Utilize advanced control functions and implement easy to ... · from the temperature sensor input....
Transcript of Utilize advanced control functions and implement easy to ... · from the temperature sensor input....
August 2011
No. 327E
Mitsubishi Electric Programmable Controller
Q64TCTTN, Q64TCRTN
Temperature control moduleQ64TCTTBWN, Q64TCRTBWN
Temperature control module with disconnection detection function
Utilize advanced control functions and implement easy to use, highly stable temperature control.
Q64TCTTBWNHBA
NC
NC
Q64TC
TTBWN
CT1
CT2
CT3
CT4
CT5
CT6
CT7
CT8
OUT1
OUT2
OUT3
OUT4
NC
NC
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2+
1-
2-
IN1
IN2
IN3
IN4
3+
4+
3-
4-
Q64TCTTN
Q64TCTTBWNQ64TCRTBWNDisconnection detection function
Q64TCTTNQ64TCRTN
Point 1Point 1Highly stable temperature control
Heating and cooling control• Devices which demand highly stable temperature control, such as an extrusion molding machine, will benefi t from this module's ability to limit temperature and prevent overcooling or overheating.
Achieve precision control!
Point 2Point 2Convenient functions that are easy to use!
Peak current suppression function• This function controls the current of a heater while not turning on the outputs at the same time. Reduce running costs by taking advantage of the energy-saving effect.
Simultaneous temperature rise function• This function ensures uniform temperature by synchronizing the set value arrival time of two or more loops. Save energy and reduce running costs by avoiding idle time.
Self-tuning function• This function automatically adjusts the PID constant while in operation.The cost (time, material, and electric power) of auto tuning can be reduced.
Reduce running costs!
Enhanced control
capabilities!
Advancedfunctionality!
1
When two or more loads are being controlled, the peak current can be minimized by spreading the total load out over time.
Features
Point 1Point 1 Highly stable temperature control
Prevent overheating and overcooling in devices which require a high level of temperature stability, such as in an extrusion molding machine. In addition to standard temperature control (heating or cooling), control of cooling may be performed.Furthermore, mix control (a combination of heating and cooling control) can be performed.
Standard control/heating and cooling control
Point 2Point 2 Convenient functions make this module easy to use!
This function reduces the peak current by automatically adjusting the upper bound and output limiter of each channel and dividing transistor output timing. Output timing can be split between up to 4 outputs.
Peak current control function
Example: Standard control (heating)
The temperature of the object is controlled by adjusting the heater output based on the PID calculations resulting from the temperature sensor input.
Example: Heating-cooling control (heating and cooling elements controlled simultaneously)
Heating is performed when the control object's temperature is lower than the target temperature, and cooling is performed when it is hotter or the humidity needs to be reduced.
Q64TCTTN
Temperature sensor input
Control output (heating)Heater coil
Q64TCTTN
Temperature sensor input
Control output (heating)
Control output (cooling)
Refrigeration unit
Heater coil
Power control unit(conditioning)
ChannelCH1-CH4
ChannelCH1-CH4
ChannelCH1-CH4
ChannelCH1-CH4
Switch gear
Switch gear
Switch gear
Switch gear
By controlling the output timing, the peak current can be reduced by 75%.
By controlling the output timing, the peak current can be reduced by 75%.
5s
CH1Transistor output
Peak current
CH2Transistor output
CH3Transistor output
CH4Transistor output
5s
20s
5s 5s
Because all transistor outputs are turned on at the same time,
the peak current is high.
Because all transistor outputs are turned on at the same time,
the peak current is high.
It is possible to space the outputs out over a longer period of time.It is possible to space the outputs out over a longer period of time.
20s
A very fi ne level of control can be achieved!
The maximum power supply capacity requirement is lowered.
We can save money on our electricity contract!
2
Using this function, it is possible to coordinate the control of two or more loops to reach their target values (SV) at the same time. Control the simultaneous rise in temperature of separate loops by setting a channel group (Max. 2 groups)
This is an effective way to control applications where differing target temperature arrival times can result in undesirable temperature differentials.
Using this function, 2 or more control loops can be set to reach their set values at the same time.Perform a uniform temperature rise using two or more control loops without going over temperature or resulting in unexpected thermal expansion.
Simultaneous temperature rise function
Part mold
Heating coils
Heating cylinder
Example: Temperature control of injection molding machine
Wafer
Setting value 1
Setting value 2
Setting value 3
Setting value 4Hot plate
Example: Wafer heating process for semiconductor manufacturing
Temperature
Time
Setting value 1
CH2Temperature
rise completion
CH1Temperature
rise completion
CH3Temperature
rise completion
CH4Temperature
rise completion
Setting value 2Setting value 3Setting value 4
Temperature
Time
Setting value 1
The time it takes each channel to reach it's set value is matched to the slowest time of CH4.
Setting value 2Setting value 3Setting value 4
Simultaneous temperature rise completion
CH1Temperature measurements
CH2Temperature measurements
CH3Temperature measurements
CH4Temperature measurements
CH1Temperature measurements
CH2Temperature measurements
CH3Temperature measurements
CH4Temperature measurements
• Without the simultaneous temperature rise function • With the simultaneous temperature rise function
The running costs is reduced!
Replacing modules is easy!
Old temperature control modules can be replaced without any changes. Because modules are hot-swappable, they can be replaced without stopping the system.
Backwards compatability
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Q64TCTT(Old module)
Q64TCTTN
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Function List
Item Description
Enable or disable
Standard control
Heating -coolingcontrol
Control mode selection functionThe control mode can be selected from the following modes. • Standard control • Heating-cooling control (normal mode) • Heating-cooling control (expanded mode)• Mix control (normal mode) • Mix control (expanded mode)
Output setting at CPU stop errorWhether to clear or hold the transistor output status when a CPU stop error occurs or when a CPU module is turned from RUN to STOP can be selected.
Control methodThe following control methods can be used with the settings of proportional band (P), integral time (I), and derivative time (D).• Two-position control • P control • PI control• PD control • PID control
Manual reset function The stable status position in the P control or PD control can be moved manually.
Manual control The manipulated value (MV) can be set manually by users without automatic calculation by the PID control.
Auto tuning function The Q64TCN sets the optimal PID constants automatically.
Simple two-degree-of-freedomIn addition to the PID control, the response speed responding to the change of the set value (SV) can be selected from three levels.The simple two-degree-of-freedom PID control can be realized.
Derivative action selection function Dynamic performance can be improved by selecting the suitable derivative action for the fi xed value action and the ramp action.
Setting change rate limiter setting function
Change rate setting of the set value (SV) per set time unit when this value is changed. The batch setting or individual setting can be selected for the temperature rise and drop.
Temperature process value (PV) scaling function
The temperature process value (PV) can be converted to the set width and this value can be imported into the buffer memory.
Alert function The modules goes to the alert status when the temperature process value (PV) or deviation (E) meets the condition set in advance.
RFB limiter functionWhen the deviation (E) continues for a long time, the PID operation result (manipulated value (MV)) by the integral action can be prevented from exceeding the effective range of the manipulated value (MV).
Sensor compensation function
If a difference between a temperature process value (PV) and an actual temperature occurs due to the measurement status, the error can be corrected. Select a correction method from the following two types.• 1-point sensor compensation (standard) function: The percentage of the full scale of the set input range can be corrected as an error
corrected value.• 2-point compensation function: An error is corrected by setting any two points (corrected offset value and corrected gain value).
Auto-setting at input range changeWhen the input range is changed, the related buffer memory data is changed automatically so that errors outside the setting range does not occur.
Input/output (with another analog module) function
Data can be input/output using another analog module (A/D conversion module or D/A conversion module) on the system.
ON delay output function Setting with considering delay time (response/scan time delay) of actual transistor output is possible.
Self-tuning functionThe Q64TCN monitors the control status constantly. If the control system oscillates due to a status soon after the control starts, a change of the set value (SV), and property fl uctuation of a controlled object, PID constants are changed automatically.
×
Peak current suppression functionChanging automatically the upper limit output limiter value of each channel and dividing the timing of transistor output can suppress the peak current.
×
Simultaneous temperature rise function This function allows several loops to reach the set value (SV) at the same time. ×
Forward action/reverse action selection function
Whether to perform PID operations in the forward action or reverse action can be selected. ×
Loop disconnection detection function Errors in the control system (control loop) can be detected. ×
Proportional band setting function The proportional band (P) can be individually set for heating or cooling. ×
Cooling method setting functionWhen the auto tuning is executed, an auto tuning formula is automatically selected according to the selected cooling method and the operation starts.
×
Overlap/dead band functionBy changing the temperature where the cooling transistor output is started, whether control stability is prioritized or energy saving is prioritized can be selected.
×
Temperature conversion function (using unused channels)
In heating-cooling control (normal mode) and mix control (normal mode), only temperature measurement is allowed by using unused temperature input terminals.
×
Heater disconnection detection function The current which fl ows in the heater main circuit can be measured and disconnections can be detected.
Output off-time current error detection function
An error of when the transistor output is off can be detected.
Buffer memory data backup function The buffer memory data can be stored and backed up in the E2PROM.
Error history function Up to 16 errors and alarms that occur on the Q64TCN are stored in the buffer memory as history.
Module error history collection function
Error contents can be notifi ed to the CPU module when errors and alarms occur on the Q64TCN. Error information is held in the memory inside of the CPU module as module error history.
Error clear function When an error occurs, the error can be cleared on the system monitor.
: Enable, ×: Disable
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Performance Specifi cations
Item Specifi cations
Q64TCTTN Q64TCRTN Q64TCTTBWN Q64TCRTBWN
Control outputs Transistor output
Number of temperature input points 4 channels/module
Applicable temperature sensors Thermocouple Resistive thermal device Thermocouple Resistive thermal device
Accuracy*1
Indication accuracy
Ambient temperature: 25±5°C Full scale × (±0.3%)
Ambient temperature: 0 to 55°C Full scale × (±0.7%)
Cold junction temperature compensation accuracy: (ambient temperature: 0°C to 55°C)
Temperature process value (PV): −100°C or more
Within ±1.0°C
−
Within ±1.0°C
−Temperature process value (PV): −150 to −100°C
Within ±2.0°C Within ±2.0°C
Temperature process value (PV): −200 to −150°C
Within ±3.0°C Within ±3.0°C
Sampling cycle 500ms/4 channels (constant independently of the number of channels used)
Control output cycle 1 to 100s
Input impedance 1MΩ
Input fi lter 0 to 100s (0: input fi lter OFF)
Sensor correction value setting −50.00 to 50.00%
Operation at sensor input disconnection Upscale processing
Temperature control method PID ON/OFF pulse or two-position control
PID constants range
PID constants setting Can be set by auto tuning
Proportional band (P) 0.0 to 1000.0% (0: Two-position control)
Integral time (I) 0 to 3600s (set 0 for P control and PD control)
Derivative time (D) 0 to 3600s (set 0 for P control and PI control)
Set value (SV) setting range Within the temperature range set in the used thermocouple/platinum resistance thermometer to be used
Dead band setting range 0.1 to 10.0%
Transistor output
Output signal ON/OFF pulse
Rated load voltage 10 to 30VDC
Max. load current 0.1A/point, 0.4A/common
Max. inrush current 0.4A 10ms
Leakage current at OFF 0.1mA or less
Max. voltage drop at ON 1.0VDC (TYP) at 0.1A, 2.5VDC (MAX) at 0.1A
Response time OFF → ON: 2ms or less, ON → OFF: 2ms or less
Number of accesses to non-volatile memory Max. 1012 times
Insulation methodBetween input terminal and programmable controller power supply: Transformer insulation
Between input channels: Transformer insulation
Dielectric withstand voltageBetween input terminal and programmable controller power supply: 500VAC for 1 minute
Between input channels: 500VAC for 1 minute
Insulation resistanceBetween input terminal and programmable controller power supply: 500VDC 20MΩ or more
Between input channels: 500VDC 20MΩ or more
Heater disconnection detection specifi cations
Current sensor
−
CTL-12-S36-8 (0.0 to 100.0A)*3 *4
CTL-12-S36-10 (0.0 to 100.0A)*3
CTL-12-S56-10 (0.0 to 100.0A)*3
CTL-6-P (0.00 to 20.00A)*3 *4
CTL-6-P-H (0.00 to 20.00A)*3
Input accuracy Full scale × (±1.0%)
Number of alert delay 3 to 255
I/O occupied points*2 16 points/slot(I/O assignment: 16 intelligent points)
32 points/2 slots(I/O assignment: Vacancy for 16 points + 16 intelligent points)
Connection terminal 18-point terminal block Two 18-point terminal blocks
Applicable wire size 0.3mm2 to 0.75mm2
Applicable solderless terminal R1.25-3 (Crimping terminal with sleeve is unavailable)
Internal current consumption 0.29A 0.33A
Weight 0.20kg 0.30kg
Outline dimensions 27.4(W)mm × 98(H)mm × 112(D)mm 55.2(W)mm × 98(H)mm × 112(D)mm
*1: Calculate the accuracy in the following method (only when it is not affected by noise). Accuracy (°C) = full scale × indication accuracy + cold junction temperature compensation accuracy Example) Accuracy at the input range of 38 (-200.0 to 400.0°C), the operating ambient temperature of 35°C, and the temperature process value (PV) of 300°C
(Full scale) × (indication accuracy) + cold junction temperature compensation accuracy= (400.0°C- (-200.0°C)) × (±0.007) + (±1.0°C)= ± 5.2°C
*2: When the Q64TCTTBWN or Q64TCRTBWN is used, the device numbers of the I/O signals increase by 16 points depending on how many free points the left-hand side slots have. Hence, as I/O signals are given as indicated below in this manual, read them according to the module used.
Example) When 0 is set as the start I/O number, Yn1 is assigned as follows.When the Q64TCTTN or Q64TCRTN is used: Y1When the Q64TCTTBWN or Q64TCRTBWN is used: Y11
*3: U_RD Corporation Ltd. For more information, visit http://www.u-rd.com/
*4: The CTL-12-S36-8 and CTL-6-P can be used although they have been discontinued.
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MDOC(1108) This document is printed on recycled paper.
Manuals
Equipment Name Part number
Temperature control moduleQ64TCTTN 1W4295
Q64TCRTN 1W4296
Temperature control module with disconnection detection functionQ64TCTTBWN 1W4297
Q64TCRTBWN 1W4298
Spring clamp terminal block* Q6TE-18SN 1W4299
* Please use Q6TE-18SN for Q64TCRTN or Q64TCRTBWN.It is not possible to use the previous model Q6TE-18S.
External Dimensions
Q64TCTTN, Q64TCRTN Q64TCTTBWN, Q64TCRTBWN
22
23
22 55.2
50.8
90 90
98 98
4 4
27.4
Unit: mm
Point 1
Point 2