all-in-one PLC

KV Nano Application Guide

Vol. 6

KV Nano Temperature Control Function

Cost reduction through PLC-integrated control
without temperature controllers!

Points
1. Cost reduction due to no need for temperature controllers.
2. Temperature can be controlled by a PLC using an instruction specifically prepared for temperature control.
3. Integrated temperature control of multiple devices by a PLC is possible.
 Temperature Control......................................................................

<Conventional>

External device (PC, HMI, etc.)

Temperature

Temperature Temperature Temperature

controller controller controller

Control target

A temperature controller was required for each control target in order to control the temperature of
multiple devices.
Additionally, wiring for each device and communication programming were also required when
managing temperature data from an external device.

<With the KV Nano>

External device (PC, HMI, etc.)

Temperature
PLC management

Control target

A single PLC can control the temperature of multiple devices.

Communication is required only for a single PLC even when temperature data management is necessary.
Further, the KV Nano connector type allows acquired temperature data to be easily recorded on an SD card.

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 System Configuration....................................................................

KV-NC32T + KV-NC4TP *1

Temperature input Temperature sensor *2

Control target
Control output

Heater Heater power

source

SSR(Solid State Relay)

The KV Nano Series basic unit has a temperature control instruction (PIDAT instruction), which allows a
PLC to acquire control target temperature data and control it. In addition, the PIDAT instruction has an
auto tuning function that significantly reduces time required for adjusting PID control parameters which
was conventionally troublesome.

*1 A converter unit (KV-N1) is separately required when a terminal block type basic unit is used.
*2 Both a thermocouple and platinum resistance temperature detector can be used for sensing temperature.
Select the appropriate method according to the measurement temperature range and required resolution.

ONE POINT
A PLC can control temperature without using temperature controllers.
A combination of a PLC and the KV-NC4TP unit can control the temperature of four targets.
Temperature of up to 28 targets can be controlled.

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 Example of temperature control applications
Soldering tank for electronic PC boards Liquid crystal drying/burning processes

Quenching furnace Moulding machine

Sterilisation equipment for pharmaceutical and

Food drying furnace
food products

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 Preparation for Wiring...................................................................
Prepare and connect the required devices
1. KV-N14/24/40/60xT or KV-NC32T × 1 unit
2. Temperature input unit KV-NC4TP × 1 unit
3. Other devices (SSR, temperature sensor, heater, etc.)

Notes
• A converter unit (KV-N1) is required separately when the KV-N14/24/40/60xT is used.

Wiring..................................................................................................

1. Wiring for temperature input

Notes for wiring
A cold junction compensation resistor is connected to the NC terminal. Do not remove it.
Either a thermocouple or platinum resistance temperature detector can be selected for each channel.

A. When using thermocouples

* Use a compensating lead wire cable corresponding to each thermocouple when extending the thermocouple cable.
Using cables other than compensating lead wire cables causes errors in measurement values.

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 B. When using platinum resistance temperature detectors (RTDs)

• All channels are non-isolated when using RTDs.

Do not connect terminals that have different electric potentials.
• When extending the RTD cable, the three extension cables need to be the same type and the
same length. If different types of cables are used or the extension length of the three cables is
different, errors may occur in measurement values. Normal lead wire cables can be used.
• Set the wiring resistance to less than 100 Ω per cable.

2. Wiring for control output

The following is a wiring example for the output terminal (transistor (sink) output) equipped with the
KV-NC32T.
The rated load is 30 VDC, 0.3 A (1.6 A/Common).

KV-NC32T output
terminal assignment

When using R500

(*Relays other than R500 can also be used.)

Heater
Output circuit

Input circuit

Power for load

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 How to Set the Temperature Input Unit..................................
Start KV STUDIO (Ver. 7 or later) and create a new project.
([KV-NC32] is selected as the supported model in this document.)

1. Select [Tool] > [Unit Editor] from the menu.

In the Unit Editor, add the temperature input unit KV-NC4TP.

2. Double-click the KV-NC4TP and set parameters in the “Setup unit(2)” tab.
The following are the initial setting values. Change them according to the usage conditions.

Select [Convert] > [Auto-assign Relay/DM] from the Unit Editor menu to set the addresses and
then exit the Unit Editor.

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 3. ‌Select [View] > [Device comment edit window] from the KV STUDIO menu and register device
comments for the temperature input unit.

* If device comments have been registered, candidate device comments are displayed when directly entering a desired
comment with keys, which reduces steps required for programming.

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 Sample Programming...................................................................
[Operation Contents]
Switch to Run mode and set PID control initial parameters.
When MR000 is turned on, control starts based on the temperature changing rate set by the RAMP
instruction.
A manipulated value is calculated from a set value and the temperature measurement input value
and pulses are output from R500.
Control the target temperature by controlling the ON/OFF state of the heater through SSR.

[Device specifications]
Device Device comment Device Device comment
MR000 PID control start DM1000 PID setting value
MR001 AT Execution condition DM2000 Manipulated value
MR002 In automatic tuning DM10000 ch0 Measured input value
DM3000 Target value
DM1001 to DM1020 to
PID control parameter PID operation work area*
DM1019 DM1051

* The system uses those devices. Do not use the devices within this area.

[PID Operation]
The PIDAT instruction adds the AT (Auto tuning) function to the PID calculation. With the limit cycle
method, the PID constants (proportional constant, integral constant, differential constant) can be
calculated and set automatically according to each control target.

Value observed from PID control target Manipulated value obtained

the control target value, etc. * by PID calculation

* With the leading device specified here, 52 consecutive words are occupied.

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 Set the following parameters before executing the PID control.
(Set other parameters as necessary.)

Parameter
PID setting value
AT start/operating flag (DM1002.2)
Operation setting (DM1003)
Sampling setting (DM1004)
Proportional constant (DM1005)
Integral constant (DM1006)
Differential constant (DM1007)
Minimum Manipulated value (DM1011)
Maximum Manipulated value (DM1012)
Auto tuning
When not used When used
 
— 
 
 
 —
 —
 —
 
 

* ‌When auto tuning is complete, the tuned PID constants (proportional constant, integral constant, differential
constant) are applied to DM at the same time as the AT start/operating flag is turned off.

1. PID setting value (DM1000)

Enter a value calculated from the value set in DM3000 into DM1000.

°C
DM3000 value
2000

PID control temperature :DM3000

change rate
:DM1000
Example below) 50/sec

Using the RAMP instruction

gives an inclination in the PID
setting value, which allows for
gradual changes.

0
0 40 t

0: Change rate per second

1: Change rage per minute
2: Change rage per hour

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2. Sampling cycle (DM1004)
A cycle to acquire a measurement value for the PID calculation
Setting range: 1 to 60000 (0.001 to 60.000 [S])

Set the sampling cycle according to the response speed of the measurement target.

3. Proportional constant (DM1005)

The constant for proportional operations; Setting range: 1 to 50000 (0.001 to 50.000)

(1) A larger proportional constant decreases the deviation between the set value and
measurement value, but increases hunting.
(2) A medium proportional constant keeps both the deviation and hunting at medium levels.
(3) A smaller proportional constant increases the deviation, but decreases hunting.

* The deviation needs to be adjusted with an integral constant because it cannot be eliminated by adjusting a
proportional constant.

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 4. Integral constant (DM1006)
An integral constant is used for reducing the deviation between the set value and measurement
value that occurs during proportional constant operations.
Setting range: 0 to 3 0001 (Integral operations are not performed when “0”, “30001” or higher is set.)
When bit 4 for DM1000.4 is OFF, setting range: 0.1 to 3000.0 [S] (100 ms increments)
When bit 4 for DM1000.4 is ON, setting range: 0.001 to 30.000 [S] (1 ms increments)

(1) A smaller integral constant quickly raises temperature, but increases hunting.
(2) A medium integral constant keeps both the rising speed and hunting at medium levels.
(3) A larger integral constant slows down temperature rising, but decreases hunting.

* Set a larger value if long-cycled hunting occurs.

5. Differential constant (DM1007)

Use the differential constant to increase the response to sudden changes such as interference.
Setting range: 0 to 30000 (Differential operations are not performed when “0” is set.)
When bit 4 for DM1000.4 is OFF, setting range: 0.00 to 300.00 [S] (10 ms increments)
When bit 4 for DM1000.4 is ON, setting range: 0.000 to 30.000 [S] (1 ms increments)

(1) A larger differential constant responds to interference quickly, but increases hunting.
(2) A medium differential constant keeps both the interference response speed and hunting at
medium levels.
(3) A smaller differential constant slows down the response to interference, but decreases hunting.

* Set a smaller value when short-cycled hunting occurs. Set a smaller value for systems with quick response
(pressure, flow rate, etc.) and those with vibration factors.

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6. Minimum manipulated value (DM1011), maximum manipulated value (DM1012)
Make sure to set the maximum manipulated value > minimum manipulated value.
ON/OFF control is performed within this value range during auto tuning.

7. Operation setting flag (DM1003.0)

Temperature is controlled by direct operation when the operation setting flag (DM1003.0) is ON.
Temperature is controlled by reverse operation when the operation setting flag (DM1003.0) is OFF.
(Set DM1003.0 to OFF because reverse operation needs to be set in this sample.)
For details on other operation setting flags, refer to the instruction manual.

8. AT start/operating flag (DM1002.2)

Auto tuning starts in the sampling cycle directly after the AT start/operating flag (DM1002.2) is
turned ON. When auto tuning is complete, the AT start/operating flag (DM1002.2) is automatically
turned off, tuned PID constant parameters are set, and then the PID control starts based on the set
PID constants.

ONE POINT
The KV script reduces the time required for parameter setting.

<When a ladder is used>

<When the KV script is used>

Select [Script] >

[Insert box script] to
enter the scripts.

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 Example ladder programme

Set to 1 temporarily because setting to 0 causes an error.

When auto tuning is complete, the parameters are automatically set.

The PID control setting value changes according to the inclination set by
the RAMP instruction.

PID calculation is performed with
the ch0 Measured input value
(DM10000) and PID setting value
(DM1000) and the manipulated
value (DM2000) is calculated.
Enter the manipulated value (DM2000) in the
ON time and convert the manipulated value
(DM2000) into the pulse output in a cycle of the
PIDAT instruction’s maximum manipulated
value.

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 Auto unit starts at rise of MR001 during execution of the PIDAT instruction.

Check the ON/OFF state of MR002 to determine whether or not auto tuning is being
executed. When auto tuning is complete, the execution condition MR001 is reset.

Unit Monitor. .....................................................................................

Select [Monitor/Simulator] > [Unit Monitor] from the menu.

Measurement values, analogue data, and line break information for the temperature input units can
be monitored on the list

Registration Monitor......................................................................
Select [Monitor/Simulator] > [Registration Monitor Window] from the menu.

Register devices in
advance to make
debugging even easier.

Double-click to switch
the ON/OFF state.

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