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CPC400 Series User’s Guide Chapter 4: Tuning and Control
Doc. 0600-2900-2000 Watlow Anafaze 85
Manually Tuning PID Loops
We recommend using the CPC400's advanced autotuning
and TRU-TUNE+™ adaptive control capabilities to set up
and maintain the PID control parameter settings. See Au-
totuning on page 62. It is, of course, possible to tune the
controller manually. The information in this section is in-
tended as a guide to that end.
When tuning a loop, choose PID parameters that will best
control the process. This section gives PID values for a va-
riety of heating and cooling applications.
NOTE!
Tuning is a slow process. After adjusting a loop,
allow about 20 minutes for the change to take ef-
fect.
Proportional Band Settings
Table 4.1 shows proportional band settings for various
temperatures in degrees Fahrenheit or Celsius.
Table 4.1 Proportional Band Settings
As a general rule, set the proportional band to ten percent
of the set point below 1000° and five percent of the set point
above 1000°. This setting is useful as a starting value.
Integral Settings
The controller’s integral parameter is set in seconds per re-
peat. Some other products use an integral term called re-
set, in units of repeats per minute. Table 4.2 shows integral
settings versus reset settings.
Temperature
Set Point
PB
Temperature
Set Point
PB
Temperature
Set Point
PB
-100 to 99 20 1100 to 1199 75 2200 to 2299 135
100 to 199 20 1200 to 1299 80 2300 to 2399 140
200 to 299 30 1300 to 1399 85 2400 to 2499 145
300 to 399 35 1400 to 1499 90 2500 to 2599 150
400 to 499 40 1500 to 1599 95 2600 to 2699 155
500 to 599 45 1600 to 1699 100 2700 to 2799 160
600 to 699 50 1700 to 1799 105 2800 to 2899 165
700 to 799 55 1800 to 1899 110 2900 to 2999 170
800 to 899 60 1900 to 1999 120 3000 to 3099 175
900 to 999 65 2000 to 2099 125 3100 to 3199 180
1000 to 1099 70 2100 to 2199 130 3200 to 3299 185
- CPC400 Series 1
- User’s Guide 1
- Warranty 2
- Table of Contents 3
- List of Figures 7
- 7 Specifications 165 9
- List of Tables 11
- Values for BCD Job Load 12
- System Overview 15
- Getting Started 16
- Product Features 16
- CPC400 Parts List 18
- 40 _ -1 _ _ _ _ _ _ 19
- Technical Description 20
- CPCSI _ _ - _ _ - _ _ 20
- Front Panel Description 21
- Figure 1.4 CPC400 Front Panel 21
- CPC400 Cabling 22
- External Safety Devices 23
- Power-Fail Protection 24
- Installation 25
- Typical Installation 26
- Recommended Tools 27
- Mounting the Controller 27
- Figure 2.3 Wiring Clearances 28
- Figure 2.4 Mounting Bracket 29
- Mounting the TB50 30
- Mounting with Standoffs 31
- Mounting the Power Supply 32
- Mounting 33
- System Wiring 34
- Noise Suppression 35
- Avoiding Noise 36
- Power Connections 37
- Wiring the Power Supply 38
- Testing the System 40
- Sensor Wiring 41
- Input Wiring Recommendations 42
- Thermocouple Connections 42
- RTD Input Connections 43
- Reference Voltage Terminals 44
- Voltage Input Connections 44
- Current Input Connections 44
- Pulse Input Connections 45
- Output Wiring Recommendations 46
- Cable Tie Wraps 46
- Digital Outputs 46
- Stored in the Controller 47
- Configuring Outputs 48
- Digital Inputs 50
- TB18 Connections 51
- TB50 Connections 52
- Wiring the Serial DAC 54
- Serial Communications 55
- EIA/TIA-485 Interface 57
- Cable Recommendations 58
- Connections 58
- Signal Common 59
- Termination 59
- Operation and Setup 61
- General Navigation Map 62
- Figure 3.2 Keypad Navigation 63
- Displays 64
- Alarm Displays 65
- How to Acknowledge an Alarm 66
- System Alarm Messages 66
- Job Display 67
- Changing the Set Point 68
- How to Access the Setup Menus 70
- How to Edit a Setup Parameter 70
- Feedback 71
- Control Algorithm 71
- TRU-TUNE+™ 71
- Control Output Signal Forms 71
- Heat and Cool Outputs 71
- Input Scaling 72
- Figure 3.6 Input Scaling 73
- Situation 73
- (dc) Sensor 74
- Table 3.7 Scaling Values 75
- Autotuning 76
- Setting Up Alarms 77
- Thermocouple Open Alarm 78
- Thermocouple Reversed Alarm 78
- Alarm High and Alarm Low 80
- Deviation Alarms 80
- Global Alarm 81
- Variable Retransmit 82
- Setting Up Cascade Control 83
- Loop Has Heat Output Only 84
- How To Set Up Cascade Control 85
- Setting Up Ratio Control 87
- How to Set Up Ratio Control 88
- Loop (Loop 2) in the Example 89
- Loop (Loop 2) for the Example 90
- Loop (Loop 1) in the Example 91
- Non-Numeric Settings 92
- Bit-Wise Values 92
- Tuning and Control 95
- On/Off Control 96
- Proportional Control (P) 96
- Proportional 97
- Manually Tuning PID Loops 99
- Derivative Settings 100
- Proportional Band Only (P) 101
- Control Outputs 102
- Output Filter 103
- Reverse and Direct Action 104
- Menu and Parameter Reference 105
- Operator Parameters 106
- Heat/Cool Output 107
- Process Variable 107
- Overview of the Setup Menus 108
- >< 109
- Global Setup Menu 110
- BCD Job Load 111
- BCD Job Load Logic 112
- Mode Override 113
- Logic Program 113
- Power Up Alarm Delay 114
- Power Up Loop Mode 114
- Power Up With Logic 114
- Keypad Lock 115
- Thermocouple Short Alarm 115
- Controller Address 115
- Communications Baud Rate 116
- Communications Parity 116
- AC Line Frequency 116
- Digital Output Alarm Polarity 117
- Model and Firmware Version 117
- Input Menu 118
- Input Units 119
- Input Pulse Sample 119
- Calibration Offset 119
- Display Format 120
- Input Range High 121
- Input High Signal 121
- Input Range Low 122
- Input Low Signal 122
- Channel Menu 123
- PV Source 124
- Control Menu 125
- Heat/Cool Integral 126
- Heat/Cool Derivative 126
- Heat/Cool Manual Reset 126
- Heat/Cool Filter 127
- Hysteresis 127
- Restore Automatic Mode 128
- Tune Band 128
- Tune Gain 128
- Overshoot Reduction 129
- Control Type 129
- Output Menu 130
- Heat/Cool Cycle Time 131
- Heat/Cool SDAC Signal 131
- Heat/Cool SDAC Low Signal 131
- Heat/Cool SDAC High Signal 132
- Heat/Cool Action 132
- Heat/Cool Power Limit 132
- Heat/Cool Power Limit Time 133
- Sensor Fail Heat/Cool Output 133
- Heat/Cool Output Curve 134
- Alarms Menu 135
- Alarm High Function 136
- Alarm High Output 136
- High Deviation Value 136
- High Deviation Function 137
- High Deviation Output 137
- Low Deviation Value 137
- Low Deviation Function 137
- Low Deviation Output 137
- Alarm Low Set Point 138
- Alarm Low Function 138
- Alarm Low Output 138
- Alarm Hysteresis 138
- Alarm Delay 139
- Heat/Cool Output Retransmit 140
- Cascade Menu 141
- Ratio Menu 142
- Ratio Low Set Point 143
- Ratio High Set Point 143
- Control Ratio 143
- Soft Integers Menu 144
- Soft Booleans Menu 145
- I/O Tests Menu 145
- Keypad Test 146
- Test Digital Output 1 to 35 146
- Alarm Acknowledge 146
- Alarm Enable 147
- Alarm Function 147
- Alarm Status 148
- Ambient Sensor Reading 148
- Analog Input 148
- Data Changed Register 149
- Firmware Identification 149
- Firmware Version 149
- System Status 150
- Full Scale Calibration 150
- Zero Calibration 151
- When There is a Problem 153
- Returning a Unit 154
- Process Alarms 155
- Failed Sensor Alarms 156
- System Alarms 157
- Other Behaviors 157
- Low Power 159
- Battery Dead 159
- Ambient Warning 160
- H/W Failure: Gain or Offset 160
- H/W Failure: Ambient 160
- Keys Do Not Work 161
- Checking Analog Inputs 162
- Earth Grounding 163
- Checking Control Outputs 164
- Testing the TB18 and TB50 164
- Testing Digital Inputs 165
- Computer Problems 166
- Communications 166
- Clearing the RAM 167
- CAUTION! 168
- Installing Scaling Resistors 171
- Input Circuit 172
- Current Inputs 173
- Voltage Inputs 174
- RTD Inputs 175
- SERIAL DAC 176
- Configuring Dual DAC Outputs 177
- DUAL DAC 177
- Specifications 179
- Table 7.3 Physical Dimensions 180
- SCSI Cable 181
- TB50 Physical Specifications 182
- Figure 7.4 TB50 Dimensions 183
- Table 7.8 TB50 Connections 183
- Table 7.11 Analog Inputs 186
- Table 7.12 Pulse Inputs 186
- Table 7.13 Programmable Logic 187
- Resolution 187
- Table 7.17 Digital Inputs 188
- Analog Outputs 188
- CPC400 Power Supply 190
- Dual DAC Specifications 192
- Dual DAC Inputs 193
- Serial DAC Specifications 194
- Serial DAC Inputs 195
- Serial DAC Analog Outputs 196
- Appendix A: Modbus Protocol 197
- Response 198
- Modbus ASCII and RTU Modes 199
- Message Framing 199
- Address Field 200
- Function Field 200
- Data Field 201
- Error Checking Field 201
- Error Checking Methods 202
- CRC Checking 203
- Function Codes 204
- Force Single Coil 05 205
- Preset Single Register 06 205
- Diagnostics 08 205
- Force Multiple Coils 15 206
- Examples 207
- Write Examples 208
- Glossary 209
- — A standard for interface 210
- — A power 213
- 53, 146 217
- Parameter Address Reference 223
- Input (page 104) 224
- Channel (page 109) 224
- Control (page 111) 224
- Output (page 116) 225
- Alarms (page 121) 226
- Firmware Version (page 135) 228
- Declaration of Conformity 229
- Menu Structure 230
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