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CLS200 Series User's Guide

1. Table 2 5 TB18 Connections Control Output Terminal Function CLS204 CLS208 1 5V dc 2 CTRL COM 3 Watchdog timer 4 Global alarm 5 Output 1 Loop 1 heat Loop 1 heat 6 Output 2 Loop 2 heat Loop 2 heat 7 Output 3 Loop 3 heat Loop 3 heat 8 Output 4 Loop 4 heat Loop 4 heat 9 Output 5 Pulse loop heat Loop 5 heat 10 Output 6 Loop 1 cool Loop 6 heat 11 Output 7 Loop 2 cool Loop 7 heat 12 Output 8 Loop 3 cool Loop 8 heat 13 Output 9 Loop 4 cool Pulse loop heat 14 Output 10 Pulse loop cool Loop 1 cool 15 Output 34 Serial DAC clock Serial DAC clock 16 Input 1 17 Input 2 18 Input 3 Pulse input 40 1 The indicated outputs are dedicated for 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 2 yf you install a Watlow Anafaze Serial DAC the CLS200 series controller uses digital output 34 for a clock line You cannot use output 34 for anything else when you have a Serial DAC installed Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide TB50 Connections Chapter 2 Installation Table 2 6 TB50 Connections for CLS204 and CLS208 Control Output Control Output Ter Function CLS208 CLS204 Ter Function CLS208 CLS204 minal minal 1 5V dc 2 5V dc 3 CTRL COM 4 CTRL COM 5 Not Used 6 Watchd
2. 0 162 in diameter 4 mm 0 3 in 0 4 in 8 mm 10 mm Figure 11 8 Dual DAC Dimensions Watlow Anafaze 207 Chapter 11 Specifications Dual DAC Inputs CLS200 Series User s Guide The Dual DAC accepts an open collector signal from the CLS200 controller and the power from an external power supply See Table 11 31 Table 11 31 Dual DAC Power Requirements Parameter Description Voltage 12 to 24V dc Current 100 mA 15V dc Dual DAC Analog Outputs Table 11 32 Dual DAC Specifications by Output Range Version 4 20 mA 0 5V 0 10 V Units Gain Accuracy 6 6 6 o Output Offset 0 75 0 75 0 75 poh Ml scale range o Ripple 1 6 1 6 1 6 Mgt Mil scale range Time Constant 2 2 2 seconds Maximum Current Output 20 10 10 mA dc Load Resistance 12V 250 maximum 500 minimum 1000 minimum Q Load Resistance 24V 850 maximum n a n a Q 208 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 11 Specifications Serial DAC Specifications Watlow Anafaze offers a Serial DAC for precision open loop analog outputs The Serial DAC is jumper selectable for a 0 to 10V dc or 4 to 20 mA output Multiple Serial DAC modules can be used with one CLS200 The Serial DAC car ries a CE mark Table 11 33 Serial DAC Environmental Specifi cations Storage Temperature 20 to 60 C Operating Temperature Oto 70 C Humidit
3. English Classification Installation Category Il Pollution Degree Il Rated Voltage 15 to 24 VDC Rated Current 610mA maximum Meets the essential requirements of the following European Union Directive s using the relevant section s of the normalized standards and related documents shown 89 336 EEC Electromagnetic Compatibility Directive EN 61326 1997 Electrical equipment for measurement control and laboratory use EMC requirements Class A EN 61000 3 2 1995 Limits for harmonic current EN 61000 3 3 1995 Limitations of voltage fluctuations and flicker EN 61000 4 2 1995 Electrostatic discharge EN 61000 4 3 1997 Radiated immunity EN 61000 4 4 1995 Electrical fast transients EN 61000 4 5 1995 Surge immunity EN 61000 4 6 1994 Conducted immunity EN 61000 4 11 1994 Voltage dips short interruptions and voltage variations immunity ENV 50204 1995 Cellular phone D clare que le produit suivant D signation Num ro s de mod le s Fran ais S rie CLS200 2 04 08 ou 16 1 2 3 ou 4 0 1 ou 2 0 1 ou 2 0 1 2 ou 3 0 1 2 ou 3 0 1 ou 2 1 ou 2 lettres ou chiffren Classification Installation cat gorie II degr de pollution II Tension nominale 15 24V c c Courant nominal 610 mA maximum Conforme aux exigences de la ou des directive s suivante s de l Union Europ enne figurant aux sections correspondantes des normes et documents associ s ci dessous 89 336 EEC Directive de
4. HEAT RETRANS MIN INP HEAT RETRANS MIN OUT HEAT RETRANS MAX INP CASCADE MIN SP CASCADE MAX SP RATIO CONTROL MAX SP RATIO CONTROL CTRL RATIO COPY SETUP FROM PROFILE HEAT RETRANS MIN OUT HEAT RETRANS MAX INP HEAT RETRANS MAX OUT CASCADE HT SPAN RATIO CONTROL SP DIFF READY SEGMENT SETPOINT OUT OF TOLRNCE ALARM TIME HEAT RETRANS MAX OUT COOL OUTPUT RETRANS PV COOL RETRANS MIN INP COOL RETRANS MIN OUT COOL RETRANS MAX INP COOL RETRANS MAX OUT CASCADE CL SPAN READY SEGMENT EDIT EVENTS COOL RETRANS MIN INP COOL OUTPUT RETRANS PV READY EVENT OUTPUT EXTERNAL RESET INPUT NUMBER COOL RETRANS MIN OUT EDIT SEGMENT NUMBER COOL RETRANS MAX INP COOL RETRANS MAX OUT SEGMENT SEG TIME SEGMENT SEG SETPT SEGMENT EDIT SEG EVENTS SEG EVENT OUTPUT SEG EV DO ACTIVE STATE SEGMENT EDIT SEG TRGGRS SEG TRIG INPUT NR SEG TR DI ACTIVE STATE SEG TR Di TRIG SEGMENT SEG TOLERANCE SEGMENT LAST SEGMENT REPEAT CYCLES Declaration of Conformity Declaration of Conformity CLS200Series WATLOW ANAFAZE 314 Westridge Drive Watsonville California 95076 USA Declares that the following product Designation CLS200 Series Model Number s 2 04 08 or 16 1 2 3 or 4 0 1 or 2 0 or 2 0 1 2 or 3 0 1 2 or 3 0 1 or 2 1 or 2 letters or numbers
5. LOOP PROCESS UNITS 01 HI PROC ALARM SETPT 1000 ALARM SETPOINT STATUS OUT Selectable values Any point within the scaled sensor range High Process Alarm Type Select an alarm type for the high process alarm LOOP PROCESS UNITS 01 HI PROC ALARM TYPE OFF ALARM _ SETPOINT STATUS OUT Selectable values OFF ALARM or CONTROL High Process Alarm Output Number Choose a digital output to activate when the high process alarm occurs if desired LOOP PROCESS UNITS 01 HI PROC ALARM OUTPUT NONE ALARM SETPOINT STATUS OUT Selectable values NONE or any output from 1 to 34 not enabled for closed loop control or for the Serial DAC clock Deviation Alarm Value Set the deviation from setpoint at which the high and low deviation alarms occur LOOP PROCESS UNITS 01 DEV ALARM VALUE 5 ALARM SETPOINT STATUS OUT Selectable values 0 to 255 25 5 2 55 255 or 0255 depending on the INPUT TYPE and DISP FORMAT settings 100 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 4 Setup High Deviation Alarm Type Select an alarm type for the high deviation alarm LOOP PROCESS UNITS 01 HI DEV ALARM TYPE OFF ALARM _ SETPOINT STATUS OUT Selectable values ALARM CONTROL or OFF High Deviation Alarm Output Number Choose a digital output to activate when the high deviation alarm occurs if desired LOOP PROCESS UNITS
6. The control status indicator shows MAN AUTO or TUNE modes If both control outputs for a loop are enabled and the loop is in automatic control then the single loop display shows HEAT or COOL as the control status P Variabl ei PUR Engineering Units Loop Number or Name ptoor T Cool Output 02 160 F 0 Percentage 180HEAT100 ALAR Heat Output Setpoint Control Status Percentage Figure 3 5 Single Loop Display Heat and Cool Outputs Enabled Navigating the Single Loop Display Doc 0600 3050 2000 In the single loop display e Press YES to go to the next loop e Press NO to go to the previous loop e Press BACK once to go to the job display if enabled or bar graph display e Press ENTER twice to start the single loop scanning dis play The single loop scanning display shows informa tion for each loop in sequence Data for each loop displays for one second e Press any key to stop scanning Watlow Anafaze 57 Chapter 3 Using the CLS200 Alarm Displays CLS200 Series User s Guide If a process deviation failed or system sensor alarm oc curs the controller switches from any Single Loop display or Bar Graph display to the Single Loop display for the loop with the alarm The global alarm output turns on and a two character alarm code appears in the lower left corner of the Single Loop display If the alarm is for a failed sen sor a short message appears in place of the process vari able an
7. a io 00 000 lt 3 7 in Y ee a H 3 00 in 91 mm 76 mm 94 mm Electrical connections CI a 4 40 in gt 112 mm 20 CLS200 Series User s Guide Installation of the Dual DAC and Serial DAC is essentially the same The main differences are in the dimensions and the wiring Follow this procedure to correctly install these devices The output signal range of the Dual DAC and Serial DAC modules is configured with jumpers See Configuring Dual DAC Outputs on page 186 and Configuring Serial DAC Outputs on page 188 for information on setting these jump ers 1 Select a location The unit is designed for wall mount ing Install it as close to the controller as possible 2 Mark and drill four holes for screw mounting Holes accommodate 8 4 0 mm size screws See Figure 2 11 for screw locations Install the unit with the four screws Serial DAC 0 3 in 0 3 in 8 mm 4 holes for 8 4 0 mm 8 mm screws or bolts ooo 3 62 in Electrical connections 76 mm 0 37 in wt 87 in 9 mm lt lt 47 in gt 9 mm 119 mm lt 0 65 in 0 65 in 17 mm ir mim 1 75 in Emm connections mm en EES 5 40 in 3 137 mm Figure 2 11 Dual DAC and Serial DAC Dimensions Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 2
8. Any unused inputs should be set to SKIP or jumpered to avoid thermocouple break alarms Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 2 Installation Thermocouple Connections Doc 0600 3050 2000 NOTE A CAUTION Connect the positive lead of any of the supported thermo couple types to the IN terminal for one of the loops and the negative lead to the corresponding IN terminal Use 18 or 20 AWG 0 5 or 0 75 mm for all the thermocou ple inputs Most thermocouple wire is solid unshielded wire When using shielded wire ground one end only CHN White Type J semis we Red thermocouple Shield if present NAN Earth Ground For CLS216 use Com at Process End Figure 2 16 Thermocouple Connections When mixing current inputs with low voltage inputs thermocouples or voltage inputs lt 1V to a CLS216 connect the current signal to the IN and Ref Com terminals If no low voltage sensors are used connect current inputs to the IN and Com terminals on TB1 For all in puts to a CLS204 or CLS208 connect the sensors to the IN and Com terminals Ground loops and common mode noise can damage the controller or disrupt measure ments To minimize ground loops and com mon mode noise e With a CLS216 use only ungrounded ther mocouples with each thermocouple sheath electrically connected to earth ground The negative sensor terminals on the CLS216 are
9. Doc 0600 3050 2000 Watlow Anafaze 27 Chapter 2 Installation CLS200 Series User s Guide Testing Your System This section explains how to test the controller after instal lation and prior to making field wiring connections TB50 or TB18 Test Use this procedure to verify that the TB50 or TB18 is prop erly connected and supplied with power 1 Turn on power to the CLS200 The display should read CALCULATING CHECKSUM then show the bar graph display See Figure 3 3 If you do not see these dis plays disconnect power and check wiring and power supply output 2 Measure the 5V dc supply at the TB50 or TB18 a Connect the voltmeter s common lead to TB50 or TB18 terminal 3 or TB18 terminal 2 b Connect the voltmeter s positive lead to TB50 or TB18 screw terminal 1 The voltage should be 4 75 to 5 25V de Digital Output Test Use this procedure to test the controller s outputs before loads are connected If using it at another time for trouble shooting disconnect loads from outputs before testing 1 Connect a 500 to 100 kQ resistor between TB50 or TB18 screw terminal 1 and a digital output terminal See Table 2 5 TB18 Connections on page 40 Table 2 6 TB50 Connections for CLS204 and CLS208 on page 41 or Table 2 7 TB50 Connections for CLS216 on page 42 2 Connect the voltmeter s positive lead to screw terminal 1 Connect the common lead to the digital output terminal 4 Use the digital
10. Indicates pertinent information or an item that may be useful to document or label for later reference Accessories may or may not be shipped in the same con tainer as the CLS200 depending upon their size Check the shipping invoice carefully against the contents received in all boxes Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Product Features Doc 0600 3050 2000 Chapter 1 System Overview The CLS200 series controllers provide 4 8 or 16 fully inde pendent control loops When used as a stand alone control ler you may operate the CLS200 via the two line 16 character display and touch keypad You can also use it as the key element in a computer supervised data acquisition and control system the CLS200 can be locally or remotely controlled via an EIA TIA 232 or EIA TIA 485 serial com munications interface The CLS200 features include e Direct Connection of Mixed Thermocouple Sen sors Connect most thermocouples to the controller with no hardware modifications Thermocouple inputs feature reference junction compensation lineariza tion process variable offset calibration to correct for sensor inaccuracies detection of broken shorted or re versed thermocouples and a choice of Fahrenheit or Celsius display e Accepts Resistive Temperature Detectors RTDs Use 3 wire 100 9 platinum 0 00385 curve sensors with two choices for range and precision of measurements To use this input order
11. 233 COMMUNICATIONS PROTOCOL default value 74 description 80 location 73 233 computer see communications 174 control algorithms 153 156 on off 154 proportional P 154 161 proportional with integral PI 155 161 proportional integral and derivative PID 155 161 control outputs 157 162 action 96 automatic control see automatic control cascade control see cascade control control algoritms see control algorithms control status see control status curve 98 cycle time 95 direct action 96 159 disabling 94 distributed zero crossing 94 158 Dual DAC see Dual DAC enabling 94 filter 91 158 limit 96 manual control see manual control on off 94 157 222 Watlow Anafaze CLS200 Series User s Guide process variable retransmit 113 ratio control see ratio control reverse action 96 159 SCRs 37 Serial DAC see Serial DAC solid state relays 37 spread 92 status on power up 78 time proportioning 94 157 troubleshooting 172 173 wiring 37 control parameters 90 92 control status 61 64 symbols on display 56 unexpected switches from automatic to manual 167 controller agency compliance 193 clearance 13 195 connecting to TB50 27 dimensions 194 environment 194 input specifications 200 202 mounting 13 16 output specifications 202 204 specifications 193 196 terminal specifications 196 troubleshooting see troubleshooting wire sizes 196 CONTROLLER ADDRESS default value 74 description 79 location 73 233 COOL 56 COOL CONTRO
12. Check the display or software for a failed sensor message Digital job select feature is enabled and has changed jobs Set JOB SELECT DIG INPUTS to NONE This parameter is only accessile using the controller s keypad and display See Job Select Digital Inputs on page 76 All loops are set to manual 0 Power is intermittent Check wiring and service See Wiring the Power Supply on page 25 Use a separate dc supply for the controller Provide backup power UPS Set POWER UP OUTPUT STATUS to MEM ORY See Power Up Output Status on page 78 Analog reference voltage is overloaded Disconnect any wiring from the 5V Ref connection on TB1 Hardware failure Check the controller front panel for a hard ware alarm See System Alarms on page 166 Controller does not behave as expected Corrupt or incorrect values in RAM Perform a NO key reset See NO Key Reset on page 176 Doc 0600 3050 2000 Watlow Anafaze 167 Chapter 9 Troubleshooting and Reconfiguring CLS200 Series User s Guide Corrective and Diagnostic Procedures Low Power Battery Dead Ambient Warning 168 NOTE The following sections detail procedures you may use to di agnose and correct problems with the controller If the controller displays LOW POWER or the display is not lit 1 Acknowledge the alarm 2 If the error message remains turn the power to the controller off then on again 3 If the e
13. Installation System Wiring Successful installation and operation of the control system can depend on placement of the components and on selec tion of the proper cables sensors and peripheral compo nents Routing and shielding of sensor wires and proper ground ing of components can insure a robust control system This section includes wiring recommendations instructions for proper grounding and noise suppression and consider ations for avoiding ground loops A WARNING To reduce the risk of electrical shock fire and equipment damage follow all local and national electrical codes Correct wire sizes fuses and thermal breakers are essential for safe operation of this equipment A CAUTION Do not wire bundles of low voltage signal and control circuits next to bundles of high voltage ac wiring High voltage may be induc tively coupled onto the low voltage circuits which may damage the controller or induce noise and cause poor control Physically separate high voltage circuits from low voltage circuits and from CLS200 hardware If possible install high voltage ac power circuits in a separate panel Wiring Recommendations Follow these guidelines for selecting wires and cables e Use stranded wire Solid wire can be used for fixed service it makes intermittent connections when you move it for maintenance e Use 20 AWG 0 5 mm thermocouple extension wire Larger or smaller sizes may be difficult to instal
14. PROCESS UNITS A READY EVENT OUTPUT 15 OFF ALARM SETPOINT STATUS OUT Selectable values ON or OFF When you are done press BACK to return to READY SEG MENT EDIT EVENTS then press NO to go to the next pa rameter External Reset Input Number Doc 0600 3050 2000 Select one of the eight digital inputs as an external reset When the reset input is on the profile is set to RUN mode at the beginning of the first segment As long as the reset in put is on the profile is held at the beginning of the first seg ment Once the reset input turns off the profile begins to run LOOP PROCESS UNITS A EXTERNAL RESET INPUT NUMBER N ALARM __ SETPOINT STATUS OUT Selectable values 1 to 8 or N for no external reset Watlow Anafaze 139 Chapter 7 Ramp Soak Edit Segment Number Segment Time Segment Setpoint 140 CLS200 Series User s Guide Each profile is made up of several segments up to 20 Choose the segment to edit LOOP PROCESS UNITS A EDIT SEGMENT NUMBER 15 ALARM _ SETPOINT STATUS OUT Selectable values 1 to 20 The first time you use this parameter it defaults to seg ment 1 When you finish editing a segment the controller goes to the next segment This loop continues until you make a segment the last segment of a profile Enter the duration of the segment LOOP PROCESS UNITS A SEGMENT 11 SEG TIME 000 00 ALARM SETPOINT STATUS OUT Selectabl
15. Set the setpoint to a value as near the normal operat ing temperature as is safe for the system WARNING During autotuning the controller will set the Using Alarms Alarm Delay 64 output to 100 until the process variable rises near the setpoint Set the setpoint within the safe operating limits of your system 4 Use the three key sequence ENTER ALARM ACK CHNG SP to access the setup menus In the SETUP LOOP INPUT menu locate the INPUT FILTER parameter Note the setting and then change it to 0 SCANS Press the BACK key until the single loop display appears Press the MAN AUTO key Press the NO key to toggle to the TUNE mode Press the ENTER key to begin tuning the loop TUNE flashes throughout the tuning process When tuning is completed the control status indicator changes to AUTO 9 Adjust the setpoint to the desired temperature 10 Restore the INPUT FILTER parameter to its original value The CLS200 has three main types of alarms e Failed sensor alarms e Process alarms e System alarms You can set the controller 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 at the STARTUP ALARM DELAY parameter in the SETUP GLOBAL PARAMETERS menu e Loop alarm delay delays failed sensor alarms and pro cess alarms for one loop until the alarm condition is conti
16. TB50 Physical Specifications 196 Inputs 200 Outputs 202 CLS200 Power Supply 205 Dual DAC Specifications 207 Dual DAC Inputs 208 Dual DAC Analog Outputs 208 Serial DAC Specifications 209 Serial DAC Inputs 210 Serial DAC Analog Outputs 211 Glossary 213 Index 221 Menu Structure 233 Declaration of Conformity 234 viii Watlow Anafaze Doc 0600 3050 2000 List of Figures 1 System Overview Figure 1 1 CLS200 Part Numbering 5 Figure 1 2 CLS200 Special Inputs Parts List 6 Figure 1 3 CLS200 Rear Views 7 Figure 1 4 CLS200 Front Panel 8 Figure 1 5 TB50 8 2 Installation Figure 2 1 CLS200 System Components 12 Figure 2 2 Clearance with Straight SCSI Cable 14 Figure 2 3 Clearance with Right Angle SCSI Cable 14 Figure 2 4 Wiring Clearances 15 Figure 2 5 Mounting Bracket 16 Figure 2 6 Mounting the TB50 16 Figure 2 7 TB50 Mounted on a DIN Rail Front 17 Figure 2 8 TB50 Mounted on DIN Rail Side 17 Figure 2 9 Mounting a TB50 with Standoffs 18 Figure 2 10 CLS200 Power Supply Mounting Bracket 19 Figure 2 11 Dual DAC and Serial DAC Dimensions 20 Figure 2 12 CLS200 Series Controller with TB18 25 Figure 2 13 CLS200 Series Controller with TB50 25 Figure 2 14 Power Connections with the CLS200 Power Supply 27 Figure 2 15 CLS200 Connector Locations 30 Figure 2 16 Thermocouple Connections 31 Figure 2 17 RTD Connections to CLS204 or CLS208 32 Figure 2 18 Linear Voltage Signal Con
17. Table 9 6 Resistor Values for CLS204 and CLS208 Current Inputs Input Range Resistor Value RD 0 to 10 mA 6 0 Q 0 to 20 mA 3 0 Q Resistor tolerance 0 1 RP ma RD Table 9 7 Resistor Locations for CLS204 and CLS208 Current Inputs Resistor Resistor Loop Location RD Loop Location RD 1 RPI 5 RP5 2 RP2 6 RP6 3 RP3 7 RP7 4 RP4 8 RP8 Doc 0600 3050 2000 Watlow Anafaze 181 Chapter 9 Troubleshooting and Reconfiguring CLS204 and CLS208 Voltage Inputs For each voltage input on a CLS204 and CLS208 controller you must install two resistors The resistances must be cor rect for the expected input range Note the resistor pack RP locations have three through holes Install the RD re sistor as indicated in the illustration below Table 9 8 Resistor Values for CLS204 and CLS208 Voltage Inputs 182 CLS200 Series User s Guide Resistor Values Input Range RC RD 0 to100mV dc 499 Q 750 Q 0 to 500mV dc 5 49 kQ 750 Q 0 to 1V dc 6 91 kQ 442 02 0 to 5V dc 39 2 KQ 475 0 Q 0 to 10V dc 49 9 kQ 301 0 Q 0 to 12V dc 84 5 KQ 422 02 Resistor tolerance 0 1 RP a RD Table 9 9 Resistor Locations for CLS204 and CLS208 Voltage Inputs Resistor Locations Loop RC RD 1 R58 RP1 2 R56 RP2 3 R54 RP3 4 R52 RP4 5 R50 RP5 6 R48 RP6 7 R46 RP7 8 R44
18. derivative constant see derivative integral term see integral proportional band see proportional band settings for various applications 162 settings from other controllers 161 tuning 159 161 PLC transmitting process data to 113 using to set a setpoint example 129 see also communications power failure 10 output status upon restart 78 ramp soak profile upon restart 152 Watlow Anafaze 227 Index power supply dimensions 205 206 dimensions of mounting bracket 19 for Dual DAC 43 inputs 206 mounting 18 19 outputs 206 powering loads with 36 requirements 18 specifications 205 206 wiring 25 27 POWER UP OUTPUT STATUS default value 74 description 78 effect on ramp soak profiles 152 location 73 233 process alarms alarm high 67 alarm low 67 boost output 67 function 67 high deviation 68 low deviation 68 outputs 67 setting up 66 PROCESS POWER DIGIN default value 74 description 79 location 73 233 process variable not displayed correctly 22 167 171 retransmit see process variable retransmit process variable retransmit 113 118 application example 115 scaling the output 115 setting up example 116 setup parameters 113 profile see ramp soak proportional band and cascade control 123 description 154 guidelines for setting 159 161 162 setting a value 91 settings for various temperature ranges 159 settings from other controllers 161 protocol 80 pulse inputs display format 87 encoder signals 34 engineering units 84 loop
19. head of the screw facing the back of the processor module Push each bracket backward then to the side to secure it to the processor module case 8 Make sure the case is seated properly Tighten the in stallation screws firmly against the mounting collar to secure the unit Ensure that the end of the mounting screws fit into the indentations on the mounting collar Mounting the TB50 There are two ways you can mount the TB50 Use the pre installed DIN rail mounting brackets or use the plastic standoffs Follow the corresponding procedures to mount the board TB50 Mounted with Standoffs PEUEGEREGUER TB50 Mounted to DIN Rail Figure 2 6 Mounting the TB50 16 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 2 Installation DIN Rail Mounting Snap the TB50 on to the DIN rail by placing the hook side on the rail first then pushing the snap latch side in place See Figure 2 7 8O98O8O8O88OO 208008008009 EEEEEEEEECEENEN Figure 2 7 TB50 Mounted on a DIN Rail Front To remove the TB50 from the rail use a flathead screwdriv er to unsnap the bracket from the rail See Figure 2 8 S5 D Removal catch for screwdriver DIN Rail snap latch Hook side Figure 2 8 TB50 Mounted on DIN Rail Side Doc 0600 3050 2000 Watlow Anafaze 17 Chapter 2 Installation CLS2
20. on page 68 e Activates the digital output that is assigned to the pro cess alarm if applicable The digital output remains active until the process variable returns within the corresponding limit and deadband The alarm output deactivates when the process returns to normal Any digital output that is not used as a control output can be assigned to one or more process alarms The controller activates the output if any alarm assigned to the output is active Process alarm outputs are non latch ing that is the output is deactivated when the process re turns to normal whether or not the alarm has been acknowledged Specify the active state of process alarm outputs at the DIG OUT POLARITY ON ALARM setting in the SETUP GLOBAL PARAMETERS You can configure each process alarm as either a control or alarm e Alarm configuration provides traditional alarm func tionality The operator must acknowledge the alarm message on the controller display a latching global alarm is activated and the alarm can activate a user specified non latching alarm output e Control configuration provides on off control output using the alarm setpoints For example you could con figure a high deviation alarm to turn on a fan The alarm activates a user specified non latching output Alarm messages do not have to be acknowledged and the global alarm is not activated A high process alarm occurs if the process variable rises above a user specif
21. tied to analog common e With a CLS204 or CLS208 do not mix grounded and ungrounded thermocouples If any thermocouple connected to the control ler is of grounded construction all thermo couples should be of grounded construction Watlow Anafaze 31 Chapter 2 Installation RTD Input Connections CLS200 Series User s Guide and each should be connected to ground at the process end e Connect the earth ground terminal on TB2 to a good earth ground but do not connect the analog common to earth ground The CLS200 uses a floating analog common for sensor measurements The noise protection circuits on the sensor inputs function cor rectly only when the controller is correctly in stalled See Ground Loops on page 24 This input type requires scaling resistors Watlow Anafaze recommends that you use a 100 3 wire platinum RTD to prevent reading errors due to cable resistance If you use a 2 wire RTD jumper the negative input to common If you must use a 4 wire RTD leave the fourth wire unconnected CH IN 100 QRTD CH IN e Com e Figure 2 17 RTD Connections to CLS204 or CLS208 Reference Voltage Terminals Voltage Input Connections 32 The 5V Ref and Ref Com terminals are provided in order to power external bridge circuits for special sensors Do not connect any other types of devices to these terminals This input type requires scaling resistors Special input re sistors installed at W
22. 01 HI DEV ALARM OUTPUT NONE ALARM _ SETPOINT STATUS OUT Selectable values NONE or any output from 1 to 34 not enabled for closed loop control or for the Serial DAC clock Low Deviation Alarm Type Select an alarm type for the low deviation alarm LOOP PROCESS UNITS 01 LO DEV ALARM TYPE OFF ALARM _ SETPOINT STATUS OUT Selectable values ALARM CONTROL or OFF Low Deviation Alarm Output Number Choose a digital output to activate when the low deviation alarm occurs if desired LOOP PROCESS UNITS 01 LO DEV ALARM OUTPUT NONE ALARM _ SETPOINT STATUS OUT Selectable values NONE or any output from 1 to 34 not enabled for closed loop control or for the Serial DAC clock Doc 0600 3050 2000 Watlow Anafaze 101 Chapter 4 Setup CLS200 Series User s Guide Low Process Alarm Setpoint Set a low process alarm setpoint See Process Alarms on page 66 LOOP PROCESS UNITS 01 LO PROC ALARM SETPT 0 ALARM SETPOINT STATUS OUT Selectable values Any value within the input sensor s range Low Process Alarm Type Select an alarm type for the low process alarm LOOP PROCESS UNITS 01 LO PROC ALARM TYPE OFF ALARM _ SETPOINT STATUS OUT Selectable values ALARM CONTROL or OFF Low Process Alarm Output Number Choose a digital output to activate when the low process alarm occurs if desired LOOP PROCESS UNITS 01 LO PROC ALARM OUTPUT
23. 112 233 RATIO CONTROL MSTR LOOP description 125 location 112 233 RATIO CONTROL SP DIFF description 126 location 112 233 READY EVENT OUTPUT description 139 location 136 233 READY SEGMENT EDIT EVENTS description 139 location 136 233 READY SEGMENT SETPOINT description 138 Doc 0600 3050 2000 CLS200 Series User s Guide location 136 233 Ref terminals see reference voltage reference voltage 32 204 remote analog setpoint see ratio control repair returning controller for 164 REPEAT CYCLES description 144 location 136 233 reset external 139 integral see integral NO key reset 176 RESET PROFILE 148 RESET WITH DEFAULTS 176 RESTORE PID DIGIN default value 90 description 92 location 73 233 RestoreAuto parameter 66 retransmit see process variable retransmit returning the controller 164 reverse action see control outputs REVERSED T C DETECT default value 82 description 85 location 73 233 RFI see noise RMA number 164 RO alarm code 166 RS alarm code 166 RS 232 see EIA TIA 232 RS 485 see EIA TIA 485 RT alarm code 166 RTD accuracy 201 offset 84 range 201 recommended type 32 resolution 201 scaling resistors 32 183 troubleshooting 171 wiring 32 RTD open alarm 66 RTD shorted alarm 66 S safety external safety devices 9 output status on power up 10 symbols and signal words in this manual 2 SAVE SETUP TO JOB CANNOT SAVE JOB 75 default value 74 description 75 location 73 233 scaling parameters
24. 115 derivative description 155 guidelines for setting 160 162 setting a value 91 settings from other controllers 161 term versus rate settings 160 DEV ALARM VALUE default value 99 description 100 location 73 233 deviation alarms see process alarms differential control see ratio control 131 DIG OUT POLARITY ON ALARM default value 74 description 81 location 73 233 DIGITAL INPUTS default value 103 description 103 Doc 0600 3050 2000 Index location 73 233 using for testing 29 digital inputs external switching devices 39 functions activated 39 output override 77 ramp soak external reset 139 ramp soak triggers 142 remote job selection 76 77 restoring control after sensor failure 92 specifications 202 technical information 38 testing 29 103 thermocouple short detection 79 troubleshooting 173 wiring 38 DIGITAL OUTPUT NUMBER default value 103 description 104 location 73 233 digital outputs polarity for alarms 81 ramp soak events 141 specifications 203 testing 28 104 troubleshooting 173 will not turn on 22 wiring 35 36 dimensions controller 194 Dual DAC 20 207 power supply 205 206 power supply bracket 19 Serial DAC 20 209 TB50 196 199 direct action see control outputs DISP FORMAT default value 82 description 87 effect on ramp soak parameters 144 location 73 233 scaling parameters 86 values 87 display bar graph see bar graph display does not work 167 job display 60 process variable not correct 167
25. 125 Remote Analog Setpoint Example Setting a Setpoint with a PLC Remote analog setpoint allows external equipment such as a PLC or other control system to change the setpoint of a loop Both the remote analog setpoint feature and the process variable retransmit feature can be used with PLC systems as the link between multiloop PID control systems and PLC systems For example a 0 to 5 V dc signal representing 0 to 300 F will be used as a remote setpoint input to the CLS200 The input signal will be received on loop 1 with the control being performed on loop 2 Note that proper scaling resis tors must be installed on the input of loop 1 to allow it to accept a 0 to 5 V dc input To set up this application you would do the following 1 Intheloop1SETUP LOOP INPUT menu set the INPUT TYPE to LINEAR set HI PV to 300 set LO PV to 0 set HI RDG to 100 0 and set LO RDG to 0 0 2 Change the display to loop 2 and then enter the setup parameters Go to the first screen in Table 6 4 3 Follow the steps in Table 6 4 to configure the process variable retransmit option Doc 0600 3050 2000 Watlow Anafaze 129 Chapter 6 Enhanced Features CLS200 Series User s Guide Table 6 4 Application Example Setting Up Remote Setpoint Display LOOP PROCESS UNITS SETUP LOOP 02 RATIO CONTROL ALARM _ SETPOINT STATUS OUT User Input Press YES to set up the ratio control parameters for loop 2 LOO
26. 171 single loop see single loop display distributed zero crossing 94 158 down arrow key 53 Dual DAC configuring outputs 186 188 dimensions 20 207 environment 207 input specifications 208 jumper settings 187 mounting 19 20 output specifications 208 process variable retransmit 113 118 specifications 207 208 wiring 43 44 dust 12 DZC see distributed zero crossing Watlow Anafaze 223 Index E earth see ground EDIT RAMP amp SOAK PROFILE description 137 location 136 233 EDIT SEGMENT NUMBER description 140 location 136 233 EIA TIA 232 45 46 connections 46 jumper configurations 179 jumpers in connectors 46 specifications 204 troubleshooting 174 175 see also communications EIA TIA 485 47 49 EIA TIA 232 to 485 converter 47 49 jumper configurations 179 network connections 47 48 signal common 48 specifications 204 termination 48 troubleshooting 175 see also communications electrostatic discharge 177 EMI see noise encoders 34 enhanced features option 111 132 cascade control see cascade control firmware code shown on display 81 menu tree 112 process variable restransmit see process variable retransmit ENTER key 53 environment 12 controller 194 Dual DAC 207 power supply 205 Serial DAC 209 EPROM checksum 81 replacing 176 178 error checking 80 ESD see electrostatic discharge external bridge circuit 32 EXTERNAL RESET INPUT NUMBER description 139 location 136 233 external safety devices 9 external switchin
27. 3000 ALARM _ SETPOINT STATUS OUT Selectable values The controller has several available display formats as shown in Table 4 9 The table also shows the maximum and minimum process variable for each display format Table 4 9 Display Formats Maximum Minimum Display Format Process Process Variable Variable 9999 TO 30000 30 000 9 999 999 TO 3000 3 000 999 999 9 TO 3000 0 3 000 0 999 9 99 99 TO 300 00 300 00 99 99 9 999 TO 30 000 30 000 9 999 9999 TO 3 0000 3 0000 0 9999 Doc 0600 3050 2000 Watlow Anafaze 87 Chapter 4 Setup High Process Variable High Reading Low Process Variable 88 CLS200 Series User s Guide Set a high process variable for input scaling purposes The high process variable and the high reading HI RDG to gether define one of the points on the linear scaling func tion s conversion line Set HI PV to the value you want displayed when the signal is at the level set for the high reading HI RDG LOOP PROCESS UNITS 01 INPUT SCALING HI PV 1000 ALARM _ SETPOINT STATUS OUT Selectable values Any value between the low process variable LO PV and the maximum process variable for the selected display format See Table 4 9 Enter the input signal level that corresponds to the high process variable HI PV you entered in the previous pa rameter LOOP PROCESS UNITS 01 INPUT SCALING HI RDG 100 0 FS ALARM SETP
28. 40 0 66 15 0 25 45 0 75 20 0 33 50 0 83 25 0 41 55 0 91 30 0 50 60 1 0 160 As a general rule set the derivative to 15 of integral as a starting value Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 8 Tuning and Control NOTE While the basic PID algorithm is well defined and widely recognized various controllers implement it differently Parameters may not be taken from one controller and applied to another with optimum results even if the above unit conversions are performed 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 Set the proportional band to 7 of the setpoint Example Setpoint set to 450 proportional band set to 31 Proportional with Integral Pl e Set the proportional band to 10 of setpoint Example Setpoint set to 450 proportional band set to 45 e Set integral to 60 e Set derivative to Off e Set the output filter to 2 PI with Derivative PID e Set the proportional band to 10 of the setpoint Example Setpoint set to 450 proportional band set to 45 e Set the integral to 60 e Set the derivative to 15 of the integral Example Integral set to 60 derivative set to 9 e Set the output filter to 2 Table 8 4 on page 162 shows general PID constants by ap plication Doc 0600 305
29. 7 4 Ramp Soak Single Loop Display 146 Table 7 5 Ramp Soak Control Status Symbols 147 Table 7 6 Ramp Soak Profile Modes 150 8 Tuning and Control Table 8 1 Proportional Band Settings 159 Table 8 2 Integral Term and Reset Settings 160 Table 8 3 Derivative Term Versus Rate 160 Table 8 4 General PID Constants 162 9 Troubleshooting and Reconfiguring Table 9 1 Controller Alarm Codes for Process and Deviation Alarms 164 Table 9 2 Operator Response to Alarms 165 Table 9 3 Failed Sensor Alarm Codes 166 Table 9 4 Hardware Error Messages 166 Table 9 5 Other Symptoms 167 Table 9 6 Resistor Values for CLS204 and CLS208 Current Inputs 181 Table 9 7 Resistor Locations for CLS204 and CLS208 Current Inputs 181 Table 9 8 Resistor Values for CLS204 and CLS208 Voltage Inputs 182 Table 9 9 Resistor Locations for CLS204 and CLS208 Voltage Inputs 182 Table 9 10 Resistor Values for CLS204 208 RTD and Thermistor Inputs 183 Table 9 11 Resistor Locations for CLS204 208 RTD and Thermistor Inputs 183 Table 9 12 Resistor Values for CLS216 Current Inputs 184 Table 9 13 Resistor Locations for CLS216 Current Inputs 185 Table 9 14 Resistor Values for CLS216 Voltage Inputs 185 Table 9 15 Resistor Locations for CLS216 Voltage Inputs 186 Table 9 16 Dual DAC Jumper Settings 187 10 Linear Scaling Examples xiv Table 10 1 Input Readings 190 Table 10 2 Scaling Values 190 Table 10 3 Input Readings and Calculations 19
30. 9 Safety 9 External Safety Devices 9 Power Fail Protection 10 2 Installation 11 Typical Installation 12 Mounting Controller Components 12 Recommended Tools 13 Mounting the Controller 13 Mounting the TB50 16 Mounting the Power Supply 18 Mounting the Dual DAC or Serial DAC Module 19 System Wiring 21 Wiring Recommendations 21 Noise Suppression 22 Ground Loops 24 Power Connections 25 Wiring the Power Supply 25 Connecting TB50 to CLS200 27 Testing Your System 28 TB50 or TB18 Test 28 Digital Output Test 28 Digital Input Test 29 Doc 0600 3050 2000 Watlow Anafaze Table of Contents Sensor Wiring 29 Input Wiring Recommendations 30 Thermocouple Connections 31 RTD Input Connections 32 Reference Voltage Terminals 32 Voltage Input Connections 32 Current Input Connections 33 Pulse Input Connections 34 Wiring Control and Digital I O 35 Output Wiring Recommendations 35 Cable Tie Wraps 35 Digital Outputs 35 Digital Inputs 38 TB18 Connections CLS204 and CLS208 Only 40 TB50 Connections 41 Analog Outputs 43 Wiring the Dual DAC 43 Wiring the Serial DAC 44 Serial Communications 45 EIA TIA 232 Interface 45 EIA TIA 485 Interface 47 EIA TIA 485 Converters and Laptop Computers 49 3 Using the CLS200 51 Front Panel 52 Front Panel Keys 53 Displays 55 Bar Graph Display 55 Single Loop Display 57 Alarm Displays 58 System Alarms 60 Job Display 60 Changing the Setpoint 61 Selecting the Control Status 61 Manual and Automatic Contr
31. A Serial Motorized Control Valve 2 DAC Motorized Control Serial Valve 1 DAC Mixture Output Figure 6 8 Application Using Ratio Control To set up this application you would do the following 1 Adjust and tune loop 1 H320 for optimal performance before implementing the ratio setup 2 Switch the controller to display loop 2 KOH and then enter the three key sequence ENTER then ALARM ACK then CHNG SP and go to the first screen in Table 6 3 3 Follow the steps in Table 6 3 to configure ratio control Doc 0600 3050 2000 Watlow Anafaze 127 Chapter 6 Enhanced Features CLS200 Series User s Guide Table 6 3 Application Example Setting Up Ratio Control 02 RATIO CONTROL MSTR LOOP 01 ALARM _ SETPOINT STATUS OUT Display User Input LOOP PROCESS UNITS SETUP LOOP 02 RATIO CONTROL Press YES to set up the ratio control parameters for loop 02 ALARM SETPOINT STATUS OUT LOOP PROCESS UNITS N Assign loop 01 as the master loop Press ENTER LOOP PROCESS UNITS 02 RATIO CONTROL MIN SP 0 0 ALARM SETPOINT STATUS OUT Enter the minimum ratio loop setpoint For this example we will use 0 0 gallons per second as a minimum Press ENTER LOOP PROCESS UNITS N 02 RATIO CONTROL MAX SP 7 0 STATUS ALARM SETPOINT OUT J Enter the maximum ratio loop setpoint For this example we will use 7 0 gallons per second as a
32. CONTROL PB HEAT CONTRO TI 500 sec repeat HEAT CONTROL TD 125 sec HEAT CONTROL FILTER 6 COOL CONTROL PB COOL CONTROL TI COOL CONTROL TD 90 sec COOL CONTROL FILTER 2 50 for J type thermocouple depends on Input Type setting 70 for J type thermocouple depends on Input Type setting 500 sec repeat Doc 0600 3050 2000 Watlow Anafaze 109 Chapter 5 Extruder Control CLS200 Series User s Guide Extruder Control Algorithm The Extruder Control Firmware uses a control algorithm that has been optimized for controlling temperature loops in plastic extruder equipment Typically overshoot is un desirable and ambient cooling is not sufficient to dampen the effects of self heating that are inherent in the extrusion process This control method uses both heat and cool out puts Under some conditions both heat and cool outputs may be on at the same time 110 Watlow Anafaze Doc 0600 3050 2000 Enhanced Features This chapter explains five additional features for the CLS200 controller when enabled with enhanced features option firmware e Process variable retransmit e Cascade control e Ratio control e Remote analog setpoint e Differential control Doc 0600 3050 2000 Watlow Anafaze 111 Chapter 6 Enhanced Features CLS200 Series User s Guide SETUP SETUP SETUP SETUP SETUP SETUP SETUP SETUP MANUAL GLOBAL LOOP LOOP CONTROL LOOP
33. Cool Output Limit Time 96 Sensor Fail Heat or Cool Output 97 Heat or Cool Thermocouple Break Output Average 97 Heat or Cool Linearity 98 Setup Loop Alarms Menu 99 High Process Alarm Setpoint 100 High Process Alarm Type 100 High Process Alarm Output Number 100 Deviation Alarm Value 100 High Deviation Alarm Type 101 High Deviation Alarm Output Number 101 Low Deviation Alarm Type 101 Low Deviation Alarm Output Number 101 Low Process Alarm Setpoint 102 Doc 0600 3050 2000 Watlow Anafaze V Table of Contents CLS200 Series User s Guide Low Process Alarm Type 102 Low Process Alarm Output Number 102 Alarm Deadband 102 Alarm Delay 103 Manual I O Test 103 Digital Inputs 103 Test Digital Output 104 Digital Output Number 104 Keypad Test 105 Display Test 105 5 Extruder Control 107 Setup Loop Outputs Menu 107 Cool Output Nonlinear Output Curve 107 Defaults 108 Extruder Control Algorithm 110 6 Enhanced Features 111 Process Variable Retransmit 113 Setup Loop Process Variable Retransmit Menu 113 Process Variable Retransmit Example Data Logging 115 Cascade Control 118 Setup Loop Cascade Menu 119 Cascade Control Example Water Tank 121 Ratio Control 124 Setup Loop Ratio Control Menu 125 Ratio Control Example Diluting KOH 126 Remote Analog Setpoint 129 Remote Analog Setpoint Example Setting a Setpoint with a PLC 129 Differential Control 131 Differential Control Example Thermoforming 131 7 Ramp Soak 133 Features 134 Ramp Soak
34. Cool Output Type Select the output type LOOP PROCESS UNITS 01 HEAT OUTPUT TYPE TP ALARM SETPOINT STATUS OUT Selectable values TP DZC SDAC ON OFF 3P DZC See Table 4 12 for a description of the output types NOTE The controller assigns digital output 34 as a clock line for the Serial DAC You will not be able to assign another function to output 34 if any loop s output is set to SDAC Table 4 12 Heat Cool Output Types ee Output Type Definition bos Percent output converted to a percent duty Li Time Proporioming cycle over the user selected fi ed time base DZC Distributed Zero Output on off state calculated for every ac line Crossing cycle Use with Dual DAC SDAC Serial DAC Use with Serial DAC ON OFF On Off Output either full on or full off ee Use with 3 phase heaters when wired in delta 3P DZC 2 Phasa Pisirigued configu ation For grounded Y configu ation Zero Crossing use DZC instead For an expanded description of these output types see Chapter 8 Tuning and Control 94 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Heat or Cool Cycle Time SDAC Mode SDAC Low Value SDAC High Value Doc 0600 3050 2000 Chapter 4 Setup Set the cycle time for time proportioning outputs LOOP PROCESS UNITS 01 HEAT OUTPUT CYCLE TIME 10S ALARM _ SETPOINT STATUS OUT This parameter appears only if the heat or cool outpu
35. Doc 0600 3050 2000 Set the polarity of all digital outputs used for alarms If LOW is selected if an alarm occurs the outputs sink to analog common If HIGH is selected the outputs sink to common when no alarm is active and go high when an alarm occurs LOOP PROCESS UNITS DIG OUT POLARITY ON ALARM LOW ALARM SETPOINT STATUS OUT Selectable values HIGH or LOW This parameter does not affect the Global Alarm output or the Watchdog Alarm output The display shows the controller type firmware options the firmware version and the EPROM checksum Table 4 4 lists the available firmware options Firmware Option LOOP PROCESS l CLS208 RS CS ED74 V03 13 Table 4 4 Firmware Option Codes EPROM Checksum Firmware Option Description none Standard Firmware EF Enhanced Features Option RS Ramp Soak Option EX Extruder Option Watlow Anafaze 81 Chapter 4 Setup NOTE CLS200 Series User s Guide If the EPROM information does not match this description the EPROM probably con tains a custom program Custom programs may not work as described in this manual If that is the case contact your dealer for more information about the firmware Setup Loop Input Menu 82 LOOP PROCESS UNITS SETUP LOOP 01 INPUT ALARM SETPOINT STATUS OUT The SETUP LOOP INPUT menu includes parameters related to the loop input e Input type e Input units
36. IN USE DIGITAL OUTPUT NUMBER XX OFF KEYPAD TEST N A The DIGITAL OUTPUT NUMBER screen ap pears only if an unassigned output has been selected in the TEST DIGITAL OUTPUT screen View the logic state of the eight digital inputs as H high meaning the input is not pulled low or L low meaning the input is connected to the controller common Watlow Anafaze 103 Chapter 4 Setup Test Digital Output Digital Output Number 104 CLS200 Series User s Guide This screen shows the state of inputs 1 to 8 from left to right See Figure 4 5 Since inputs are pulled high when they are not connected test an input by shorting it to con troller common and making sure this screen shows the cor rect state for that input LOOP PROCESS UNITS DIGITAL INPUTS Input 8 HHHHHHH at ALARM SETPOINT STATUS OUT Input 1 Figure 4 5 Digital Inputs Screen When you are done testing digital inputs press YES or NO to advance to the next screen or press BACK to return to the MANUAL I 0 TEST menu Select one of the digital alarm outputs to test You will test the output on the next screen You cannot force the state of an output enabled for control LOOP PROCESS UNITS TEST DIGITAL OUTPUT 1 IN USE ALARM SETPOINT STATUS OUT Selectable values Any output from 1 to 34 that is not en abled for closed loop control or for the Serial DAC clock and GA the global alarm output This screen appears on
37. NONE ALARM SETPOINT STATUS OUT Selectable values NONE or any output from 1 to 34 not enabled for closed loop control or for the Serial DAC clock Alarm Deadband Set an alarm deadband This deadband value applies to the high process low process high deviation and low deviation alarms for the loop Use the alarm deadband to avoid re peated alarms as the process variable cycles around an alarm value LOOP PROCESS UNITS 01 ALARM DEAD BAND 2 ALARM _ SETPOINT STATUS OUT Selectable values 0 to 255 25 5 2 55 255 or 0255 depending on the INPUT TYPE and DISP FORMAT settings 102 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Alarm Delay Manual I O Test Digital Inputs Doc 0600 3050 2000 NOTE Chapter 4 Setup Set a loop alarm delay This parameter delays failed sensor and process alarms until the alarm condition has been con tinuously present for longer than the alarm delay time LOOP PROCESS UNITS 01 ALARM DELAY 0 SECONDS ALARM SETPOINT STATUS OUT Selectable range 0 to 255 seconds This menu facilitates testing of e Digital inputs e Digital outputs e The keypad buttons LOOP PROCESS UNITS MANUAL 1 0 TEST ALARM _ SETPOINT STATUS OUT Table 4 14 shows the screens available in the MANUAL 1 0 TEST menu Table 4 14 Manual I O Test Parameter a DIGITAL INPUTS HHHHHHHH TEST DIGITAL OUTPUT 1
38. SETPOINT STATUS OUT 3 Press YES to set the mode While the profile is run ning the only mode you will be able select is HOLD 4 Press ENTER to hold the profile Continuing a Profile To resume or continue a profile that is holding 1 In the single loop display switch to the loop you want to run 2 Press the RAMP SOAK key three times The SET MODE parameter appears 3 PressYES to set the mode While the profile is holding the only mode you will be able select is cont continue 4 Press ENTER to run the profile 150 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 7 Ramp Soak Responding to a Tolerance Alarm Resetting a Profile Doc 0600 3050 2000 A tolerance can be set for each segment The following oc curs when the process variable goes outside this tolerance e The profile goes into tolerance hold e The segment timer holds e The loop s single loop display shows TOHO e The tolerance alarm timer starts If the process variable returns within the segment toler ance before the tolerance alarm time elapses the profile re turns to RUN mode and the tolerance alarm timer resets The following occurs if the profile remains out of tolerance for longer than the tolerance alarm time e The controller displays the single loop display with the tolerance alarm a flashing T e The global alarm output turns on Press ALARM ACK to e Turn off the global alarm output
39. The EPROM is a 32 pin socketed chip that is labeled with the mod el version and checksum EPROM Detail U2 EPROM MP QLLLELILE AM Notch Figure 9 3 EPROM Location 7 Remove the existing EPROM from its socket with an IC extraction tool or a jeweler s flathead screwdriver Figure 9 4 Remove EPROM 8 Carefully insert the new EPROM into the EPROM socket Make sure that the chip is oriented so that its notch fits in the corresponding corner of the socket 9 Reverse steps 2 through 4 to reassemble the unit 10 Power up the controller 11 Re enter parameters 178 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 9 Troubleshooting and Reconfiguring Changing Communications To switch between EIA TIA 232 and EIA TIA 485 change the jumpers as shown in Figure 9 5 JU1 ea e e qe ep a JU2 eb 4 o epg ep a JU3 e 4 o epa ope JU4 ea e opd opb g JU5 Ba e ep d e p a A B A B A B Configured for Configured for Last controller in EIA TIA 232 EIA TIA 485 system configured for EIA TIA 485 Figure 9 5 Jumper Configurations You will need tweezers and a Phillips head screwdriver to switch between EIA TIA 232 and EIA TIA 485 Follow these steps 1 Power down the unit 2 Remove the controllers metal casing See Replacing the EPROM on page 176 for step by step instructions Find jumper
40. and loop alarm delay If you have enabled the remote job select function see Job Select Digital Inputs on page 76 you will not be able to load a job If you try you will see this message LOOP PROCESS UNITS CANNOT LOAD JOB REMOTE SELECT ON ALARM _ SETPOINT STATUS OUT Save the job information for every loop to one of eight jobs in the battery backed RAM LOOP PROCESS UNITS SAVE SETUP TO JOB 1 ALARM _ SETPOINT STATUS OUT Selectable values 1 to 8 If you have enabled the remote job select function see Job Select Digital Inputs on page 76 you will not be able to save a job If you try you will see this message LOOP PROCESS UNITS CANNOT SAVE JOB REMOTE SELECT ON ALARM SETPOINT STATUS OUT Watlow Anafaze 75 Chapter 4 Setup Job Select Digital Inputs 76 CLS200 Series User s Guide 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 parameter controls the number of jobs you can select remotely If you select NONE digital inputs do not affect job selection Jobs may be loaded and saved using the LOAD SETUP FROM JOB and SAVE SETUP TO JOB parameters LOOP PROCESS UNITS JOB SELECT DIG INPUTS NONE ALARM __ SETPOINT STATUS OUT Selectable values 1 2 or 3 inputs or NONE These choices have the following effect Table 4 2 Job Select Inp
41. and may be used as feedback for control loops It also accepts digital TTL inputs which may be used to trigger certain firmware features Table 11 11 Analog Inputs Parameter Description Number of Control Loops CLS204 5 CLS208 9 CLS216 17 Number of Analog Inputs CLS204 4 with full range of input types plus one pulse CLS208 8 with full range of input types plus one pulse CLS216 16 with full range of input types plus one pulse Input Switching CLS204 and CLS208 Differential solid state multiplexer CLS216 Single ended solid state multiplexer Input Sampling Rate CLS204 6 Hz 167 ms at 60 Hz 5 Hz 200 ms at 50 Hz CLS208 3 Hz 333 ms at 60 Hz 2 5 Hz 400 ms at 50 Hz CLS216 1 5 Hz 667 ms at 60 Hz 1 25 Hz 800 ms at 50 Hz Analog Over Voltage Protection 20V referenced to digital ground Maximum Common Mode Voltage 5V input to input or input to analog common CLS204 and CLS208 Common Mode Rejection CMR For inputs that do not exceed 5V 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 60mYV or 0 to 25V with scaling resistors Resolution 0 006 greater than 14 bits internal 0 03 of full scale 60mV at 25 C Accuracy 0 08 of full scale 60mV at 0 to 50 C Calibration Automatic zero and full scale DC Common to Frame Ground Maximum Potential
42. as the Serial DAC TB50 or TB18 Dual DAC 5V dc 5V CTRL Supply Control Output DZC CTRL PID Output 12 24V dc External Power Supply V dc Load Connection mA Load mA dc Load Connection External Power Supply V dc Load Connection 12 to 24V dc Power Supply Figure 2 28 Dual DAC with Current Output Watlow Anafaze 43 Chapter 2 Installation Wiring the Serial DAC 44 CLS200 Series User s Guide TB50 or TB18 Dual DAC 5V dc 1 1 5V dc CTRL PID Loop Output 2 DZC CTRL PID Output 3 12 24V dc Exter nal Power Supply V dc Load 4 V dc Load Conn il 5 mA dc Load Conn 6 External Power Supply V dc Load Conn 12 to 24V dc Power Supply Figure 2 29 Dual DAC with Voltage Output The Serial DAC provides a robust analog output signal The module converts the proprietary Serial DAC signal from the controller s open collector output in conjunction with the clock signal to an analog current or voltage See Figure 2 30 for wiring The Serial DAC is user configurable for voltage or current output through firmware configura tion See Configuring Serial DAC Outputs on page 188 The Serial DAC optically isolates the controller s control output from the load When a single Serial DAC is used it may be powered by the 5V dc found on the TB50 or by an external supply referenced to the controller
43. circuit must be modified When configured for thermocouple inputs 0 Q re sistors are installed in all RC locations To accommodate milliamp current signals or voltage signals outside the standard range resistors are added or replaced to scale the signals to the standard range These resistors can be in stalled by Watlow Anafaze or by a qualified electronics technician using scaling resistors supplied by Watlow Anafaze Figure 9 7 shows the schematic for one single ended sensor input to the CLS216 See CLS216 Current Inputs on page 184 and CLS216 Voltage Inputs on page 185 for specific in structions and resistor values for voltage and current in puts Voltage only To CLS200 IN Measurement eae RC Circuitry npu Terminals RD Voltage and Current Com e Figure 9 7 CLS216 Input Circuit For each current input on a CLS216 controller you must install one resistor The value of the resistor must be cor rect for the expected input range Install the resistor in the listed resistor location Table 9 12 Resistor Values for CLS216 Cur rent Inputs Input Range Resistor Value RD O to 10 mA 6 0Q 0 to 20 mA 3 00 Resistor tolerance 0 1 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 9 Troubleshooting and Reconfiguring Table 9 13 Resistor Locations for CLS216 Current Inputs Resistor Resistor Loop Location Loop Location RD RD 1 R
44. communications cable DB 9 female bare wire Serial Communications Jumper Settings 0 EIA TIA 232 1 EIA TIA 485 2 EIA TIA 485 terminated Special Inputs one or two digits Standard unit is conf gured for thermocouples and 10 to 60mV linear inputs For other sensors special inputs are required 00 Thermocouples and 10 to 60mV inputs only XX Number of current and voltage inputs RTDs are not available on the CLS216 Include leading zero as needed Figure 1 1 CLS200 Part Numbering Doc 0600 3050 2000 Watlow Anafaze 5 Chapter 1 System Overview CLS200 Series User s Guide If special inputs are ordered in the controller part number the following is specified in the pa t description Special Input Type Not required for thermocouple sensor inputs 20 RTD1 0 1 100 0 to 275 0 C 148 0 to 572 0 F Not available on CLS216 21 RTD2 1 120 0 to 840 0 C 184 0 to 1544 0 F Not available on CLS216 43 0 to 10 mA dc 44 0 to 20mA dc 4 to 20mA dc 50 0 to 100mV dc 52 0 to 500mV dc 53 0 to 1V dc 55 0 to 5V dc 56 0 to 10V dc 57 0 to 12V dc Start Channel XX Channel number XX End Channel XX Channel number XX Note Make sure the number of special inputs specif ed is equal to the number of special inputs in the controller part number Uninstalled kits are available Figure 1 2 CLS200 Special I
45. compatibilit lectromagn tique EN 61326 1995 Appareillage lectrique pour la mesure la commande et l usage de laboratoire Prescriptions relatives la Compatilit Electro Magn tique Classe A EN 61000 3 2 1995 Limites d mission de courant harmon ique EN 61000 3 3 1995 Limites de fluctuation de tension EN 61000 4 2 1995 D charge lectrostatique EN 61000 4 3 1997 Insensibilit l nergie rayonn e EN 61000 4 4 1995 Courants lectriques transitoires rapides EN 61000 4 5 1995 Insensibi lit aux surtensions EN 61000 4 6 1996 Insensibilit l nergie par conduction EN 61000 4 11 1994 Insensibilit aux chutes subites aux courtes interruptions et aux variations de tension ENV 50204 1995 T l phone cellulaire 30590 00 REV E Erkl rt da das folgende Produkt Beschreibung Serie CLS200 Modellnummer n 2 04 08 oder 16 1 2 3 oder 4 0 1 oder 2 0 1 oder 2 0 1 2 oder 3 0 1 2 oder 3 0 1 oder 2 1 oder 2 Buchstabe oder Ziffern Deutsch Klassifikation Installationskategorie II Emissionsgrad IlI Nennspannung 15 bis 24 Vde Nominaler Stromverbrauch max 610 mA Erf llt die wichtigsten Normen der folgenden Anweisung en der Europ ischen Union unter Verwendung des wichtigsten Abschnitts bzw der wichtigsten Abschnitte der normalisierten Spezifikationen und der untenstehenden einschlagigen Dokumente 89 336 EEC Elektromagnetische Ubereinstimmungsanw_ amp EN 6
46. describes how to wire and configure the control outputs for the CLS200 series controller NOTE Control outputs are connected to the CLS200 s common when the control output is on low Be careful when you connect ex ternal devices that may have a low side ata voltage other than controller ground since you may create ground loops If you expect grounding problems use isolat ed solid state relays and isolate the control device inputs The CLS200 provides dual PID control outputs for each loop These outputs can be enabled or disabled and are connected via TB50 or TB18 Output Wiring Recommendations When wiring output devices use multicolored stranded shielded cable for analog outputs and digital outputs con nected to panel mounted solid state relays e Analog outputs usually use a twisted pair e Digital outputs usually have 9 to 20 conductors de pending on wiring technique Cable Tie Wraps Once you have wired outputs to the TB50 install the cable tie wraps to reduce strain on the connectors 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 attached to that terminal block Digital Outputs The CLS200 series provides dual control outputs for up to 16 loops The controller s default configuration has all heat outputs enabled and all cool outputs disabled Disabling a heat output makes that outp
47. 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 offset or droop between setpoint and actual process temperature J Job A set of operating conditions for a process that can be stored and recalled in a controller s memory also called a recipe Junction The point where two dissimilar metal conduc tors join to form a 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 Doc 0600 3050 2000 CLS200 Series User s Guide Linearity The deviation in response from an expected or theoretical straight line value 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 amp
48. installation 28 to power encoders 34 troubleshooting 173 Doc 0600 3050 2000 CLS200 Series User s Guide TD see derivative temperature incorrect on display 167 171 operating 194 205 207 209 storage 194 205 207 209 terminal specifications controller 196 TB50 197 TEST DIGITAL OUTPUT default value 103 description 104 location 73 233 testing TB18 after installation 28 TB50 after installation 28 see also troubleshooting thermistor inputs scaling resistors for 183 Thermocouple Short Alarm parameter 66 thermocouples accuracy 201 ground loops 31 manual mode if break occurs 97 offset 84 polarity checking 85 range 201 resolution 201 reversed detection 85 short detection 79 troubleshooting 171 types supported 83 wiring 31 32 thermoforming example 131 three key sequence 71 TI see integral tie wraps 35 TIM REM 147 time proportioning 94 cycle time 95 description 157 TOHO 151 torque see terminal specifications triggers ramp soak 142 troubleshooting 163 176 alarms 164 166 all loops are set to manual 0 167 AMBIENT WARNING 168 check these things first 163 communications 174 176 control outputs 172 173 control status switches unexpectedly 167 digital inputs 29 103 173 digital outputs 28 104 173 display does not work 167 grounding problems 172 175 H W AMBIENT FAILURE 169 H W GAIN FAILURE 170 H W OFFSET FAILURE 170 keypad 105 167 170 LOW POWER 168 Index tolerance alarms 151 unexpected behavi
49. minutes or MINS SECS minutes seconds Setup Ramp Soak Profile Menu The SETUP RAMP SOAK PROFILE menu is located be tween the SETUP LOOP ALARMS and the MANUAL 1 0 TEST menus if the ramp soak option is installed LOOP PROCESS UNITS SETUP RAMP SOAK PROFILE ALARM __ SETPOINT STATUS OUT Press YES to set up or edit ramp soak profiles Edit Ramp Soak Profile 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 Doc 0600 3050 2000 Watlow Anafaze 137 Chapter 7 Ramp Soak Copy Setup From Profile Tolerance Alarm Time Ready Segment Setpoint 138 CLS200 Series User s Guide Set up similar profiles quickly by copying the setup of an existing profile LOOP PROCESS UNITS COPY SETUP FROM PROFILE Q ALARM SETPOINT STATUS OUT Selectable values A to Q Set a limit on how long the process variable can be outside the tolerance set for the segment before the tolerance alarm occurs LOOP PROCESS UNITS A OUT OF TOLRNCE ALARM TIME 1 00 ALARM SETPOINT STATUS OUT If the process variable does not return within the tolerance the tolerance alarm will recur after the tolerance alarm time elapses again If the alarm persists you may want to reset the profile Selectable values 0 00 to 99 59 minutes or hours de pending on the time base setting When yo
50. process through the controller to ground This can cause instru ment errors or malfunctions A ground loop may follow one of these paths among others e From one sensor to another e From a sensor to the communications port e From a sensor to the dc power supply The best way to avoid ground loops is to minimize unneces sary connections to ground Do not connect any of the fol lowing terminals to each other or to earth ground e Power supply de common e TB1 terminals 5 6 11 12 analog common e TB1 terminal 17 reference voltage common e TB1 terminals 23 24 communications common e TB2 terminal 2 dc power common Special Precautions for the CLS216 The CLS216 has single ended inputs All the negative sen sor leads are tied to the analog common That means there is no sensor to sensor isolation Proper grounding is critical for this unit Take these additional precautions with a CLS216 e Use all ungrounded or all well grounded thermocou ples not a mix e If using a mixture of thermocouples or low voltage in puts lt 500 mV and current inputs connect the nega tive leads of the current transmitters to terminal 17 Ref Com on TB1 e If using voltage transmitters use only sourcing mod els or configuration Sinking configurations will not work e Isolate the controller s communication port if used by using an optically isolated 232 to 485 converter Personal Computers and Ground Loops 24
51. process variable causes a decrease in the output 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 sin gle communication channel EIA TIA 232 An Electronics Industries of America EIA standard for interface between data terminal equipment and data communi cations equipment for serial binary data inter change This is usually for communications over a short distance 50 feet 15 m or less and to a single device EIA TIA 485 An Electronics Industries of America EIA standard for electrical charac teristics of generators and receivers for use in balanced digital multipoint systems This is usually used to communicate with multiple devices over a common cable or where dis tances over 50 feet 15 m are required Setpoint SP The desired value programmed into a control ler For example the temperature at which a system is to be maintained Shield A metallic foil or braided wire layer surround ing conductors that is designed to prevent elec trostatic or electromagnetic interference from external sources Signal Any electrical transmittance that conveys information Solid State Relay SSR See Relay Solid State Span The difference between the lower and upper Doc 0600 3050 2000 Glossary limits of a range expressed in the same units as th
52. profile then copy it and alter it to set up the rest External reset Select a digital input you can use to hold a profile in the start state and restart it Table 7 1 summarizes the ramp soak features of the CLS200 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 7 Ramp Soak Table 7 1 Ramp Soak Specifications Number of possible profile 17 Number of times to repeat a profil to 99 S Continuous Number of segments per profil 1 to 20 Number of triggers per segment Up to 2 On Type of triggers On Latched Off Off Latched Number of possible inputs for triggers 8 Number of events per segment Up to 4 Number of possible outputs for events At least one of these outputs must be 34 used for control Doc 0600 3050 2000 Watlow Anafaze 135 Chapter 7 Ramp Soak Ramp Soak Menus CLS200 Series User s Guide The SETUP R S PROFILES menu appears between the SETUP LOOP ALARMS and MANUAL I 0 TEST menus Fig ure 7 2 shows the ramp soak setup menu tree SETUP SETUP SETUP SETUP SETUP SETUP SETUP MANUAL GLOBAL LOOP LOOP CONTROL LOOP PV LOOP LOOP RAMP SOAK 1 0 PARAMETERS INPUTS PARAMETERS RETRANSMIT OUTPUTS ALARMS PROFILE TEST YES J YES RAMP SOAK T 136 ME BASE EDIT RAMP amp SOAK PROFILE COPY SETUP FROM PROFILE OUT OF TOLRNCE ALARM TIME READY SEGMENT SETPO
53. provides three linear scaling examples The examples describe e A pressure sensor generating a 4 to 20 mA signal e A flow sensor generating a 0 to 5V signal e A pulse encoder generating 900 pulses per inch of movement Example 1 A 4 to 20 mA Sensor Situation A pressure sensor that generates a 4 to 20 mA signal is con nected to the controller The specifications of the sensor state it generates 4 mA at 0 0 pounds per square inch PSI and 20 mA at 50 0 PSI Setup The sensor is connected to a loop input set up with a resis tor scaling network producing 60mV at 20 mA The INPUT TYPE for the loop is set to LINEAR The sensor measures PSI in tenths so the DISP FORMAT is set to 999 9 TO 3000 0 Doc 0600 3050 2000 Watlow Anafaze 189 Chapter 10 Linear Scaling Examples 190 CLS200 Series User s Guide Table 10 1 Input Readings Process r Sensor Reading Percent of Bigplaved Input Full Scale FS 50 0 PSI 20 mA 100 FS 0 0 PSI 4mA 100 x 4 mA 20 mA 20 FS The scaling values setup in the SETUP LOOP INPUT menu are shown in Table 10 2 Table 10 2 Scaling Values Parameter Prompt Value High Process Variable HIGH PV 50 0 PSI High Sensor Reading HIGH RDG 100 0 FS Low Process Variable LO PV 0 0 PSI Low Sensor Reading LO RDG 20 0 FS Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 10 Linear Scaling Examples Example 2 A 0 to 5
54. referenced to one another the con troller s outputs will not be able to switch the loads When making screw terminal connections tighten to 4 5 to 5 4 inch pound 0 5 to 0 6 Nm Without proper grounding the CLS200 may not operate properly or may be damaged Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 2 Installation A CAUTION To prevent damage from incorrect connec tions do not turn on the ac power before test ing the connections as explained in Testing Your System on page 28 NOTE Do not connect the controller s dc common COM to earth ground 7 Doing so will de feat the noise protection circuitry making measurements less stable Power Supply V1 ey bie Add jumper y o N PGT SM CLS200 mD V2 15V SSR SSR s p O COM 15v COM SSR SSB o V2 15V e e e 7 Ground e i 5 3 Serial DAC ACL AC Line tC e 570 ACN AC Neutral M e N white 120 240 V ac A black Supply green 77 D If using 5V dc for outputs jumper 5V common to 15V common Connect terminals to ac panel ground Figure 2 14 Power Connections with the CLS200 Power Supply Connecting TB50 to CLS200 1 Connect the SCSI cable to the controller 2 Connect the SCSI cable to the TB50
55. system there is no way to recover your original parameters If you have a computer super vised system with AnaWin or Anasoft a copy of your pa rameters can be saved to a job file Replacing the EPROM 176 Replacing the EPROM involves minor mechanical disas sembly and reassembly of the controller You will need a Phillips screwdriver and a small flathead screwdriver Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 9 Troubleshooting and Reconfiguring A CAUTION The EPROM and other components are sen sitive to damage from electrostatic discharge ESD To prevent ESD damage use an ESD wrist strap or other antistatic device NOTE Replacing the EPROM with another version results in full erasure of RAM Make a record of all parameters before changing the EPROM Make a record of system parameters Power down the controller Remove the four screws from the sides of the controller front panel 4 Remove the electronics assembly from the case as shown in Figure 9 1 Figure 9 1 Removal of Electronics Assembly from Case 5 Unscrew the four screws at the corners of the top board and carefully unplug this board to access the bottom board processor board Figure 9 2 shows the screws to remove Doc 0600 3050 2000 Watlow Anafaze 177 Chapter 9 Troubleshooting and Reconfiguring CLS200 Series User s Guide Figure 9 2 Screws Locations on PC Board 6 Locate the EPROM on the circuit board
56. the HEAT parameter Selectable values Any loop or NONE Minimum Input Enter the lowest value of the process variable to be retrans mitted This value is expressed in the same engineering units as the input loop LOOP PROCESS UNITS 02 HEAT RETRANS MIN INP 1000 ALARM SETPOINT STATUS OUT If the process variable falls below the minimum the output will stay at the minimum value Selectable values Any value in the input loop s range Minimum Output Enter the output value 0 to 100 that corresponds to the minimum input LOOP PROCESS UNITS 02 HEAT RETRANS MIN OUT 0 ALARM SETPOINT STATUS OUT Selectable values 0 to 100 If you select a minimum output value other than 0 the output will never drop below MIN OUT even if the process variable drops below the MIN INP that you specified Maximum Input Enter the highest value of the process variable to be re transmitted This value is expressed in the same engineer ing units as the input loop LOOP PROCESS UNITS 02 HEAT RETRANS MAX INP 10000 ALARM SETPOINT STATUS OUT Ifthe process variable goes above the maximum the output will stay at the maximum value Selectable values Any value in the input loop s range 114 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Maximum Output Chapter 6 Enhanced Features By adjusting the maximum and minimum inputs you can scale the output appropri
57. the SENSOR FAIL HT OUTPUT or SENSOR FAIL CL OUTPUT parameter in the SETUP LOOP OUTPUTS menu LOOP PROCESS UNITS PROCESS POWER DIGIN NONE ALARM _ SETPOINT STATUS OUT Selectable values 1 to 8 or NONE Set the communications address for the controller On an EIA TIA 485 communication loop each controller must have a unique 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 to 247 When using one controller with Anasoft select address 1 When using multiple con trollers with Anasoft use consecutive addresses from 1 to 16 only Watlow Anafaze 79 Chapter 4 Setup CLS200 Series User s Guide Communications Baud Rate Communications Protocol NOTE Set the communications baud rate LOOP PROCESS UNITS COMMUNICATIONS BAUD RATE 9600 ALARM SETPOINT STATUS OUT Selectable values 9600 2400 or 19200 Set the baud rate to the same speed in both the controller and the HMI software or panel Set the communications protocol Choose the correct proto col for the software or device with which the controller will communicate You must switch power to the controller off then back on to make a change to this parameter take ef fect LOOP PROCESS UNITS COMMUNICATIONS PROTOCOL ANA ALARM _ SETPOINT STA
58. them in a panel with CLS200 series equip ment use a 0 01 microfarad capacitor rated at 1000V ac or higher in series with a 47 Q 0 5 watt resistor across the N O contacts of the relay load This is known as a snubber network and can reduce the amount of electrical noise 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 130V for 120V ac control circuits across the load which lim its the peak ac voltage to about 180V ac Watlow Anafaze part number 26 130210 00 You can also place a transorb back to back zener diodes across the digital output which limits the digital output voltage Additional Recommendations for a Noise Immune System It is strongly recommended that you Doc 0600 3050 2000 Isolate outputs through solid state relays where pos sible Isolate RTDs or bridge type inputs from ground Isolate digital inputs from ground through solid state relays If this is not possible then make sure the digi tal input is the only connection to earth ground other than the chassis ground If you are using EIA TIA 232 from a non isolated host either 1 do not connect any other power common point to earth ground or 2 use an optical isolator in the communications line Watlow Anafaze 23 Chapter 2 Installation Ground Loops CLS200 Series User s Guide Ground loops occur when current passes from the
59. to apply to the master loop s process variable LOOP PROCESS UNITS 02 RATIO CONTROL CTRL RATIO 1 0 ALARM SETPOINT STATUS OUT Selectable values 0 1 to 999 9 Enter the value to add or subtract from the ratio loop set point calculation before using it as the setpoint This value is expressed in the same engineering units as the ratio loop s process variable LOOP PROCESS UNITS 02 RATIO CONTROL SP DIFF 0 ALARM SETPOINT STATUS OUT Selectable values 9999 to 9999 with the decimal placement determined by the DISP FORMAT setting for the ratio loop Ratio Control Example Diluting KOH 126 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 so the KOH should flow at 5 gps Separate pipes for each chemical feed a common pipe The flow rate of each feeder pipe is measured by a CLS200 with H30 flow as process variable 1 and KOH flow as process variable 2 The outputs of loops 1 and 2 adjust motorized valves Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 6 Enhanced Features Water Input KOH Input Loop 1 Water Flow Control Loop Loop 2 KOH Flow Control Loop Loop 1 Input Flow Process Variable Loop 1 PID Output Transducer Loop 2 Input CLS200 Process Variable Loop 2 PID Output
60. use a switching device with the appropriate impedances in the on and off states and do not connect the inputs to external power sources When off the swiching device must provide an impedance of at least 11 kQ to ensure that the voltage will rise to greater than 3 7V dc When on the switch must provide not more than 1 KQ impedance to ensure the voltage drops below 1 3V do To install a switch as a digital input connect one lead to the common terminal on the TB50 terminals 3 and 4 or TB18 terminal 2 Connect the other lead to the desired digital input terminal on the TB50 terminals 43 to 50 or TB18 terminals 16 to 18 Functions Activated by Digital Inputs Doc 0600 3050 2000 Use digital inputs to activate the following functions e Load a job that is stored in controller memory See Job Select Digital Inputs on page 76 e Change all loops to manual mode at specified output levels See Output Override Digital Input on page 77 e Enable thermocouple short detection See Process Power Digital Input on page 79 e Restore control automatically after a failed sensor has been repaired See Restore PID Digital Input on page 92 External TB50 A Switching Input Pa Device Control Com Figure 2 27 Wiring Digital Inputs Watlow Anafaze 39 Chapter 2 Installation TB18 Connections CLS204 and CLS208 Only CLS200 Series User s Guide
61. with three functions Proportional action dampens the system response integral corrects for droops and derivative 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 PV 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 setpoint 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 also PID Proportional Control A control using only the P proportional value of PID control Pulse Input Digital pulse signals from devices such as optical encoders 218 Watlow Anafaze CLS200 Series User s Guide R Ramp A programmed increase in the temperature of a setpoint system Range The area between two limits in which a quan tity or value is measured It is usually described in terms
62. 0 F 212 to 760 C K T C 450 to 2 500 F 268 to 1 371 C T T C 450 to 750 F 268 to 399 C S T C 0 to 3 200 F 18 to 1 760 C R T C 0 to 3 210 F 18 to 1 766 C B T C 150 to 3 200 F 66 to 1 760 C E T C 150 to 3 200 F 66 to 1 760 C RTD1 148 0 to 572 0 F 100 0 to 275 0 C RTD2 184 to 1 544 F 120 to 840 C PULSE 0 to 2 kHz SKIP Loop not used LINEAR See Linear Scaling Parameters on page 86 Watlow Anafaze 83 Chapter 4 Setup Loop Name Input Units Input Reading Offset 84 CLS200 Series User s Guide Assign a two character name to the loop This name is shown on the single loop display in place of the loop number LOOP PROCESS UNITS 01 LOOP NAME 01 ALARM SETPOINT STATUS OUT Selectable values 0 to 9 A to Z degree symbol For loops with temperature sensor input types choose a temperature scale Fahrenheit or Celsius For a linear or pulse loop choose a three character description of the loop s engineering units LOOP PROCESS UNITS 01 INPUT UNITS F ALARM _ SETPOINT STATUS OUT Selectable values The table below shows the character set for input units Table 4 7 Input Character Sets Input Character Sets for Units Thermocouple o o or RTD KOR Linear or Pulse 0 to 9 A to Z space If the input type
63. 0 2000 Watlow Anafaze 161 Chapter 8 Tuning and Control CLS200 Series User s Guide Table 8 4 General PID Constants TEP Proportional een Output Cycle Application Band Integral Derivative Filter Type Time Action Electrical heat with solid state 50 60 15 4 DZC Reverse relays Electrical heat with electrome 50 60 15 6 TP 20 Reverse chanical relays Cool witiisele 70 500 90 4 TP 10 Direct noid valve Cool with fans 10 Off 10 4 TP 10 Direct Electric heat with open heat 30 20 Off 4 DZC Reverse coils Gas heat with 60 120 25 motorized valves 8 Analog Reverse Setpoint gt 1200 100 240 40 162 Watlow Anafaze Doc 0600 3050 2000 Troubleshooting and Reconfiguring When There is a Problem Doc 0600 3050 2000 NOTE A CAUTION The controller is only one part of your control system Of ten what appears to be a problem with the controller is re ally a problem with other equipment so check these things first e Controller is installed correctly See Chapter 2 In stallation for help e Sensors such as thermocouples and RTDs are in stalled correctly and working If you suspect your controller has been dam aged do not attempt to repair it yourself or you may void the warranty If the troubleshooting procedures in this chapter do not solve your system s problems call Application Engineering for additional troubleshooting help If y
64. 0 to 3199 180 1000 to 1099 70 2100 to 2199 130 3200 to 3299 185 Doc 0600 3050 2000 As a general rule set the proportional band to 10 of the setpoint below 1000 and 5 of the setpoint above 1000 This setting is useful as a starting value Watlow Anafaze 159 Chapter 8 Tuning and Control Integral Settings CLS200 Series User s Guide The controller s integral parameter TI is set in seconds per repeat Some other products use an integral term called reset in units of repeats per minute Table 8 2 shows inte gral settings versus reset settings Table 8 2 Integral Term and Reset Settings Integral Reset Integral Reset Seconds Repeat Repeats Minute Seconds Repeat Repeats Minute 30 2 0 210 0 28 45 1 3 240 0 25 60 1 0 270 0 22 90 0 66 300 0 20 120 0 50 400 0 15 150 0 40 500 0 12 180 0 33 600 0 10 Derivative Settings As a general rule use 60 120 180 or 240 as a starting val ue for the integral The controller s derivative parameter TD is programmed in seconds Some other products use a derivative term called rate programmed in minutes Use the table or the formula to convert parameters from one form to the other Table 8 3 shows derivative versus rate Rate Derivative 60 Table 8 3 Derivative Term Versus Rate Derivative Rate Derivative Rate seconds minutes seconds minutes 5 0 08 35 0 58 10 0 16
65. 00 3050 2000 Chapter 9 Troubleshooting and Reconfiguring range of 23 to 32 F or 122 to 131 F 5 to 0 C or 50 to 55 C The operating limits are 32 to 122 F 0 to 50 C If the controller displays AW in the lower left corner of the display 1 2 Acknowledge the alarm If the error message remains check the ambient air temperature near the controller Adjust ventilation cooling or heating to ensure that the temperature around the controller is 32 to 122 F 0 to 50 C If the unit is functioning correctly the error will clear when the ambient temperature is within range and the alarm has been acknowledged If the ambient temperature is within range and the er ror persists a Turn the power to the controller off b Remove the boards from the CLS200 housing See Replacing the EPROM on page 176 c Reseat the boards and turn the power on If the error persists make a record of the settings then perform a NO key reset See NO Key Reset on page 176 If the error is not cleared contact your supplier for fur ther troubleshooting guidelines See Returning Your Unit on page 164 The hardware ambient failure alarm indicates that the am bient sensor in the CLS200 is reporting that the tempera ture around the controller is outside of the acceptable range of 0 to 50 C This error can also occur when there is a hardware failure If the controller displays H W AMBIENT FAILURE 1 2 Acknowledge th
66. 00 Series User s Guide Mounting with Standoffs 1 Remove the DIN rail mounting brackets from the TB50 2 Select a location with enough clearance to remove the TB50 its SCSI cable and the controller itself Mark the four mounting holes 4 Drill and tap four mounting holes for 6 3 5 mm screws or bolts 5 Mount the TB50 with four screws There are four smaller holes on the terminal board Use these holes to secure wiring to the terminal block with tie wraps 4 holes for 3 4 in 6 3 5 mm 86 mm screws or bolts A ax 0 2 in 0 2 in 3 6 in ey 5 mm 91 mm Figure 2 9 Mounting a TB50 with Standoffs Mounting the Power Supply If you use your own power supply for the CLS200 refer to the power supply manufacturer s instructions for mounting information Choose a Class 2 power supply that supplies an isolated regulated 12 to 24V dc at 1 A 18 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 2 Installation Mounting Environment Leave enough clearance around the power supply so that it can be removed Mounting the Dual DAC or Serial DAC Module This section describes how to install the optional Dual DAC and Serial DAC digital to analog converters Doc 0600 3050 2000 Watlow Anafaze 19 Chapter 2 Installation Installation Jumpers Mounting Dual DAC 4 holes for 8 4 0 mm screws or bolts 000000 3 62 in Electrical 91 mm connections
67. 050 2000 CLS200 Series User s Guide Chapter 3 Using the CLS200 Changing the Setpoint Select the single loop display for the loop you want to change Press CHNG SP This display appears LOOP PROCESS UNITS 01 SETPOINT 25 F ALARM _ SETPOINT STATUS OUT e Press YES to change the setpoint Press the up or down keys YES or NO to increase or de crease the setpoint value e Press ENTER to save your changes and return to single loop display r Press NO or BACK without pressing ENTER to return to single loop display without saving the new setpoint Selecting the Control Status If you set the control status to AUTO the controller auto matically controls the process according to the configura tion information you give it If you set the control status to MAN you need to set the out put level If you set the control status to TUNE the controller performs an autotune and chooses PID parameters NOTE If the loop outputs are disabled you cannot toggle between manual and automatic con trol If you try it the screen shows an error message telling you that the outputs are dis abled as shown below Use the SETUP LOOPS OUTPUT menu to enable the outputs See Setup Loop Outputs Menu on page 93 LOOP PROCESS UNITS MAN AUTO CONTROL OUTPUTS DISABLED ALARM SETPOINT STATUS OUT Manual and Automatic Control 1 Switch to the single loop display for the loop 2 Press MAN AUTO 3 Press YE
68. 1 Table 10 4 Scaling Values 191 Table 10 5 Scaling Values 192 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide List of Tables 11 Specifications Table 11 1 Agency Approvals Compliance 193 Table 11 2 Environmental Specifications 194 Table 11 3 Physical Dimensions 194 Table 11 4 Processor with Straight SCSI 195 Table 11 5 Processor with Right Angle SCSI 195 Table 11 6 Processor Connections 196 Table 11 7 TB50 Physical Dimensions 196 Table 11 8 TB50 Connections 197 Table 11 9 TB50 with Straight SCSI 198 Table 11 10 TB50 with Right Angle SCSI 199 Table 11 11 Analog Inputs 200 Table 11 12 Pulse Inputs 201 Table 11 13 Thermocouple Range and Resolution 201 Table 11 14 RTD Range and Resolution 201 Table 11 15 Input Resistance for Voltage Inputs 202 Table 11 16 Digital Inputs 202 Table 11 17 Digital Outputs Control Alarm 203 Table 11 18 CPU Watchdog Output 203 Table 11 19 5V dc Output Power to Operate Solid State Relays 204 Table 11 20 Reference Voltage Output Power to Operate Bridge Circuit Sensors 204 Table 11 21 Processor Serial Interface 204 Table 11 22 Processor Power Requirements 204 Table 11 23 Power Supply Environmental Specifications 205 Table 11 24 Power Supply Agency Approvals Compliance 205 Table 11 25 Power Supply Physical Specifications 205 Table 11 26 Power Supply with Mounting Bracket 205 Table 11 27 Power Supply Inputs
69. 1000 4 2 1995 Descarga electrost tica EN 61000 4 3 1997 Inmunidad radiada EN 61000 4 4 1995 Perturbaciones transitorias el ctricas r pidas EN 61000 4 5 1995 Sobretension EN 61000 4 6 1994 Inmunidad conducida EN 61000 4 11 1994 Ca das de tensi n interrupciones breves y variaciones de tensi n ENV 50204 1995 Tel fono port til Watsonville California USA Place of Issue Sean Wilkinson Name of Authorized Representative Feb 28 2003 Date of Issue Manager Title of Authorized Representative Signature of Authorized Representative E
70. 1326 1997 Elektroger te zur Messung Regelung und zum Laboreinsatz EMC Richtlinien Klasse A EN 61000 3 2 1995 Grenzen der Oberwellenstromemissionen EN 61000 3 3 1995 Grenzen der Spannungsschwankungen EN 61000 4 2 1995 Elektrostatische Entladung EN 61000 4 3 1997 Strahlungsimmunitat EN 61000 4 4 1995 Elektrische schnelle St e EN 61000 4 5 1995 SpannungsstoRimmunit t EN 61000 4 6 1994 St rimmunit t EN 61000 4 11 1994 Immunit t gegen Spannungsgef lle kurze Unterbrechungen und Spannungsabweichungen ENV 50204 1995 Mobiltelefon Declara que el producto siguiente Designaci n Serie CLS200 N meros de modelo 2 04 08 16 1 2 3 4 0 1 2 0 1 2 0 1 2 3 0 1 2 3 0 1 2 1 2 letras numeros Espa ol Clasificaci n Categor a de instalaci n II grado de contaminaci n ambiental II Tension nominal 15 a 24Vcc Consumo nominal de energia 610 mA maximo Cumple con los requisitos esenciales de las siguientes Directivas de la Union Europea usando las secciones pertinentes de las reglas normalizadas y los documentos relacionados que se muestran 89 336 EEC Directiva de Compatibilidad Electromagn EN 61326 1997 Equipo el trico para medici n control y uso en laboratorios Requisitos de compatibilidad electromagn tica Clase A EN 61000 3 2 1995 L mites para emisiones de corriente arm nica EN 61000 3 3 1995 Limitaciones de fluctuaciones del voltaje EN 6
71. 15 ALARM SETPOINT STATUS OUT From the single loop display press the RAMP SOAK key three times The SET MODE parameter allows you to change the ramp soak mode LOOP PROCESS UNITS 01 A SEGO1 05 R SET MODE START ALARM __ SETPOINT STATUS OUT Watlow Anafaze 147 Chapter 7 Ramp Soak CLS200 Series User s Guide See Running a Profile on page 148 and Holding a Profile or Continuing from Hold on page 150 for instructions on changing the ramp soak mode Assigning a Profile to a Loop Use this parameter to assign a profile to a loop LOOP PROCESS UNITS 01 ASSIGN R S PROFILE A ALARM _ SETPOINT STATUS OUT Selectable Values A to Q or NONE Assigning a Profile the First Time To assign a profile to a loop that does not have a profile cur rently assigned 1 In the single loop display switch to the loop you want to assign a profile to 2 Press the RAMP SOAK key The ASSIGN R S PRO FILE parameter appears 3 Choose one of the available profiles and press ENTER or press BACK to return to single loop display without sending profile data to the controller Assigning Changing and Unassigning a Profile To assign a new profile to a loop that already has one assigned 1 In the single loop display switch to the loop in which you want to change or unassign the profile 2 Press the RAMP SOAK key three times 3 Press the NO key You will see the RESET PROFILE parameter See Resetting a Pro
72. 200 66 to 1 760 7 2 4 0 22 1 12 3 E 328 to 1 448 200 to 787 1 8 1 0 2 9 1 6 True for 10 to 100 of span except type B which is specified for 800 F to 3200 F Table 11 14 RTD Range and Resolution Accuracy Accuracy at M at 25 C 0 to 50 C Name Range Range Resolution ikain pal Ambient Ambient in F in C in C in C F C oF C 148 0 to 100 0 to 25 40 7 404 1 0 40 6 RTD1 0 023 527 0 275 0 275 1 9 1 14 42 8 1 6 k 25 2 5 1 4 5 9 3 3 RTD2 180 120to840 0 023 840 2 9 1 6 8 6 4 8 Doc 0600 3050 2000 Watlow Anafaze 201 Chapter 11 Specifications CLS200 Series User s Guide Table 11 15 Input Resistance for Voltage Inputs Range Input Resistance 0 to 12V 85 kQ 0 to 10V 50 kQ 0 to 5V 40 kQ 0to1V 7 4 KQ 0 to 500mV 6 2 kQ 0 to 100mV 1 2 KQ Table 11 16 Digital Inputs Parameter Description Number 8 Configu ation 8 selectable for output override remote job selection Input Voltage Protection Diodes to supply and common Source must limit current to 10 mA for override conditions Voltage Levels lt 1 3V Low gt 3 7V High TTL 5V maximum OV minimum Maximum Switch Resistance to Pull Input Low 1kQ Minimum Switch Off Resistance 11 KQ Update Rate 6 Hz Outputs 202 The controller directly accommodates switched de and open collector outputs only These outputs can be used to co
73. 206 Table 11 28 Power Supply Outputs 206 Table 11 29 Dual DAC Environmental Specifications 207 Table 11 30 Dual DAC Physical Specifications 207 Table 11 31 Dual DAC Power Requirements 208 Table 11 32 Dual DAC Specifications by Output Range 208 Table 11 33 Serial DAC Environmental Specifications 209 Table 11 34 Serial DAC Physical Specifications 209 Table 11 35 Serial DAC Agency Approvals Compliance 210 Table 11 36 Serial DAC Inputs 210 Table 11 37 Serial DAC Power Requirements 210 Table 11 38 Serial DAC Analog Output Specifications 211 Doc 0600 3050 2000 Watlow Anafaze XV List of Tables CLS200 Series User s Guide xvi Watlow Anafaze Doc 0600 3050 2000 System Overview Manual Contents Doc 0600 3050 2000 This manual describes how to install set up and operate a CLS204 CLS208 or CLS216 controller Each chapter cov ers a different aspect of your control system and may apply to different users Chapter 1 System Overview provides a component list and summary of features for the CLS200 series controllers Chapter 2 Installation provides detailed instruc tions on installing the CLS200 series controller and its peripherals Chapter 3 Using the CLS200 provides an overview of operator displays used for system monitoring and job selection Chapter 4 Setup provides detailed descriptions of all menus and parameters for controller setup Chapter 5 Extruder Control explains the addi
74. 20V Thermocouple Break Detection Pulse type for upscale break detection Milliampere Inputs 0 to 20 mA 3 resistance or 0 to 10 mA 6 Q resistance with scaling resistors Linear Voltage Input Ranges Avail able 0 to12V 0 to 10V 0 to 5V 0 to 1V 0 to 500 mV 0 to 100 mV with scaling resistors Source Impedance For 60mV thermocouple measurements are within specifica tion with up to 500 Q source resistance For other types of analog signals the maximum source imped ance is 5 000 Q 200 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chap Table 11 12 Pulse Inputs ter 11 Specifications Parameter Description Number Frequency Range 1 0 to 2 000 Hz Input Voltage Protection Diodes to supply and common Voltage Levels Pull Input Low Maximum Switch Resistance to lt 1 3V Low gt 3 7V High TTL 2 kQ Minimum Switch Off Resistance 30 kQ Table 11 13 Thermocouple Range and Resolution Accuracy at aaa as Thermocouple Range Range 25 C Ambient Ambient Type in F in C oF C F C J 350 to 1 400 212 to 760 2 2 1 2 3 3 1 8 K 450 to 2 500 268 to 1371 2 4 1 3 3 8 2 1 T 450 to 750 268 to 399 42 9 1 6 45 8 43 2 S 0 to 3 200 18 to 1 760 5 0 42 8 8 8 44 9 R 0 to 3 210 18 to 1 766 5 0 2 8 8 8 4 9 B 150 to 3
75. 3 Bar Graph Display Table 3 1 explains the symbols you see on the top line of the bar graph display These symbols appear when the con troller is in dual output mode heat and cool outputs en abled and single output mode heat or cool outputs enabled but not both Table 3 1 Bar Graph Display Symbols Symbol Description lt Loop is in low process or low deviation alarm gt Loop is in high process or high deviation alarm Loop is above setpoint If you enable the high L or low deviation alarm this symbol is scaled to il it If you do not 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 y low deviation alarm this symbol is scaled to it If you do not enable these alarms these sym bols are scaled to the setpoint 5 of the sen sor s range Loop is below setpoint If you enable the high T T or low deviation alarm this symbol is scaled to it If you do not enable these alarms these symbols are scaled to the setpoint 5 of the sensor s range blank LOOp s input type is set to SKIP Open thermocouple T C shorted T C F reversed T C open RTD or shorted RTD Watlow Anafaze 55 Chapter 3 Using the CLS200 CLS200 Series User s Guide Table 3 2 explains the control status symbols on the bot tom line of bar graph display Additional symbols may ap pear with the ramp soak opti
76. 42 9 R41 2 R40 10 R39 3 R38 11 R37 4 R36 12 R35 5 R34 13 R33 6 R32 14 R31 7 R30 15 R29 8 R28 16 R27 CLS216 Voltage Inputs For each voltage input on a CLS216 controller you must in stall two resistors The resistance must be correct for the expected input range Install the resistors in the listed lo cations Table 9 14 Resistor Values for CLS216 Doc 0600 3050 2000 Voltage Inputs Resistor Values Input Range RC RD 0 to 100mV dc 499 Q 750 Q 0 to 500mV dc 5 49 kQ 750 Q 0 to 1V dc 6 91 kQ 442 02 0 to 5V dc 39 2 kQ 475 0 Q 0 to 10V dc 49 9 kQ 301 0 Q 0 to 12V dc 84 5 KQ 422 0 Q Watlow Anafaze Resistor tolerance 0 1 185 Chapter 9 Troubleshooting and Reconfiguring CLS200 Series User s Guide Table 9 15 Resistor Locations for CLS216 Voltage Inputs Resistor Locations Resistor Locations 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 Scaling and Calibration The controller provides offset calibration for thermocouple RTD and other fixed ranges and offset and span gain cal ibration for linear and pulse inputs In order to scale linear input signals you must 1 Install appropriate scaling resistors Contact Watlow Anafaze s Customer Service Department
77. 600 3050 2000 Doc 0600 3050 2000 A WARNING A WARNING Installation This chapter describes how to install the CLS200 series controller and its peripherals Installation of the controller involves the following procedures e Determining the best location for the controller e Mounting the controller and TB50 e Power connection e nput wiring e Communications wiring EIA TIA 232 or EIA TIA 485 e Output wiring Risk of electric shock Shut off power to your entire process before you begin installation of the controller The controller may fail in a 0 or 100 power output state To prevent death personal inju ry equipment damage or property damage install external safety shutdown devices If failure may cause death or injury you must install FM approved safety shutdown devic es that operate independently from the pro cess control equipment Watlow Anafaze 11 Chapter 2 Installation Typical Installation CLS200 Series User s Guide Figure 2 1 shows typical installations of the controller with the TB50 and the TB18 terminal blocks The type of termi nal block you use greatly impacts the layout and wiring of your installation site See Figures 2 2 to 2 11 We recommend that you read this entire chapter first be fore beginning the installation procedure This will help you to carefully plan and assess the installation CLS200 with TB50 CSI Cable 8 Digital Inputs 35 Digital Outp
78. 73 233 location of 64 Alarm High SP parameter 67 Alarm Low SP parameter 67 alarms acknowledging 59 60 alarm high see process alarms alarm low see process alarms codes 164 166 deadband 102 delaying 64 100 103 deviation 164 deviation see process alarms digital output polarity 81 disabling control on alarm outputs 94 displays 58 failed sensor 65 166 global 99 global alarm output 68 high deviation alarm settings 100 101 high process alarm settings 100 hysteresis 68 loop delay 64 low deviation alarm settings 100 101 low process alarm settings 102 messages 166 process 164 resetting 165 restoring control after sensor failure 92 reversed thermocouple 85 RTD see failed sensor alarms SCRs 37 sensor fail percent output power 97 setting up 66 69 setup parameters 99 103 solid state relays 37 startup delay 64 78 system 60 166 T C BREAK switching to manual mode 97 Doc 0600 3050 2000 Index thermocouple see failed sensor alarms tolerance 138 151 troubleshooting 164 166 wiring 37 ambient temperature H W AMBIENT FAILURE message 169 operating range 12 AMBIENT WARNING 168 ANAINSTL 80 analog inputs see sensor inputs analog output 158 see also Dual DAC or Serial DAC ASSIGN R S PROFILE 148 AUTO 56 61 automatic control selecting 61 automatic mode restoring after failed sensor repair 66 autotuning 62 64 B BACK key 53 bar graph display 55 56 control status symbols 56 navigating in 56 ramp soak symbols 147 sy
79. 73 233 parameters in menu 93 SETUP LOOP PV RETRANSMIT description 113 location 112 233 230 Watlow Anafaze CLS200 Series User s Guide SETUP LOOP RATIO CONTROL description 125 location 112 233 SETUP RAMP SOAK PROFILE 137 location 136 233 shutdown devices 9 single loop display 56 control status symbols 56 navigating 57 ramp soak symbols 146 when running ramp soak profile 146 solid state relays 5 Vdc power from controller 204 distributed zero crossing 158 troubleshooting controller connections 173 specifications 193 211 communications 204 controller 204 controller inputs 200 202 controller outputs 202 204 CPU watchdog timer 203 Dual DAC 207 208 power supply 205 206 Serial DAC 209 211 TB50 196 SPREAD default value 90 description 92 156 location 73 spread 92 ST alarm code 166 STARTUP ALARM DELAY default value 74 description 78 location 73 233 T T control status symbol 56 TB18 alarm outputs 37 38 connections 40 CPU watchdog timer output 38 digital output wiring 36 testing after installation 28 to power encoders 34 troubleshooting 173 TB50 alarm outputs 37 38 connecting to controller 27 connections for CLS204 41 connections for CLS208 41 connections for CLS216 42 CPU watchdog timer output 38 digital output wiring 36 dimensions 196 199 for powering Serial DAC 44 mounting on DIN rail 17 mounting with standoffs 18 specifications 196 technical description 8 terminal specifications 197 testing after
80. 9 description 101 location 73 233 LO DEV ALARM TYPE default value 99 description 101 location 73 233 LO PROC ALARM OUTPUT default value 99 description 102 location 73 233 LO PROC ALARM SETPT default value 99 description 102 location 73 233 LO PROC ALARM TYPE default value 99 description 102 location 73 233 LOAD SETUP FROM JOB CANNOT LOAD JOB 75 default value 74 description 75 job display 60 location 73 233 locking the keypad 78 LOOP NAME default value 82 description 84 location 73 233 loops autotuning see autotuning naming 84 Doc 0600 3050 2000 CLS200 Series User s Guide number available 200 ramp soak profiles see ramp soak 148 single loop display see single loop display tuning 159 161 low deviation alarm see process alarms LOW POWER 166 168 LP alarm code 164 M control status symbol 56 MAN 56 61 MAN AUTO CONTROL OUTPUTS DISABLED 61 MAN AUTO key 54 does not work 170 locking and unlocking 78 switching control statuses 61 manual control selecting 61 setting the output level 62 MANUAL I O TEST 103 location 73 233 parameters in menu 103 menu tree all setup menus 233 enhanced features 112 ramp soak profiles 136 standard setup menus 73 menus accessing 71 global parameters 74 loop alarms 99 loop control 90 loop input 82 loop outputs 93 manual I O test 103 menu tree see menu tree process variable retransmit 113 ramp soak profile 137 model information accessi
81. A 232 46 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide EIA TIA 485 Interface Personal Computer Chapter 2 Installation To communicate with more than one CLS200 series con troller on a controller network or to use communication ca ble lengths greater than 50 feet 15 2 m from PC to controller you must use EIA TIA 485 communications When using EIA TIA 485 communications you must at tach an optically isolated EIA TIA 232 to EIA TIA 485 con verter to the computer Figure 2 32 and Figure 2 33 show the recommended system wiring To avoid ground loops use an optically isolated EIA TIA 232 to EIA TIA 485 converter between the com puter and the EIA TIA 485 network EIA TIA 485 Converter First CLS200 Last CLS200 JU1 JUT eA eA TXA TDA TX RXA 25 e B RXA 25 B TXB TDB TX RXB 23 i RXB 23 RXA RDA RX TXA 26 TXA 26 RXB RDB RX TXB 24 TXB 24 Do not connect shield to CLS200 Cable Recommendations Figure 2 32 EIA TIA 485 Wiring Watlow Anafaze recommends Belden 9843 cable or its equivalent This cable includes three 24 AWG 0 2 mm shielded twisted pairs It should carry signals of up to 19 2k baud with no more than acceptable losses for up to 4 000 feet 1 220 m EIA TIA 485 Network Connections Doc 0600 3050 2000 Walow Anafaze recommends that you use a single daisy chain configuration rather than spurs Run a twisted pair cable from
82. ALING FILTER HT OUTPUT OUTPUT Ramp soak HI PV Linear and pulse SPREAD HEAT T C BRK LO PROC ALARM KEYBOARD LOCK TET OUT AVG SETPT STATUS RDG f RESTORE PID HEAT OUTPUT LO PROC ALARM aNERAUE ear and pulse inteiny TYPE PROCESS POWER DIGIN inear and pulse UT SCALING CONTROLLER RDG ADDRESS ear and pulse P TER COMMUNICATIONS INPUT FILTER BAUD RATE COMMUNICATIONS PROTOCOL COMMUNICATIONS ERR CHECK AC LINE FREQ DIG OUT POLARITY ON ALARM CLS 200 FIRMWARE INFO Ifthe enhanced features option or ramp soak feature is installed refer to Chapter 6 En hanced Features or Chapter 7 Ramp Soak for additional menus Doc 0600 3050 2000 Figure 4 1 COOL OUTPUT TYPE ALARM DEADBAND COOL OUTPUT CYCLE TIME TP ALARM DELAY SDAC PARAMETERS SDAC COOL OUTPUT ACTION FAIL CL OUTPUT COOL T C BRK OUT AVG COOL OUTPUT Watlow Anafaze CLS200 Menu Tree 73 Chapter 4 Setup Setup Global Parameters Menu LOOP PROCESS UNITS SETUP GLOBAL PARAMETERS ALARM __ SETPOINT STATUS OUT CLS200 Series User s Guide Table 4 1 shows the parameters available in this menu Table 4 1 Global Parameters Parameter Default Value LOAD
83. ARD COMPONENT SIDE J Figure 2 13 CLS200 Series Controller with TB50 Wiring the Power Supply A WARNING Use a power supply with a Class 2 rating only UL approval requires a Class 2 power supply Connect power to the controller before any other connec tions This allows you to ensure that the controller is work ing before any time is taken installing inputs and outputs Doc 0600 3050 2000 Watlow Anafaze 25 Chapter 2 Installation NOTE NOTE A CAUTION 26 CLS200 Series User s Guide Table 2 2 Power Connections Function Power Supply CLS200 TB2 DC Power Controller 12 to 24V dc i DC Common 12 to 24V dc l Common Earth Ground Ground b 1 Connect the dc common terminal on the power supply to the dc common terminal on CLS200 TB2 2 Connect the positive terminal on the power supply to the dc positive terminal on CLS200 TB2 3 Ifusing an isolated dc output or another power supply to power the loads connect the dc common of the sup ply powering the loads to the dc common of the supply powering the controller 4 Use the ground connector on TB2 for chassis ground This terminal is connected to the CLS200 chassis and must be connected to earth ground 5 Connect 120 240V ac power to the power supply Connect the dc common of the power supply used for loads to the dc common of the sup ply powering the controller If the supplies are not
84. ARM _ SETPOINT STATUS OUT Selectable values NONE or input number 1 to 8 Use the next parameter OVERRIDE DIG IN ACTIVE toset the signal state that activates the output override feature Do not rely solely on the output override fea ture to shut down your process Install exter nal safety devices or over temperature devices for emergency shutdowns Override Digital Input Active Doc 0600 3050 2000 Specify whether a low or high signal activates the output override feature see OUTPUT OVERRIDE DIG INPUT above LOOP PROCESS UNITS OVERRIDE DIG IN ACTIVE LOW ALARM SETPOINT STATUS OUT Selectable values HIGH or LOW Watlow Anafaze 77 Chapter 4 Setup Startup Alarm Delay Keyboard Lock Status Power Up Output Status 78 A WARNING CLS200 Series User s Guide You can set the input to be active when low or active when high When the input selected for OUTPUT OVERRIDE DIG INPUT changes to the specified state all the loop s outputs are set to their sensor fail levels Set a startup 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 This feature does not delay failed sensor alarms LOOP PROCESS UNITS STARTUP ALARM DELAY 0 MINS ALARM _ SETPOINT STATUS OUT Selectable values 0 to 60 minutes Set this parameter to ON to disable the CHN
85. ATUS OUT Enter the minimum output percentage from 0 to 100 For this example we will assume a full span with a minimum of 0 Press ENTER LOOP PROCESS UNITS 02 HEAT RETRANS MAX INP 1000 ALARM SETPOINT STATUS OUT Enter the maximum input value which corresponds to the maxi mum output percentage For a range of 0 to 1000 F set the maxi mum input value to 1000 F Press ENTER LOOP PROCESS UNITS 02 HEAT RETRANS MAX OUT 100 STATUS OUT ALARM SETPOINT Enter the maximum output percentage from 0 to 100 For this example we will assume a full span with a maximum of 100 Press ENTER LOOP PROCESS UNITS 02 COOL OUTPUT RETRANS PV NONE ALARM _ SETPOINT STATUS OUT The process variable retransmit section of the controller program ming is now completed We are not using the cool output of loop 2 to retransmit a process variable so choose NONE Press ENTER Doc 0600 3050 2000 Watlow Anafaze 117 Chapter 6 Enhanced Features Cascade Control 118 CLS200 Series User s Guide Notes about this application e This is not a thermocouple curve type of signal and re quires a linear input range in the recorder e To complete this configuration the loop 2 output must be enabled and tailored to meet the requirements of the data application In this example the data logger requires an analog input of 4 to 20 mA e The CLS200 Series controllers must be used with a Wat
86. CLS200 Parts List You may have received one or more of the following compo nents See Figure 2 1 on page 12 for CLS200 configuration information e CLS200 series controller e Controller mounting kit e TB50 with 50 pin SCSI cable e EJA TIA 232 or EJA TIA 485 communications cable e Power supply with mounting bracket and screws e Serial DAC digital to analog converter e Special input resistors installed in CLS200 e Users guide Number of Loops 04 4 loops 08 8 loops 16 16 loops Controller Type 1 Standard EPROM 2 Extruder applications 3 Ramp soak option 4 Enhanced features option includes cascade PV retransmit ratio remote setpoint Terminal Board 0 No terminal board accessory 1 18 terminal block mounted on unit no SCSI cable required 2 50 pin terminal board includes 3 ft SCSI cable Power Supply 0 No power supply 2 120 240V ac 50 60Hz panel mount power supply adapter 5V dc 4A 15V dc 1 2A CE approved SCSI Cables for use with 50 pin terminal board 0 No special SCSI cable 3 ft cable is included with 50 pin terminal board 1 6 ft SCSI cable 2 3 ft right angle SCSI cable 3 6 ft right angle SCSI cable Communications Cables For ElIA TIA 232 communications with computer 0 No communications cable 1 10 ft 3 0 m communications cable DB 9 female bare wire 2 25 ft 7 6 m communications cable DB 9 female bare wire 3 50 ft 15 2 m
87. CLS200 Series User s Guide Watlow 1241 Bundy Boulevard Winona MN 55987 Customer Service Phone 1 800 414 4299 Faxes ace 1 800 445 8992 Technical Support Phone 1 507 494 5656 FaX noana 1 507 452 4507 Email wintechsupport watlow com Part No 0600 3050 2000 Rev A November 2008 Copyright 1998 2003 Watlow Anafaze Information in this manual is subject to change without notice No part of this publi cation 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 Agree ment will be free from defects in material and workmanship for a period of three years from the date of shipment 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 defec tive 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 l
88. G SP MAN AUTO and RAMP SOAK keys on the keypad If the keys are dis abled pressing them 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 Do not set the controller to start from memo ry if it may be unsafe for your process to have outputs on upon power up Set the initial power up state of the control outputs If you choose OFF all loops are initially set to manual mode at 0 output If you choose MEMORY the loops are restored to the control status and output value prior to powering down See In Case of a Power Failure on page 152 for information about how this feature affects ramp soak profiles Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 4 Setup LOOP PROCESS UNITS POWER UP OUTPUT STATUS OFF ALARM _ SETPOINT STATUS OUT Selectable values OFF or MEMORY Process Power Digital Input Controller Address Doc 0600 3050 2000 To enable the thermocouple short detection feature select a digital input 1 to 8 Connect the specified input to a de vice that pulls the input low when the process power is on A short is indicated when the process power is on and the temperature does not rise as expected If the controller determines that there is a thermocouple short it sets the loop to manual mode at the power level set for
89. INT READY SEGMENT EDIT EVENTS EXTERNAL RESET INPUT NUMBER EDIT SEGMENT NUMBER SEGMENT JHF SEG TIME SEGMENT 4 SEG SETPT SEGMENT JHF EDIT SEG EVENTS READY EVENT YES OUTPUT lt BACK See Process Variable Retransmit on page 113 ENTER Y __YES lt BACK SEG JHF EVENT OUTPUT SEG dH EV DOdH ACTIVE STATE SEGMENT JHF EDIT SEG TRGGRS YES gt a BACK SEG H TRIG INPUT NR SEG JHF TRI DIdHE fy ACTIVE STATE SEGMENT JHF SEG TOLERANCE SEGMENT 4 LAST SEGMENT REPEAT CYCLES ENEA TR SEG JHF TR DIdHE 1G lt q Figure 7 2 Setup Ramp Soak Profiles Menu Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 7 Ramp Soak Setup Global Parameters Menu With the Ramp and Soak option an additional menu ap pears on the Setup Global Parameters Menu Ramp Soak Time Base The RAMP SOAK TIME BASE parameter is in the SETUP GLOBAL PARAMETERS menu Use this parameter to set the time base in all your ramp soak profiles When set to HOURS MINS the setpoint is up dated once every minute When set to MINS SECS the set point is updated once every second LOOP PROCESS UNITS RAMP SOAK TIME BASE HOURS MINS ALARM _ SETPOINT STATUS OUT Selectable values HOURS MINS hours
90. L FILTER default value 90 description 91 location 73 233 COOL CONTROL OUTPUT default value 93 description 94 location 73 233 COOL CONTROL PB default value 90 description 91 location 73 233 COOL CONTROL TD default value 90 description 91 location 73 233 COOL CONTROL TI default value 90 description 91 location 73 233 COOL OUTPUT curves 98 description 98 location 73 233 COOL OUTPUT ACTION description 96 location 73 233 COOL OUTPUT CYCLE TIME description 95 location 73 233 Doc 0600 3050 2000 CLS200 Series User s Guide COOL OUTPUT LIMIT description 96 location 73 233 COOL OUTPUT LIMIT TIME description 96 location 73 233 COOL OUTPUT RETRANS PV description 114 location 112 233 COOL OUTPUT TYPE description 94 location 73 233 cool output see control outputs COOL RETRANS MAX INP description 114 location 112 233 COOL RETRANS MAX OUT description 115 location 112 233 COOL RETRANS MIN INP description 114 location 112 233 COOL RETRANS MIN OUT description 114 location 112 233 COOL T C BRK OUT AVG description 97 location 73 233 COPY SETUP FROM PROFILE description 138 location 136 233 CPU watchdog timer 38 203 CRC see cyclic redundancy check C UL see agency compliance current inputs scaling resistors 33 181 184 wiring 33 CYCLE NR 147 cycle time 95 cyclic redundancy check 80 D D O alarm polarity parameter 68 DAC see Dual DAC or Serial DAC data logging 113
91. LE TIME COOL CONTROL TI SDAC HI VALUE HI DEV ALARM OUTPUT STARTUP ALARM DELAY DISP FORMAT COOL CONTROL TD HEAT OUTPUT ACTION LO DEV ALARM TYPE RAMP SOAK TIME BASE INPUT SCALING HI PV COOL CONTROL FILTER HEAT OUTPUT LIMIT LO DEV ALARM OUTPUT KEYBOARD LOCK STATUS INPUT SCALING HI RDG SPREAD HEAT OUTPUT LIMIT TIME LO PROC ALARM SETPT POWER UP OUTPUT STATUS INPUT SCALING LO PV RESTORE PID DIGIN SENSOR FAIL HT OUTPUT LO PROC ALARM TYPE PROCESS POWER DIGIN CONTROLLER ADDRESS INPUT SCALING LO RDG INPUT FILTER COMMUNICATIONS BAUD RATE COMMUNICATIONS PROTOCOL COMMUNICATIONS ERR CHECK AC LINE FREQ DIG OUT POLARITY ON ALARM CLS200 FIRMWARE INFO Additional Enhanced Features Option Menus HEAT T C BRK OUT AVG LO PROC ALARM OUTPUT HEAT OUTPUT ALARM DEADBAND COOL CONTROL OUTPUT ALARM DELAY COOL OUTPUT TYPE COOL OUTPUT CYCLE TIME SDAC PARAMETERS COOL OUTPUT ACTION COOL OUTPUT LIMIT COOL OUTPUT LIMIT TIME SENSOR FAIL CL OUTPUT COOL T C BRK OUT AVG COOL OUTPUT Additional Ramp Soak Option Menus SETUP LOOP PV RETRANSMIT HEAT OUTPUT RETRANS PV SETUP LOOP CASCADE p 119 CASCADE PRIM LOOP SETUP LOOP RATIO CONTROL p 125 RATIO CONTROL MSTR LOOP SETUP LOOP PV RETRANSMIT HEAT OUTPUT RETRANS PV HEAT RETRANS MIN INP CASCADE BASE SP RATIO CONTROL MIN SP SETUP RAMP SOAK PROFILE p 137 EDIT RAMP amp SOAK PROFILE
92. LOOP PV LOOP LOOP RATIO LooP 1 0 PARAMETERS INPUTS PARAMETERS OUTPUTS RETRANSMIT CASCADE CONTROL ALARMS TEST ll YES YES YES l y HEAT OUTPUT CASCADE RATIO CONTROL RETRANS PV PRIM LOOP MSTR LOOP eee Enter 1 9 v HEAT RETRANS CASCADE RATIO CONTROL MIN INP BASE SP MIN SP Enter NONE or NO HEAT RETRANS CASCADE RATIO CONTROL MIN OUT MIN SP MAX SP Enter NONE or NO HEAT RETRANS CASCADE RATIO CONTROL MAX INP MAX SP CTRL RATIO l i HEAT RETRANS CASCADE RATIO CONTROL MAX OUT UT SPAN SP DIFF 112 _ Enter 1 9 COOL OUTPUT RETRANS PV COOL RETRANS MIN INP COOL RETRANS MIN OUT COOL RETRANS MAX INP COOL RETRANS MAX OUT Figure 6 1 Enhanced Features Option Menus Watlow Anafaze CASCADE CL SPAN Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 6 Enhanced Features Process Variable Retransmit The process variable retransmit feature retransmits the process signal of one loop primary via the control output of another loop secondary This signal is linear and pro portional to the engineering units of the primary loop in put Typical uses include data logging to analog recording sys tems and long distance transmission of the primary signal to avoid degradation of the
93. Latched e The unlatched trigger starts continues a segment One Trigger Unlatched e The latched trigger has no effect This parameter appears only if you answered YES to EDIT SEG TRGGRS LOOP PROCESS UNITS A SEGO1 TR1 DI08 TRIG UNLATCHED ALARM SETPOINT STATUS OUT Selectable values LATCHED or UNLATCHED Segment Tolerance Set a positive or negative tolerance value for each segment Tolerance works as shown in Figure 7 3 Positive Tolerance Value Negative Tolerance Value eee of Tolerance Within Tolerance Tolerance Setpoint gt Setting Setpoint 4 w an Setting Within Tolerance Out of Tolerance Figure 7 3 Positive and Negative Tolerances If you enter a positive tolerance the process is out of toler ance when the process variable goes above the setpoint plus the tolerance Doc 0600 3050 2000 Watlow Anafaze 143 Chapter 7 Ramp Soak CLS200 Series User s Guide If you enter a negative tolerance the process goes out of tol erance when the process variable 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 limit See Setpoints and Tolerances for Various Input Types on page 144 Last Segment Specify whether the current segment is the last one in the profile LOOP PROCESS UNITS A SEGMENT 01 LAST
94. Many PC communications ports connect the communica tions common to chassis ground When such a PC is con nected to the controller this can provide a path to ground for current from the process that can enter the controller through a sensor such as a thermocouple This creates a ground loop that can affect communications and other con troller functions To eliminate a ground loop either use an optically isolated communications adapter or take mea sures to ensure that sensors and all other connections to the controller are isolated and not conducting current into the unit Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 2 Installation Power Connections This section covers making the power connections to the CLS200 and connecting the TB50 AAAA AAAA AAAA TB1 to signal 2000 0e 0 000002 TB2 20O DoOod0000000000000 inputs to power oo0000000000000000 COMPONENT SIDE supply eeooegeoejeogooeooq B18 o0000000000000000000000000 to digital e0070D0000000D2000020000000000 outputs XN S Figure 2 12 CLS200 Series Controller with TB18 TB1 to signal inputs O WN D 2 2 D BO o OO000000000000000 o Do 222eegeoog2oo g oooo90o0o0900000000009 supply su p p y O oogoo0p000000000000000000 O Ba e ood world ARARE BERS SRE ESETES O SCSI 2 TB BO S N b c to TB50 BO
95. Menus 136 Setup Global Parameters Menu 137 Ramp Soak Time Base 137 Setup Ramp Soak Profile Menu 137 Edit Ramp Soak Profile 137 Copy Setup From Profile 138 Tolerance Alarm Time 138 Ready Segment Setpoint 138 Ready Segment Edit Events 139 External Reset Input Number 139 Edit Segment Number 140 Segment Time 140 Segment Setpoint 140 Edit Segment Events 141 Edit Segment Triggers 142 Segment Tolerance 143 vi Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Table of Contents Last Segment 144 Repeat Cycles 144 Setpoints and Tolerances for Various Input Types 144 Using Ramp Soak 145 Ramp Soak Displays 146 Assigning a Profile to a Loop 148 Running a Profile 148 Holding a Profile or Continuing from Hold 150 Responding to a Tolerance Alarm 151 Resetting a Profile 151 In Case of a Power Failure 152 8 Tuning and Control 153 Control Algorithms 153 On Off Control 154 Proportional Control 154 Proportional and Integral Control 155 Proportional Integral and Derivative Control 155 Heat and Cool Outputs 156 Control Outputs 157 Output Control Signals 157 Output Filter 158 Reverse and Direct Action 159 Setting Up and Tuning PID Loops 159 Proportional Band PB Settings 159 Integral Settings 160 Derivative Settings 160 General PID Constants by Application 161 Proportional Band Only P 161 Proportional with Integral Pl 161 PI with Derivative PID 161 9 Troubleshooting and Reconfiguring 163 When There is a Pr
96. OINT STATUS OUT Selectable values For linear inputs any value between 99 9 and 999 9 of full scale where 100 corresponds to 60mV and 0 corresponds to OmV For pulse inputs any value between 0 and 2000 HZ The high reading must be greater than the low reading LO RDG Set a low process variable for input scaling purposes The low process variable and the low reading LO RDG together define one of the points on the linear scaling function s con version line Set LO PV to the value you want displayed when the signal is at the level set for the low reading LO RDG LOOP PROCESS UNITS 01 INPUT SCALING LO PV 0 ALARM _ SETPOINT STATUS OUT Selectable values Any value between the minimum pro cess variable and the high process variable for the selected display format See Table 4 9 on page 87 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Low Reading Input Filter Doc 0600 3050 2000 Chapter 4 Setup Enter the input signal level that corresponds to the low process variable LO PV you entered in the previous pa rameter LOOP PROCESS UNITS 01 INPUT SCALING LO RDG 0 0 FS ALARM __ SETPOINT STATUS OUT Selectable values For linear inputs any value between 99 9 and 999 9 percent of full scale where 100 cor responds to 60mV and 0 corresponds to OmV For pulse inputs any value between 0 and 2000 HZ The low reading must be less than the high r
97. P PROCESS UNITS 02 RATIO CONTROL MSTR LOOP 01 ALARM SETPOINT STATUS OUT Assign loop 01 to be the master loop Press ENTER LOOP PROCESS UNITS 02 RATIO CONTROL MIN SP 0 ALARM SETPOINT STATUS OUT Enter the minimum ratio loop setpoint For this example we will use 0 F Press ENTER LOOP PROCESS UNITS 02 RATIO CONTROL MAX SP 300 0 ALARM __ SETPOINT STATUS OUT Enter the maximum ratio loop setpoint For this example we will use 300 0 F as a maximum Press ENTER LOOP PROCESS UNITS 02 RATIO CONTROL CTRL RATIO 1 0 ALARM __ SETPOINT STATUS OUT Enter the control ratio which is the multiple applied to the master process variable In this example the ratio is 1 0 Press ENTER LOOP PROCESS UNITS 02 RATIO CONTROL SP DIFF 0 ALARM SETPOINT STATUS OUT Enter the setpoint differential or offset For this example we have no offset requirement and will use 0 Press ENTER 130 4 Press BACK several times until the normal loop display appears The setpoint of loop 2 will now be equal to the process variable of loop 1 5 To complete the remote analog setpoint setup loop 1 may be configured for outputs and alarms Likewise loop 2 must be configured for inputs outputs and alarms See Chapter 4 Setup for information on loop setup Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Differential Control Chap
98. Problems WatView AnaWin or Anasoft User Written Software NO Key Reset If the controller and serial communications connections seem to be working correctly but you are still not getting the result you expect consult the resources you have avail able for the software program you are using Consult the AnaWin or Anasoft User s Guide for help with the user interface WatView comes with a context sensitive help explaining operation of the software Context sensi tive means that you can press the F1 key to get help related to the part of the program you are using You can request a communications specification from Wat low Anafaze if you want to write your own software Wat low Anafaze will answer technical questions that arise during your software development process but does not otherwise support user developed or third party software in any way Performing a NO key reset returns all controller settings to their defaults All recipes are also cleared To perform a NO key reset 1 Make a record of the controller s settings 2 Turn off power to the unit 3 Press and hold the NO key on the keypad 4 Turn on power to the controller still holding the NO key 5 When prompted RESET WITH DEFAULTS release the NO key and press the YES key 6 Ifyou do not see the RESET WITH DEFAULTS prompt or do not get a chance to press YES repeat the proce dure 7 Restore the controller settings If you have a stand alone
99. RP8 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 9 Troubleshooting and Reconfiguring CLS204 and CLS208 RTDs and Thermistors For each RTD or thermistor input on a CLS204 or CLS208 controller you must install three resistors RA RB and RC The resistance must be correct for the expected input range RA and RB are a matched pair of resistors Install them in the resistor pack RP locations as shown in the il lustration below Table 9 10 Resistor Values for CLS204 208 RTD and Thermistor Inputs Resistor Values Input RA RB RC RTD1 10 0 kQ 80 Q RTD2 25 0 kQ 100 Q Resistor tolerances RA RB matched to 0 02 2 ppm C and absolute tolerance is 0 1 10 ppm C RC accurate to 0 05 RP fen RA RB Table 9 11 Resistor Locations for CLS204 208 RTD and Thermistor Inputs Resistor Locations Loop RA RB RC 1 RPI R57 2 RP2 R55 3 RP3 R53 4 RP4 R51 5 RP5 R49 6 RP6 R47 7 RP7 R45 8 RP8 R43 Doc 0600 3050 2000 Watlow Anafaze 183 Chapter 9 Troubleshooting and Reconfiguring CLS200 Series User s Guide CLS216 Input Circuit CLS216 Current Inputs 184 The CLS216 can accept single ended thermocouple mV dc V dc and mA dc inputs Unless ordered with special inputs the controller accepts only signals within the standard range of 10 to 6 0mV dc To accommodate other signals the input
100. S to change the mode if the mode is MAN press NO to set the output power Doc 0600 3050 2000 Watlow Anafaze 61 Chapter 3 Using the CLS200 Manual Output Levels Autotuning a Loop Prerequisites 62 CLS200 Series User s Guide Go to the next subsection Manual Output Levels press NO if in AUTO to cancel and remain in AUTO mode 4 Select a mode by pressing the up or down key YES or NO to scroll through the modes 5 Press ENTER to make the mode change press BACK to return to the single loop display without saving the new mode setting 6 Ifyou set the loop to manual you are prompted for the output power Go to Manual Output Levels below If the loop to is set to manual control the controller prompts for output levels for the enabled control outputs Use this menu to set the manual heat and cool output lev els You should see a display like this LOOP PROCESS UNITS 01 SET HEAT OUTPUT 90 ALARM SETPOINT STATUS OUT 1 Press YES to change the output power level If the heat outputs are enabled you will be able to change the heat output power level If only the cool outputs are enabled you will be able to change only the cool output power level _or Press NO to go to the cool output if available and then press YES to change the cool output 2 Press up or down YES or NO to select a new output power level 3 Press ENTER to store your changes press BACK to discard your changes and ret
101. S200 Series User s Guide Table 6 5 Application Example Setting Up Differential Control Display User Input LOOP PROCESS UNITS SETUP LOOP 02 Press YES to setup the ratio control parameters for loop 2 RATIO CONTROL ALARM _ SETPOINT STATUS OUT LOOP PROCESS UNITS 02 RATIO CONTROL MSTR LOOP 01 ALARM SETPOINT STATUS OUT Assign loop 01 to be the master loop Press ENTER LOOP PROCESS UNITS 02 RATIO CONTROL MIN SP 300 0 ALARM SETPOINT STATUS OUT Enter the minimum ratio loop setpoint For this example we will use 300 0 F Press ENTER 02 RATIO CONTROL MAX SP 400 0 ALARM __ SETPOINT STATUS OUT Enter the maximum ratio loop setpoint For this example we will use 400 0 F Press ENTER LOOP PROCESS UNITS 02 RATIO CONTROL CTRL RATIO 1 0 ALARM _ SETPOINT STATUS OUT Enter the control ratio which is the multiple applied to the master process variable In this example the ratio is 1 0 Press ENTER LOOP PROCESS UNITS 02 RATIO CONTROL SP DIFF 50 Enter the setpoint differential or offset For this example we have an offset of 50 Press ENTER ALARM SETPOINT STATUS OUT 3 Press BACK several times until the normal loop display appears The setpoint of loop 2 will now be equal to process variable of loop 1 plus 50 F 4 To complete the differential control setup loop 1 and loop 2 must be configured for inputs outputs an
102. SEGMENT NO ALARM SETPOINT STATUS OUT Selectable values NO or YES Repeat Cycles Set the number of times you want a profile to repeat or cycle The profile returns to START mode after completing the number of cycles specified here LOOP PROCESS UNITS A REPEAT CYCLES 1 ALARM SETPOINT STATUS OUT Selectable values 1 to 99 or C continuous cycling Setpoints and Tolerances for Various Input Types Setpoints and tolerances are set in segments before the profile is assigned to a particular loop When the profile is used with a loop the INPUT TYPE and DISP FORMATS set tings are applied to the following parameters e Ready setpoint e Segment setpoint e Segment tolerance Refer to Table 7 3 to determine how these parameters are affected for the various INPUT TYPE and DISP FORMAT settings 144 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Table 7 3 Chapter 7 Ramp Soak Display Formats Input Type Display Format Effect on Parameter Thermocouples and RTDs N A No decimal shift 999 to 3000 No decimal shift 9999 to 30000 Setting multiplied by 10 999 9 to 3000 0 No decimal shift additional tenth in display Linear 99 99 to 300 00 Settings divided by 10 9 999 to 30 000 Settings divided by 100 0 9999 to 3 0000 Using Ramp Soak Settings divided by 1 000 This section explains how to assign a profile to a loop how t
103. SETUP FROM JOB 1 SAVE SETUP TO JOB 1 JOB SELECT DIG INPUTS NONE JOB SEL DIG INS ACTIVE LOW OUTPUT OVERRIDE DIG INPUT NONE OVERRIDE DIG IN ACTIVE LOW STARTUP ALARM DELAY 0 MINS RAMP SOAK TIME BASE HOURS MINS KEYBOARD LOCK STATUS OFF POWER UP OUTPUT STATUS OFF PROCESS POWER DIGIN NONE CONTROLLER ADDRESS 1 COMMUNICATIONS BAUD RATE 9600 COMMUNICATIONS PROTOCOL ANA COMMUNICATIONS ERR CHECK BCC AC LINE FREQ 60 HERTZ DIG OUT POLARITY ON ALARM LOW CLS200 model no fi mware rev The RAMP SOAK TIME BASE parameter appears only if the ramp soak feature is installed 74 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Load Setup From Job NOTE Save Setup to Job Doc 0600 3050 2000 Chapter 4 Setup Current settings are overwritten when you select a job from memory Save your current settings to another job number if you want to keep them Load any one of eight jobs saved in battery backed RAM LOOP PROCESS UNITS LOAD SETUP FROM JOB 1 ALARM SETPOINT STATUS OUT Selectable values 1 to 8 The following parameters are loaded for each loop 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 function off alarm control setpoints high low process setpoints high low deviation setpoints and deadband settings
104. T Selectable values CURVE 1 CURVE 2 or LINEAR Refer to Figure 4 4 100 80 60 Actual Output 40 20 PID Calculation Figure 4 4 Linear and Nonlinear Outputs If curve 1 or 2 is selected a PID calculation results in a low er actual output level than the linear output requires One of the nonlinear curves may be used when the response of the system to the output device is nonlinear 98 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 4 Setup Setup Loop Alarms Menu Use the SETUP LOOP ALARMS menu to set e High and low process and deviation alarm limits e Alarm outputs e Alarm control behavior e Alarm deadband e Alarm delay LOOP PROCESS UNITS SETUP LOOP 01 ALARMS ALARM _ SETPOINT STATUS OUT Table 4 13 shows the parameters available in the SETUP LOOP ALARMS menu Table 4 13 Setup Loop Alarms Parameter Ree HI PROC ALARM SETPT 1000 HI PROC ALARM TYPE OFF HI PROC ALARM OUTPUT NONE DEV ALARM VALUE 5 HI DEV ALARM TYPE OFF HI DEV ALARM OUTPUT NONE LO DEV ALARM TYPE OFF LO DEV ALARM OUTPUT NONE LO PROC ALARM SETPT 0 LO PROC ALARM TYPE OFF LO PROC ALARM OUTPUT NONE ALARM DEADBAND 2 ALARM DELAY 0 SECONDS Doc 0600 3050 2000 Watlow Anafaze 99 Chapter 4 Setup CLS200 Series User s Guide High Process Alarm Setpoint Set the value at which the high process alarm activates
105. T default value 93 description 96 location 73 233 HEAT OUTPUT LIMIT TIME default value 93 description 96 location 73 233 HEAT OUTPUT RETRANS PV description 114 location 112 233 HEAT OUTPUT TYPE default value 93 description 94 location 73 233 heat output see control outputs HEAT RETRANS MAX INP description 114 location 112 233 HEAT RETRANS MAX OUT description 115 location 112 233 HEAT RETRANS MIN INP description 114 location 112 233 HEAT RETRANS MIN OUT description 114 location 112 233 HEAT T C BRK OUT AVG default value 93 description 97 location 73 233 HEAT COOL SPREAD location 233 Heat Cool Thermocouple Break Out 65 HI DEV ALARM OUTPUT default value 99 description 101 location 73 233 HI DEV ALARM TYPE default value 99 description 101 location 73 233 HI PROC ALARM OUTPUT default value 99 description 100 location 73 233 HI PROC ALARM SETPT default value 99 description 100 location 73 233 HI PROC ALARM TYPE default value 99 description 100 location 73 233 high deviation alarm see process alarms HP alarm code 164 humidity controller 194 Dual DAC 207 power supply 205 Serial DAC 209 hysteresis alarm 68 hysteresis see spread Doc 0600 3050 2000 Index INPUT FILTER default value 82 description 89 location 73 233 setting before autotuning 64 input power see power supply INPUT PULSE SAMPLE TIME default value 82 description 85 location 73 233 INPUT READING OFFSET default valu
106. TUP LOOP OUTPUTS menu is set to ON then the con troller sets the output power to an average of the re cent output e IftheHEAT COOL T C BRK OUT AVG parameter is set to OFF then the controller sets the output to the level indicated by the SENSOR FAIL HT CL OUTPUT pa rameter in the SETUP LOOP OUTPUTS menu The thermocouple reversed alarm occurs if the tempera ture goes in the opposite direction and to the opposite side of ambient temperature than expected for example a loop is heating and the measured temperature drops below the ambient temperature The thermocouple reversed alarm is disabled by default To enable this alarm set the REVERSED T C DETECT param eter in the SETUP LOOP INPUTS menu to ON It may be dis abled if false alarms occur in your application Watlow Anafaze 65 Chapter 3 Using the CLS200 Thermocouple Short Alarm CLS200 Series User s Guide The thermocouple short alarm occurs if the process power is on and the temperature does not rise or fall as expected To enable the thermocouple short alarm you must do the following e Choose a digital input for the PROCESS POWER DIGIN parameter in the SETUP GLOBAL PARAMETERS menu e Connect the digital input to a device that connects the input to controller common when the process power is on RTD Open or RTD Shorted Alarm The RTD open alarm occurs if the controller detects that the positive or negative RTD lead is broken or disconnected The RTD sho
107. TUS OUT Selectable values MOD Modbus RTU ANA Anafaze AB Allen Bradley Communications Error Checking 80 NOTE If you selected the ANA or AB communications protocol set the data check algorithm for CLS200 communications CRC Cyclic Redundancy Check is a more secure error checking algorithm than BCC but it requires more calcu lation time and slows communications BCC Block Check Character ensures a high degree of communications integ rity We recommend BCC unless your application requires CRC LOOP PROCESS UNITS COMMUNICATIONS ERR CHECK BCC ALARM _ SETPOINT STATUS OUT Selectable values BCC or CRC If you are using Anasoft configure it with ANAINSTL for the same error checking meth od and baud rate set in the controller Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide AC Line Frequency Chapter 4 Setup Specify the ac line frequency Since the controller reduces the effect of power line noise on the analog measurement by integrating the signal over the period of the ac line frequen cy the controller must know the frequency of power in use You must switch power to the controller off then back on to make a change to this parameter take effect LOOP PROCESS UNITS AC LINE FREQ 60 HERTZ ALARM _ SETPOINT STATUS OUT Selectable values 50 or 60 Hz Digital Output Polarity on Alarm EPROM Information Controller Model Firmware Version
108. V dc They cannot source current to a load TB50 or TB18 External 5V dc Power Supply Loads Digital Output 1 Do not connect Digital Output 2 to earth ground or equipment ground TB50 or TB18 Using Internal Power Supply Control Common Loads Digital Output 1 Digital Output 2 Using External Power Supply Vv Figure 2 22 Digital Output Wiring Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Configuring Outputs Chapter 2 Installation Keep in mind the following points as you choose outputs for control and alarms e You can enable or disable the control outputs The de fault setting is heat outputs enabled cool outputs dis abled e You can program each control output individually for on off time proportioning distributed zero crossing or Serial DAC control e You can individually program each control output for direct or reverse action e Alarm outputs other than the global alarm are non latching e Alarms can be suppressed during process start up and for preprogrammed durations See Alarm Delay on page 103 e Alarm outputs can be configured as a group as normal ly on low or normally off high See Digital Output Polarity on Alarm on page 81 Control and Alarm Output Connections NOTE Doc 0600 3050 2000 Typically control and alarm outputs use external optically isolated solid state relays SSR
109. V dc Sensor Situation A flow sensor connected to the controller measures the flow in a pipe The sensor generates a 0 to 5V signal The sen sor s output depends on its installation Independent cali bration measurements of the flow in the pipe indicate that the sensor generates 0 5V at three gallons per minute GPM and 4 75V at 65 GPM The calibration instruments are accurate to within 1 gallon per minute Setup The sensor is connected to a loop input set up with a resis tor voltage divider network producing 60mV at 5V The INPUT TYPE for the loop is set to LINEAR The calibrat ing instrument is precise to 1 GPM so the DISP FORMAT is set to 999 to 3000 This table shows the input readings and the percentage calculation from the 60mV full scale input Table 10 3 Input Readings and Calculations ee Sensor Reading Percent of Displayed put Full Scale FS 65 GPM 4 75 4 75V 5 00V x 100 95 FS 3 GPM 0 5 0 5V 5 00V x 100 10 FS Table 10 4 Scaling Values Parameter Prompt Value High Process Variable HIGH PV 65 GPM High Sensor Reading HIGH RDG 95 0 FS Low Process Variable LO PV 0 0 GPM Low Sensor Reading LO RDG 10 0 FS Doc 0600 3050 2000 Watlow Anafaze 191 Chapter 10 Linear Scaling Examples CLS200 Series User s Guide Example 3 A Pulse Encoder Situation A pulse encoder which measures the movement of a convey or is connected to the con
110. Win and Watview works with all tested converters without an external 232 in put Doc 0600 3050 2000 Watlow Anafaze 49 Chapter 2 Installation CLS200 Series User s Guide 50 Watlow Anafaze Doc 0600 3050 2000 Using the CLS200 This chapter explains how to use the keypad and display to operate the controller Figure 3 1 shows the operator menus and displays accessible from the front panel To change global parameters loop inputs control parame ters outputs and alarms using the setup menus see Chap ter 4 Setup BACK Power on BACK j BACK Bar Graph Single Loop Job gt Display gt Display gt Display ENTER A Any ENTER Any scHne Kee A Scanning Scanning Bar Graph Single Loop Secon Display Display RAMP MAN SOAK BASN AUTO BACK y Y ENTER Manual Manual Coa utomatic Ramp Soak or Autot ne Percentage Mone BACK Gode only Figure 3 1 Operator Displays Doc 0600 3050 2000 Watlow Anafaze 51 Chapter 3 Using the CLS200 CLS200 Series User s Guide Front Panel The CLS200 front panel provides a convenient interface with the controller You can use the front panel keys to pro gram and operate the CLS200 RAMP WATLOW ANAFAZE CLS200 SOAK e Assigns and monitors profile PROCESS UNITS ALARM ACK e Acknowledges alarms MAN AUTO a e Changes loop output control from automa
111. a CLS204 or CLS208 controller with scaling resistors e Automatic Scaling for Linear Analog Inputs The CLS200 series automatically scales linear inputs used with industrial process sensors Enter two points and all input values are automatically scaled in your units Scaling resistors must be installed e Dual Outputs The CLS200 series includes both heat and cool control outputs for each loop Independent control parameters are provided for each output e Independently Selectable Control and Output Modes You can set each control output to on off time proportioning Serial DAC digital to analog convert er or distributed zero crossing mode Set up to two outputs per loop for on off P PI or PID control with re verse or direct action e Control Outputs Set high low deviation and high low process limits to operate digital outputs as on off control functions or alarms e Flexible Alarm Outputs Independently set high low process alarms and a high low deviation band alarm for each loop Alarms can activate a digital out put by themselves or they can be grouped with other alarms to activate an output e Global Alarm Output When any alarm is triggered the global alarm output is also triggered and it stays on until you acknowledge it Watlow Anafaze 3 Chapter 1 System Overview CLS200 Series User s Guide CPU Watchdog The CLS200 series CPU watchdog timer output notifies you of system failure Use it to hold a re
112. able 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 C 5 9 CF 32 Failed Sensor Alarm Warns that an input sensor no longer produces a valid signal For example when there are thermocouple breaks infrared problems or resistance temperature detector RTD open or short failures 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 unrealistically 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 change in the response of the heat or cool output 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 Watlow Anafaze 215 Glossary 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 electri cal circuit Gain can also refer to th
113. ad or use a load that can be visually verified such as a light bulb 1 Turn on power to the controller 2 Measure the 5V dc supply at the TB18 or TB50 The voltage should be 4 75 to 5 25V de a Connect the voltmeter s common lead to the TB18 screw terminal 2 or TB50 screw terminal 3 b Connect the voltmeter s positive lead to the TB18 or TB50 screw terminal 1 Outputs 1 Turn off power to the controller 2 Disconnect any process output wiring on the output to be tested 3 Connect a 500 Q to 100 kQ resistor between the 5V terminal TB18 or TB50 screw terminal 1 and the output terminal you want to test 4 Connect the voltmeter s common lead to the output terminal and connect the voltmeter s positive lead to the 5V terminal Restore power to the controller If you are testing a PID control output use the MAN AUTO key to turn the output on 100 and off 0 When the output is off the output voltage should be less than 1V When the output is on the output volt age should be between 3 75 and 5 25V 7 Ifyou are testing a digital output not used for control use the MANUAL I 0 TEST menu to turn the output on and off See Manual I O Test on page 103 Turn off power to the controller 2 Disconnect any system wiring from the input to be Doc 0600 3050 2000 tested Watlow Anafaze 173 Chapter 9 Troubleshooting and Reconfiguring CLS200 Series User s Guide Restore power to t
114. age signals outside the standard range milliamp cur rent signals or RTDs resistors are added or replaced to scale the signals to the standard range These resistor can be installed by Watlow Anafaze or by a qualified electronics technician using scaling resistors supplied by Watlow Anafaze Figure 9 6 shows the input circuit for one differential ana log input See CLS204 and CLS208 Current Inputs on page 181 through CLS204 and CLS208 RTDs and Thermistors on page 183 for specific instructions and resistor values for voltage current and RTD inputs When adding your own scaling resistors to the controller for voltage and RTD inputs you will have to carefully remove one of the RC resistors in order to install the resistor listed in the table Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 9 Troubleshooting and Reconfiguring RC Voltage IN e v gt Internal RP 5V dc To CLS200 Analog Reference s RD Circuitry Input Terminal RC RTD IN e VVV kd gt Com e V Figure 9 6 CLS204 and CLS208 Input Circuit CLS204 and CLS208 Current Inputs For each current input on a CLS204 or CLS208 controller you must install a resistor The value of the resistor must be correct for the expected input range Install the resistor in the listed resistor pack RP location Note the resistor pack locations have three through holes Install the resis tor as shown in the illustration below
115. al 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 in which the output on off state is calculated for every ac line cycle Power is switched at the zero cross which reduces electrical noise See also Zero Cross 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 EIA TIA See Serial Communications Electrical Noise See Noise Electromagnetic Interference EMI Electrical and magnetic noise imposed on a system There are many possible causes such as switching ac power on inside the sine wave EMI can interfere with the operation of con trols and other devices Electrical Mechanical Relays See Relay Electromechanical Emissivity The ratio of radiation emitted from a surface compared to radiation emitted from a black Doc 0600 3050 2000 Glossary body at the same temperature Engineering Units Selectable units of measure such as degrees Celsius 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 Eras
116. alid Doc 0600 3050 2000 Watlow Anafaze 59 Chapter 3 Using the CLS200 System Alarms Job Display 60 CLS200 Series User s Guide When a system alarm occurs the global alarm output turns on and an alarm message appears on the display The mes sage continues to be displayed until the error condition is removed and the alarm is acknowledged The CLS200 can display the following system alarms e BATTERY DEAD See Battery Dead on page 168 e LOW POWER See Low Power on page 168 e AW See Ambient Warning on page 168 e H W FAILURE AMBIENT See H W Ambient Failure on page 169 e H W FAILURE GAIN See H W Gain or Offset Failure on page 170 H W FAILURE OFFSET See H W Gain or Offset Failure on page 170 The job display appears only if e You have enabled JOB SELECT DIG INPUTS See Load Setup From Job on page 75 and e You have selected a job from the job load menu After loading a job using the LOAD SETUP FROM JOB menu the job display shows you the following screen LOOP PROCESS UNITS JOB 3 RUNNING ALARM SETPOINT STATUS OUT If parameters are modified while the job is running this screen will display LOOP PROCESS UNITS JOB 3 RUNNING DATA MODIFIED ALARM _ SETPOINT STATUS OUT If the job was loaded using digital inputs the display shows LOOP PROCESS UNITS JOB 3 RUNNING REMOTELY LOADED ALARM _ SETPOINT STATUS OUT Watlow Anafaze Doc 0600 3
117. ameters in the SETUP LOOP CONTROL PARAMS menu Furthermore a unique set of control de faults are asserted whenever the COOL OUTPUT parame ter on the SETUP LOOP OUTPUTS menu is changed Table 5 1 through Table 5 3 on page 109 list the default pa rameter settings for each cool output curve Changing the cool output curve parameter will change control parameter settings to de faults for that particular cool output curve Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 5 Extruder Table 5 1 Default Control Parameters for Fan Cool Output Parameter Default Value HEAT CONTROL PB HEAT CONTROL TI 50 for J type thermocouple depends on Input Type setting 500 sec repeat HEAT CONTROL TD 125 sec HEAT CONTROL FILTER 6 COOL CONTROL PB COOL CONTROL TI COOL CONTROL TD ene COOL CONTROL FILTER 4 10 for J type thermocouple depends on Input Type setting 0 sec repeat Table 5 2 Default Control Parameters for Oil Cool Output Parameter Default Value HEAT CONTROL PB HEAT CONTROL TI 50 for J type thermocouple depends on Input Type setting 500 sec repeat HEAT CONTROL TD 425 sec HEAT CONTROL FILTER 6 COOL CONTROL PB COOL CONTROL TI COOL CONTROL TD A COOL CONTROL FILTER 35 for J type thermocouple depends on Input Type setting 300 sec repeat Table 5 3 Default Control Parameters for H2O Cool Output Parameter Default Value HEAT
118. and con troller must be set the same CRC or BCC e Hardware protocol PC and controller must use the same protocol or a converter must be used The con troller is typically configured for EIA TIA 232 when it is shipped See Changing Communications on page 179 to change between EJA TIA 232 and ETA TIA 485 To communicate with more than one controller or when more than 50 feet of cable is required use EIA TIA 485 Even for a single controller you may use EIA TIA 485 and an optically isolating converter to eliminate ground loops e Converter Make sure that the EIA TIA 232 to 485 converter is powered configured and wired correctly e Cables Check continuity by placing a resistor across each pair of wires and measuring the resistance with an ohmmeter at the other end Many PC communications ports have their common wires connected to chassis ground Once connected to the control ler this can provide a path to ground for current from the process that can enter the controller through a sensor such as a thermocouple This creates a ground loop that can af fect communications and other controller functions To eliminate a ground loop either use an optically isolated communications adapter or take measures to ensure that sensors and all other connections to the controller are iso lated and not conducting current into the unit Watlow Anafaze 175 Chapter 9 Troubleshooting and Reconfiguring CLS200 Series User s Guide Software
119. annel you are testing Doc 0600 3050 2000 Watlow Anafaze 171 Chapter 9 Troubleshooting and Reconfiguring CLS200 Series User s Guide Earth Grounding Checking Control Outputs 172 If you suspect a problem with the ac ground or a ground loop e Measure for ac voltage between ac neutral and panel chassis ground If ac voltage above 2V ac is ob served then there may be a problem with the ac power wiring This should be corrected per local electrical codes e With ac power on measure for ac voltage that may be present between control panels chassis grounds Any ac voltage above 2V ac may indicate problems with the ac ground circuit e Check for ac voltage on thermocouples with the heater power on A control output providing power to the heaters will increase the ac voltage if there is heater leakage and an improper grounding circuit Measure from either positive or negative thermocouple lead to ac ground AC voltage above 2V ac may indicate the ground lead is not connected to the CLS200 TB2 ground terminal If the above tests indicate proper ac grounding but the con troller is indicating incorrect temperatures or process read ings e Verify which type of sensor is installed and that the INPUT TYPE parameter is set accordingly e Foran RTD or linear voltage or current input check that the correct input scaling resistors are installed page 180 and check the input scaling parameter set tings page 86 e If
120. ar acter D DAC See Digital to Analog Converter Data Logging A method of recording a process variable over a period of time Used to review process perfor mance DC See Direct Current 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 Opera tors select the deadband It is usually above the heating proportional 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 pro cess and compensates to minimize overshoot and undershoot 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 vari able PV that decreases over the time of the derivative TD The TD is in units of seconds Deutsche Industrial Norms DIN Doc 0600 3050 2000 CLS200 Series User s Guide 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 sig n
121. ar Graph Display The ramp soak mode is also displayed on the bar graph dis play Symbol PROCESS UNITS L lt an lt 08 ROMA STATUS OUT Loop Number SETPOINT Ramp Soak Mode Table 7 5 describes the control status symbols used for loops with ramp soak profiles assigned 146 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Time Remaining Display Cycle Number Display Set Mode Display Doc 0600 3050 2000 Loop Number Chapter 7 Ramp Soak Table 7 5 Ramp Soak Control Status Symbols Seal Description R A profile is unning H A profile is holding S A profile is in ready stat 0 A profile is in tole ance hold W A profile is in t igger wait From the single loop display press the RAMP SOAK key once This screen shows how much time remains to complete the profile All screens that are accessed by pressing RAMP SOAK key have the same information on the top line Profile Letter Number of Segments Current Segment in Profile Ramp Soak Mode 04 A SEG10 20 R TIM REM 32 11 ALARM SETPOINT OUT STATUS Time Remaining From the single loop display press the RAMP SOAK key twice This screen displays the number of times the profile has run out of the total number of cycles In this example the ramp soak profile is on the 10th of 15 cycles to be per formed LOOP PROCESS UNITS 04 A SEG10 20 R CYCLE NR 10
122. ariable CLS200 Series User s Guide On off control is the simplest way to control a process The controller turns an output on or off when the process vari able reaches limits around the desired setpoint This limit is adjustable Watlow Anafaze controllers use an adjust able spread For example if the setpoint is 1 000 F and the spread is 20 F the heat output switches on when the process vari able drops below 980 F and off when the process rises above 1 000 F A process using on off control cycles around the setpoint Figure 8 1 illustrates this example Heat Off Heat Off ONS PS ENG Set A Setpoint a 2 1 000 F Setpoint Spread On ee Oa oa 980 F I I I l I I Off l Figure 8 1 On Off Control Proportional control eliminates cycling by increasing or de creasing the output proportionally with the process vari able s deviation from the setpoint The magnitude of proportional response is defined by the proportional band Outside this band the output is either 100 or 0 Within the proportional band the output pow er is proportional to the process variable s deviation from the setpoint For example if the setpoint is 1 000 F and the proportional band is 20 F the output is e 0 when the process variable is 1 000 F or above 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 However a proc
123. arm occurs or when the OUTPUT OVERRIDE DIG INPUT page 77 becomes active on a loop that is in automatic control that loop goes to manual con trol at the percent power output set here LOOP PROCESS UNITS 01 SENSOR FAIL HT OUTPUT 0 ALARM SETPOINT STATUS OUT Selectable values 0 to 100 When a sensor fails or the override input is detected both the heat and cool outputs are set to their fail settings In most applications SENSOR FAIL HT OUTPUT and SENSOR FAIL CL OUTPUT should be set to 0 Do not rely solely on the sensor fail alarm to adjust the output in the event of a sensor fail ure If the loop is in manual control when a failed sensor alarm occurs the output is not adjusted Install independent external safety devices that will shut down the system if a failure occurs Heat or Cool Thermocouple Break Output Average Doc 0600 3050 2000 If you set this parameter to ON and a thermocouple break occurs a loop set to automatic control status will go to man ual mode at a percentage equal to the average output prior to the break LOOP PROCESS UNITS 01 HEAT T C BRK OUT AVG OFF ALARM SETPOINT STATUS OUT Selectable range ON or OFF Watlow Anafaze 97 Chapter 4 Setup CLS200 Series User s Guide Heat or Cool Linearity Select an output curve For a nonlinear process select CURVE lor CURVE 2 LOOP PROCESS UNITS 01 HEAT OUTPUT LINEAR ALARM SETPOINT STATUS OU
124. arms or ramp soak events 2 Tf you install a Watlow Anafaze Serial DAC the controller uses digital output 34 terminal 10 for a clock line You cannot use out put 34 for anything else when you have a Serial DAC installed 42 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Analog Outputs Wiring the Dual DAC Doc 0600 3050 2000 Chapter 2 Installation Analog outputs can be provided by using a Dual DAC or Se rial DAC module to convert the open collector outputs from the controller Use multicolored stranded shielded cable for analog outputs Analog outputs generally use a twisted pair wiring The following sections describe how to connect the Dual DAC and Serial DAC modules to power the con troller outputs and the load A Dual DAC module includes two identical circuits Each can convert a distributed zero cross DZC signal from the controller to a voltage or current signal Watlow Anafaze strongly recommends using a power supply separate from the controller supply to power the Dual DAC Using a sep arate power supply isolates the controller s digital logic cir cuits and analog measurement circuits from the frequently noisy devices that take the analog signal from the Dual DAC Several Dual DAC modules may be powered by one power supply Consult the Specifications chapter for the Dual DAC s power requirements Also note in the specifications that the Dual DAC does not carry the same industry ap provals
125. arts Up to 20 segments per profile The controller can store up to 17 profiles each with up to 20 segments Multiple profiles run independently Each loop can run a different profile or the same profile can be run independently on more than one loop Up to two triggers per segment Triggers are digi tal inputs that can be programmed to start and hold segments based on the trigger s digital state You can use any one of the eight digital inputs for triggers You can also use the same trigger for more than one seg ment or more than one profile Up to four events per segment Digital outputs con trolled by the ramp soak profile Events outputs are set at the end of a segment You can use any of the dig ital outputs that are not used for control or for the Se rial DAC clock Tolerance hold ensures time at temperature Set a limit on how far the process variable can vary above or below setpoint The profile clock only runs when the process variable is within the limit Tolerance alarm indicates process not tracking setpoint Set a maximum amount of time for the tol erance hold to wait for a process deviation before noti fying the operator The operator can acknowledge the alarm and proceed if desired User configurable time base Program profiles to run for hours and minutes or for minutes and seconds Repeatable profiles Set any profile to repeat from 1 to 99 times or continuously Fast setup for similar profiles Set up one
126. asuring the load s temperature e The deviation limit is too narrow e The system is so poorly tuned that the temperature is cycling about setpoint by more than the alarm limit NOTE In cooling applications similar issues cause high process and high deviation alarms In a heating application a high process alarm or high devi ation alarm may indicate one of the following e The setpoint and high process limit have been lowered and the system has not had time to cool to within the new alarm limit e The control status is set to manual and the heat out put is greater than 0 e The load has decreased such that the temperature has risen e The heater is full on due to a hardware failure e The system is so poorly tuned that the temperature is cycling about setpoint by more than the alarm limit Resetting a Process or Deviation Alarm Your response to an alarm depends upon the alarm type setting as explained in Table 9 2 below Table 92 Operator Response to Alarms Alarm Type Operator Response The operator does not need to do anything Control The alarm clears automatically when the pro cess variable returns within limits Acknowledge the alarm by pressing ALARM ACK on the controller or by using software Alarm The alarm clears after the process variable returns within the limits and the operator has acknowledged it Doc 0600 3050 2000 Watlow Anafaze 165 Chapter 9 Troubleshooting and Reconfigur
127. ately See Figure 6 2 100 Maximum Q Output D A a Minimum Output 7 ben i 0 Minimum Maximum Input Input Input Process Variable Figure 6 2 Linear Scaling of Process Variable for Retransmit Enter the output value 0 to 100 which corresponds to the maximum input LOOP PROCESS UNITS 02 HEAT RETRANS MAX OUT 100 ALARM SETPOINT STATUS OUT The output will never go above the this maximum output percentage regardless of how high the process variable goes Selectable values 0 to 100 Process Variable Retransmit Example Data Logging Doc 0600 3050 2000 The CLS200 controls the temperature of a furnace The thermocouple in one of the zones is connected to the con troller and is used for closed loop PID control An analog re corder data logging system is also in place and a recording of the process temperature is required The recorder input is a linear 4 to 20 mA dc signal representing a process variable range of 0 to 1000 F Watlow Anafaze 115 Chapter 6 Enhanced Features 116 CLS200 Series User s Guide Loop 1 Input Process Variable Loop 1 PID Output a Loop 2 PID Output F urnace ciei Heater MWA Serial DAC Power Controller To Data Logger Figure 6 3 Application Using Process Vari able Retransmit To set up this application you would do the following 1 First set up the standard co
128. ational Do not exceed 5V dc 10 mA dc rating for the watchdog output The output is low on when the microprocessor is operating when it stops operating the output goes high off Figure 2 25 and Figure 2 26 show the recommended circuit for the watchdog timer output for the TB50 and the TB18 TB50 5V dc Terminal 1 SSR Watchdog Timer Terminal 6 Figure 2 25 TB50 Watchdog Timer Output TB18 SV dc x Terminal 1 SSR Watchdog Timer Terminal 3 Figure 2 26 TB18 Watchdog Timer Output All digital inputs are transistor transistor logic TTL level inputs referenced to control common and the internal 5V power supply of the CLS200 When an input is connected to the controller common the input is considered on Otherwise the input is considered Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide External Switching Devices Chapter 2 Installation off Most features that use the digital inputs can be user configured to activate when an input is either on or off In the off state internal 10 k resistors pull the digital in puts high to 5V dc with respect to the controller com mon Table 2 4 Digital Inputs States and Values Stored in the Controller State Value Description Off High Open circuit On Low Digital Input connected to controller common To ensure that the inputs are reliably switched
129. atlow Anafaze divide analog input voltages such that the controller sees a 10 to 60 mV signal on the loop Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide CLS204 and CLS208 CH IN e Chapter 2 Installation Device with CH IN e Voltage Output CLS216 CH IN Device with Com e Voltage Output Figure 2 18 Linear Voltage Signal Connections Current Input Connections This input type requires scaling resistors Special input re sistors installed at Watlow Anafaze for analog current sig nals are such that the controller sees a 10 to 60 mV signal across its inputs for the loop CLS204 and CLS208 CH IN Device with Current CHIN e CLS216 e Output CH IN e Device with Current Com Ref Com e Figure 2 19 Linear Current Signal Connections e Output NOTE When mixing current inputs with low voltage inputs thermocouples or voltage inputs lt 1V to a CLS216 connect the current signal to the IN and Ref Com terminals When no low voltage sensors are used connect current in puts to the IN and Com terminals on TB1 For all inputs to a CLS204 or CLS208 con nect the sensors to the IN and Com termi nals Doc 0600 3050 2000 Watlow Anafaze Chapter 2 Installation Pulse Input Connections 34 NOTE CLS200 Series User s Guide The CLS200 ca
130. ble signal degrada tion Watlow Anafaze 219 Glossary U Upscale Break Protection A form of break detection for burned out ther mocouples Signals the operator that the ther mocouple 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 voltage or electromotive force EMF See also Voltage Voltage V The difference in electrical potential between two points in a circuit It s the push or pres sure 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 current 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 220 Watlow Anafaze CLS200 Series User s Guide Doc 0600 3050 2000 CLS200 Series User s Guide Index A A control status symbol 56 AC LINE FREQ default value 74 description 81 location 73 233 agency compliance controller 193 power supply 205 Serial DAC 210 ALARM ACK key acknowledging alarms 59 60 description 54 does not work 170 ALARM DEADBAND default value 99 description 102 location 73 233 ALARM DELAY default value 99 description 103 location
131. d a 50 terminal block TB50 Table 11 1 Agency Approvals Compliance CE Directive Electromagnetic Compatibility EMC Directive 89 336 EEC UL and C UL UL 916 Standard for Energy Manage ment Equipment File E177240 Doc 0600 3050 2000 Watlow Anafaze 193 Chapter 11 Specifications CLS200 Series User s Guide CLS200 Processor Physical Specifications Table 11 2 Environmental Specifications Storage Temperature 20 to 60 C Operating Temperature 0 to 50 C Humidity 10 to 95 non condensing The controller is for indoor Environment use only Table 11 3 Physical Dimensions Weight 1 98 Ibs 0 9 kg Length 8 0 inches 203 mm Width 3 78 inches 96 mm Height 1 96 inches 50 mm Without SCSI connector or with TB18 option Figure 11 1 CLS200 Processor Module Dimensions 194 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 11 Specifications Table 11 4 Processor with Straight SCSI Length 9 6 inches 244 mm Width 3 78 inches 96 mm Height 1 96 inches 50 mm 1 0 in 7 0 in 1 6 in 25 mm 178 mm 41 mm lt p 1 96 in 50 mm Figure 11 2 CLS200 Clearances with Straight SCSI Cable Table 11 5 Processor with Right Angle SCSI Length 8 6 inches 218 mm Width 3 78 inches 96 mm Height 1 96 inches 50 mm 1 0 in i 60 in In 7 0 in end 1 96 in 50 mm Figu
132. d alarms See Chapter 4 Setup for information on loop setup 132 Watlow Anafaze Doc 0600 3050 2000 Ramp Soak This chapter covers setup and operation of ramp soak pro files in CLS200 series controllers These features are available in controllers that have the optional ramp soak firmware installed The ramp soak feature turns your controller into a power ful and flexible batch controller Ramp soak lets you pro gram 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 higher or lower than the previous segment s setpoint it is called a ramp segment e Ifthe current segment s setpoint is the same as the previous segment s setpoint it is called a soak seg ment Profile K Q mie Soak S Q a K D amp O Q A gt Segment 1 Segment 2 Segment 3 Figure 7 1 Sample Ramp Soak Profile Doc 0600 3050 2000 Watlow Anafaze 133 Chapter 7 Ramp Soak Features 134 CLS200 Series User s Guide Ramp soak in the CLS200 includes the following features Ready segment sets loop up for profile Ready segment can control at setpoint until profile needs to run Ready segment events set all available event out puts to desired states before profile st
133. d units Control outputs associated with failed sensors are set to the value of the SENSOR FAIL HT CL OUTPUT parameter default 0 The alarm code blinks and displays cannot be changed until the alarm has been acknowledged Once the alarm is acknowledged the alarm code stops blinking When the condition that caused the alarm is corrected the alarm messages disappear Alarm Code Loop Number i LOOP PROCESS UNITS 02 180 F LP 180AUTO ALARM __ SETPOINT STATUS OUT Figure 3 6 Single Loop Display with a Process Alarm 4 Alarm Code PROCESS UNITS T C BREAK 25MAN 0 OUT 03 Failed Sensor Description FS ALARM _ SETPOINT STATUS Figure 3 7 Failed Sensor Alarm in the Single Loop Display Alarms that still exist but have been acknowledged are dis played on the Bar Graph display A letter or symbol indi cates the alarm condition See Table 3 3 on page 59 for a full list of alarm codes failed sensor messages and alarm symbols Open Thermocouple on Loop 1 Low Process or Low Deviation on Loop 5 DSQP PROCESS y lt lt 08 AAAA MAMA ALARM SETPOINT O1 gt F OUT STATUS 58 Figure 3 8 Alarm Symbols in the Bar Graph Display Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 3 Using the CLS200 Table 3 3 shows the symbols used in each form of the alarm display Table 3 3 Alarm Type and S
134. e 82 description 84 location 73 233 values 85 INPUT SCALING HI PV default value 82 description 88 location 73 233 scaling parameters 86 INPUT SCALING HI RDG default value 82 description 88 location 73 233 scaling parameters 86 INPUT SCALING LO PV default value 82 description 88 location 73 233 scaling parameters 86 INPUT SCALING LO RDG default value 82 description 89 location 73 233 scaling parameters 86 INPUT TYPE default value 82 description 83 effect on ramp soak parameters 144 location 73 233 values 83 INPUT UNITS default value 82 description 84 location 73 233 inputs analog see sensor inputs current see current inputs digital see digital inputs filter 89 pulse see pulse inputs RTD see RTD scaling resistors 180 186 sensor see sensor inputs setup parameters 82 89 specifications 200 202 thermocouple see thermocouples voltage see voltage inputs wiring see installation installation 11 49 alarm wiring 37 clearance 13 15 195 communications 45 49 Watlow Anafaze 225 Index control output wiring 37 controller 13 16 CPU watchdog timer 38 digital output wiring 35 36 Dual DAC 19 20 environment 12 ground loops see ground loops location 12 noise suppression see noise overview 11 panel hole dimensions 15 panel thickness 15 power supply 18 19 25 27 reference voltage terminals 32 sensor input wiring 29 34 Serial DAC 19 20 TB50 16 18 27 testing 28 29 tie wrapping cables 35 tools 13 torque fo
135. e Input scaling and calibration e Input filtering Table 4 5 Setup Loop Input Parameter Default Value INPUT TYPE J LOOP NAME 01 INPUT UNITS F INPUT READING OFFSET 0 F REVERSED T C DETECT OFF INPUT PULSE SAMPLE TIME 1 DISP FORMAT 2 999 TO 3000 INPUT SCALING HI PV 1000 INPUT SCALING HI RDG 100 0 FS INPUT SCALING LO PV 2 0 INPUT SCALING LO RDG 0 0 FS INPUT FILTER 3 SCANS 1 This parameter is available only for the pulse loop loop 5 on CLS204 loop 9 on CLS208 loop 17 on CLS216 2 These parameters are available only if LINEAR is selected for INPUT TYPE 3 These parameter is available only if INPUT TYPE is set to one of the thermocouple or RTD options Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Input Type Doc 0600 3050 2000 Chapter 4 Setup Specify the type of input sensor used on this loop e Thermocouple type J K T S R B or E e RTITD1orRTD2 e Linear input e Skip an input type available for unused loops Alarms are not detected and the scanning display does not show loops that are set to SKIP e Pulse input available only for loop 5 on CLS204 loop 9 on CLS208 or loop 17 on CLS216 LOOP PROCESS UNITS 01 INPUT TYPE J T C ALARM _ SETPOINT STATUS OUT Selectable values See Table 4 6 Table 4 6 CLS200 Input Types and Ranges Input Type Input Range J T C 350 to 1 40
136. e Propor tional 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 potential as the surrounding earth Electrical systems are usually grounded to protect people and equipment from shocks due to malfunc tions Also referred to a safety ground 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 As defined by Watlow Anafaze Any voltage above 24 Vac or Vdc and any current 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 Process Variable See Process Variable PV High Reading An input level that corresponds to the high 216 Watlow Anafaze CLS200 Series User s Guide process value For linear inputs the high read ing is a percentage of the full scale input range For pulse inputs the high reading is expressed in cycles per second Hz Infrared IR A region of the electromagnetic spectrum with wavelengths ranging
137. e Reset the tolerance alarm timer e Clear the tolerance alarm If the process variable does not return within the tolerance the tolerance alarm will recur after the tolerance alarm time elapses again If the alarm persists you may want to reset the profile To reset a profile follow these steps 1 In the single loop display switch to the loop you want to reset 2 Press the RAMP SOAK key three times to see the SET MODE parameter 3 Press the NO key The following screen will display LOOP PROCESS UNITS 01 A SEGO1 05 R SET MODE RESET ALARM _ SETPOINT STATUS OUT 4 PressYES to reset the profile and then ENTER to con firm your choice When you reset a profile the following happens e The profile returns to the ready segment The setpoint goes to the ready setpoint and the event outputs go to the states you specified for the READY EVENT OUTPUT parameter in the READY SEGMENT EDIT EVENTS sub menu See Ready Segment Edit Events on page 139 Watlow Anafaze 151 Chapter 7 Ramp Soak CLS200 Series User s Guide e The controller shows you the ASSIGN R S PROFILE screen in case you would like to assign a different pro file to the loop or select NONE to unassign the profile In Case of a Power Failure If the power fails or the controller is otherwise powered down while running a ramp soak profile by default the pro file is set to the START mode when power is restored Ifthe POWER UP OUTPUT STATUS parameter i
138. e alarm If the error message remains check the ambient air temperature near the controller Adjust ventilation cooling or heating to ensure that the temperature around the controller is 0 to 50 C If the unit is func tioning correctly the error will clear automatically when the ambient temperature is within range and the alarm has been acknowledged Remove any connections to the 5V dc reference TB1 18 on the back of the controller If this corrects the problem there was an error in the wiring You may need to consult technical support to determine the correct wiring If the ambient temperature is within range and the er ror persists Watlow Anafaze 169 Chapter 9 Troubleshooting and Reconfiguring CLS200 Series User s Guide NOTE H W Gain or Offset Failure NOTE Keys Do Not Respond 170 a Turn the power to the controller off b Remove the boards from the CLS200 housing c Reseat the boards and turn power on 5 If the error persists make a record of the settings then perform a NO key reset See NO Key Reset on page 176 6 Ifthe error is not cleared contact your supplier for fur ther troubleshooting guidelines See Returning Your Unit on page 164 If the controller has failed it is likely that it was damaged by excessive voltage or noise Before replacing the controller troubleshoot for noise and ground loops If the controller displays H W GAIN FAILURE or H W OFFSET FAILURE 1 Ackno
139. e in the process variable causes a decrease in the output Conversely with direct ac tion an increase in the process variable causes an increase in the output Heating applications normally use reverse action and cooling applications usually use direct action Setting Up and Tuning PID Loops NOTE After installing your control system tune each control loop and then set the loop to automatic control When tuning a loop choose PID parameters that will best control the pro cess This section gives PID values for a variety of heating and cooling applications Tuning is a slow process After adjusting a loop allow about 20 minutes for the change to take effect Proportional Band PB Settings Table 8 1 shows proportional band settings for various temperatures in degrees Fahrenheit or Celsius Table 8 1 Proportional Band Settings Setpoint PB Setpoint PB Setpoint PB 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 1899 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 3099 175 900 to 999 65 2000 to 2099 125 310
140. e is already installed and wired Unplug the two terminal blocks Depending on the installation you may need to un mount the Dual DAC module before proceeding Re move the four screws from the end plate on the opposite side of the module from the terminal blocks Doc 0600 3050 2000 Watlow Anafaze 187 Chapter 9 Troubleshooting and Reconfiguring 13 CLS200 Series User s Guide If necessary remove the two mounting screws holding the loosened end plate in place Slide the board out of the housing Set the jumpers for the two outputs as desired See Table 9 16 Replace the board such that the connectors extend through the opposite end plate The board fits in the third slot from the bottom Reconnect the two terminal blocks to the DAC1 and DAC2 connectors Replace the end plate end plate screws and if neces sary mounting screws Check the wire connections to the DAC1 and DAC2 terminal blocks Ifnecessary change the wiring connections to the cor rect configuration for the new output type See Wiring the Dual DAC on page 43 Restore system power Configuring Serial DAC Outputs The Serial DAC s voltage and current output is jumper se lectable Refer to Figure 9 9 Configure the jumpers as in dicated on the Serial DAC label Jumper Figure 9 9 Serial DAC Voltage Current Jump 188 er Positions Watlow Anafaze Doc 0600 3050 2000 Linear Scaling Examples This chapter
141. e range Spread In heat cool applications the difference between heat and cool Also known as process deadband See also Deadband Stability The ability of a device to maintain a constant output 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 ther mocouple 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 semi conductor material that exhibits a large change in resistance for a small change in tem perature Thermistors usually have negative temperature coefficients although they are also available with positive temperature coeffi cients Thermocouple T C A temperature sensing device made by joining two dissimilar metals This junction produces an electrical voltage in proportion to the differ ence in temperature between the hot junction sensing junction and the lead wire connection to the instrument cold junction 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 as a variable resistor with respect to its input signal Transmitters are desirable when long lead or extension wires produce unaccepta
142. e ratio control parameters with loop number 2 as the ratio loop Enter the master loop which will provide the output to the internal controller setpoint calculation for the ratio loop setpoint LOOP PROCESS UNITS 02 RATIO CONTROL MSTR LOOP NONE ALARM __ SETPOINT STATUS OUT Selectable values Any loop except the loop currently se lected in this case loop 02 Choose NONE for no ratio con trol Enter the lowest allowable setpoint for the ratio loop This minimum setpoint overrides any ratio calculation calling for a lower setpoint This value is expressed in the same en gineering units as the ratio loop s process variable LOOP PROCESS UNITS 02 RATIO CONTROL MIN SP 25 ALARM __ SETPOINT STATUS OUT Selectable values Any value from the minimum value of the ratio loop s process variable to its maximum value Enter the highest allowable setpoint for the ratio loop This maximum setpoint overrides any ratio calculation calling Watlow Anafaze 125 Chapter 6 Enhanced Features Control Ratio Setpoint Differential CLS200 Series User s Guide for a higher setpoint This value is expressed in the same engineering units as the ratio loop s process variable LOOP PROCESS UNITS 02 RATIO CONTROL MAX SP 25 ALARM _ SETPOINT STATUS OUT Selectable values Any value from the minimum value of the ratio loop s process variable to its maximum value Enter the multiplier
143. e set point and process variable differ by more than the de viation setting regardless of whether the process vari able has been within the deviation band This allows you to use boost control upon power up and setpoint changes Global Alarm The CLS200 comes equipped with a global alarm output The global output is activated if one or more of the follow ing conditions occurs e Asystem alarm occurs or e A failed sensor alarm occurs and is unacknowledged or 68 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Ramp Soak Doc 0600 3050 2000 NOTE Chapter 3 Using the CLS200 e A process alarm occurs and is unacknowledged The global alarm occurs only if the alarm type is set to ALARM in the SETUP LOOP ALARMS menu The global alarm does not occur if the alarm function is set to CONTROL The global alarm output stays active until all alarms have been acknowledged When the global alarm output is active it conducts current to the controller s de common When the global alarm out put is not active it does not conduct current You cannot configure any parameters for the global alarm The active state of the global alarm output is NOT affected by the DIG OUT POLARITY ON ALARM polarity parameter in the SETUP GLOBAL PARAMETERS menu If you have a controller without the Ramp Soak option pressing the RAMP SOAK key has no effect If you have a controller with this option installed s
144. e values 0 00 to 999 59 hours and minutes or minutes and seconds depending on the selected time base Enter the ending setpoint for the segment you are editing For aramp the setpoint changes steadily over the segment time from the end setpoint of the previous segment to the value set here For a soak set the value here equal to the end setpoint of the previous segment LOOP PROCESS UNITS C SEGMENT 5 SEG SETPT OFF ALARM SETPOINT STATUS OUT Selectable values 999 to 3276 or OFF no output dur ing segment See Setpoints and Tolerances for Various In put Types on page 144 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Edit Segment Events NOTE Segment Event Output Segment Events Output States Doc 0600 3050 2000 Chapter 7 Ramp Soak You can assign up to four digital outputs or events to each segment When the segment ends the outputs you select are set to the state you specify Press YES to select outputs and specify their states LOOP PROCESS UNITS A SEGMENT 5 EDIT SEG EVENTS ALARM SETPOINT STATUS OUT Press NO to advance to the EDIT SEG TRGGRS parameter Events are set at the end of segments If you want a segment to start with an event pro gram the event in the previous segment You can also create a segment with zero time pre ceding the segment during which you want the event on Select a digital output for the event Use a digital out
145. ead screwdriver e 1 8 in 3 mm flathead screwdriver for wiring e Multimeter Mount the controller before you mount the terminal block or do any wiring The controller s placement affects place ment and wiring considerations for the other components of your system Ensure there is enough clearance for mounting brackets terminal blocks and cable and wire connections the con troller extends up to 7 0 inches 178 mm behind the panel face and the screw brackets extend 0 5 inch 13 mm above and below it If using a straight SCSI cable allow for an ad ditional 1 6 inches 41 mm beyond the terminal block If using a right angle SCSI cable allow an additional 0 6 inch 15 mm See Figure 2 2 and Figure 2 3 Watlow Anafaze 13 Chapter 2 Installation CLS200 Series User s Guide 1 0 inch 7 0 inches 1 6 inch 25 mm 178 mm 41 oO Figure 2 2 Clearance with Straight SCSI Cable 1 0 inch 7 0 inches 0 6 inch 7 Figure 2 3 Clearance with Right Angle SCSI Cable 14 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 2 Installation Maximum Panel Thickness 0 2 inch 5 mm 1 80 0 020 inch 45 7 0 5 mm 3 63 0 020 inches 92 2 0 5 mm Figure 2 4 Wiring Clearances We recommend you mount the controller in a panel not more than 0 2 in 5 mm thick 1 Choose a panel location free from excessive heat more than 50 C 122 F dust and unauthorized ha
146. eading HI RDG The controller has two types of input filtering e The rejection filter ignores sensor readings outside the acceptance band when subsequent readings are within the band For temperature sensors the band is 5 about the last accepted reading For linear inputs the band is 0 5 of the input range This filter is not ad justable e A simulated resistor capacitor RC filter damps the input response if inputs change unrealistically or change faster than the system can respond If the in put 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 LOOP PROCESS UNITS 01 INPUT FILTER 3 SCANS ALARM _ SETPOINT STATUS OUT Selectable values 0 to 255 scans 0 disables the filter Watlow Anafaze 89 Chapter 4 Setup CLS200 Series User s Guide Setup Loop Control Parameters Menu Use the SETUP LOOP CONTROL PARAMS menu to adjust heat and cool control parameters including e Proportional band PB or gain integral TI or reset and derivative TD or rate settings e Output filter e Spread between heat and cool outputs The controller has separate PID and filter settings for heat and cool outputs The screens used to set these parameters are nearly identical In this section only the heat screens are shown and explained The heat and cool parameters ap pear only if the corresponding output is enabled See Setup L
147. ed txB TxA F gt TB1L1 3151719 1315117 19 21123125 1 s908 CHICH CHICH c CHICH pe CH CH Gna Rx 1 2 0 4 0 5 6 7 18 7 7 CE TB2 IN IN m IN IN m IN IN C0M IN IN RXB RXA 214161 8 110112 14 16 18 20 22 24 26 MADE CHICH c CH CH c CHICH 5 CH CH Gndf Tx IN THE 1 2 o0 3 4 0 5 7 8 7 47 USA N IIN m IN IN m JIN lIN Ref liIN lIN TxB TXA TB 315 719 iti 3 15 17 1921123 25 c1S916 CHICH c CHICHI c CHICH CH CH Gnd RX Z o13 ols 6 lz ele 7 CAS200 TB2 IN IN m IN IN m IN IN COM IN IN IRXB RXA 7 b 214176 8 10112 14 16 18 120 22 24 26 MADE V1C lena CHICH c CHICH c CHICH 5yICH CH Gnd Tx IN THE o 71 19 10 o 11 12 o 13 14 15 16 7 7 USA m IN HIN m IN IN m JIN IN ReflIN IN TXB TXA Figure 2 15 CLS200 Connector Locations Input Wiring Recommendations 30 Use multicolored stranded shielded cable for analog inputs Watlow Anafaze recommends that you use 20 AWG wire 0 5 mm2 If the sensor manufacturer requires it you can also use 24 or 22 AWG wiring 0 2 mm Most inputs use a shielded twisted pair some require a 3 wire input Follow the instructions pertaining to the type s of input s you are installing The controller accepts the following inputs without any special scaling resistors e J K T S R B and E thermocouples e Linear inputs with ranges between 10 and 60 mV
148. ee Chapter 7 Ramp Soak Watlow Anafaze 69 Chapter 3 Using the CLS200 CLS200 Series User s Guide 70 Watlow Anafaze Doc 0600 3050 2000 Setup The setup menus let you change detailed configuration in formation This section describes how to set up the control ler from menus in the controller firmware The following information is included in this chapter e Accessing the setup menus e Changing parameter settings e Description of controller parameters If you have not set up a CLS200 series controller before or if you do not know what values to enter please read Chap ter 8 Tuning and Control which contains PID tuning con stants and useful starting values How to Access the Setup Menus Doc 0600 3050 2000 Use the three key sequence to enter the setup menus 1 Select the single loop display for the loop you wish to edit 2 Press ENTER then ALARM ACK then CHNG SP to access the setup menus Do not press these keys at the same time press them one at a time ALARM CHNG ACK SP 3 The first setup menu appears To prevent unauthorized personnel from accessing setup parameters the controller reverts to the single loop display if you do not press any keys for three minutes Watlow Anafaze 71 Chapter 4 Setup CLS200 Series User s Guide How to Change a Parameter To change a parameter first select the appropriate menu then the parameter When you enter the setup menus the first men
149. eed not reach or cross set point to successfully determine the PID parameters While autotuning the controller looks at the delay between when power is applied and when the system responds in order to determine the proportional band PB The controller then looks for the slope of the rising temperature to become con stant in order to determine the integral term TD The de rivative term TD is derived mathematically from the TI When the controller has finished autotuning the loop s control status switches to AUTO If the process reaches 75 of the setpoint or the autotuning time exceeds ten minutes the controller switches to AUTO and applies the PID con stants it has calculated up to that point The Watlow Anafaze autotune is started at ambient tem perature or at a temperature above ambient However the temperature must be stable and there must be sufficient time for the controller to determine the new PID parame ters A loop must be stable at a temperature well below the setpoint in order to successfully autotune The controller will not complete tuning if the temperature exceeds 75 of set point before the new parameters are found The following procedure explains how to autotune a loop 1 Select the single loop display of the loop to be tuned Watlow Anafaze 63 Chapter 3 Using the CLS200 A CLS200 Series User s Guide 2 Ensure the loop s process variable is stable and the loop is in MAN control status 3
150. er 1 System Overview Watlow Anafaze provides cables required to install your CLS200 A 50 pin SCSI cable connects the TB50 to the CLS200 The optional cable used to connect the CLS200 to a comput er using EIA TIA 232 communications has a DB9 or DB25 connector for the computer and bare wires for connecting to the CLS200 Watlow Anafaze has made every effort to ensure the reli ability and safety of this product In addition we have pro vided recommendations that will allow you to safely install and maintain this controller The CLS200 controller may fail full on 100 output pow er or full off 0 output power or may remain full on if an undetected sensor failure occurs For more information about failed sensor alarms see Failed Sensor Alarms on page 65 Design your system to be safe even if the controller sends a 0 or 100 output power signal at any time Install inde pendent external safety devices that will shut down the system if a failure occurs Typically a shutdown device consists of an FM approved high low process limit controller that operates a shutdown device such as an mechanical contactor The limit control ler monitors for a hazardous condition such as an under temperature or over temperature fault If a hazardous con dition is detected the limit controller sends a signal to open the contactor The safety shutdown device limit controller and contactor must be independent from the process control equipme
151. ess which uses only proportional control settles at a point above or below the setpoint it never reaches the setpoint by itself This behavior is known as off set or droop Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 8 Tuning and Control m4 Setpoint Proportional Band t process Variable Figure 8 2 Proportional Control Proportional and Integral Control With proportional and integral control the integral term corrects for offset by repeating the proportional band s er ror correction until there is no error For example if a pro cess tends to settle about 5 F below the setpoint appropriate integral control brings it to the desired setting by gradually increasing the output until there is no devia tion Setpoint az ge a a ae Over Proportional Band t process Variable Figure 8 3 Proportional and Integral Control Proportional and integral action working together can bring a process to setpoint and stabilize it However with some processes the user may be faced with choosing be tween parameters that make the process very slow to reach setpoint and parameters that make the controller respond quickly but introduce some transient oscillations when the setpoint or load changes The extent to which these oscilla tions of the process variable exceed the setpoint is called overshoot Proportional Integral and Derivative Control Deriva
152. example settings flow sensor with 0 5 Vde signal 191 example settings pressure sensor with 4 20mA signal 190 example settings pulse encoder 192 linear inputs 86 89 process variable retransmit 114 115 pulse inputs 86 89 Doc 0600 3050 2000 Index scaling resistors CLS204 and CLS208 input circuit 180 CLS216 input circuit 184 for current inputs 33 181 184 for RTD inputs 32 183 for thermistor inputs 183 for voltage inputs 32 182 185 installing 180 186 SCSI cable 7 9 clearance 13 14 195 installing 27 SDAC HI VALUE default value 93 description 95 location 233 SDAC LO VALUE default value 93 description 95 location 233 SDAC MODE default value 93 description 95 location 233 SEG EV DO ACTIVE STATE description 141 location 136 233 SEG EVENT OUTPUT description 141 location 136 233 SEG TR DI ACTIVE STATE description 142 location 136 233 SEG TR DI TRIG description 143 location 136 233 SEG TRIG INPUT NR description 142 location 136 233 SEGMENT EDIT SEG EVENTS description 141 location 136 233 SEGMENT EDIT SEG TRGGRS description 142 location 136 233 SEGMENT LAST SEGMENT description 144 location 136 233 SEGMENT SEG SETPT description 140 location 136 233 SEGMENT SEG TIME description 140 location 136 233 SEGMENT SEG TOLERANCE description 143 location 136 233 SENSOR FAIL CL OUTPUT and output override feature 77 and reversed thermocouple detect
153. ffas the temperature rises and the point at which it turns back on as the temperature falls For a loop using PID control the spread determines how far the process variable must be from the setpoint before the controller can switch from heating to cooling A loop will not switch from heat to cool or vice versa unless the process variable deviates from setpoint by more than the spread When the loop is using PID control and the spread is set to 0 the PID calculation alone determines when the heat or cool output should be on LOOP PROCESS UNITS 01 SPREAD 5 ALARM _ SETPOINT STATUS OUT Selectable values 0 to 255 25 5 2 55 255 or 0255 depending upon the DISP FORMAT setting To enable the sensor failure recovery feature select a digi tal input at this parameter If the specified input is held low when the sensor fails the loop returns to automatic control after a failed sensor is corrected LOOP PROCESS UNITS 01 RESTORE PID DIGIN NONE ALARM _ SETPOINT STATUS OUT Selectable range NONE disable the sensor failure recov ery feature 1 to 8 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 4 Setup Setup Loop Outputs Menu Use the SETUP LOOP OUTPUTS menu to e Enable or disable outputs e Set output type e Set cycle time for time proportioning outputs e Enter Serial DAC parameters for Serial DAC out puts e Select control action e Set output level limit and
154. file on page 151 4 Press YES then ENTER to reset the profile You will see the ASSIGN PROFILE parameter See Assigning a Profile to a Loop on page 148 5 Choose one of the available profiles or NONE to unassign and press ENTER 6 To return to the single loop display without changing the profile assignments press BACK Running a Profile When you assign a profile it does not start running imme diately Instead the loop is in the START mode and the 148 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Starting a Profile Chapter 7 Ramp Soak READY segment segment 0 Use the SET MODE parameter to start a profile put it in RUN mode LOOP PROCESS UNITS 01 A SEGO1 05 R SET MODE RUN ALARM _ SETPOINT STATUS OUT You can start a profile only when it is in the READY seg ment 1 In the single loop display switch to the loop you want to start 2 Press the RAMP SOAK key three times The SET MODE parameter appears 3 Press YES and ENTER to start the profile While the profile is in START mode the only mode available is the RUN mode Running Several Profiles Simultaneously To run several profiles simultaneously follow these steps 1 Set up 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 Trip the trigger Ed
155. for more in formation about installing scaling resistors 2 Select the display format The smallest possible range is 9999 to 3 0000 the largest possible range is 9 999 to 30 000 3 Enter the appropriate scaling values for your process Configuring Dual DAC Outputs Dual DAC modules ship with both outputs configured for the signal type and span ordered The module contains two independent circuits DAC1 and DAC2 These circuits can be configured for different output types Remove the board from the housing and set the jumpers The odd numbered jumpers determine the signal from DAC1 the even num bered jumpers determine the output from DAC2 186 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 9 Troubleshooting and Reconfiguring Figure 9 8 Dual DAC Table 9 16 Dual DAC Jumper Settings Jumper Settings Output Type 1 2 3 4 5 6 7 8 9 10 11 12 13 14 0 to 5V dc B A A O B A O 0 to 10V dc B A A O B O O 4 to 20 mA O A B A A O A two pins A Load jumper in the A position or load jumper if header has only B Load jumper in the B position O Open Do not load jumper 1 Power down the system if the Dual DAC is already in stalled and wired Ensure the DAC1 and DAC2 terminal blocks or asso ciated wires are labeled such that you will know which terminal block connects to which side of the board if the modul
156. g devices 39 extruder control 107 110 extruder control algorithm 110 extruder firmware option code 81 F failed sensor alarms restoring automatic control after sensor repair 66 RTD open 66 RTD shorted 66 setting up 65 66 thermocouple open 65 thermocouple short 66 224 Watlow Anafaze CLS200 Series User s Guide filter output 91 158 sensor input 89 firmware custom 82 version 81 frequency 81 front panel 8 navigation 51 overview 52 FS alarm code 166 functions activated by digital inputs 39 G gain see proportional band ground loops 24 communications 47 isolation 35 paths 24 and personal computers 24 and thermocouples 31 troubleshooting 172 175 grounding troubleshooting 172 H H W AMBIENT FAILURE 166 169 H W GAIN FAILURE 166 170 H W OFFSET FAILURE 166 170 HD alarm code 164 HEAT 56 HEAT CONTROL FILTER default value 90 description 91 location 73 233 HEAT CONTROL OUTPUT default value 93 description 94 location 73 233 HEAT CONTROL PB default value 90 description 91 location 73 233 HEAT CONTROL TD default value 90 description 91 location 73 233 HEAT CONTROL TI default value 90 description 91 location 73 233 HEAT OUTPUT curves 98 default value 93 description 98 location 73 233 HEAT OUTPUT ACTION default value 93 description 96 location 73 233 HEAT OUTPUT CYCLE TIME default value 93 description 95 location 73 233 Doc 0600 3050 2000 CLS200 Series User s Guide HEAT OUTPUT LIMI
157. ged 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 Current AC An electric current that reverses at regular intervals and alternates positive and negative values Ambient Temperature The temperature of the air or other medium that surrounds the components of a thermal Doc 0600 3050 2000 Glossary 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 electric ity current in the circuit Units are one cou lomb 6 25 x 1018 electrons per second Analog Output A continuously variable signal that is used to represent a value such as the process value or setpoint value Typical hardware configurations are 0 to 20mA 4 to 20mA or 0 to 5 V de Aut
158. has the desired relationship to the process variable of the primary loop In this application the pro portional band PB of the primary loop is set to 10 F and the integral and derivative are turned off 190 F 170 F 150 F 4 0 50 100 Heat Output 150 F 145 F 140 F Process Variable 1 eng units SP1 SP1 PB1 Primary Loop Output Figure 6 6 Secondary Loop Setpoint Related to Primary Loop Output As the temperature of loop 1 drops the output of loop 1 goes up proportionally and the setpoint of loop 2 goes up propor tionally Thus heat is added to the system at the element Watlow Anafaze 123 Chapter 6 Enhanced Features Ratio Control 124 CLS200 Series User s Guide even though the temperature near the element may have been at setpoint 150 F With proportional control when loop 1 is at setpoint its output is 0 and the setpoint of loop 2 is equal to the base setpoint 150 F If the temperature of loop 1 drops to 149 F the deviation results in a proportional output of 10 This times the span of 40 F results in an increase in set point for loop 2 of 4 F The loop 2 setpoint increases to 154 F For every degree that loop 1 drops loop 2 increases by 4 F until the output of loop 1 is 100 and the loop 2 setpoint is 190 F Any further drop in the loop 1 process variable does not affect loop 2 The PID parameters of loop 2 must be tuned to perform ef ficien
159. he controller Go to the DIGITAL INPUTS parameter in the MANUAL I 0 TEST menu This parameter shows whether the digital inputs are H high or open or L low or closed Attach a wire to the terminal of the digital input to test When the wire is connected only to the digital in put terminal the DIGITAL INPUTS parameter should show that the input is H high When you connect the other end of the wire to controller common TB50 ter minal 3 the DIGITAL INPUTS parameter should show that the input is L low Additional Troubleshooting for Computer Supervised Systems Computer Problems 174 These four elements must work properly in a computer su pervised system The controller The computer and its EIA TIA 232 or EIA TIA 485 se rial interface The EJA TIA 232 or EIA TIA 485 communication lines The computer software For troubleshooting disconnect the communications line from the computer and follow the troubleshooting steps in the first section of this chapter The next few sections ex plain troubleshooting for the other elements of computer supervised systems If you are having computer or serial interface problems check the following Check your software manual and make sure your com puter meets the software and system requirements Check the communications interface cables and con nections Make sure the serial interface is set accord ing to the manufacturer s instructions To test an EIA TIA 232 in
160. he following sections list symptoms in each of these cate gories and suggest possible causes and corrective actions Process and Deviation Alarms When a process or deviation alarm occurs the controller switches to the single loop display for the loop with the alarm and displays the alarm code on the screen Software such as AnaWin or WatView displays a message on the alarm screen and logs the alarm in the event log Table 9 1 Controller Alarm Codes for Process and Deviation Alarms Code Alarm Description HP High Process Process variable has risen above the high process alarm setpoint HD High Deviation Process variable has risen above the setpoint by more than the devia tion alarm value LD Low Deviation Process variable has dropped below the setpoint by more than the deviation alarm value LP Low Process Process variable has dropped below the low process alarm setpoint 164 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 9 Troubleshooting and Reconfiguring Responding to Process and Deviation Alarms In a heating application a low process or low deviation alarm may indicate one of the following e The heater has not had time to raise the temperature e The load has increased and the temperature has fall en e The control status is set to manual instead of automatic e The heaters are not working due to a hardware failure e The sensor is not placed correctly and is not me
161. he same as DZC except that the minimum switching time is three ac line cycles This may be advantageous in some applications using three phase heaters and three phase power switching Analog Outputs For analog outputs the PID algorithm calculates an output between 0 and 100 This percentage of the analog output range can be applied to an output device via a Dual DAC or a Serial DAC Output Filter The output filter digitally smooths PID control output sig nals It has a range of 0 to 255 scans which gives a time constant of 0 to 170 seconds for a CLS216 0 to 85 seconds for a CLS208 or 0 to 43 seconds for a CLS204 Use the out put filter if you need to filter out erratic output swings due to extremely sensitive input signals like a turbine flow sig nal or an open air thermocouple in a dry air gas oven The output filter can also enhance PID control Some pro cesses are very sensitive and would otherwise require a large proportional band making normal control methods ineffective Using the output filter allows a smaller propor tional band to be used achieving better control Also use the filter to reduce the process output swings and output noise when a large derivative is necessary or to make badly tuned PID loops and poorly designed processes behave properly 158 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Reverse and Direct Action Chapter 8 Tuning and Control With reverse action an increas
162. i cations Parameter Description Absolute Maximum Common Mode Voltage Measured between output terminals and controller common 1 000V Resolution 15 bits plus polarity bit for voltage outputs 0 305mV for 10V output range 0 00061 mA for 20 mA output range Accuracy Calibrated for Voltage Output For voltage output 0 005V 0 05 at full scale For current output 0 1 mA 0 5 at full scale Temperature coefficien 440 ppm C typical Isolation Breakdown Voltage 1 000V between input power and signals Current 0 to 20 mA 500 Q load max Voltage 0 to 10V dc with 10 mA source capability Output Response Time 1 ms typical Update Rate Once per controller A D cycle nominal Twice per second max imum for 60 Hz clock rate Output changes are step changes due to the fast time con stant All Serial DAC loop outputs are updated at the same time Doc 0600 3050 2000 Watlow Anafaze 211 Chapter 11 Specifications CLS200 Series User s Guide 212 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide 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 measuring instrument and a physical constant or known standards Action The response of an output when the process variable is chan
163. iability for any products or parts that have been sub ject to misuse accident negligence failure of electric power or modification by the Customer without the written approval of Watlow Anafaze Incorporated Final deter mination 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 han dling 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 Customer 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 merchantabil ity or fitness for a particular purpose Please Note External safety devices must be used with this equipment Table of Contents List of Figures xi List of Tables xv 1 System Overview 1 Manual Contents 1 Getting Started 2 Safety Symbols 2 Initial Inspection 2 Product Features 3 CLS200 Parts List 5 Technical Description 7 CLS200 7 TB50 8 CLS200 Cabling
164. ide Table 2 7 1TB50 Connections for CLS216 Terminal Function a i Terminal Function Ea ciate 1 5V dc 2 5V dc 3 CTRL COM 4 CTRL COM 5 Not Used 6 Watchdog Timer 7 Pulse Input 8 Global Alarm 9 Output 1 Loop 1 heat 10 Output 342 Pulse loop cool 11 Output 2 Loop 2 heat 12 Output 33 Loop 16 cool 13 Output 3 Loop 3 heat 14 Output 32 Loop 15 cool 15 Output 4 Loop 4 heat 16 Output 31 Loop 14 cool 17 Output 5 Loop 5 heat 18 Output 30 Loop 13 cool 19 Output 6 Loop 6 heat 20 Output 29 Loop 12 cool 21 Output 7 Loop 7 heat 22 Output 28 Loop 11 cool 23 Output 8 Loop 8 heat 24 Output 27 Loop 10 cool 25 Output 9 Loop 9 heat 26 Output 26 Loop 9 cool 27 Output 10 Loop 10 heat 28 Output 25 Loop 8 cool 29 Output 11 Loop 11 heat 30 Output 24 Loop 7 cool 31 Output 12 Loop 12 heat 32 Output 23 Loop 6 cool 33 Output 13 Loop 13 heat 34 Output 22 Loop 5 cool 35 Output 14 Loop 14 heat 36 Output 21 Loop 4 cool 37 Output 15 Loop 15 heat 38 Output 20 Loop 3 cool 39 Output 16 Loop 16 heat 40 Output 19 Loop 2 cool 41 Output 17 Pulse loop heat 42 Output 18 Loop 1 cool 43 Input 1 44 Input 2 45 Input 3 46 Input 4 47 Input 5 48 Input 6 49 Input 7 50 Input 8 1 The indicated outputs are dedicated for 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 al
165. ied value A low process alarm occurs if the process variable drops below a separate user specified value See Figure 3 9 Enter the alarm high and low process setpoints at the HI PROC ALARM SETPT and LO PROC ALARM SETPT param eters in the SETUP LOOP ALARMS menu Watlow Anafaze 67 Chapter 3 Using the CLS200 CLS200 Series User s Guide High process alarm on High process alarm off High process alarm set point Deadband High deviation alarm off Setpoint Deviation alarm value Deadband Setpoint Low deviation alarm off RN enn Al Deadband Setpoint Deviation alarm value Low deviation A Sey e e eee alarmon______ mere Deadband Low process alarm setpoint Low process alarm on Low process alarm off Figure 3 9 Activation and Deactivation of Process Alarms Deviation Alarms A deviation alarm occurs if the process deviates from set point by more than a user specified amount See Figure 3 9 Set the deviation with the DEV ALARM VALUE param eter in the SETUP LOOP ALARMS menu Upon power up or when the setpoint changes the behavior of the deviation alarms depends upon the alarm function e If the alarm type parameter is set to ALARM then de viation alarms do not activate until the after the pro cess variable has first come within the deviation alarm band This prevents nuisance alarms e Ifthe alarm type parameter is set to CONTROL then the deviation output switches on whenever th
166. ing Failed Sensor Alarms CLS200 Series User s Guide When a failed sensor alarm occurs the controller switches to the single loop display for the loop with the alarm and displays an alarm code on the screen AnaWin or WatView displays a message on the alarm screen and logs the alarm in the event log Table 93 Failed Sensor Alarm Codes Code Alarm Description FS Failed Sensor Open thermocouple Reversed ee RT Thermocouple Temperature changed in the opposite direction than expected ST ilar Temperature failed to change as expected Thermocouple RO RTD Open Positive or negative lead is broken or disconnected RS RTD Shorted Positive and negative leads are shorted System Alarms A failed sensor alarm clears once it has been acknowledged and the sensor is repaired If the controller detects a hardware problem it displays a message The message persists until the condition is cor rected Table 9 4 Hardware Error Messages Message Possible Cause Recommended Action LOW POWER Power supply failed See Low Power on page 168 BATTERY DEAD RAM battery is dead See Battery Dead on page 168 AW Ambient warning Ambient tem perature exceeds operating lim its by less than 5 C 9 F See Ambient Warning on page 168 H W AMBIENT FATLURE H W GAIN FAILURE Ambient temperature exceeds operating limits by 5 C 9 F Reference voltage 5V dc shorted to commo
167. inou ype H Z Reading Input Reading Reading pur yp Figure 4 2 Two Points Determine Process Variable Conversion Before you enter the values determining the two points for the conversion line you must choose an appropriate dis play format The controller has six characters available for process display select the setting with the desired number of decimal places Use a display format that matches the range of the process variable and resolution of the sensor The display format you choose is used for the process vari able setpoint alarms limits deadband spread and propor tional band The process variable range for the scaled input is between the process variable values that correspond to the 0 and 100 input readings For the pulse input it is between the 0 Hz and 2000 Hz readings The process variable range de fines the limits for the setpoint and alarms See Figure 4 3 86 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 4 Setup 20 i ee R High Proces Variabale Process Variable Range Low Process Variabale 0 PSI ty Linear input type 0 omy Low High OHz Reading Input Reading Reading 2000 Hz Pulse input type Figure 4 3 Process Variable Limited by Input Reading Range Display Format Select a display format for a linear or pulse input Choose a format appropriate for the input range and sensor accu racy LOOP PROCESS UNITS 01 DISP FORMAT 999 TO
168. ion 85 and thermocouple short detection 79 description 97 location 73 233 values 97 Sensor Fail Cool Output parameter and failed sensor alarm 65 Watlow Anafaze 229 Index Sensor Fail Heat Output parameter and failed sensor alarm 65 SENSOR FAIL HT OUTPUT and output override feature 77 and reversed thermocouple detection 85 and thermocouple short detection 79 default value 93 description 97 location 73 233 values 97 sensor inputs engineering units 84 failed sensor alarms 166 filter 89 offset 84 ranges 83 specifications 200 troubleshooting 171 type setting 83 wiring 29 34 Serial DAC agency compliance 210 clock input 210 configuring outputs 188 configuring the controller output 94 dimensions 20 209 environment 209 input specifications 210 jumper positions 188 mounting 19 20 output specifications 211 process variable retransmit 113 118 specifications 209 211 wiring 44 45 SET COOL OUTPUT 62 SET HEAT OUTPUT 62 SET MODE 147 148 SETPOINT 61 setpoint changing 61 ramp soak ready setpoint 138 using cascade control to set 118 using PLC to set example 129 using ratio control to set 124 SETUP GLOBAL PARAMETERS 74 location 73 233 parameters in menu 74 SETUP LOOP ALARMS 99 location 73 233 parameters in menu 99 SETUP LOOP CASCADE 119 location 112 233 SETUP LOOP CONTROL PARAMS 90 location 73 233 parameters in menu 90 SETUP LOOP INPUT 82 location 73 233 parameters in menu 82 SETUP LOOP OUTPUTS 93 location
169. is a thermocouple or RTD specify the off set to correct for signal inaccuracy at a given point For ex ample at temperatures below 400 F a type J thermocouple may be inaccurate or offset by several de grees Use an independent thermocouple or your own cali bration equipment to find the offset for your equipment A positive value increases the reading and a negative value decreases it LOOP PROCESS UNITS 01 INPUT READING OFFSET O0 F ALARM SETPOINT STATUS OUT Selectable values See Table 4 8 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Reversed T C Detection Input Pulse Sample Time Doc 0600 3050 2000 Chapter 4 Setup Table 4 8 Input Reading Offset Offset Range Type of Sensor oF C RTD2 7 300 to 300 300 to 300 T RTD1 300 0 to 300 0 300 0 to 300 0 3 300 to 76 300 to 300 R 300 to 66 300 to 300 Set this parameter to ON to enable polarity checking for thermocouples If a reversed thermocouple is detected the controller sets the loop to manual control at the SENSOR FAIL HT OUTPUT or SENSOR FAIL CL OUTPUT power level and displays the alarm LOOP PROCESS UNITS 01 REVERSED T C DETECT OFF ALARM SETPOINT STATUS OUT Selectable values ON or OFF You can connect a digital pulse signal of up to 2 kHz to the pulse input Use this parameter to set the time over which pulses are counted The controller coun
170. is section describes how to properly connect thermocou ples RTDs current and voltage inputs to your controller The controller can accept any mix of available input types Some input types require that special scaling resistors be installed generally done by Watlow Anafaze before the controller is delivered Allinputs are installed at the CH input connectors TB1 at the back of the controller The illustrations below show the connector locations for all the CLS200 series controllers A CAUTION Never run input leads in bundles with high power wires or near other sources of EMI This could inductively couple voltage onto the input leads and damage the controller or could induce noise and cause poor measure ment and control Doc 0600 3050 2000 Watlow Anafaze 29 Chapter 2 Installation CLS200 Series User s Guide TB1 1 13151719 1113 15 17 19 21123 25 CH CH C CHICH C Re Re Reg Re Re Gnd RX CLS204 1 2 o0o 3 4 0o ser ser ser ser CE TB2 IN IN m JIN IN m ved ved Comlved vedirxB RxA 4 214176 8 10 12 14 16 18 20 22 24 26 Ae C CHICH C ICHICH C IRe R Re Re Gnd TX a ate 1 2 o0 3 4 0 ser leer OV ser leer USA m IN IN m IN IN m ved ved Ref vedjv
171. iting a Profile While It ls Running Doc 0600 3050 2000 You can edit a profile while it is running Changes made to segments after the current segment will take effect when the segment is reached Changes made to the segments that have already been completed will take effect the next time the profile is run Do not edit the current segment Changes to the current segment can have unexpected con sequences Watlow Anafaze 149 Chapter 7 Ramp Soak CLS200 Series User s Guide Holding a Profile or Continuing from Hold Use the SET MODE parameter to select the ramp soak pro file mode Table 7 6 shows the available modes Table 7 6 Ramp Soak Profile Modes Current Available ati Mode Mode Description START RUN Begin running the assigned profil Continue from user selected hold The pro file uns from the point when you put the pro file in HOLD mode You cannot continue from HOLD CONT a tolerance hold or a trigger wait After you choose this mode the controller switches back to RUN mode RUN HOLD Hold the profil Holding a Profile In HOLD mode all loop parameters stay at their current set tings until you change the mode or reset the profile To put a profile into HOLD mode follow these steps 1 In the single loop display switch to the loop you want to hold 2 Press the RAMP SOAK key three times to see the SET MODE parameter LOOP PROCESS UNITS 01 A SEGO1 05 R SET MODE HOLD ALARM _
172. l may break easily or may cause intermittent connections e Use shielded wire The electrical shield protects the signals and the CLS200 from electrical noise Connect one end of the input and output wiring shield to earth ground e Use copper wire for all connections other than thermo couple sensor inputs Doc 0600 3050 2000 Watlow Anafaze 21 Chapter 2 Installation CLS200 Series User s Guide Table 2 1 Cable Recommendations A No of 2 Maximum Function Mfr P N Wires AWG mm Length Anaoa ioii Belden 9154 2 20 0 5 MAA Belden 8451 2 22 0 5 Belden 8772 3 20 0 5 pau Belden 9770 3 22 0 5 Thermocouple Inputs T C Ext Wire 2 20 0 5 Belden 9539 9 24 0 2 cule ia on Belden 9542 20 24 0 2 g Ribbon Cable 50 22 t014 0 5 to 2 5 Belden 9154 2 20 0 5 Pnaleg Upu Belden 8451 2 22 0 5 Belden 9729 4 24 0 2 4 000 ft 1 219 m Computer Communica Belden 9730 6 24 0 2 tion EIA TIA 232 422 Belden 9842 4 24 0 2 4 000 ft 1 219 m or 485 or 20 mA Belden 9843 6 24 0 2 Belden 9184 4 22 0 5 6 000 ft 1 829 m Noise Suppression Symptoms of RFI EMI 22 The CLS200 s outputs are typically used to drive solid state relays These relays may in turn operate more inductive types of loads such as electromechanical relays alarm horns and motor starters Such devices may generate elec tromagnetic interference EMI or noise If the controller is placed close to sources of EMI it may not function cor
173. l switches between heating and cooling Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Control Outputs Output Control Signals On Off Time Proportioning TP Doc 0600 3050 2000 Chapter 8 Tuning and Control The controller provides open collector outputs for control These outputs normally control the process using solid state relays Open collector outputs can be configured to drive a serial digital to analog converter Serial DAC which in turn can provide 0 to 5 V dc 0 to 10 V dc or 4 to 20 mA control signals to operate field output devices The following sections explain the different control output signals available When on off control is used the output is on or off depend ing on the difference between the setpoint and the process variable PID algorithms are not used with on off control The output variable is always off or on 0 or 100 With time proportioning outputs the PID algorithm calcu lates an output between 0 and 100 which is represented by turning on an output for that percent of a fixed user se lected time base or cycle time The cycle time is the time over which the output is propor tioned and it can be any value from 1 to 255 seconds For example if the output is 30 and the cycle time is 10 sec onds then the output will be on for 3 seconds and off for 7 seconds Figure 8 5 shows examples of time proportioning and distributed zero crossing DZC wavef
174. lay 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 controller from the front panel or from a local or remote computer Watlow Anafaze offers WatView a Windows compatible Human Machine Interface HMI software package that includes data logging and graphing features in addition to process monitor ing and parameter setup screens Modbus RTU Protocol EIA TIA 232 and 485 Communications Connect to PLCs operator inter face terminals and third party software packages us ing the widely supported Modbus RTU protocol Multiple Job Storage Store up to eight jobs in mem ory 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 Nonlinear Output Curves Select either of two non linear output curves for each control output Autotuning Use the autotune feature to set up your system quickly and easily The CLS200 internal ex pert system table finds the correct PID parameters for your process Pulse Counter Input Use the pulse counter input for precise control of motor or belt speed Low Power Shutdown The controller shuts down and turns off all outputs when it detects the input volt age drop below the minimum safe operating level Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 1 System Overview
175. limit time e Select sensor fail output output override e Select a nonlinear output curve LOOP PROCESS UNITS SETUP LOOP 01 OUTPUTS ALARM SETPOINT STATUS OUT Table 4 11 shows the parameters available in the SETUP LOOP OUTPUTS menu Both heat and cool outputs have the same parameters only one of each parameter is shown Table 4 11 Setup Loop Outputs Doc 0600 3050 2000 Parameter Default Value HEAT CONTROL OUTPUT ENABLED HEAT OUTPUT TYPE TP HEAT OUTPUT CYCLE TIME 10S SDAC MODE VOLTAGE SDAC LO VALUE 0 00 VDC SDAC HI VALUE 10 00 VDC HEAT OUTPUT ACTION REVERSE HEAT OUTPUT LIMIT 100 HEAT OUTPUT LIMIT TIME CONT SENSOR FAIL HT OUTPUT 0 HEAT T C BRK OUT AVG OFF HEAT OUTPUT LINEAR COOL CONTROL OUTPUT DISABLED The SDAC parameters are available only if you select SDAC as the output type Use these parameters to configure the Serial DAC signal output Watlow Anafaze 93 Chapter 4 Setup CLS200 Series User s Guide Enable or Disable Heat or Cool Outputs Enable or disable the heat or cool output for the loop If you want the loop to have a control output you must enable at least one output You can also disable a heat or cool control output and use the output for something else such as an alarm LOOP PROCESS UNITS 01 HEAT CONTROL OUTPUT ENABLED ALARM SETPOINT STATUS OUT Selectable values ENABLED or DISABLED Heat or
176. low Anafaze Serial DAC Consult Chapter 4 Setup for information on setting up the other options of the controller 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 con trol The cascade control feature allows the output percentage of one control loop to determine the setpoint of a second con trol loop By adjusting the setpoint SP parameters the user can adjust the influence that the primary loop has on the setpoint of the secondary loop See Figure 6 4 Some applications such as aluminum casting use two zone cascade control where the primary output is used for the primary heat control and the cascaded output is used for boost heat The CLS200 allows you to use the primary heat output for both control and for determining the set point of the secondary loop Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 6 Enhanced Features Maximum SP Base SP Minimum SP Secondary Loop s Setpoint 100 Cool 0 Heat 100 Primary Loop s Output Calculation of new secondary loop setpoint SP2 Base SP Cool Output Power Cool Span Heat Output Power Heat Span Figure 6 4 Relationship Between the Primary Loop s Output and the Secondary Lo
177. ly if you selected an output that is not in use for control at the TEST DIGITAL OUTPUT screen Use this parameter to manually toggle a digital output on or off to test it Toggling an output ON sinks current from the output to the controller common Toggling the output OFF stops current flow All tested outputs are set to OFF when you exit the MANUAL I 0 TEST menu You cannot toggle outputs enabled for control To test a control loop output first disable it using the SETUP LOOP OUTPUTS menu LOOP PROCESS UNITS DIGITAL OUTPUT NUMBER XX OFF ALARM SETPOINT STATUS OUT Selectable values ON or OFF Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Keypad Test Display Test Doc 0600 3050 2000 Chapter 4 Setup Test the keypad The test begins automatically when the screen appears LOOP PROCESS UNITS KEYPAD TEST QUIT NO NO ALARM __ SETPOINT STATUS OUT e Press any key to test the keypad The controller will display the name of the key you have pressed e Press NO twice to end the test and return to the top of the MANUAL I 0 TEST menu Use this function to test the display LOOP PROCESS UNITS DISPLAY TEST ALARM SETPOINT STATUS OUT Press YES to enter the test and display the instruction screen LOOP PROCESS UNITS TO TEST DISPLAY Y TOGGLE N QUIT ALARM SETPOINT STATUS OUT Press YES to begin the display of a discernable pixel pat te
178. maximum Press ENTER LOOP PROCESS UNITS 02 RATIO CONTROL CTRL RATIO 0 5 ALARM _ SETPOINT STATUS OUT Enter the control ratio which is the multiple applied to the master The H20 fl w rate is multiplied by 0 5 to obtain the KOH fl w rate setpoint Press ENTER LOOP PROCESS UNITS 02 RATIO CONTROL SP DIFF 0 ALARM SETPOINT STATUS OUT Enter the setpoint differential or offset For this example we have no offset requirement and will use 0 Press ENTER 128 4 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 5 To complete the ratio setup configure both loops 1 and 2 for inputs outputs and alarms See Chapter 4 Setup for information on loop setup Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 6 Enhanced Features Remote Analog Setpoint The remote analog setpoint is set up identically to ratio control To provide a setpoint remotely typically a voltage or current source is connected to an analog input on the controller This input is configured as a linear input type and the master loop for ratio control All other input types are also usable as remote analog setpoint inputs Specify the loop to which the analog input is connected as the master loop and setup the rest of the ratio control pa rameters as outlined in Setup Loop Ratio Control Menu on page
179. mbols 55 58 when running ramp soak profile 146 battery 7 BATTERY DEAD 166 baud rate 80 BCC see block check character block check character 80 boost output 67 bridge circuit 32 Cc cables communications 9 47 SCSI 7 9 tie wrapping 35 troubleshooting 175 CALCULATING CHECKSUM 28 CANNOT LOAD JOB 75 CANNOT SAVE JOB 75 CASCADE BASE SP description 120 location 112 233 CASCADE CL SPAN description 121 location 112 233 cascade control 118 124 application example 121 relationship of secondary setpoint to primary output 123 setting up example 122 setup parameters 119 121 testing setup example 123 CASCADE HT SPAN description 121 location 112 233 CASCADE MAX SP description 120 location 112 233 Watlow Anafaze 221 Index CASCADE MIN SP description 120 location 112 233 CASCADE PRIM LOOP description 119 location 112 233 case removing 177 CE see agency compliance CHNG SP key changing the setpoint 61 description 54 does not work 170 locking and unlocking 78 clearance see installation communications baud rate 80 cable 9 47 controller address 79 error checking algorithm 80 ground loops 24 175 installation 45 49 jumper configurations 179 protocol 80 software problems 176 specifications 204 troubleshooting 174 176 wire sizes and lengths 22 see also EIA TIA COMMUNICATIONS BAUD RATE default value 74 description 80 location 73 233 COMMUNICATIONS ERR CHECK default value 74 description 80 location 73
180. n Hardware failed due to exces sive voltage on inputs Hardware failed due to exces sive voltage on inputs See H W Ambient Failure on page 169 See H W Gain or Offset Failure on page 170 H W OFFSET FAILURE Hardware failed due to exces sive voltage on inputs See H W Gain or Offset Failure on page 170 166 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Other Behaviors Chapter 9 Troubleshooting and Reconfiguring The following table indicates potential problems with the system or controller and recommends corrective actions Table 9 5 Other Symptoms Symptom Possible Causes Recommended Action Indicated tempera ture not as expected Controller not communicating Sensor wiring incorrect Noise See Checking Analog Inputs on page 171 CLS 200 display is not lit Power connection incorrect Check wiring and service See Wiring the Power Supply on page 25 No EPROM or bad EPROM Replace the EPROM See Replacing the EPROM on page 176 CLS200 damaged or failed Return the CLS200 for repair See Return ing Your Unit on page 164 CLS200 display is lit but keys do not work Keypad is locked See Keys Do Not Respond on page 170 CLS200 damaged or failed Return the CLS200 for repair See Return ing Your Unit on page 164 Control status of one or more loops changes from auto matic to manual Failed sensor
181. n accept a pulse input of up to 2000 Hz from a device such as an encoder The frequency of this input is scaled with user set parameters See Setup Loop Input Menu on page 82 and Chapter 9 Linear Scaling Examples This scaled value is the process variable for loop 5 on a CLS204 loop 9 on a CLS208 or loop 17 on a CLS216 The CLS200 can accommodate encoder signals up to 24V dc using a voltage divider or can power encoders with the 5V dc from the TB50 or TB18 The following figures il lustrate connecting encoders A pull up resistor in the CLS200 allows open collector inputs to be used If the signal on the pulse input exceeds 10kHz the controller s operation may be dis rupted Do not connect the pulse input to a signal source that may exceed 10kHz CLS200 and TB50 or TB18 Pulse Input Encoder Com Figure 2 20 Encoder with 5V dc TTL Signal CLS200 and TB50 or TB18 5V dc 10 kag R1 f Pulse Input Encoder R2 e Com Figure 2 21 Encoder Input with Voltage Divider For encoders with signals greater than 5V dc use a volt age divider to drop the voltage to 5 volts at the input Use appropriate values for R and R depending on the encoder excitation voltage Be sure not to exceed the specific cur rent load on the encoder Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 2 Installation Wiring Control and Digital I O This section
182. n the SETUP GLOBAL PARAMETERS menu is set to MEMORY then after a power failure the profile will resume operation at the elapsed time of the segment that was active when the pow er failure occurred 152 Watlow Anafaze Doc 0600 3050 2000 Tuning and Control Control Algorithms NOTE Doc 0600 3050 2000 This chapter describes the different methods of control available with the CLS200 This chapter covers control al gorithms control methods PID control starting PID val ues and tuning instructions to help appropriately set control parameters in the CLS200 system For more infor mation on PID control consult the Watlow Anafaze Practi cal Guide to PID This section explains the algorithms available for control ling a loop The control algorithm dictates how the controller responds to an input signal Do not confuse control algorithms with control output signals for example analog or pulsed de voltage There are several control algorithms available e On off e Proportional P e Proportional and integral PI e Proportional with derivative PD e Proportional with integral and derivative PID P PI or PID control is necessary when process variable cy cling is unacceptable or if the load or setpoint varies For any of these control statuses to function the loop must be in automatic mode Watlow Anafaze 153 Chapter 8 Tuning and Control On Off Control Proportional Control 154 Process V
183. ndling Make sure there is adequate clearance for the mount ing hardware terminal blocks and cables The con troller extends 7 40 in 178 mm behind the panel Allow for an additional 0 60 to 1 60 in 15 to 41 mm beyond the connectors 2 Temporarily cover any slots in the metal housing so that dirt metal filings and pieces of wire do not enter the housing and lodge in the electronics 3 Cuta hole in the panel 1 80 in 46 mm by 3 63 in 92 mm as shown below This picture is NOT a template it is for illustration only Use caution the dimensions given here have 0 02 in 1 mm tolerances 4 Remove the brackets and collar from the processor module if they are already in place Slide the processor module into the panel cutout Slide the mounting collar over the back of the proces sor module making sure the mounting screw indenta tions face toward the back of the processor module Doc 0600 3050 2000 Watlow Anafaze 15 Chapter 2 Installation CLS200 Series User s Guide Bracket top and bottom lt Panel _ m a m LF O H g o D OF Oa LF H i n A o z a i H o Bezel Mounting Collar Figure 2 5 Mounting Bracket 7 Loosen the mounting bracket screws enough to allow for the mounting collar and panel thickness Place each mounting bracket into the mounting slots
184. nections 33 Figure 2 19 Linear Current Signal Connections 33 Figure 2 20 Encoder with 5V dc TTL Signal 34 Figure 2 21 Encoder Input with Voltage Divider 34 Figure 2 22 Digital Output Wiring 36 Figure 2 23 Sample Heat Cool and Alarm Output Connections 37 Figure 2 24 Output Connections Using External Power Supply 38 Figure 2 25 TB50 Watchdog Timer Output 38 Figure 2 26 TB18 Watchdog Timer Output 38 Figure 2 27 Wiring Digital Inputs 39 Figure 2 28 Dual DAC with Current Output 43 Figure 2 29 Dual DAC with Voltage Output 44 Doc 0600 3050 2000 Watlow Anafaze ix List of Figures CLS200 Series User s Guide Figure 2 30 Single Multiple Serial DACs 45 Figure 2 31 Connecting One CLS200 to a Computer Using EIA TIA 232 46 Figure 2 32 EIA TIA 485 Wiring 47 Figure 2 33 Recommended System Connections 48 3 Using the CLS200 Figure 3 1 Operator Displays 51 Figure 3 2 CLS200 Front Panel 52 Figure 3 3 Bar Graph Display 55 Figure 3 4 Single Loop Display 57 Figure 3 5 Single Loop Display Heat and Cool Outputs Enabled 57 Figure 3 6 Single Loop Display with a Process Alarm 58 Figure 3 7 Failed Sensor Alarm in the Single Loop Display 58 Figure 3 8 Alarm Symbols in the Bar Graph Display 58 Figure 3 9 Activation and Deactivation of Process Alarms 68 4 Setup Figure 4 1 CLS200 Menu Tree 73 Figure 4 2 Two Points Determine Process Variable Conversion 86 Figure 4 3 Process Variable Limi
185. ner and outer thermocouple The outer thermocouple is located in the center of the water The inner thermocouple is located near the heating ele ment The desired temperature of the water is 150 F which is measured at the outer thermocouple Using cas cade control the outer thermocouple is used on the primary loop in this example loop 1 and the inner thermocouple is used on the secondary loop loop 2 The heater is con trolled by loop 2 with a setpoint range of 150 to 190 F Loop 1 Primary Cascade Loop Loop 2 Secondary Cascade Loop Water 150 Loop 1 Input Process Variable Outer Loop 2 PID Output Thermocouple Loop 2 Input Process Variable CLS200 Heater MA Inner Thermocouple Power Controller Figure 6 5 Application Using Cascade Control Doc 0600 3050 2000 Watlow Anafaze 121 Chapter 6 Enhanced Features CLS200 Series User s Guide To set up this application you would do the following 1 Change the display to loop 2 which will be the second ary loop and then enter the three key sequence EN TER then ALARM ACK then CHNG SP and go to the first screen in Table 6 2 2 Follow the steps in Table 6 2 to configure cascade control Table 6 2 Application Example Setting Up Cascade Control Display User Input LOOP PROCESS UNITS SETUP LOOP 02 CASCADE ALARM _ SETPOINT STATUS OUT Press YES to set up the cascade parameters wi
186. ng and go to the next parameter Start scanning mode if pressed twice Watlow Anafaze 53 Chapter 3 Using the CLS200 54 eal CHNG i J SP Do x Ad AUTO RAMP SOAK SOAK ALARM ACK CLS200 Series User s Guide Press CHNG SP to change the loop setpoint Press MAN AUTO to e Toggle a loop between manual and automatic control e Adjust the output power level of manual loops e Automatically tune the loop If your controller has the ramp soak option press RAMP SOAK to e Assign a ramp soak profile to the current loop e Select the ramp soak mode e See the status of a running profile Your controller may not have the ramp soak option If it does not pressing the RAMP SOAK key displays the message OPTION UNAVATLABLE Press ALARM ACK to e Acknowledge an alarm condition e Reset the global alarm output Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Displays Bar Graph Display Doc 0600 3050 2000 Chapter 3 Using the CLS200 This section discusses the controller s main displays bar graph single loop and job On power up the controller displays general symbolic in formation for up to eight loops This screen is called the bar graph display The diagram below shows the symbols used in the bar graph display Symbol f Q PROCESS _UNITS Loop Number O1l gt m gt an 1 lt aK 08 or Name AAAA MAMA ALARM _ SETPOINT STATUS OUT Control Status Figure 3
187. ng through display 81 location in firmware 73 model number description 5 mounting see installation N NO key description 53 NO key reset 176 noise eliminating problems with 23 isolation 23 reducing with zero cross switching 158 suppression 22 23 symptoms 22 O on off control control signal 157 description 154 selecting 94 spread 92 operator displays 51 Doc 0600 3050 2000 Index OUT OF TOLRNCE ALARM TIME description 138 location 136 233 output override 77 97 OUTPUT OVERRIDE DIG INPUT default value 74 description 77 location 73 233 outputs 5 Vdc output power 204 alarm see alarms analog see Dual DAC or Serial DAC boost output 67 control see control outputs CPU watchdog timer see CPU watchdog timer digital see digital outputs filter 91 process variable retransmit see process variable retransmit ramp soak ready state 139 reference voltage see reference voltage setup parameters 93 98 solid state relays 37 specifications 202 204 wiring see installation OVERRIDE DIG IN ACTIVE default value 74 description 77 location 73 233 over temperature shutdown devices 9 P panel see installation parameters accessing 71 alarm 99 103 changing values 72 control 90 92 global 74 82 input 82 89 menu tree see menu tree output 93 98 process variable retransmit 113 ramp soak profile 137 143 storage ofin RAM 7 test 103 parts list 5 personal computer see communications 174 PID autotuning see autotuning
188. nputs Parts List 6 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 1 System Overview Technical Description This section contains a technical description of each compo nent of your CLS200 series controller CLS200 The CLS200 is housed in an 1 8 DIN panel mount package It contains the CPU RAM with a built in battery EPROM serial communications digital I O analog inputs the screen and touch keypad CLS200 Series with SCSI Connector CLS204 or CLS208 with TB18 Connector Figure 1 3 CLS200 Rear Views The CLS200 has the following features e Keypad and 2 line 16 character display e Screw terminals for the power and analog inputs and communications e Input power is 12 to 24V dc at 1 Amp e A50 pin SCSI cable connects the digital inputs and outputs to the 50 terminal block TB50 The CLS204 and CLS208 are available with an 18 terminal block TB18 in place of the SCSI connector as shown in Fig ure 1 3 The firmware resides in an EPROM See Replacing the EPROM on page 176 for information on removing and re placing the EPROM The operating parameters are stored in battery backed RAM If there is a power loss the operating parameters are unchanged The battery has a ten year shelf life and it is not used when the unit is on The microprocessor performs all calculations for input sig nal linearization PID control alarms and communica tions Doc 0600 3050 2000 Wa
189. nt The controller may fail in a 0 or 100 power output state To prevent death personal inju ry equipment damage or property damage install external safety shutdown devices If death or injury may occur you must install FM approved safety shutdown devices that operate independently from the process con trol equipment With proper approval and installation thermal fuses may be used in some processes Watlow Anafaze 9 Chapter 1 System Overview Power Fail Protection CLS200 Series User s Guide In the occurrence of a sudden loss of power this controller can be programmed to reset the control outputs to off this is the default Typically when power is re started the con troller restarts to data stored in memory If you have pro grammed the controller to restart with control outputs on the memory based restart might create an unsafe process condition for some installations Therefore you should only set the restart with outputs on if you are certain your sys tem will safely restart See the Process Power Digital In put on page 79 When using a computer or host device you can program the software to automatically reload desired operating con stants or process values on power up Keep in mind that these convenience features do not eliminate the need for in dependent safety devices Contact Watlow Anafaze immediately if you have any ques tions about system safety or system operation Watlow Anafaze Doc 0
190. ntrol a wide variety of loads They are typically used to control SSRs or other power switching devices which in turn control for example heaters They may also be used to signal another device of an alarm condition in the con troller Analog outputs may be accomplished by using Dual DAC or Serial DAC modules in conjunction with one of the control outputs An open collector CPU watchdog output is also provided so that an external device may monitor the CPU state Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 11 Specifications Analog Outputs No direct analog outputs are provided The digital outputs may be used in conjunction with Dual DAC or Serial DAC modules to provide analog signals See Dual DAC Specifications on page 207 and Serial DAC Spec ifications on page 209 Digital Outputs Table 11 17 Digital Outputs Control Alarm Parameter Description Number 35 Operation Open collector output ON state sinks to logic common 34 Outputs selectable as closed loop control or alarm control Function Number of Control Outputs per PID Loop 1 global alarm output 2 maximum Control Output Types Time proportioning distributed zero crossing Serial DAC 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 Control Action 1 to 255 seconds programmable for each
191. ntrol loop parameters ac cording to the furnace application in this case on loop 1 2 Select another unused PID output for retransmitting the thermocouple value for example loop 2 heat out put 3 Change the display to loop 2 and then enter the three key sequence ENTER then ALARM ACK then CHNG SP and go to the first screen in Table 6 1 4 Follow the steps in Table 6 1 to configure the process variable retransmit option 5 After following the steps in Table 6 1 press BACK sev eral times until the normal loop display appears The controller will now produce an output on loop 2 which is linear and proportional to the loop 1 process vari able Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 6 Enhanced Features PV RETRANSMIT ALARM SETPOINT STATUS OUT Table 6 1 Application Example Setting Up Process Variable Retransmit Display User Input LOOP PROCESS UNITS SETUP LOOP 02 Press YES LOOP PROCESS UNITS 02 HEAT OUTPUT RETRANS PV 01 ALARM _ SETPOINT STATUS OUT Enter 01 for loop 1 process variable Press ENTER LOOP PROCESS UNITS 02 HEAT RETRANS MIN INP 0 ALARM SETPOINT STATUS OUT Enter the minimum input value which corresponds to the minimum output percentage For a range of 0 to 1000 F set the minimum input value to 0 F Press ENTER LOOP PROCESS UNITS 02 HEAT RETRANS MIN OUT 0 ALARM _ SETPOINT ST
192. nuously present for longer than the loop alarm delay time you set Failed sensor alarms are affected by the loop alarm delay even during the start up alarm delay time period Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Failed Sensor Alarms Chapter 3 Using the CLS200 Failed sensor alarms alert you if one of the following condi tions occurs e Thermocouple open e Thermocouple shorted must be enabled e Thermocouple reversed must be enabled e RTD open positive input or open negative input e RTD short between the positive and negative inputs What Happens if a Failed Sensor Alarm Occurs Thermocouple Open Alarm Thermocouple Reversed Alarm Doc 0600 3050 2000 If a failed sensor alarm occurs e The controller switches to manual mode at the output power indicated by the SENSOR FAIL HT OUTPUT and SENSOR FAIL CL OUTPUT parameters in the SETUP LOOP OUTPUTS menu The output power may be dif ferent for a thermocouple open alarm see Thermocou ple Open Alarm on page 65 e The controller displays an alarm code and alarm mes sage on the display See Alarm Displays on page 58 e The global alarm output is activated The thermocouple open alarm occurs if the controller de tects a break in a thermocouple or its leads If a thermocouple open alarm occurs the controller switch es to manual mode The output level is determined as fol lows e Ifthe HEAT COOL T C BRK OUT parameter in the SE
193. o put a profile in RUN or HOLD mode how to reset a profile and how to display profile statistics Figure 7 4 shows the ramp soak screens BACK No Profile Single RAmp Assigned ASSIGN R S Display i Profile Assigned y TIME REMAINING BACK RAMP SOAK f BACK CYCLE NUMBER 5 a a g RAMP y SOAK BACK SET MODE NO NO RESET a Figure 7 4 Ramp Soak Screens Doc 0600 3050 2000 Watlow Anafaze 145 Chapter 7 Ramp Soak CLS200 Series User s Guide Ramp Soak Displays The single loop and bar graph displays show additional codes when ramp soak firmware is installed Single Loop Display When the controller is running a profile the single loop dis play shows the ramp soak mode where it would usually show MAN or AUTO Table 7 4 describes the modes Table 7 4 Ramp Soak Single Loop Display oe Description STRT The profile is in the ready segment RUN The profile is unning HOLD The user has put the profile in hold mod TOHO The profile is in tole ance hold WAIT The profile is in t igger wait state This is the single loop display when a profile is running If a tolerance alarm occurs the controller displays a flashing T in the alarm symbol position Process Variable WA PROCESS WS Loop Number T F nee milk Lt 180TOHO50 Alarm Symbol Output Percentage Setpoint Ramp Soak Mode B
194. oblem 163 Returning Your Unit 164 Troubleshooting Controllers 164 Process and Deviation Alarms 164 Failed Sensor Alarms 166 System Alarms 166 Other Behaviors 167 Corrective and Diagnostic Procedures 168 Low Power 168 Battery Dead 168 Ambient Warning 168 H W Ambient Failure 169 H W Gain or Offset Failure 170 Keys Do Not Respond 170 Checking Analog Inputs 171 Earth Grounding 172 Checking Control Outputs 172 Testing Control Output Devices 173 Doc 0600 3050 2000 Watlow Anafaze vii Table of Contents Testing the TB18 and TB50 173 Testing Control and Digital Outputs 173 Testing Digital Inputs 173 CLS200 Series User s Guide Additional Troubleshooting for Computer Supervised Systems 174 Computer Problems 174 Communications 175 Ground Loops 175 Software Problems 176 NO Key Reset 176 Replacing the EPROM 176 Changing Communications 179 Installing Scaling Resistors 180 CLS204 and CLS208 Input Circuit 180 CLS204 and CLS208 Current Inputs 181 CLS204 and CLS208 Voltage Inputs 182 CLS204 and CLS208 RTDs and Thermistors 183 CLS216 Input Circuit 184 CLS216 Current Inputs 184 CLS216 Voltage Inputs 185 Scaling and Calibration 186 Configuring Dual DAC Outputs 186 Configuring Serial DAC Outputs 188 10 Linear Scaling Examples 189 Example 1 A 4 to 20 mA Sensor 189 Example 2 A 0 to 5V dc Sensor 191 Example 3 A Pulse Encoder 192 11 Specifications 193 CLS200 System Specifications 193 CLS200 Processor Physical Specifications 194
195. 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 switching device that completes or inter rupts a circuit by physically moving electri cal contacts into contact with each other Not recommended for PID control Solid State Relay SSR A switching device with no moving parts that completes or interrupts a circuit electrically Reset Control action that automatically eliminates offset 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 set point after the system stabilizes The inverse of integral Resistance Opposition to the flow of electric current mea sured in ohms 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 tempera ture coefficient sensor only while the ther mistor can have either a negative or positive Doc 0600 3050 2000 CLS200 Series User s Guide temperature coefficient Reverse Action An output control action in which an increase in the
196. og Timer 7 Pulse Input 8 Global Alarm 9 Output 1 Loop 1 heat Loop 1 heat 10 Output 342 11 Output 2 Loop 2 heat Loop 2 heat 12 Output 33 13 Output 3 Loop 3 heat Loop 3 heat 14 Output 32 15 Output 4 Loop 4 heat Loop 4 heat 16 Output 31 17 Output 5 Loop 5 heat Pulse loop heat 18 Output 30 19 Output 6 Loop 6 heat Loop 1 cool 20 Output 29 21 Output 7 Loop 7 heat Loop 2 cool 22 Output 28 23 Output 8 Loop 8 heat Loop 3 cool 24 Output 27 25 Output 9 Pulse loop Loop 4 cool 26 Output 26 heat 27 Output 10 Loop 1 cool Pulse loop cool 28 Output 25 29 Output 11 Loop 2 cool 30 Output 24 31 Output 12 Loop 3 cool 32 Output 23 33 Output 13 Loop 4 cool 34 Output 22 35 Output 14 Loop 5 cool 36 Output 21 37 Output 15 Loop 6 cool 38 Output 20 39 Output 16 Loop 7 cool 40 Output 19 41 Output 17 Loop 8 cool 42 Output 18 Pulse loop cool 43 Input 1 44 Input 2 45 Input 3 46 Input 4 47 Input 5 48 Input 6 49 Input 7 50 Input 8 Doc 0600 3050 2000 1 The indicated outputs are dedicated for 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 2 f you install a Watlow Anafaze Serial DAC the controller uses digital output 34 terminal 10 for a clock line You cannot use out put 34 for anything else when you have a Serial DAC installed Watlow Anafaze 41 Chapter 2 Installation CLS200 Series User s Gu
197. ol 61 Autotuning a Loop 62 Using Alarms 64 Alarm Delay 64 Failed Sensor Alarms 65 Process Alarms 66 Global Alarm 68 Ramp Soak 69 4 Setup 71 How to Access the Setup Menus 71 How to Change a Parameter 72 Setup Global Parameters Menu 74 Load Setup From Job 75 Save Setup to Job 75 Job Select Digital Inputs 76 Watlow Anafaze CLS200 Series User s Guide Doc 0600 3050 2000 CLS200 Series User s Guide Table of Contents Job Select Digital Inputs Active 77 Output Override Digital Input 77 Override Digital Input Active 77 Startup Alarm Delay 78 Keyboard Lock Status 78 Power Up Output Status 78 Process Power Digital Input 79 Controller Address 79 Communications Baud Rate 80 Communications Protocol 80 Communications Error Checking 80 AC Line Frequency 81 Digital Output Polarity on Alarm 81 EPROM Information 81 Setup Loop Input Menu 82 Input Type 83 Loop Name 84 Input Units 84 Input Reading Offset 84 Reversed T C Detection 85 Input Pulse Sample Time 85 Linear Scaling Parameters 86 Input Filter 89 Setup Loop Control Parameters Menu 90 Heat or Cool Control PB 91 Heat or Cool Control TI 91 Heat or Cool Control TD 91 Heat or Cool Output Filter 91 Spread 92 Restore PID Digital Input 92 Setup Loop Outputs Menu 93 Enable or Disable Heat or Cool Outputs 94 Heat or Cool Output Type 94 Heat or Cool Cycle Time 95 SDAC Mode 95 SDAC Low Value 95 SDAC High Value 95 Heat or Cool Output Action 96 Heat or Cool Output Limit 96 Heat or
198. omatic Mode A feature that allows the controller to set PID control outputs in response to the Process Variable PV and the setpoint Autotune A feature that automatically sets temperature control PID values to match a particular ther mal system AWG See American Wire Gauge B Baud Rate The rate of information transfer in serial com munications measured in bits per second Block Check Character BCC A serial communications error checking method An acceptable method for most appli cations BCC is the default method See also Cyclic Redundancy Check Bumpless Transfer A smooth transition from automatic closed loop to manual open loop operation The con trol output does not change during the trans fer Watlow Anafaze 213 Glossary Cc 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 formula for conversion to the Fahrenheit scale F 1 8 x C 32 Central Processing Unit CPU The unit of a computing system that includes the circuits controlling the interpretation of instructions and their execution Circuit Any closed path for electrical current A config uration of electrically or electromagnetically connected components or devices Closed Loop A control system that uses a
199. on See Bar Graph Display on page 146 Table 3 2 Control Status Symbols on the Bar Graph and Single Loop Displays Bar Graph a Display Display Description Symbol Symbol M MAN One or both outputs are enabled Loop is in manual con trol A AUTO Only one output heat or cool is enabled Loop is in automatic control T TUNE The loop is in autotune mode H HEAT Both heat and cool outputs are T enabled Loop is in automatic control and heating C COOL Both heat and cool outputs are L enabled Loop is in automatic control and cooling Both outputs disabled or input blank blank type is set to SKIP Navigating in Bar Graph Display When the bar graph display is visible e Press the YES up or NO down key to see a new group of loops e Press ENTER twice to scan all groups of loops The groups will display sequentially for three seconds each This is called scanning mode e Press any key to stop scanning e Press BACK once to go to the job display if enabled or the single loop display 56 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Single Loop Display Chapter 3 Using the CLS200 The single loop display shows detailed information for one loop at a time Process Variable UNITS Loop Number or Name Engineering Units 80AUTO100 SETPOINT STAY OUT Output Setpoint Control Status Percentage Figure 3 4 Single Loop Display
200. ons depending upon protocol Form of ANSI X3 28 1976 D1 F1 compatible with Allen Bra Prorgagl dley PLC full duplex or Modbus RTU Table 11 22 Processor Power Requirements Parameter Description Voltage 15 to 24V dc 3V dc Maximum Current 1A 204 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 11 Specifications CLS200 Power Supply Complete specifications for the CLS200 power supply are available at www watlow com See the links on the CLS200 page Doc 0600 3050 2000 Watlow Anafaze 205 Chapter 11 Specifications CLS200 Series User s Guide 206 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 11 Specifications Dual DAC Specifications Doc 0600 3050 2000 The Watlow Anafaze Dual DAC digital to analog convert er is an optional module for the CLS200 series controller The Dual DAC converts a distributed zero crossing DZC output signal to an analog process control signal Watlow Anafaze provides the following version of the Dual DAC e 4to 20 mAdc e Oto 5V de e Oto 10V de Table 11 29 Dual DAC Environmental Specifi cations Storage Temperature 20 to 60 C Operating Temperature 0 to 50 C Humidity 10 to 95 non condensing Table 11 30 Dual DAC Physical Specifications Weight 0 42 Ib 0 19 kg Length 4 4 inches 112 mm Width 3 6 inches 91 mm Height 1 8 inches 44 mm
201. ons on PC Board 178 Figure 9 3 EPROM Location 178 Figure 9 4 Remove EPROM 178 Figure 9 5 Jumper Configurations 179 Figure 9 6 CLS204 and CLS208 Input Circuit 181 Figure 9 7 CLS216 Input Circuit 184 Figure 9 8 Dual DAC 187 Figure 9 9 Serial DAC Voltage Current Jumper Positions 188 11 Specifications Figure 11 1 CLS200 Processor Module Dimensions 194 Figure 11 2 CLS200 Clearances with Straight SCSI Cable 195 Figure 11 3 CLS200 Clearances with Right Angle SCSI Cable 195 Figure 11 4 TB50 Dimensions 197 Figure 11 5 TB50 Dimensions with Straight SCSI Cable 198 Figure 11 6 TB50 Dimensions with Right Angle SCSI Cable 199 Figure 11 7 Power Supply Dimensions Bottom View 206 Figure 11 8 Dual DAC Dimensions 207 Figure 11 9 Serial DAC Dimensions 209 Doc 0600 3050 2000 Watlow Anafaze Xi List of Figures CLS200 Series User s Guide xii Watlow Anafaze Doc 0600 3050 2000 List of Tables 2 Installation Table 2 1 Cable Recommendations 22 Table 2 2 Power Connections 26 Table 2 3 Digital Output States and Values Stored in the Controller 36 Table 2 4 Digital Inputs States and Values Stored in the Controller 39 Table 2 5 TB18 Connections 40 Table 2 6 TB50 Connections for CLS204 and CLS208 41 Table 2 7 TB50 Connections for CLS216 42 Table 2 8 EIA TIA 232 Connections 46 Table 2 9 RTS CTS Pins in DB 9 and DB 25 Connectors 46 3 Using the CLS200 Table 3 1 Bar Graph Display Symbol
202. ool span of the secondary loop For this example we will assume no low side adjustment to the setpoint so the cool span is 0 F Press ENTER 122 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide BASE SP HT SPAN BASE SP Secondary Loop Setpoint eng units SP Setpoint PB Proportional Band Doc 0600 3050 2000 Chapter 6 Enhanced Features 3 Press BACK several times until the normal loop display appears The output percentage of loop 1 will now con trol the setpoint of loop 2 To verify that cascade is working as expected you would follow these steps 1 Setloop 1 to MANUAL and the OUTPUT to 0 Loop 2 set point should equal 150 BASE SP 2 Adjust loop 1 MANUAL OUTPUT to 50 Loop 2 setpoint should equal 170 BASE SP 50 of HT SPAN 3 Adjust loop 1 MANUAL OUTPUT to 100 Loop 2 set point should equal 190 BASE SP HT SPAN 4 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 1 must be tuned to produce the desired effect for the application on the set point of loop 2 For a cascade control application that uses the secondary loop for PID control loop 1 typically uses only proportional mode This must be set for the amount of change in the process variable to cause a 100 change in the output level The proportional band is selected so the setpoint of the sec ondary loop
203. oop Outputs Menu on page 93 for help enabling and disabling heat and cool outputs LOOP PROCESS UNITS SETUP LOOP 01 CONTROL PARAMS ALARM __ SETPOINT STATUS OUT Table 4 10 shows the parameters available in the SETUP LOOP CONTROL PARAMS menu Table 4 10 Setup Loop Control Parameters Parameter Default Value HEAT CONTROL PB Depends upon the INPUT TYPE setting 50 for J type thermocouple HEAT CONTROL TI Depends upon the INPUT TYPE setting 180 SEC R for J type ther mocouple HEAT CONTROL TD 0 HEAT CONTROL FILTER 3 COOL CONTROL PB 50 COOL CONTROL TI Depends upon the INPUT TYPE setting 60 SEC R for J type ther mocouple COOL CONTROL TD Depends upon the INPUT TYPE setting 0 SECONDS for J type ther mocouple COOL CONTROL FILTER 3 SPREAD 5 RESTORE PID DIGIN NONE 90 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Heat or Cool Control PB Heat or Cool Control TI Heat or Cool Control TD Heat or Cool Output Filter Doc 0600 3050 2000 Chapter 4 Setup Set the proportional band also known as gain A larger value yields less proportional action for a given deviation from setpoint LOOP PROCESS UNITS 01 HEAT CONTROL PB 50 ALARM _ SETPOINT STATUS OUT Selectable values Dependent upon sensor type The controller internally represents the proportional band PB as a gain value When you edit the pro
204. op s Setpoint NOTE Cascade control cannot be used on the same control loop as ratio control However both features may be used in the same multiloop controller Setup Loop Cascade Menu The setup parameters for cascade control appear under the SETUP LOOP CASCADE menu LOOP PROCESS UNITS SETUP LOOP 02 CASCADE ALARM __ SETPOINT STATUS OUT Press YES to set up the cascade parameters The loop cur rently displayed loop 02 in this case will be the secondary control loop which performs the actual control Primary Loop Enter the primary loop number The output percentage of this loop will control the setpoint of the secondary loop LOOP PROCESS UNITS 02 CASCADE PRIM LOOP 03 ALARM _ SETPOINT STATUS OUT Selectable values Any loop except the secondary loop Doc 0600 3050 2000 Watlow Anafaze 119 Chapter 6 Enhanced Features Base Setpoint Minimum Setpoint Maximum Setpoint 120 CLS200 Series User s Guide Enter the setpoint that corresponds to 0 heat and cool output from the primary loop PRIM LOOP This value is expressed in the same engineering units as the secondary loop s process variable LOOP PROCESS UNITS 02 CASCADE BASE SP 25 ALARM SETPOINT STATUS OUT Selectable values Any value from the secondary loop s minimum process variable to its maximum process vari able Enter the lowest value of the secondary loop setpoint This minimum set
205. or 167 TUNE 56 61 64 tuning control loops 159 161 U UL see agency compliance under temperature shutdown devices 9 unlocking the keypad 78 up arrow key 53 V voltage inputs ranges 202 resistance 202 scaling resistors 32 182 185 wiring 32 W weight controller 194 Dual DAC 207 power supply 205 Serial DAC 209 TB50 196 wire sizes controller 196 wiring see installation Y YES key 53 process variable incorrect on display 167 171 sensor inputs 171 software 176 TB18 173 TB50 173 Doc 0600 3050 2000 Watlow Anafaze 231 Index CLS200 Series User s Guide 232 Watlow Anafaze Doc 0600 3050 2000 Menu Structure SETUP GLOBAL PARAMETERS p 74 SETUP LOOP INPUT p 82 SETUP LOOP CONTROL PARAMS p 90 SETUP LOOP OUTPUTS p 93 SETUP LOOP ALARMS p 99 MANUAL I O TEST p 103 LOAD SETUP FROM JOB INPUT TYPE HEAT CONTROL PB HEAT CONTROL OUTPUT HI PROC ALARM SETPT DIGITAL INPUTS SAVE SETUP TO JOB LOOP NAME HEAT CONTROL TI HEAT OUTPUT TYPE HI PROC ALARM TYPE TEST DIGITAL OUTPUT JOB SELECT DIG INPUTS INPUT UNITS HEAT CONTROL TD HEAT OUTPUT CYCLE TIME HI PROC ALARM OUTPUT DIGITAL OUTPUT NUMBER XX JOB SEL DIG INS ACTIVE INPUT READING OFFSET HEAT CONTROL FILTER SDAC MODE DEV ALARM VALUE KEYPAD TEST OUTPUT OVERRIDE DIG INPUT REVERSED T C DETECT COOL CONTROL PB SDAC LO VALUE HI DEV ALARM TYPE TEST DISPLAY OVERRIDE DIG IN ACTIVE INPUT PULSE SAMP
206. or EIA TIA 485 signals to be transmitted proper ly each pair must be properly terminated The value of the termination resistor should be equal to the impedance of the communications cable used Values are typically 150 to 200 Q The receive lines at the converter or host device should be terminated in the converter the connector to the host de vice or the device itself Typically the converter documenta tion provides instructions for termination Use a terminating resistor on the receive lines on the last controller on the 485 line Set JU1 inside the CLS200 in po sition B to connect a 200 Q resistor across the receive lines Refer to Changing Communications on page 179 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 2 Installation EIA TIA 485 Converters and Laptop Computers In order for an EJA TIA 232 to 485 converter to optically isolate the computer from the 485 network the 232 and 485 sides must be powered independently Many 232 to 485 converters can be powered by the computer s communica tions port Some computers laptops in particular do not automatically provide the appropriate voltages These com puter converter combinations can usually be used by con necting an external power supply to the 232 side of the converter Not all converters have power inputs for the 232 side however NOTE When using Anasoft with a laptop computer choose a converter with an external 232 pow er input Ana
207. orms Distributed Zero Time Proportioning 30 Crossing 33 On Off 0 3 10 Os 1 3 4 6 Seconds Cycle Time set to 10 AC Cycle Figure 8 5 Time Proportioning and Distributed Zero Crossing Waveforms Watlow Anafaze 157 Chapter 8 Tuning and Control CLS200 Series User s Guide Distributed Zero Crossing DZC With DZC outputs the PID algorithm calculates an output between 0 and 100 but the output is distributed on a variable time base For each ac line cycle the controller de cides whether the power should be on or off There is no fixed cycle time since the decision is made for each line cy cle When used in conjunction with a zero crossing device such as a solid state relay SSR switching is done only at the zero crossing of the ac line which helps reduce electri cal noise Using a DZC output should extend the life of heaters Since the time period for 60 Hz power is 16 6 ms the switching interval is very short and the power is applied uniformly DZC should be used with SSRs 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 Note however DZC switching does not limit the current and voltage applied to the heater as phase an gle firing does Three Phase Distributed Zero Crossing 3P DZC This output type performs exactly t
208. orque 4 4 to 5 3 in lb 0 5 to 0 6 Nm SCSI Connector on Board SCSI 2 female Output Terminals Captive screw cage clamp Multiconductor cables 24 AWG l 0 2 mm Output Wire Gauge Single wire 22 to 18 AWG 0 5 to 0 75 mm Output Terminal Torque 4 4 to 5 3 in lb 0 5 to 0 6 Nm Doc 0600 3050 2000 Watlow Anafaze 197 Chapter 11 Specifications 198 CLS200 Series User s Guide Table 11 9 TB50 with Straight SCSI Length 6 4 inches 163 mm Width 4 0 inches 102 mm Height 1 5 inches 37 mm CooCoo Coosa DON G8 GG8GG9 Figure 11 5 TB50 Dimensions with Straight SCSI Cable Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 11 Specifications Table 11 10 TB50 with Right Angle SCSI Length 5 4 inches 137 mm Width 4 0 inches 102 mm Height 1 5 inches 37mm A 5 4 in 8 137 mm of L Q co co co co co lol co co co co co Ee o s sls je co coe D co co co co LEBIR ee N co co S co _ 9 Seat 102 mm Q 1 5 in 37 mm Figure 11 6 TB50 Dimensions with Right Angle SCSI Cable Doc 0600 3050 2000 Watlow Anafaze 199 Chapter 11 Specifications Inputs CLS200 Series User s Guide The controller accepts analog sensor inputs which are mea sured
209. ou need to return the unit to Watlow Anafaze for testing and repair Custom er Service will issue you an RMA number See Returning Your Unit on page 164 Before trying to troubleshoot a problem by replacing your controller with another one first check the installation If you have short ed sensor inputs to high voltage lines or a transformer is shorted out and you replace the controller you will risk damage to the new controller Watlow Anafaze 163 Chapter 9 Troubleshooting and Reconfiguring CLS200 Series User s Guide If you are certain the installation is correct you can try re placing the controller If the second unit works correctly then the problem is specific to the controller you replaced Returning Your Unit Before returning a controller contact your supplier or call Watlow for technical support Controllers purchased as part of a piece of equipment must be serviced or returned through the equipment manufac turer Equipment manufacturers and authorized distribu tors should call customer service to obtain a return materials authorization RMA number Shipments with out an RMA will not be accepted Other users should con tact their suppliers for instructions on returning products for repair Troubleshooting Controllers A problem may be indicated by one or more of several types of symptoms e A process or deviation alarm e A failed sensor alarm e Asystem alarm e Unexpected or undesired behavior T
210. output Reverse heat or direct cool independently selectable for each output Off State Leakage Current lt 0 01 mA to dc common Maximum Current Maximum Voltage Switched 60 mA for each output 5V power supply from the processor module can supply up to 350 mA total to all outputs 24V dc Table 11 18 CPU Watchdog Output Parameter Description Number 1 Operation Open collector output ON state sinks to logic common Function Monitors the processor module microprocessor Maximum Current 10 mA 5V power supply in the processor module can supply up to 350 mA total to all outputs Maximum Voltage Switched 5V dc Doc 0600 3050 2000 Watlow Anafaze 203 Chapter 11 Specifications CLS200 Series User s Guide Table 11 19 5V dc Output Power to Operate Solid State Relays Parameter Voltage Description 5V dc Maximum Current 350 mA Table 11 20 Reference Voltage Output Power to Operate Bridge Circuit Sensors Parameter Voltage Description 5V dc Maximum Current 100 mA Table 11 21 Processor Serial Interface Parameter Description Type EIA TIA 232 3 wire or EIA TIA 485 4 wire Isolation None Baud Rate 2 400 9 600 or 19 200 user selectable Error Check BCC or CRC user selectable 1 with EIA TIA 232 communications up to 32 with EIA Number of Controllers TIA 485 communicati
211. output test in the MANUAL I 0 TEST menu to turn the digital output on and off See Test Digital Output on page 104 and Digital Output Num ber on page 104 When the output is ON the output voltage should be less than 1V When the output is OFF the output voltage should be between 4 75 and 5 25V NOTE By default heat outputs are enabled Only disabled outputs may be turned on using the manual I O test To test heat outputs set the corresponding loop to manual mode 100 output See Selecting the Control Status on page 61 28 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 2 Installation Digital Input Test Use the following procedure to test digital inputs before connecting to field devices 1 Disconnect any system wiring from the input to be tested 2 Gotothe DIGITAL INPUTS test in the MANUAL I 0 TEST menu See Digital Inputs on page 103 This test shows whether the digital inputs are H high or open or L low or closed 3 Attach a wire to the terminal of the digital input you want to test See tables 2 5 to 2 7 on pages 40 to 42 for connections a When the wire is connected only to the digital in put terminal the digital input test should show that the input is H high or open b When you connect the other end of the wire to the controller common TB50 terminal 3 or TB18 ter minal 2 the digital input test should show that the input is L low or closed Sensor Wiring Th
212. pin and 9 pin connectors or cables that are supplied by the factory EIA TIA 232 may be used to connect a computer through a 232 485 converter to an EIA TIA 485 communications net work with up to 32 CLS200 controllers Watlow Anafaze 45 Chapter 2 Installation CLS200 Series User s Guide Table 2 8 EIA TIA 232 Connections Wire CLS200 DB 9 DB 25 Color TB1 Connector Connector White TX Pin 26 RX Pin 2 RX Pin 3 Red RX Pin 25 TX Pin 3 TX Pin 2 Black GND Pin 23 GND Pin 5 GND Pin 7 Green GND Pin 24 N U Pin 9 N U Pin 22 Shield N C GND Pin 5 GND Pin 7 Jumpers in EIA TIA 232 Connectors Some software programs and some operator interface ter minals require a Clear to Send CTS signal in response to their Request to Send RTS signal or a Data Set Ready DSR in response to their Data Terminal Ready DTR The CLS200 is not configured to receive or transmit these signals To use such software with the CLS200 jumper the RTS to the CTS and the DTR to the DSR in the DB connec tor Table 2 9 lists the standard pin assignments for DB 9 and DB 25 connectors Table 2 9 RTS CTS Pins in DB 9 and DB 25 Connectors DB 9 DB 25 RTS 7 4 CTS 8 5 DTR 4 20 DSR 6 6 Cables manufactured by Watlow Anafaze for EIA TIA 232 communications include these jumpers Neither AnaWin nor Anasoft software requires these jumpers Figure 2 31 Connecting One CLS200 to a Com puter Using EIA TI
213. point overrides any calculation caused by the primary loop calling for a lower setpoint This value is ex pressed in the same engineering units as the secondary loop s process variable LOOP PROCESS UNITS 02 CASCADE MIN SP 25 ALARM SETPOINT STATUS OUT Selectable values Any value from the secondary loop s minimum process variable to its maximum process vari able Enter the highest value of the secondary loop setpoint This maximum setpoint overrides any calculation caused by the primary loop calling for a higher setpoint This value is ex pressed in the same engineering units as the secondary loop s process variable LOOP PROCESS UNITS 02 CASCADE MAX SP 180 ALARM _ SETPOINT STATUS OUT Selectable values Any value from the secondary loop s minimum process variable to its maximum process vari able Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 6 Enhanced Features Heat Span Enter the multiplier to apply to the primary loop heat out put percentage LOOP PROCESS UNITS 02 CASCADE HT SPAN 9999 ALARM _ SETPOINT STATUS OUT Selectable values 9999 to 9999 Cool Span Enter the multiplier to apply to the primary loop cool out put percentage LOOP PROCESS UNITS 02 CASCADE CL SPAN 9999 ALARM SETPOINT STATUS OUT Selectable values 9999 to 9999 Cascade Control Example Water Tank A tank of water has an in
214. portional band you will see the values change in predefined steps small steps for narrow proportional band values and large steps for wide proportional band values The controller calculates the default proportional band for each input type according to the following equation High Range Low Range Default PB Gain Set the integral term also known as reset A larger value yields less integral action LOOP PROCESS UNITS 01 HEAT CONTROL TI 180 SEC R ALARM SETPOINT STATUS OUT Selectable values 0 off to 6000 seconds Set the derivative constant A larger value yields greater derivative action LOOP PROCESS UNITS 01 HEAT CONTROL TD 0 ALARM _ SETPOINT STATUS OUT Selectable values 0 to 255 seconds Dampen the response of the heat or cool output 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 A Watlow Anafaze 91 Chapter 4 Setup Spread Restore PID Digital Input 92 CLS200 Series User s Guide larger value results in a slower or more dampened re sponse to changes in the process variable LOOP PROCESS UNITS 01 HEAT CONTROL FILTER 3 ALARM SETPOINT STATUS OUT Selectable values 0 to 255 0 disables the output filter For a loop using on off control the spread is the control hys teresis This determines the difference between the point at which a heat output turns o
215. primary signal The signal can also be used as an input to other types of control systems such as a PLC Any available output heat or cool may be used as a re transmit output Any process variable including the same loop number input may be retransmitted The controller output signal must be connected to a Dual DAC or Serial DAC converter to get a 4 to 20 mA dc or 0 to 5V dc signal The choice of converter depends on ap plication requirements The process variable retransmit feature is included in both the ramp soak and enhanced features options NOTE If an output is defined as a process variable retransmit it cannot be used for PID control Setup Loop Process Variable Retransmit Menu The setup parameters for the process variable retransmit feature appear in the SETUP LOOP PV RETRANSMIT menu LOOP PROCESS UNITS SETUP LOOP 02 PV RETRANSMIT ALARM _ SETPOINT STATUS OUT Press YES to view the process variable retransmit parame ters Doc 0600 3050 2000 Watlow Anafaze 113 Chapter 6 Enhanced Features CLS200 Series User s Guide Retransmit Process Variable Enter the number of the loop that provides the process variable for the retransmit calculation LOOP PROCESS UNITS 02 HEAT OUTPUT RETRANS PV 02 ALARM __ SETPOINT STATUS OUT If you set this parameter NONE and press NO the controller skips to the COOL OUTPUT RETRANS PV screen The COOL parameter is set up the same way as
216. put that is not being used for PID control or for Serial DAC clock This parameter appears only if you answered YES to EDIT SEG EVENTS LOOP PROCESS UNITS A SEG 20 EVENT 3 OUTPUT 30 ALARM SETPOINT STATUS OUT Selectable values Any digital output from 1 to 34 except those in use or NONE no event When you are done setting segment events press BACK to return to EDIT SEG EVENTS then press NO to go to the next parameter Assign a state to the event At the end of the segment the output goes to the state you assign here This parameter appears only if you answered YES to EDIT SEG EVENTS LOOP PROCESS UNITS A SEG20 EV3 DO 30 ACTIVE STATE OFF ALARM __ SETPOINT STATUS OUT Selectable values OFF high or ON low Watlow Anafaze 141 Chapter 7 Ramp Soak Edit Segment Triggers Trigger Input Number Trigger Active State 142 CLS200 Series User s Guide Each segment may have up to two triggers digital inputs Both triggers must be true in order for the segment to run If a trigger is not true the profile goes into the trigger wait state LOOP PROCESS UNITS A SEGMENT 15 EDIT SEG TRGGRS ALARM _ SETPOINT STATUS OUT Press YES to edit triggers for the current segment or NO to advance to the SEGMENT TOLERANCE parameter Assign a digital input to a segment trigger You can assign any digital input to any trigger You can also assign the same digital input as a t
217. r screw terminals 26 typical 12 wire recommendations 21 30 35 47 wire sizes 22 wiring 21 27 29 49 integral description 155 guidelines for setting 160 162 setting a value 91 settings from other controllers 161 term versus reset settings 160 J JOB RUNNING 60 JOB RUNNING DATA MODIFIED 60 JOB RUNNING REMOTELY LOADED 60 JOB SEL DIG INS ACTIVE default value 74 description 77 location 73 233 JOB SELECT DIG INPUTS default value 74 description 76 location 73 233 jobs loading from memory 75 remote selection 76 77 saving to memory 75 jumpers Dual DAC 187 EIA TIA 232 179 EIA TIA 485 179 in EJA TIA 232 connectors 46 power supply common 27 Serial DAC 188 unused inputs 30 when using 2 wire RTD 32 K KEYBOARD LOCK STATUS default value 74 description 78 location 73 233 226 Watlow Anafaze CLS200 Series User s Guide keypad ALARM ACK see ALARM ACK key BACK see BACK key CHNG SP see CHNG SP key ENTER see ENTER key keys do not work 167 170 locking 78 MAN AUTO see MAN AUTO key NO see NO key overview 52 RAMP SOAK see RAMP SOAK key testing 105 unlocking 78 YES see YES key KEYPAD TEST description 105 how to quit 105 location 73 233 L LD alarm code 164 limit controller 9 limit output 96 linear inputs decimal shift in ramp soak parameters 145 display format 87 engineering units 84 scaling and calibration 186 scaling examples 189 192 scaling parameters 86 89 LO DEV ALARM OUTPUT default value 9
218. re 11 3 CLS200 Clearances with Right Angle SCSI Cable Doc 0600 3050 2000 Watlow Anafaze 195 Chapter 11 Specifications CLS200 Series User s Guide Table 11 6 Processor Connections Power Terminals TB2 Captive screw cage clamp Power Wire Gauge TB2 22 to 18 AWG 0 5 to 0 75 mm Power Terminal Torque TB2 4 4 to 5 3 in Ib 0 5 to 0 6 Nm Sensor Terminals TB1 Captive screw cage clamp Sensor Wire Gauge TB1 Thermocouples 20 AWG 0 5 mm Linear 22 to 20 AWG 0 5 mm Communications 24 AWG 0 2 mm Sensor Terminal Torque TB1 4 4 to 5 3 in Ib 0 5 to 0 6 Nm Output Terminals TB18 Captive screw cage clamp Output Wire Gauge TB18 Multiconductor cables 24 AWG 0 2 mm Single wire 22 to 18 AWG 0 5 to 0 75 mm Output Terminal Torque TB18 SCSI Connector 4 4 to 5 3 in lb 0 5 to 0 6 Nm SCSI 2 female TB50 Physical Specifications 196 Table 11 7 TB50 Physical Dimensions Weight 0 32 Ib 0 15 kg Length 4 1 inches 104 mm Width 4 0 inches 102 mm Height 1 5 inches 37 mm Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 11 Specifications 4 1 in 104 mm 808888808880 BUBERRRR BEBE 208 008 008088 DY RUBBEBREGREBREE d 1 5 in 37 mm Figure 11 4 TB50 Dimensions Table 11 8 TB50 Connections Screw Terminal T
219. readings are erratic look for sources of electrical noise See Noise Suppression on page 22 e Eliminate possible ground loops See Ground Loops on page 24 e Contact your supplier for further troubleshooting guidance See Returning Your Unit on page 164 To check control outputs e Set the loop you want to check to manual mode e Set the output power percentage to the desired level e Set the output type to ON OFF or TP see Chapter 4 Setup If the control output is not connected to an output device like an SSR connect an LED in series with a 1 kQ resistor from 5V to the output Tie the anode of the LED to 5V The LED should be off when the output is 0 and on when the output is 100 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 9 Troubleshooting and Reconfiguring Testing Control Output Devices Testing the TB18 and TB50 Testing Control and Digital Testing Digital Inputs Connect the solid state relay SSR control terminals to the CLS200 control output and connect a light bulb or other load that can easily be verified to the output terminals on the SSR Put the loop in manual mode and set the output to 100 The ac load should turn on Do not attempt to measure ac voltage at the SSR s output terminals Without a load connected the SSR s output ter minals do not turn off This makes it difficult to determine whether the SSR is actually working Measure the voltage across a lo
220. rect ly Below are some tips on how to recognize and avoid prob lems with EMI For earth ground wire use a large gauge and keep the length as short as possible Additional shielding may be achieved by connecting a chassis ground strap from the panel to CLS200 case If your controller displays the following symptoms suspect EMI e The controller s display blanks out and then reenergiz es as if power had been turned off for a moment e The process variable does not display correctly EMI may also damage the digital output circuit so digital outputs will not turn on If the digital output circuit is dam aged return the controller to Watlow Anafaze for repair Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Avoiding RFI EMI Chapter 2 Installation To avoid or eliminate most RFI EMI noise problems Connect the CLS200 case to earth ground The CLS200 system includes noise suppression circuitry This circuitry requires proper grounding Separate the 120 or 240V ac power leads from the low level input and output leads connected to the CLS200 series controller Do not run the digital I O or control output leads in bundles with ac wires Where possible use solid state relays SSRs instead of electromechanical relays If you must use electro mechanical relays try to avoid mounting them in the same panel as the CLS200 series equipment If you must use electromechanical relays and you must place
221. rigger in more than one segment and more than one profile This parameter appears only if you answered YES to EDIT SEG TRGGRS LOOP PROCESS UNITS A SEG 15 TRIG 1 INPUT NR NONE ALARM SETPOINT STATUS OUT Selectable values Any digital input from 1 to 8 or NONE disable trigger When you are done editing segment triggers press BACK to return to EDIT SEG TRGGRS Choose the state that will satisfy the trigger condition A trigger input is ON when pulled low by an external device A trigger input is OFF when the digital input is high This parameter appears only if you answered YES to EDIT SEG TRGGRS LOOP PROCESS UNITS A SEGO1 TR1 DI08 ACTIVE STATE 0FF ALARM SETPOINT STATUS OUT Selectable values OFF or ON Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 7 Ramp Soak Trigger Latch Status Choose whether the trigger is 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 running If an unlatched trigger becomes false the segment timer stops and the loop goes into trigger wait state When using two triggers with a segment the following log ic applies Table 7 2 Trigger Latch Logic Trigger Settings Trigger Logic Both Triggers Latched ORed Trigger starts a segment Both Triggers Unlatched ANDed Triggers start continue a segment One Trigger
222. rn e Press YES to toggle the pixel pattern e Press NO to end the test and return to the top of the MANUAL I 0 TEST menu Watlow Anafaze 105 Chapter 4 Setup CLS200 Series User s Guide 106 Watlow Anafaze Doc 0600 3050 2000 Extruder Control This chapter explains the additional features for the CLS200 series controller equipped with Extruder Control Firmware Except for setup default and control algorithm differences described below the Extruder Control Firm ware operates the same as the standard control firmware Setup Loop Outputs Menu The SETUP LOOP OUTPUTS menu contains a parameter with descriptors for the selections that are different than those in the standard control firmware LOOP PROCESS UNITS SETUP LOOP 01 OUTPUTS ALARM _ SETPOINT STATUS OUT Cool Output Nonlinear Output Curve Select linear or nonlinear output curves for the cool output LOOP PROCESS UNITS 01 COOL OUTPUT FAN ALARM _ SETPOINT STATUS OUT Selectable Values FAN OIL or H20 See Figure 5 1 Doc 0600 3050 2000 Watlow Anafaze 107 Chapter 5 Extruder Control Defaults 108 NOTE CLS200 Series User s Guide Calculated by PID Figure 5 1 Cool Output Nonlinear Output Curve The COOL OUTPUT parameter is located in the SETUP LOOP OUTPUTS menu Select one of three nonlinear or lin ear output curves for cooling The Extruder Control Firmware uses different defaults for some par
223. rror message returns check that the power supplied to the controller is at least 12 0V dc 1 A See Wiring the Power Supply on page 25 4 Ifthe error message returns again make a record of the settings if possible using software Then perform a NO key reset see NO Key Reset on page 176 5 Ifthe error is not cleared contact your supplier for fur ther troubleshooting guidance See Returning Your Unit on page 164 The dead battery alarm indicates that the CLS200 battery is not functioning correctly or has low power or no power If this alarm occurs parameters have reset to the factory de fault settings The controller will retain its settings when powered The battery is required to keep the settings in memory only when the controller is powered down If the controller displays BATTERY DEAD 1 Acknowledge the alarm 2 If the error message remains turn the power to the controller off then on again 3 Ifthe error message returns when power is restored perform a NO key reset See NO Key Reset on page 176 4 Ifthe erroris not cleared contact your supplier for fur ther troubleshooting guidelines See Returning Your Unit on page 164 The ambient warning alarm indicates that the ambient temperature of the controller is too hot or too cold Ambient warning occurs when the controller s temperature is in the Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide H W Ambient Failure Doc 06
224. rted alarm occurs if the controller detects that the positive and negative RTD leads are shorted You do not have to set any parameters for the RTD alarms Restore Automatic Control After a Sensor Failure Process Alarms Setting Up Alarms 66 This feature returns a loop to automatic control after a failed sensor is repaired To enable this feature e Choose a digital input for the RESTORE PID DIGIN parameter in the SETUP LOOP CONTROL PARAMS menu e Connect the digital input to the dc common terminal on the controller The CLS200 has four process alarms each of which you can configure separately for each loop e Low process alarm e High process alarm e Low deviation alarm e High deviation alarm To set up an alarm e Set the alarm setpoint limit e Set the alarm type e Choose an output if desired e Set the alarm deadband e Set an alarm delay if desired The setpoints deviation alarm values and deadband all use the same decimal format as the loop s process variable Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 3 Using the CLS200 What Happens If a Process Alarm Occurs Process Alarm Outputs Alarm Type Control or Alarm High and Low Process Alarms Doc 0600 3050 2000 If a process alarm occurs the controller does the following e Shows an alarm code on the display See Alarm Dis plays on page 58 e Activates the global alarm output See Global Alarm
225. s SSRs accept a 3 to 32V dc input for control and some can switch up to 100 Amps at 480 V ac For larger currents use silicon control rec tifier SCR power controllers up to 1000 Amps at 120 to 600V ac You can also use SCRs and a Serial DAC for phase angle fired control The 34 control and alarm outputs are open collector out puts referenced to the CLS200 s common Each output sinks up to 60 mA dc to the controller common when on Control outputs are SINK outputs They are Low when the output is ON Connect them to the negative side of solid state relays Figure 2 23 shows sample heat cool and alarm output con nections TB50 orTB18 SSR SSR SSR Heat Output Cool Output a Alarm Output 5V dc e Figure 2 23 Sample Heat Cool and Alarm Output Connections Watlow Anafaze 37 Chapter 2 Installation CPU Watchdog Timer Digital Inputs 38 CLS200 Series User s Guide TB50 or TB18 SSR SSR SSR oe t Heat Output __ Cool Output An Alarm Output mP mm Common Figure 2 24 Output Connections Using External Power Supply The CPU watchdog timer constantly monitors the micro processor It is a sink output located on TB50 terminal 6 or TB18 terminal 3 The output can be connected to an exter nal circuit or device in order to determine if the controller is powered and oper
226. s or resistance ohms The item or substance that is to be heated or cooled Loop Alarm Any alarm system that includes high and low process deviation band deadband digital out puts 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 pro cess value For linear inputs the low reading is a percentage 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 con trol aspects The operator sets output levels Manual Reset See Reset Milliampere mA One thousandth of an ampere MMI Man machine interface N Doc 0600 3050 2000 Glossary NO Key Reset A method for resetting the controller s memory for instance after an EPROM change Noise Unwanted electrical signals that usually pro duce signal interference in sensors and sensor circuits See also Electromagnetic Interfer ence Noise Suppression The use of components to reduce electrical interference that is caused by making or breaking electrical contact or by inductors Nonlinear Through Anafaze software the Nonlinear field sets
227. s 55 Table 3 2 Control Status Symbols on the Bar Graph and Single Loop Displays 56 Table 3 3 Alarm Type and Symbols 59 4 Setup Table 4 1 Global Parameters 74 Table 4 2 Job Select Inputs 76 Table 4 3 Job Selected for Various Input States 76 Table 4 4 Firmware Option Codes 81 Table 4 5 Setup Loop Input 82 Table 4 6 CLS200 Input Types and Ranges 83 Table 4 7 Input Character Sets 84 Table 4 8 Input Reading Offset 85 Table 4 9 Display Formats 87 Table 4 10 Setup Loop Control Parameters 90 Table 4 11 Setup Loop Outputs 93 Table 4 12 Heat Cool Output Types 94 Table 4 183 Setup Loop Alarms 99 Table 4 14 Manual I O Test 103 5 Extruder Control Table 5 1 Default Control Parameters for Fan Cool Output 109 Table 5 2 Default Control Parameters for Oil Cool Output 109 Table 5 3 Default Control Parameters for H2O Cool Output 109 Doc 0600 3050 2000 Watlow Anafaze xiii List of Tables CLS200 Series User s Guide 6 Enhanced Features Table 6 1 Application Example Setting Up Process Variable Retransmit 117 Table 6 2 Application Example Setting Up Cascade Control 122 Table 6 3 Application Example Setting Up Ratio Control 128 Table 6 4 Application Example Setting Up Remote Setpoint 130 Table 6 5 Application Example Setting Up Differential Control 132 7 Ramp Soak Table 7 1 Ramp Soak Specifications 135 Table 7 2 Trigger Latch Logic 143 Table 7 3 Display Formats 145 Table
228. s JU2 JU3 JU4 and JU5 on the board Use tweezers to carefully grasp the jumpers and gen tly slide them off the pins 5 Use tweezers to gently slide jumpers JU2 JU3 JU4 and JU5 onto the correct pins see Figure 9 5 6 Ifyou are configuring the controller as the last device on an EIA TIA 485 network move JU1 to the B posi tion 7 Reassemble the controller Doc 0600 3050 2000 Watlow Anafaze 179 Chapter 9 Troubleshooting and Reconfiguring CLS200 Series User s Guide Installing Scaling Resistors A CAUTION Resistors are installed for all inputs on the CLS200 Inputs with signal ranges between 10 and 60 mV use 0 Q resis tors in the RC position only All other input signals require special input scaling resistors Scaling resistors are soldered to the circuit board Only qualified technicians should at tempt to install or remove these components Improper techniques tools or materials can result in damage to the controller that is not covered by the warranty CLS204 and CLS208 Input Circuit NOTE 180 The CLS204 and CLS208 can accept differential thermo couple mV dc V dc mA dc and RTD inputs Un less ordered with special inputs these controller accept only signals within the standard range 10 to 60mV dc To accommodate other signals the input circuit must be modified When configured for thermocouple inputs 0 Q re sistors are installed in all RC locations To accommodate volt
229. s available on 34 sample time 85 scaling and calibration 186 scaling parameters 86 89 specifications 201 technical information 34 wiring 34 PV see process variable R RAM 7 177 ramp soak 133 152 assigning profiles to loops 148 continuing from hold 150 228 Watlow Anafaze CLS200 Series User s Guide cycle number 147 decimal shift 145 editing a profile while it is running 149 events 141 firmware option code 81 holding a profile 150 mode symbols on display 146 147 mode setting 147 overview 133 135 power failure while running profile 152 process variable retransmit see process variable retransmit profile setup parameters 137 143 resetting a profile 151 running a profile 148 screens for RAMP SOAK key 145 specifications 135 time base 137 time remaining 147 tolerance 143 tolerance alarm see alarms tolerance triggers 142 RAMP SOAK key 54 assigning profiles 148 cycle number 147 does not work 64 69 170 locking and unlocking 78 screens accessed by pressing 145 set mode 147 time remaining 147 unassigning profiles 148 RAMP SOAK TIME BASE default value 74 description 137 location 73 136 233 ratio control 124 132 application example 126 129 131 differential control 131 remote analog setpoint 129 setting up example 127 129 131 setup parameters 125 126 RATIO CONTROL CTRL RATIO description 126 location 112 233 RATIO CONTROL MAX SP description 125 location 112 233 RATIO CONTROL MIN SP description 125 location
230. s power sup ply When using multiple Serial DACs the controller can not provide sufficient current use the 5V dc output from the CLS200 power supply Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 2 Installation Daisy chain up to Controller 16 Serial DACs Power Supply Serial DAC 5V 1 5V In 5V Common 7 2 COM In 15V Common 3 CLK In TB50 or TB18 4 Data In Serial DAC Clock 5 Out Control Output 6 Out Load 4 Figure 2 30 Single Multiple Serial DACs Serial Communications EIA TIA 232 Interface Doc 0600 3050 2000 The CLS200 series controllers are factory configured for EIA TIA 232 communications unless otherwise specified when purchased However the communications are jump er selectable so you can switch between EJA TIA 232 and EIA TIA 485 See Changing Communications on page 179 EIA TIA 232 provides communication to the serial port of an IBM PC or compatible computer It is used for single controller installations where the cable length does not ex ceed 50 feet 15 2 m The EIA TIA 232 interface is a standard three wire inter face See the table below for connection information If you are using EIA TIA 232 communications with grounded thermocouples use an optical isolator between the controller and the computer to prevent ground loops Table 2 8 shows EIA TIA 232 connections for 25
231. sensor to measure a process variable and makes decisions based on that feedback Cold Junction Connection point between thermocouple met als 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 Communications The use of digital computer messages to link components See also Serial Communications Baud Rate Control Action The response of the PID control output relative to the error between the process variable and the setpoint For reverse action usually heat ing as the process decreases below the set point the output increases For direct action usually cooling as the process increases above the setpoint the output increases Control Status The type of action that a controller uses For example on off time proportioning PID auto matic or manual and combinations of these 214 Watlow Anafaze CLS200 Series User s Guide 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 Character BCC See also Block Check Ch
232. t type for the affected loops b Verify that sensors are properly connected 3 Ifthe sensors are correctly connected with power on to the heaters check for high common mode voltage a Seta voltmeter to measure volts ac b Connect the negative lead to a good earth ground c One by one check each input for ac voltage by connecting the positive lead on the voltmeter to the positive and negative sensor input connec tions The process variable should indicate ambi ent temperature If it does not contact your supplier to return the unit for repair See Return ing Your Unit on page 164 NOTE Noise in excess of 1V ac should be elimi nated by correctly grounding the CLS200 See Wiring the Power Supply on page 25 4 Verify the sensors e For thermocouples remove the thermocouple leads and use a digital voltmeter to measure the resistance between the positive and negative thermocouple leads A value of 2 to 20 Q is nor mal Readings in excess of 200 Q indicate a prob lem with the sensor e For RTDs measure between the IN and IN ter minals of TB1 RTD inputs should read between 20 and 250 Q 5 To verify that the controller hardware is working cor rectly check any input except the pulse input or an RTD as follows a Disconnect the sensor wiring b Setthe INPUT TYPEtoJ T Cinthe SETUP LOOP INPUT menu c Place a short across the input The controller should indicate the ambient temperature on the ch
233. t control For two zone cascade control systems the PID settings for both loops the primary plus the secondary must be opti mized for good temperature control See Chapter 4 Setup for information on tuning PID loops Ratio control allows the process variable of one loop mas ter loop multiplied by a ratio to be the setpoint of another loop ratio loop You can assign any process variable to de termine the setpoint of a ratio loop By adjusting the ratio control parameters you can adjust the influence that the master loop process variable has on the setpoint of the ratio loop Maximum SP O Q D 99 Q fa re 2 T fo ad Minimum SP SP Differential Minimum Maximum PV PV Master Loop Process Variable SP Setpoint PV Process Variable Figure 6 7 Relationship Between the Master Loop s Process Variable and the Ratio Loop s Setpoint Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide NOTE Chapter 6 Enhanced Features 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 Setup Loop Ratio Control Menu Master Loop Minimum Setpoint Maximum Setpoint Doc 0600 3050 2000 The ratio control parameters appear in the SETUP LOOP RATIO CONTROL menu LOOP PROCESS UNITS SETUP LOOP 02 RATIO CONTROL ALARM SETPOINT STATUS OUT Press YES to set up th
234. t type for the loop is set to time proportioning TP Selectable values 1 to 255 seconds Select the Serial DAC output signal LOOP PROCESS UNITS 01 SDAC MODE VOLTAGE ALARM SETPOINT STATUS OUT Selectable values CURRENT or VOLTAGE Set the low output signal level for the Serial DAC The Se rial DAC converts 0 output from the controller to the val ue set here Set the high and low values to match the input range of the output device For instance if the output device has a 0 00 10 00 V range set the SDAC LO VALUE to0 00 VDC and set the SDAC HI VALUE to 10 00 VDC LOOP PROCESS UNITS 01 SDAC LO VALUE 0 00 VDC ALARM _ SETPOINT STATUS OUT Selectable values 0 00 to 9 00 VDC or 0 0 to 19 90 MA This value must be less than the SDAC HI VALUE Set the high output signal level for the Serial DAC The Se rial DAC converts 100 output from the controller to the value set here Set the high and low values to match the range of the out put device For instance if the output device has a 4 to 20 Watlow Anafaze 95 Chapter 4 Setup CLS200 Series User s Guide mA range set the SDAC HI VALUE to 20 00 MA and the SDAC LO VALUE to 4 00 MA LOOP PROCESS UNITS 01 SDAC HI VALUE 10 00 VDC ALARM SETPOINT STATUS OUT Selectable values 0 10 to 10 00 VDC or 0 10 to 20 00 mA This value must be greater than the SDAC LO VALUE Heat or Cool Output Action Select the control action for
235. ted by Input Reading Range 87 Figure 4 4 Linear and Nonlinear Outputs 98 Figure 4 5 Digital Inputs Screen 104 5 Extruder Control Figure 5 1 Cool Output Nonlinear Output Curve 108 6 Enhanced Features Figure 6 1 Enhanced Features Option Menus 112 Figure 6 2 Linear Scaling of Process Variable for Retransmit 115 Figure 6 3 Application Using Process Variable Retransmit 116 Figure 6 4 Relationship Between the Primary Loop s Output and the Secondary Loop s Setpoint 119 Figure 6 5 Application Using Cascade Control 121 Figure 6 6 Secondary Loop Setpoint Related to Primary Loop Output 123 Figure 6 7 Relationship Between the Master Loop s Process Variable and the Ratio Loop s Setpoint 124 Figure 6 8 Application Using Ratio Control 127 7 Ramp Soak Figure 7 1 Sample Ramp Soak Profile 133 Figure 7 2 Setup Ramp Soak Profiles Menu 136 Figure 7 3 Positive and Negative Tolerances 143 Figure 7 4 Ramp Soak Screens 145 x Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide List of Figures 8 Tuning and Control Figure 8 1 On Off Control 154 Figure 8 2 Proportional Control 155 Figure 8 3 Proportional and Integral Control 155 Figure 8 4 Proportional Integral and Derivative Control 156 Figure 8 5 Time Proportioning and Distributed Zero Crossing Waveforms 157 9 Troubleshooting and Reconfiguring Figure 9 1 Removal of Electronics Assembly from Case 177 Figure 9 2 Screws Locati
236. ter 6 Enhanced Features Differential control is a simple application of the ratio con trol option used to control one process ratio loop at a dif ferential or offset to another master loop To use differential control set the ratio value to 1 0 to provide the desired offset Differential Control Example Thermoforming Doc 0600 3050 2000 A thermal forming application requires that the outside heaters operate at a higher temperature than the center heaters The differential control point is determined by the master loop which is using infrared IR sensors for temper ature feedback Secondary loops use thermocouples for feedback The loop using the IR sensor as an input is assigned to the master loop in the SETUP LOOP RATIO CONTROL menu The secondary loop is the differential control loop Setting the setpoint differential SP DIFF to the desired offset will produce the desired offset between the secondary and mas ter loops For example the master loop can be controlled at 325 F and the secondary loop at 375 F by using a differential of 50 F Loop 1 must be set up for PID control of the setpoint at 325 F To set up this application you would do the following 1 Change the display to loop 2 and then enter the setup parameters Go to the first screen in Table 6 5 2 Follow the steps in Table 6 5 to configure the process variable retransmit option Watlow Anafaze 131 Chapter 6 Enhanced Features CL
237. terface purchase an EKIA TIA 232 tester with LED indicators Attach the tester between the controller and the computer When the computer sends data to the controller the tester s TX LED should blink When the computer receives data from the controller the RX LED should blink You can also connect an oscilloscope to the transmit or receive line to see whether data is being sent or re ceived If the serial port does not appear to be working the software setup may need to be modified or the hardware may need to be repaired or replaced Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Communications Ground Loops Doc 0600 3050 2000 Chapter 9 Troubleshooting and Reconfiguring Most communications problems are due to incorrect wiring or incorrectly set communications parameters Therefore when there is a problem check the wiring and communica tions settings first Verify the following e Communications port Software must be configured to use the communications port to which the controller is connected e Software protocol Set the controller to MOD Modbus for AnaWin or WatView ANA Anafaze for Anasoft or Anascan e Controller address Configure software to look for the controller at the correct address In a multiple control ler installation each controller must have a unique address e Baud rate Software and controller must be set the same e Error checking ANA protocol only Software
238. th loop 2 as the sec ondary loop LOOP PROCESS 02 CASCADE LOOP 01 STATUS UNITS PRIM ALARM _ SETPOINT OUT Enter 01 to make loop 1 the primary loop Press ENTER LOOP PROCESS 02 CASCADE BASE SP 150 ALARM _ SETPOINT UNITS STATUS OUT The base setpoint corresponds to the 0 level output of the primary loop Enter the base setpoint of the secondary loop For this exam ple we will assume a base setpoint of 150 F which is the desired water temperature Press ENTER 02 CASCADE MIN SP 350 ALARM _ SETPOINT PROCESS STATUS UNITS N Enter the minimum setpoint of the secondary loop For this example we will use a minimum setpoint of 350 F Press ENTER LOOP PROCESS 02 CASCADE MAX SP 1400 ALARM _ SETPOINT UNITS STATUS Enter the maximum setpoint of the secondary loop For this exam ple we will use a maximum setpoint of 1400 F Press ENTER _LOoP PROCESS 02 CASCADE HT SPAN 40 ALARM __ SETPOINT UNITS STATUS OUT Enter the heat span of the secondary loop This is the span over which the primary output from 0 to 100 is used to change the set point The desired setpoint range is 150 to 190 F We will assume a linear rise in setpoint so the heat span is 40 F Press ENTER LOOP 02 CASCADE CL SPAN 0 ALARM _ SETPOINT PROCESS UNITS STATUS OUT Enter the c
239. the single loop display 72 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 4 Setup OUTPUT STATUS UT SCALING PV COOL CONTROL OUTPUT LO PROC ALARM OUTPUT SETUP GLOBAL SETUP LOOP SETUP LOOP SETUP LOOP SETUP LOOP MANUAL 1 0 PARAMETERS INPUT CONTROL PARAMS OUTPUTS ALARMS TEST LOAD SETUP INPUT TYPE HEAT CONTROL PB HEAT CONTROL HI PROC ALARM DIGITAL INPUTS FROM JOB OUTPUT SETPT SAVE SETUP LOOP NAME HEAT CONTROL TI HEAT OUTPUT TYPE HI PROC ALARM TEST DIGITAL TO JOB TYPE OUTPUT JOB SELECT INPUT UNITS HEAT CONTROL TD HEAT OUTPUT HI PROC ALARM DIGITAL OUTPUT DIG INPUTS CYCLE TIME TP OUTPUT NUMBER XX JOB SEL DIG INS INPUT READING HEAT CONTROL SDAC PARAMETERS DEV ALARM KEYPAD TEST ACTIVE OFFSET FILTER SDAC VALUE OUTPUT OVERRIDE REVERSED T C COOL CONTROL PB HEAT OUTPUT HI DEV ALARM DISPLAY TEST DIG INPUT DETECT ACTION TYPE OVERRIDE DIG INPUT PULSE COOL CONTROL TI HEAT OUTPUT HI DEV ALARM IN ACTIVE SAMPLE TIME LIMIT OUTPUT Pulse input STARTUP ALARM COOL CONTROL TD HEAT OUTPUT LO DEV ALARM DELAY DISP FORMAT LIMIT TIME TYPE Linear and pulse RAMP SOAK COOL CONTROL SENSOR FAIL LO DEV ALARM TIME BASE INPUT SC
240. the host or the converter to the first CLS200 and from that point run a second cable to the next CLS200 and so on See Figure 2 33 If necessary for servicing instead of connecting each con troller directly into the next install a terminal strip or con nector as close as possible to each CLS200 run a communications cable from one terminal strip to the next and connect the controllers to the bus with short lengths of cable Watlow Anafaze 47 Chapter 2 Installation 232 Communications CLS200 Series User s Guide To avoid unacceptable interference use less than 10 feet 3 m of cable from the terminal or connector to the CLS200 serial port Some systems may experience problems with sensor signal reading if the commons of multiple controllers are connect ed See Signal Common on page 48 Refer to Termination on page 48 for more on terminating resistors Connect the shield drain to earth ground only at computer or host end 485 Communications Serial Port Optically Isolatin 232 to 485 Converter Shielded Twisted Pair Cable x oN First CLS200 Second CLS200 Last CLS200 Signal Common Termination 48 Figure 2 33 Recommended System Connections For usual installations do not connect the dc commons of the controllers together or to the converter or host device Use an optically isolating EIA TIA 232 to 485 converter to prevent problems with sensor readings In order f
241. the output Normally heat out puts are set to reverse action and cool outputs are set to di rect action When output action is set to REVERSE the output goes up when the process variable goes down When set to DIRECT the output goes up when the process vari able goes up LOOP PROCESS UNITS 01 HEAT OUTPUT ACTION REVERSE ALARM _ SETPOINT STATUS OUT Selectable values REVERSE or DIRECT Heat or Cool Output Limit This parameter limits the maximum PID control output for a loop s heat or cool output This limit may be continuous or it or it may be in effect for a specified number of seconds see the next parameter If you choose a timed limit the output limit time restarts when the controller powers up and whenever the loop goes from manual to automatic con trol 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 values 0 to 100 Heat or Cool Output Limit Time Set a time limit for the output limit set at the previous pa rameter LOOP PROCESS UNITS 01 HEAT OUTPUT LIMIT TIME CONT ALARM SETPOINT STATUS OUT Selectable values 1 to 999 seconds or to CONT continu ous 96 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 4 Setup Sensor Fail Heat or Cool Output NOTE A WARNING When a sensor fail al
242. the system to linear control or to one of two nonlinear control options Input 0 for lin ear 1 or 2 for nonlinear O Offset The difference in temperature between the set point and the actual process temperature Off set 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 continuity between the two networks Output Control signal action in response to the differ ence between setpoint and process variable Output Type The form of PID control output such as time Watlow Anafaze 217 Glossary proportioning distributed zero crossing Serial DAC or analog Also the description of the elec trical hardware that makes up the output Overshoot The amount by which a process variable exceeds the setpoint before it stabilizes P Panel Lock A feature that prevents operation of the front panel by unauthorized people PID Proportional Integral Derivative A control status
243. tic to manual or tune ALARM SETPOINT STATUS OUT ENTER Stores data or settings e Assigns output power and advances to the next level of manual loops BACK parameter e Selects a menu e Cancels editing Starts scanning mode or parameter and returns to a if pressed twice CHNG Answers YES to previous menu SP YES NO prompts e Changes process Increases a setpoint value or choice ne e Skips a menu or parameter e Answers NO to YES NO prompts e Decreases a value or choice Figure 3 2 CLS200 Front Panel 52 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Front Panel Keys YES up Chapter 3 Using the CLS200 Press YES to kd NO down Select a menu or parameter Answer YES to the flashing prompts Increase a value or choice when editing Stop scanning mode Press NO to Skip a menu or parameter when the prompt is blinking Answer NO to the flashing prompts Decrease a value or choice when editing Stop scanning mode Perform a NO key reset NOTE Pressing the NO key on power up performs a NO key reset This procedure clears the RAM and sets the controller s parameters to their default values See NO Key Reset on page 176 B BACK Press BACK to ENTER Cancel editing Return to a previous menu Switch between bar graph single loop and job displays Stop scanning mode Press ENTER to Doc 0600 3050 2000 Store data or a parameter choice after editi
244. tion al features of a CLS200 controller equipped with Ex truder Control Firmware Chapter 6 Enhanced Features describes process variable retransmit ratio differential and cascade control features available with the enhanced features option Chapter 7 Ramp Soak explains how to set up and use the features of the ramp soak option Chapter 8 Tuning and Control describes available control algorithms and provides suggestions for appli cations Chapter 9 Troubleshooting and Reconfiguring includes troubleshooting upgrading and reconfigur ing procedures for technical personnel Watlow Anafaze 1 Chapter 1 System Overview Getting Started Safety Symbols WARNING CAUTION Initial Inspection A A NOTE CLS200 Series User s Guide e Chapter 10 Linear Scaling Examples provides an example configuring a pressure sensor a flow sensor and an encoder using linear scaling e Chapter 11 Specifications lists detailed specifica tions of the controller and optional components The following sections provide information regarding prod uct features technical descriptions safety requirements and preparation for operation These symbols are used throughout this manual Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury or property damage
245. tive control corrects for overshoot by anticipating the behavior of the process variable and adjusting the out put appropriately For example if the process variable is Doc 0600 3050 2000 Watlow Anafaze 155 Chapter 8 Tuning and Control Heat and Cool Outputs 156 CLS200 Series User s Guide rapidly approaching the setpoint from below derivative control reduces the output anticipating that the process variable will reach setpoint Use it to reduce overshoot and oscillation of the process variable common to PI control Figure 8 4 shows a process under full PID control x Setpoint Proportional Band t process Variable Figure 8 4 Proportional Integral and Deriva tive Control Each loop may have one or two outputs Often a heater is controlled according to the feedback from a thermocouple in which case only one output is needed In other applications two outputs may be used for control according to one input For example a system with a heater and a proportional valve that controls cooling water flow can be controlled according to feedback from one thermo couple In such systems the control algorithm avoids switching too frequently between heat and cool outputs The on off algo rithm uses the SPREAD parameter to prevent such oscilla tions see Spread on page 92 When PID control is used for one or both loop outputs both the SPREAD parameter and PID parameters determine when contro
246. tlow Anafaze 7 Chapter 1 System Overview Front Panel Description TB50 CLS200 Series User s Guide The display and touch keypad provide an intelligent way to operate the controller The display has 16 alphanumeric or graphic characters per line The 8 key keypad allows you to change the operating parameters controller functions and displays The information packed displays show process variables setpoints and output levels for each loop A bar graph dis play single loop display scanning display and an alarm display offer a real time view of process conditions Two ac cess levels allow operator changes and supervisor changes WATLOW ANAFAZE CLS200 PROCESS UNITS ALARM SETPOINT STATUS OUT MAN CHNG AUTO SP YES Figure 1 4 CLS200 Front Panel The TB50 is a screw terminal interface for control wiring which allows you to connect relays encoders and discrete I O devices to the CLS200 The screw terminal blocks accept wires as large as 18 AWG 0 75 mm2 A 50 pin SCSI cable connects the TB50 to the CLS200 Q a co co co co co o co l sls j 8 cos S co co co co co co 8 co co o c02 O co 8 co NS fall E N ED 8 so 2e B Q Figure 1 5 TB50 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide CLS200 Cabling Safety External Safety Devices Doc 0600 3050 2000 A WARNING Chapt
247. troller The encoder generates 900 pulses for every inch the conveyor moves You want to mea sure conveyor speed in feet per minute FPM Setup The encoder input is connected to the controller s pulse in put The INPUT TYPE for the loop is set to PULSE A one second sample time gives adequate resolution of the con veyor s speed The resolution is 1 pulse _ 60 seconds 1 inch 1 foot 1 second 1 minute 900 pulses 12 inches 0 006 FPM A DISP FORMAT of 99 99 TO 300 00 is appropriate The input readings are as follows e At 0 Hz the input reading will be 0 00 FPM e At the maximum pulse rate of the CLS200 2000 Hz 2000 pulses 60 seconds 1 inch 1 foot _ 1 second 1 minute 900 pulses 12 inches _ AT EEM Table 10 5 Scaling Values Parameter Prompt Value High Process Variable HIGH PV 11 11 FPM High Sensor Reading HIGH RDG 2000 Hz Low Process Variable LO PV 0 FPM Low Sensor Reading LO RDG 0 Hz 192 Watlow Anafaze Doc 0600 3050 2000 Specifications This chapter contains specifications for the CLS200 series controllers TB50 terminal board Dual DAC module Serial DAC module and the CLS200 power supply CLS200 System Specifications This section contains CLS200 series controller specifica tions for environmental specifications and physical dimen sions inputs outputs the serial interface and system power requirements The controller described consists of a processor module an
248. ts pulses for the amount of time you set here before calculating the frequn cy The controller scales this frequency and uses the result ing value as the process variable for the pulse loop Generally the longer the pulse sample time the more sta ble the process variable but the slower the response of the pulse loop This parameter is available only for loop 5 on the CLS204 loop 9 on the CLS208 or loop 17 on the CLS216 LOOP PROCESS UNITS 17 INPUT PULSE SAMPLE TIME 1S ALARM SETPOINT STATUS OUT Selectable values 1 to 20 seconds Watlow Anafaze 85 Chapter 4 Setup CLS200 Series User s Guide Linear Scaling Parameters The following parameters are only available if the input type is LINEAR or PULSE These parameters let you scale the raw input readings in millivolts or Hertz to the engi neering units of the process variable For linear inputs the input reading is in percent 0 to 100 representing the 0 to 60mV input range of the con troller For pulse inputs the input reading is in Hertz cy cles per second The scaling function is defined by two points on a conver sion line This line relates the process variable PV to the input signal The engineering units of the process variable can be any units the graph in Figure 4 2 shows PSI as an example 20 PSI High Process Variable Process Variable Low Process Variable 0 PSI o omv Low High samy Loar
249. u assign a profile to a loop the profile does not start immediately Instead it goes to the ready segment segment 0 and stays there until you put the profile in run mode You can set a setpoint assign events and set event states for the ready segment Use this parameter to set the ready segment setpoint Setting the setpoint to OFF ensures that control outputs for the loop running the profile will not come on LOOP PROCESS UNITS A READY SEGMENT SETPOINT OFF ALARM SETPOINT STATUS OUT Selectable values 999 to 9999 or OFF See Setpoints and Tolerances for Various Input Types on page 144 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 7 Ramp Soak Ready Segment Edit Events Ready Event Output Press YES to set or edit the ready state for all outputs that are not used for control or for the Serial DAC clock When you assign a profile the controller starts the ready seg ment it goes to the setpoint and puts all the outputs in the state you set here The outputs stay in the states they are set to until their states are changed at the end of subse quent segments LOOP PROCESS UNITS A READY SEGMENT EDIT EVENTS ALARM SETPOINT STATUS OUT Press NO to advance to EXTERNAL RESET INPUT NUMBER Press NO to increment the output number PressYES to set the event state to ON or OFF This parameter appears only if you answered YES to READY SEGMENT EDIT EVENTS LOOP
250. u is SETUP GLOBAL PARAMETERS Refer to Figure 4 1 for a listing of all top level menus and their related parameters 1 Select the single loop display for the loop to set up 2 Enter the three key sequence See How to Access the Setup Menus on page 71 The first menu is displayed SETUP GLOBAL PARAMETERS 3 To select the appropriate menu e Press NO to move from one menu to the next The menus wrap around pressing NO continuously advances through the top level menus e Press YES to enter the displayed menu 4 To select the parameter to be edited e Press NO to advance from one parameter to the next Parameters do not wrap around e Press YES to edit the displayed parameter 5 To edit the parameter setting e Press up or down YES or NO to scroll to the value or choice you want to select e Press ENTER to accept the change or press BACK to cancel the change without saving 6 Select another parameter and repeat from step 4 or press BACK to return to the top level menu 7 Select another menu and repeat from step 3 or press BACK to exit the setup menus The following sections tell more about the parameters for each of the six top level menus Each display illustration contains the default value for that specific parameter If you have a controller with the enhanced features option there will be additional menus See Chapter 6 Enhanced Features Figure 4 1 shows the top level menus accessible from
251. urn to sin gle loop display Repeat from Step 1 for the cool output if available Press BACK at any time to discard your changes and return to single loop display Autotuning is a process by which a controller determines the correct PID parameters for optimum control This sec tion explains how to autotune the CLS200 Before autotuning the controller it must be installed with control and sensor circuitry and the thermal load in place Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Background Performing an Autotune Doc 0600 3050 2000 NOTE Chapter 3 Using the CLS200 It must be safe to operate the thermal system and the ap proximate desired operating temperature setpoint must be known The technician or engineer performing the autotune should know how to use the controller front panel or MMI software interface e g AnaWin or Anasoft to do the following 1 Select a loop to operate and monitor 2 Seta loop s setpoint 3 Change a loop s control status MAN TUNE AUTO 4 Read and change the controller s global and loop setup parameters Autotuning is performed at the maximum allowed output If you have set an output limit autotuning occurs at that value Otherwise the control output is set to 100 during the autotune Only the heat output output 1 of a loop may be autotuned The PID constants are calculated according to process s re sponse to the output The loop n
252. ut available to be used as a control or an alarm output See Enable or Disable Heat or Cool Outputs on page 94 The CPU watchdog timer output can be used to monitor the state of the controller with an external circuit or device See CPU Watchdog Timer on page 38 Doc 0600 3050 2000 Watlow Anafaze 35 Chapter 2 Installation 36 CLS200 Series User s Guide Table 2 3 Digital Output States and Values Stored in the Controller State Value Description Off High Open circuit On Low Sinking current to common The digital outputs sink current from the load to the con troller common The load may powered by the 5V dc supplied by the controller at the TB50 Alternately an ex ternal power supply may be used to drive loads Keep in mind the following points when using an external power supply e The CLS200 power supply available from Watlow Anafaze includes a 5V dc supply When using it to supply output loads connect the 5V dc common to the 15V dc common at the power supply e Do not exceed 24 volts e Ifyou tie the external load to earth ground or if you cannot connect it as shown in See Figure 2 22 then use a solid state relay All digital outputs are sink outputs referenced to the CLS200 series controller common supply These outputs are low pulled to common when they are on The outputs conduct current when they are low or on The maximum current sink capability is 60 mA at 24
253. uts Setting Enables 1 Jobs 1 2 2 Jobs 1 4 3 Jobs 1 8 NONE Disables remote job selection Table 4 3 shows which input states select which jobs When nothing is connected the inputs are all false and job 1 is se lected Table 4 3 Job Selected for Various Input States re C ai Job Digital Input 3 Digital Input 2 Digital Input 1 No F F F 1 F F T 2 F T F 3 F T T 4 T F F 5 T F T 6 T T F 7 T T T 8 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 4 Setup Job Select Digital Inputs Active Specify which state is considered true for the digital in puts used for job selection Default is LOW meaning that an input must be pulled low to be considered true If HIGH is selected an input will be considered true unless it is pulled low LOOP PROCESS UNITS JOB SEL DIG INS ACTIVE LOW ALARM SETPOINT STATUS OUT Selectable values HIGH or LOW Changing this setting has the effect of reversing the order of the jobs in Table 4 3 Output Override Digital Input A WARNING To enable the output override feature select a digital in put When the specified input is activated the controller sets all loops to manual mode at the output levels specified atthe SENSOR FAIL HT OUTPUT and SENSOR FAIL CL OUTPUT parameters in the SETUP LOOP OUTPUTS menu LOOP PROCESS UNITS OUTPUT OVERRIDE DIG INPUT NONE AL
254. uts Control Alarm Pulse Input a Signal Inputs ROO Q yy D CLS200 Power supply g amp o gt CLS200 with TB18 Signal Inputs 11 Digital Outputs Control Alarm 2 Digital Inputs 1 Digital Pulse Input Power supply Figure 2 1 CLS200 System Components Mounting Controller Components NOTE Install the controller in a location free from excessive heat more than 50 C 122 F dust and unauthorized han dling Electromagnetic and radio frequency interference can induce noise on sensor wiring Select locations for the CLS200 and TB50 such that wiring can be routed clear of sources of interference such as high voltage wires power switching devices and motors For indoor use only Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide A WARNING Recommended Tools Mounting the Controller Doc 0600 3050 2000 Chapter 2 Installation To reduce the risk of fire or electric shock in stall the CLS200 in a controlled environment relatively free of contaminants Use any of the following tools to cut a hole of the appropri ate size in the panel e Jigsaw and metal file for stainless steel and heavy weight panel doors e Greenlee 1 8 DIN rectangular punch Greenlee part number 600 68 for most panel materials and thick nesses e Nibbler and metal file for aluminum and lightweight panel doors You will also need these tools e Phillips h
255. wledge the alarm 2 If the error message remains turn the power to the controller off then on again 3 Ifthe H W Gain error is reported remove any connec tions to the 5V dc reference TB1 18 on the back of the controller If this corrects the problem there was an error in the wiring You may need to consult tech nical support to determine the correct wiring 4 Ifthe error persists make a record of the settings us ing software then perform a NO key reset See NO Key Reset on page 176 5 Ifthe error is not cleared contact your supplier for fur ther troubleshooting guidelines See Returning Your Unit on page 164 If the controller has failed it is likely that it was damaged by excessive voltage or noise Before replacing the controller troubleshoot for noise and ground loops If the CLS200 seems to function but the MAN AUTO CHNG SP ALARM ACK and RAMP SOAK keys do not respond when you press them the keypad is probably locked Unlock the keypad according to the instructions in Keyboard Lock Sta tus on page 78 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 9 Troubleshooting and Reconfiguring Checking Analog Inputs If the process variable displayed in the software and on the controller do not agree 1 Verify that the controller is communicating 2 Ifthe process variable indicated on the controller dis play is incorrect a Verify that you have selected the correct inpu
256. y 10 to 95 non condensing Table 11 34 Serial DAC Physical Specifications Weight 0 76 Ib 0 34 kg Length 5 4 inches 137 mm Width 3 6 inches 91 mm Height 1 8 inches 44 mm 0 162 in diameter 91 mm 0 3 in 8 mm lt gt 10 mm Figure 11 9 Serial DAC Dimensions Doc 0600 3050 2000 Watlow Anafaze 209 Chapter 11 Specifications Serial DAC Inputs CLS200 Series User s Guide Table 11 35 Serial DAC Agency Approvals Compliance cot Electromagnetic Compatibility EMC CE Directive directive 89 336 EEC UL 916 Standard for Energy Manage ment Equipment File E177240 UL and C UL The Serial DAC requires a proprietary serial data signal and the clock signal from the CLS200 via the TB50 Any control output can be configured to provide the data signal The Serial DAC also requires a 5V dc power input Table 11 36 Serial DAC Inputs Parameter Description Data 4 mA maximum to DC COM Open collector or HC CMOS logic levels Clock 0 5 mA maximum to DC COM Open collector or HC CMOS logic levels Table 11 37 Serial DAC Power Requirements Parameter Description Voltage 4 75 to 5 25V dc 300 mA maximum Current 210 mA typical 20V dc out 210 Watlow Anafaze Doc 0600 3050 2000 CLS200 Series User s Guide Chapter 11 Specifications Serial DAC Analog Outputs Table 11 38 Serial DAC Analog Output Specif
257. ymbols Alarm Code Bar Graph Symbol Alarm Message Alarm Description FS F T C BREAK Failed Sensor Break detected in thermocouple circuit RO RTD OPEN RTD Open Break detected in RTD circuit RS RTD SHORTED RTD Short Short detected in RTD circuit RT REVERSED TC Reversed Thermocouple Reversed polarity detected in thermocouple circuit ST T C SHORTED Shorted Thermocouple Short detected in thermocouple cir cuit HP No message High Process Alarm Process variable has risen above the set limit HD No message High Deviation Alarm Process variable has risen above the setpoint plus the deviation alarm value LP No message Low Process Alarm Process variable has dropped below the set limit LD No message Low Deviation Alarm Process variable has dropped below the setpoint minus the deviation alarm value AW No message Ambient Warning Controller s ambient temperature has exceeded operating limits by less than 5 C 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 the keypad and dis play won t work for anything else until you acknowledge each alarm The alarm symbols are displayed as long as the alarm condition is v

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