Watlow F4P系列96mmx96mm过程控制器用户手册

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"WATLOW F4P系列控制器用户手册（英文）.pdf" 这篇用户手册详细介绍了WATLOW公司的F4P系列控制器，这是一种96mm x 96mm（1/4 DIN）尺寸的工艺控制器。手册的版本为0600-0032-0013RevD，发布于2003年1月，价格标注为$15.00。该控制器的特点是具备引导式设置和编程功能，旨在帮助用户更方便地操作和配置。在安全信息部分，手册使用了"注释"、"警告"和"警示"符号来突出关键的操作和安全注意事项。"注释"用于提醒用户注意重要的细节；"警告"用于保护设备和性能，使用者应特别小心阅读并遵循所有适用的警告；而"警示"则用于防止人员、他人和设备受到损害，对这些警示的重视程度应非常高。安全警示符号包括一个三角形中的感叹号，用以标记一般的"警告"或"警示"信息。另外，电气危险符号——一个三角形内的闪电标志，预示着可能的电击危险，同样需要用户特别留意。手册中可能涵盖了以下内容： 1. 产品概述：介绍F4P系列控制器的基本功能和设计特点，包括其在温度控制和其他过程控制应用中的用途。 2. 硬件和接口：详细描述控制器的物理结构，如接线端子、显示屏和按键布局，以及与外部设备（如传感器、执行器和PLC）的连接方法。 3. 引导式设置：提供逐步指导，帮助用户进行控制器的初始配置，包括网络设置、通信协议选择、输入/输出映射等。 4. 编程指南：详细解释编程语言和逻辑，用户可以学习如何编写和修改控制逻辑，以满足特定的工艺需求。 5. 操作说明：阐述日常操作步骤，包括启动、运行、监控和故障排查。 6. 维护和故障排除：提供定期保养建议和常见问题的解决方案，帮助用户快速诊断和修复问题。 7. 安全规程：列出在安装、操作和维护控制器时必须遵守的安全规定，以防止电气伤害、火灾或其他潜在危险。 8. 技术规格：列出控制器的性能参数，如精度、响应时间、电源要求和环境适应性等。 9. 联系信息：提供Watlow公司的联系方式，包括地址、电话和网址，以便用户在需要支持时能及时联系。通过这份用户手册，用户将能够全面了解WATLOW F4P系列控制器的功能、操作方式以及确保安全操作的关键要点。对于那些需要使用或维护这种控制器的人来说，这是一份非常重要的参考资料。

3.2 ■ Operations Page Watlow Series F4P

Autotune PID

In autotuning, the controller automatically selects the

PID parameters for optimal control, based on the ther-

mal response of the system. In the Series F4P, five sets of

PID values are available. Default PID values exist for all

PID sets, although these values typically do not provide

optimal control. PID values can be auto-tuned or adjust-

ed manually. When autotuning is complete, the PID val-

ues will be stored in the Edit PID Menu.

Set point changes for remote, ratio and differential con-

trol are ignored until autotuning is complete.

Autotuning Procedure

Autotuning is initiated from the Operation Menu.

1. Before initiating auto-tune, go to the System Menu

(Setup Page), and establish the Autotune Set Point

to a percentage of set point. This percentage is based

on your knowledge of the system and how much

overshoot or undershoot there is likely to be in on-off

control.

Select to display Tune Status in the Custom Main

Page Menu.

2. Go to the Main Page and adjust set point.

3. Go to the Autotune PID Menu (Operations Page) and

choose the PID set in which to store the values. You

must exit back to Main Page with the left arrow. A

message will be displayed on the Main Page during

the autotuning process.

4. When autotuning is complete, the controller will

store the values for optimum control in the specified

PID set.

For additional information about autotuning and propor-

tional, integral and derivative control, see the Features

Chapter.

✔ Note: While the controller is autotuning, only the Op-

eration Page of the software can be entered.

CAUTION: Choose an autotune set point value that will

protect your product from possible damage from overshoot

or undershoot during the autotuning oscillations. If the

product is sensitive, select the autotune set point very

carefully to prevent product damage.

Edit PID

The Edit PID Menu is useful when Auto-tune PID does

not provide adequate control. Each of the PID parame-

ters can be adjusted manually:

Proportional Band: Define a band for PID control, en-

tered in degrees or units. Lower values increase gain,

which reduces droop but can cause oscillation. Increase

the proportional band to eliminate oscillation.

Integral (Reset): Define the integral time in minutes

per repeat; define reset in repeats per minute. Set re-

peats per minute if units are U.S.; minutes per repeat if

units are SI.

Derivative (Rate): Define the derivative (rate) time in

minutes. Large values prevent overshoot but can cause

sluggishness. Decrease if necessary.

Dead Band: Define the dead band in degrees or units.

Heating dead band shifts the set point down. Cooling

dead band shifts the set point up. For more information,

see the Features Chapter.

For background information, see Chapter 7, Features.

Manual Tuning Procedure

1. Apply power to the Series F4P and establish a set

point on the Main Page.

2. Establish Cycle Time in the Control Output Menu

(Setup Page), as required. Typical cycle times are 1.0

second for an SSR and 5.0 seconds for a mechanical

relay. Faster cycle times sometimes achieve the best

system control. However, if a mechanical contactor or

solenoid is switching power to the load, a longer cy-

cle time may be desirable to minimize wear on the

mechanical components. Experiment until the cycle

time is consistent with the desired quality of control.

3. Go to the Edit PID Menu (Operations Page), and

choose the channel and PID set. Establish values for

the PID parameters: Proportional Band, 5; Integral

(Reset), 0; Derivative (Rate), 0; and Autotune, Tune

Off. Tuning begins when you choose a PID set.

4. When the system stabilizes, watch the value of Input

1 on the Main Page. If this value fluctuates, increase

the proportional band setting until it stabilizes. Ad-

just the proportional band in 3° to 5° increments, al-

lowing time for the system to stabilize between ad-

justments.

5. When Input 1 has stabilized, watch the percent pow-

er on the Main Page. It should be stable, ±2%. At

this point, the process temperature should also be

stable, but it will exhibit droop (stabilized below set

point). The droop can be eliminated with integral (re-

set).

Watlow Series F4P Operations Page ■ 3.3

6. Start with an integral setting of 99.9 minutes and al-

low 10 minutes for the process temperature to get to

set point. If it has not, decrease the setting by half

and wait another 10 minutes. Then halve the setting

again and wait another 10 minutes until the process

value equals the set point. If the process becomes un-

stable, the integral value is too small. Increase it un-

til the process stabilizes.

7. Increase Derivative/Rate to 0.10 minute. Then in-

crease the set point by 11° to 17°C. Watch the sys-

tem's approach to the set point. If the process value

overshoots the set point, increase Derivative/Rate to

0.50 minute.

Increase the set point by 11° to 17°C and watch the

approach to the new set point. If you increase

Derivative/Rate too much, the approach to the set

point will be very sluggish. Repeat as necessary until

the system rises to the new set point without over-

shoot or sluggishness.

For additional information about the burst fire feature,

manual tuning and PID control, see the Features Chapter.

Multiple PID Sets

Environmental chambers, ovens and furnaces typically

have different thermal requirements at high and low

temperatures or pressures. To accommodate this, the Se-

ries F4P can store five different PID sets.

Multiple Tuning Procedure

To autotune multiple PID sets, follow the Autotuning

procedure above for each PID set. When autotuning is

finished for one set, proceed with another.

Cascade

Cascade control is available on enhanced (F4P _ - _ _ AB

- _ _ _ _) Series F4P controllers. For background informa-

tion about cascade control, see the Features Chapter.

Select cascade control through the Analog Input 3 Menu

(Setup Page), and choose Process Cascade or Deviation

Cascade. To set the range for the inner loop set point,

Process Cascade uses Low and High Range settings that

are independent of set point; Deviation Cascade uses De-

viation Low and High settings that are deviations from

the primary set point.

When tuning a cascade system, the inner loop must be

tuned first. The inner loop comprises outputs 1A and 1B

and the Analog Input 1 sensor, which usually measures

the energy source temperature. The output device con-

trols a power switching device, which in turn switches

the heating and cooling. The set point for the inner loop

is generated by the outer loop. For Process Cascade, this

will have a range between the Cascade Low Range and

Cascade High Range.

Cascade Setup Procedure

1. First, configure Analog Input 3, Cascade Low Range

and Cascade High Range.

Go to the Analog Input 3 Menu (Setup Page). Choose

Process or Deviation Cascade. Deviation Cascade refer-

ences Channel 1 set point allowing a range above and

below the current control set point. For Process Cascade

control of a heat/cool or cool only system, set the Cascade

Low Range to a value slightly lower than the lowest

temperature desired in the chamber. For heat-only sys-

tems, set the Cascade Low Range to a value slightly low-

er than the ambient temperature; otherwise the heat

output will never turn fully off.

For heat/cool or heat only systems , set the Cascade

High Range to a value slightly higher than the highest

temperature desired in the chamber. For cool-only

systems, set the Cascade High Range to a value slightly

higher than the ambient temperature; otherwise the

cooling will never fully turn off.

2. Next, configure the controller to tune and display data

for the outer loop. To view Inner Loop Set Point in the

upper display, go to the Setup Page, Custom Main Page

Menu, select the Inner Set point as one of the parame-

ters, P1 to P16, to be displayed in the Main Page.

To also view Analog Input 3 in the upper display, go to

the Setup Page, Process Display Menu, and choose Al-

ternating. Under Set Display Time, choose a duration

for the display of the Input 1 and Input 3 variables.

Cascade Autotuning Procedure

1. Go to Setup Page, Custom Main Page Menu. Choose

Tune Status 1 and Tune Status 2 to appear as 2 of the

16 parameters that can be displayed on the Main Page.

The Main Page will now display the status of the auto-

tuning process.

2. Autotune the inner loop. Go to the Autotune PID Menu

(Operations Page), and select Cascade Inner-loop.

Choose Cascade Inner Loop PID Set 1 to 5, where PID

values will be stored after autotuning. Autotuning be-

gins when you choose the PID set. While autotuning,

the F4 controller will control the energy source in an

on-off mode to a temperature equal to the Cascade High

Range setting x Channel 1 Autotune Set Point. For best

results, use proportional control only on the inner loop.

Watlow Series F4P Setup Page ■ 4.1

Chapter Four: Setup Page

Parameter Setup Order . . . . . . . . . . . . . . . . . . . . . .4.1

Customizing the Main Page . . . . . . . . . . . . . . . . . .4.2

Static Messages . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2

This chapter explains how to configure the controller

software through the Setup Page menus. Setup Page pa-

rameters affect the way the controller responds to your

application, which parameters and functions are visible

in other pages, and the way information is displayed on

the Main Page. Set up the controller properly to provide

a sound foundation for settings in other pages.

For ranges, defaults and other information about specific

parameters, see the Parameters Chapter. Record your

settings in the Parameter Setup Record, also in that

chapter.

For background information about inputs, outputs,

alarms and other features, see the Features Chapter.

Parameter Setup Order

Initial configuration of the Series F4P is best done in the

following order:

1. Go to the System Menu (Setup Page) to configure:

• PID units — SI (Integral, Derivative) or U.S. (Re-

set, Rate);

• Celsius or Fahrenheit scales;

• display of units in the controller’s upper display;

• Autotune set point;

• open-loop detection warnings; and

• controller response to a power outage.

2. Go to other menus on the Setup Page to configure:

• Analog Input x (1 to 3);

• Digital Input x (1 to 4);

• Control Output x (1A, 1B);

• Alarm Output x (1 or 2);

• Retransmit Output x (1 or 2);

• Communications; and

• Custom Main Page and Custom Messages.

3. Go to the Operations Page to tune the PID sets.

4. Go to the Operations Page to set the alarm set

points.

After this initial configuration, the most frequent

changes will be to the Operations Page (alarm set points

and PID sets).

If the Series F4P is already installed in an environmen-

tal chamber, oven, furnace or other equipment, most pa-

rameters will already be configured and access to the

Setup Page may be limited (see Chapter 5, Factory

Page).

Changing Setup Page parameters may change other pa-

rameters. In some cases, a change in one parameter will

affect the defaults of others. To see how all the pages,

menus and parameters are grouped, see the software

map on the inside back cover of this manual.

✔ Note: For more information about how parameter set-

tings affect the controller’s operation, see the Features

Chapter.

çWARNING: Only authorized and qualified personnel

should change the factory-default settings, which may

cause changes in other settings. Failure to comply with

this recommendation may result in damage to equipment

and property and injury to personnel.

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