Fuji Electric CC-M User manual

COMPACT CONTROLLER M

(CC-M)

TYPE: PDA3

INP-TN1PDA3d-E

Instruction Manual

iINP-TN1PDA3-E

We thank you very much for purchasing Fuji Electric’s compact controller M (CC-M Type: PDA3).

•Carefully read the instruction manual and sufficiently be familiar with its contents before install-

ing, operating and maintaining the compact controller M. Improper handling may cause acci-

dents or injuries.

•The specifications of compact controller M are subject to change without prior notice for im-

provement of the product.

•It is strictly forbidden to remodel the compact controller M without permission. We will not be

responsible for any accident attributable to such remodeling without permission.

• The person in charge of operating the compact controller M is requested to keep the instruction

manual.

•After reading the manual, it must be kept at a place always accessible by personnel in charge of

its operation.

• An arrangement must be taken so that the instruction manual will be handed over to the end user.

•The contents of this manual have been prepared carefully. However, it should be noted that Fuji

is not responsible for any loss caused indirectly from errors in wiring or missing of information.

Note: Windows is the registered trademark of Microsoft Corporation.

Note: Modbus is the registered trademark of MODICON.

Note: Sandisk and Compact Flash are the trademarks of Sandisk Corporation.

Note: Pentium is the registered trademark of Intel Corporation.

Note: Acrobat Reader is the registered trademark of Adobe Systems Incorporated.

Note: OPTO22 is the trademark of OPTO22.

Note: ISaGRAF is the registered trademark of ICS Triplex ISaGRAF.

Manufacturer : Fuji Electric Instrumentation Co., Ltd.

Type : Described in nameplate on main frame

Date of manufacture : Described in nameplate on main frame

Product nationality : Japan

Request

•It is forbidden to transfer a part or the whole of contents of the

manual without permission.

•Contents of the manual are subject to change without prior

notice.

Issued in Aug., 1999

Rev. 1st edition January, 2000

Rev. 2nd edition July, 2000

Rev. 3rd edition October, 2001

Rev. 4th edition January, 2004

INTRODUCTION

ii INP-TN1PDA3-E

DANGER

Before use, carefully read the safety precautions for correct operation.

•The precautions concern important matters related to safety. Be sure to observe them. The safety

matters are ranked to “DANGER”, “CAUTION”.

Indications and meanings are as follows.

If the handling is wrong, dangerous situations might occur,

causing death or serious injury.

If the handling is wrong, dangerous situations might occur,

causing medium or slight degree of injury or physical damage

only.

SAFETY PRECAUTIONS

• If the fault or anomaly of the device may cause serious accident or troubles to other devices,

externally install appropriate emergency stop circuit and protective circuit to avoid accidents.

•

The instrument has no power switch nor fuse. Install them if necessary. (Fuse rating 250 V, 2 A)

• For avoiding device breakage and fault, supply a power voltage matching the rating.

•For avoiding electric shock, maloperation and device troubles, do not turn on power until all

installation and wiring have ended.

• The instrument is not an intrinsically-safe explosion-proof type. Do not use it in atmosphere of

combustible or explosive gases.

•Never disassemble, retouch, remodel nor repair the instrument. Otherwise, abnormal operation,

electric shock or fire may occur.

•While turned on, do not touch the terminals. Otherwise, electric shock or maloperation may

occur.

•Before engaging or disengaging the module or unit, turn off power. Otherwise, electric shock,

maloperation or troubles may occur.

• Periodic maintenance is recommended so that the instrument can be used continuously and

safely. Some parts installed on the device have limited service life or are subjected to secular

change.

•Do not block the ventilation opening located on the top and bottom of the main unit. Otherwise,

fault, abnormal operation, shortened service life or fire may occur.

DANGER

CAUTION

iiiINP-TN1PDA3-E

DANGER

ZOver-temperature Protection

Any control system should be designed with prior consideration that any part of the system has

potential to fail.

In case of temperature controlling, a continuance of heating on should be regarded as the most

dangerous state.

The followings are the most probable causes of inducing continuance of heating on:

1) The failure of the controller with heating output constantly on

2) The disengagement of the temperature sensor out from the system

3) The short circuit in the thermocouple wiring

4) Valve or switch contact point outside the system is locked to keep heating on

In any application in which it is apprehended that physical injury or destruction of equipment

might occur, we recommend to install an independent safeguard equipment to prevent over-

temperature which shut down the heating circuit and for additional safety, we also recommend

this equipment to have its own temperature sensor.

The alarm output signal of the controller is not designed to work as protective measures when

the controller is in failure condition.

iv INP-TN1PDA3-E

CAUTION

•Do not use any instrument which is found damaged or deformed when unpacked. Otherwise, fire,

maloperation or fault may occur.

•Make sure the product is as specified before use. Otherwise, the product may break or be troubled.

•Do not drop, tip over nor give a shock to the product. Otherwise, the product may break or suffer

from a fault.

•Install the device so that dust, wire chip, iron powder or other foreign matters will not enter it.

Otherwise, maloperation or fault may occur.

•Periodically make sure terminal screws and setscrews are securely tightened. Use at a loosened

status may cause fire or maloperation.

•Before changing the setting while operating, forced output, startup, shutdown or other actions, suf-

ficiently check the safety. Wrong operation may break or trouble the machine.

•During the running, the furnished terminal cover must be put on the terminal block. Otherwise,

electric shock or fire may occur.

• For mounting the device, avoid the following place.

Ambient temperature is beyond 0 to 50ºC (0 to 40ºC at close mounting sidewise).

Ambient humidity is beyond 5 to 90% RH.

A condensation occurs.

Exposed to corrosive gases (particularly, sulfuric gas, ammonia or the like) or combustible gases.

Vibration or impact is exerted to the main unit.

Splashed with water, oil, chemical, steam or vapor

Exposed to dust, salt or iron excessively.

Inductive disturbance is so excessive as to easily produce electrostatic charge, magnetic field or

noise.

A heat accumulation occurs by radiation heat, etc.

•Install this controller on the panel so as not to apply stress to the case, otherwise it may result in

damage to the case.

•If dipped in water, do not use the instrument. Otherwise, there may be a fear of electric leakage,

electric shock or fire.

•For connecting a thermocouple input, do not use wires other than specified compensating wires.

Otherwise, reading error or abnormal operation may occur.

•For connecting a resistance bulb input, use wires of a resistance which is low enough and uniform

between 3 wires. Otherwise, reading error or abnormal operation may occur.

• If noise from the source is excessive, add an insulating transformer and use a noise filter.

•For cleaning the main unit, clean the front panel to use dry cloth, and do not use alcohol, benzine or

other organic solvents. Do not directly splash water to the main unit. Otherwise, deterioration,

fault, electric leakage, electric shock or fire may occur.

•When discarding the product, handle it as an industrial waste.

• Be sure to carry out grounding. Otherwise, electric shock or maloperation may occur.

•Wiring must be carried out by qualified specialists. Wrong wiring may cause fire, fault or electric

shock.

vINP-TN1PDA3-E

CONTENTS

INTRODUCTION ........................................................................................................i

SAFETY PRECAUTIONS ......................................................................................... ii

CONTENTS.................................................................................................................v

1. GENERAL ....................................................................................................... 1-1

2. PACKING LIST ............................................................................................... 2-1

2.1 Checking the delivered equipments....................................................................2-1

2.2 Names of each part .............................................................................................2-2

3. CODE SYMBOLS ........................................................................................... 3-1

4. FROM UNPACKING TO RUNNING............................................................. 4-1

4.1 General................................................................................................................4-1

4.2 Unpacking...........................................................................................................4-1

4.3 Mounting.............................................................................................................4-2

4.4 Wiring .................................................................................................................4-2

4.5 Turning on power ...............................................................................................4-3

4.6 Setting .................................................................................................................4-4

4.7 Running.............................................................................................................4-23

4.8 Tunning off power ............................................................................................4-29

5. BASIC OPERATION....................................................................................... 5-1

5.1 Configuration of screen ......................................................................................5-1

5.1.1 Alarm window ............................................................................................5-2

5.1.2 Chameleon keys..........................................................................................5-2

5.2 Key operation......................................................................................................5-3

5.2.1 Description of MENU key..........................................................................5-3

5.2.2 Description of Operation keys....................................................................5-3

5.2.3 Description of chameleon keys ..................................................................5-4

5.2.4 Example of using chameleon keys .............................................................5-4

5.3 Example of operation on screen .........................................................................5-5

Only an experienced engineer should perform the tasks described in items

4.3, 4.4, 8, 9 and 12.2.

CAUTION

vi INP-TN1PDA3-E

6. OPERATION ON SCREEN ............................................................................ 6-1

6.1 8 loop display screen ..........................................................................................6-1

6.2 4LOOP display screen ........................................................................................6-3

6.3 2LOOP display screen ........................................................................................6-5

6.4 1LOOP display screen ........................................................................................6-8

6.5 Tuning display screen .......................................................................................6-11

6.6 Trend display screen .........................................................................................6-14

6.7 Alarm/fault screen ............................................................................................6-17

6.7.1 Alarm logging display screen...................................................................6-17

6.7.2 Alarm status display screen ......................................................................6-19

6.7.3 Fault logging display screen....................................................................6-20

6.7.4 Fault status display screen .......................................................................6-22

7. VARIOUS SETTING....................................................................................... 7-1

7.1 Menu screen........................................................................................................7-1

7.1.1 Function of screen ......................................................................................7-1

7.1.2 Description of screens ................................................................................7-1

7.2 Status display screen...........................................................................................7-6

7.2.1 Function of screen ......................................................................................7-6

7.2.2 Description of screen..................................................................................7-6

7.3 Parameter setting screen ...................................................................................7-12

7.3.1 Outline ......................................................................................................7-12

7.3.2 Description of each screen........................................................................7-13

7.4 Constant setting screen .....................................................................................7-20

7.4.1 Outline ......................................................................................................7-20

7.4.2 Description of each screen........................................................................7-21

7.5 Linearize setting screen ....................................................................................7-22

7.5.1 Outline ......................................................................................................7-22

7.5.2 Description of each screen........................................................................7-23

7.6 Gain schedule screen ........................................................................................7-25

7.6.1 Gain schedule setting screen ....................................................................7-25

7.7 Trend setting screen..........................................................................................7-27

7.7.1 Trend setting screen..................................................................................7-27

7.8 Alarm setting screen .........................................................................................7-31

7.8.1 Alarm setting screen .................................................................................7-31

7.9 DISP SETING screen ......................................................................................7-33

7.9.1 DISPLAY setting screen...........................................................................7-33

7.9.2 1LOOP screen ..........................................................................................7-34

7.9.3 2LOOP screen ..........................................................................................7-35

7.9.4 4LOOP screen ..........................................................................................7-36

7.9.5 8LOOP screen ..........................................................................................7-37

viiINP-TN1PDA3-E

7.10 Control panel ....................................................................................................7-38

7.10.1 Outline ......................................................................................................7-38

7.10.2 Description of each screen........................................................................7-38

7.11 System Setting screen .......................................................................................7-44

7.11.1 BASIC COMPONENT screen .................................................................7-44

7.11.2 ALARM SET screen ................................................................................7-46

7.11.3 SETTING LOCK screen ..........................................................................7-48

7.11.4 COMMUNICATION screen ....................................................................7-50

7.11.5 AI CHECK SET screen ............................................................................7-52

7.11.6 START MODE screen ..............................................................................7-54

7.12 Configuration settting .......................................................................................7-55

7.12.1 Configuration menu screen.......................................................................7-55

7.12.2 Module setting screen...............................................................................7-56

7.12.3 Instrument graphic display wafer setting screen ......................................7-61

7.12.4 Control type settting screen ......................................................................7-64

7.12.5 Analog output settting screen ...................................................................7-65

7.12.6 Analog input settting screen .....................................................................7-67

7.12.7 Direct input settting screen......................................................................7-69

7.12.8 Trend jumpt settting screen ......................................................................7-71

7.13 Connection screen.............................................................................................7-72

7.13.1 Wafer connection screen...........................................................................7-72

7.13.2 Output connection menu screen ...............................................................7-76

7.13.3 T-LINK / OPTO22 output connection screen...........................................7-77

7.13.4 Analog output connect screen ..................................................................7-79

7.13.5 Digital output connect screen ...................................................................7-81

7.13.6 Internal setting output connect screen ......................................................7-83

7.14 Communication screen .....................................................................................7-86

7.14.1 Communication menu screen ...................................................................7-86

7.14.2 OPTO22 communication status display screen ........................................7-87

7.14.3 OPTO22 communication setting screen ...................................................7-88

7.14.4 SNAP I/O (OPTO22) Manual for CC-M .................................................7-91

8. MOUNTING .................................................................................................... 8-1

8.1 Mounting.............................................................................................................8-1

8.1.1 Mounting place...........................................................................................8-1

8.1.2 Temperature in panel ..................................................................................8-1

8.1.3 Mounting method .......................................................................................8-1

9. WIRING ........................................................................................................... 9-1

9.1. Wiring to the terminals .......................................................................................9-2

9.2 Description on the terminals...............................................................................9-3

9.3 Transmission connector cable.............................................................................9-4

viii INP-TN1PDA3-E

9.4 Wiring to instrument...........................................................................................9-6

9.4.1 Connection of power supply.......................................................................9-6

9.4.2 Grounding...................................................................................................9-7

9.4.3 Wiring of analog input signal .....................................................................9-8

9.4.4 Wiring of digital input/output signals.........................................................9-9

10. TROUBLESHOOTING ................................................................................. 10-1

10.1 Troubleshooting................................................................................................10-1

10.2 List of messages displayed on MENU 1/3-ALM/FLT screen..........................10-3

11. DIFFERENCE FROM PAST MODELS ....................................................... 11-1

12. APPENDIX .................................................................................................... 12-1

12.1 SPECIFICATIONS...........................................................................................12-1

12.2 Maintenance....................................................................................................12-17

12.3 Logical operation of run mode change signal.................................................12-18

13. EXPLANATION ON WAFER ...................................................................... 13-1

13.1 How to see table of wafers................................................................................13-2

13.1.1 Outline of wafers ......................................................................................13-2

13.2 List of wafers ....................................................................................................13-3

13.2.1 Primary control block ...............................................................................13-4

13.2.2 Secondary control block ...........................................................................13-5

13.2.3 Computation wafers (1)............................................................................13-6

13.2.4 Computation wafers (2)............................................................................13-8

13.3 Explanation of wafers .....................................................................................13-10

13.3.1 Primary PID control block wafer ...........................................................13-10

13.3.2 Secondary PID position type control block............................................13-27

13.3.3 Operation wafer ......................................................................................13-37

14. SETTING LIST .............................................................................................. 14-1

1 - 1INP-TN1PDA3-E

The compact controller M (CC-M) is a multi-loop (4 loops max.) process controller.

Using a resistance bulb and thermocouple direct input as an input signal besides a unified signal of 1 to 5

V DC and through abundant control and arithmetic functions, the controller can configure a high cost

performance and flexible system.

Soft Logic function, industry standard (Modbus) communicating function, O TO 22 general purpose I/O

link (MISTIC) communication function, memory card (compact flash), data logging function, front loader

communication function, hard manual (HMV) unit and other versatile functions can be installed.

Function principle diagram

1. GENERAL

Color graphic LCD

Max. 4 units

DOS/V PC

Main unit Soft Logic (IEC 61131)

Up to

4 loops

(8PID)

Control and

arithmetic

wafer area

RS-232C

Direct input unit

RS-485

Compact

flash

memory

card

MOD BUS

RS-485

OPTO 22

master



Loop

Secondary

PID

Primary

PID

External expansion

I/O

Soft Logic

OPT022

SNAP I / O

Max. 10 units

External

terminal

Max. 10 units

Pt/TC

Max. 2 units

Max. 6 units

Max. 4 units

Backup operation unit

Programming loader

(wafer loader)

Data logging

Expansion

unit

Expansion

unit

Expansion

unit

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