Controller-Based Temperature Control Application Building Block
Controller-Based Temperature Control Application Building Block
Controller-Based Temperature Control Application Building Block
Original Instructions
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are
required to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may
be impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from
the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Where to Start
This Temperature Control Building Block is designed for slow applications such as ovens, autoclave machines, and
chillers. These applications typically display a significantly slower passive rate than active rate. Active rate refers to the
rate of temperature change from activating the heating or cooling element. Passive rate refers to the rate of temperature
change by the environment.
Notes:
Preface
About This Publication
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Available Connected Components Accelerator Toolkits. . . . . . . . . . . 9
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 1
Set Up the Temperature Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Controller for your Application What You Need. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Configure Your Control Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Analog Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PWM Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Configure Your Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Wire Your Temperature Control System. . . . . . . . . . . . . . . . . . . . . . . . 18
Wiring Diagram for the 2080-TC2 Thermocouple . . . . . . . . . . . 20
Wiring Diagram for the 2080-RTD Thermocouple . . . . . . . . . . 21
Chapter 2
Validate Your System Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
What You Need. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Review the System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Configure the Controller Communication Ports. . . . . . . . . . . . . . . . . 26
Configure the PanelView Graphic Terminal Communication
Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Download Your Program to the Controller. . . . . . . . . . . . . . . . . . . . . . 30
Configure the IP address for your PanelView Terminal . . . . . . . . . . . 32
Transfer your HMI Application to the PanelView Terminal . . . . . . 32
Validate Your System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Understand the Machine Functions Screen . . . . . . . . . . . . . . . . . . 33
Understand the Control and Auto Tune screen . . . . . . . . . . . . . . 34
Understand the Fault Help screen . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Verify the Control and Auto Tune screen . . . . . . . . . . . . . . . . . . . 35
Cold Start Your Temperature Control System . . . . . . . . . . . . . . . 37
Appendix A
User-defined Function Blocks for RA_TEMP_CONTROLLER Function Block . . . . . . . . . . . . . . . . . . 39
TempControl BB Autotune Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
How to Autotune with the RA_Temp_Controller . . . . . . . . . . . 41
RA_TEMP_CONTROLLER_TC_RTD Function Block . . . . . . . 42
RA_TEMP_CONTROLLER_PWM Function Block . . . . . . . . . . . 43
Appendix B
Global Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
This quick start is designed to provide a way to implement common control tasks by aiding in the selection of products
and providing access to panel and wiring information. Each section is designed with a different task as a standalone
machine, or implemented in a larger system.
IMPORTANT Use this publication together with other Connected Components Accelerator Toolkit quick starts to aid in building your
Micro800™ based application. Refer to Available Connected Components Accelerator Toolkits on page 9 for where to find
other quick starts.
To help with the design and installation of your system, application files and other information are provided on the
Connected Components Accelerator Toolkit (CCAT). The CCAT provides bills of materials (BOM), CAD drawings
for panel layout and wiring, control programs, Human Machine Interface (HMI) screens, and more. With these tools
and the built-in best-practices design, you are free to focus on the design of your machine control and not on design
overhead tasks.
The CCAT is available on the Connected Components Accelerator Toolkit DVD, publication CC-QR002, or through
the Rockwell Automation® Software Download and Registration System (SDRS) at
http://www.rockwellautomation.com/rockwellautomation/products-technologies/connected-components/tools/
accelerator-toolkit.page.
The beginning of each chapter contains the following information. Read these sections carefully before you begin work
in each chapter:
• Before You Begin - The chapters in this quick start do not have to be completed in the order in which they appear.
However, this section defines the minimum amount of preparation that is required before completing the current
chapter.
• What You Need - This section lists the tools that are required to complete the steps in the current chapter,
including, but not limited to, hardware and software.
• Follow These Steps - This section illustrates the steps in the current chapter and identifies the steps that are
required to complete the examples.
Terminology
Term (Abbreviation) Definition
Application Sequence Programs User-modified programs that work together with the standard state machine logic to control what the machine does
while in the abort, clear, reset, run, and stop states.
Auto/manual operation When the PanelView™ 800 terminal is in Auto mode, the controller logic controls the machine and monitors machine status.
When the PanelView 800 terminal switches to Manual mode, the terminal takes over control. Command buttons and
numeric entry fields are available only when the machine is in Manual mode.
Bill of Materials (BOM) A list of components that are needed for your system.
Building block (BB) Tools to accelerate and simplify the development of a Micro800 controller-based application. A typical building block
includes a starting Bill of Material (BOM), Computer-Aided Design (CAD) drawings, Micro800 controller programs,
PanelView 800 terminal applications, and a quick start document.
Computer-Aided Design (CAD) A computer-based system that is developed to facilitate design of mechanical parts.
Connected Components Accelerator Toolkit (CCAT) Software with application files and other information to speed the design and startup of component-based machines.
CCAT project A project that consists of these items:
• A ProposalWorks™-based bill of materials
• A set of CAD drawings (dimensions and schematics)
• A Connected Components Workbench™ project
• HMI displays
• A set of Quick Start documents
• A project document with information about the project components and links to reference materials
Connected Components Workbench™ software Software environment to configure or program Micro800 controllers, PanelView 800 terminals, PowerFlex® drives, and
other component-level products.
Connected Components Workbench project A project that consists of one or more of these items:
• Micro800 controller configuration
• Up to 256 Micro800 programs, each with program local variables
• Micro800 global variables
• PanelView 800 terminal application
• PowerFlex drive parameter lists
Global variables Project variables that any program can access, which includes all I/O and system variables.
State Machine control code Machine logic to coordinate overall machine operation that is based on states. The state machine broadcasts commands
and receives feedback information from each of the building blocks via user-modified application sequence programs.
Tags A PanelView 800 term for variables.
User-defined Function Blocks (UDFBs) Function block instructions that can be used like standard function block instructions within any Connected Components
Workbench programming language. Anyone who uses Connected Components Workbench software can write these
functions blocks. Many UDFBs are posted on the Rockwell Automation sample code website:
http://samplecode.rockwellautomation.com/idc/groups/public/documents/webassets/sc_home_page.hcst.
User-defined Object (UDO) A collection of PanelView 800 terminal screen objects that can be pasted into a new screen.
Additional Resources
These resources contain information about related products from Rockwell Automation.
Resource Description
Micro820™ 20-point Programmable Controllers User Manual, Provides a reference guide for Micro820 controller systems. It also contains procedures to install, wire, and
publication 2080-UM005 troubleshoot your controller.
Micro830™ and Micro850™ Programmable Controllers User Provides information to install, wire, and troubleshoot the Micro830 and Micro850 programmable controllers.
Manual, publication 2080-UM002
Micro800 Digital and Analog Plug-in Modules and Accessories Provides information to install, wire, and troubleshoot Micro800 plug-in modules and accessories.
User Manual, publication 2080-UM004
PanelView 800 HMI Terminals Installation Instructions, Provides information to install, wire, ground, and troubleshoot PanelView 800 HMI terminals.
publication 2711R-IN001
PanelView 800 HMI Terminals User Manual, publication Provides information to configure, operate, and troubleshoot the PanelView 800 HMI terminals.
2711R-UM001
Notes:
The temperature controller is located within the Micro800™ controller. Configuration is done through the ladder editor
of the Connected Components Workbench™ software.
Start
In this section, you configure the temperature control building block for analog output control. See PWM Control
Mode on page 15, if you are using PWM control mode.
1. Start the supplied Automated Tuning Temperature Control Building Block project for your specific Micro800
controller with Connected Components Workbench software.
2. To launch the controller configuration screen, double-click Micro850.
3. By default, a Thermocouple plug-in (2080-TC2) is configured for you in slot 1. To add an analog output plug-in
(2080-OF2), right-click slot 2.
Note: If your project is generated by CCAT, you must manually add your temperature sensor plug-in.
6. Assign your analog output in the 'Analog Output Branch' of Rung 2 of the 'TC2_01' program as shown in the
diagram.
7. Delete the 'PWM Output Branch' because you are not using it.
In this section, you configure the temperature control building block for PWM control. See Analog Control Mode on
page 12, if you are using analog control mode.
1. Start the supplied Automated Tuning Temperature Control Building Block project for your specific Micro800
controller with Connected Components Workbench software.
2. To launch the controller configuration screen, double-click Micro850.
3. Review your PWM output configuration in the 'PWM Output Branch' of Rung 2 of the 'TC2_01' program. as
shown in the diagram.
4. Delete the 'Analog Output Branch' because you are not using it.
2. By default, a thermocouple sensor plug-in (2080-TC2) is configured for you in slot 1. Right-click and change the
plug-in if you must replace it with an RTD type.
Note: If your project is generated by CCAT, you must manually add your temperature sensor plug-in.
3. Configure the thermocouple or RTD type based on the temperature sensor you selected for your application.
4. To assign your analog input in the program, complete the following steps:
a. Double-click the 'TC2_01' ladder program.
b. In rung 1, assign the analog input to the appropriate UDFB input based on the channel information you want
to read. For more information, see the Micro800 Plug-in Modules User Manual, publication 2080-UM004.
Pin B1 V0-0
Voltage Load Pin B2 C0-0
Pin A1 COM
Pin A2 COM
Cable Shield
Pin B3 V0-1
Pin B4 C0-1
Current Load Pin A3 COM
Pin A4 COM
Cable Shield
24V
Supply
S
DC COM
Fuse
D DC COM
The 2080-TC2 thermocouple requires a cold junction compensation (CJC) sensor to function. This sensor is a non-
polarized, passive negative temperature co-efficient thermistor (EPCOS B57869S0502F140). It is readily available
through most third-party vendors. For further information, see the Micro830 and Micro850 Programmable Controllers
User Manual, publication 2080-UM002.
Thermistor
B1 B2 B3 B4 B5 B6
5 mm
5 mm
B3
A3
A1 A2 A3 A4 A5 A6
Cable Tray/Conduit
Blue Red Green
Red
Blue 3
1 2 4 5 6
Process 1 2 3 4 5 6
temperature
measurement
A 2080-RTD thermocouple does not require a CJC sensor. You can connect the RTD wire directly to the input
terminal. For further information, see Micro830 and Micro850 Programmable Controllers User Manual, publication
2080-UM002.
IMPORTANT The illustration shows channel 0 only for 2-wire and 3-wire single sensor connections. The wire colors illustrate a specific RTD
sensor type available in the market.
Notes:
This chapter shows you how to configure and connect the devices in your Automated AutoTune Temperature Control
Building Block system, and validate that all devices communicate properly with each other.
Start
Both methods of connection are explained in this manual, but choose only one method for your project.
You can have multiple temperature-controller building blocks within a Micro800 controller. However, you have to
ensure that the controller has the required hardware configuration and sufficient program memory. Typically, a
temperature sensor has two identical sensor inputs and you can easily have another temperature control loop with the
second sensor terminal.
Follow these steps to modify these settings in the default Connected Components Workbench project:
1. Open the Automated AutoTune TempControl Building Block generated from CCAT or downloaded from the
sample code website.
2. In the project Organizer, double-click the controller icon.
This example shows a Micro850® controller. The Controller Detail view appears in the main project window.
3. Configure the settings for your PanelView graphic terminal communication port:
a. If a CIP serial connection is used, select the embedded serial port in the controller configuration list and edit
the required settings.
Follow these steps to modify these settings in the default Connected Components Workbench project.
The PanelView Communication Settings pane appears in the main project window.
b. For CIP on Ethernet communication, configure the settings as shown in the graphic.
If you are prompted to install any driver, use the recommended drivers.
2. In your Connected Components Workbench project, in the Project Organizer, right-click your controller icon
and choose Download.
The software automatically builds the program before download. If the build is successful, the Output pane at the
bottom of your project window displays a success message. Or, if the build was unsuccessful, an error list appears.
7. The Connection Browser window appears when the build is successful. Select your controller and click OK.
8. The software prompts you to select one of the following download options:
• Download: Download the project with initial values.
• Download with Project Values: Download project the with project values previously uploaded.
9. If you are prompted to change the controller mode to Remote Program mode, click Yes.
10. When the download is completed, set the controller back to Remote Run mode.
The controller automatically goes online.
1. To open the Communication screen, from the Main menu, press Communication.
2. Press Set Static IP Address.
3. Configure the IP Address and Mask values so they are in the same range as your Micro800 controller.
4. To return to the Main menu, press Main.
1. In the Project Organizer, right-click the PanelView 800 terminal icon and choose Download. If the project is not
validated, choose validate before download.
The software validates the application and thereafter, the Connection Browser window appears.
2. Select the PanelView 800 terminal and click OK.
4. From the Main menu of your PanelView 800 terminal, press File Manager.
5. On the File Manager screen, select Internal as your Source.
6. Select your application 'TC2_T10T_M800_ETN_r9'.
7. Press Run.
1. Return to the Machine Overview screen by pressing the 'X' in the upper right-hand corner of the screen.
2. View a device in detail by pressing its button.
3. View the current machine Auto/Manual state.
4. Change the current machine Auto/Manual state.
5. Clear machine faults, start/stop the machine (while in Auto mode) and go to the machine state diagram overview
screen.
The border of the device button changes color to indicate a specific status. For the Pump Control Building Block,
the button border colors indicate the following status:
• Green indicates that the drive is active and running
• Gray indicates that there is no alarm.
• Red indicates that there is a fault or an alarm is present.
This screen allows you to use the basic and advanced features of the temperate controller building block. Basic operations
include, changing temperature controller mode or control direction, and adjusting setpoint or control output. Advanced
operations include, auto tuning, manual tuning, and logging trend data onto the SD card.
Kp Set Proportional Gain (P). This parameter can only be set when machine is in
manual mode
Ti Set Time Integral (I). This parameter can only be set when machine is in manual
mode
Td Set Time derivative (D). This parameter can only be set when machine is in
manual mode
DG Set Derivative gain (Act as the effect for D). This parameter can only be set when
machine is in manual mode
Log Data Press to log chart data
Fault Help Press to go to Fault Help screen
This screen provides diagnostic status. If there is any issue with temperature sensors, it is reported here.
The top half of the screen displays indicators that turn red when the specific error occurs. The bottom half is the fault
description and the possible action you can take to rectify the error. If there are multiple errors, tap the blue button to
navigate through the fault messages. When the error is cleared, the indicator becomes gray again.
The building block has a machine auto mode/ machine manual mode and temperature controller auto mode/
temperature controller manual mode.
Machine auto/ manual mode switches between a fully automated program that uses the application sequences and
manual control of the individual building block.
Temperature control auto/manual mode switches between the PID loop and the operator controlling the Control Value.
The auto tune status bar displays the state of auto tune. When auto tune is completed, you should get a set of PID
parameters.
8. The temperature controller is set to auto mode when auto tune is completed.
This appendix describes the available user-defined function blocks and the associated inputs and outputs.
Autotune Procedure
It is important that you understand the autotune procedure before you use it. You must also verify that it is safe for your
process to operate under the autotune procedures.
1. Check that SP is not '0.0'. If you must tune for 0.0 degrees Celsius, use the next closest value that you can accept
(for example, 0.001).
2. Output is set to 100% when autotune is activated.
3. The direction of the process is determined.
4. When PV exceeds the targeted SP, Output is set to 0%.
5. When PV rebounds and passes the SP, Output is set to 100% again.
6. When PV exceeds the targeted SP, Output is set to 0%.
7. When PV rebounds and passes the SP again, autotune is completed.
8. The new gain is updated internally.
9. The controller switches to auto mode and the PID loop is in operation with the auto-tuned gains.
Notes:
Global Variables
These global variables are for machine auto mode. The temperature controller operates based on the value in these
variables.
Table 9 - Global Variables Used for Machine Auto Mode
Variable Data Type Description
TC2_01_Cmd_SP_Auto REAL Command Set Point.
TC2_01_Cmd_Auto_Auto BOOL Command input to set temperature controller to auto mode.
TC2_01_Cmd_Man_Auto BOOL Command input to set temperature controller to manual mode.
TC2_01_Cmd_MV_Auto REAL Command Manipulated Value for controlling the control value during temperature controller Auto mode.
TC2_01_Cmd_Run_Auto BOOL Trigger to run temperature controller .
TC2_01_Cmd_Stop_Auto BOOL Trigger to stop temperature controller.
TC2_01_Cmd_Abort_Auto BOOL Trigger to abort autotune.
TC2_01_Cfg_Gains GAIN_PID Gain setting for temperature controller.
TC2_01_Cfg_Datalog BOOL Set to TRUE to enable data logging.
TC2_01_Out_Temp REAL Scaled temperature value.
TC2_01_Out_CV REAL PID Control Value.
TC2_01_Sts_Man BOOL When TRUE indicates that the controller is in manual mode.
TC2_01_Sts_Auto BOOL When TRUE indicate that controller is in auto mode.
TC2_01_Sts_Stop BOOL When TRUE indicate that controller is stopped.
TC2_01_Sts_Run BOOL When TRUE indicate that controller is running.
TC2_01_Sts_AT BOOL When TRUE indicate that autotune is in progress.
TC2_01_Sts_AT_ID INT Indicate the autotune status.
TC2_01_Sts_Logging BOOL When TRUE indicate that trend data is being logged.
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route your call directly to a technical support engineer.
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