MLC 9000 Bus Compatible PID

Transcription

1 MLC 9000 Bus Compatible PID Modbus, DeviceNet, Profibus Compatable The MLC 9000 is a unique, stand alone PID control solution to use instead of discrete DIN controllers. Reduce Wiring Costs Clean up the panel Simplified Interface, Fewer buttons to push Maintain Single Loop Integrity The MLC 9000 simplifies single loop control by providing a single user interface with access to all control loops. The cost of installation is dramatically reduced by eliminating wiring, reducing the number of holes that have to be cut into the panel, and reducing the overall panel size. Configuration is accomp lished via a windows based software program eliminating the need to configure each controller individually and allowing programs to be saved in simple recipe files. This ensures the integrity of all control loops by making sure that multiple configurations are loaded identically, accurately and quickly. A higher level of configuration security can be maintained by eliminating configuration interfaces and reducing operator access to sensitive configuration parameters. Although the system is a multi-loop platform, the unique architecture allows the system to maintain single loop integrity while offering "hot swap" and auto-configuration capability for each loop. The MLC 9000 System... is a complete PID control system with individual controllers connected together via an internal communications bus. Controllers use advanced PID, self tuning and Fuzzy Logic algorithms to provide tight control of system PID loops. The MLC system can communicate with other devices via various industrial communications protocols. BCM - The Bus Communication Module... contains an on board microprocessor to handle all system and network communications for the individual controllers. The BCM also stores a backup copy of the configurations for each individual controller module. When an individual controller module is changed, this backup copy is automatically downloaded to the new unit. Industry standard protocols such as DeviceNet, Profibus and MODBUS are available to allow transfer of PID control and process data from the individual controllers to other external devices. Up to 32 BCM units can be connected together via a two wire system.

2 LCM -The Loop Controller Module... is an independent PID controller. There can be up to 8 LCM s per BCM Module. By daisy chaining BCM s, up to 256 controllers can be connected to a single node. The LCM contains all process control capabilities as well as all input and output connections. Each individual LCM can be removed and replaced while the system is under power. LCM's are available in the following configurations: Inputs Outputs Loops plus CT LIM - The Loop Interconnect Module... allows for a "building block" approach to system assembly so the user only purchases the number of loops required for the application. Individual loops can be removed without affecting the performance of other modules in the system. In addition, the LCM design enables individual loop integrity to be maintained and also has the added benefit of allowing auto-configuration and hot-swapping of each individual module as described above. The MLC 9000 is a unique PID controller that replaces PLC PID-control and I/O cards. PID control does not affect PLC processor speed. Lower per loop cost; only purchase the loops you need Fast, easy configuration The MLC 9000 offers a simple way to control PID loops in a PLC system without compromising the speed and performance of the PLC as current solutions do. With advanced autotuning, the RaPID TM fuzzy logic algorithm and simple Windows Based configuration, the MLC 9000 can be configured to control PID loops more effectively than current PLC solutions, minimizing upsets and overshoots and reducing out of quality production. By removing the burden of PID processing from the PLC, the MLC 9000 leaves the PLC to do the digital processing that it was originally designed for, thereby increasing PLC speed and efficiency while dramatically reducing overall cost of system ownership. The building block approach to the MLC architecture allows a user to add up to 256 loops of high speed PID control without having to increase PLC processor capabilities. This feature also allows a user to purchase only the loops they need; no block purchasing of PID loops is necessary. Since the controllers behave as discrete units, no additional PLC programming is required to set up PID loops, further reducing cost and simplifying start up. With the integration of the PID information into the PLC system, the PLC operator interface can now be used to effectively monitor, tune and adjust the controller parameters if required, eliminating the need to train personnel on several different user interfaces. McGoff-Bethune, Inc Unity Drive Suite A Norcross, GA Fax: sales@mcgoff-bethune.com Website:

3 MLC9000 Ordering Guide Bus Modules Description MLC9002-B210 Bus Module, no network comms MLC9002-B220 Bus Module, Modbus RTU comms MLC9002-B230 Bus Module, DeviceNet Comms MLC9002-B240 Bus Module, Profibus DP comms (B240 module sold as MLC9002-B220+MLC9002-G010, order separately) Loop Modules MLC9002-C120 MLC9002-C130 MLC9002-C230 MLC9002-C460 MLC9002-C461 MLC9002-C462 MLC9002-C463 Description Single input, 2 output Single input, 3 output Single input, 3 output with CT input 4 temp. in, 4 SSR out, 2 relay out 4 process in, 4 SSR out, 2 relay out 4 temp. in, 6 relay out 4 process in, 6 relay out MLC9002-H010 MLC9002-H040 MLC9002-H555 MLC9002-H585 Software MLC9002-F010 MLC9002-F030 MLC9002-F040 4x20 ESA Alphanumeric display 4x20 ESA Alphanumeric display with keypad 5" ESA monochrome touchscreen 10" ESA color touchscreen Description MLC configuration software HMI configuration software REV 1 Jan 02

4 10 TECHNICAL SPECIFICATIONS 10.1 BUS COMMUNICATIONS MODULE (B210, B220) GENERAL RS232 Port: MODBUS Port (Module B220 only) Input Power This is a local port for connection to an RS232 port on a PC for local operator configuration and operator displays. It has EIA-232-E (RS232)-compatible inputs and outputs for TxD and RxD and provides facilities via application software to allow an installer to configure or an operator to view the operation of Loop Controller Modules connected to the Bus Communications Module. This is via a special two-metre interface lead which is available by special order. This is an optional RS485 port for connection to a MODBUS master device. Data rate and format are configurable via the RS232 port. The MODBUS Port can fulfil a variety of roles: Multi-drop configuration: Configuration and monitoring of the system may be performed with a local RS485 MODBUS network. Fieldbus: When a plant uses MODBUS as its Fieldbus choice, this permits the system to be integrated into a Fieldbus network. Multi-Drop Operator Interface: A third party operator interface may be connected which can read and change parameters over this port. MODBUS RTU protocol is supported, using an RS485 physical layer. The load is no greater than one-quarter unit load. The data rate is selectable from 4800, 9600 or Baud. It is factory-set to 9600 Baud. Parity is selectable from none, even or odd. Each system can consist of up to eight Loop Controller Modules (each with its Interconnect Module) plus the Bus Communications Module - a total of nine addresses. The base address can be set in the range (default = 96) Node addressing, data rate and character format are selectable via the Application Software running on the PC connected to the RS232 Port. 30W maximum ENVIRONMENTAL Operating Conditions Ambient Temperature: 0 C to 55 C Relative Humidity: 30% to 90% non-condensing Supply Voltage: 18 to 30V DC (including ripple) Storage Conditions Ambient Temperature: -20 C to 80 C Relative Humidity: 30% to 90% non-condensing APPROVALS Product Family EMC: EN NOTE: For line-conducted AM signals in the frequency range 400kHz to 1.65MHz, communications with the RS485 MODBUS and RS232 ports may be disrupted but will self-recover when the interfering signals are removed. Safety: Complies with EN and UL PHYSICAL Dimensions Mounting Height - 100mm; Width - 30mm; Depth - 120mm Directly mounted on the DIN rail Connectors Power input: 2-way 5.08mm Combicon type RS232 port: 6-way RJII Type MODBUS port (optional): 2-way 5.08mm Combicon type Weight: 0.21kg 10-1

5 10.2 BUS COMMUNICATIONS MODULE (B230) GENERAL RS232 Port: DeviceNet Port Input Power This is a local port for connection to an RS232 port on a PC for local operator configuration and operator displays. It has EIA-232-E (RS232)-compatible inputs and outputs for TxD and RxD and provides facilities via the Application Software to allow an installer to configure or an operator to view the operation of Loop Controller Modules connected to the Bus Communications Module. This is a port for connection to a DeviceNet master device. Data rate and MAC ID are configurable via the RS232 port. The data rate is selectable from (in kbps) 125, 250 or 500. It is factory-set to 125kbps. Parity is fixed at none. The MAC ID can be set in the range 0-63 (default = 63). 30W maximum ENVIRONMENTAL Operating Conditions Storage Conditions Ambient Temperature: 0 C to 55 C Relative Humidity: 30% to 90% non-condensing Supply Voltage: 18 to 30V DC (including ripple) Ambient Temperature: -20 C to 80 C Relative Humidity: 30% to 90% non-condensing APPROVALS Product Family EMC EN NOTE: For line-conducted AM signals in the frequency ranges 16-20MHz and MHz, the DeviceNet port can suffer intermittent loss of function which is self- recoverable. In the frequency range 1-6MHz, communications with the RS232 port may be disrupted but will self-recover when the interfering signals are removed. Safety Complies with EN and UL PHYSICAL Dimensions Mounting Height - 100mm; Width - 30mm; Depth - 120mm Directly mounted on the 35mm Top Hat DIN rail Connectors Power input: 2-way 5.08mm Combicon type RS232 port: 6-way RJII Type DeviceNet port: 5-way 5.08mm Combicon type Weight: 0.21kg 10-2

6 10.3 BUS COMMUNICATIONS MODULE (B240) GENERAL RS232 Port PROFIBUS Port Input Power This is a local port for connection to an RS232 port on a PC for local operator configuration and operator displays. It has EIA-232-E (RS232)-compatible inputs and outputs for TxD and RxD and provides facilities via the Application Software to allow an installer to configure or an operator to view the operation of Loop Controller Modules connected to the Bus Communications Module. This port is for connection to a PROFIBUS DP network. The PROFIBUS data rate is automatically detected and set by the BCM. The PROFIBUS interface can communicate at the following data rates; 9.6kbps, 19.2kbps, 45.45kbps, 93.75kbps, 187.5kbps, 500kbps, 1.5Mbps, 3Mbps, 6Mbps, 12Mbps. PROFIBUS address and byte order are configurable via the RS232 port. The PROFIBUS address can be set in the range 0 to 126 (126=default). 30W maximum ENVIRONMENTAL Operating Conditions Storage Conditions Ambient Temperature: 0 C to 55 C Relative Humidity: 30% to 90% non-condensing Supply Voltage: 18 to 30V DC (including ripple) Ambient Temperature: -20 C to 80 C Relative Humidity: 30% to 90% non-condensing APPROVALS Product Family EMC EN61326:1998. Safety Complies with EN :1995 and UL :1998. PHYSICAL Dimensions Mounting Height - 100mm; Width - 30mm; Depth - 120mm Directly mounted on the DIN rail Connectors Power input: 2-way 5.08mm Combicon type RS232 port: 6-way RJII Type PROFIBUS port: 9-way D-type Weight 0.21kg 10-3

7 10.4 SINGLE-LOOP LOOP CONTROLLER MODULES (C120, C130, C230 AND C231) GENERAL Function: Types available: Process Input: Heater Current Input Outputs: Each Loop Controller Module performs the control function and provides the input and output connections for its own control loop. One universal process input and two outputs are provided as standard. An optional third output and Heater Break detection input are available. C120: Two output, single loop C130: Three output, single loop C230: Three output, single loop with Heater Break detection C231: Three output, single loop with Heater Break detection and redundant thermocouple Type and scale user-selectable (see below). Sample rate = 10/second (For redundant thermocouple variant, unused thermocouple sample rate = 1/second) Generates a Heater Current Input value for use by the Heater Break Alarm function. Output 1 - Relay or SSR Drive Output 2 - Relay or SSR Drive Output 3 (optional) - Relay, SSR Drive or Linear PROCESS INPUT Types available Thermocouple RTD DC Linear B ( C) B ( F) N ( C) N ( F) C F 0-20mA 4-20mA J ( C) J ( F) R ( C) R ( F) 0-50mV 10-50mV K ( C) K ( F) S ( C) S ( F) 0-5V 1-5V L ( C) L ( F) T ( C) T ( F) 0-10V 2-10V NOTE: RTD and DC Linear inputs are not available on C231. PROCESS INPUT Over-range Detection, Under-range Detection and Sensor Break Detection Under-range Detection Over-range Detection Sensor Break Detection Under-range is detected when the input value is lower than Range Minimum. The input value is valid for reading and control for up to 5% of input span under-range. The accuracy is reduced when the input is under-range. Over-range is detected when the input value exceeds Range Maximum. The input value is valid for reading and control for up to 5% of input span over-range. The accuracy is reduced when the input is over-range. Primary thermocouple input: wire break detected within two seconds. Secondary thermocouple input (redundant thermocouple variant only): wire break detected typically within three seconds. Control outputs set to OFF (0% power); All alarms become active (with the exception of heater break if present). For DC Linear inputs, applicable to 4-20mA, 10-50mV, 1-5V and 2-10V ranges only. NOTE: On the Redundant Thermocouple variant, control outputs and alarms are affected only when a sensor break is detected on both thermocouple inputs. During the two seconds required to detect a break on the primary thermocouple, "fleeting" alarms will occur. When the secondary thermocouple switches in, these alarms will cease. See also Under-range Detection and Over-range Detection above. 10-4

8 THERMOCOUPLE INPUTS Types/Ranges Measurement Accuracy Linearisation Accuracy Cold Junction Compensation Sensor Resistance Influence See above Better than ±0.1% of range span ±1 LSD. NOTE: Reduced performance with Type B Thermocouple between C ( F). Type T accuracy is ±0.5% below 100 C. Better than ±0.2 C any point, any 0.1 C resolution range (±0.05 C typical). Better than ±0.5 C any point, any 1 C resolution range. Better than ±1 C over operating temperature range. Secondary Input: Better than ±2 C over operating temperature range. <10Ω: as measurement accuracy 100Ω: <0.1% of span error 1000Ω: <0.5% of span error RTD INPUTS - Not on C231 Type and Connection: Measurement Accuracy Linearisation Accuracy Temperature Stability Lead Compensation: RTD Sensor Current: Three-wire (Pt100). ±0.1% of range span ±1 LSD. Better than ±0.2 C any point (±0.05 C typical). 0.01% of range span/ C change in ambient temperature. Automatic to 50Ω maximum lead resistance, giving less than 0.5% of span additional error. 150µA ±10µA DC LINEAR INPUTS - Not on C231 Measurement Accuracy Temperature Stability Input Resistance Max. Resolution Better than ±0.1% of range span ±1 LSD. 0.01% of range span/ C change in ambient temperature. mv Input: >1MΩ V Input: 47kΩ ma Input: 4.7Ω to Equivalent to a 16-bit ADC. HEATER CURRENT INPUT - C230 and C231 only Input Sampling Method: Input Resolution: Delta-sigma at 1kHz 8 bits over 250 msec rolling window Accuracy: Better than ±2%. Isolation: Internal Burden: Source Selection: Input Span: Range Maximum: Range Minimum: Via external current transformer 15 ohm SSR linear output 3 or Heater Current input. 0 50mA rms. (assuming sinusoidal input current waveform) Adjustable 0.1A to 100A Fixed 0A RELAY OUTPUTS (Output 1, 2 or 3) Contact Type: Rating: Lifetime: Single pole double throw (SPDT). 2A 120/240V AC >500,000 operations at rated voltage/current. 10-5

9 SSR DRIVE OUTPUTS (Output 1, 2 or 3) Drive Capability: Isolation: 12V DC nominal (10V DC minimum) at up to 20mA load. Isolated from process input and relay outputs. Not isolated from each other or linear outputs. Not isolated from other similar outputs in the same system. LINEAR OUTPUT (Output 3 only) Resolution: Eight bits in 250msecs. (10 bits in 1 second typical). Accuracy: ±0.25% (ma into 250Ω load, V into 2kΩ load). Degrading linearly to ±0.5% for increasing burden to maximum drive capability. Update Rate: Drive Capability: Isolation: 10samples/second. 0-20mA: 500Ω maximum 4-20mA: 500Ω maximum 0-5V: 500Ω minimum 0-10V: 500Ω minimum Isolated from process input and relay outputs. Not isolated from SSR Drive outputs or other similar outputs in the same system. ALARM CONTROL Maximum No. of Alarms: Maximum No. of Alarm Outputs Available: Alarm Types Available: Combinatorial Alarms: Two soft alarms plus Loop Alarm. Any output can be used for any alarm indication. Process High Alarm Process Low Alarm Band Alarm Deviation Alarm Logical OR of alarms to an individual hardware output is available. OPERATING CONDITIONS Ambient Temperature: Relative Humidity: Supply Voltage: 0 C to 55 C (operating); 20 C to 80 C (storage) 30% - 90% non-condensing (operation and storage). Powered by Bus Communications Module within its operating conditions. APPROVALS Product Family EMC: EN NOTE: For line-conducted AM signals in the frequency range 400kHz to 1.65MHz, communications with the RS485 MODBUS and RS232 ports may be disrupted but will self-recover when the interfering signals are removed. Safety: Complies with EN and UL PHYSICAL Dimensions: Mounting: Connector Types: Weight: Height - 100mm; Width - 22mm; Depth - 120mm 35mm Top Hat DIN rail mounting via Interconnect Module. All 5.08mm Combicon type. 0.15kg. 10-6

10 LOOP LOOP CONTROLLER MODULES (C460, C461, C462 AND C463) GENERAL Function: Types available: Process Input: Outputs: Each LCM performs the control functions and provides the input and output connections for its own control loops. Four process inputs (temperature or DC) and four SSR Drive or relay (SPST) outputs are provided, along with two relay (SPDT) outputs. C460: Four temperature/mv process inputs, four SSR drive outputs, two SPDT relay outputs. C461: Four DC process inputs, four SSR drive outputs, two SPDT relay outputs. C462: Four temperature/mv process inputs, four SPST relay outputs, two SPDT relay outputs. C463: Four DC process inputs, four SPST relay outputs, two SPDT relay output. Type and scale user-selectable (see below). Sample rate = 10/second.Temperature process inputs:, thermocouple, RTD or DC (mv) ranges are available. DC process inputs: DC (V) or DC (ma) ranges are available. Outputs 1-4: SPST Relay or SSR Drive Outputs 5 and 6: SPDT Relay PROCESS INPUT Types available (Range Minimum - Range Maximum) Thermocouple RTD DC Linear B ( C) B ( F) N ( C) N ( F) C F 0-20mA 4-20mA J ( C) J ( F) R ( C) R ( F) 0-50mV 10-50mV (available only on temperature versions) K ( C) K ( F) L ( C) L ( F) S ( C) S ( F) 0-5V 1-5V T ( C) T ( F) 0-10V 2-10V PROCESS INPUT Over-range Detection, Under-range Detection and Sensor Break detection Under-range Detection Over-range Detection Sensor Break Detection Sensor Short Detection Under-range is detected when the input value is lower than Range Minimum. The input value is valid for reading and control for up to 5% of input span under-range. The accuracy may be reduced when the input is under-range. Over-range is detected when the input value exceeds Range Maximum. The input value is valid for reading and control for up to 5% of input span over-range. The accuracy may be reduced when the input is over-range. Wire break detected within two seconds. Control outputs set to OFF (0% power); All alarms become active. For DC Linear inputs, applicable to 0-50mV, 10-50mV, 4-20mA, 1-5V and 2-10V ranges only. See also Under-range Detection and Over-range Detection above. Thermocouple: Input reads ambient; not detected. RTD: As for under-range operation. THERMOCOUPLE INPUTS Types/Ranges Measurement Accuracy Linearisation Accuracy Cold Junction Compensation See above Better than ±0.2% of range span ±1 LSD. NOTE: Reduced performance with Type B Thermocouple between C ( F). Type T accuracy is ±0.5% below 100 C, Better than ±0.2 C any point, any 0.1 C resolution range (±0.05 C typical). Better than ±0.5 C any point, any 1 C resolution range. Better than ±1 C over operating temperature range. 10-7

11 THERMOCOUPLE INPUTS Sensor Resistance Influence <10Ω: as measurement accuracy 100Ω: <0.1% of range span error 1000Ω: <0.5% of range span error RTD INPUTS Type and Connection: Measurement Accuracy Linearisation Accuracy Temperature Stability Lead Compensation: RTD Sensor Current: Three-wire (Pt100) ±0.2% of range span ±1 LSD. Better than ±0.2 C any point (±0.05 C typical). 0.01% of range span/ C change in ambient temperature. Automatic to 50Ω maximum lead resistance, giving less than 0.5% of range span additional error. 150µA ±10µA DC LINEAR INPUTS Measurement Accuracy Temperature Stability Better than ±0.1% of range span ±1 LSD. 0.01% of range span/ C change in ambient temperature. Input Resistance mv Input: >1MΩ; V Input: 47kΩ; ma Input: 4.7Ω Max. Resolution to Equivalent to a 16-bit ADC. RELAY OUTPUTS Contact Type: Rating: Lifetime: Isolation: RLY1 - RLY4: Single pole single throw (SPST) N/O RLY5 and RLY6: Single pole changeover (SPDT). 2A 120/240V AC >500,000 operations at rated voltage/current. Inherent. SSR DRIVE OUTPUTS Drive Capability: Isolation: 12V DC nominal (10V DC minimum) at up to 20mA load. Isolated from process input and relay outputs. Not isolated from each other. Not isolated from other similar outputs in the same system. ALARM CONTROL Maximum No. of Alarms: Maximum No. of Alarm Outputs Available: Alarm Types Available: Combinatorial Alarms: Two soft alarms per input plus four loop alarms. Any output can be used for any alarm indication. Process High Alarm, Process Low Alarm, Band Alarm Deviation Alarm Logical OR of alarms to an individual hardware output is available. LOOP CONTROL PID Single Output Loop Control PID Dual Output Loop Control Automatic Tuning: Easy Tune, Pre-Tune and RaPID. Manual Reset (Bias): Added each control algorithm execution. Auto/Manual Control: User-selectable with bumpless transfer into and out of Manual Control. Automatic Tuning: Pre-Tune and RaPID. Manual Reset (Bias): Added each control algorithm execution. Auto/Manual Control: User-selectable with bumpless transfer into and out of Manual Control. OPERATING CONDITIONS Ambient Temperature: Relative Humidity: Supply Voltage: 0 C to 55 C (operating); 20 C to 80 C (storage) 30% - 90% non-condensing (operation and storage). Powered by BCM within its operating conditions. 10-8

12 MLC 9000 User Guide APPROVALS Product Family EMC: Safety: EN NOTE: For line-conducted AM signals in the frequency range 400kHz to 1.65MHz, communications with the RS485 MODBUS and RS232 ports may be disrupted but will self-recover when the interfering signals are removed. Complies with EN and UL PHYSICAL Dimensions: Mounting: Connector Types: Weight: Height - 100mm; Width - 22mm; Depth - 120mm 35mm Top Hat DIN rail mounting via Interconnect Module. 5.08mm Combicon type in all cases. 0.15kg. 10-9