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CLS User's Guide

1. Symbol Alarm Message Alarm Type FS TC Break Thermocouple break FS RO RTD Open RTD break FS RS RTD Short RTD Short HP No message High process alarm HD No message High deviation alarm LD No message Low deviation alarm LP No message Low process alarm Acknowledging an Alarm Press Alarm Ack to acknowledge the alarm If there are other loops with alarm conditions the Alarm display switches to the next loop in alarm Acknowledge all alarms to clear the global alarm digital output You must acknowledge each alarm before displays and keyboard operation will resume SE NOTE In the 4 and 8 CLS the controller cannot detect all RTD open and RTD short failures Detection of open or shorted RTDs depends on which wires are open or shorted Job Display Using the CLS Job display appears only if e You have turned on the Remote Job Select function This function is explained in Setup e You have selected a job from the job load menu When you load a job Job display shows you the following screen LOOP _ PROCESS _ UNITS JOB 3 RUNNING If you remotely loaded the job Job display looks like this LOOP PROCESS _ UNITS JOB 3 RUNNING REMOTELY LOADED ALARM SETPOINT _ STATUS __OUT If you modify a job s parameters while the job is running you ll see this job message LOOP PROCESS _ UNITS JOB 3 RUNNING DATA MODIFIED ALARM SETPOINT _ STATUS __ OUT If an alarm occurs the c
2. Low Process Alarm Output High Deviation Alarm Type Alarm Deadband High Deviation Alarm Output Alarm Delay The CLS has three different kinds of alarms failed sensor alarms global alarms and process alarms Failed Sensor Alarms Failed sensor alarms alert you to T C breaks and these RTD open or short failures e Open input e Open input e Short between and input Failed sensor alarms alert you to T C breaks When the loop is in Automatic or Tune mode and a failed sensor alarm occurs the CLS sets the loop to Manual control at the output override percentage you set in the Set up Loop Outputs menus CLS User s Guide 87 Setup 88 CLS User s Guide Global Alarms Global alarms occur when a loop alarm set to Alarm not Control is unacknowledged or when there are any unacknowledged failed sensor alarms If an alarm occurs the CLS front panel displays an appropriate alarm code see Using the CLS section Even if the alarm condition goes away the global alarm stays on until you use the front panel Alarm Ack key or ANASOFT to acknowledge it Process Alarms Process alarms include high and low deviation and high and low process alarms You can set each of these alarms to Off Alarm or Control as shown here Function Description Off No alarm or control function Alarm Standard alarm function Control Digital output activities on alarm deactivat
3. Changing a Trigger s True State Use this menu to toggle a trigger s true state On or Off This menu appears only if you answered YES to the Edit Segment triggers menu LOOP PROCESS _ UNITS C SEG03 TR2DI09 ACTIVE STATE OFF ALARM SETPOINT _ STATUS __ OUT Selectable Values Off or On Latching or Unlatching a Trigger Use this menu to make a trigger latched or unlatched e A latched trigger is checked once at the beginning of a segment e An unlatched trigger is checked constantly while a segment is run ning If an unlatched trigger becomes false the segment timer stops and the loop goes into trigger wait state LOOP _ PROCESS _ UNITS B SEGO1 TR2 DI08 TRIG UNLATCHED ALARM SETPOINT _ STATUS _ OUT Selectable Values Latched or Unlatched CLS User s Guide 127 Appendix A Ramp Soak Setting Segment Tolerance Setpoint Ending a Profile Repeating a Profile 128 CLS User s Guide Use this menu to set a positive or negative tolerance value for each segment this value is displayed in the engineering units of the process and is a deviation from the setpoint Tolerance works as shown in this diagram Positive Tolerance Value Negative Tolerance Value PV out of tolerance PY within tolerance F Setpoint ro _ PV within tolerance v PV out of tolerance If you enter a positive tolerance the process is out of tolerance when the PV goes above the setpo
4. GND RX IN 2 log IN IN log IN IN Com IN IN IN Com Com RXB RXA 2 4 16 8 10 12 14 16 18 20 22 24 26 TB2 4 2 CH9 CH Ana CH CH Ana CH CH 5V CH CH GND TX IN 10 log 11 12 log 13 14 Ref 15 16 V Pwr IN Com IN IN Com IN IN IN IN TXB TXA pwr Com 42 CLS User s Guide Serial Communications RS 232 Interface Installation The CLS is factory configured for RS 232 communications However the communications are jumper selectable so you can switch between RS 232 and RS 485 See Configuring Communications below You can also order a communications cable from Watlow Anafaze or make your own cable With RS 232 communications you can connect the CLS directly to the serial communications connector on an IBM PC or compatible computer PC compatible computers typically use RS 232 communications The RS 232 interface is a standard three wire interface See the table below for connection information Some computers reverse transmit TX and receive RX so check your computer manual to verify your connections You can use either RS 232 or RS 485 communications in these situations e When you are using local communications up to 50 feet e When you are using a single CLS If you are using RS 232 communications with grounded thermocouples use an
5. Keyboard Lock Status Use this menu to lock the front panel operator function keys Change SP Man Auto and Ramp Soak so that pressing these keys has no effect If you want to use these functions turn off the Keyboard Lock LOOP__ PROCESS _ UNITS KEYBOARD LOCK STATUS OFF ALARM SETPOINT _ STATUS __OUT Selectable values On or Off Power Up Output Status Use this menu to set the initial power up state of the control outputs to Off or Memory If you choose Off all control outputs are initially set to Manual mode at 0 output level If you choose Memory the outputs are restored to the last output state stored in memory LOOP PROCESS _ UNITS POWER UP OUTPUT STATUS OFF Do not set the CLS to start from memory if a memory based restart is unsafe for your process Selectable values Off or Memory Controller Address Use this menu to set the CLS address The controller address is used for multiple controller communications on a single 485 cable so each CLS must have a different address Begin with address 1 for the first controller and assign each subsequent controller the next higher address LOOP _ PROCESS _ UNITS CONTROLLER ADDRESS 1 ALARM SETPOINT STATUS __ OUT Selectable values 1 32 CLS User s Guide 67 Setup Communications Baud Rate Communications Protocol Use this menu to set the Communications Baud Rate LOOP _ PROCESS _ UNITS COMMUNICATIONS BAUD RATE 9600 A
6. RTD 1 100 0 to 10 0 Kohms 10 0 Kohms 80 ohms 275 0 C 25 0 Kohms 25 0 Kohms 100 ohms RTD 2 120 to 840 C 0 10 mA DC Jumper 6 0 ohms 0 20 mA DC Jumper 3 0 ohms 0 100 mV 499 ohms 750 ohms 0 500 mV 5 49 Kohms 750 ohms 0 1 VDC 6 91 Kohms 422 0 ohms 0 5 VDC 39 2 Kohms 475 0 ohms 0 10 VDC 49 9 Kohms 301 0 ohms 0 12 VDC 84 5 Kohms 422 0 ohms The following tables show the location of RA RB RC and RD on the analog input boards of the 4CLS and the 8CLS The analog input board is the upper board of the two board set 36 CLS User s Guide Installation 4CLS Voltage Current Inputs Loop RC RD 1 58 RP1 2 56 RP2 3 54 RP3 4 52 RP4 SCLS Voltage Current Inputs Loop RC RD Loop RC RD 1 58 RP1 5 50 RP5 2 56 RP2 6 48 RP6 3 54 RP3 7 46 RP7 4 52 RP4 8 44 RP8 4CLS RTD Thermister Inputs Loop RA RB RC 1 RP1 57 2 RP2 55 3 RP3 53 4 RP4 51 8CLS RTD Thermister Inputs Loop RA RB RC Loop RA RB RC 1 RP1 57 5 RP5 49 2 RP2 55 6 RP6 47 3 RP3 53 7 RP7 45 4 RP4 51 8 RP8 43 Place resistors RA RB and RD in the resistor pair locations this way RP RP RA RB RD A wire trace on the printed circuit board jumpers the RC position When you place a resistor in the RC position cut the wire trace that connects the two resistor terminals CLS User s Guide 37 Installation 16 CLS Scaling Valu
7. or 0 1 Vdc or 1 5 Vdc or 0 5 Vdc The CLS MLS line of controllers must be used with an Watlow Anafaze Dual Dac Digital to Analog Converter or SDAC Serial Digital to Analog Converter for proper signal conversion The Dual Dac accuracy on retransmit is 75 of reading which matches the standard T C rated accuracy statement of 75 of reading For higher accuracies of 05 of full scale the SDAC is recommended Please consult the SETUP Section of this manual for information on setting up the other options of the controller Cascade Control Appendix B Enhanced Process Control Cascade Control is used to control thermal systems with long lag times which cannot be as accurately controlled with a single control loop The output of the first primary loop is used to adjust the setpoint of the second secondary loop The secondary loop normally executes the actual PID control In some applications there are two zone cascade control systems where the primary channel PID output is used for the primary heat control and the secondary cascaded channel PID output is used for a heat boost in a second zone These are used in the metals market such as aluminum casting industries You can use the primary heat output for both control and for determining the setpoint of the secondary loop A customer has a tank of water which has an inner and outer thermocouple The inner thermocouple is located in the center of the water The outer thermo
8. ALARM SETPOINT STATUS __OUT Selectable Values Hours Mins or Mins Secs You can reach the rest of the menus in this section from the Setup Ramp Soak profile main menu This menu is located between the Setup Loop Alarms main menu and the Manual I O Test main menu LOOP PROCESS _ UNITS SETUP RAMP SOAK PROFILE ALARM SETPOINT STATUS __OUT Answering Yes to this prompt allows you to setup or edit R S profiles Use this menu to choose a profile to set up or edit LOOP PROCESS _ UNITS EDIT RAMP amp SOAK PROFILE A ALARM SETPOINT STATUS __OUT Selectable Values A to Q 17 profiles CLS User s Guide 121 Appendix A Ramp Soak Copying the Setup from Another Profile Use this menu to setup similar profiles quickly by copying a profile to another one LOOP _ PROCESS _ UNITS COPY SETUP FROM PROFILE A ALARM SETPOINT _ STATUS __OUT Selectable Values A to Q Editing the tolerance Alarm Time Use this menu to set a tolerance time that applies to the entire profile LOOP PROCESS _ UNITS A OUT OF TOLRNCE ALARM TIME 1 00 ALARM SETPOINT STATUS __OUT When the segment goes out of tolerance e The segment goes into tolerance hold e The segment timer holds e The loop s single loop display shows TOHO Tolerance Hold When the segment has been out of tolerance for more than the tolerance alarm time e The controller goes into tolerance alarm e The tolerance timer resets You must ac
9. Band PB or Gain Integral TI or Reset and Deriva tive TD or Rate settings e Output Filter e Spread between heat and cool outputs LOOP __ PROCESS _ UNITS SETUP LOOP 01 CONTROL PARAMS ALARM SETPOINT STATUS __ OUT Below is the setup control parameters menu tree ASA NOTE Both heat and cool outputs have the same menus so only one of each menu is shown here The controller will show both heat and cool menus even if the heat or cool output is disabled See Set up Loop Outputs for help enabling or disabling the heat or cool output Refer to Tuning and Control for help in selecting control Setup Loop Control Params Heat Cool Control PB Heat cool Control TI Heat Cool Control TD Heat Cool Control Filter Heat Cool Spread 5 lt P lt 78 CLS User s Guide Heat or Cool Control PB Setup This menu allows you to set the Proportional Band also known as Gain LOOP __ PROCESS _ UNITS 02 HEAT CONTROL Sx 4 NOTE Heat or Cool Control TI Heat or Cool Control TD The CLS internally represents the proportional band PB as a gain value When you edit the PB you ll see the values change in predefined steps small steps for narrow PB val ues and large steps for wide PB values The controller calculates the default PB for each input type according to the following equation High Range Low Range Default PB Hig g ge
10. C 0 to 3210 18 to 1766 2 5 4 5 5 6 10 1 B T C 150 to 3200 66 to 1760 6 6 12 0 14 9 27 0 E T C 328 to 1448 200 to 787 True for 10 to 100 of span RTD Ranges and Resolution 4 and 8 CLS only Measure Accuracy Accuracy Range in Range in Resolution ment 25 C 0 50 C oF oc Temp In Ambient Ambient oc oc oF oc oF RTD1 148 0 to 100 0 to 0 023 C 25 0 35 0 63 0 5 0 9 527 0 275 0 275 1 1 8 1 5 42 7 RTD2 184 to 120 to 840 0 062 C 25 0 9 1 62 2 8 5 04 Di 840 1 1 4198 4 3 7 74 T C Break Detection Pulse type for upscale break detection Milliamp inputs 0 20 mA 3 ohms resistance or 0 10 mA 6 ohms resistance with scaling resistors Voltage inputs 0 12V 0 10V 0 5V 0 1V 0 500mV 0 100 mV with scaling resistors Input Range Reene 0 12 V 85 Kohms 0 10 V 50 Kohms 0 5 V 40 Kohms 0 1 V 7 4 Kohms 0 500 mV 6 2 Kohms 0 100 mV 1 2 Kohms Source Impedance For 60 mV T C measurements are within specification with up to 500 ohms source resistance 8 CLS User s Guide Digital Inputs Introduction Number 8 Configuration 8 selectable for output override remote job selection Input Voltage Protection Diodes to supply and common Source must limit to 10 mA for override conditions Voltage Levels lt 1 3V Low gt 3 7V High TTL Maximum Switch Resistance to Pull Input Low 1 Kohms Minimum Swit
11. Control 140 PV Retransmit Menus By adjusting the Maximum and Minimum inputs you can scale the output appropriately Linear Scaling of PV for Retransmit Output OV 100 Max Output Min Output 0 l Min Min Input PV Input Input The Setup menus for the PV Retransmit feature appear under the Setup Loop PV Retransmit menu In order to view the PV retransmit menus you need to select Yes at the following prompt LOOP _ PROCESS __ UNITS SETUP LOOP 02 PV RETRANSMIT ALARM SETPOINT__ STATUS __ OUT If you select No to the above screen the controller skips down to the retransmit for cool Cool is set up the same way that the heat is set up PV Assignment LOOP _ PROCESS _ UNITS 02 HEAT OUTPUT RETRANS PV 03 ALARM SETPOINT STATUS __OUT Selectable Values Any loop or None in this case loop No 02 Appendix B Enhanced Process Control Minimum Input LOOP__ PROCESS _ UNITS 02 HEAT RETRANS MIN INP 1000 ALARM SETPOINT _ STATUS __ OUT Selectable Values From the input loop PV minimum reading to the maximum reading Minimum Output LOOP __ PROCESS _ UNITS 02 HEAT RETRANS MIN OUT 0 If you select a Min Out other than 0 one output will never drop below Min Out even if the PV drops below the Min Input you specify Selectable Values 0 100 Maximum Input LOOP PROCESS _ UNITS 02 HEAT RETRANS MAX INP 10000
12. Current AC An electric current that reverses at regular inter vals and alternates positive and negative values Ambient Temperature The temperature of the air or other medium that surrounds the components of a thermal system American Wire Gauge AWG A standard of the dimensional characteristics of wire used to conduct electrical current or signals AWG is identical to the Brown and Sharpe B amp S wire gauge Ammeter An instrument that measures the magnitude of an electric current Ampere Amp A unit that defines the rate of flow of electricity current in the circuit Units are one coulomb 6 25 x 1018 electrons per second Analog Output A continuously variable signal that is used to rep resent a value such as the process value or set point value Typical hardware configurations are 0 20mA 4 20mA or 0 5 Vdc Automatic Mode A feature that allows the controller to set PID control outputs in response to the Process Vari able PV and the setpoint Autotune A feature that automatically sets temperature control PID values to match a particular thermal system Bandwidth A symmetrical region above and below the set point in which proportional control occurs Baud Rate The rate of information transfer in serial commu nications measured in bits per second 163 Glossary Block Check Character BCC A serial communications error checking method An acceptable method for most applications BCC is the def
13. HEAT OUTPUT ACTION REVERSE ALARM SETPOINT STATUS __ OUT Selectable values Reverse or direct For heat outputs set to reverse for cool outputs set to direct Heat or Cool Output Limit Setup Use this menu to limit the maximum PID control output for a loop s heat and cool outputs This limit may be continuous or it may be in effect for a specified number of seconds see Output Limit Time below If you choose a timed limit the output limit restarts when the controller powers up and when the output goes from Manual to Automatic control via the front panel when the controller changes jobs or from ANASOFT The output limit only affects loops under automatic control It does not affect loops under manual control LOOP _ PROCESS _ UNITS 01 HEAT OUTPUT LIMIT 100 ALARM SETPOINT _ STATUS __ OUT Selectable range 0 100 Heat or Cool Output Limit Time Use this menu to set a time limit for the output limit LOOP _ PROCESS _ UNITS 03 HEAT OUTPUT LIMIT TIME CONT ALARM SETPOINT STATUS __OUT Selectable values 1 999 seconds 1 second to over 16 minutes or to CONT continuous Heat or Cool Output Override Use this menu to set an output override percentage You can configure a digital input for the output override in the Set up Global Parameters main menu If the current loop is in Automatic mode and a sensor failure occurs the loop switches to the output override percentage If you change
14. High and low process alarm type setpoint and digital output e High and low deviation alarm type deviation alarm value and digi tal output e Alarm deadband e Alarm delay The setpoints deviation alarm values and deadband all use the same decimal format as the loop s process variable Alarm Delay You can set the CLS to delay normal alarm detection and alarm reporting There are two kinds of alarm delay e Start up alarm delay delays process alarms but not failed sensor alarms for all loops for a time period you set in the Set up Global Parameters main menu e Loop alarm delay delays failed sensor alarms and process alarms for one loop until the alarm condition is continuously present for longer than the loop alarm delay time you set NOTE Failed sensor alarms are affected by the loop alarm delay even during the start up alarm delay time period CLS User s Guide 89 Setup High Process Alarm Setpoint High Process Alarm Type Use this menu to select the setpoint temperature or other value within the scaled sensor range at which the high process alarm activates The high process alarm activates when the process variable PV goes above the high process setpoint It deactivates when the PV goes below the high process setpoint minus the deadband value if you have set a deadband value LOOP __ PROCESS _ UNITS 04 HI PROC ALARM SETPT 1000 F ALARM SETPOINT _ STATUS __ OUT Selectable range an
15. Input Testing 1 Go to the digital input test menu under the Manual I O Test main menu This menu shows whether the digital inputs are H high or open or L Low or closed 2 Attach a wire to the terminal of the digital input you want to test A When the wire is connected only to the digital input terminal the digital input test menu should show that the input is H High or open B When you connect the wire to logic ground TB 18 pin 2 TB 50 pin 3 the digital input test menu should show that the input is L Low or closed CLS User s Guide 109 Troubleshooting Checking Computer Supervised Systems Computer Problems 110 CLS User s Guide Four elements must work properly in a computer supervised system that uses an IBM compatible computer and ANASOFT e The CLS e The computer and its RS 232 or RS 485 serial interface e The RS 232 or RS 485 communications line e The computer s software For CLS troubleshooting disconnect the communications line from the computer before you follow the troubleshooting steps explained in the previous sections Troubleshooting for the computer and communications are explained in the sections below If you are having computer or serial interface problems check the following e Make sure you are using DOS 5 0 or a later version of DOS e Check the communications interface cables and connections Make sure the serial interface is set according to the manufacturer s
16. Retrans Cascade Ratio Control Min Out Min SP Max SP Heat Retrans Cascade Ratio Control Max Inp Max SP CTRL Ratio Enter None or a i No Heat Retrans Cascade Ratio Control Max Out HT Span SP Diff Enter i Cool Output Cascade Retrans PV CL Span Cool Retrans Min Inp Appendix B Enhanced Process Control Process Variable Retransmit The PV Retransmit feature allows you to select the PV of any loop in the controller to be directed to any heat or cool output including the loop which is providing the PV to be retransmitted Once an output is defined as a PV Retransmit it cannot be used for PID control Setting Up a PV Retransmit In order to set up a PV Retransmit you must configure the following variables 1 PV assignment the number of the loop that provides the PV for the retransmit calculation 2 Minimum input the lowest value of the PV input If the PV falls below the minimum the output will stay at the minimum value This value is expressed in the same engineering units as the input loop 3 Minimum output the output value 0 100 which corresponds to the minimum input 4 Maximum input the highest value of the PV input If the PV goes above the maximum the output will stay at the maximum value This value is expressed in the same engineering units as the input loop 5 Maximum output the output value 0 100 which corresponds to the maximum input 139 Appendix B Enhanced Process
17. SETPT OFF ALARM SETPOINT STATUS __OUT Selectable Values 999 to 9999 or Off no segment setpoint Configuring Segment Events You can assign up to four digital outputs Events to each segment When the segment ends the events you select go to the output state you specify Use this menu to select events and specify their output states LOOP PROCESS UNITS A SEGMENT 5 EDIT SEG EVENTS ALARM SETPOINT STATUS __OUT Selectable Values YES or NO Starting a segment with an event If you want a segment to start with an event usually events happen at the end of the segment program the previous segment for the event You can also use this trick Setup the segments that come before the first segment 2 Setup an extra segment with time 000 00 and with the events for the first segment 3 Setup the first segment If you also want to have events at the end of the segment or you want the event to go off at the end of the segment setup the first segment with the desired event number and event output state CLS User s Guide 125 Appendix A Ramp Soak Editing Event Outputs Changing Event States Editing Segment Triggers 126 CLS User s Guide This menu appears only if you answered YES to the previous menu Use it to assign a digital output to each event Assign digital outputs that are not being used for PID control or for SDAC clock LOOP _ PROCESS _UNITS A SEG 20 EVENT 3 OUTPUT 30 ALARM S
18. STATUS __OUT Assigning a profile the first time To assign a profile to a loop that doesn t have a profile follow these steps CLS User s Guide 129 Appendix A Ramp Soak 1 In Single Loop display switch to the loop you want to edit 2 Press the RAMP SOAK key The assigning menu appears See menu in previous page Choose one of the available profiles and press ENTER 4 Press BACK if you wish to return to Single Loop display without saving any changes Assigning a different profile To assign a new profile to a loop that already has one assigned follow these steps 1 Press the RAMP SOAK key three times 2 Press the NO key You will see the Reset Profile menu Press YES then ENTER to reset the profile You will see the Assign Profile menu See previous page Choose one of the available profiles and press ENTER 5 Press BACK if you wish to return to Single Loop display without saving any changes Assigning a Profile to a Linear Input Loop 130 CLS User s Guide If you assign a profile to a loop with a linear input these variables will depend on the display format setting you chose for the linear input e Ready setpoint e Segment setpoint e Segment tolerance Before you assign a profile to a linear input loop Consult the following table Display Format Effect on Parameter setting 999 to 3000 Parameter is as set in profile 9999 to 30000 Controller multiplies your para
19. User s Guide 91 Setup Low Deviation Alarm Type Use this menu to turn Off the low deviation alarm or set it to Alarm or Control mode LOOP _ PROCESS _ UNITS 01 LO DEV ALARM TYPE OFF ALARM SETPOINT _ STATUS __ OUT Selectable values Off Alarm or Control Low Deviation Alarm Output Number Use this menu to assign a digital output that activates when the loop is in low deviation alarm LOOP __ PROCESS _ UNITS 04 LO DEV ALARM OUTPUT NONE ALARM SETPOINT STATUS __OUT NOTE All digital outputs are OR d together combined There fore you can assign more than one alarm to the same output number and that output will be On if any of those alarms is On Selectable values 1 and 34 as long as that output is not already used for control or the SDAC clock or you may select None Low Process Alarm Setpoint 92 CLS User s Guide Use this menu to set a low process alarm setpoint The low process alarm activates when the process variable goes below the low process alarm setpoint It deactivates when the process variable goes above the low process alarm setpoint plus the deadband LOOP _ PROCESS _ UNITS 01 LO PROC ALARM Selectable range Any value within the input sensor s range Setup Low Process Alarm Type This menu lets you turn off the low process alarm or set it to the Alarm or Control function LOOP PROCESS _ UNITS 02 LO PROC ALARM TYPE OFF ALARM SETPOINT _ STAT
20. a process variable exceeds the setpoint before it stabilizes 168 P Panel Lock A feature that prevents operation of the front panel by unauthorized people PID Proportional Integral Derivative A control mode with three functions Proportional action dampens the system response Integral corrects for droops and Deriv ative prevents overshoot and undershoot Polarity The electrical quality of having two opposite poles one positive and one negative Polarity determines the direction in which a current tends to flow Process Variable The parameter that is controlled or measured Typical examples are temperature relative humidity pressure flow fluid level events etc The high process variable is the highest value of the process range expressed in engineering units The low process variable is the lowest value of the process range Proportional P Output effort proportional to the error from set point For example if the proportional band is 20 and the process is 10 below the setpoint the heat proportioned effort is 50 The lower the PB value the higher the gain Proportional Band PB A range in which the proportioning function of the control is active Expressed in units degrees or percent of span See PID Proportional Control A control using only the P proportional value of PID control Pulse Input Digital pulse signals from devices such as opti cal encoders R Ramp A programmed i
21. are shielded Ss 4 NOTE These recommendations are conservative to ensure that your controller will operate reliably Expect satisfactory performance even if you must deviate slightly from a design specification CLS User s Guide 47 Installation 48 CLS User s Guide Using the CLS Using the CLS Introduction This chapter will show you how to use the CLS from the front panel If you are using ANASOFT or AnaWin please see the related User s Guide The next diagram shows how to reach the operator menus from Single Loop display To change global parameters loop inputs control parameters outputs and alarms from the setup menus you must enter a special sequence of keys To learn how see the next chapter setup Back Power On Bar Back Single Back Job Graph Loop gt Displa Display Display isplay a 5 2 wS a BIS SIS Manual Bar Graph Single Loop Automatic Change ae alll or Autotune Setpoint Display Display Mode Heat Cool Ramp Output Soak Percentage ua Only if mode is Only if this option set to manual is installed CLS User s Guide 49 Using the CLS Front Panel The front panel provides a convenient interface with the controller You can program and operate the CLS with the front panel keys shown below or you can use ANASOFT a program de
22. as a variable resistor with respect to its input signal Transmitters are desirable when long lead or extension wires pro duce unacceptable signal degradation U Upscale Break Protection A form of break detection for burned out thermo couples Signals the operator that the thermocou ple has burned out Undershoot The amount by which a process variable falls below the setpoint before it stabilizes V Volt V The unit of measure for electrical potential volt age or electromotive force EMF See Voltage Voltage V The difference in electrical potential between two points in a circuit It s the push or pressure behind current flow through a circuit One volt V is the difference in potential required to move one coulomb of charge between two points in a circuit consuming one joule of energy In other words one volt V is equal to one ampere of cur rent I flowing through one ohm of resistance R or V IR Z Zero Cross Action that provides output switching only at or near the zero voltage crossing points of the ac sine wave Glossary 171 Glossary 172
23. calling for a higher SP This value is expressed in the same engi neering units as the Ratio loop PV adjustable from the minimum reading to the maximum reading 4 Control Ratio The multiplier which is applied to the Master loop PV 5 SP Differential The amount to be added or subtracted from the Ratio loop SP calculation before it is used as a SP This value is expressed in the same engineering units as the Ratio loop PV adjustable from the minimum reading to the maximum reading By adjusting the Ratio control parameters you can adjust the influence the Master loop PV has on the SP of the Ratio loop Master loop Process Variable Calculation of new Ratio loop SP SP SP Differential Master PV Control Ratio UH ELIT Min Ratio Loop Max setpoint setpoint 147 Appendix B Enhanced Process Control Ratio Control Menus The Ratio control parameters appear under a new menu option which follows the Cascade menu LOOP _ PROCESS _ UNITS SETUP LOOP 02 RATIO CONTROL ALARM SETPOINT _ STATUS __ OUT Answering YES to this prompt will allow you to set up the Ratio control parameters with loop number 02 as the Ratio loop which performs the actual control of the final control element Ratio PV Assignment LOOP PROCESS _ UNITS 02 RATIO CONTROL MSTR LOOP NONE ALARM SETPOINT __ STATUS __ OUT Selectable Values You may select from all the loops in the controller except the loop curr
24. change in the response of the heat or cool out put The output responds to a step change by going to approximately 2 3 its final value within the numbers of scans that are set Frequency The number of cycles over a specified period of time usually measured in cycles per second Also referred to as Hertz Hz The reciprocal is called the period G Gain The amount of amplification used in an electrical circuit Gain can also refer to the Proportional P mode of PID Global Alarm Alarm associated with a global digital output that is cleared directly from a controller or through a user interface Global Digital Outputs A pre selected digital output for each specific alarm that alerts the operator to shut down critical processes when an alarm condition occurs Ground An electrical line with the same electrical poten tial as the surrounding earth Electrical systems are usually grounded to protect people and equip ment from shocks due to malfunctions Also referred to a safety ground 166 H Hertz Hz Frequency measured in cycles per second High Deviation Alarm Warns that the process is above setpoint but below the high process variable It can be used as either an alarm or control function High Power Any voltage above 24 VAC or Vdc and any cur rent level above 50 mAac or mAdc High Process Alarm A signal that is tied to a set maximum value that can be used as either an alarm or control function High
25. display should appear If you have not connected analog inputs yet the CLS may dis play a T C Break alarm message for each channel This is normal to clear the alarm messages press ALARM ACK once for each alarm message Outputs Installation DE NOTE Your CLS is shipped with heat outputs enabled and cool outputs disabled You can disable any PID output and use it for other digital output functions All digital outputs and PID outputs are sink outputs referenced to the 5Vdc supply These outputs are Low pulled to common when they are On All digital inputs are Transistor Transistor Logic TTL level inputs referenced to control common The control outputs are located on the 50 pin header which connects to the TB 18 or TB 50 pin flat ribbon cable This section explains how to wire and configure them Wiring Outputs The CLS provides dual PID control outputs for each loop The digital outputs sink current from a load connected to the CLS s internal power supply or from an external power supply referenced to CLS ground e If you use an external power supply do not exceed 12 volts e If you tie the external load to ground or if you cannot connect it as shown below then use a solid state relay e If you connect an external supply to earth or equipment ground use solid state relays to avoid ground currents Ground currents may degrade analog measurements in the CLS The outputs conduct current when they
26. instructions e To test an RS 232 interface buy an RS 232 troubleshooter from Radio Shack or an equivalent supplier Attach the trou bleshooter between the CLS and the computer When ANA SOFT sends data to the CLS the troubleshooter s TX LED should blink When ANASOFT receives data from the CLS the RX LED should blink e You can also connect an oscilloscope to the transmit or receive line to see whether data is being sent or received If the serial interface does not function contact your computer service representative NOTE Most communications problems are due to incorrect wiring or incorrectly set communications parameters Therefore check the wiring and communications settings first If you have more than one controller or you are using more than 50 feet of communications wiring you must use RS 485 communications Otherwise you can use RS 232 communications The CLS is configured for RS 232 communications when it is shipped If you are using RS 485 communications you must set the internal RS232 RS485 selection jumpers to the correct position See Chapter 2 Installation for information about changing jumpers Software Problems Changing the EPROM Troubleshooting From the setup menus make sure that the communications parameters address error checking and baud rate are set correctly for each CLS in your system Every controller must have a separate address starting with 1 and increasing by 1 for each c
27. limit time Alarm delay Cool override output Cool output Setup Global Setup Loo Setup Loo Setup Loo Setup Loo Manual I O P P p P p P p P p Parameters Inputs Control Params Outputs Alarms Test Load setup Input type Heat control PB Heat oaa Hi proc alarm Digital inputs from job output setpt Pulse sample Heat control TI H 9 Save setup time eat output type Hi proc alarm Test digital to job type tput l 3 5 Heat control TD os ates TP ue A oop name cycle time ob select Hi proc alarm Keypad test dig inputs Heat control filter SDAC menus v gt output Input units SDAC only p J ob E dig ins Cool control PB Heat output Dev alarm active action value Set up Global Parameters Menu The Set up Global Parameters menu looks like this LOOP __ PROCESS _ UNITS SETUP GLOBAL PARAMETERS ALARM SETPOINT STATUS __ OUT Below is the setup global parameters menu tree Notice the default values inside the boxes Setup Global Parameters Load setup from job 1 Power up output status OFF Save setup to job 1 Job select dig inputs NONE Controller address 1 Job sel dig ins active LOW Communications baud rate 9600 Communications protocol ANA Output override dig input NONE Communications err check BCC Override dig in active LOW AC line freq 60 HE
28. maximum ALARM SETPOINT STATUS OUT Press Enter LOOP PROCESS UNITS Enter the control ratio which is the mul 02 RATIO CONTROL tiple applied to the master Process Vari CTRL RATIO 0 5 able the H O flow rate is multiplied by ALARM SETPOINT STATUS _OUT 0 5 to obtain the KOH flow rate set point Press Enter LOOP PROCESS UNITS Enter the setpoint differential or offset 02 RATIO CONTROL For this example we have no offset SP DIFE 0 requirement and will use 0 RM SETPOINT __ STA ALA TUS __OUT Press Enter Now press Back several times until the normal loop display appears The setpoint of loop 2 will now be equal to one half of the process variable of loop 2 To complete the ratio setup configure both loops 1 and 2 for inputs outputs and alarms Please consult the Setup section of the manual for information on PID loop setup 157 Appendix B Enhanced Process Control Remote Setpoint Remote Setpoint can be used to allow external equipment such as a PLC or other control system to provide an analog output 4 20 mA 0 5 Vdc etc used to change the setpoint of a loop The method of configuring the Remote Setpoint is the same as Ratio Control In the previous example loop would be the remote analog value and loop 2 would be the PID control loop Both the remote setpoint feature and the PV retransmit feature can be used with PLC systems as the link between multi loop PID control systems and PL
29. offset calibration for thermocouple RTD and other fixed ranges and offset and span gain calibration for linear and pulse inputs Offset and span calibration convert linear analog inputs into engineering units using the Mx B function In order to scale linear input signals you must 1 Install appropriate scaling resistors Contact Watlow Anafaze s Customer Service Department for more information about install ing scaling resistors 2 Select the display format The smallest possible range is 9999 to 3 0000 the largest possible range is 9999 to 30000 3 Enter the appropriate scaling values for your process For more information about input scaling and input offset see Setup Loop Inputs in Chapter 4 Setup AN WARNING The CLS uses a floating ground system Therefore Isolate input devices or host computers connected through communications cables like RS 232 from earth ground Use ungrounded thermocouples with the thermocouple sheath electrically connected to earth ground Use optically isolated RS 232 devices to isolate earth grounded host computers from the CLS When you use grounded T Cs tie the thermocouple shields to a common earth ground in one place Otherwise any common mode voltages that exceed 5 volts may cause incorrect readings or damage to the controller AN WARNING The 16CLS has single ended inputs offering little protec tion from common mode voltage sources Therefore Watlow Anafaze h
30. place a transorb back to back zener diodes across the digital output which limits the digital output loop to 5 Vdc All the parts mentioned here are available from Watlow Anafaze The above steps will eliminate most noise problems If you have further problems or questions please contact Watlow Anafaze Installation General Wiring The following sections explain how to test your installation before you connect power to it and how to connect inputs and outputs to it Power Wiring and Controller Test When you have installed each component of the controller and the TB 50 if used use this checklist to connect them These instructions are written so that non electricians can understand them If you are an experienced electrician they may seem elementary to you If so feel free to skim them Connecting Power and TB 50 to CLS Remove the temporary covers on the CLS housing 2 The plug in power supply included with your controller has two bare wires The side connects to TB2 1 and the side to TB2 2 As a precaution you should check the polarity of the wires with a multimeter color coding of the wires is not always reliable with older power supplies Do not turn on the AC power yet 3 Connect the ribbon cable to the controller as shown here Plug it in so the red stripe is on the left side as you face the back of the con troller Red PES 4 Connect the ribbon
31. see the menu below Press YES to reset the profile and then ENTER to confirm your choice LOOP __ PROCESS _ UNITS 01 A SEGOI 05 R SET MODE RESET ALARM SETPOINT STATUS __OUT CLS User s Guide 135 Appendix A Ramp Soak 136 CLS User s Guide Appendix B Enhanced Process Control Appendix B Enhanced Process Control This Appendix explains five new features added to the CLS and MLS controllers e Process Variable Retransmit e Cascade Control e Ratio Control e Remote Analog Setpoint e Differential Control 137 Appendix B Enhanced Process Control Enhanced Process Control Menus 138 Min Out Cool Retrans Max Inp Cool Retrans Max Out Cool Retrans Setup Setup Setup Setup Setup Setup Setup Setup Manual Global Loop Loop Control Loop Loop PV Loop Loop Ratio Loop VO Parameters Inputs Parameters Outputs Retransmit Cascade Control Alarms Test Yes Yes t Yes i Heat Output Cascade Ratio Control Retrans PV Prim Loop MSTR Loop Enter 1 9 v v v Heat Retrans Cascade Ratio Control Min Inp Base SP Min SP Enter l None or No Heat
32. ssesseccsceeseeeeserereres 9 System Digital Outputs ssseeessseseeesseseseeesseeessressersseesseee 9 Analog OuUtp tS secsi i e 10 Miscellaneous Specifications sssseeeseseseeeesseeeresressereeseresee 11 Physical Dime nsiGns 2sscc zssecsscecsuayoszedssedoedscateeteeesateeaniacve 11 Installation 13 Precautions and Warnings 93 scsi nngetsincs vege earns 14 Recommended Tools senccossisescanscarebiatorceaiaasiedensaunscaseasmenisions 15 Panel Hole Cutters scsssiniissorcientinaninariit 15 Other Tools rti s sie e e Sed Seay 15 CLS Mounting Procedure ssssssessssseeseeesseesseeesseeessesseesseesseee 16 Mounting Environment saccc chante alone tenised Gaetano 16 S 0 fc ot Ro Ror test BRC RSET ea MRR nar leer oe neem ore 16 TB 18 Mounting Instructions 00 0 eeeeeseeesneeeeeeeeeeeeaeees 17 TB 50 Mounting Instructions 0 0 0 ee eeeeeeeeceseceeeeeeeeeeneees 18 General Wiring Recommendations 0 0 0 0 eeeeeeeeseeeeeeeeeeees 20 Grounding soian iise a ia i 21 Thermocouple Wiring esessessseesesseesssesseesseresseesseesseessee 22 Inp t Witing Soci vesaadissairesavsaveiaiiegesderseavadeataes saananeaceunegeens 22 Output WINS s eean E A Reese chs ae ndee 23 Communications Wiring esesseesssseesssrsserssesssseeessressresse 23 Wiring Noise Suppression ssessesssssessssessessesssseeessreserssee 24 General WINS lt a vesessevspencagetassansvqraneaeneaenteneeediaay E ASS 25 Power Wiring and Controller Test ce eeeeeeeeeeeeeee
33. the polarity of the override output to the active state for instance by flipping a kill switch you have set up every loop switches to the output override percentage you set here LOOP PROCESS _ UNITS 03 HEAT OVERRIDE OUTPUT 0 ALARM SETPOINT STATUS __OUT Selectable range 0 100 CLS User s Guide 85 Setup Heat or Cool Nonlinear Output Curve Use this menu to select one of two nonlinear output curves for nonlinear processes LOOP PROCESS _ UNITS 03 HEAT OUTPUT LINEAR ALARM SETPOINT _ STATUS __OUT Selectable values Curve 1 Curve 2 or Linear These curves are shown in the figure below 100 80 60 ongina 40 20 g AS gg Bo 17 9 pe 2 o mE 20 40 60 80 100 Cakulted by PD 86 CLS User s Guide Set up Loop Alarms Alarm Types Setup Press Yes at the Set up Loop Alarms prompt to access menus which change alarm function parameters for the current loop The main alarms menu looks like this LOOP _ PROCESS _ UNITS SETUP LOOP 04 ALARMS ALARM SETPOINT _ STATUS __ OUT Below is the setup alarms menu tree Setup Loop Alarms Low Deviation Alarm Type High Process Alarm Setpoint Low Deviation Alarm Output High Process Alarm Type Low Process Alarm Setpoint High Process Alarm Output Low Process Alarm Type Deviation Alarm Value
34. the setpoint differential or offset 02 RATIO CONTROL For this example we have an offset of SP DIFF 50 ie ALARM SETPOINT _STATUS _OUT Press Enter Now press the Back key several times until the normal loop display appears The setpoint of loop 2 will now be equal to SP of Loop 1 plus 50 F To complete the Differential Control setup Loop 1 and Loop 2 must be configured for inputs outputs and alarms Please consult The SETUP Section of the manual for information on PID loop setup 161 Appendix B Enhanced Process Control 162 Glossary A AC See Alternating Current AC Line Frequency The frequency of the AC power line measured in Hertz Hz usually 50 or 60 Hz Accuracy Closeness between the value indicated by a mea suring instrument and a physical constant or known standards Action The response of an output when the process vari able is changed See also Direct action Reverse action Address A numerical identifier for a controller when used in computer communications Alarm A signal that indicates that the process has exceeded or fallen below a certain range around the setpoint For example an alarm may indicate that a process is too hot or too cold See also Deviation Alarm Failed Sensor Alarm Global Alarm High Deviation Alarm High Process Alarm Loop Alarm Low Deviation Alarm Low Process Alarm Alarm Delay The lag time before an alarm is activated Alternating
35. to 0 Channel 2 SP should 150 Adjust Channel 1 Manual Output to 50 Channel 2 SP should 170 Adjust Channel 1 Manual Output to 100 Channel 2 SP should 190 To complete the cascade setup both loop 1 and loop 2 must be configured for inputs outputs and alarms In addition the PID parameters of loop must be tuned to produce the desired effect for the application on the setpoint of loop 2 For a cascade control application that uses the secondary loop for PID control then Loop 1 must use only proportional mode This must be set for the amount of change in the PV to cause a 100 change in the output level It is necessary for the temperature of Loop temperature to drop only 10 F in order for Loop 2 to change from 150 to 190 F Then set the PB of loops 1 to 10 and turn off Intergal and Derivative terms by setting TI and TD to 0 The PID parameters of loop 2 must be tuned to perform efficient control For two zone cascade control systems the PID settings for both loops the primary plus the secondary must be optimized for good temperature control Please consult the SETUP Section of this manual for information on tuning PID loops 155 Appendix B Enhanced Process Control Ratio Control A chemical process requires a formula of two parts Water H20 to one part Potassium Hydroxide KOH to produce diluted Potassium Hydroxide The desired flow of H30 is 10 gallons per second gps and the KOH should be 5 gps Ea
36. wiring The controller s placement affects place ment and wiring considerations for the other components of your system Install the CLS in a location free from excessive gt 50 C heat dust and unauthorized handling The controller can mount in any panel material up to 0 2 thick Make sure there is enough clearance for mounting brackets and terminal blocks the controller extends 6 2 behind the panel face and the screw brackets extend 0 5 above and below it 1 Cut a hole 3 630 0 020 long by 1 800 0 020 tall in the panel This figure shows the mounting hole The figure is not a template Cut carefully the 0 020 0 5 mm tolerances don t allow much room for error Use a punch nibbler or jigsaw and file the edges of the hole Screw Bracket _ 7 Sr ee 0 375 l x 1 800 0 020 3 u Screw Bracket age 0 500 ie 3 630 0 020 gt 2 Insert the controller into the hole through the front of the panel 3 Screw the top and bottom clips in place insert the screw s lip into the cutout in the metal housing just behind the front panel Tighten the screw 4 Ifyou expect much panel vibration use a rear support for the CLS and its interconnecting cables Installation TB 18 Mounting Instructions These steps describe how to mount the TB 18 on the rear of the CLS Please follow these steps exactly so you do not damage either the terminal block or the controller 1 Install t
37. 25 COGS sas Sage bates E r ah Grae ce eens en dean bord aceh ea leceinen team 27 PID Control and Alarm Output Connections 2 30 Watchdog Timer nisreen rin 30 TB 18 Connections aes ecAces ete cte ato Cel ec 31 TB 50 Connections cccccccccccccesesseseececcccceeseseesscesceseeeees 32 Contents CLS User s Guide TIPUES sisesta ie E KE a E i EE 34 Input Scaling sse ne nane EE EENET SAEN 34 4 and 8 CLS Scaling Values 0 eee eeseeceesseceesteeeeneees 35 1G COTES SCANS Vales seieren a a a N 38 Scaling and Calibration soesssesesseessessesesseeessresseesseeseee 39 T C Inputs e n i E E E 39 RTD Inputs 4 and 8 CLS only eee eeeseeeesteeeeneees 40 Current IN Puts seson E a aR 41 Voltage Talis aeee i o A EAE eeeee asnene 41 Unused INputs snena a a As ar Sis 41 Back Terminal Block Connections ssssesssesesseeessressees 42 Serial Communications s lt esascecosaseasansastarssoenteresvonsaaarcoonteeoean 42 RS 232 Interface scaltinccnenietnn nenea n 43 RS485 Interface nnus eia o N ENE 43 Using the CLS 49 Introd ction aae e E E E E 49 Front Pai bio Gas dates trcanst e a a E E RA 50 Front Pane KGVS eestisse gna eraa 50 Displays eienenn E E a E 53 Bar Graph Display wceiacas ete cateoacareie htaciaias ote 53 Single Loop Display 22 602 2 o contd uaa been 54 ATAMER ea A en alee Bd 56 JODS Lay e east n ghana act dutecadey Stes ane tnget tne lawas eapeaasont 57 Operator Meus eG ah cess casucosis
38. 85 curve RTD input ranges as shown here RTD Ranges in Degrees Name Temp Range Temp Resolution Measurement Error 25 Error 0 50 in F Range in Temperature C Ambient C Ambient C RTD1 148 0 to 100 0 to 0 023 C 25 C 0 35 C 0 5 C 0 o RTD2 184 to 1544 120 to 840 0 062 C 25 C 0 9 C 2 8 C o o k C 840 C 1 1 C 4 3 C 40 CLS User s Guide Installation Below is a typical RTD Back Terminal Block Connections In 0 Ped Se 100 Q RTD J In Black Analog Black Common Current Inputs To connect current milliamp inputs install resistors that convert the milliamp input to a voltage Watlow Anafaze offers resistors for 0 20 mA and 0 10 mA current inputs Voltage Inputs e Connect the side of the voltage input to the In terminal e Connect the side of the input to the In terminal for the 4 and 8CLS or analog common for the 16CLS The Ovoltage input range is 10 to 60 mV e Scale signals larger than 60 mV with scaling resistors that make full scale input 60 mV For more information see the Input Scaling sec tion The figures below show typical voltage input 16CLS Back Terminal Block Connections In Analog Common 4 and 8 CLS Back Terminal Block Connections In CLS User s Guide 41 Installation Unused Inputs Set the input type for unused inputs to S
39. 9 175 900 to 999 65 2000 to 2099 125 3100 to 3199 180 1000 to 1099 70 2100 to 2199 130 3200 to 3299 185 As a general rule set the PB to 10 of the setpoint below 1000 and 5 of the setpoint above 1000 This setting is useful as a starting value CLS User s Guide 103 PID Tuning and Control Integral Term TT Settings This table shows TI settings vs Reset settings TI Reset TI Reset secs repeat repeats min secs repeat0 repeats min 30 2 0 210 0 28 45 1 3 240 25 60 1 0 270 22 90 66 300 20 120 50 400 AS 150 40 500 12 180 33 600 10 As a general rule use 60 120 180 or 240 as a starting value for the TI Derivative Term TD Settings This table shows Derivative term TD versus Rate Minutes RM Rate TD 60 TD Rate TD Rate secs repeat repeats min secs repeat repeats min 5 08 35 58 10 16 40 66 15 25 45 75 20 33 50 83 25 41 55 91 30 50 60 1 0 As a general rule set the TD to 15 of TI as a starting value 104 CLS User s Guide PID Tuning and Control General PID Constants by Application This section gives PID values for many applications They are useful as control values or as starting points for PID tuning Proportional Band Only P PB Set the PB to 7 of the setpoint SP Example Setpoint 450 so Proportional Band 31 Proportional with Integral PI PB Set
40. ALARM SETPOINT STATUS __OUT Selectable Values From the input loop PV minimum reading to the maximum reading 141 Appendix B Enhanced Process Control Maximum Output LOOP__ PROCESS _ UNITS 02 HEAT RETRANS MAX OUT 100 ALARM SETPOINT _ STATUS __ OUT Output will never go above the this Maximum Output percentage regardless of how high the PV goes Selectable Values 0 100 Y y NOTE 142 Any available output heat or cool may be used as a retransmit output Any PV including the same loop num ber input may be retransmitted Cascade Control Appendix B Enhanced Process Control The Cascade control feature allows the output percentage of one control loop to influence the setpoint of a second control loop A loop designated as a Cascade output loop primary loop can still be used for direct PID control of an output A single loop can be either set up as Cascade or Ratio control but not both The Cascade output loop is assigned to another control loop secondary loop which performs the actual control of the final control element Setting Up Cascade Control In order to set up Cascade control you need to configure these variables 1 Cascade output assignment The control output primary loop num ber which will provide the output to the internal controller SP calcu lation for the secondary loop 2 Base SP The SP corresponding to 0 output heat and cool from the primary loop This
41. C systems For example a 0 5 Vdc signal representing 0 300 F will be used as a remote SP input to the CLS The input signal will be received on Loop 1 with the control being performed on Loop 2 Note that proper scaling resisters must be installed on the input of Loop to allow it to accept a 0 5 Vdc input From the loop 1 input channel select the Linear Input Type Set HiPV 300 LoPV 0 HiRDG 100 0 and LoRDG 0 0 Next go to loop 2 and enter the programming menus Go to the Ratio Option Menu and press the YES key to select the Ratio Menu Display User Input LOOP PROCESS _ UNITS Press Yes to setup the Ratio parameters SETUP LOOP 02 for loop 02 RATIO CONTROL ALARM SETPOINT _ STATUS __OUT LOOP PROCESS _ UNITS Assign loop 01 to be the master loop 02 RATIO CONTROL Press Enter MSTR LOOP 01 ALARM SETPOINT STATUS __OUT LOOP PROCESS _ UNITS Enter the minimum Ratio loop SP For 02 RATIO CONTROL this example we will use 0 F MIN SP 0 Press Enter ALARM SETPOINT STATUS __ OUT 158 Appendix B Enhanced Process Control Display User Input LOOP PROCESS _ UNITS Enter the maximum Ratio loop SP For 02 RATIO CONTROL this example we will use 300 F as a MAX SP 300 ana ALARM SETPOINT STATUS __OUT Press Enter LOOP PROCESS UNITS Enter the control ratio which is the mul 02 RATIO CONTROL tiple applied to the master Process Vari CTRL RATIO 1 0 able In this example the ratio
42. CLS User s Guide Watlow Controls 1241 Bundy Blvd Winona MN 55987 Customer Service Phone 800 414 4299 Fax 800 445 8992 Technical Support Phone 507 494 5656 Fax 507 452 4507 Email wintechsupport watlow com Part No 21952 00 Revision 3 2 October 1996 Copyright 1996 Watlow Anafaze Information in this manual is subject to change without notice No part of this publication may be reproduced stored in a retrieval system or transmitted in any form without written permission from Watlow Anafaze Warranty Watlow Anafaze Incorporated warrants that the products furnished under this Agreement will be free from defects in material and workmanship for a period of three years from the date of ship ment The Customer shall provide notice of any defect to Watlow Anafaze Incorporated within one week after the Customer s discovery of such defect The sole obligation and liability of Watlow Anafaze Incorporated under this warranty shall be to repair or replace at its option and without cost to the Customer the defective product or part Upon request by Watlow Anafaze Incorporated the product or part claimed to be defective shall immediately be returned at the Customer s expense to Watlow Anafaze Incorporated Replaced or repaired products or parts will be shipped to the Customer at the expense of Watlow Anafaze Incorporated There shall be no warranty or liability for any products or parts that
43. ETPOINT STATUS __ OUT Selectable Values Any digital output from 1 to 34 except those IN USE or None no event Use this menu to assign an output state to each event On High or Off Low When the event occurs the output goes to the state you assign here LOOP PROCESS _ UNITS A SEG14 EV3 DO 4 OUTPUT STATE OFF ALARM SETPOINT STATUS __ OUT Selectable Values Off Low or On High Each segment has two triggers digital inputs One of these triggers must be true before the segment can begin If a segment times out and at least one of the next segment s triggers is not true the profile goes into trigger wait state Use this menu to edit triggers for the current segment LOOP PROCESS _ UNITS C SEGMENT 15 EDIT SEG TRGGRS ALARM SETPOINT STATUS __OUT Selectable Values YES to edit triggers of current segment or NO to advance to the Edit Segment Tolerance menu Appendix A Ramp Soak Assigning an Input to a Trigger This menu appears only if you answered YES to the Edit Segment Triggers menu Use it to assign one of the controller s eight digital inputs to a segment trigger You can assign any digital input to any trigger You can also assign the same digital input to multiple triggers LOOP __ PROCESS _ UNITS C SEG18 TRIGI INPUT NR NONE ALARM SETPOINT STATUS __OUT Selectable Values Any digital input from 1 8 or None no input assigned Setting a trigger to None disables it
44. F to the desired offset this will produce the desired offset between the secondary and master loop setpoints for differential control For example setpoints the Master Loop can be controlled at 325 F and the secondary loop at 375 F by using a differential of 50 F Channel 1 must be set up for PID control of the SP at 325 F Go to Channel 2 and enter the programming menus Go to the Ratio Option Menu and press the YES Key to select the Ratio Menu Display User Input LOOP PROCESS UNITS Press Yes to setup the Ratio parameters SETUP LOOP 02 for loop 02 RATIO CONTROL ALARM SETPOINT STATUS __ OUT LOOP PROCESS _ UNITS Assign loop 01 to be the master loop 02 RATIO CONTROL Press Enter MSTR LOOP 01 ALARM SETPOINT STATUS __ OUT LOOP PROCESS _ UNITS Enter the maximum Ratio loop SP For 02 RATIO CONTROL i MAX SP 400 max mum ALARM SETPOINT__ STATUS _ OUT this example we will use 400 F as a Press Enter LOOP PROCESS UNITS Enter the minimum Ratio loop SP For 02 RATIO CONTROL MIN SP 300 Press Enter ALARM SETPOINT STATUS _ OUT this example we will use 300 F 160 Appendix B Enhanced Process Control Display User Input LOOP PROCESS UNITS Enter the control ratio which is the mul 02 RATIO CONTROL tiple applied to the master Process Vari CTRL RATIO 1 0 able In this example the ration is 1 0 ALARM SETPOINT STATUS _OUT Press Enter LOOP PROCESS UNITS Enter
45. Gain This menu lets you set the Integral term or Reset LOOP __ PROCESS __UNITS 02 HEAT CONTROL TI 180 Sec R ALARM SETPOINT__ STATUS __ OUT Selectable range 0 off 6000 seconds This menu lets you set the derivative constant LOOP __ PROCESS _ UNITS 03 HEAT CONTROL Selectable range 0 255 seconds CLS User s Guide 79 Setup Heat or Cool Output Filter Use this menu to dampen the heat or cool output s response The output responds to a step change by going to approximately 2 3 of its final value within the number of scans you set here LOOP _ PROCESS _ UNITS 04 HEAT CONTROL FILTER 2 SCANS ALARM SETPOINT __ STATUS __OUT Selectable range 0 255 Setting the output filter to 0 turns it off Heat and Cool Spread Use this menu to set the spread between the heat and cool output and the spread of the On Off control action LOOP __ PROCESS _ UNITS 01 SPREAD Selectable ranges 0 255 25 5 2 55 255 or 0255 depending on the way you set up the Input menus 80 CLS User s Guide Setup Set up Loop Outputs SDAC Mode SDAC High Value SDAC Low Value Press Yes at this prompt to access menus to change loop output parameters for the current loop including Enable or disable outputs Output type Cycle time for TP outputs SDAC parameters for SDAC outputs Control action Output level limit and limit time Output override N
46. KIP to avoid the default T C break alarms See Input Type in Chapter 4 Setup for information on setting the input type Back Terminal Block Connections Wire inputs to the back terminal block as shown below 4CLS TBI 1 315 7 9 11 13 15 17 19 21 23 25 CH1 CH Ana CH3 CH4 Ana Re Re Ref Re Re GND RX IN 2 log IN IN log ser ser Com ser ser IN Com Com ved ved ved ved RXB RXA 2 4 6 8 10 12 14 16 18 20 22 24 26 TB2 4 2 CH 1 CH Ana CH3 CH4 Ana Re Re 5V Re Re GND TX IN 2 log IN IN log ser ser Ref ser ser I V Pwr IN Com Com ved ved ved ved TXB TXA pwr Com 8CLS TB 1 315 7 9 11 13 15 17 19 21 23 25 CH 1 CH Ana CH3 CH 4 Ana CH5 CH6 Ref CH 7 CH 8 GND RX IN 2 log IN INt log IN IN Com IN IN IN Com Com RXB RXA 2 4 6 amp 8 10 12 14 161 18 20 22 24 26 TB2 4 2 CH 1 CH Ana CH3 CH4 Ana CH5 CH6 5V CH7 CH8 GND TX IN 2 log IN IN log IN IN Ref IN IN V Pwr IN Com Com TXB TXA pwr Com 16 CLS TBI 14 345 71 9 411 13 15 17 19 21 23 25 CH1 CH Ana CH3 CH4 Ana CH5 CH6 Ref CH7 CH8
47. LARM SETPOINT _ STATUS __ OUT Selectable values 2400 or 9600 Use this menu to set the communications protocol type LOOP PROCESS _ UNITS COMMUNICATIONS PROTOCOL ANA ALARM SETPOINT _ STATUS __OUT Selectable values ANA Watlow Anafaze s protocol AB Allen Bradley s MOD Modbus Communications Error Checking 68 CLS User s Guide This menu appears only when you choose ANA or AB as your communications protocol Use it to set the data check algorithm used in the CLS communications protocol to Block Check Character BCC or to Cyclic Redundancy Check CRC LOOP _ PROCESS _UNITS COMMUNICATIONS ERR CHECK BCC ALARM SETPOINT STATUS __OUT Selectable values BCC or CRC CRC is a more secure error checking algorithm than BCC but it requires more calculation time and slows the CLS communications BCC ensures a high degree of communications integrity so Watlow Anafaze recommends that you use BCC unless your application specifically requires CRC NOTE If you are using ANASOFT be sure to configure ANAIN STL for the same Error Checking method and the same Baud Rate that you set in this menu and in the next one AC Line Frequency Setup Use this menu to configure the controller to match an AC line frequency of 50 or 60 Hz This function is provided for international users who require 50 Hz lines Since the controller reduces the effect of power line noise on the analog measurement by i
48. M SETPOINT STATUS _ _ OUT Press Enter Enter the maximum input value which corresponds to the maximum output per LOOP __ PROCESS _ UNITS 02 HEAT RETRANS centage MAX INP 1000 For a range of 0 1000 F the maximum input value is 1000 F Change the MAX ALARM SETPOINT STATUS __ OUT INP to1000 Press Enter 151 Appendix B Enhanced Process Control Display User Input LOOP PROCESS _ UNITS Enter the maximum output percentage 02 HEAT RETRANS from 0 to 100 For this example we will MAX OUT 100 assume a full span with a maximum of 100 ALARM SETPOINT STATUS __OUT Press Enter LOOP PROCESS UNITS programming is now completed You are 02 COOL OUTPUT RETRANS PV NONE retransmitting a PV so choose None ALARM SETPOINT STATUS __OUT The PV retransmit section of the CLS not using the cool output of loop 2 for Press Enter 152 Now press the Back key several times until the normal loop display appears The Process Variable Retransmit will now produce an output on Channel 2 Output which is linear and proportional to Channel 1 Process Variable This is not a T C curve type of signal and requires a linear input range in the recorder To complete this configuration the Channel 2 Output must be enabled and tailored to meet the requirements of the data application In this example using a data logging recorder the data logger will most likely require an analog output 4 20 mA
49. OTE 143 Setting Up Cascade Control 0000 eeecceeesceeesseeeesteeeenteeees 143 Cascade Control Menus cceccccessccecececeeeesessnteeeeeeees 144 Ratio Control edain a a od oes A EN 147 Setting Up Ratio Control sesssssessssssesssesesseeesseessersseeesees 147 Ratio Control Menus ccccccccccessssscecececeeeesessntseeeesees 148 Remote Analog setpoint 5 50ssiecesscascessadestecs snnsnsedsacdannsasveasaee 149 Differential Control n a a a RER iS 149 Typical Applications oerste e REE T EE 150 Process Variable Retransmit ccccceccceeeeeeeseeeeees 150 Cascade Control irr r eas teci tense Roeete E 153 Ratio Control Pear n sd bagevaass a deusasnvs vec ETNAS 156 R mote Setpoint nsien ra n a ace eae 158 Differential Control cc cc ccccccesssssccececececeesesssteceeesees 159 Glossary 163 Overview Overview This manual describes how to install setup and operate a 4CLS an 8CLS or a 16CLS Included are seven chapters two Appendices and a glossary of terms Each chapter covers a different aspect of your control system and may apply to different users The following describes the chapters and their purpose Introduction Gives a general description of the CLS and its related specifications Installation Describes how to install the CLS and its peripheral devices Using the CLS Provides an overview of operator displays used for system monitoring Setup Describes all the setup displays fo
50. PID or control when enabled in the loop setup If one or both of a loop s outputs are disabled the corresponding digital outputs become available for alarms or ramp soak events 32 CLS User s Guide 16 CLS TB 50 Connections Installation Function PID Output Function PID Output 1 5 Vdc 5 Vdc 3 Digital Ground Digital Ground 5 Not Used Watchdog Timer 7 Pulse Input 8 Global Alarm 9 DIG output 1 Loop heat 10 DIG output 34 Pulse loop cool 11 DIG output 2 Loop 2 heat 12 DIG output 33 Loop 16 cool 13 DIG output 3 Loop 3 heat 14 DIG output 32 Loop 15 cool 15 DIG output 4 Loop 4 heat 16 DIG output 31 Loop 14 cool 17 DIG output 5 Loop 5 heat 18 DIG output 30 Loop 13 cool 19 DIG output 6 Loop 6 heat 20 DIG output 29 Loop 12 cool 21 DIG output 7 Loop 7 heat 22 DIG output 28 Loop 11 cool 23 DIG output 8 Loop 8 heat 24 DIG output 27 Loop 10 cool 25 DIG output 9 Loop 9 heat 26 DIG output 26 Loop 9 cool 27 DIG output 10 Loop 10 heat 28 DIG output 25 Loop 8 cool 29 DIG output 11 Loop 11 heat 30 DIG output 24 Loop 7 cool 31 DIG output 12 Loop 12 heat 32 DIG output 23 Loop 6 cool 33 DIG output 13 Loop 13 heat 34 DIG output 22 Loop 5 cool 35 DIG output 14 Loop 14 heat 36 DIG output 21 Loop 4 cool 37 DIG output 15 Loop 15 heat 38 DIG output 20 Loop 3 cool 39 DIG output 16 Loop 16 heat 40 DIG output 19 Loop 2 cool 41 DIG output 17 Pulse loop heat 42 DIG ou
51. Process Variable PV See Process Variable PV High Reading An input level that corresponds to the high pro cess value For linear inputs the high reading is a percentage of the full scale input range For pulse inputs the high reading is expressed in cycles per second Hz Infrared A region of the electromagnetic spectrum with wavelengths ranging from one to 1 000 microns These wavelengths are most suited for radiant heating and infrared noncontact temperature sensing Input Process variable information that is supplied to the instrument Input Scaling The ability to scale input readings readings in percent of full scale to the engineering units of the process variable Input Type The signal type that is connected to an input such as thermocouple RTD linear or process Integral Control I Control action that automatically eliminates off set or droop between setpoint and actual process temperature See Auto reset Job A set of operating conditions for a process that can be stored and recalled in a controller s mem ory also called a Recipe Junction The point where two dissimilar metal conductors join to forma thermocouple L Lag The delay between the output of a signal and the response of the instrument to which the signal is sent Linear Input A process input that represents a straight line function Linearity The deviation in response from an expected or theoretical straight line val
52. RTZ Startup alarm delay 0 MINS Dig out polarity on alarm LOW Keyboard lock status OFF EPROM information CLS User s Guide 63 Setup Load a Job Save Setup to Job 64 CLS User s Guide Use this menu to load any one of 8 saved jobs from the controller s front panel LOOP __ PROCESS _ UNITS LOAD SETUP FROM JOB 1 ALARM SETPOINT STATUS __ OUT The following parameters are loaded as part of a job e PID constants filter settings setpoints and spread values e Loop control status Automatic or Manual and output values if the loop is in Manual control e Alarm functions Off Alarm Control setpoints high low process setpoints high low deviation setpoints and deadband settings and loop alarm delay AN WARNING All current job settings will be overwritten if you select a job from memory Save your current programming to a job number if you want to keep it If you have enabled the remote job control function this menu will be disabled you will not be able to load a job from the front panel If you try it you ll see the message below LOOP _ PROCESS __UNITS CANNOT LOAD JOB REMOTE SELECT ALARM SETPOINT STATUS __ OUT Use this menu to save the job information for every loop to one of 8 jobs in the CLS battery backed RAM LOOP _ PROCESS _ UNITS SAVE SETUP TOJOB 1 ALARM SETPOINT STATUS __OUT If you have enabled the remote jo
53. Relay SSR See Relay Solid State Span The difference between the lower and upper lim its of a range expressed in the same units as the range Spread In heat cool applications the difference between heat and cool Also known as process deadband See deadband Stability The ability of a device to maintain a constant out put with the application of a constant input T T C Extension Wire A grade of wire used between the measuring junction and the reference junction of a thermo couple Extension wire and thermocouple wire have similar properties but extension wire is less costly TD Timed Derivative The derivative function Thermistor A temperature sensing device made of semicon ductor material that exhibits a large change in resistance for a small change in temperature Thermistors usually have negative temperature coefficients although they are also available with positive temperature coefficients Thermocouple T C A temperature sensing device made by joining two dissimilar metals This junction produces an electrical voltage in proportion to the difference in temperature between the hot junction sensing junction and the lead wire connection to the instrument cold junction 170 TI Timed Integral The Integral term Transmitter A device that transmits temperature data from either a thermocouple or RTD by way of a two wire loop The loop has an external power sup ply The transmitter acts
54. S i Lheari Omv IhputR eading RDG 60mvV OHz RDG 2000 Hz Puke NOTE For example linear scaling calculations see Linear Scaling section 74 CLS User s Guide Display Format High Process Value Setup This menu appears under the Set up Loop Inputs main menu It lets you select a display format for a linear input Choose a format appropriate for your input range and accuracy You will only see the Display Format menu if you are editing a linear input LOOP _ PROCESS _ UNITS 04 DISP FORMAT 999 to 3000 ALARM SETPOINT STATUS __OUT Selectable values The CLS has several available display formats as shown below This table also shows the high and low PV values Display Format Default High PV Default Low PV 9999 to 30000 10000 0 999 to 3000 1000 0 999 9 to 3000 0 1000 0 0 99 99 to 300 00 100 00 00 9 999 to 30 000 10 000 000 9999 to 3 0000 1 0000 0000 This menu appears under the Set up Loop Inputs main menu Use it to enter a high process value The high process value and the high reading value together define one of the points on the linear scaling function s conversion line LOOP _ PROCESS _UNITS 01 INPUT SCALING 1000 F ALARM SETPOINT STATUS __ OUT Selectable values See table on the previous page CLS User s Guide 75 Setup High Reading Low Process Value Low Reading 76 CLS User s Guide Use this menu to enter the input l
55. See the Linear Scaling section True for 10 to 100 of span CLS User s Guide 71 Setup RTD Ranges 4 and 8CLS Accuracy 25 C Accuracy 0 Rangein F Rangein C Resolution Prope Ambient 50 C Ambient Temp In C F F RTD1 148 0 to 100 0 to 0 023 C 25 0 35 0 63 0 5 0 9 527 0 275 0 275 1 1 8 1 5 2 7 RTD2 184 to 120 to 840 0 062 C 25 0 9 1 62 2 8 5 04 1544 840 11 4198 43 7 74 Pulse Sample Time You can connect a digital pulse signal of up to 2 KHz to the controller s pulse input In this menu you specify the pulse sample period This is the second menu of the Set up Loop Inputs menu for the pulse input loop only Every sample period the number of pulses the controller receives is divided by the sample time The controller scales this number and uses it as the pulse loop s process variable LOOP PROCESS __ UNITS 05 INPUT PULSE SAMPLE TIME 1s Selectable Range 1 20 seconds Loop Name Use this menu to name your loop using two characters After specifying a new name it is placed on the single loop display instead of the loop s number LOOP _ PROCESS _ UNITS A5 LOOP NAME A5 ALARM SETPOINT_ STATUS OUT Input Units Use this menu to choose a three character description of the loop s engineering units LOOP PROCESS _UNITS 02 INPUT UNITS F ALARM SETPOINT STATUS __OUT 72 CLS User s Guide Setup S
56. US __OUT Selectable values Off Alarm or Control Low Process Alarm Output Number Use this menu to assign the digital output that activates when the loop is in low process alarm LOOP _ PROCESS _ UNITS 04 LO PROC ALARM OUTPUT NONE ALARM SETPOINT STATUS __OUT SX y NOTE All digital outputs are OR d together combined There fore you can assign more than one alarm to the same output number and that output will be On if any of those alarms is On Selectable values any from 1 34 that are not used for control or the SDAC clock Alarm Deadband Use this menu to set an alarm deadband This deadband value applies to the high process low process high deviation and low deviation alarms for the loop you are editing Use the Alarm Deadband to avoid repeated alarms as the PV cycles slightly around an alarm value LOOP PROCESS _ UNITS 03 ALARM DEAD BAND 2 C ALARM SETPOINT _ STATUS __OUT Selectable values 0 255 25 5 2 55 255 or 0255 depending on the way you set up the Input menus CLS User s Guide 93 Setup Alarm Delay 94 CLS User s Guide Use this menu to set a loop alarm delay There are two types of alarm delay the start up alarm delay and loop alarm delay Start up alarm delay which you can set in the Set up Global Parameters main menu delays process alarms but not failed sensor alarms for all loops for a specified time after the controller powers up The loop ala
57. Use multicolored stranded shielded cable for analog inputs Watlow Anafaze recommends that you use 20 AWG wire If the sensor manufacturer requires it you can also use 22 or 24 AWG wiring Most inputs use a shielded twisted pair some require a 3 wire input Output Wiring Communications Wiring Installation Use multicolored stranded shielded cable for analog outputs if you have installed an SDAC and PID digital outputs connected to panel mount SSRs Analog outputs generally use a twisted pair while digital outputs have 9 20 conductors depending on wiring technique For instructions on using the cable tie wraps included in the TB 50 s packaging see the Wiring Outputs section Large systems can pull in an extra pair to the computer communications wiring The extra pair services a sound power phone system for communications between the Watlow Anafaze controller and a computer If you choose this option for maintenance calibration checking et cetera Watlow Anafaze recommends a David Clark H5030 system CLS User s Guide 23 Installation Wiring Noise Suppression 24 CLS User s Guide If the CLS s outputs control dry contact electromechanical relays with inductive loads like alarm horns and motor starters you may get Electro magnetic Interference EMI or noise The following section explains how to avoid noise problems read it before you wire the CLS Symptoms of RFI EMI If your controller displays t
58. Watlow Anafaze Practical Guide to PID The control mode dictates how the controller responds to an input signal The control mode is different from the type of control output signal like analog or pulsed DC voltage There are several control modes available On Off Proportional P Proportional and Integral PI Proportional with Derivative and Proportional with Integral and Derivative PID P PI or PID control are necessary when process variable PV cycling is unacceptable or if the process or setpoint SP is variable NOTE For any of these control modes to function the loop must be in automatic mode CLS User s Guide 97 PID Tuning and Control Control Modes On Off Control Proportional Control 98 CLS User s Guide The next sections explain the different modes you can use to control a loop On Off control is the simplest way to control a process a controller using On Off control turns an output on or off when the process variable reaches a certain limit above or below the desired setpoint You can adjust this limit since Watlow Anafaze controllers use an adjustable spread For example if your setpoint is 1000 F and your limit spread is 20 F the output switches On when the process variable goes below 980 F and Off when the process goes above 1000 F The next diagram shows a process under On Off control On Off PB SP were oe Time A process us
59. al control PB SP CLS User s Guide 99 PID Tuning and Control Proportional Integral and Derivative Control Control Outputs For an improved level of control use Derivative control with Proportional or Proportional and Integral control Derivative control corrects for overshoot by anticipating the behavior of the process variable and adjusting the output appropriately For example if the process variable is rapidly approaching the setpoint Derivative control reduces the output anticipating that the process variable will reach setpoint Use it to eliminate the process variable overshoot common to PI control This figure shows a process under full PID Proportional Integral and Derivative control PID PB SP woreoae The CLS provides a 5 Vdc digital output signal for PID control outputs These outputs normally control the process using relays Watlow Anafaze can also provide a Serial Digital to Analog converter SDAC for 0 5 Vdc 0 10 Vdc or 4 20 mA analog output signals Digital Output Control Forms 100 CLS User s Guide The next section explains different modes for control outputs On Off On Off output is very simple it turns the output on or off according to the control signal of the On Off control PID Tuning and Control Time Proportioning TP Time Proportioning attempts to digitally simulate an analog output percentage by turning the out
60. appropriate e After you change the EPROM See Chapter 6 Troubleshooting e In some cases when troubleshooting see Chapter 6 Troubleshoot ing e When you install the controller Back The Back key works like an escape key Press it to e Abort editing e Return to a previous menu e Switch between Bar Graph Single Loop and Job Control displays Enter Press Enter to e Store data or menu choices after editing and go on to the next menu e Start scanning mode if pressed twice Change SP e Press this key to change the loop setpoint W Man Auto MAN AUTO Press the Man Auto key to e Toggle a loop between manual and automatic control e Adjust the output power level of loops in Manual control e Automatically tune a loop CLS User s Guide 51 Using the CLS 52 CLS User s Guide we RAMP SOAK Ramp Soak If Ramp Soak is installed on your controller press the Ramp Soak key to e Assign a ramp soak profile to the current loop e Perform operations on an assigned profile e See the status of a running profile ALARM ACK NOTE Your CLS may not have the Ramp Soak feature If it does not then the Ramp Soak key will not operate If you press the Ramp Soak key you ll see the following message LOOP __ PROCESS _ UNITS OPTION UNAVAILABLE ALARM SETPOINT STATUS __ OUT Alarm Ack Press Alarm Ack to acknowledge an alarm condition and reset the global a
61. are True The maximum current sink capability is 20 mA when all outputs are used They cannot source current to a ground load CLS User s Guide 27 Installation 28 CLS User s Guide Digital Output 1 Digital Output 2 Using internal power supply Digital Output 1 Digital Output 2 Using internal power supply 12V Control Common Do not connect to earth or equipment ground TB 50 Digital Output 1 Digital Output 2 12V Control Common vA Do not connect to earth or equipment ground Using the Cable Tie Wraps When you have wired outputs to the TB 50 use the cable tie wraps shipped with it This diagram shows the cable tie wrap holes A fo ETS 38B 39 40 41 42 43 44 45 46 47 48 49 50 Va LT OY LY SNOT Cc LC FOR ON ES DS DP LD ND ERD DOR PACD Ma RD Es C E T aA SyS NPD ON GOYA EN CoP QD Ov amp LA RAR KARA OD On DD 38a 37 36 35 34 33 32 31 30 29 28 27 26 13B 14 15 16 17 18 19 20 21 22 23 24 25 5 SN FN N A y Sannn r KODO ODO OO TONNO O e Si ae VINOD a OOOOOOOOO0O00 0 Mey ABR 19 TAE S100 909 8 OE 6 SB BS ak AN Hoks bbekd A are mountng hoks Hoks hbekd B are te wrap hoks Installation Each row of terminals has a cable tie wrap hole at one end Thread the cable tie wrap through the cable tie wrap hole Then wrap the cable tie wrap around the wires at
62. asing before please don t try to figure it out yourself see Chang ing the PROM in the Troubleshooting section for step by step instructions Find jumpers JU2 JU3 JU4 and JUS above 4 This part of the explanation assumes that you re changing the com munications from RS 232 to RS 485 If you re not follow the next two steps but move the jumpers from the B position to the A posi tion Use tweezers to carefully grasp the jumpers and gently slide them off the pins 5 Use tweezers to gently slide the jumpers onto the B pins Move jumpers JU2 JU3 JU4 and JUS to the B position as shown above 6 If you have changed the controller to 485 communications put the 200 ohm terminating resistor on the RX line of the last controller in the system If you re only using one controller it s the last control ler in the system Place jumper JU1 in the B position All other controllers in the system should have JU1 in the A position 7 Put the casing back on If you haven t removed or reinstalled the CLS s casing before see Chapter 7 Troubleshooting for instruc tions Installation Recommended Wire Gauges Watlow Anafaze recommends the following maximum distances and wire gauges Recommen Distance Wire Gauge scommenmded Cable 4000 ft 24 AWG Belden 9729 Belden 9842 6000 ft 22 AWG Belden 9184 You may wish to use a shield depending on your noise environment and grounding problems The above cables
63. assume a base SP of ee 150 F which is the desired water temper ature Press Enter Enter the minimum SP of the secondary LOOP _ PROCESS _ UNITS loop For this example we will use a mini Ue eee mum SP of 350 F Normal cascade MIN SP 350 applications will not require this to be ALARM SETPOINT STATUS __OUT changed Press Enter Enter the maximum SP of the secondary LOOP PROCESS UNITS loop For this example we will use a max 02 CASCADE imum SP of 1400 F Normal cascade MAX SP 1400 applications will not require this to be ALARM SETPOINT __ STATUS _ OUT changed Press Enter 154 Appendix B Enhanced Process Control Display User Input LOOP __ PROCESS _ UNITS 02 CASCADE HT SPAN 40 setpoint For this example we will assume ALARM SETPOINT STATUS __OUT Enter the heat span of the secondary loop This is the span over which the primary output from 0 100 is used to change the a linear rise in SP so the heat span is 40 F Press Enter CL SPAN 0 ALARM SETPOINT _ STATUS __OUT LOOP PROCESS _ UNITS 02 CASCADE Enter the cool span of the secondary loop For this example we will assume no low side adjustment to the SP so the cool span is O F Press Enter Now press the Back key several times until the normal loop display appears The output percentage of loop 1 will now control the setpoint of loop 2 You may set Channel 1 to Manual and the Output
64. ault method See CRC Bumpless Transfer A smooth transition from Auto closed loop to Manual open loop operation The control output does not change during the transfer C Calibration The comparison of a measuring device an unknown against an equal or better standard Celsius Centigrade Formerly known as Centigrade A temperature scale in which water freezes at 0 C and boils at 100 C at standard atmospheric pressure The for mula for conversion to the Fahrenheit scale is F 1 8x C 32 Central Processing Unit CPU The unit of a computing system that includes the circuits controlling the interpretation of instruc tions and their execution Circuit Any closed path for electrical current A configu ration of electrically or electromagnetically con nected components or devices Closed Loop A control system that uses a sensor to measure a process variable and makes decisions based on that feedback Cold Junction Connection point between thermocouple metals and the electronic instrument Common Mode Rejection Ratio The ability of an instrument to reject electrical noise with relation to ground from a common voltage Usually expressed in decibels dB 164 Communications The use of digital computer messages to link components See Serial Communications See Baud Rate Control Action The response of the PID control output relative to the error between the process variable and the setpoint For rev
65. b control function you will not be able to save a job If you try it you ll see this message LOOP PROCESS _ UNITS CANNOT SAVE JOB REMOTE SELECT ALARM SETPOINT __ STATUS __OUT Job Select Inputs Job Select Input Polarity Setup Use this menu to set the number of job select inputs The controller uses these inputs as a binary code that specifies the job number to run The number of inputs you choose in this menu controls the number of jobs you can select remotely LOOP _ PROCESS _ UNITS JOB SELECT DIG INPUTS NONE ALARM SETPOINT _ STATUS __ OUT Below is the truth table that tells you which input states select which jobs Digital Input 3 Digital Input 2 Digital Input1 Job alallala mlm om alal malala e alallala alls ol uI DA NT BI WwW wv Selectable values 1 2 or 3 inputs or None These choices have the following effect Setting Enables 1 input Jobs 1 2 2 inputs Jobs 1 4 3 inputs Jobs 1 8 None no inputs Remote Select disabled Use this menu to set the polarity of the digital outputs used for job selection LOOP PROCESS _ UNITS JOB SEL DIG INS ACTIVE LOW ALARM SETPOINT _ STATUS __ OUT Selectable values High or Low When nothing is connected the inputs are all False and Job 1 is selected as shown in the truth table above CLS User s Guide 65 Setup Output Override Digital Input Use this me
66. cable to the TB 50 The cable is keyed so you cannot insert it backwards AN WARNING Do not turn on the AC power yet Test the connections first as explained in the Connections Test section below Excessive voltage to the CLS will damage it and you will need to return it to Watlow Anafaze for repair If you use your own power supply read the next section completely and follow its instructions before you apply power to the CLS CLS User s Guide 25 Installation 26 CLS User s Guide Connections Test Again follow these instructions if you have purchased your own power supply or if you are using a Watlow Anafaze power supply you don t need to perform this test Unscrew the two screws on the sides of the CLS front panel 2 Gently slide the electronics assembly out of the case You have now removed the parts of the CLS which will be damaged by excess voltage so plug in the transformer power supply and use a voltme ter to check voltages 3 Touch the meter Common lead to the back Terminal Block 2 TB2 terminal 2 on the CLS The voltage on TB2 terminal 1 should then be 12 to 24 Vdc 4 Ifthe voltages are within the limits described above a Turn off power b Slide the electronics assembly back into the processor mod ule s casing c Reinsert screws into the screw holes on the casing and lighten them d Turn the power back on The CLS display should light up and after about a second the Bar Graph
67. cetera don t fall through the slots Remove these covers after installation Install the CLS so the slots in the housing receive unre stricted airflow after installation Make sure that other equipment does not block airflow to the housing slots Use 20 or 22 AWG wires and trim wire insulation to 1 4 5 mm Wire should fit inside the terminal with no bare wire exposed to prevent contact between wires and the grounded case Tin any stranded wire Support power input and output cables to reduce strain on the terminals and to prevent wire removal NOTE Be sure to select a panel location that leaves enough clear ance to install and remove the CLS and its components Recommended Tools Panel Hole Cutters Other Tools Installation Use these tools to install the CLS Use any of the following tools to cut a hole of the appropriate size in the panel e Jigsaw and metal file for stainless steel and heavyweight panel doors e Greenlee 1 8 DIN rectangular punch Greenlee part 600 68 for most panel materials and thicknesses e Nibbler and metal file for aluminum and lightweight panel doors You will also need these tools e Phillips head screwdriver e Flathead screwdriver for wiring e Multimeter CLS User s Guide 15 Installation CLS Mounting Procedure YX y NOTE Mounting Environment Steps 16 CLS User s Guide Mount the controller before you mount the terminal block or do any
68. ch Off Resistance 11 Kohms User Selectable Digital Outputs System Digital Outputs Number 34 Operation Open collector output On state sinks to logic common Current lt 20 mA for 35 loads Single load lt 40 mA I total lt 700 mA Function Selectable as PID control or alarm control Number of PID Control Outputs per PID Loop 2 max PID Control Output Types Time Proportioning Distributed Zero Crossing SDAC or On Off all independently selectable for each output Heat and cool control outputs can be individually disabled for use as alarm outputs Time Proportioning Cycle Time 1 255 seconds programmable for each output PID Control Action Reverse heat or direct cool independently selectable for each output Off State Leakage Current lt 01 mA to DC common System Digital Outputs 1 Global Alarm 1 CPU watchdog Operation Open collector output On state sinks to logic common Current lt 20 mA for 35 loads Single load lt 40 mA I total lt 700 mA CLS User s Guide 9 Introduction Analog Outputs 10 CLS User s Guide The Watlow Anafaze Digital to Analog Converter DAC is an optional module for the CLS It lets you convert a Distributed Zero Crossing control output signal to an analog process control signal You can purchase a 4 20 mAdc 0 5 Vdc and 0 10 Vdc versions of the DAC Watlow Anafaze also offers the Serial DAC for precision open loop control 0 5 Vdc 4 20 mAdc jumper selectab
69. ch chemical has a pipe feeding a common pipe The flow rate of each feeder pipe is measured and supplied to a 4CLS with H O flow as PV1 and KOH flow as PV2 The outputs of loops 1 and 2 adjust motorized valves Water Input KOH Input Loop 1 Water Flow Control Loop Loop 2 KOH Flow Control Loop Loop 1 Input PV Loop 1 PID Output Flow Xducer e Loop 2 Input PV Loop 2 PID Output Flow Xducer CLS Motorized Control Motorized Valve 1 Control Valve 2 Mixture Output y 1 Adjust and tune Loop 1 H20 for optimal performance before implementing the Ratio setup 2 Switch the controller to display loop 2 KOH and then enter the 3 key sequence to display the following Display User Input LOOP PROCESS _ UNITS Press Yes to setup the Ratio parameters SETUP LOOP 02 for loop 02 RATIO CONTROL ALARM SETPOINT STATUS __OUT LOOP PROCESS _ UNITS Assign loop 01 to be the master loop 02 RATIO CONTROL Press Enter MSTR LOOP 01 ALARM SETPOINT STATUS __ OUT 156 Appendix B Enhanced Process Control Display User Input LOOP PROCESS _ UNITS Enter the minimum Ratio loop SP For 02 RATIO CONTROL this example we will use 0 gallons per MIN SP 0 0 minute as a minimum ALARM SETPOINT STATUS _OUT Press Enter LOOP PROCESS _ UNITS Enter the maximum Ratio loop SP For 02 RATIO CONTROL this example we will use 7 0 gallons per MAX SP 7 0 minute as a
70. couple is located near the heating element The desired temperature of the water is 150 F which is measured at the inner thermocouple Using cascade the inner thermocouple is used on the primary loop in this example PID loop 1 and the outer thermocouple is used on the secondary loop PID loop 2 The heater will be controlled by loop 2 with a SP range of 150 190 F Loop 1 Primary Cascade Loop Loop 2 Secondary Cascade Loop Water 150 F Loop 1 Input PV Inner T C Loop 2 Input PV Loop 2 PID Output CLS Heater Outer T C INA lt Power Control Using the 4CLS Watlow Anafaze controller equipped with the Enhanced Control Option firmware the programming sequence is described below 153 Appendix B Enhanced Process Control First switch the controller to display loop 2 which will be the secondary loop and then enter the 3 key sequence to display the following Display User Input LOOP PROCESS UNITS Press Yes to setup the Cascade parame SETUP LOOP 02 ters with loop 2 as the secondary loop CASCADE ALARM SETPOINT _ STATUS _ OUT Enter 01 to make loop the primary loop LOOP _ PROCESS _ UNITS Press Enter 02 CASCADE PRIM LOOP 01 ALARM SETPOINT STATUS __OUT The base setpopint corresponds to the 0 LOOP _ PROCESS _ UNITS level output of the primary channel Enter 0C ete the base SP of the secondary loop For BASE SP 150 this example we will
71. cscecccecontaesceetaiansedtazeveelelenccoscanernestens 84 Heat or Cool Output Action seid gcc seticeesierpeartesneeauaee 84 Heat or Cool Output Limit 3535 55 5 oecassocteushcdtecadedescononees 85 Heat or Cool Output Limit Time eee eeeeeeeenteee 85 Heat or Cool Output Override eeeeeeeseeeseeeeeteees 85 Heat or Cool Nonlinear Output Curve ou eeeeeeeeeee 86 DEL UP Loop Alarms oee EE A E RE 87 Alarm Type S eneeier en r AS a a Eiaa 87 High Process Alarm Setpoint 0 cccceeeseeeesseeeesteeeensees 90 High Process Alarm Type sesseesesseesseesesssesesssesssresses 90 High Process Alarm Output Number sseeeeseeeeeeeen 90 Deviation Band V dle ss cap seie E E ER 91 High Deviation Alarm Type ssssssessssssesesssesssseressresssesee 91 Contents CLS User s Guide High Deviation Alarm Output Number sesser 91 Low Deviation Alarm Type eecceesssceesseeeesteeeenaees 92 Low Deviation Alarm Output Number c eeeeeee 92 Low Process Alarm Setpoint sssssssssssssssesssesesseeessresses 92 Low Process Alarm Type ssessesssssesssssesesssesssseressresseese 93 Low Process Alarm Output Number ceeeeeeeeneee 93 Alarm Deadband at sis fase rece cae octet ol nace tad tee ie eas et 93 Alarmi IDEA ynberne e a R p a R a 94 Manual WO Test cerren n e an aeetgiee 95 Digital Input Testing eseeeeseseeeeesereseereeseessrsrrrsresreseresreses 95 Test Digital Output ssssssesssessssesesseesseesseesserssssesss
72. d Controller Test section CLS User s Guide 19 Installation General Wiring Recommendations Use the cables below or their equivalent For best results use appropriate materials proper installation techniques and the correct equipment For example choose wire type by function installation requirements and the likelihood of mechanical or electrical problems at your installation Function MFR P N Analog inputs Belden 9154 2 20 Belden 8451 2 22 RTD Inputs 4 amp 8 CLS Belden 8772 3 20 Belden 9770 3 22 T C Inputs T C Ext Wire 2 20 Digital PID outputs and Dig Belden 9539 9 24 ital I O Belden 9542 20 24 Ribbon Cable 50 Computer Communication Belden 9729 4 24 RS232 or RS485 Belden 9730 6 24 Belden 9842 4 24 Belden 9843 6 24 AN WARNING Never wire bundles of low power controller circuits next to bundles of high power AC wiring Instead physically sepa rate high power circuits from the controller If possible install high voltage AC power circuits in a separate panel e Use stranded wire Solid wire is used for fixed service it makes intermittent connections when you move it for maintenance e Use 20 or 22 AWG wire Larger or smaller sizes may be difficult to install may break easily or may cause intermittent connections e Use shielded wire The electrical shield helps protect the CLS from electrical noise Connect one end of the input wiring s
73. da cacas sass dusnctas ec i 58 Change Setpoint igh teysiedy Aaya ey aa anna 58 Manual Automatic Control ccceeseceessceesteeeesteeeenaees 58 Ramp Soak ouni na EE AES 60 61 How to Enter the Setup Menus 0 00 eeeeeeeeeeeteeeeteees 61 How to edit a menu 4 5 ccsccvagssieeasenscessascsedteeeasesaaseieeness 61 Set up Global Parameters Menu 2 0 cee ceeesseceeneeceeeeeeeeteeeees 63 Lad oe JOD sacramen ea teat E aaRS 64 Save Set p LOMO sah e a a E mah RONA 64 Job S lect Inputs e i a ees emeeens es 65 Job Select Input Polarity sacsccsciccccciccsssscatenas chastiasseaciounnecs 65 Output Override Digital Input ssesesesesessseesseessessseseseee 66 Output Override Input Polarity eeeeeeeteeenteeees 66 Start up Alarm Delay ss asa cncunace ane we edeuss cnoeue ences 66 Keyboard Lock Stats c cdiscsc acassccexehicisscedsatvqiesciaaeaseaate 67 Power Wp Output Status ic xccruentcd aan sas hatelentiecsameasteetes 67 Controller Address ccisiseseiassnieenscssghasmasetedcdantooiaoiarens 67 Communications Baud Rate ce eeeeeesceeesteeeenteeeennees 68 CLS User s Guide Contents Communications Protocol 2 05 gees sesadee Ganesan 68 Communications Error Checking ecceesseeeesteeeeeees 68 AC Lime Frequency sii cscacecesszaedesvactesnscatensecoaadehavecevestecs 69 Digital Output Polarity wisscc iccssccecassasteccasdeccessseeondtavesavens 69 EPROM Information oiccccscsstesaceeasisiccssvacanes te cddansassedetoenn
74. e inputs remove the thermocouple leads and use an ohm meter to measure between the In and In terminals of TBI Thermocouple inputs should not read above 200 ohms To check RTD inputs measure between the In and In terminals of TB1 RTD inputs should read between 20 and 250 ohms Checking Digital I O Troubleshooting The following steps will help you test digital inputs and outputs TB 18 and TB 50 Test 1 Plug in the CLS power supply if you have not already done so 2 Measure the 5Vdc supply at your TB 18 or TB 50 A Connect the voltmeter s Common lead to your TB 18 screw terminal 2 or TB 50 screw terminal 3 B Connect the voltmeter s Power lead to your TB 18 or TB 50 screw terminal 1 The voltage should be 4 75 to 5 25 Vdc Control and Digital Output Testing 1 Connect a 500 ohm to 100 Kohm resistor between the 5V pin TB 18 or TB 50 screw terminal 1 and the output pin you want to test 2 Connect the Common lead to the output pin Connect the voltmeter positive lead to the 5V pin 4 Ifyou are testing a PID control output use the Man Auto front panel key to turn the output on 100 and off 0 When the out put is off the output voltage should be less than 1V When the out put is on the output voltage should be between 3 75 and 5 5V 5 Ifyou are testing a digital output use the Manual I O Test menu to turn the output on and off See Setup for information on the Man ual I O Test menu Digital
75. eccsenneee 126 Changing Event States ssessseeessseesseesseesseressseessressresse 126 Editing Segment Triggers 0 ceceeeseceesseeesteeeenteeeenaees 126 Assigning an Input to a Trigger eeesessessesesserssressees 127 Changing a Trigger s True State oe eeeeceeeeteeeeteeee 127 Latching or Unlatching a Trigger 0 ee eeeeeeeeeteeeeeeees 127 Setting Segment Tolerance 200 0 eeeeceeeeeeeseeeenteeeeneeeees 128 Ending a Promilestiseisssecasierdedissaceedensdendenes steseteecdleleceansiens 128 Repeating a Profile lt ox esas ease dexsoutesasesaveeotendea saeceeneene 128 Usin IR AIP SOAK sss a a a tase O ARAT 129 Assigning a profile to a l00p sseeeseseeeseeeresrseerersresersereses 129 Assigning a Profile to a Linear Input Loop 130 Running a Profile sssiessicsavecvsiseeonaedeavascarasase Mena vedactesesedes 131 Ramip Soak Displays 5 ciisesisihesssesvscsdataadaasdonedavrdows eds Genens 131 Holding a Profile or Continuing from Hold 134 Resettins a Orol lend sicmtenisasccsseieinrsasacss ERE 135 Appendix B Enhanced Process Control 137 Enhanced Process Control Menus eecccceeeeeecceeeeceeceeeeees 138 vContents CLS User s Guide Process Variable Retransmit cccccccccccssssssecececeeeesensnsees 139 Setting Up a PV Retransmit 0000 eeeeeceeeeeeeteeeeeeeees 139 PV Retransmit Menus cccccccsesssccecececeessssrseceeeeees 140 Cascade Control repesne eet bis Gtete sean dee
76. ecs 69 Setup Loop INp t sicsicun semen sas i r pant a 70 MARIO a o oases sos E A E EE 71 Pulse Sample Time sccevdcaissieisaetesteiedesnalaavasiadaceoatdeneestens 72 Poop IN GING horses san tosvaneay baneduds aestecatvectia ss aneas 12 Input UNITS neria E AE RES 12 Taput Reading Oliset ca200u satin e e 73 Linear Scaling MGiUsi s cssessecdua voces seteadsec tne ceesaieeantaers 13 Display Format 53 pauhuntewussaadecincatelatetoeteantesmianunias 75 High Process V le rrenen 75 High Reading sit csstisseccccusnseaisiausacesdestdacastosdaeasieiecsussians 76 Low PLOCess Vale nerean e eas 76 DOV Ra E a a SE i 76 put Fiter oo laces a ER ie E ET T11 Set up Loop Control Parameters ceeeceeeseeeesteeeeneeees 78 Heat or Cool Control PB oui eeeceeesceesseceesteeeenteeeenaees 79 Heat or Cool Control TI juscsiassissieensatoqnasaaboncseasseqoateersseces 79 Heat or Cool Control TD sssssessssssssssssssssesssesssseeessresseesse 79 Heat or Cool Output Pierro sce sateccedinSdaeisiaedit castes 80 Heat and Cool Spread nesin in h 80 Set up Loop Outputs ssssssesssesessseesseessesssesssetssstessresseesseeesseee 81 Enable Disable Heat or Cool Outputs 00 0 eee 82 Heat or Cool Output Type ssecacescadcecseocteesecssttenvedececnanes 82 Heat r Cool ycle Times cancsatieaswniegauaatauat 83 SDAC Men s dw A ec ete a ee ce neha ee aces 83 SDAC MO cesnciivasunninesdus niannnnnenunmienie 83 BDAC High Valie resien aeea a i sek 84 SDAC LOW WalUG is sc
77. electable values The table below shows the character set for input units Input Character Sets for Units Thermocouple and RTD F or C Linear amp Pulse 0 to 9 A to Z degrees space Input Reading Offset Linear Scaling Menus This menu does not appear if the input type is linear pulse or skip Use it to make up for the input signal s inaccuracy at any given point For example at temperatures below 400 F a type J thermocouple may be inaccurate offset by several degrees F Use an independent thermocouple or your own calibration equipment to find the offset for your equipment To correct for offset errors change the factory default setting to a positive or negative value for the loop you are editing A positive value increases the reading and a negative value decreases it LOOP __ PROCESS _ UNITS 02 INPUT READING OFFSET 0 F ALARM SETPOINT STATUS __ OUT Selectable range For thermocouples infrared inputs and RTD2s the offset correction ranges from 300 to 300 For RTD1s and IR inputs set to Average mode the offset range is 300 0 to 300 0 The linear scaling menus appear under the Set up Loop Inputs main menu Linear scaling is available for linear and pulse inputs only It lets you scale the raw input readings readings in millivolts or Hertz to the engineering units of the process variable NOTE Linear scaling menus appear only if the loop s input type i
78. end the legs one at a time instead gently press the legs against a flat surface until they re at a 90 degree angle to the EPROM body as shown below Carefully insert the new EPROM into the EPROM socket Make sure that the chip is oriented so that its notch faces the same way as the part outline on the board Reverse steps 2 through 4 to reassemble the unit Do a No key reset to reinitialize the battery backed RAM You must perform a No key reset for the unit to operate properly To do a No key reset power down the controller Then press the No key and power up the controller CLS User s Guide 113 Troubleshooting 114 CLS User s Guide Linear Scaling Examples Linear Scaling Examples Example 1 Situation A pressure sensor that generates a 4 20 milliamp signal is connected to the CLS The specifications of the sensor state that it generates 4 milliamps at 0 0 PSI and 20 mA at 50 0 PSI Setup The sensor is connected to a loop input set up with a resistor scaling network to produce 60 millivolts at 20 mA See the Inputs section of Installation for more information on scaling networks The sensor measures PSI in tenths so the appropriate display format is 999 9 to 3000 0 This table shows the input readings PV et Displayed Sensor Input Reading FS 50 0 PSI 20 100 0 0 PSI 4 100 x 4ma 20 ma 20 The scaling values are therefore Parameter Low Value Hig
79. ently selected in this example loop 02 Choose NONE for no Ratio control Minimum Setpoint LOOP __ PROCESS _ UNITS 02 RATIO CONTROL MIN SP 25 ALARM SETPOINT STATUS __ OUT Selectable Values From the ratio loop PV minimum reading to the maximum reading Maximum Setpoint LOOP __ PROCESS _ UNITS 02 RATIO CONTROL MAX SP 25 ALARM SETPOINT STATUS __ OUT Selectable Values From the ratio loop PV minimum reading to the maximum reading Control Ratio LOOP _ _ PROCESS _ UNITS 02 RATIO CONTROL CTRL RATIO 1 0 ALARM SETPOINT STATUS __ OUT Selectable Values 0 1 to 999 9 148 Appendix B Enhanced Process Control Setpoint Differential LOOP __ PROCESS _ UNITS 02 RATIO CONTROL SP DIFF 0 ALARM SETPOINT _ STATUS _ OUT Selectable Values From the ratio loop PV minimum reading to the maximum reading SX y NOTE Ratio control cannot be used on the same control loop as Cascade control however both features may be used in the same multi loop controller Remote Analog setpoint Differential Control The Remote Analog Setpoint Remote SP is set up identically to the Ratio control If you wish to use a Remote SP an analog input from one of the control loops is typically connected to an external current or voltage source which can be defined as Linear All other input types are also usable as Remote SP inputs The loop which contains the Remote SP input is the Master lo
80. er of segments per profile 1 20 Number of triggers per segment Up to 2 Type of triggers Latched Unlatched Number of possible inputs for triggers 8 Number of events per segment 4 Number of possible outputs for events 34 At least one of these outputs must be used for control Configuring Ramp Soak This section will teach you how to set up R S profiles The following diagram shows the R S configuration menu tree Setup R S profiles Edit R S profile Copy Setup from lprofile Tolerance alarm Time Ready segment setpoint Ready segment Ready event edit events output XX External reset input number Edit segment number Segment time Back Segment setpoint Edit segment Segment event gt Segment event events output active state Edit segment gt triggers lt _ lt Trigger input pe Trigger active state Edit segment tolerance Trigger latch lt lt Ne Last segment Back status Repeat cycles 120 CLS User s Guide Setting the R S Time Base Editing R S Parameters Choosing a Profile to Edit Appendix A Ramp Soak The R S time base menu is in the Setup Globals main menu Use this menu to set the time base in all your R S profiles LOOP _ PROCESS _ UNITS RAMP SOAK TIME BASE HOURS MINS
81. erse action usually heating as the process decreases below the setpoint the out put increases For direct action usually cooling as the process increases above the setpoint the output increases Control Mode The type of action that a controller uses For example On Off time proportioning PID Auto matic or manual and combinations of these Current The rate of flow of electricity The unit of mea sure is the ampere A 1 ampere 1 coulomb per second Cycle Time The time required for a controller to complete one on off on cycle It is usually expressed in seconds Cyclic Redundancy Check CRC An error checking method in communications It provides a high level of data security but is more difficult to implement than Block Check Charac ter BCC See Block Check Character D Data Logging A method of recording a process variable over a period of time Used to review process perfor mance Deadband The range through which a variation of the input produces no noticeable change in the output In the deadband specific conditions can be placed on control output actions Operators select the deadband It is usually above the heating propor tional band and below the cooling proportional band Default Parameters The programmed instructions that are perma nently stored in the microprocessor software Derivative Control D The last term in the PID algorithm Action that anticipated the rate of change of the p
82. es For linear mVdc Vdc and mAdc ranges use 0 1 tolerance resistors Higher tolerances may cause significant errors Correct any errors due to resistor tolerance with the CLS built in linear scaling You can also install other components like capacitors for signal conditioning please consult Watlow Anafaze for more information Analog Input Terminals IN IN RC RD Analog Common CLS Measurement Circuitry The next table shows scaling resistor values Input Range RC RD All T C 0 60 mV DC Jumper 0 10 mA DC Jumper 6 0 ohms 0 20 mA DC Jumper 3 0 ohms 0 100 mV 499 ohms 750 ohms 0 500 mV 5 49 Kohms 750 ohms 0 1 VDC 6 91 Kohms 422 0 ohms 0 5 VDC 39 2 Kohms 475 0 ohms 0 10 VDC 49 9 Kohms 301 0 ohms 0 12 VDC 84 5 Kohms 422 0 ohms The next table shows the location of RC and RD on the analog input board The analog input board is the upper board of the two board set Loop RC RD Loop RC RD 1 R58 R42 9 R57 R41 2 R56 R40 10 R55 R39 3 R54 R38 11 R53 R37 4 R52 R36 12 R51 R35 5 R50 R34 13 R49 R33 6 R48 R32 14 R47 R31 7 R46 R30 15 R45 R29 8 R44 R28 16 R43 R27 38 CLS User s Guide A wire trace on the printed circuit board jumpers the RC position When you place a resistor in the RC position cut the wire trace that connects the two resistor terminals Installation Scaling and Calibration T C Inputs The CLS provides
83. es when loop is not in alarm Global alarm output does not activate e High process and high deviation alarms activate when the process variable goes above a value you set They remain active until the process variable goes below that value minus the deadband See the next diagram e Any digital output not used as a control output can be assigned to one or more process variable alarms The output is active if any of its alarms are active All alarm outputs are active Low or active High depending on the global alarm output polarity setting e Low process and low deviation alarms activate when the process variable goes below a value you set They remain active until the process variable goes above that value plus the deadband The next diagram shows these alarms High Alarm Limit SP Deviation Setpoint SP Deviation Low Alarm Limit Setup When the controller powers up or the setpoint changes deviation alarms do not activate until the process goes inside the deviation alarm band preventing deviation alarms during a cold start High and low process alarms are always enabled High process alarm on igh process alarm off Deadband High deviation alarm on Deadband High deviation alarm off Low deviation alarm off Deadband ow deviation alarm on Deadband Low process alarm on Low process alarm off Use menus to set the following process alarm parameters for each loop e
84. et to SKIP F Sensor has failed CLS User s Guide 53 Using the CLS The next table explains the symbols you see on the bottom line of Bar Graph display These symbols appear when the controller is in both dual output mode and single output mode If an alarm occurs the controller automatically switches to Single Loop display and shows an alarm code Symbol Symbol s Meaning M One or both outputs enabled Loop is in manual control A Only one output heat or cool but not both is enabled Loop is in automatic control T Loop is in Autotune mode H Both heat and cool outputs are enabled Loop is in Automatic T control and heating C Both heat and cool outputs are enabled Loop is in Automatic L control and cooling Single Loop Display 54 CLS User s Guide Navigating in Bar Graph Display e Press Yes up or No down to see Bar Graph Display for the Pulse Input loop e Press Enter twice to start Bar Graph scanning mode In scanning mode the controller alternately displays the first four loops and then the pulse input loop for three seconds each e Press any key to stop scanning mode e From Bar Graph Display press Back once to go to Single Loop dis play Single Loop display below shows detailed information for only one loop If the heat and cool outputs are enabled Single Loop display looks like this Process Variable f 160 F 180 AUTO 100 n Control Sta
85. etic Interference Noise Suppression The use of components to reduce electrical inter ference that is caused by making or breaking electrical contact or by inductors 167 Glossary Non Linear Through Watlow Anafaze software the Non Lin ear field sets the system to linear control or to one of two non linear control options Input 0 for Linear 1 or 2 for non linear O Offset The difference in temperature between the set point and the actual process temperature Offset is the error in the process variable that is typical of proportional only control On Off Control A method of control that turns the output full on until setpoint is reached and then off until the process error exceeds the hysteresis Open Loop A control system with no sensory feedback Operator Menus The menus accessible from the front panel of a controller These menus allow operators to set or change various control actions or features Optical Isolation Two electronic networks that are connected through an LED Light Emitting Diode and a photoelectric receiver There is no electrical con tinuity between the two networks Output Control signal action in response to the difference between setpoint and process variable Output Type The form of PID control output such as Time Proportioning Distributed Zero Crossing SDAC or Analog Also the description of the electrical hardware that makes up the output Overshoot The amount by which
86. evel that corresponds to the high process value you entered in the previous menu For linear inputs the high reading is a percentage of the full scale input range For pulse inputs the high reading is expressed in Hz The 100 full scale input value is 60 mV for the linear input type LOOP __ PROCESS _ UNITS 04 INPUT SCALING HI RDG 100 0 FS ALARM SETPOINT STATUS __OUT Selectable range Any value between 99 9 and 999 9 However you cannot set the high reading to a value less than or equal to the low reading Use this menu to set a low process value for input scaling purposes The low process value and the low reading value together define one of the points on the linear scaling function s conversion line LOOP__ PROCESS _ UNITS 01 INPUT SCALING LO PV 0 F ALARM SETPOINT _ STATUS _ OUT Selectable values See table under Display Format Use this menu to enter the input level that corresponds to the low process value you selected in the previous menu For linear inputs the low reading is a percentage of the full scale input range for pulse inputs the low reading is expressed in Hz LOOP __ PROCESS _ UNITS 01 INPUT SCALING LORDG 0 0 FS ALARM SETPOINT STATUS __OUT The full scale input value for the linear input type is 60 mV For pulse inputs it is 2000 Hz Selectable range 99 9 999 9 You cannot set the low reading to a value greater than or equal to the high reading Setup Input F
87. f controls and other devices Electrical Mechanical Relays See Relay electromechanical Emissivity The ratio of radiation emitted from a surface compared to radiation emitted from a blackbody at the same temperature Engineering Units Selectable units of measure such as degrees Cel sius and Fahrenheit pounds per square inch newtons per meter gallons per minute liters per minute cubic feet per minute or cubic meters per minute EPROM Erasable Programmable Read Only Memory inside the controller Error The difference between the correct or desired value and the actual value F Fahrenheit The temperature scale that sets the freezing point of water at 32 F and its boiling point at 212 F at standard atmospheric pressure The formula for conversion to Celsius is C 5 9 F 32 F Failed Sensor Alarm Warns that an input sensor no longer produces a valid signal For example when there are thermo couple breaks infrared problems or resistance 165 Glossary temperature detector RTD open or short fail ures Filter Filters are used to handle various electrical noise problems Digital Filter DF A filter that allows the response of a system when inputs change unreal istically or too fast Equivalent to a standard resistor capacitor RC filter Digital Adaptive Filter A filter that rejects high frequency input signal noise noise spikes Heat Cool Output Filter A filter that slows the
88. for closed loop PID control An analog recorder data logging system is also in place and a recording of the process temperature is required The recorder input is a linear 4 20mAdc signal representing a range of 0 1000 F Furnace Loop 1 Input PV Loop 1 PID Output Loop 2 PID Output CLS Heater Mw Power Control To Data Logger Appendix B Enhanced Process Control 1 First set up the standard control loop parameters according to the fur nace application in this case on loop 1 2 Select another unused PID output for retransmitting the thermocouple value for example loop 2 heat output 3 Change the display to loop 2 and then enter the 3 key sequence to display the following Display User Input LOOP __ PROCESS _ UNITS Press Yes SETUP LOOP 02 PV RETRANSMIT ALARM SETPOINT STATUS __OUT LOOP __ PROCESS _ UNITS Enter 01 for loop 01 PV 02 HEAT OUTPUT Press Enter RETRANS PV 01 ALARM SETPOINT STATUS __OUT Enter the minimum input value which LOOP PROCESS _ UNITS will correspond to the minimum output 02 HEAT RETRANS percentage MIN INP 0 For a range of 0 1000 F the minimum ALARM SETPOINT STATUS OUT input value is 0 F Change the MIN INP to 0 Press Enter LOOP PROCESS _ UNITS Enter the minimum output percentage 02 HEAT RETRANS from 0 to 100 For this example we will MIN OUT 0 assume a full span with a minimum of 0 ALAR
89. gment e If the current segment s setpoint is the same as the previous seg ment s setpoint it is called a soak segment Each segment can have up to two triggers At least one of these two triggers must be true before the segment can start While the input is not true the profile waits this wait state is called trigger wait You can use any one of the eight digital inputs for triggers You can also use the same trigger for more than one segment or more than one profile Each segment can also have up to four events external signals connected to the digital outputs Events occur at the end of a segment You can use any of the digital outputs that are not used for control or for the SDAC clock for events e User configurable time base Watlow Anafaze s Ramp Soak lets you set your profiles to run for hours and minutes or for minutes and seconds Whichever is appropriate for your installation e Repeatable profiles You can set any profile to repeat from 1 to 99 times or continuously e Fast setup for similar profiles You can set up one profile then copy it and alter it to set up the rest e External reset Use the CLS external reset menu to configure a dig ital input you can use to reset a profile to the Ready state CLS User s Guide 119 Appendix A Ramp Soak Specifications Number of possible profiles 17 Number of times to repeat a profile 1 99 or con tinuous Numb
90. h Value Process Value PV 0 0 PSI 50 0 PSI Input Reading RDG 20 0 100 0 CLS User s Guide 115 Linear Scaling Example 2 116 CLS User s Guide Situation A flow sensor connected to the CLS measures the flow in a pipe The sensor generates a 0 5V signal The sensor s output depends on its installation Independent calibration measurements of the flow in the pipe indicate that the sensor generates 0 5 volts at three gallons per minute GPM and 4 75 volts at 65 GPM The calibration instruments are precise to fil gallon per minute Setup The sensor is connected to a loop input set up with a resistor voltage divider network to produce 60 millivolts at 5 volts See the Inputs section of the Installation chapter for information on scaling networks The calibrating instrument is precise to 1 gallon per minute so the appropriate display format is 999 to 3000 This table shows the input readings PV Sensor etre Displayed Input Reading ES 65 GPM 4 75 4 75V 5 00V x 100 95 3 GPM 0 5 0 5V 5 00V x 100 10 The scaling values are therefore Parameter Low Value High Value Process Value PV 3 GPM 65 GPM Input Reading RDG 10 0 95 0 Example 3 Linear Scaling Examples Situation A pulse encoder which measures the movement of a conveyor is connected to the CLS The encoder generates 900 pulses for every inch the conveyor moves You want to measure conveyor speed i
91. have been subject to misuse accident negligence failure of electric power or modification by the Customer without the written approval of Watlow Anafaze Incorporated Final determination of warranty eligibility shall be made by Watlow Anafaze Incorporated If a warranty claim is considered invalid for any reason the Customer will be charged for services performed and expenses incurred by Watlow Anafaze Incorporated in handling and shipping the returned unit If replacement parts are supplied or repairs made during the original warranty period the warranty period for the replacement or repaired part shall terminate with the termination of the warranty period of the original product or part The foregoing warranty constitutes the sole liability of Watlow Anafaze Incorporated and the Cus tomer s sole remedy with respect to the products It is in lieu of all other warranties liabilities and remedies Except as thus provided Watlow Anafaze Inc disclaims all warranties express or implied including any warranty of merchantability or fitness for a particular purpose Please Note External safety devices must be used with this equipment CLS User s Guide Contents Contents Overview 1 System Diap a a oes Sl au E R a 2 Parts List sesarinosuisuiunssiiniieni naina 2 Safe nene e a a E A na 3 Introduction 5 Specifications nena a e Aai 7 An alos Nputsmenn e e T aa untiees 7 Digital Inputs en R 9 User Selectable Digital Outputs
92. he cable support on the underside of the CLS The TB 18 was shipped to you in a plastic bag The bag also contained a cable tie the long plastic strip and a cable tie mount the square plastic piece with one sticky side a Stick the cable tie mount to the underside of the CLS Install it in a spot that won t block the vents b Thread the cable tie through the hole in the cable tie mount When you re finished wiring the outputs it should look like this illustration Cable Support 2 Next wire outputs to the terminal block For help see Wiring Out puts later in this chapter Route wires through the cable support leaving about 9 of wire between the TB 18 and the support 3 Gently slide the female part of the terminal block into the 50 pin header on the rear of the controller as shown here AN WARNING Do not connect power to the CLS now Test the unit first as explained in the Power Wiring and Controller Test section CLS User s Guide 17 Installation TB 50 Mounting Instructions 18 CLS User s Guide These steps tell you how to mount the TB 50 Please follow these steps exactly so you don t damage the terminal block the ribbon cable or the controller 1 Choose a mounting location Be sure there is enough clearance to install and remove the TB 50 it measures 3 4 long X 3 2 wide X 1 27 ta
93. he following symptoms suspect EMI e The CLS s display blanks out and then reenergizes as if power had been turned off for a moment e The process value does not display correctly EMI may also damage the digital output circuit so digital outputs will not energize If the digital output circuit is damaged return the controller to Watlow Anafaze for repair Avoiding Noise Problems To avoid noise problems Where possible use solid state relays SSRs instead of electromechanical EM relays If you must use EM relays try to avoid mounting them in the same panel as the CLS equipment Separate the 120 Vac power leads from the low level input and output leads connected to the CLS Don t run the digital output or PID control output leads in bundles with 120 Vac wires Never run input leads in bundles with high power leads See the General Wiring section If you must use EM relays and you must place them in a panel with CLS equipment use a 01 microfarad capacitor rated at 1000 Vac or higher in series with a 47 ohm Y2 watt resistor across the NO contacts of the relay load This network is known as an arc suppressor or snubber network You can use other voltage suppression devices but they are not usually required For instance you can place a metal oxide varistor MOV rated at 130 Vac for 120 Vac control circuits across the load which limits the peak AC voltage to about 180 Vac Watlow Anafaze P N 26 130210 00 You can also
94. hield to the CLS panel s 120 Vac panel ground and connect one end of the out put wiring shield to the CLS panel s 120 Vac panel ground Some installations may require a different shield configuration Contact Watlow Anafaze for more information if these instructions do not apply to your system For more noise suppression measures see Noise Suppression 20 CLS User s Guide Grounding Installation Connect the CLS chassis to an external ground at only one point to avoid ground loops that can cause instrument errors or malfunctions Since the CLS uses a non isolated measurement system it has the following connections to power supply common Analog common TB1 pins 5 6 11 amp 12 Reference common TB pin 17 Communications ground TB1 pins 23 amp 24 if using RS 232 Power supply ground TB2 pin 2 Control common TB 18 pin 2 TB 50 pin 3 and 4 Watlow Anafaze strongly recommends that you Do not connect any one of these pins to earth ground Do not tie them together externally Isolate outputs through solid state relays where possible Isolate RTDs or bridge type inputs from ground if used Isolate digital inputs from ground through solid state relays If you can t do that then make sure the digital input is the only place that one of the above pins connects to ground If you are using RS 232 from an un isolated host don t connect any other power common point to earth ground CLS User s Guide 21 Ins
95. ications for inputs outputs the serial interface system power requirements environmental specifications and the CLS physical dimensions Number of Control Loops 4 4CLS 8 8CLS 16 16CLS plus one pulse loop Number of Analog Inputs 4 4CLS 8 8CLS 16 16CLS Input Switching differential solid state MUX switching Input Sampling Rate 4CLS 6x sec 167 ms at 60 Hz 5x sec 200 ms at 50 Hz 8CLS 3x sec 333 ms at 60 Hz 2 5x sec 400 ms at 50 Hz 16CLS 1 5x sec 667 ms at 60 Hz 1 25x sec 300 ms at 50 Hz Analog Over Voltage Protection 20 V referenced to digital ground Common Mode Rejection CMR For inputs that don t exceed 5 V gt 60 dB DC to 1 kHz and 120 dB at selected line frequency A D Converter Integrates voltage to frequency Input Range 10 to 60 mV Other ranges are available with scaling resistors Resolution 0 006 greater than 14 bits This is the internal measurement resolution not the display resolution Calibration Automatic zero and full scale CLS User s Guide 7 Introduction Thermocouple Ranges and Resolution Accuracy Accuracy Range in F Range in C 25 C 0 50 C Full Ambient Temp Range g oR C F J T C 350 to 1400 212 to 760 0 5 0 9 1 1 2 0 K T C 450 to 2500 268 to 1371 0 6 1 2 1 35 2 7 T T C 450 to 750 268 to 399 1 3 2 4 2 9 5 4 S T C 0 to 3200 18 to 1760 2 5 4 5 5 6 10 1 R T
96. ighly recommend that you use ungrounded thermocouples with the external thermocou ple sheath electrically connected to earth ground CLS User s Guide 39 Installation You can connect J K T S R B and E thermocouples directly to the CLS Watlow Anafaze provides standard linearization and cold junction compensation for these thermocouple types Other thermocouple types require custom linearization please contact Watlow Anafaze for more information about them Connecting Thermocouples Connect the positive T C lead to the In terminal Connect the negative T C lead to the TB1 In 4 or 8CLS or analog common 16CLS terminal A typical thermocouple connection is shown in the figure below e Use 20 gauge thermocouple extension wire for all thermocouple inputs e If you use shielded wire tie it to panel ground or to ground at the measurement end White IN Type J T C Red N ae U Case Shield if present SNA Frame Ground RTD Inputs 4 and 8 CLS only The standard industrial RTD is an 100 ohm 3 wire platinum assembly as shown in the figure below Watlow Anafaze highly recommends that you use the 3 wire RTD to prevent reading errors due to cable resistance e If you order an RTD1 or RTD2 configuration Watlow Anafaze will configure your CLS for the standard 3 wire RTD e If you must use a 4 wire RTD leave the fourth wire unconnected Watlow Anafaze offers 2 standard DIN 3
97. ilter The CLS has two different types of input filter e A noise rejection filter that rejects high frequency input signal noise This filter keeps a trend log of input readings If a reading is out side the filter s acceptance band and later readings are within the acceptance band the CLS ignores the anomalous reading The acceptance band for thermocouples is 5 degrees above and 5 degrees below the input reading For linear inputs it s 0 5 above and 0 5 below the input reading If later readings are also outside the accep tance band the CLS accepts the anomalous reading and calculates a new acceptance band You cannot adjust this input filter e A standard resistor capacitor RC filter that lets you dampen the input response if inputs change unrealistically or change faster than the system can respond If the input filter is enabled the process variable responds to a step change by going to 2 3 of the actual value within the number of scans you set If all input loops are enabled none of them are set to SKIP the CLS scans each input loop 6 times per second The input filter applies to all input types except those set to SKIP LOOP __ PROCESS _ UNITS 01 INPUT FILTER Selectable range 0 255 scans 0 disables the filter CLS User s Guide 77 Setup Set up Loop Control Parameters Use these menus to change control parameters for heat and cool outputs of the selected loop including e Proportional
98. ing On Off control frequently cycles around the setpoint When process variable cycling is unacceptable or the process or setpoint are variable use proportional control Proportional control or Gain eliminates cycling by increasing or decreasing the output proportional to the process variable s distance from the setpoint The limits of proportional control are defined by the Proportional Band PB outside this band of control the output is either 100 or 0 For example using the same values from the example above and a PB of 20 the output is e 50 when the process variable is 990 F e 75 when the process variable is 985 F e 100 when the process variable is 980 F or below PID Tuning and Control However a process which uses only Proportional control may settle at a point above or below the setpoint it may never reach the setpoint at all This behavior is known as offset or droop This diagram shows a process under proportional control only SP Proportional and Integral Control For Proportional and Integral control use the Integral term or Reset with Proportional control The Integral term corrects for offset by repeating the Proportional band s error correction until there is no error For example if a process tends to settle about 5 F below the setpoint use Integral control to bring it to the desired setting The next diagram shows a process under proportional and integr
99. int plus the tolerance If you enter a negative tolerance the process goes out of tolerance when the PV goes below the setpoint minus the tolerance LOOP _ PROCESS ___UNITS A SEGMENT 01 SEG TOLERNCE OFF ALARM SETPOINT STATUS __ OUT Selectable Values 99 to 99 or Off no tolerance Use this menu to make a segment the last one in the profile LOOP PROCESS _ UNITS A SEGMENT 01 LAST SEGMENT NO ALARM SETPOINT STATUS __OUT Selectable Values No or Yes Use this menu to set the number of times you want a profile to repeat or cycle LOOP PROCESS _ UNITS A REPEAT CYCLES Selectable Values 1 99 or C continuous cycling Appendix A Ramp Soak Using Ramp Soak This section explains how to assign a profile to a loop how to put a profile in Run Continue or Hold mode how to reset a profile and how to display profile statistics The next figure shows the Ramp Soak key menus a Press R S Key Assign Ramp Soak peaked already Profile Y Time Remaining Y Press R S Key Cycle Number Press R S Key F Mode y Press R S Key Ramp Soak Reset From the Ramp Soak Reset display e Press NO to return to Single Loop display e Press BACK to return to the Time Remaining display Assigning a profile to a loop Use this menu to assign a profile to a loop LOOP _ PROCESS ___UNITS 01 ASSIGN R S PROFILE A ALARM SETPOINT
100. int setpoint The Setup menus for the Cascade control feature appear under the Setup Loop Cascade main menu See Setup section in this manual In order to view the Cascade control menus you need to choose Yes on the following menu LOOP PROCESS _ UNITS SETUP LOOP 02 CASCADE ALARM SETPOINT _ STATUS __OUT Answering YES to this prompt will allow you to set up the Cascade parameters with the loop currently displayed which performs the actual control of the final control element Cascade Output Assignment LOOP __ PROCESS _ UNITS 02 CASCADE PRIM LOOP 03 ALARM SETPOINT STATUS __OUT Selectable Values Any loop except the secondary loop in this case loop No 02 Appendix B Enhanced Process Control Base Setpoint LOOP___ PROCESS _ UNITS 02 CASCADE BASE SP 25 ALARM SETPOINT _ STATUS __OUT Selectable Values From the secondary loop PV minimum reading to the maximum reading Minimum Setpoint LOOP _ PROCESS _ UNITS 02 CASCADE MIN SP 25 ALARM SETPOINT _ STATUS __ OUT Selectable Values From the secondary loop PV minimum reading to the maximum reading Maximum Setpoint LOOP _ PROCESS _ UNITS 02 CASCADE MAX SP 180 ALARM SETPOINT __ STATUS __OUT Selectable Values From the secondary loop PV minimum reading to the maximum reading Heat Cascade Span LOOP___ PROCESS _ UNITS 02 CASCADE HT SPAN 9999 ALARM SETPOINT STATUS __ OUT Selectable Value
101. ir default values so you must reenter the desired values from ANASOFT or from the controller front panel after you change the EPROM 1 Power down the controller Be sure to take antistatic precautions CLS User s Guide 111 Troubleshooting 112 CLS User s Guide X Remove the two screws from the sides of the controller front panel Remove the electronics assembly from the case as shown below Unscrew the four screws at the corners of the top board and care fully unplug this board to access the bottom board processor board as shown below Find the installed EPROM This is a 28 pin socketed chip which should have an Watlow Anafaze label on top of it If there is no label a small window will be visible in the middle of the top of the chip Do not confuse the EPROM with the RAM the RAM also has 28 pins but it s in high profile socket and it does not have a label or a window The component designation U2 is printed on the processor board next to the EPROM socket The next figure shows the EPROM and RAM chip 10 Troubleshooting Remove the existing EPROM from its socket by prying it out with a small flathead screwdriver as shown below A The EPROM is shipped with its legs bent at an angle that best fits its packaging Bend the legs slightly so that the legs line up with the holes in the EPROM socket Don t try to b
102. knowledge the tolerance alarm by pressing the ALARM ACK key before you can do any other editing Selectable Values 0 00 to 99 59 minutes or hours depending on the time base setting 122 CLS User s Guide Appendix A Ramp Soak Editing the Ready Setpoint When you assign a profile to a loop the profile doesn t start immediately instead it goes to the ready segment segment 0 and stays there until you put the profile in Start mode You can set a setpoint assign events and set event states for the ready segment Use this menu to set the ready segment setpoint LOOP __ PROCESS _ UNITS A READY SEGMENT SETPOINT OFF ALARM SETPOINT STATUS __ OUT Selectable Values 999 to 9999 or Off Editing the Ready Event States Use this menu to set the ready state for all outputs that are not used for control or for the SDAC clock When you assign a profile the controller starts the ready segment it goes to the ready setpoint and puts all the outputs in the ready state you set here The outputs stay in the ready state until the end of segment 1 when segment 1 s events become active LOOP __ PROCESS _ UNITS B READY SEGMENT EDIT EVENTS ALARM SETPOINT STATUS __ OUT When you press NO you will advance to the next menu If you press YES this menu appears LOOP __ PROCESS _ UNITS READY EVENT OUTPUT 15 OFF ALARM SETPOINT STATUS __ OUT Selectable Values You can toggle inputs that are not IN USE
103. l control 100 output If you selected a continuous output limit the controller sets the loop to the output limit The autotune function then calculates the appropriate PID constants for the loop and puts the loop in automatic control with the calculated PID values The Autotune function will abort if e Process variable goes over 75 of the setpoint Remember the con troller is at 100 output or at the output limit you set e It has not calculated PID constants after 10 minutes due to heater failure sensor failure et cetera If the autotune function aborts it puts the loop into its previous control state Automatic control or Manual control at the previous output percentages To automatically tune a loop follow these steps 1 Make sure the process is cold or stable and well below setpoint 2 Initiate Autotune a Use the front panel keypad to go to Single Loop Display b Press the Man Auto key c Choose Tune d Press Enter The Tune indicator will begin flashing and the controller will go back to Single Loop Display The Tune indicator will keep flashing as long as the loop is tuning If you have a CLS without the Ramp Soak option pressing the Ramp Soak key has no effect If you have a CLS with Ramp Soak installed please refer to the Ramp Soak Appendix at the end of this manual Setup The Setup menus let you change the CLS detailed configuration information If you have not set up a CLS before or if
104. larm digital output Displays Bar Graph Display Using the CLS The next section discusses the CLS main displays Bar Graph Single Loop and Job displays On power up the CLS displays general symbolic information for all four primary loops This display is called Bar Graph mode The diagram below shows the symbols used in Bar Graph mode Alarm Symbol Loop Number or Name Loop Status The next table explains the symbols you see on the top line of the Bar Graph display These symbols appear when the controller is in dual output mode heat and cool outputs enabled and single output mode heat or cool outputs enabled but not both Symbol Symbol s Meaning lt Loop is in low process or low deviation alarm Loop is in high process or high deviation alarm Lis Loop is above setpoint If you enable the high or low devia tion alarm this symbol is scaled to it If you don t enable these alarms these symbols are scaled to the setpoint 5 of the sensor s range Loop is at setpoint If you enable the high or low deviation alarm this symbol is scaled to it If you don t enable these alarms these symbols are scaled to the setpoint 5 of the sensor s range TTT Loop is below setpoint If you enable the high or low devia tion alarm this symbol is scaled to it If you don t enable these alarms these symbols are scaled to the setpoint 5 of the sensor s range Blank Loop is s
105. le Contact Watlow Anafaze for more information about the DAC and Serial DAC Introduction Miscellaneous Specifications Physical Dimensions Serial Interface Type RS 232 3 wire or RS 485 4 wire Isolation RS 232 None RS 485 To EIA RS 485 Specification Baud Rate 2400 or 9600 user selectable Error Check BCC or CRC user selectable Number of Controllers 1 with RS 232 communications 32 with RS 485 communications Protocol Form of ANSI X3 28 1976 D1 F1 compatible with Allen Bradley PLC full duplex System Power Requirements Voltage 12 24 Vdc Input Current no load 300 mA max Maximum Current Requirement 610 mA If the reference voltage is externally loaded add 1 mA supply current for every 1 mA of load up to a maximum load of 100 mA If using the 5V logic supply to power digital outputs add 0 6 mA supply current for every 1 mA of load up to a maximum load of 350 mA Therefore the maximum current requirement is 300 100 0 6 x 350 610 mA Environmental Specifications Storage Temperature 20 to 60 C Operating Temperature 0 to 50 C Humidity 10 to 95 non condensing CLS 1 75 lbs 1 98 x 3 78 x 7 10 8 kg 50 mm x 96 mm x 180 mm TB 18 1 025 x 3 700 2 57 cm x 9 29 cm TB 50 3 2 x 3 4 8 03 cm x 8 53 cm CLS User s Guide 11 Introduction 12 CLS User s Guide Installation Installation These installation instructions are written for non technical users if y
106. ll 2 Watlow Anafaze shipped the TB 50 to you in an antistatic bag Make sure these parts are also in the bag e Five plastic standoffs e Five 6 32 screws e Five cable tie wraps e One 50 pin ribbon cable e Five ribbon cable clamps 3 Snap four of the plastic standoffs into the four mounting holes on the TB 50 There are also four smaller holes on the terminal board as shown here These holes are for the cable tie wraps the plastic standoffs won t fit them You ll use these holes to secure wiring to the termi nal block See Wiring Outputs in this chapter for help installing cable tie wraps FN Tai B 38B 39 40 41 42 43 44 45 46 47 48 49 50 fal QOTO COOCOO y 138 14 15 16 17 48 19 20 21 22 27y 24 25 a B 13A 12 11 10 9 8 7 6 5 4 3 2 Ti S Hoks hbekd A ar m ounthg hoks Hots bbekd B ar te wrap hoks Installation 4 Place the TB 50 where you will mount it and use a pencil to trace around the standoffs Drill and tap 6 32 holes in the locations you marked Place the TB 50 where you will mount it Insert the 6 screws in the standoffs and tighten them Y y NOTE Save the cable tie wraps ribbon cable and ribbon cable clamps You ll use them when you wire outputs to the TB 50 and when you connect the ribbon cable AN WARNING Do not connect power to the CLS now Test the unit first as explained in the Power Wiring an
107. lobal alarm output Global Alarm Output When any alarm is triggered the Global Alarm Output is also triggered and it stays on until you acknowledge it CLS User s Guide 5 Introduction 6 CLS User s Guide Watchdog Timer The CLS watchdog timer output notifies you of system failure You can use it to hold a relay closed while the controller is running so you are notified if the microprocessor shuts down Front Panel or Computer Operation Set up and run the CLS from the front panel or from a local or remote computer Watlow Anafaze offers ANASOFT our IBM AT or IBM PC compatible software you can use to operate the CLS ANASOFT has these features e Process Overviews e Parameter Setup e Graphic Trend Plotting e Data Logging Multiple Job Storage Store up to 8 jobs in protected memory and access them locally by entering a single job number or remotely via digital inputs Each job is a set of operating conditions including setpoints and alarms Non Linear Output Curves Standard Select either of two non linear output curves for each control output Autotuning Makes Setup Simple Use the Autotune feature to set up your system quickly and easily The CLS internal expert system table finds the correct PID parameters for your process Pulse Counter Input Standard Use the pulse counter input for precise control of motor or belt speed Specifications Analog Inputs Introduction The following section contains specif
108. meter by ten 999 9 to 3000 0 Controller adds a decimal point and a zero to your parameter 99 9 to 300 0 Controller divides your parameter by ten 9 999 to 30 000 Controller divides your parameter by 100 0 999 to 3 00 Controller divides your parameter by 1000 Running a Profile Ramp Soak Displays Appendix A Ramp Soak When you assign a profile it does not start running immediately instead the loop enters the Ready segment segment 0 Use this menu to start a profile put it in Start mode LOOP __ PROCESS _ UNITS 01 A SEGOI 05 R SET MODE START ALARM SETPOINT _ STATUS __OUT Starting a profile You can start a profile only when it s in the Ready segment 1 Press the RAMP SOAK key repeatedly until you see the Ramp Soak mode menu 2 While the profile is in Ready segment the only mode available is the Run mode 3 Press YES to start the profile and then ENTER to advance to the next menu Running several profiles simultaneously To run several profiles simultaneously follow these steps 1 Setup the profiles so that segment 1 of each profile has the same latched trigger 2 Assign the profiles to the appropriate loops The loops will go to the Ready segment of each profile Set each profile to Run mode 4 Trip the trigger Editing a profile while it is running You can edit a profile while it is running but the changes you have made will not take effect until the next time i
109. n Hold Hold the profile Holding a profile In Hold mode all loop parameters stay at their current settings until you change the mode or reset the profile To put a profile in hold follow these steps e Press RAMP SOAK key repeatedly until you see the R S mode menu LOOP PROCESS _ UNITS 01 A SEGOI 05 R SET MODE HOLD ALARM SETPOINT STATUS _ OUT e While the profile is running the only mode you will be able select is Hold e Press YES to hold the profile and then ENTER to advance to the next menu Continuing a profile If a profile is holding and you want it to run you can put it in Continue mode e Press RAMP SOAK key repeatedly until you see the R S mode menu e While the profile is holding the only mode you will be able select is Cont Continue e Press YES to continue the profile and then ENTER to advance to the next menu 134 CLS User s Guide Appendix A Ramp Soak Resetting a profile Use this menu to reset a profile When you reset a profile the following happens e The profile returns to the ready segment The PV goes to the ready setpoint and the ready segment events go to the state you specified in the Edit Ready Event State menu e The controller shows you the Assign Profile menu in case you would like to assign a different profile to the loop To reset a profile follow these steps 1 Press RAMP SOAK key repeatedly until you see the R S mode menu 2 Press the NO key You should
110. n feet per minute f m Setup The encoder input is connected to the CLS pulse input An one second sample time gives adequate resolution of the conveyor s speed The resolution is 1 pulse 60 seconds 1 inch 1 foot 0 006 f m 1 second 1 minute 900 pulses 12 inches So a display format of 99 99 to 300 00 is appropriate The input readings are as follows At the maximum pulse rate of the CLS 2000 Hz 2000 pulses 60 seconds 1 inch 1 foot f 11 11 f m 1 second 1 minute 900 pulses 12 inches At zero hertz the input reading will be 0 00 f m Therefore the scaling values are Parameter Low Value High Value Process Value PV 0 f m 11 11 f m Input Reading RDG 0 Hz 2000 Hz CLS User s Guide 117 Linear Scaling 118 CLS User s Guide Appendix A Ramp Soak Appendix A Ramp Soak Introduction R S Features This Appendix will teach you how to set up and use Ramp Soak profiles in CLS controllers The Ramp Soak feature turns your controller into a powerful and flexible batch controller Ramp Soak lets you program the controller to change a process setpoint in a preset pattern over time This preset pattern or temperature profile consists of several segments During a segment the temperature goes from the previous segment s setpoint to the current segment s setpoint e Ifthe current segment s setpoint is larger or smaller than the previ ous segment s setpoint it is called a ramp se
111. n is 1 0 ALARM SETPOINT STATUS __OUT Press Enter LOOP PROCESS UNITS Enter the setpoint differential or offset 02 RATIO CONTROL For this example we have no offset SP DIFE 0 requirement and will use 0 ALARM SETPOINT STATUS __OUT Press Enter Differential Control Now press the Back key several times until the normal loop display appears The setpoint of loop 2 will now be equal to the Input range of Loop 1 which is 0 5 Vdc which is representative of the 0 300 F To complete the Remote SP setup Loop 1 may be configured for outputs and alarms Likewise Loop 2 must be configured for inputs outputs and alarms Please consult the SETUP Section of this manual for information on PID loop setup Differential Control is a simple application of the Ratio Control option used to control one process at a differential or offset to another A thermal forming application requires that the outside heaters operate at a higher temperature than the center heaters In some applications these may be in bands of temperatures The diferential control point is determined by the Master channel which is using IR sensors for temperture feedback Secondary loops will be using T Cs for feedback 159 Appendix B Enhanced Process Control The loops using the IR sensor as an input is assigned to the Master Loop in the Ratio Control Option Menu The secondary loop is the Differential control loop By setting the setpoint differential SP DIF
112. n the CLS However damage to the CLS due to improper resis tor installation is not covered under warranty and repairs can be expensive If you have any doubts about your ability to install scaling resistors send your CLS to Watlow Anafaze for resistor installation 34 CLS User s Guide Installation 4 and 8 CLS Scaling Values e For RTD inputs RA and RB are a matched pair RP Their match ing tolerance is 0 02 2 ppm C and their absolute tolerance is 0 1 10 ppm C RC has 0 05 tolerance e For RTD2 inputs use 0 05 tolerance resistors e For linear mVdc Vdc and mAdc ranges use 0 1 tolerance resis tors Higher tolerances may cause significant errors Correct any errors due to resistor tolerance with the CLS s built in linear scaling You can also install other components like capacitors for signal conditioning please consult Watlow Anafaze for more information Analog To Input CLS Terminal Circuitry At IN RC Voltage Current RA Internal i 5 Vdc RD Reference RTD Thermister RB RC A R IN C 47 uF A COM ae FTA C 47 uF LA V I NOTE When adding your own scaling resisters to the 4 and 8 CLS the shorting pads of the RC must be cut before installing to the bottom of the PC board CLS User s Guide 35 Installation The next table shows scaling resistor values Input Range RA RB RC RD All T C 0 60 mV DC Jumper
113. ncrease in the temperature of a setpoint system Range The area between two limits in which a quantity or value is measured It is usually described in terms of lower and upper limits Recipe See Job Reflection Compensation Mode A control feature that automatically corrects the reading from a sensor Relay A switching device Electromechanical Relay A power switch ing device that completes or interrupts a circuit by physically moving electrical contacts into con tact with each other Not recommended for PID control Solid State Relay SSR A switching device with no moving parts that com pletes or interrupts a circuit electrically Reset Control action that automatically eliminates off set or droop between setpoint and actual process temperature See also Integral Automatic Reset The integral function of a PI or PID temperature controller that adjusts the process temperature to the setpoint after the sys tem stabilizes The inverse of integral Automatic Power Reset A feature in latch ing limit controls that Resistance Opposition to the flow of electric current mea sured in ohms Glossary Resistance Temperature Detector RTD A sensor that uses the resistance temperature characteristic to measure temperature There are two basic types of RTDs the wire RTD which is usually made of platinum and the thermistor which is made of a semiconductor material The wire RTD is a positive tempe
114. nput reading offset T C Cool control TI Heat output limit Cool control TD Hi dev alarm type Cool control filter Heat output limit time Heat Cool spread Heat override output Hi dev alarm output Tf Ramp Soak is installed in your controller see Ramp Soak Appendix at the end of this Guide dig input Disp format Override dig Linear in active Input scaling Startup alarm Hi PV Linear amp delay Pulse Input scalin p 8 Ramp Soak Hi RDG Linear time base only amp Pulse if R S installed Keyboard lock Input scaling Lo PV Linear amp status Pulse Power up output status Input scaling Lo RDG Linear Controller amp Pulse address Input Filter Communications baud rate Communication protocol Communications ERR check AC line freq Dig out polarity on alarm EPROM information 62 CLS User s Guide Heat output Lo dev alarm type Cool control output Lo dev alarm output Cool output type Lo proc alarm setpt Cool output cycle time TP SDAC menus SDAC only Lo proc alarm type Cool output action Lo proc alarm output Cool output limit Alarm dead band Cool output
115. nstallation Use a 200 ohm terminating resistor on the RX line of the last controller in the system If you have only one controller it is the last controller in the system Use jumper JU1 to select the terminating resistor place it in B position for termination and A position for non termination Computer CLS 1 Last CLS TXA RXA 25_ g 4 B TXB RXB 2 RXA TXA 26 RXB TXB 24 Do not connect shield to CLS NOTE Connect the shields to earth ground only at the computer or other 485 interface Do not connect the shield to the controller If you connect RS 485 communications and they do not function properly or if you have measurement problems when communications lines are connected request addi tional technical information from the Watlow Anafaze Customer Service Department CLS User s Guide 45 Installation 46 CLS User s Guide Configuring Communications Your controller is shipped configured for RS 232 To switch between RS 232 and RS 485 change the jumpers as shown here g e e Ju2 e g g e e e JU3 e e e g g ry JU4 g g e e e JUS e e e A B A B RS 232 RS 485 RS 232 RS 485 Configured for RS 232 Configured for RS 485 You ll need tweezers and a Phillips head screwdriver to switch between RS 232 and RS 485 Follow these steps Power down the unit 2 Remove the controller s metal casing If you haven t removed the c
116. ntegrating the signal over the period of the AC line frequency the controller s noise rejection will suffer if the line frequency is not set correctly LOOP ___PROCESS _ UNITS AC LINE FREQ 60 HERTZ ALARM SETPOINT _ STATUS _ OUT Selectable values 50 Hz or 60 Hz ASA NOTE Digital Output Polarity EPROM Information You must switch power to the CLS on and off for a change in AC line frequency to take effect Use this menu to set the polarity of the digital outputs used for alarms LOOP _PROCESS___UNITS DIG OUT POLARITY ON ALARM LOW ALARM SETPOINT _ STATUS __OUT Selectable values High or Low This is a view only display It shows the controller s EPROM version and checksum LOOP __ PROCESS _ UNITS CLS 164 V03 02 CS 2233 ALARM SETPOINT STATUS __OUT Press any key to return to the Set up Global Parameters menu CLS User s Guide 69 Setup Set up Loop Input 70 CLS User s Guide The Set up Loop Input main menu lets you access menus which change parameters related to the loop input e Input type e Input units e Input scaling and calibration e Input filtering The next section explains how to use the Input menus to configure your controller LOOP _ PROCESS _ UNITS SETUP LOOP 02 INPUT ALARM SETPOINT STATUS __OUT Below is the setup inputs menu tree Notice the default values inside the boxes Setup Loop Inputs Input Type J T C Pulse Sample Time 1
117. nu to set a digital input that sets all loops in manual output at output levels you select in the Outputs menu This menu and the next one let you configure a panic button or kill switch that sets all outputs to the output override percentage you set in the Set up Loop Outputs main menu LOOP PROCESS _ UNITS OUTPUT OVERRIDE DIG INPUT NONE ALARM SETPOINT _ STATUS _OUT Selectable values NONE or input number 1 8 AN WARNING Watlow Anafaze recommends that you install additional external safety devices or over temperature devices for emergency shutdowns Do not rely solely on the output override feature to shut down your process Output Override Input Polarity Start up Alarm Delay 66 CLS User s Guide Use this menu to toggle the polarity of the Output Override digital input You can set the input to be active when Low or active when High LOOP PROCESS _ UNITS OVERRIDE DIG IN ACTIVE LOW ALARM SETPOINT _ STATUS __OUT Selectable values High or Low Use this menu to set a start up delay for process and deviation alarms for all loops The controller does not report these alarm conditions for the specified number of minutes after the controller powers up The controller will always report failed sensor alarms no matter what start up delay you set LOOP PROCESS _ UNITS STARTUP ALARM DELAY 0 mins ALARM SETPOINT _ STATUS __ OUT Selectable values 0 60 minutes Setup
118. number of times the profile has cycled Appendix A Ramp Soak All the menus you can reach from the RAMP SOAK key have the same information on the top line Profile letter Number of segments in profile Current segment Loop number LOOP PROCESS NITS 01 A SEG01 05 R SET MODE START Mode Run Hold Continue How long has the profile run From Single Loop display press the RAMP SOAK key once The next menu appears only if you have already assigned a profile to the loop LOOP _ PROCESS ___UNITS 04 A SEG10 20 R TIM REM 32 11 ALARM SETPOINT STATUS __ OUT How many times has it cycled From Single Loop display press the RAMP SOAK key twice The next menu will appear This menu displays the number of times the profile has run out of the total number of cycles LOOP _ PROCESS _ UNITS 04 A SEG10 20 R CYCLE NR 10 15 ALAI RM SETPOINT__ STATUS OUT CLS User s Guide 133 Appendix A Ramp Soak Holding a Profile or Continuing from Hold Use the profile mode menu to hold a profile or continue from Hold The next table shows the available modes Current PCE Le Description Mode Mode P Start Run Begin running the assigned profile Hold Cont Continue from user selected hold Profile runs from the point when you put the profile in Hold mode You cannot continue from a tolerance hold or a trigger wait After you choose this mode the controller switches back to Run mode Ru
119. o controller common When you do that the input s state should change to L e Press Yes or No to advance to the next menu e Press Back to return to the Manual I O test main menu CLS User s Guide 95 Setup Test Digital Output Toggle Digital Output Keypad Test 96 CLS User s Guide Use this menu to select one of the digital alarm outputs to test in the next menu LOOP PROCESS _ UNITS TEST DIGITAL OUTPUT 34 ALARM SETPOINT _ STATUS __ OUT Use this menu to manually toggle a digital output On or Off to test it You select the output to test in the previous menu On may be Low or High depending on the digital output polarity you set in the Output Polarity menu All outputs are set to Off when you exit Manual I O Test menu LOOP __ PROCESS _ UNITS DIGITAL OUTPUT NUMBER 17 OFF ALARM SETPOINT _ STATUS __OUT Selectable values On or Off Use this menu to test the keypad LOOP PROCESS _ UNITS KEYPAD TEST QUIT NO NO ALARM SETPOINT STATUS __OUT e Press any key to test the keypad The CLS will display the name of the key you have pressed e Press No twice to advance to the next menu PID Tuning and Control PID Tuning and Control Introduction This chapter explains PID control and supplies some starting PID values and tuning instructions so that you can use control parameters appropriate for your system If you would like more information on PID control consult the
120. ol setpoints so that for example a high deviation alarm turns on a fan and a low deviation alarm turns on a heater LOOP _ PROCESS _ UNITS 02 DEV ALARM VALUE 5 F ALARM SETPOINT _ STATUS __ OUT Selectable values 0 255 25 5 2 55 255 or 0255 depending on the way you set up the Input menus High Deviation Alarm Type Use this menu to disable the high deviation alarm function or set it to the alarm or control function The high deviation alarm activates if the process value PV rises above the deviation band value and remains active until the PV goes below the deviation band value minus the deadband value LOOP _ PROCESS _ UNITS 03 HIDEV ALARM TYPE OFF ALARM SETPOINT STATUS __OUT Selectable values Alarm Control Off High Deviation Alarm Output Number Use this menu to assign a digital output which activates when the loop is in high deviation alarm The digital output only activates if you have set the high deviation alarm type to Alarm or Control LOOP __ PROCESS _ UNITS 01 HIDEV ALARM OUTPUT NONE ALARM SETPOINT STATUS __OUT SX y NOTE All digital outputs are OR d together combined There fore you can assign more than one alarm to the same output number and that output will be On if any of those alarms is On Selectable values Any output number between 1 and 34 as long as that output is not already used for control or the SDAC clock or you may select None CLS
121. onlinear output curve LOOP__ PROCESS _ UNITS SETUP LOOP 03 OUTPUTS ALARM SETPOINT ___STATUS__OUT Below is the setup outputs menu tree Both heat and cool outputs have the same menus so only one of each menu is shown here Setup Loop Outputs Heat Cool Output Action Heat Cool Control Output Heat Cool Output Limit Heat Cool Output Type Heat Cool Output Limit Time Heat Cool Output Cycle Time TP only Heat Cool Override Output SDAC Menus SDAC only Heat Cool Output CLS User s Guide 8 amp 1 Setup Enable Disable Heat or Cool Outputs From this menu you can enable or disable the heat or cool output for the current loop If you want the loop to have PID control you must enable one output You can also disable a heat or cool control output and use the output pin for something else like an alarm LOOP __ PROCESS _ UNITS 01 HEAT CONTROL OUTPUT ENABLED ALARM SETPOINT STATUS __ OUT Selectable values Enabled or Disabled Heat or Cool Output Type This menu lets you set the output type LOOP PROCESS _ UNITS 03 HEAT OUTPUT TYPE TP ALARM SETPOINT STATUS __OUT This table shows the available output types Display Output Definition Code Type TP Time Percent output converted to a per proportioning cent duty cycle over the pro grammed cycle time DZC Distributed O
122. ontroller The error checking method and baud rate must be set the same way in the controller s setup menus and in ANASOFT Ground Loops On some computers the RS 232 common wire is tied to earth ground Since the CLS ground is also tied to earth ground this arrangement creates a ground loop which may affect communications and other CLS functions To avoid ground loops either use an optically isolated communications adapter or disconnect the CLS from earth ground and tie a 1 UF capacitor from CLS DC common to earth ground ANASOFT Consult the ANASOFT User s Guide for help with ANASOFT User Written Software If you don t want to use ANASOFT as your software interface to the CLS you are responsible for the correct operation of the software you buy or write You can request technical documentation from Watlow Anafaze if you want to write your own software Watlow Anafaze will answer any technical questions that arise during your software development process but Watlow Anafaze does not otherwise support user software in any way Changing the EPROM involves minor mechanical disassembly and reassembly of the controller but you don t need any soldering or electrical expertise The only tools you need are a Phillips head screwdriver and a small flathead screwdriver ey NOTE If you change the EPROM you must perform a No Key Reset for the EPROM change to take effect A No Key Reset changes all controller parameters back to the
123. ontroller switches to Single Loop Display CLS User s Guide 57 Using the CLS Operator Menus Change Setpoint Manual Automatic Control 58 CLS User s Guide You can reach the following Operator Menus from Single Loop Display If your CLS is already installed try each procedure as you read about it To change the setpoint go to Single Loop display of the loop you wish to change and then press the Change Setpoint key The setpoint is the desired temperature pH et cetera for the process You should see a display like this LOOP __ PROCESS _ UNITS 03 SETPOINT e Press Yes to change the setpoint e Then press Yes or No to change the setpoint value e When you are satisfied with the setpoint value you have chosen press Enter to save your changes and return to Single Loop Display or e To return to Single Loop display without saving your changes press No or Back Press the Man Auto key to set a loop s control mode set manual output levels or automatically tune a loop The control mode determines whether the CLS automatically controls the process according to the configuration information you give it Automatic control or you set the output to a constant level Manual control If both outputs are disabled when you press the Man Auto key you ll see a display like this one LOOP _ PROCESS _ UNITS MAN AUTO CONTROL OUTPUTS DISABLED ALARM SETPOINT STATUS __ OUT Using the CLS Press any ke
124. op and the Ratio control parameters are set up as outlined in the Ratio control section of this appendix Differential control is a function you enable through the Ratio control feature which allows a process to be controlled at a difference to another process You enable the Differential control by setting the Ratio value to 1 0 and adjusting the differential to accommodate the desired offset 149 Appendix B Enhanced Process Control Typical Applications This section provides usage examples of the Enhanced features for the CLS and MLS manuals Process Variable Retransmit 150 The Process Variable Retransmit PVR feature provides retransmission of the process signal of one channel primary via the control output of another channel secondary This signal is a linear output signal which is proportional to the engineering units of the primary channel input The controller output signal must be connected to a DAC converter in order to get an analog signal of 4 20 MAdc or 0 5 Vdc The type of DAC ordered depends on application requirements Some typical uses would be for data logging to older style analog recording systems or long distance transmission of the primary signal to avoid degradation of the primary signal The signal can also be used as an input to other types of control systems such as a PLC An 8CLS controls the temperature of a furnace The thermocouple in one of the zones is connected to the CLS and is used
125. optical isolator between the controller and the computer This table shows RS 232 connections for 25 pin and 9 pin connectors neat Peake CEs Beck TE de RX Pin 3 RX Pin 2 TX Pin 26 White TX Pin 2 TX Pin 3 RX Pin 25 Red GND Pin 7 GND Pin 5 GND Pin 23 Black RS 485 Interface e Ifyou use more than one CLS you must use RS 485 communica tions e Ifyou have connected the CLS to a computer more than 50 feet away Watlow Anafaze recommends that you use RS 485 communi cations If you use RS 485 communications attach an optically isolated RS 232 to RS 485 converter to the computer You can use an internal converter card or an external plug in converter CLS User s Guide 43 Installation 44 CLS User s Guide The diagram on the next page shows the recommended system hookup To avoid ground loops it uses an optically isolated RS 232 to RS 485 converter at the host computer The system is powered from the CLS s power source or from a secure isolated supply Power Supply 7 Host Optically Compute Isolated CLS Converter Fifth Wire gt Power Supply CLS Optional Capacitor Ta Wire equipment in a single daisy chain using twisted shielded pairs for the RS 485 cables Don t use octopus connections or spurs I
126. ou are an electrician or you are technically proficient they may seem simple to you Please at least skim all of the instructions to make sure you don t miss anything vital This section explains installation for the CLS only If you are installing another Watlow Anafaze product such as an SDAC see the manual shipped with it to learn how to install it These symbols are used throughout the rest of this manual Naps DANGER kA This symbol warns you about hazards to human life AN WARNING This symbol warns you of possible damage to property or equipment Y y NOTE This symbol denotes information you must know in order to proceed CLS User s Guide 13 Installation Precautions and Warnings 14 CLS User s Guide Nap DANGER 8 Shut off power to your process before you install the CLS High voltage may be present even when power is turned off Reduce the danger of electric shock after installation by mounting the CLS in an enclosure that prevents per sonal contact with electrical components The CLS measures input signals that are not normally ref erenced to ground so the CLS inputs and other signal lines can have high voltage present even when power is turned off for example if you inadvertently short a thermocouple to the AC power line AN WARNING During installation and wiring place temporary covers over the housing slots and the rear of the CLS so dirt pieces of wire et
127. pap iets Function Se cic 1 5 Vdc 2 5 Vdc 3 CTRL COM 4 CTRL COM 5 Not Used 6 Watchdog Timer 7 Pulse Input 8 Global Alarm 9 DIG output 1 Loop 1 heat Loop heat 10 DIG output 34 11 DIG output 2 Loop 2 heat Loop 2 heat 12 DIG output 33 13 DIG output 3 Loop 3 heat Loop 3 heat 14 DIG output 32 15 DIG output 4 Loop 4 heat Loop 4 heat 16 DIG output 31 17 DIG output 5 Loop 5 heat Pulse loop 18 DIG output 30 heat 19 DIG output 6 Loop 6 heat Loop 1 cool 20 DIG output 29 21 DIG output 7 Loop 7 heat Loop 2 cool 22 DIG output 28 23 DIG output 8 Loop 8 heat Loop 3 cool 24 DIG output 27 25 DIG output 9 Pulse loop Loop 4 cool 26 DIG output 26 heat 27 DIG output 10 Loop 1 cool Pulse loop 28 DIG output 25 cool 29 DIG output 11 Loop 2 cool 30 DIG output 24 31 DIG output 12 Loop 3 cool 32 DIG output 23 33 DIG output 13 Loop 4 cool 34 DIG output 22 35 DIG output 14 Loop 5 cool 36 DIG output 21 37 DIG output 15 Loop 6 cool 38 DIG output 20 39 DIG output 16 Loop 7 cool 40 DIG output 19 41 DIG output 17 Loop 8 cool 42 DIG output 18 Pulse loop cool 43 DIG input 1 44 DIG input 2 45 DIG input 3 46 DIG input 4 47 DIG input 5 48 DIG input 6 49 DIG input 7 50 DIG input 8 If you install a Watlow Anafaze Serial Digital to Analog Converter SDAC the CLS uses digital output 34 for a clock line You cannot use output 34 for anything else when you have an SDAC installed The indicated outputs are dedicated to
128. ptional analog output module for the CLS It lets the controller output precision analog voltages or currents typically for precision open loop control motor or belt speed control or phase angle fired control To use it set the output type for the appropriate loop to SDAC Output Digital Filter The output filter digitally filters the PID control output signal It has a range of 0 255 levels which gives a time constant of 0 127 5 seconds Use the output filter if you need to filter out erratic output swings due to extremely sensitive input signals like a turbine flow signal or an open air thermocouple in a dry air gas oven CLS User s Guide 101 PID Tuning and Control 102 CLS User s Guide The output filter can also enhance PID control Some processes are very sensitive and require a high PB so normal control methods are ineffective You can use a smaller PB and get better control if you use the digital filter to reduce the high and low process output swings You can also use the filter to reduce output noise when a large derivative is necessary or to make badly tuned PID loops and poorly designed processes behave properly Reverse and Direct Action Reverse action is an output control action in which an increase in the process variable causes a decrease in the output Direct action is an output control action in which an increase in the process variable causes an increase in the output Heating applications normally use re
129. put goes High off which de energizes the SSR This figure shows the recommended circuit for the watchdog timer output 5 Vde TB 18 Pin 1 GB te Pins Timer TB 18 Pin 5 Vde TB 50 Pin 1 GB 50 Pin 6 Timer TB 50 Pin 30 CLS User s Guide Installation TB 18 Connections This table shows TB 18 connections to the 4CLS and the 8CLS PID Output PIN Function ACLS P 8CLS 1 5 Vdc 2 Digital ground 3 Watchdog timer 4 Global alarm 5 Digital output 1 Loop heat Loop heat 6 Digital output 2 Loop 2 heat Loop 2 heat 7 Digital output 3 Loop 3 heat Loop 3 heat 8 Digital output 4 Loop 4 heat Loop 4 heat 9 Digital output 5 Pulse loop heat Loop 5 heat 10 Digital output 6 Loop 1 cool Loop 6 heat 11 Digital output 7 Loop 2 cool Loop 7 heat 12 Digital output 8 Loop 3 cool Loop 8 heat 13 Digital output 9 Loop 4 cool Pulse loop heat 14 Digital output 10 Pulse loop cool Loop 1 cool 15 Digital output 34 SDAC clock SDAC clock 16 Digital input 1 17 Digital input 2 18 Digital input 3 Pulse input If you install a Watlow Anafaze Serial DAC SDAC the CLS uses digital output 34 for a clock line You cannot use output 34 for anything else when you have an SDAC installed CLS User s Guide 31 Installation TB 50 Connections 4 and 8 CLS TB 50 Connections Pin Function 8
130. put on or off for each time step so that the cumulative average of the output is the desired setting You must enter a cycle time for TP outputs The cycle time is the time over which the output is proportioned and it can be any value from 1 to 255 seconds For example if the output is 30 and the Cycle Time is 10 seconds then the output will be on for 3 seconds and off for seven seconds The figure below shows typical TP and DZC graphs TP 30 DZC 33 Off 0 10 0 1 3 ao gt cA Seconds Cycle Time 10 AC Cycle Distributed Zero Crossing DZC DZC output is essentially a Time Proportioning output However for each AC line cycle the controller decides whether the power should be On or Off There is no Cycle Time since the decision is made for each line cycle Since the time period for 60 Hz power is 16 6 ms the switching interval is very short and the power is applied uniformly Switching is done only at the zero crossing of the AC line which helps reduce electrical noise DZC output is primarily used for very fast acting electrical heating loads using Solid State Relays SSRs For instance the open air heater coil is an example of a fast acting load Do not use DZC output for electromechanical relays The combination of DZC output and a solid state relay can inexpensively approach the effect of analog phase angle fired control Analog Outputs The Serial DAC is an o
131. r the controller and how to access them Tuning and Control Explains PID control and provides tips for tuning your system Troubleshooting Gives some basic guidelines for solving control problems Linear Scaling Examples Provides an example configuring a pres sure sensor and one configuring a flow sensor Appendix A Ramp and Soak This section explains how to setup and use Ramp Soak profiles in your application Appendix B Enhanced Process Control This appendix describes optional process variable retransmit and cascade control features CLS User s Guide 1 Overview System Diagram Parts List 2 CLS User s Guide The illustration below shows how the parts of the CLS are connected When unpacking your system use the diagrams and parts list below to ensure all parts have been shipped Please don t hesitate to call Watlow Anafaze s Technical Service Department if you have problems with your shipment or if the CLS components are missing or damaged Signal Inputs 50 Pin Ribbon Cable To CLS Controller an AC Adapter 110 or 220 Volt Outputs E Control Alarm TB 50 Terminal Block 8 amp 16 CLS e CLS controller e Controller mount kit e AC adapter 110V or 220V e Terminal Block TB 50 or TB 18 e TB 50 or TB 18 mounting kit e 50 pin flat ribbon cable 50 pin ribbon cable e DAC or SDAC optional e User Manual Safety Overview Watlow Anafaze has made efforts
132. racies T C upscale break detection and a choice of Fahrenheit or Celsius display Resistive Temperature Detector Sensors are Standard Inputs Two types of standard three wire 100 ohm platinum DIN curve sensor are standard inputs for the CLS To use this input order the CLS with scaling resistors Automatic Scaling for Linear Analog Inputs The CLS automatically scales linear inputs used with other industrial process sensors Simply enter two measurement points For example to scale a PSI sensor enter the endpoints Low PV is 10 PSI while High PV is 100 PSI All other values for that loop will automatically be in PSI Dual Outputs Standard The CLS includes dual control outputs for each loop with independent control constants for each output Independently Selectable PID Output Modes You can set each control output to ON OFF Time Proportioning Serial DAC or Distributed Zero Crossing mode You can set each output control mode for ON OFF P PI or PID control with reverse or direct action Flexible Alarm Outputs Independently set high low process alarms and a high low deviation band alarm for each loop Alarms can activate a digital output by themselves or they can be grouped with other alarms to activate an output Alarm or Control Outputs You can set high low deviation and high low process setpoints to operate digital outputs as on off control functions instead of alarms The control function has no alarm notification or g
133. rature coefficient sensor only while the thermistor can have either a negative or positive temperature coefficient Reverse Action An output control action in which an increase in the process variable causes a decrease in the out put Heating applications usually use reverse action RTD See Resistance Temperature Detector S Serial Communications A method of transmitting information between devices by sending all bits serially over a single communication channel RS 232 An Electronics Industries of America EIA standard for interface between data termi nal equipment and data communications equip ment for serial binary data interchange This is usually for communications over a short distance 50 feet or less and to a single device RS 485 An Electronics Industries of America EIA standard for electrical characteristics of generators and receivers for use in balanced digi tal multipoint systems This is usually used to communicate with multiple devices over a com mon cable or where distances over 50 feet are required Setpoint SP The desired value programmed into a controller For example the temperature at which a system is to be maintained Shield A metallic foil or braided wire layer surrounding conductors that is designed to prevent electro static or electromagnetic interference from exter nal sources 169 Glossary Signal Any electrical transmittance that conveys infor mation Solid State
134. resseesse 96 Toggle Digital Output seeseseeeeeeeseseessesresseserrsresseseresresss 96 Keypad Test orousisiracriiinini iden Ea 96 PID Tuning and Control 97 Introductions EEE A T A 97 Control Modes sioe step cessntovedhinies aran LORETA DEE 98 OnOff Control senaera a iA 98 Proportional Control ssssesseseeseesereseseesressrserrsresseseresresss 98 Proportional and Integral Control s es 99 Proportional Integral and Derivative Control 100 Control OPUS a e aE ER TR 100 Digital Output Control Forms seeeeseeseesesreeseereerreererress 100 Setting Up and Tuning PID Loops eesesesesesesreesesersserereeresse 103 Proportional Band PB Settings eeeeeeeecseseeeerereree 103 Integral Term TD Settings i203 did deed 104 Derivative Term TD Settings sseessesesesseessseressresses 104 General PID Constants by Application 2 00 0 eee eeeeeeeeteeees 105 Proportional Band Only P o eee eeeeeceeeeeeeneeesseeneeeeeees 105 Proportional with Integral PD 0 eee eeeeeeseeeesteeeeneees 105 PI with Derivative PID oo ccccccsccccccceeessssssseeeeeeeees 105 Troubleshooting 107 No Key Reset sncciitcticeetni cain anaso 107 Returning your Unit sc 2 ceti estes he ao ete eh uae on Sea 108 Troubleshooting Stand Alone Systems ceeeeeeeeeeeeteeees 108 Checking an Analog Input 00 0 eee eeecceeseeceeteeeeeeeees 108 Checking Digital TA cscs caskcascescoees ss anveedoudioeeuaviunvsea 109 Checking Computer Supervised S
135. rm delay in contrast is set separately for each loop It delays failed sensor and process alarms until the alarm condition has been continuously present for longer than the alarm delay time Failed sensor alarms are not subject to the start up alarm delay but they are affected by the loop s alarm delay during the start up alarm delay period LOOP ___ PROCESS _ UNITS 04 ALARM DELAY 0 SECONDS ALARM SETPOINT _ STATUS __ OUT Selectable range 0 255 seconds Manual I O Test Digital Input Testing Setup Press Yes at this prompt to see menus which can help you test the digital inputs digital outputs and the controller s keypad LOOP___ PROCESS _ UNITS MANUAL I O TEST ALARM SETPOINT _ STATUS _ OUT Below is the manual I O menu tree Manual I O Test Digital Inputs Test Digital Output 34 Digital Output Number 34 Off Keypad Test Use this menu to view the logic state of the 8 digital inputs as H High the input is at 5 volts or is not connected or L Low the input is at zero volts The menu displays inputs 1 to 8 from left to right Since inputs are pulled High when they are not connected test an input by shorting it to controller common and making sure this menu shows the correct state for that input LOOP _ PROCESS _ UNITS DIGITAL INPUTS HHHHHHHH ALARM SETPOINT _ STATUS __OUT Using This Menu e Short the digital input you are testing t
136. rocess and compensates to minimize overshoot and under shoot Derivative control is an instantaneous change of the control output in the same direction as the proportional error This is caused by a change in the process variable PV that decreases over the time of the derivative TD The TD is in units of seconds Deutsche Industrial Norms DIN A set of technical scientific and dimensional standards developed in Germany Many DIN standards have worldwide recognition Deviation Alarm Warns that a process has exceeded or fallen below a certain range around the setpoint Digital to Analog Converter DAC A device that converts a numerical input signal to a signal that is proportional to the input in some way Direct Action An output control action in which an increase in the process variable causes an increase in the output Cooling applications usually use direct action Direct Current DC An electric current that flows in one direction Distributed Zero Crossing DZC A form of digital output control Similar to burst fire Glossary E Earth Ground A metal rod usually copper that provides an electrical path to the earth to prevent or reduce the risk of electrical shock Electrical Noise See Noise Electromagnetic Interference EMI Electrical and magnetic noise imposed on a sys tem There are many possible causes such as switching ac power on inside the sine wave EMI can interfere with the operation o
137. rol system Often what appears to be a problem with the CLS is really a problem with other equipment so check these things first e Controller is installed correctly See Installation for help e Inputs like thermocouples and RTDs are installed correctly and they re working Second Replace Unit If you are certain that the controller is installed correctly you can try replacing the CLS with a spare CLS If the spare unit works correctly then the problem is specific to the CLS you replaced AN WARNING If the controller wasn t installed correctly for instance if you have shorted sensor inputs to high voltage lines or a transformer is shorted out and you replace the CLS with a spare unit the spare unit will break and you ll need to send both units to Watlow Anafaze for repair Therefore make sure you have checked the installation before replac ing the controller If you need to update the CLS Erasable Programmable Read Only Memory EPROM please refer to the third section in this chapter Changing the EPROM If the instructions in this manual tell you to perform a No Key Reset please do the following 1 Power down the unit 2 Press and hold the No key on the front panel Power up the unit CLS User s Guide 107 Troubleshooting y NOTE A No key reset clears the CLS memory and resets its parameters to their default values If you have a stand alone system there is no way to reco
138. s only for pulse input Input Scaling Hi RDG 100 0 FS linear amp pulse Input Scaling Lo PV O linear amp pulse Input Scaling Lo RDG OO FS linear amp pulse Input Filter Input Units F Input Reading Offset F only for T C inputs Disp Format 999 to 3000 only for linear Input Scaling Hi PV 1000 linear amp pulse Setup Input Type Use this menu to configure the input sensor for each loop as one of these input types e Thermocouple types J K T S R B and E e RTD 4 and 8CLS Two ranges RTD1 Platinum Class A and RTD2 Platinum Class B e Linear inputs e Skip an input type available for unused channels The scanning dis play doesn t show loops you ve set to Skip LOOP __ PROCESS _ UNITS 01 INPUT TYPE JT C ALARM SETPOINT STATUS __ OUT The following tables show the input types and ranges Accuracy Accuracy Input Type Range in F Range in C 25 C 0 50 C Full Ambient Temp Range C F aC F J T C 350 to 1400 212 to 760 0 5 0 9 1 1 2 0 K T C 450 to 2500 268 to 1371 0 6 1 2 1 35 2 7 T T C 450 to 750 268 to 399 1 3 2 4 2 9 5 4 S T C 0 to 3200 18 to 1760 2 5 45 5 6 10 1 RT C 0 to 3210 18 to 1766 2 5 4 5 5 6 10 1 B T C 150 to 3200 66 to 1760 6 6 12 0 14 9 27 0 E T C 328 to 1448 200 to 787 Pulse 0 2 KHz Skip Loop is not scanned or displayed Linear
139. s Maximum setpoint to Base setpoint 145 Appendix B Enhanced Process Control Cool Cascade Span LOOP _ PROCESS _ UNITS 02 CASCADE CL SPAN 9999 ALARM SETPOINT STATUS __ OUT Selectable Values 9999 to 9999 x N ASA NOTE Cascade control cannot be used on the same control loop as Ratio control however both features may be used in the same multi loop controller 146 Ratio control Setting Up Ratio Control Appendix B Enhanced Process Control Ratio control allows you to specify a process variable of one loop Master loop multiplied by a Ratio to be the SP of another loop Ratio loop A single loop can be either set up as Cascade or Ratio control but not both You can assign any Process Variable to determine the SP of a Ratio loop In order to set up Ratio control you must configure the following variables 1 Ratio Process Variable assignment The Master loop PV which will provide the output to the internal controller SP calculation for the Ratio loop SP 2 Minimum SP The lowest allowable value of the Ratio loop SP The minimum SP overrides any calculation caused by the Ratio calcula tion calling for a lower SP This value is expressed in the same engi neering units as the Ratio loop PV adjustable from the minimum reading to the maximum reading 3 Maximum SP The highest allowable value of the Ratio loop SP The maximum SP overrides any calculation caused by the Ratio calcula tion
140. s set to Linear or for some menus to Pulse For linear inputs the input reading is in percent O to 100 representing the 0 60 mV input range of the CLS For pulse inputs the input reading is in Hertz cycles per second CLS User s Guide 73 Setup The scaling function is defined by two points on a conversion line It relates the high PV to the high reading and the low PV to the low reading to define the line The engineering units of the process variable can be any arbitrary units The graph below shows PSI as an example 20 PSI Hi PV abn il Se es Process Variable Lo PV 0 Lo Hi 100 0 mV Rdg Rdg 60 mV Before you enter the values that determine the two points for the conversion line you must choose an appropriate display format The CLS has six characters available for process variable display select the setting with the desired number of decimal places before and after the decimal point Use a display format that matches the range and resolution of the process variable The display format you choose is used for the setpoint alarms deadband spread and proportional band The PV Process Variable range for the scaled input is between the PV values that correspond to the 0 and 100 input readings For the pulse input it is between the 0 Hz and 2000 Hz readings This PV range defines the limits for the setpoint and alarms as shown here HiPV Process Varabk Range Lo PV Hi 1100 3 4 i
141. signed specifically for Watlow Anafaze controllers Ramp Soak if installed Assigns ramp soak profiles Performs operations on profiles ANAFAZE CLS LOOP a PROCESS UNITS Alarm Ack Acknowledges alarms ALARM SETPOINT STATUS OUT Enter Stores data of menu choices Back amp advances to the next menu Man Auto Yes Aborts editing and Starts scanning mode Changes loop control Selects a menu returns to a previous menu if pressed twice between automatic amp Answers Yes to Yes No prompts manual control Increases a number or choice Assigns output power level of manual loops Sets loop to Auto No tune mode Change Setpoint Skips a menu Changes process setpoint Answers No to Yes No prompts Decreases a number or choice you re editing Front Panel Keys 50 CLS User s Guide Yes Up Press Yes to e Select a menu e Answer Yes to Yes No questions e Increase a number or choice you re editing No Down Press No to e Skip a menu you don t want to edit when the prompt is blinking e Answer No to Yes No prompts e Decrease a number or choice when editing e Perform a No Key Reset Using the CLS AN WARNING Pressing the No key on power up will clear the RAM mem ory and reinitialize the CLS factory default values To do a No Key Reset power down the controller press and hold the No key and power up the controller while holding the No key A No Key Reset is
142. t runs The Single loop and Bar Graph displays show additional codes for R S controllers Single loop display When the controller is running a profile the Single Loop display shows the profile mode where it would usually show MAN or AUTO The next table shows the available codes and their meaning CLS User s Guide 131 Appendix A Ramp Soak 132 CLS User s Guide oreye Mode STRT The profile is in the Ready segment RUN The profile is running HOLD The user has put the profile in Hold mode TOHO The profile is in tolerance hold WAIT The profile is in trigger wait state This is the Single Loop display when a profile is running LOOP PROCESS _ UNITS 0 347 F 180 RUN 50 Engineering units Loop number Process variable Output percentage Setpoint Profile mode Bar graph display Loops that are running R S profiles have different Bar Graph display codes For these loops you will see the first letter of each mode where the controller would normally display M for Manual control or A for Automatic control Loop number The next table shows the codes you would see in loops running R S profiles Code Meaning R A profile is running H A profile is holding S A profile is in Ready state O A profile is in tolerance hold Ramp Soak Key Displays Use the RAMP SOAK key to see the time left in the current profile the profile s status or the
143. tached to that terminal block Configuring Outputs e You can enable or disable the control outputs The default setting is heat outputs enabled cool outputs disabled e You can program each control output individually for On Off TP SDAC or DZC control e You can individually program each control output for direct or reverse action CLS User s Guide 29 Installation PID Control and Alarm Output Connections Typical digital control outputs use external optically isolated solid state relays SSRs The SSRs use a 3 to 32 Vdc input for control and you can size them to switch up to 100 amps at 480 Vac For larger currents you can use these optically isolated relays to drive contactors You can also use Silicon Control Rectifiers SCRs and an SDAC for phase angle fired control NS NOTE Control outputs are SINK outputs They are Low when the output is On Connect them to the negative side of Solid State Relays The figure below shows sample heat cool and alarm output connections SSR SSR SSR es PID Heat PID Cool AN Digital Output AN AS 5 Vde e e Watchdog Timer The CLS watchdog timer constantly monitors the CLS microprocessor It is a sink output located on TB 18 terminal 3 or on TB 50 terminal 6 Do not exceed the 10 mAdc rating for the watchdog timer Its output is Low on when the microprocessor is operating when it stops operating the out
144. tallation Thermocouple Wiring Input Wiring 22 CLS User s Guide Use 18 or 20 AWG thermocouple T C extension wire for all the T C inputs Sx 4 NOTE Most thermocouple wire is solid unshielded wire Use shielded wire if required at your installation ground one end only AN WARNING The CLS uses a floating ground system Therefore Isolate input devices or host computers connected through communications cables like RS 232 from earth ground Use ungrounded thermocouples with the thermocouple sheath electrically connected to earth ground Use optically isolated RS 232 devices to isolate earth grounded host computers from CLSs When you use grounded T Cs tie the thermocouple shields to a common earth ground in one place Otherwise any common mode voltages that exceed 5 volts may cause incorrect readings or damage to the controller AN WARNING The 16CLS has single ended inputs offering little protec tion from common mode voltage sources Therefore Watlow Anafaze highly recommends that you use ungrounded thermocouples with the external thermocou ple sheath electrically connected to earth ground You can use 400 to 500 of thermocouple extension wire depending on wire type and wire size and keep to accuracy and source impedance specifications Be sure to install thermocouple wiring in a separate conduit away from AC power the 120 Vac control supply and high power 240 Vac or higher wiring
145. the PB to 10 of SP Example Setpoint 450 so PB 45 Set TI to 60 Set TD to Off Set the Output Filter to 2 PI with Derivative PID PB Set the PB to 10 of the SP Example Setpoint 450 so PB 45 Set the TI to 60 Set the TD to 15 of the TI Example TI 60 so TD 9 Set the Output Filter to 2 The next table shows general PID constants by application Output Cycle Application TD Filter Action PpiICaNO S Type Time Ai Electrical heat w SSR 50 60 15 4 TP 3 Reverse Electrical heat w EM 50 60 15 6 TP 20 Reverse relays Cool w solenoid valve 70 500 90 4 TP 10 Direct Cool w fans 10 off 10 4 TP 10 Direct Electric heat w open 30 20 off 4 DZC Reverse heat coils Gas heat w motorized 60 120 25 8 DAC or Reverse valves SDAC SP gt 1200 100 240 40 Electric heat w phase 60 60 15 4 DAC or Reverse angle controlled SCR SDAC Extuders w cooling gas 50 300 120 4 TP 3 Reverse heat w SSR set spread to 8 CLS User s Guide 105 PID Tuning and Control 106 CLS User s Guide Troubleshooting Troubleshooting No Key Reset The next few sections describe general troubleshooting for the CLS Later sections describe specific procedures like checking an input changing the EPROM and testing the controller First Check your Installation Please bear in mind that even in stand alone systems the controller is only part of your cont
146. to On or Off CLS User s Guide 123 Appendix A Ramp Soak Choosing an External Reset Input Editing a Segment Setting Segment Time 124 CLS User s Guide Use this menu to select an external reset input Toggle the input to reset a profile to Ready state when it is in Run Hold or Wait mode You can make any of the eight digital inputs the external reset input LOOP _ PROCESS _ UNITS C EXTERNAL RESET INPUT NUMBER N ALARM SETPOINT STATUS __OUT Selectable Values 1 8 or N for no external reset Each profile is made up of several segments up to 20 Use this menu to choose the segment to edit LOOP PROCESS _ UNITS D EDIT SEGMENT NUMBER 15 ALARM SETPOINT _ STATUS __OUT Selectable Values 1 20 The first time you use this menu it defaults to segment 1 when you have finished editing a segment the controller returns you to this menu and goes to the next segment This loop continues until you make a segment the last segment of a profile Use this menu to change the segment time LOOP PROCESS _ UNITS B SEGMENT 11 SEG TIME 000 00 ALARM SETPOINT STATUS __ OUT Selectable Values 000 00 to 999 59 minutes or seconds depending on the selected time base Appendix A Ramp Soak Setting a Segment Setpoint Use this menu to set a setpoint for the segment you are editing The process will go to this setpoint by the end of the segment time LOOP __ PROCESS _ UNITS C SEGMENT 5 SEG
147. to ensure the reliability and safety of the CLS Controller and to recommend safe usage practices in systems applications Please note that in any application failures can occur These failures may result in full control outputs or other outputs which may cause damage to or unsafe conditions in the equipment or process connected to the CLS Controller Good engineering practices electrical codes and insurance regulations require that you use independent external safety devices to prevent potentially dangerous or unsafe conditions Assume that the Watlow Anafaze CLS Controller can fail with outputs full on outputs full off or that other unexpected conditions can occur Install high or low temperature protection in systems where an overtemperature or undertemperature fault condition could present a fire hazard or other hazard Failure to install temperature control protection where a potential hazard exists could result in damage to equipment and property and injury to personnel The CLS includes a reset circuit that sets the control outputs off or to the data stored in memory if the microprocessor resets normally the result of a power failure and power return If a memory based restart will be unsafe for your process program the CLS Controller to restart with outputs off For additional safety program the computer or other host device to automatically reload the desired operating constants or process values on return of operating power Howe
148. tput 18 Loop 1 cool 43 DIG input 1 44 DIG input 2 45 DIG input 3 46 DIG input 4 47 DIG input 5 48 DIG input 6 49 DIG input 7 50 DIG input 8 If you install a Watlow Anafaze Serial digital to Analog Converter SDAC the CLS uses digital output 34 for a clock line You cannot use output 34 for anything else when you have an SDAC installed The indicated outputs are dedicated to PID or control when enabled in the loop setup If one or both of a loop s outputs are disabled the corresponding digital outputs become available for alarms or ramp soak events CLS User s Guide 33 Installation Inputs This section covers input scaling and input installation for all input types including thermocouples RTDs current inputs and voltage inputs Input Scaling The CLS analog input circuitry accepts any mix of thermocouples 2 or 3 wire RTD inputs current inputs and voltage inputs You can directly connect the following inputs e J K T S R B and E thermocouples e Linear inputs with ranges between 10 and 60 mV Other inputs require custom scaling resistors If you didn t order your unit with the appropriate resistors you have the following options e Watlow Anafaze can install scaling resistors on your unit for a nomi nal fee e Watlow Anafaze can supply a scaling resistor kit that a qualified technician can use to install scaling resistors AN WARNING A qualified technician can install scaling resistors i
149. tus Loop Number or Name Engineering Units Output percentage Setpoint The control status indicator shows HEAT or COOL if the loop is in automatic control and MAN or TUNE if the loop is in manual control Using the CLS If only one output is enabled heat or cool but not both Single Loop display looks like this Process Variable Engineering Units Loop Number Output Percenta Woes as P ge on Natie 160 F 40 Cool Setpoint 180 AUTO 100 Output Percentage Heat Control Status From Single Loop Display e Press Yes to go to the next loop e Press No to go to the previous loop e Press the Back key once to go to Job display if enabled or Bar Graph display e Press Enter twice to start Single Loop Scanning display The Single Loop Scanning Display shows information for each loop in sequence Data for each loop displays for one second e Press any key to stop scanning mode CLS User s Guide 55 Using the CLS Alarms 56 CLS User s Guide If an alarm occurs a two character alarm code appears in the lower left corner of the display below If a Failed Sensor alarm occurs the controller also displays a short alarm message Process Variable Seos unis 02 180 Os LP 180 AUTO 0 LARM SETPOINT Alarm Symbols Setpoint Engineering Units Loop number or Name Output Percentage ga These alarm codes and messages are shown in the table below
150. ue for instruments and transducers also called Linearity Error Liquid Crystal Display LCD A type of digital display made of a material that changes reflectance or transmittance when an electrical field is applied to it Load The electrical demand of a process expressed in power watts current amps or resistance ohms The item or substance that is to be heated or cooled Glossary Loop Alarm Any alarm system that includes high and low pro cess deviation band deadband digital outputs and auxiliary control outputs Low Deviation Alarm Warns that the process is below the setpoint but above the low process variable It can be used as either an alarm or control function Low Process Alarm A signal that is tied to a set minimum value that can be used as either an alarm or control function Low Reading An input level corresponding to the low process value For linear inputs the low reading is a per centage of the full scale input range For pulse inputs the low reading is expressed in cycles per second Hz Manual Mode A selectable mode that has no automatic control aspects The operator sets output levels Manual Reset See Reset Milliampere mA One thousandth of an ampere N No Key Reset A method for resetting the controller s memory for instance after an EPROM change Noise Unwanted electrical signals that usually produce signal interference in sensors and sensor circuits See Electromagn
151. ut device For instance if the output device has a 4 20 mA range set the SDAC high value to 20 00 mA and the SDAC low value to 4 00 mA The controller converts 0 output to a 4 00 mA signal and 100 output to a 20 00 mA signal LOOP _ PROCESS _ UNITS 03 SDAC HI VALUE 10 00 VDC ALARM SETPOINT STATUS __ OUT Selectable values If the output is set to Voltage the default high value is 10 00 volts If the output is set to Current the default high value is 20 00 mA You cannot set the high value to be less than or equal to the low value Use this menu to set a low value for the SDAC output Set the high and low value to match the range of the output device For instance if the output device has a 0 00 10 00 V range set the SDAC high value to 10 00 V and the SDAC low value to 0 00 V The controller converts 0 output to a 0 00 V signal and 100 output to a 10 00 V signal LOOP PROCESS _ UNITS 04 SDAC LO VALUE 0 00 VDC ALARM SETPOINT _ STATUS _ OUT Selectable values If the output is set to Voltage the default low value is 0 00 volts If the output is set to Current the default low value is 4 00 mA You cannot set the low value to be greater than or equal to the high value Heat or Cool Output Action 84 CLS User s Guide Use this menu to select the control action for the current output Normally heat outputs are set to reverse action and cool outputs are set to direct action LOOP __ PROCESS _ UNITS 01
152. utput on off state calculated for Zero Crossing every AC line cycle SDAC Serial DAC Output type for optional Serial Digital to Analog Converter ON OFF On Off Output either full ON or full OFF For an expanded description of these output types see Tuning and Control 82 CLS User s Guide Heat or Cool Cycle Time SDAC Menus SDAC Mode Setup From this menu you can set the Cycle Time for Time Proportioning outputs LOOP __ PROCESS _ UNITS 02 HEAT OUTPUT CYCLE TIME 10s ALARM SETPOINT __ STATUS __OUT NOTE The Cycle Time menu will only be present if the output type for the current loop is Time Proportioning Selectable range 1 255 seconds If you attach the optional SDAC to an output you must configure that output for the SDAC using the following series of menus The CLS will also assign digital output 34 as a clock line for the SDAC You won t be able to assign another function to output 34 while any loop s output is set to SDAC From this menu you can toggle the SDAC between current and voltage output The SDAC menus only appear if the output type for the loop is set to SDAC LOOP PROCESS _ UNITS 01 SDAC MODE VOLTAGE ALARM SETPOINT STATUS __OUT Selectable values Current or voltage CLS User s Guide 83 Setup SDAC High Value SDAC Low Value Use this menu to set a high value for the SDAC output Set the high and low value to match the range of the outp
153. value is expressed in the same engineering units as the secondary loop PV adjustable from the minimum reading to the maximum reading 3 Minimum SP The lowest value of the secondary loop SP The mini mum SP overrides any calculation caused by the primary loop calling for a lower SP This value is expressed in the same engineering units as the secondary loop PV adjustable from the minimum reading to the maximum reading 4 Maximum SP The highest value of the secondary loop SP The max imum SP overrides any calculation caused by the primary loop call ing for a higher SP This value is expressed in the same engineering units as the secondary loop PV adjustable from the minimum reading to the maximum reading 5 Heat cascade span The multiplier which is applied to the primary loop heat output percentage The default value Maximum SP Base SP The range is 9999 to 9999 6 Cool cascade span the multiplier which is applied to the primary loop cool output percentage The default value Minimum SP Base SP The range is 9999 to 9999 143 Appendix B Enhanced Process Control 144 Cascade Control Menus 7 By adjusting the SP parameters the user can adjust the influence the primary loop has on the SP of the secondary loop Primary loop output Calculation of new secondary loop setpoint SP base sp primary heat output heat span primary cool output cool span Min Secondary Loop Max setpo
154. ver these safety features do not eliminate the need for external independent safety devices in potentially dangerous or unsafe conditions Watlow Anafaze also offers ANASOFT an optional software program for IBM AT or IBM PC compatible computers In the event of a reset ANASOFT will reload the CLS Controller with the current values in computer memory The user must ensure that this reset will be safe for the process Again use of ANASOFT does not eliminate the need for appropriate external independent safety devices Contact Watlow Anafaze immediately if you have any questions about system safety or system operation CLS User s Guide 3 Overview 4 CLS User s Guide Introduction Introduction The CLS is a modular control system with up to 16 fully independent loops of PID control 16 CLS It functions as a stand alone controller the CLS 1 8 DIN front panel has a Liquid Crystal Display LCD and touch keypad for local display and local parameter entry You can also use it as the key element in a computer supervised data acquisition and control system the CLS can be locally or remotely controlled via an RS 232 or RS 485 serial communications interface The CLS features include Direct Connection of Mixed Thermocouple Sensors Directly connect most thermocouples with the CLS versatile hardware Thermocouple inputs feature reference junction compensation linearization PV offset calibration to correct for sensor inaccu
155. ver your original parameters If you have a computer supervised system with ANASOFT ANASOFT can store a copy of your parameters to a job file AN WARNING Returning your Unit Do not attempt to repair the controller yourself If the trou bleshooting procedures in this chapter do not solve your system s problems call the Technical Services department for additional troubleshooting help If you need to return the unit to Watlow Anafaze for testing and repair Techni cal Services will issue you an RMA number see Returning the Unit below If you need to return the CLS please contact Watlow by phone fax or e mail see contact information on cover for a Returned Materials Authorization RMA number The RMA number helps us track your equipment and return it to you as soon as possible Troubleshooting Stand Alone Systems Checking an Analog Input 108 CLS User s Guide The CLS is only part of a control system be sure to check other parts of the system like thermocouples before you assume that the unit is broken To check inputs and outputs follow these procedures To check any input except the pulse input follow these steps 1 Disconnect the sensor wiring 2 Set the input sensor to type J T C from the Setup menus 3 Place a short across the input The process variable should indicate ambient temperature If it does not call Watlow Anafaze for an RMA number and return the unit for repair To check thermocoupl
156. verse action and cooling applications usually use direct action PID Tuning and Control Setting Up and Tuning PID Loops After you have installed your control system tune each control loop and then set the loop to automatic control When you tune a loop you choose PID parameters that will best control the process If you don t mind minor process fluctuations you can tune the loop in automatic control mode This section gives PID values for a variety of heating and cooling applications If you don t know the PID values that are best for your process try the CLS Autotune feature The autotune feature is accessible from the controller s Man Auto key For more information about Autotune see Using the CLS Sx 4 NOTE Tuning is a slow process After you have adjusted a loop allow about 20 minutes for the change to take effect Proportional Band PB Settings The table below shows PB settings for various temperatures in degrees F setpoint Ml setpoint setpoint 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 309
157. y point within the scaled sensor range Use this menu to turn off the high process alarm or set it to the alarm or control function See the previous description for an explanation of these choices LOOP __ PROCESS _ UNITS 02 HIPROC ALARM TYPE OFF ALARM SETPOINT STATUS __OUT Selectable values Off Alarm or Control High Process Alarm Output Number 90 CLS User s Guide Use this menu to choose the digital output that activates when the loop is in high process alarm You can use this output to activate a second alarm horn or buzzer You can also use it to control your process For example you can set the output you have chosen to activate heating or cooling mechanisms or to turn off the system LOOP _ PROCESS _ UNITS 01 HI PROC ALARM OUTPUT NONE ALARM SETPOINT STATUS __OUT NOTE All digital outputs are OR d together combined There fore you can assign more than one alarm to the same output number and that output will be On if any of those alarms is On Selectable values any output number between 1 and 34 as long as it s not already used for control or the SDAC clock or you may select None Setup Deviation Band Value Use this menu to set the deviation bandwidth a positive and negative alarm or control point relative to the setpoint If the setpoint changes the alarm or control points also change You can assign a separate digital output to the high and low deviation alarm contr
158. y to exit this display If at least one control output heat or cool is enabled you ll see this display LOOP _ PROCESS _ UNITS 01 CONTROL STATUS AUTO ALARM SETPOINT _ STATUS __OUT e Press Yes to change the mode e Press Yes or No to switch between Manual Automatic and Tune e To exit this menu and return to the Single Loop Display without sav ing your changes press Back e Press Enter to save your changes If you have set the mode to Man ual you can now set the manual heat and cool output levels Manual Output Levels The Manual Output Levels menu will only appear if you have set the current loop to Manual control This menu lets you set the manual output levels for the enabled outputs The cool output menu is just like the heat output menu except that the word COOL replaces the word HEAT in the display You should see a display like the one below LOOP __ PROCESS _ UNITS 01 SET HEAT OUTPUT ALARM SETPOINT STATUS __ OUT e Press Yes to change the output power e Then press Yes or No to select a new output power level e When you are satisfied with the power level you have chosen press Enter to store your changes e To discard your changes and return to Single Loop display press Back CLS User s Guide 59 Using the CLS Ramp Soak 60 CLS User s Guide Autotune If you set the current loop s control status to TUNE and press Enter the controller automatically sets the loop to Manua
159. you don t know what values to enter please read first the Tuning and Control section which contains PID tuning constants and useful starting values How to Enter the Setup Menus In Single Loop Display select the loop you wish to edit 2 While still in Single Loop Display enter the pass sequence below Press Enter Alarm Ack Change Setpoint x ALARM CHNG ACK SP x 3 The first setup menu appears Ss 4 NOTE How to edit a menu For your protection CLS reverts to Single Loop Display If you don t make any changes for three minutes e Press Yes to select this menu or No to advance to the next menu e press Yes or No to toggle between the options in your menu e Press Enter to store the value you have selected e Ifyou decide not to edit the menu press Back to stop editing and return to the main menu Each display contains the default value for that specific menu and below each display you will see the range of choices for that menu The following sections tell more about the submenus for each of the six main menus If you have a CLS with the Ramp Soak option there will also be a Ramp Soak menu Please refer to the Ramp Soak documentation included with your CLS for use instructions The next page shows the setup menus accessible from Single Loop Display CLS User s Guide 61 Setup Output override I
160. ystems 00 0 0 eee eeeeeeeeees 110 Computer Problems Aaa isadeyecoceeeeters agus even eee 110 Software Pro lenis scorni iari niina nR ceases 111 Changing the EPROM cist ce eee dass 111 CLS User s Guide Contents Linear Scaling Examples 115 Example tl tei ent as Gute ee Saas ee ote eeu 115 Example 2 gather cot a Nain a 2 Aral Gah a acta sarnsl 116 Example 3 henin eean E R ENE 117 Appendix A Ramp Soak 119 Tntrod ction e n es ia a ars r ie 119 R S Features cisscinerenonsinienassni sni 119 SPECINCALONG ai wi E E T EE RER E s 120 Configuring Ramp Soak sseesssesssssessseessessserssseessseesseesseeeses 120 Setting the R S Time Base eeeccceeeeceeeeteeeeeteeeenneeees 121 Editing R S Parameters ajgoeelaete spends dahcadevenndedarssoeaeeoincens 121 Choosing a Profile to Edit 0 eee eeeceeeseeesteeeenteeeenaees 121 Copying the Setup from Another Profile 00 122 Editing the tolerance Alarm Time ou eeeeeeeeteeeeeeee 122 Editing the Ready Setpoint 4usas sucked dann 123 Editing the Ready Event States 123 Choosing an External Reset Input 0 0 0 eeeeeeeseeeeeteee 124 Editing a Segment sisis nisi osi rn seaneeiegnanass 124 Setting Segment Time sssssssesssesseessessseresseeessresseesseeesees 124 Setting a Segment Setpoint ssessssssesssesssseeessresserssereseee 125 Configuring Segment Events ssssssssssssesesssesessseessressres 125 Editing Event Outputs ccccscccsssccecnsccccnsccssn

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