB 162 indicates a parameter assignment error (error number 1). IP244 C79000-B8576-C861-02 5-57 Application of the Function Block Special features of the commands KS, PA and AE KS: the command KS (cold restart) must only be used in one of the start-up OBs (OB 20, OB 21 or OB 22). The command KS must be used to assign parameters: - when the module is first put into operation - if you are not sure that the memory of the IP 244 has been backed up continuously. PA/AE: the commands PA (assign parameters) and AE (change parameters) require at least two clock cycles before they are processed. This means that FB 162 must be called several times until parameter ANST is reset (with direct parameter assignment) or until the command in data word DW 1 of data block DB-A is cleared (with indirect parameter assignment). The command PA must only be used when: - the module has already been put into operation, - you are sure that the data in the memory of the module was backed up while the power supply was off (i.e. the CC or EU must be equipped with a back-up battery and the IP 244 must be inserted in a battery backed slot), - the module has not been removed from the rack since its previous operation. 5-58 IP244 C79000-B8576-C861-02 Appendix Appendix A Notes on Operating the IP 244 with the Self-Tuning Function with FB 162 for 64 Messages A.1 Requirements A.1.1 Controlled System - The controlled system must permit a physical setpoint jump of 37 C for 2-step controllers or up to 110 C for 3-step controllers. - The controlled system must demonstrate low pass characteristics. - The rate of rise of the actual value must not exceed maximum 60 C/min at full heating power or when simultaneously heating and cooling or the actual value may not fall more than 60 C/min. - The maximum rise of the actual value must be 0.05 C/min with full heating power. - The heating procedure must not take longer than 12 hours. With pure Pt 100 operation only 11.6 h is permitted. With mixed operation and one standard controller and ADC conversion time = 50 ms, only 7.2 h permitted and ADC conversion time = 60 ms, only 8.7 h permitted - If only the cooling is active, you must guarantee that the actual value falls. - Suitable for systems in which no very large step-like disturbances (in the automation control sense) occur. A.1.2 Parameter Assignment - - - - - Main control byte 1, bit 2 = 1 DL n + 11, bit 1 = 1 Controller has heating output No hot channel controller No master controller with cascaded control A.2 Recommended Procedure for Single Self-Tuning Function A.2.1 All the parameters not marked with "ST" in messages 0 to 12 and 30 to 42 must have values assigned and the controller must be disabled using setpoint 0 or by setting the heating switch to "Off". This prevents an unnecessary heating up before the self-tuning function is started. A.2.2 Generate an upward edge in bit 7 in the data byte n + 11 by means of the commands "ST", "CR" or "PA". (The user must make sure to allocate the data byte DLn + 11 correctly.) IP244 C79000-B8576-C861-02 5-59 Appendix A.2.3 Controller is enabled by: - command "ST" for the respective controller, or - commands "CR" or "PA" and by entering a setpoint not equal 0. (The steps "CR" or "PA" and setpoint 0 can be combined.) The self-tuning function is now active. - Status bits in DB-B, message 16, DW 34. As long as the self-tuning function is active, the bit for each controller is set and is reset by the IP on completion of the function. - Control using the entered setpoint following the tuning. If heating and cooling parameters have been determined during the self-tuning phase, this is indicated in DB-A, messages 0 to 12, DR n + 11. A.2.4 Caution! If a controller is already running with self-tuning function and another controller is being changed parameters with "AE", then the self-tuning function for the first controller also starts anew (this is necessary, as with AE also the structure of the controllers and the output allocation can be changed). After "AE" has been used, all conditions for the self-tuning controller must still be met. A.2.5 Caution! If a power failure occurs during the self-tuning function, the calculated parameters are useless. Then a new minimum setpoint jump (see section A.1) must be provided. The height of the minimum jump for each three-step controller is output in DB-A, DL n + 15 (messages 0 to 12). This is possible either by cooling down the process and restarting it (e.g. switch over to manual operation and colling with three-step controllers) or by means of a minimum setpoint jump from the current actual value on. A.2.6 Caution! If a power failure occurs following the self-tuning phase, the controller will continue to operate with the calculated parameters when the power returns, if you: - read all the calculated parameters (the FB does this automatically if DR6 DB-A, bit 0 = 1), - clear all DL n +11 (message 0 to 12) except bit 1 in DB-A: 27 26 0 0 25 0 24 0 23 0 22 0 21 1 20 0 - transfer all calculated parameters back to the IP. Further advantages: - the calculated parameters are not lost even if the battery back-up of the IP fails, - the self-tuning function is not restarted by KS during the start-up, - the self-tuning is not repeated if the battery back-up of the IP fails. 5-60 IP244 C79000-B8576-C861-02 Appendix A.3 Procedure for Self-Tuning with Repetition A.3.1 As Section A.2.1. Additionally it must be guaranteed that bit 7 = "0" in DL n + 11 or 0 is transmitted to the IP. A.3.2 Restart self-tuning function as in A.2.2. A.3.3 As Section A.2.3 (control with entered setpoint). A.3.4 As Section A.2.4. A.3.5 To restart the self-tuning function after power failure, the self-tuning function must be stopped via DL n + 11 bit 7 during the execution of OB 21/OB 22. Once the minimum setpoint jump is ensured, either by a long power failure or manual operation, which is necessary for the self-tuning function, the self-tuning function must be restarted as described in section A.2.2 and A.2.3. A.3.6 To repeat a self-tuning run without the power having been switched off, bit 7, data word n + 11 must first be set to 0 and transmitted. Then, either a minimum setpoint jump from the current actual value on must be entered or the system must be cooled down by the height of the minimum setpoint jump. A.3.7 As A.2.2 The self-tuning function is now repeated. The procedures described here must be adhered to and performed completely. IP244 C79000-B8576-C861-02 5-61 Appendix Supplement to A.2.2 and A.2.3 (data byte DL n +11): Byte for selftuning parameters Bit 7 0/1 6 0/1 5 0 4 3 0/1 0 2 0 1 1 0 0 Selftuning controller 1 = selftuning once 0 = selftuning with repetition only used by the FB 162 for 32 messages 1 = asymetrical controlled system (only with twostep controllers, otherwise 0) 0 = symmetrical controlled system 0 1 = Start of the selftuning function 1 0 = Stop of the selftuning function Note: The FB supports reading of bytes DRn + 11 (heating and cooling parameters calculated) and DLn + 15 (minimum jump) in messages 0 to 12 only if main control byte 1, bit 2 = 1. (Reason: LE is only possible if main control byte 1, bit 2 = 1.) You may only evaluate the bytes if you have previously read them. 5-62 IP244 C79000-B8576-C861-02 SIMATIC S5 Test Program for IP 244 Temperature Controller with Function Block FB 162 (64 Messages) 6ES52443AA22 and 3AB31 User's Guide C79000B8576C86202 Contents Contents Page 1 Preface on Test Program 6-3 2 Hardware Requirements 6-4 3 Signal Assignments for the Test Program 6-5 4 Using the Test Program 6-8 6-2 IP244 C79000-B8576-C862-02 Test Program 1 Preface on Test Program The chosen example shows how parameters could be assigned to a module. The example with indirect parameter assignment covers all possible modes, i.e. the complete range of commands, whereas the example for direct parameter assignment is limited to the following operating modes: Command Message number PA - assign parameters - IW - read actual value 17 LE - read the controller parameters 0 AE - change the controller parameters 0 AS - change setpoints 0 AB/HB - switch over to automatic/manual operation 0 S1/S2 - switch over setpoints 0 All the required blocks for receiving data are present and installed. The example uses data blocks with the following designations: DB-A : DB 162 DB-B : DB 163 DB-C : DB 164 DB-A' : DB 172 DB-C' : DB 173 The function block FB 62 in the test program operates with direct parameter assignment, FB 63 with indirect parameter assignment. During indirect parameter assignment the parameters are read from the data block DB 162. In a cold restart the IP 244 is assigned new parameters using the command KS (cold restart). In both "automatic warm restart" and "manual warm restart", the command PA (assign parameters) is executed. IP244 C79000-B8576-C862-02 6-3 Test Program 2 Hardware Requirements The following hardware is required for the example: - a PG 685 programmer - one of the following programmable controllers: - - - - - S5-115U (CPU 941 to CPU 944 or CPU 941B to CPU 944B) S5-115U (CPU 945) S5-135U (CPU 922 from version A09) S5-135U (CPU 928 -3UA12/-3UB11) S5-155U (CPU 946/947 or CPU 948) - one simulator suitable for the digital input module - one digital input module 6ES5 420-... coded for IB4 1) Address switch ) off Value 128 Pressed on 4 - one digital output module 6ES5 441-... coded for QB4 1) Address switch ) off Value 128 Pressed on 4 - one IP 244 temperature controller module coded with the module address 160 ) Address switch 8 7 6 5 4 3 2 1 8 off on A76 7 6 5 2) 4 3 2 pressed 1 off on A77 2) necessary in the EU The module is addressed in the P area (A77: switches 5, 7 and 8). The remaining jumpers and switches on the module must be set for the selected mode. 1) With the S5-115U the following modules are required instead of those listed above: - one digital input module 6ES5 420-... (fixed slot coding), inserted in slot 1 of the central controller (IB4 to IB7) - one digital output module 6ES5 441-... (fixed slot coding), inserted in slot 2 of the central controller (QB8 to QB11). 6-4 IP244 C79000-B8576-C862-02 Test Program 3 Signal Assignments for the Test Program Digital inputs: I I I I I I I I 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 PA IW LE AE AS AB HB S1 Assign parameters Read actual values Read the parameters of one controller Change the parameters of one controller Change the setpoints of one controller Switch over to automatic operation Switch over to manual operation Switch over to setpoint 1 I I I I I I I I 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 S2 T1 T2 G1 G2 Switch over to setpoint 2 Controller not disabled if tolerance 2 violated Controller disabled if tolerance 2 violated Do not output averaged manipulated variable (*) Output averaged manipulated variable (*) Read curve values channel 13 (direct function) (*) Read actual value channel 14 (direct function) (*) End of machine cycle (direct function) (*) I I I I I I I I 6.0 6.1 6.2 6.3 6.4 6.5 6.6 6.7 20 21 22 23 24 Free Free Free I 7.0 I I I I I I I 7.1 7.2 7.3 7.4 7.5 7.6 7.7 Type of parameter assignment (0: indirect parameter assignment, 1: direct parameter assignment) Free Free Free Free ST Start/stop self-tuning function (*) Free Clear error number (PAFE) (*) These functions can only be selected in the test program with indirect parameter assignment. IP244 C79000-B8576-C862-02 Controller number (T-NR) 6-5 Test Program Digital outputs: S5135U S5155U S5115U Q Q Q Q Q Q Q Q 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 Q 8.0 Q 8.1 Q 8.2 Q 8.3 Q 8.4 Q85 Q 8.6 Q 8.7 NEUA AFEH BFEH SFEH 20 KANR 21 KANR 22 KANR 23 KANR : request for new parameters sampling time error on the module module error (watchdog) group error number of channel with error number of channel with error number of channel with error number of channel with error QW5 QW 9 FMELD : error message for the channel specified by KANR Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q PAFE : (*) Free 20 parameter 21 parameter 22 parameter 23 parameter 24 parameter 7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 11.0 11.1 11.2 11.3 11.4 11.5 11.6 11.7 : : : : : : : parameter assignment error assignment assignment assignment assignment assignment error error error error error no. no. no. no. no. (<--> F255.0 (<--> F255.0 (<--> F255.0 (<--> F255.0 (<--> F255.0 to to to to to F255.4) F255.4) F255.4) F255.4) F255.4) (*) Free with the S5-115U and S5-135U Parameter assignment error in the warm restart (OB 21, OB 22) with the S5-155U. If, in the S5-155U, a parameter assignment error (Q 7.1 =1) occurs during warm restart, the associated parameter assignment error number then stands in the flag byte FY 100. With the programmable controller S5-135U the output parameters of the FB 162 are not written to the outputs but only to the flags during the warm restart program. The exception is the parameter PAFE. Data area occupied: The data blocks DB 150, DB 151 and DB 152 are occupied from data word DW 0 to DW 32. These data blocks are used to save the scratchpad flag area and the free system data area in the interrupt OBs. With the S5-155U, this is performed in data block DB 255 which must be set up with a length of 820 words. 6-6 IP244 C79000-B8576-C862-02 Test Program Assignment of the flag area: F F FY FY FY FY 0.0 0.1 4 5 6 7 "RLO 0" "RLO 1" corresponds to IB 4 corresponds to IB 5 corresponds to IB 6 corresponds to IB 7 FY 8 FY 9 FY 10 FY 11 corresponds to QB 4 or QB 8 with the S5-115U corresponds to QB 5 or QB 9 with the S5-115U corresponds to QB 6 or QB 10 with the S5-115U corresponds to QB 7 or QB 11 with the S5-115U F F edge trigger flag for parameter assignment error pulse flag for parameter assignment error 15.0 15.1 FW 20 FW 22 old value of IW 4 pulse flag for IW 4 (edge evaluation) FY 24 channel number F F 25.0 26.0 old value of I 7.5 pulse flag for I 7.5 (edge flag) F F F F FY FW 28.0 28.1 28.2 28.3 29 30 NEUA AFEH BFEH SFEH KANR FMLD FY 100 (only in the warm restart with S5-155U) (only in the warm restart with S5-155U) (only in the warm restart with S5-155U) (only in the warm restart with S5-155U) (only in the warm restart with S5-155U) (only in the warm restart with S5-155U) image of FY 255 when FB 162 is called in the start-up program (only with S5-155U) FY 200 - FY 255 scratchpad flags Assignment of the system data area (S5-135U) RS RS 60 61 scratchpad flags scratchpad flags IP244 C79000-B8576-C862-02 6-7 Test Program 4 Using the Test Program After an overall reset of the PLC, the whole file for the test program can be loaded in the RAM of the PLC. Following this, messages T-NR 0 to 14 in DB 162, T-NR 15 in DB 163 and T-NR 30 to 42 in DB 164 must be assigned the required values for variables and parameters. If controlled channels are not being used, the value zero must be entered for the setpoint in DW n + 0. The required controller type (2-step/3-step controller) must also be selected in control byte 1 (DL n + 4). If all the messages above have had values assigned, a cold restart can be performed. The LED "R" lights up at the top left on the front panel to signal that the module has been assigned parameters. The individual functions can now be activated via inputs I 4.0 to I 5.7 and I 7.5. The required type of parameter assignment is selected at input I 7.0. If a parameter assignment error occurs during the execution of the test program, the error number remains set at the output even after the error has been corrected until it is cleared via input I 7.7. In the test program, indirect parameter assignment is used in the startup OBs. In cyclic operation, the type of parameter assignment can be selected via input I 7.0. If, during the processing of FB 162, a parameter assignment error occurs with an error number between 1 to 8, 17 or 23 to 26, a cold restart must be performed after the error has been corrected. 6-8 IP244 C79000-B8576-C862-02 Test Program Structural diagrams of the organization blocks (program framework) OB 1 Transfer inputs to flag area IW 4 IW 6 FW 4 FW 6 Flag 7.7 ="1" ? Yes No Clear parameter assignment error number (Q 11.3 to Q 11.7) / F 7.0 ="0" ? : direct parameter assignment Yes No Indirect parameter assignment FB 63 Direct parameter assignment FB 62 Flag bytes 8 to 11 output bytes 4 to 7 (or 8 to 11 with S5115U) Rising edge on PAFE bit? Yes No Update flags F11.3 to F11.7 / Block end Interrupt OBs Process interrupt OBs and timed interrupt OBs Save flags FY 200 to FY 255 Save operating system data (S5135U) User program for interrupt Load operating system data (S5135U) Load flags FY 200 to FY 255 END IP244 C79000-B8576-C862-02 6-9 Test Program OB 20 (or OB 21 with the S5 115U) F 0.0 = RLO "0" F 0.1 = RLO "1" Call FB 162 with the command KS User program for cold restart END OB 22 (for the S5-115U) Call FB 162 with the command PA User program for automatic cold restart END OB 21/OB 22 (for the S5-135U) STP STOP at block end END OB 21/OB 22 (for the S5-155U) Save flags FY 200 to FY 255 Call FB 162 with the command PA User program for warm restart Load flags FY 200 to FY 255 END 6-10 IP244 C79000-B8576-C862-02 Test Program Structural diagrams of the function blocks FB 62 and FB 63 The function block FB 62 shows the application of FB 162 with direct parameter assignment. Structural diagram FB 62 Segment 1: parameters Segment 2: edge evaluation of flag word FW 4 (<--> IW 4) Segment 3: Is a job currently active? (ANST = 1?) No Yes Check flags of FW 4 for rising edge F 4.0 x=PA y=0 F 4.1 x=IW F 4.2 x=LE y=0 F 4.3 x=AE y=0 F 4.4 x=AS y=0 F 4.5 x=AB y=0 F 4.6 x=HB y=0 F 4.7 x=S1 y=0 F 5.0 x=S2 y=0 Check flags of FW 4 for rising edge IP244 C79000-B8576-C862-02 x=XX y=0 -- 6-11 Test Program Structural diagram FB 162 Call function block FB 162 depending on command NAME ADRA BGAD DBNR BEF TNR ANST NEUA PAFE AFEH BFEH SFEH KANR FMLD : : : : : : : : : : ; : : : : JU FB162 PER: TREG KF +0 KF +0 KY 0,0 KS x KF y F 2.0 F 8.0 F 11.0 F 8.1 F 8.2 F 8.3 FY 24 FW 9 Segment 4: channel number F 8.4 to F 8.7 Block end 6-12 IP244 C79000-B8576-C862-02 Test Program FB 63 shows the application of function block FB 162 with indirect parameter assignment. Structural diagram FB 63 Segment 1: parameters call the assigned data block Segment 2: edge evaluation of flag word FW 4 (<--> IW 4) edge evaluation of flag F 7.5 (<--> I 7.5) Segment 3: Is a job currently active? (DBA: DW1 = 0?) No Yes Check flags of FW 4 und F 7.5 for rising edge Formulate job (next page) Segment 4: Call FB 162 NAME ADRA BGAD DBNR BEF TNR ANST NEUA PAFE AFEH BFEH SFEH KANR FMLD : : : : : : : : : : : : : : : x=0 JU FB 162 PER: TREG KF +0 KF +0 KY 0,0 KS x KF +0 F 2.0 F 8.0 F 11.0 F 8.1 F 8.2 F 8.3 FY 24 FW 9 Segment 5: channel number --> F 8.4 to F 8.7 Segment 6: Block end IP244 C79000-B8576-C862-02 6-13 Test Program Segment 3: check flags of FW 4 and F 7.5 for rising edge F 4.0 x=PA F 4.1 x=IW F 4.2 x=LE F 4.3 x=AE F 4.4 x=AS F 4.5 x=AB F 4.6 x=HB F 4.7 x=S1 F 5.0 x=S2 F 5.1 x=T1 F 5.2 x=T2 F 5.3 x=G1 F 5.4 x=G2 F 7.5 x=SE / Yes Rising edge of flag F 5.5? Set "read curve value channel 13" bit: D 2.0 Yes Rising edge of flag F 5.6? Set "read actual value channel 14" bit: D 2.2 Yes Rising edge of flag F 5.7? Set "end of machine cycle" bit: D 2.7 No / No / No / Enter the message number in data byte DL 2 6-14 IP244 C79000-B8576-C862-02 SIMATIC S5 IP 244 Temperature Controller 6ES52443AA22 and 3AB31 Utilization in S7400 C79000-B8500-C866-01 Page Contents 1 Adapter Casing 7-3 1.1 Marginal Conditions 7-4 1.2 Installing the Adapter Casing in S7-400 7-5 1.3 Installing S5 Modules in Adapter Casings 7-6 1.4 Alarm Processing 7-7 1.5 Specifications 7-8 2 Addressing S5 Modules (Adapter Casing and IM 463-2) 7-9 2.1 Addressing S5 Modules 7-10 3 FC 162 (for Temperature Control) 7-13 3.1 Overview 7-14 3.2 Temperature Control Block 7-15 3.3 Programming Example 7-24 7-2 IP244 C79000-B8576-C866-01 Adapter Casing (S5 Adapter) Contents of this Chapter 1 This Chapter tells you, how you install the modules in the adapter casing what you have to observe when you use the individual S5 modules. Chapter overview IP244 C79000-B8576-C866-01 Chapter tells you about on page 1.1 Marginal conditions 3-4 1.2 Installing the adapter casing in S7-400 3-5 1.3 Installing S5 modules in adapter casings 3-6 1.4 Alarm processing 3-7 1.5 Specifications 3-8 7-3 Adapter Casing (S5 Adapter) 1.1 Marginal Conditions General conditions The following conditions must be observed when S5 modules are used in an S7-400 system: Check with your SIEMENS representative that the modules you want to employ have been released for utilization. Special standard function blocks must be used for integrating configura- ble S5 modules into a STEP 5 application program. Consequently, you must order new standard function blocks if you have only S5 standard function blocks for an S5 module that have not expressively been released (in the Device Manual or the Product Information) for utilization with STEP 7. The general technical specifications (environmental conditions in particular) of SIMATIC S5 and SIMATIC S7 differ. The more stringent environmental conditions of S5 or S7 apply if an S5 module is used in an S7-400 system. Valid racks The adapter casing may only be installed in the central unit of the S7-400 system. Note Seek advice from your SIEMENS representative if you want to use an S5 module, that has previously been used in an S5 system, in your S7 system. The information given in this Chapter only refer to the current versions and revision levels of the listed S5 modules. 7-4 IP244 C79000-B8576-C866-01 Adapter Casing (S5 Adapter) 1.2 Installing the Adapter Casing in an S7-400 System Introduction To install an S5 module in an S7-400, you must first install the adapter casing in the S7 rack. Select the address on the S5 module, and insert the module into the adapter casing. Installing the adapter casing in the rack Use the following procedure to install the adapter casing in a rack: 1. Verify that the wire jumpers at the rear of the adapter casing are closed (state upon delivery). These jumpers are used for test purposes and must always be closed. Fig. 1-1 shows the locations of these jumpers. Bild 1-1 Location of the wire jumpers on the adapter casing 2. Set the CPU mode selector switch to STOP. 3. Set the standby switch on the power supply module to voltages). (0 V output 4. Follow the instructions in the "S7-400/M7-400 Automation System" Installation Manual for installing modules in a rack. Selecting the address IP244 C79000-B8576-C866-01 Select the address on the S5 module. 7-5 Adapter Casing (S5 Adapter) 1.3 Installing S5 Modules in an Adapter Casing Procedure To install an S5 module in an adapter casing, use the following procedure: 1. Select an alarm line and thus the target CPU for alarms on the module (alarm-triggering modules only). Alarm line... ... corresponds to target CPU /INT A CPU 1 /INT B CPU 2 /INT C CPU 3 /INT D CPU 4 2. Remove the locking strap from the adapter casing. 3. Insert the module into the guide rails of the adapter casing and push it in. The rear connectors make contact with the sockets of the adapter casing. 4. Re-install the locking strap. 5. If your S5 module is equipped with a locking screw, push the locking screw in and turn the slot into a vertical position. Fig. 1-2 shows how you install an S5 module in an adapter casing. Locking strap Locking screw (not in all modules) Bild 1-2 7-6 Installing an S5 module in the adapter casing IP244 C79000-B8576-C866-01 Adapter Casing (S5 Adapter) 1.4 Alarm Processing Introduction The adapter casing converts the S5 alarms into the S7 alarm functions and alarm signals. Alarm allocation All alarms of the S5 module are transferred as (S7) process alarm. The following allocation is used: S5 alarm line Alarm with active OD S7 alarm line /INT A /I1 /INT B /I2 /INT C /I3 /INT D /I4 New alarms are not triggered as long as OD (OUTPUT DISABLE; CPU in STOP mode, for example) is active. Processing of pending alarms is continued. The rear edge of the OD signal resets the S7-related alarm functions. Whether or not the rear edge of OD resets the S5-related alarm functions depends on the individual S5 modules (see the related Manuals). If an alarm in an S5 module is not reset by the rear edge of OD, a new alarm will be triggered following the rear edge of OD. Determine alarmtriggering module If an S5 module in the adapter casing triggers an alarm, the logic address of the module is stored in the local data area of the alarm OB. Acknowledging an alarm To acknowledge an alarm you use the same familiar procedure as in S5 (see Device Manual or Product Information). The CPU automatically performs the additional alarm functions that are specific to the S7 system. IP244 C79000-B8576-C866-01 7-7 Adapter Casing (S5 Adapter) 1.5 Specifications Dimensions and weight Dimensions W H D (mm) 50290210 Weight approximately 300 g Voltage, current System voltage 1) DC 5 V Nominal voltage Range DC 5.1 V DC 4.75 V ... 5.25 V Auxiliary voltage 1) Nominal voltage Range DC 24 V DC 18 V ... 32 V Battery voltage 1) Nominal voltage Range DC 3.4 V DC 2.75 V ... 4.4 V Maximum current capacity The current taken from the adapter casing is limited to the following maximum values: From system voltage From auxiliary voltage From battery voltage 1) 3A 0.5 A 0.5 mA Looped-through from S7-400 power supply unit 7-8 IP244 C79000-B8576-C866-01 Addressing S5 Modules (Adapter Casing and IM 463-2) Contents of this Chapter 2 This Chapter tells you how you address S5 modules in adapter casings how you address S5 modules that are connected via IM 463-2 Chapter overview IP244 C79000-B8576-C866-01 Chapter 2.1 tells you Addressing S5 modules on page 7-10 7-9 Addressing S5 Modules 2.1 Addressing S5 Modules Introduction There are two different ways of using an IP xxx S5 module in an S7-400 system: In an adapter casing in the S7 central unit In the S5 extension unit with a connection via an IM 463-2 interface in the S7 central unit and an IM 314 interface in the S5 extension unit Addressing To be able to address an S5 module in an S7-400 system, you must set addresses at two different locations: The address used for addressing the module in the application program and the address set on the module must be entered under STEP 7. The address of the S5 module in a valid address range (address switches on the module). S7 address The address used for addressing the module in the S7-400 system is selected under STEP 7. Default addressing is not possible if the module is used in an S7-400 system. Specify the following values for addressing in the S7-400 system: S5 address areas - S7 address: Logic address. The range depends on the CPU. - S5 address: Assigned address on the module. Range: 0 ... 255 (in bytes) - Length: Size of address block. Range: 0 ... 128 (in bytes) - Partial PA: Partial process map allocation. Range: 0 (full PA) 1 ... 8 (partial PA) - Area: Range: P, Q, IM3, IM4. When you use S5 modules in the S7-400, you can address them in the following address areas: I/O area (P) Extended I/O area (Q, IM3, IM4) Page frame area I/O area When an S5 module is used in the adapter casing, a PESP signal is only generated in the P area. The signal is transferred to the module. A PESP signal is not generated for the Q, IM3 and IM4 areas. With a connection via IM 463-2, the IM 314 in the S5 extension unit generates the PESP signal (for the selected P, Q, IM3 or IM4 area). This corresponds to the I/O area of 256 bytes as it is defined for SIMATIC S5. Use the jumpers or switches on the module to select the S5 module address in these areas. The correct settings for the modules are specified in the related Manuals. 7-10 IP244 C79000-B8576-C866-01 Addressing S5 Modules Modules that occupy input and output areas require a separate entry for each area to be made under STEP 7. Page frame area To use an S5 module with page frame addressing you need the revised standard function blocks. These standard function blocks invoke special system functions that emulate the S5 page frame commands. The standard function blocks must be linked in the application program. With page frame addressing, too, you must assign a logic address. This logic address is stored as start information in the local data of the alarm OB. Under STEP 7 you must assign an S7 address and an S5 address of length 0 in the input area. You must not assign an address for this module in the output area. Note If you use S5 modules in your S7-400 system, you must observe the following points when you set the module address: - An S7 address must not be duplicated - An S5 address must not be duplicated in the same area (P, Q, IM3, IM4) - Even if the S5 module has an address range of length 0, its address may not be in the address area of another S5 module. Typical addressing in the page frame area Communications between CPU and an IP are performed via the S5 bus interface and a 2-kB dual-port RAM that is subdivided into two page frames. The page frames always lie in a factory-set address range. All you have to do is to select the page frame number of the module's first page frame. The two page frames of a module always occupy two consecutive numbers. The IP automatically recognizes the address of the second page frame. Upon delivery, each module has been set to the same address area for page frame addressing. When you configure your hardware under STEP 7, you must enter the following parameters in the input area: IP244 C79000-B8576-C866-01 - S7 address: Logic address - S5 address: 0 (range 0 ... 255; must not be duplicated in the selected area) - Length: 0 - Partial PA: 0 - Area: P (range P, Q, IM3, IM4) 7-11 Addressing S5 Modules Typical addressing in the P area An IP 244 needs 32 addresses for transferring the necessary parameters. Only the module's start address is selected. Internal decoding allocates the next 31 addresses. These addresses are no longer available to other modules. Addresses can be selected in multiples of 32. The module's input and output addresses (S5 and S7) must be identical. This is necessary for correct utilization of the standard function blocks. In addition, you must enter the following parameters when you configure your hardware under STEP 7: - S7 address: a logic address w512 (this address is used for addressing the module in the application program) - S5 address: same as on the module - Length: 32 bytes - Partial PA: 0 - Area: depends on the area selected on the module or the IM 314 (P, Q, IM3 or IM4) The IP 244 may not lie inside the process map. There are two alternatives to satisfy this requirement: select an S7 address w512 select a partial PA value w0 7-12 IP244 C79000-B8576-C866-01 3 FC 162 PER_TREG (for Temperature Control) Contents of this Chapter Chapter overview IP244 C79000-B8576-C866-01 This Chapter describes the FC 182 (PER_TREG) function, lists its technical specifications and the allocation of the necessary data blocks, and gives a programming example to explains the utilization of the function. Chapter tells you on page 3.1 Overview 7-14 3.2 Temperature control block 7-15 3.3 Programming example 7-24 7-13 FC162 3.1 Overview Introduction This document is a supplement to Chapter 4 of the Device Manual. It describes the standard block of the IP 244 temperature control module for SIMATIC S7-400. The IP 244 temperature control module can be used through the adapter casing in the SIMATIC S7-400 automation system or through the IM 463-2 and IM 314 interface modules in the S5 extension unit. There is a new standard block for this purpose that is executable in the CPUs of the S7-400 automation system. Software delivery form The standard function is delivered on a diskette in the form of a SETUP. The SETUP is only executable under Windows 95; it requires an installed STEP 7. When SETUP is executed, a library, that only contains the standard function for the IP 244, and a programming example are created. An on line hep is provided for the standard function. 7-14 IP244 C79000-B8576-C866-01 FC162 3.2 Temperature Control Block Function FC 162 (PER_TREG) Introduction Invocation, meaning and parameter assignments of the FC 162 function are discussed below. Invoking the function STL representation LAD representation FC 162 EN BGAD DBNR BEF T_NR ANST Explanation of the parameters Name Type ENO NEUA PAFE AFEH BFEH SFEH KANR FMLD CALL FC 162 ( BGAD := , DBNR := , BEF := , T_NR := , NEUA := , PAFE := , AFEH := , BFEH := , SFEH := , KANR := , FMLD := , ANST := ); The table below gives an overview of the parameters required by the FC 162 function. Data type Meaning BGAD INPUT INT Module address DBNR INPUT INT Data block number BEF INPUT WORD Command to be executed T_NR INPUT BYTE Message frame number NEUA OUTPUT BOOL Request for restart from the module PAFE OUTPUT BOOL Parameter setting error AFEH OUTPUT BOOL Scan error BFEH OUTPUT BOOL Module fault SFEH OUTPUT BOOL Common fault KANR OUTPUT BYTE Number of the faulty channel FMLD OUTPUT WORD Error bytes of the faulty channel ANST IN_OUT BOOL Trigger Parameter assignments DBNR: INT = x x = depends on the CPU (number 0 is not permitted) BEF: WORD = B#(i,j) The following table shows the allocation of the BEF parameter. IP244 C79000-B8576-C866-01 7-15 FC162 Command Meaning possible message frame numbers B#(0,1) KS - cold restart (only during startup) - B#(0,2) PA - setting parameters during startup - B#(0,4) S1 - changeover to setpoint 1 - B#(0,5) S2 - changeover to setpoint 2 - B#(0,6) T1 - no controller shutdown when out of tolerance - B#(0,7) T2 - controller shutdown when out of tolerance - B#(0,8) G1 - no output of averaged manipulated variable - B#(0,9) G2 - output of averaged manipulated variable - B#(1,1) AS - modify setpoint values 0 ... 15 B#(1,2) AE - modify parameters 0 ... 15 B#(2,1) LE - read controller-related data 0 ... 12 B#(2,2) AB - changeover to automatic mode 0 ... 12 B#(2,3) HB - changeover to manual mode 0 ... 12 B#(3,1) IW - read actual value 17 ... 21 B#(4,1) SE - start/stop automatic setting 0 ... 12 ANST: BOOL: The execution of the command is triggered when the ANST parameter is set to '1'. The FC162 function resets the parameter after the command has been executed or a parameter setting error has occurred. PAFE: BOOL: Illgal parameter setting causes the PAFE parameter to be set to '1'. The detected error can be read as an error number in the DBB 31 data byte of the DA-A data block. Exception: Only the PAFE parameter is set to '1' if an illegal or non-existing data block has been specified. There is no additional fault information in this case. 7-16 IP244 C79000-B8576-C866-01 FC162 The following table shows the decimal error numbers (DB-A, DBB 31) and their meanings. Error number Meaning 1 Incorrect firmware 4 Module address no multiple of 32 7 DB-B cannot be found; is too short; is write-protected; or is not sequence-relevant 8 DB-C cannot be found; is too short; is write-protected; or is not sequence-relevant 9 Illegal command 10 Invalid message frame number (T_NR) 11 DB no. DB-A' not permitted 12 DB-A' cannot be found; is too short; is write-protected; or is not sequence-relevant 13 DB-C' cannot be found; is too short; is write-protected; or is not sequence-relevant 14 The command 'LE' or 'automatic reading after automatic setting' has been selected in the FC 162, but has not been enabled on the IP 244 (i.e. bit 2 of master control byte 1 is currently '0'). 15 Automatic setting in progress, module access is therefore not possible at the moment (for the commands PA, S1, S2, AS, AE, AB, or HB). 16 Time-out during cold restart 17 IP 244 time-out 23 DB no. DB-B not permitted 24 DB no. DB-C not permitted 25 DB no. DB-C' not permitted The assignments of the other parameters are explained in the Device Manual (Register 5, Chapter 3.1 "Invoking the Funktion Block"). Assigning local variables to parameters is not permitted. IP244 C79000-B8576-C866-01 7-17 FC162 Deviation from SIMATIC S5 There is the following deviation from SIMATIC S5: Direct/indirect addressing: Distinction between direct and indirect addressing is no longer necessary in SIMATIC S7. Constants and operand areas can both be specified in the parameters. The ADRA parameter has therefore been omitted, and the areas for command, message frame number, module address, DB number for DB-a, and addressing type no longer exist. ANST: In contrast to SIMATIC S5, the ANST parameter must be set to '1' in direct and in indirect parameter setting in order to trigger the execution of a command. BEF: The parameter BEF is an input parameter. The FC 162 function does not clear this parameter after the command has been executed. Error number for PAFE: The PAFE parameter is set to '1' if the FC 162 detects an error. With the S5 bock, the additional error information is stored in flag byte MB 255. With the S7 bock, the additional error information is stored in data byte DBB 31 of the data block DB-A. Exception: Only the PAFE parameter is set to '1' if an illegal or non-existing DB-A data block has been specified. There is no additional error information in this case. The FC 162 does not clear the DBB 31 data byte. This means that an error number remains in the DB-A until it is overwritten by a new one. 7-18 IP244 C79000-B8576-C866-01 FC162 Specifications The following table lists the technical specifications of the FC 162: FC 162 Block number 162 Block name PER_TREG Version 1.0 Assignments in the data area DB-A: DBB 0 ... DBB 511 DB-B: DBB 0 ... DBB 407 DB-C: DBB 0 ... DBB 447 DB-A': DBB 0 ... DBB 447 DB-C': DBB 0 ... DBB 447 Assignments in the local data area 26 bytes Assignments in the flag area Flags are not used Invoked system functions SFC 24 TEST_DB SFC 47 WAIT SFC 49 LGC_GADR Execution time The following table lists the executon time values of the FC 162. They are valid for the CPU 416-1. FC 162 PA AE first invocation 8 ms second invocation 4 ms first invocation 4 ms second invocation 4 ms S1/S2, T1/T2, G1/G2 4 ms AS, AB, HB, SE 4 ms LE 4 ms IW 4 ms Read with error no additional time Idling 4 ms IP244 C79000-B8576-C866-01 7-19 FC162 Allocation of the Data Blocks Introduction In SIMATIC S7, the addresses of the data operands are always counted by bytes. The address of an S5 data word (DW n) corresponds to the address DBW (2*n) of the S7 data word. The data block allocation has been retained as far as possible. Sole deviation from S5: In SIMATIC S7, indirect addressing can directly be done via the block parameters. Consequently, the corresponding allocation in the work area of the DB-A data block is no longer necessary. 7-20 IP244 C79000-B8576-C866-01 FC162 Allocation of DB-A and DB-A' Data word DBW 0 DBW 2 DBW 4 DBW 6 ... DBW 10 The following table shows the allocation of DB-A and DB-A' (the shaded areas are allocated by the standard block): Allocation Data word DBW 128 ... DBW 158 Message g frame 3: DBW 160 ... DBW 190 Message frame 4: -, Direct functions DBW 12 DBW 14 DBW 16 DBW 18 DBW 20 DBW 22 DBW 24 DBW 26 DBW 28 DBW 30 DBW 32 DBW 34 DBW 36 DBW 38 DBW 40 DBW 42 DBW 44 DBW 46 DBW 48 DBW 50 DBW 52 DBW 54 DBW 56 DBW 58 DBW 60 DBW 62 -, Software switch Number of the DB-A' Number of the DB-C' Allocation DBW 192 ... DBW 222 Data for closed-loop controller 3 Data for closed-loop controller 4 Message g frame 5: Data for closed closed-loop loop controller 5 DBW 224 ... DBW 254 Message g frame 6: Number of the DB-B Number of the DB-C DBW 256 ... DBW 286 Message g frame 7: -, Error byte (with PAFE = 1) Message frame 0: Setpoint 1 Tolerance 1 Setpoint 2 Tolerance 2 Control bytes 1 and 2 Manual manipulated variable; limit Weighting factor Sampling time TA Gain KR Integral-action time TN Derivative action time TD Automatic setting parameter Upper zone limit, setpoint Lower zone limit Heating/cooling ratio, sensitivity Min. step height, message frame no. DBW 288 ... DBW 318 Message g frame 8: DBW 320 ... DBW 350 Message g frame 9: DBW 352 ... DBW 382 Message g frame 10: DBW 384 ... DBW 414 Message g frame 11: DBW 416 ... DBW 446 Message g frame 12: DBW 448 ... DBW 478 4 8 Message g frame 13: 1) DBW 64 ... DBW 94 Message frame 1: DBW 480 ... DBW 510 Message frame 14: 1) DBW 96 ... DBW 126 Message frame 2: 1) Message Data for closed-loop controller 1 Data for closed closed-loop loop controller 6 Data for closed closed-loop loop controller 7 Data for closed-loop p controller 8 Data for closed closed-loop loop controller 9 Data for closed closed-loop loop controller 10 Data for closed closed-loop loop controller 11 Data for closed closed-loop loop controller 12 Daten fur Kanal 13 Daten fur Kanal 14 Data for closed-loop controller 2 frames 13 and 14 do not exist in DB-A'. IP244 C79000-B8576-C866-01 7-21 FC162 Allocation of DB-B The following table shows the allocation of DB-B (the shaded areas are allocated by the standard block): Data word Allocation DBW 0 ... DBW 30 DBW 32 ... DBW 62 Message frame 15: DBW 64 ... DBW 94 Message frame 16: DBW 96 ... DBW 126 Message frame 17: DBW 128 ... DBW 158 Message frame 18: DBW 160 ... DBW 190 Message frame 19: DBW 192 ... DBW 222 Message frame 20: 7-22 Master control bytes, general-purpose parameters Status information, error messages Actual values Manipulated variables Minimum values Data word Allocation DBW 224 ... DBW 254 Message frame 21: DBW 256 ... DBW 284 Message frame 22: DBW 286 ... DBW 314 Message frame 23: DBW 316 ... DBW 344 Message frame 24: DBW 346 ... DBW 374 Message frame 25: DBW 376 ... DBW 406 Message frame 46: Collective setpoints (in cascaded control) Curve values 1 ... 15, channel 13 Curve values 16 ... 30, channel 13 Curve values 31 ... 45, channel 13 Curve values 46 ... 60, channel 13 Error messages, closed-loop controllers 0 ... 12 Maximum values IP244 C79000-B8576-C866-01 FC162 Allocation of DB-C and DB-C' Data word DBW 0 ... DBW 30 DBW 32 The following table shows the allocation of DB-C and DB-C': Allocation Data word Allocation DBW 160 ... DBW 190 Message frame 34: - free - Message frame 30: Normalization of actual value DBW 192 ... DBW 222 Message frame 35: DBW 224 ... DBW 254 Message frame 36: DBW 256 ... DBW 286 Message frame 37: DBW 288 ... DBW 318 Message frame 38: DBW 320 ... DBW 350 Message frame 39: DBW 352 ... DBW 382 Message frame 40: DBW 384 ... DBW 414 Message frame 41: DBW 416 ... DBW 446 Message frame 42: DBW 34 Minimum temperature difference DBW 36 - DBW 38 Maximum gradient for heating DBW 40 Delay for heating DBW 42 - DBW 44 - DBW 46 Sampling time for cooling DBW 48 Gain for cooling DBW 50 Integral-action time for cooling DBW 52 Derivative-action time for cooling DBW 54 Amount of gradient for cooling DBW 56 Delay for cooling DBW 58 - DBW 60 - DBW 62 Message frame number DBW 64 ... DBW 94 Message frame 31: DBW 96 ... DBW 126 Message frame 32: DBW 128 ... DBW 158 Message frame 33: Data for closed-loop controller 4 Data for closed loop controller 5 closed-loop Data for closed-loop controller 6 Data for closed-loop controller 7 Data for closed-loop controller 8 Data for closed-loop controller 9 Data for closed-loop controller 10 Data for closed-loop controller 1 Data for closed-loop controller 2 Data for closed-loop controller 3 IP244 C79000-B8576-C866-01 Data for closed-loop controller 11 Data for closed-loop controller 12 7-23 FC162 3.3 Programming Example Comments on the test program Introduction The selected example shows how the parameter assignments of a module could look like. Modes The example with indirect parameter assignment covers all possible modes (i.e. the entire instruction set). The example of direct parameter assignment, however, is limited to the following modes: Command Data blocks Message frame number B#(0,2) Parameter setting - B#(3,1) Read actual value 17 B#(2,1) Read controller parameters 0 B#(1,2) Modify controller parameters 0 B#(1,1) Modify setpoints 0 B#(2,2) Changeover to automatic mode 0 B#(2,3) Changeover to manual mode 0 B#(0,4) Changeover to setpoint 1 0 B#(0,5) Changeover to setpoint 2 0 All data blocks that are necessary for accommodating the data exist and have been established. The example employs data blocks of the following names: DB-A DB 162 DB-B DB 163 DB-C DB 164 DB-A' DB 172 DB-C' DB 173 The FC 62 function in the test program uses direct parameter setting; FC 63 uses indirect parameter setting. In indirect parameter setting, flag words or flag bytes are specified at the input parameters of the FC 162. The B#(0,1) (cold restart) resets the parameters upon a restart. A warm restart is not permitted. The CPU branches to STOP mode in this case. 7-24 IP244 C79000-B8576-C866-01 FC162 Hardware Requirements Introduction The example is based on the hardware shown in Fig. 2-1. It executes on any equivalent hardware basis. Power supply unit CPU 416-1 Input module Output module IP 244 in the adapter casing Bild 2-1 Settings on the IP 244 module Hardware structure required for the programming example The module has been set to address '0' in the P area. Address switch A76 (D = depressed): 8 7 6 5 4 3 2 1 off on Address switch A77 (D = depressed): 8 IP244 C79000-B8576-C866-01 7 6 5 4 3 2 1 off on 7-25 FC162 Setting the addresses for the CPU 416 When you configure the hardware, you must set the addresses of the I/O modules and the adapter casing via STEP 7. The examples assumes that the following selections have been made: I/O modules: S7 address: 4 Length: 4 bytes Adapter casing: 7-26 S7 address: 512 S5 address: 0 (I/O area: P) Length: 32 bytes IP244 C79000-B8576-C866-01 FC162 Signal Assignments for the Test Program Introduction The program has been designed such that it can easily be adapted to different input and output addresses. The programming example only uses flags. In the OB 1 and OB 100 organization blocks, these flags are assigned to the employed inputs and outputs. In the example these are the input bytes 4 through 7 and the output bytes 4 through 7. Digital inputs The following tables show the signal assignments of the digital inputs. Signal Name Meaning E 4.0 PA Set parameters E 4.1 IW Read actual values E 4.2 LE Read the parameters of one closed-loop controller E 4.3 AE Modify the parameters of one closed-loop controller E 4.4 AS Modify the setpoints of one closed-loop controller E 4.5 AB Changeover to automatic mode E 4.6 HB Changeover to manual mode E 4.7 S1 Setpoint changeover to setpoint 1 Signal Name Meaning E 5.0 S2 Setpoint changeover to setpoint 2 E 5.1 T1 No controller shutdown when the value is out of the 2nd tolerance 1) E 5.2 T2 Controller shutdown when the value is out of the 2nd tolerance 1) E 5.3 G1 Do not output averaged manipulated variable 1) E 5.4 G2 Output averaged manipulated variable 1) E 5.5 Read curve values channel 13 (direct function) 1) E 5.6 Read curve values channel 13 (direct function) 1) E 5.7 End machine cycle (direct function) 1) 1) In the test program, these functions can only be selected with indirect parameter setting. IP244 C79000-B8576-C866-01 7-27 FC162 Signal Name Meaning E 6.0 Closed-loop controller number as a dual number E 6.1 E 6.2 T_NR (E 6.0 6 0 --> 20, E 6.4 6 4 --> 24) E 6.3 E 6.4 E 6.5 free E 6.6 free E 6.7 free Signal Name Meaning E 7.0 Parameter setting method (0: indirect parameter setting, 1: direct parameter setting) E 7.1 free E 7.2 free E 7.3 free E 7.4 free E 7.5 SE Start/stop automatic setting 1) E 7.6 free E 7.7 Clear error number (PAFE) 1) In the test program, these functions can only be selected with indirect parame- ter setting. Digital outputs The following tables show the signal assignments of the digital outputs. Signal Name Meaning A 4.0 NEUA Request new parameters A 4.1 AFEH Sampling time-out on the module A 4.2 BFEH Module fault (watchdog) A 4.3 SFEH Group fault A 4.4 A 4.5 A 4.6 N b off th Number the ffaulty lt channel h l KANR (A 44.4 4 --> > 20, A 4.7 4 7 --> > 23) A 4.7 7-28 IP244 C79000-B8576-C866-01 FC162 Signal Name AW 5 FMLD Signal Meaning Error message for the channel specified under KANR Name A 7.0 PAFE A 7.1 frei A 7.2 frei Meaning Incorrect parameter setting A 7.3 No. of parameter setting error (<--> DB-A, DB X 31.0 through 31.4) 31 4) as a dual number ((A 7.3 7 3 --> > 20, A 7.7 7 7 --> > 24) A 7.4 A 7.5 A 7.6 A 7.7 Allocation of the flag area The following table shows the allocation of the flag area. Flag M 0.0 "VKE 0" M 0.1 "VKE 1" MB 4 Corresponds to EB 4 MB 5 Corresponds to EB 5 MB 6 Corresponds to EB 6 MB 7 Corresponds to EB 7 MB 8 Corresponds to AB 4 MB 9 Corresponds to AB 5 MB 10 Corresponds to AB 6 MB 11 Corresponds to AB 7 M 15.0 Edge flag for parameter setting errors M 15.1 One-shot flag for parameter setting errors MW 20 Old value of EW 4 MW 22 One-shot flag for EW 4 (edge interpretation) MB 24 Channel number M 25.0 Old value of E 7.5 M 26.0 One-shot flag for E 7.5 (edge flag) MW 40 BGAD with indirect parameter setting of the FC 162 MW 42 DBNR with indirect parameter setting of the FC 162 MW 44 BEF with indirect parameter setting of the FC 162 MB 46 T_NR with indirect parameter setting of the FC 162 M IP244 C79000-B8576-C866-01 Allocation 48.0 Trigger flag with indirect parameter setting of the FC 162 7-29 FC162 Employed code blocks The following table shows the names of the employed code blocks. Block OB 1 cyclic program execution OB 35 watchdog alarm processing OB 40 Process alarm processing OB 100 Restart FC 62 direct parameter setting of the FC 162 FC 63 indirect parameter setting of the FC 162 FC 7-30 is used for ... 162 Standard block for the IP 244 temperature control module IP244 C79000-B8576-C866-01 FC162 Utilization of the Test Program Handling steps Proceed as follows when you use the test program: 1. You can load the entire file for the test program in the CPU after an overall reset of the CPU has been performed. 2. Next, assign the values for variables and parameters to the message frames T no. 0..14 in DB 162, T no. 15 in DB 163 and T no. 30..42 in DB 164. Enter '0' for the setpoint in DBW n+0 of unused controller channels. In addition, you must select the controller type (two-step/three-step controller) in the control byte 1 (DBB n+8). 3. Once you have pre-assigned all above-mentioned message frames, you may trigger a restart. The RUN LED 'R' at the top left of the front panel lights up to indicate that the module parameters have been set. 4. The individual functions are now accessible via the inputs E 4.0 through E 5.7 and E 7.5. 5. Select the required parameter setting method via input E 7.0. If a parameter setting error occurs during the execution of the test program, the error number will remain after the fault has been eliminated until it is cleared via input E 7.7. Note The test program uses indirect parameter setting in the OB 100 startup organization block. In cyclic operation, the parameter setting method can be changed via input E 7.0. If a parameter setting error with an error number 1 through 8, 17 or 23 through 26 occurs during execution of the FC 182, a cold restart must be performed after the fault has been eliminated. IP244 C79000-B8576-C866-01 7-31 FC162 Structured Charts of the Organization Blocks Cyclic program execution (OB 1) Transfer inputs in flag area ED 4 --> MD 4 Flag 7.7 = '1'? Yes No / Clear Parameter setting error number (A 11.3 through A 11.7) Flag 7.0 = '1'? Yes No Direct parameter setting --> FC 62 Indirect parameter setting --> FC 63 Flag bytes 8 ... 11 --> copy output bytes 4 ... 7 Rising edge at PAFE bit ? Yes No Update flags M 11.3 through M 11.7 / END Alarm OBs (OB 35, OB 40) Process alarm and time alarm OBs - free for application program - END Restart OB (OB 100) M 0.0 = VKE '0' M 0.1 = VKE '1' FC 162 invocation with the command KS - free for application program upon restart - END 7-32 IP244 C79000-B8576-C866-01 FC162 Structured charts of the FC 62 and FC 63 functions The FC 62 function shows the utilization of the FC 162 with direct parameter setting. Structured chart of FC 62: Network 1: Parameter Network 2: Edge evaluation of flag word MW 4 (<--> EW 4) Network 3 Any more jobs executing at the moment? (ANST = '1' ?) No Yes Check flag from MW 4 for rising edge x = XX y=0 M 4.0 x = PA M 4.1 y=0 x = IW M4.2 x = LE M 4.3 y=0 x = AE M 4.4 y=0 x = AS M 4.5 y=0 x = AB M 4.6 y=0 x = HB M 4.7 y=0 x = S1 M 5.0 y=0 x = S2 y=0 FC 162 invocation according to command BGAD DBNR BEF T_NR NEUA PAFE AFEH BFEH SFEH KANR FMLD ANST CALL FC 162( := +512, := +160, := B#(x), := B#16#y, := M 8.0, := M 11.0, := M 8.1, := M 8.2, := M 8.3, := MB 24, := MW 9); := M 2.0, Network 4: Channel number --> M 8.4 through M 8.7 END IP244 C79000-B8576-C866-01 7-33 FC162 The FC 62 function shows the utilization of the FC 162 with direct parameter setting. Structured chart of FC 63: Network 1: Parameter Invocation of the data block with set parameters Network 2: Edge evaluation of flag word MW 4 (<--> EW 4) Edge evaluation of flag M 7.5 (<--> E 7.5) Network 3 Any more jobs executing at the moment? (ANST = '1'?) No Yes Check flags from MW 4 and M 7.5 for rising edge / Formulate job (see below) Network 4: Invocation of the FC 162 BGAD DBNR BEF T_NR NEUA PAFE AFEH BFEH SFEH KANR FMLD ANST CALL FC 162( := MW 40, := MW 42, := MW 44, := MB 46, := M 8.0, := M 11.0, := M 8.1, := M 8.2, := M 8.3, := MB 24, := MW 9); := M 2.0, Network 5: Channel number --> M 8.4 through M 8.7 Network 6: END 7-34 IP244 C79000-B8576-C866-01 FC162 Network 3 Check flags from MW 4 and M 7.5 for rising edge M4.0 x= PA M4.1 x= IW M4.2 x= LE M4.3 x= AE M4.4 x= AS M4.5 x= AB M4.6 x= HB M4.7 x= S1 M5.0 x= S2 M5.1 x= T1 M5.2 x= T2 M5.3 x= G1 M5.4 x= G2 M7.5 x= SE / Rising edge at flag M 5.5? Yes No Set 'read channel 13 curve values' bit: DBX 5.0 / Rising edge at flag M 5.6? Yes No Set 'read actual value of channel 13' bit: DBX 5.2 / Rising edge at flag M 5.7? Yes No Set 'end of machine cycle' bit: DBX 5.7 / Enter message frame number in MB 46 IP244 C79000-B8576-C866-01 7-35 FC162 7-36 IP244 C79000-B8576-C866-01 SIMATIC S5 IP 244 Temperature Controller with Function Block FB 162 6ES52443AA22 and 3AB31 Checklist for StartUp C79000B8576C86302 Checklist for Start-Up 8-2 IP244 C79000-B8576-C863-02 Checklist for Start-Up Checklist for Start-Up When installing and starting up the temperature controller module, the following instructions regarding hardware and software must be adhered to. All the points must be checked step by step in the order in which they occur below. If errors or faults occur, the checklist should prove helpful in excluding user errors. a) Hardware - Read the operating instructions thoroughly. - Decide on the PLC and slot in the PLC for the IP 244. - Select the module address within the system concept. - Set the module address and jumpers for PESP (see Operating Instructions, switches A76, 77). - Select the conversion time and clock setting and insert the jumpers (see Operating Instructions, Section 3.4). - Connect the digital inputs and outputs to socket connector X4. Take care with the pins of subminiature D connectors (use the preassembled connecting cable 6ES5 721-4xxx0). - Connect the analog signals to plug connector X3. Only use shielded cables (use preassembled connecting cable 6ES5 721-5xxx0). - Short circuit unused analog inputs and connect them to reference potential. - Connect shields to shielding bars at cabinet reference potential inside the cabinet. - Floating sensors (isolated thermocouples) must be connected at one end with the reference potential (common mode voltage between analog input and reference potential maximum 1 Vpp). - For Pt 100 operation, connect the Pt 100 element using four wires (shielded cable). - For Pt 100 operation, change the jumper setting as described in Part 2. - Connect the Pt 100 element to plug connector X3 (pin assignment see Operating Instructions, Section 2.2.1). - Establish thermal contact between the Pt 100 and the terminals of the thermocouples. Note the air flow within the cabinet. The Pt 100 element should not be blown by fans. - Connect L+ to connector X5. - Insert the module and switch on the PLC. IP244 C79000-B8576-C863-02 8-3 Checklist for Start-Up ! WARNING The temperature controller module IP 244 may only be inserted in batterybacked slots. If the module is used in slots without battery backup, undefined statuses may occur on the module. The permitted slots are shown in the following tables: S5-115U and expansion units: CR700-OLA PS CPU 0 1 2 CR700-OLB PS CPU 00 00 1 1 2 CR700-1 PS CPU 0 0 1 2 3 4 5 6 IM CR700-2 PS CPU 0 1 2 3 3 4 4 5 6 IM CR700-3 PS CPU 3 3 4 4 5 ER701-1 0 1 2 3 4 5 6 7 8 IM ER701-2 PS 0 1 2 3 4 5 6 7 IM ER701-3 PS 0 1 2 3 4 5 6 7 IM 0 8-4 0 0 0 1 2 2 00 00 11 11 22 22 1 2 3 3 3 3 4 IM IM 5 5 5 6 6 6 IM Can be used IP244 C79000-B8576-C863-02 Checklist for Start-Up S5-135U, S5-155U and expansion units: Slots 3 11 19 27 35 43 51 59 67 75 83 91 99 107 115 123 131 139 147 155 163 CC 135U CC 155U EG 183U EG 184U EG 185U EG 186U EG 187U Can be used IP244 C79000-B8576-C863-02 Can only be inserted after changing the jumper settings on the bus board 8-5 Checklist for Start-Up b) Software - Connect the programmer to the processor of the programmable controller. - Load function block FB 162 (control temperature controller) from diskette into the PLC. - Install data blocks for FB 162 and assign token values. - Enter the parameters (see Programming Instructions IP 244) in the data block (see Programming Instructions FB 162). The following points should be noted when selecting parameters: selection of sensor types selection of 2 or 3-point controllers controllers with or without self-tuning function cascaded control or normal control - Save the data blocks on diskette and transfer them to the PLC. - Install the FB 162 call in the user program. The function block FB 162 (control temperature controller) may only be called once in the user program (OB 1) per temperature controller module. - Using the STEP 5 program, the appropriate input and output variables must be made available and processed for FB 162. At this point, the test program (in Part 5 of the manual) can be loaded in the PLC to operate the temperature controller module. The test program or data blocks can then be modified to suit the application. - Using FB 162, transfer the parameters to the temperature controller module. The "cold restart" function must only be used in organization blocks OB 20, OB 21 and OB 22 (see Programming Instructions for FB 162). - The function "assign parameters" in the cycle must be initiated with the command "PA". - Check the indicated actual value. Are there discrepancies compared with measurements made with other devices? check whether the correct sensor type has been set in the parameters check the thermocouple for correct Mext connection ! WARNING If the selected sensor type does not match the sensor actually connected, dangerous situations may occur. E.g. FeConstantan thermocouple selected, Pt10%RhPt thermocouple connected actual value constantly interpreted as being too low and controller heats higher than permitted. - Check the functions of the controller, monitor the switching of the outputs. - Transfer setpoint changes with the command "AS". Following this, the lower setpoint can be activated. 8-6 IP244 C79000-B8576-C863-02 Checklist for Start-Up - Start the self-tuning function or correct and optimize parameters (see Programming Instructions for FB 244, FB 162). If the self-tuning function does not determine any parameters, check the minimum requirements of the controlled system and the setpoint step. - Store corrections - Operation c) Checking the back-up of the RAM chip (This note is only for servicing and is not required for normal operation) "Test code" to read out the back-up identifier and the CMOS test pattern (valid from module 21 onwards). DB - A: DW 245 DW 246 KY = X,25 KH = 1FF0 Transfer the codes with the command "KS", "PA", "AE (controller 14)" or "AS (controller 14)". In addition to this, at least one controller must have a sampling time longer than the minimum possible sampling time on the IP. Result: The result is entered in DB-C with the command "IW (message 21)" DB-B: DW 112 DW 113 DW 114 DW 115 DW 116 KH: KH: KH: KH: KH: back-up identifier copy of the 1st test pattern copy of the 2nd test pattern copy of the 3rd test pattern copy of the 4th test pattern Explanation: If PLC requests a cold restart, the back-up identifier is 2222. Every 50 to 80 ms a check is carried out to make sure that the CMOS test pattern is still OK. If the pattern is not OK, the identifier is set to CCCC. Otherwise, the identifier is only updated after power up. It may be 0000 briefly, otherwise, it is 1111 if there is no error. If the test patterns are not OK after power up, the identifier is set to 5555; if the Ubatt scan following power up is incorrect, the identifier is AAAA. Copies of the four test patterns as they were when the power was switched on are indicated in DW 113 to DW 116 of DB-B. IP244 C79000-B8576-C863-02 8-7 Checklist for Start-Up 8-8 IP244 C79000-B8576-C863-02 SIMATIC S5 IP 244 Temperature Controller 6ES52443AA22 and 3AB31 Glossary C79000Y8576C85802 Glossary 9-2 IP244 C79000-Y8576-C858-02 Glossary Glossary ADC Analog-to-digital converter Approach manipulated variable YAS Selectable value of manipulated variable with which a controller influences the control system during the first start-up phase in "Hot Channel Operation" Approach setpoint WA Setpoint which is controlled by a controller during approach time TAZ in "Hot Channel Operation". Approach time TAZ Selectable period of time during which a controller controls the approach setpoint WA in "Hot Channel Operation". Approach zone ZA The approach zone defines the control variable range (below the approach setpoint) in which the controller controls the approach setpoint. Automatic operation The controller processes and calculates the manipulated variable (control loop closed). Backplane connector Connection to the device bus. Back-up Battery back-up for RAM memory, supplied by the PLC. BASP Inhibit command output: disables digital outputs if the monitoring indicates undervoltage in the load voltage and/or power supply of the central controller. BCD coding Each four bits of a measured value represent a power of ten (thousands, hundreds, tens and units). Cascaded control Connection of controllers in a cascade. The first controller (master controller) either supplies a setpoint to the secondary controllers or influences their setpoints depending on the measured actual value. Clock setting Power supply interference suppression Cold restart Cold restart of the central controller following power failure. The reaction of the programmable controller is programmed in organization blocks OB 20, 21, 22. (See manual for the programmable controller.) In any case, all parameters are transmitted from the PLC to the IP 244 after the module has been switched on. Comparator Device to compare the measured voltage at channel 13 with an internally set reference and to initiate a signal when the reference voltage is exceeded. Compensation channel Measuring channel to connect a Pt 100 for the acquisition of the reference junction temperature when the reference voltage is exceeded. Control algorithm Calculation program stored in the EPROM to simulate a PID controller function. IP244 C79000-Y8576-C858-02 9-3 Glossary Control byte Eight-bit information unit to control channel functions, where each bit is assigned to a different function. Conversion time tw Corresponds to encoding time. Correction profile In cascaded control, the degree of influence of the master controller on the secondary controllers can be selected by means of an evaluation factor separately for each controller. This produces a correction profile. CPKL Central processor ready (CPKL = 1 causes a reset). CPU Central processing unit Cumulative setpoints These are the setpoints actually effective in secondary control loops (in cascaded control). D Derivative action of the controller. Data block DB Data list with values and parameters for the function block. Disturbance response Control reaction to a disturbance in the control system (e.g. change of the load, increase of the through-put etc.). The controller is assigned parameters to quickly compensate the disturbances to achieve a uniform quality. Dual-slope technique Technique for analog-to-digital conversion. The measured voltage is integrated over 20 ms or 16 2/3 ms followed by the downward integration of a reference voltage to zero. The measured voltage is proportional to the duration of the reference integration. Encoding time Period of time between the start and end of an analog-to-digital conversion. EPROM Program memory, contains the controller program of the IP 244; can only be read from. Error byte Eight-bit information unit; each bit is assigned to a particular error (1 = error). Evaluation factor F Determines the amount of influence of the master controller on a certain subsequent controller (in cascaded controls). Firmware Operating program stored on the module in the EPROM. Function block Program module in the SIMATIC S5 programmable controller. Group short circuit indication Red LED, indicates when there is a short circuit at one of the digital outputs. Heating-cooling ratio Ratio (parameter) to compensate for differences in heating and cooling times with 3-step controllers to balance the adjustment response. High byte More significant byte (DL) of a 16-bit data word (DW). Hot channel control Special control action for plastic injection molding machines. 9-4 IP244 C79000-Y8576-C858-02 Glossary I Integral action of the controller. Integration time Duration for measuring the input voltage. Interpolation Determination of intermediate values on the basis of known boundary values of an interval. L+ 24 V connection positive pole (load voltage). L- 24 V connection (reference point). Limitation value This value limits the influence of the master controller on secondary controllers (in cascaded controls). Line break monitoring Monitors breaks in the wires to the temperature sensors (thermocouples or Pt 100) and initiates the change over to a safe operating mode, e.g. by switching over to a stand-by sensor. Low byte Less significant byte (DR) of a 16-bit data word (DW). Lower setpoint Second setpoint, e.g. to allow for a lower temperature control at night. Machine cycle A production cycle (e.g. time required to inject a plastic part). Main control byte 8-bit information unit to control the channel functions on the module. Manipulated variable Y Percentage of the sampling time, obtained from the calculations of the control algorithm (see "Percentage output"). Manual manipulated variable YH Percentage time value for the operating time of the actuator output as value of manipulated variable when the controller is switched off (manual operation). Manual operation The manipulated variable is not calculated by the controller (the controller is switched off), but is specified by the operator or user program as a percentage of the range of the manipulated variable. Master controller See "Cascaded Control". Message Here, a data record (data block) 31 bytes long (for parameters, measured values etc.). Mixed operation Here, simultaneous operation of normal and hot channel controllers. Multiplexer Switch to select and connect an analog input channel to the ADC and the module processor. Operating point The operating point is the required actual value which should remain the same during control operation or whose system deviation should become zero when using P controllers. IP244 C79000-Y8576-C858-02 9-5 Glossary P Proportional action of the controller. Parallel structure Special type of controller structure (here: mathematical technique); P, I and D sections act in parallel and are then added. Parameter Variables used to adapt the controller structure and the controller action to the process. Peripheral (I/O) area Address area for peripheral modules in the programmable controller. Percentage output The output of the calculated manipulated variable (output signal of the controller) as a percentage of the sampling time referring to the approach time (cf. "Pulse Duration Modulation"). PESP Group address signal on the S5 bus to address peripheral modules. PLC Programmable controller Process identification Acquisition of characteristic values of a particular system (characterics of the control system) to optimize the tuning of the controller action. Pt 100 Platinum resistance thermometer (100 Ohms at 0 C according to DIN 43760). Pulse duration modulation See "Percentage Output". RAM Random access memory (working memory); can be read to and from. Ramp slope Here, preset rate of temperature rise per time unit. Reference junction temperature Reference temperature for the thermocouple voltage (see "Thermocouple"). Reference potential Central grounding point of the controller. Response value YA If the manipulated variable is close to 0 or 100%, the short ON and OFF intervals can be suppressed by specifying a parameter (e.g. an ON time for a fan of 100 ms is completely pointless). See Programming Instructions for the IP 244, "messages 0 ... 12". Rugged controller The rugged controller is a PID controller with supplementary characteristics: it has an oscillation detector and a so-called predictor, i.e. the actual value to be expected is calculated in advance, and the controller reacts accordingly "foresightedly". The controller parameters of the rugged controller depend on the operating point and the current system deviation. Sampling controller A controller which processes a new actual value at regular intervals and calculates a new manipulated variable. Sampling time TA Period between two processing cycles of the PID calculation program for one control channel. These periods are constant and selectable within limits. Sampling time overflow The sampling time calculated for the controller can no longer be maintained owing to excessive data exchange. 9-6 IP244 C79000-Y8576-C858-02 Glossary Secondary control loop Secondary control loop, whose setpoint is influenced by a master controller in cascaded control. Self-tuning Based on a mathematical quality criteria, the controller parameters are matched to the existing task automatically to achieve an optimum controller action. Setpoint jump (step) Entry of a new setpoint with a value different from the old setpoint. Setpoint ramping To damp setpoint jumps, the setpoint is not changed suddenly but follows a selectable ramp slope. Setpoints Desired (demanded) process value to be maintained by the controller. Software release Release of the operating program in the EPROM of the module. Special function Special mode which controls the read-in of measured values via the channels 13 and 14 in a way, which makes it possible to acquire series of measured values in curved form (channel 13) and to allocate a measured value from channel 14. Status (byte) Eight-bit information unit; each bit is assigned to a particular error (1 = error). Symmetrical/asymmetrical controlled systems If the measurement equipment (here, thermocouple) is arranged symmetrically to the actuators for the heating or cooling, the controlled system is symmetrical, otherwise it is asymmetrical (e.g. extruder heating with unequally divided heating band and thermocouple between). System deviation xd Difference between the entered setpoint and measured actual value (input variable of the controller). TA Sampling time TD Derivative action time (describes the D action). Temperature compensation When measuring temperatures with thermocouples, the voltage produced by the thermocouple is proportional to the temperature difference between the measuring junction and the reference junction. The temperature compensation value is required to compensate the ambient temperature at the reference junction, to obtain a temperature value related to 0 C. Thermocouple Temperature sensor consisting of two different metals (e.g. iron, constantan); supplies a voltage dependent on the temperature difference between the measuring junction and the reference junction. Three-step controller Controller with two switching contacts as output (heat, off, cool, or right, off, left = three switching statuses). Three-wire connection Method of connecting resistance thermometers to compensate the influence the lead resistances. TN Integral action time (describes the integral action of the controller). Tolerance values Temperature values above and below the required temperature (setpoint). If these tolerances are violated, signals are generated by the control variable so that corrective action can be taken. Transfer RAM Memory on the IP 244; can be written to and read from both by the programmable controller and by the microprocessor on the module. Two-step controller Controller with one switching contact as its output (two switching statuses). IP244 C79000-Y8576-C858-02 9-7 Glossary TZ Filter time for damping the influence of the derivative action. U-batt Back-up voltage at the bus connector of the module to supply the RAM memory if there is a power failure. Watchdog If the operating program of the IP 244 runs normally, a pulse signal is generated. If this signal is not detected, an error has occurred in the program. Wind-up effect If a manipulated variable is calculated which is greater than 100%, the integration (I action) is interrupted to allow the controller to ensure that the controller becomes effective quicker to adapt the control variable to the setpoint. Zone control The controller only operates within the specified control variable range, specified by zone upper and zone lower limits relating to the corresponding setpoint value. If the control variable is out of range, the module operates with the manipulated variable of + 100%, - 100% or 0%. 9-8 IP244 C79000-Y8576-C858-02 Glossary Symbols and abbreviations for variables and values BW Limit value, limits the influence to a secondary setpoint. F Evaluation factor, value for the influence of the master controller. HCR Heating-cooling ratio, parameter for balancing different heating or cooling capacity with three-step controllers. KP Proportional coefficient or gain factor ( = 100/XP ) KS Transfer coefficient (control system) STH Maximum slope when heating STK Maximum slope when cooling TA Sampling time TAK Sampling time when cooling TAZ Approach time Tg Response time (control system) TN Integral action time (describes integral action) TNK Integral action time for cooling TU Delay time (replaces dead time) TUH Delay time when heating TUK Delay time when cooling TV Derivative action time, describes derivative action (also TD ) TVK Derivative action time for cooling TZ Filter time constant for damping the derivative influence W1 Operational setpoint W2 Lower setpoint WA Approach setpoint Xd System deviation (system difference) XP Proportional band ( = 1/KP ) XPK Proportional band for cooling Y Manipulated variable YH Manual manipulated variable YA Response value YAS Approach manipulated variable ZA Approach zone ZONOB Zone upper limit, no control above it, manipulated variable at end or start of area. ZONUN Zone lower limit, no control below it, manipulated variable at start or end of area. IP244 C79000-Y8576-C858-02 9-9 Glossary 9-10 IP244 C79000-Y8576-C858-02 SIMATIC S5 IP 244 Temperature Controller 6ES52443AA22 and 3AB31 Index C79000S8576C85802 Index 10-2 IP244 C79000-S8576-C858-02 Index Index A Acquisition duration 4-39, 40 Actual current (heating current) 4-93, 97 ff Actual temperature 4-61 Actual value indication 4-8 Actual value normalization 4-67, 68 Actual value processing 4-7 Actual voltage (heating current) 4-88, 95 Address area 4-23 Address coding 2-29, 3-25 ADC sensitivity 2-25 Ambient conditions 3-10 Analog-digital converter 2-5, 3-5 Analog inputs (connection) 2-19, 3-19 Approach manipulated variable 4-39, 40, 74 Approach phase 4-55, 58, 73 Approach setpoint 4-39, 40, 74 Approach zone 4-39, 40, 73 Assign parameters (BEF: PA) 5-9 Automatic operation (BEF: AB) 5-10 Averaging 4-8 B BASP evaluation 2-34 BASP interpretation 3-29 BCD coding 4-8 C Calling the function block 5-7, 48 Cascaded control 4-49, 75 Central controller (CPU) 4-23 Channel group error 4-55, 57 Channel number (KANR) 5-13 Characteristic values (temperature controlled system) 4-124 Cold restart 5-48 IP244 C79000-S8576-C858-02 10-3 Index Cold restart (BEF: KS) 5-9 Cold restart request (NEUA) 5-11 Commands (FB 162) 5-9 Comparator 4-15, 104 Comparator channel 2-8, 26 Compensation channel 2-22 Configuration 4-5 Configuration (outputs) 4-8 Connecting cables 2-35, 36, 3-31.32 Control byte 4-25, 27, 28 Control command 2-5, 3-5 Controlled system (characteristics) 4-123 Controlled characteristics (parameter) 4-20, 30, 135, 5-48 Controller group error 4-55, 57 Controller messages (0 to 12) 4-25 Controller/parameter settings 4-123, 135, 141 Controller structure 4-134 Controller type 4-134 Control quality 4-20 Control zone 4-20, 25, 33, 34, 75 Conversion time 2-5, 10, 33, 3-5, 8, 10, 28, 4-103 Conversion value (comparator) 4-104, 110 Cooling parameter 4-21, 32 Cooling power 4-21 Cumulative setpoints 4-66, 77, 78, 82 Current setpoint (heating current) 4-93 D D action 4-130 Data area (assignment) 5-15 Data block 5-5, 15, 48, 49, 50 Data blocks (assignment) 5-16, 17 Data block type 5-8 Data buffer 4-23 Data exchange 4-23, 5-5 Data transfer 2-27, 3-25 Delay time for cooling 4-67 Delay time for heating 4-67, 124 Derivative action time 4-25 10-4 IP244 C79000-S8576-C858-02 Index Derivative action time for cooling 4-67 Description of the firmware 4-5 Differential input 2-19, 3-19 Digital input 2-4, 6, 7, 12, 3-4, 6, 9, 11, 12 Digital output 2-3 ff, 9, 12, 26, 3-3 ff, 9, 12, 24 Digital outputs (image) 4-64, 5-54 ff DIL-switch 2-32 Direct parameter assignment 5-48 Disturbance response 4-20, 133 Dual-slope technique 2-5, 3-5 E Encoding time 2-8 Environmental conditions 2-10 Equalizing cable 2-18, 19 Equipotential connection 3-16, 17 Error bits 4-13 Error byte 4-55, 59, 60, 69 Error number 5-12 Error processing 5-14 Error signal bytes (FMLD) 5-13 Evaluation factor 4-25, 75, 77 Event-driven interrupts 5-56 ff Extreme value acquisition 4-12 Extruder 4-75 F FB 162 5-48 Feedback 4-126, 127 Filter for actual value indication 4-49 Firmware 2-5, 3-5 Full heating power 4-21 Functional description 4-5 Function block 4-14, 5-3, 5, 48, 49, 50 Fuse 2-29 IP244 C79000-S8576-C858-02 10-5 Index G Gain 4-25 Gain for cooling 4-67 Group error 4-56, 5-13 H Heating bands 4-83 Heating cartridges 4-73 Heating-cooling ratio 4-9, 25, 35 Heating current measurement module 4-83 Heating current monitoring 4-49, 83 ff, 88, 91 Heating current monitoring (messages) 5-35 ff Heating curve 4-68 Heating parameter 4-32 Heating switch 4-9, 28 Hot channel control 4-30, 49, 73 Hot channel control (conversion time) 4-74 Hot channel control (sampling time) 4-74 I Indirect parameter assignment 5-48, 49 Input sensitivity 2-30, 3-26 Input voltage (max. values) 2-7, 9, 3-7, 9 Input wiring 2-21 ff, 3-19 ff Integral action time 4-25 Integral action time for cooling 4-67 Integration time 2-8, 3-8 Interface (PLC-IP) 2-27, 3-24 Interference suppression 2-7 J Jumper D 4-26 Jumpers 2-28 ff, 3-25 ff 10-6 IP244 C79000-S8576-C858-02 Index L Limitation value 4-25, 76, 77 Limiter 4-75, 78 Linearization of characteristic curve 4-28 Line break 2-5, 3-5 Line break monitoring 2-26, 4-7, 13, 59 List of messages 4-24 Lower setpoint 4-25, 26 Low pass response 4-21 M Machine cycle 4-75 Main control bytes 4-39, 41 ff Mains interference suppression 2-34 Mains noise suppression 3-29 Manipulated variable 2-7, 4-7, 62 Manipulated variable processing 4-8, 9 Manual manipulated variable 4-25, 29 Manual operation 4-28 Manual operation (BEF: HB) 5-10 Master controller 4-75 ff, 80 Matching value 4-104 Maximum temperature difference 4-39, 40 Maximum value 4-65 Maximum value for channel 13 4-105 Measured value acquisition/processing 2-6, 3-6 Measured value resolution 2-8, 3-8 Message assignment 5-18 ff Message number 2-27, 3-24, 4-23, 5-11 Metal foil resistors 2-25, 37 Microprocessor 2-6, 3-6 Mini-jumper 2-37, 3-33 Minimum temperature difference 4-67, 68 Minimum value 4-63 Mixed operation 4-41 Module address 2-29, 32, 5-8, 3-25, 27 Module error (BFEH) 5-12 Module number 4-15, 55 IP244 C79000-S8576-C858-02 10-7 Index Monitoring time 4-39, 40 Multiplexer 2-5, 3-5 Multiprocessor operation 5-56 N Noise suppression 3-7 Normalization (channel 13/14) 4-104, 105 Normalization factor 4-39, 40, 104 Numerical representation 4-50 O ON time (switching device) 4-52 Operating point 4-30, 129 Organization block 5-48 Oscillation detector 4-16, 70 Output configuration 2-13, 3-13 Output driver 2-5, 6, 3-5, 6 P Parameter 2-5, 3-5 Parameter assignment (direct/indirect) 5-8 Parameter assignment error (PAFE) 4-70, 5-11 Parameter monitoring 4-17, 51, 70 Parameters of the function block 5-7 ff Parameter request 4-57 P controller 4-127 PD controller 4-130 Percentage output 2-6, 3-6, 4-8, 9 PI controller 4-131 PID controller 4-6, 132 Pin assignment 2-35, 3-31 Potential difference (permissible) 2-7, 3-7 Power failure during self-tuning phase 5-60 Power supply 2-9, 3-9 Power up IP 244 5-58 Pressure curve 4-105 Process (continuous, batch process) 4-52 Process identification 4-16, 18 10-8 IP244 C79000-S8576-C858-02 Index Programmable controllers 5-3 Proportional band 4-128, 129 Proportional coefficient 4-128, 129 Pt 100 operation 2-24, 3-23 Pulse output 4-5 R Ramp slope 4-33 Rate of rise (of the controlled variable) 4-123 Read data (command) 5-52 Reading curve values 5-52 Reading the actual values (BEF: IW) 5-10 Reference junction compensation 4-7 Reference junction temperature 2-22, 3-21 Reference potential (PAL) 2-13, 19, 3-13 Reservoir head 4-75, 79 Resistance thermometer 2-22, 3-21, 4-8 Resistance-type sensor 2-24, 3-23 Response 4-20, 133 Response curve 4-123, 124 Response threshold 4-10 Response time 4-124 Response value 4-25, 35, 36, 37 Rise when heating (max. value) 4-67 Rugged controller 4-16, 17 S Sampling error (AFEH) 5-12 Sampling time 2-10, 3-10, 4-8, 25, 29, 103 Sampling time overflow 4-56 Screw speed 4-75 Secondary controller 4-81 Self-tuning controller 4-16, 18, 21 Self-tuning function 5-60 ff Self-tuning parameters 4-31, 32 Self-tuning status 4-55, 57 Setpoint processing 4-10 Setpoint ramping 4-10, 25, 28, 33 IP244 C79000-S8576-C858-02 10-9 Index Setpoint switchover 5-9 Setting the clock 2-34, 3-29 Short circuit identifier 4-70, 71 Shunt resistor 2-25 Signal lines 2-11, 3-11 Signalling message 4-55 Slope when cooling (max. values) 4-67 Slots 2-14, 15, 3-14, 15 Software release 4-15, 55 Software switch 5-51 Spare parts 2-37, 3-33 Special function 2-33, 3-28, 4-49, 73, 103, 105, 107 Standard controller 4-41 Start-up procedure (PLC) 5-56 ff Status byte 4-56 Substitute Pt 100 2-26, 4-27 Substitute thermocouple 2-26, 4-27 Switching 4-87 Switching devices 4-87 Switchover setpoint 4-39 System parameter 4-70 System parameters (determination) 4-137, 139 T Temperature compensation 4-8 Temperature control 4-5 Temperature-controlled systems (characteristic values) 4-124 Temperature of the material 4-75, 77, 79 Temperature setpoint 4-26 Temperature setpoint (C/ F) 4-51 Test points 2-30 Thermocouple 2-19 ff, 3-19 ff Three-phase heating system 4-83 Three-step controller 4-20, 27, 126 Time base 4-29 Time-driven interrupt program 5-5 Time-driven interrupts 5-56 ff Tolerance (1st and 2nd) 4-25 ff 10-10 IP244 C79000-S8576-C858-02 Index Tolerance band 4-11, 12 Tolerance evaluation 2-10 Tolerance interpretation 3-10 Transducer 2-21, 3-20 Transient response 4-124, 125 Trigger (ANST) command execution 5-11 Two-step controller 4-20, 27, 124, 126 Type of addressing 5-8 U User program (cyclic) 5-5, 56 ff V Voltage channels (13/14) 4-15, 38 Voltage divider 2-21, 25, 3-20, 23 Voltage monitoring 4-14 Voltage setpoint (heating current) 4-95 W Watchdog 4-14 Wiring 2-15, 3-15 Z Zone control 4-28, 33, 34, 75 Zone setpoint 4-75 Zone wall control 4-75 ZONOB/ZONUN 4-33, 34 IP244 C79000-S8576-C858-02 10-11 Index 10-12 IP244 C79000-S8576-C858-02