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Series D8
User’s Guide
Watlow Anafaze
1241 Bundy Blvd.
Winona, MN 55987
Customer Service:
Phone ....... 1-800-414-4299
Fax ........... 1-800-445-8992
Technical Support:
Phone ....... (507) 494-5656
Fax ........... (507) 452-4507
Email ........ [email protected]
Part No. 0600-3120-2000 Rev.
B
November 2008
Copyright © 2005, Watlow Anafaze, Incorporated
Information in this manual is subject to change without notice. No part of this publication may be reproduced, stored in a retrie val system, or transmitted in an y form without written permission from Watlow Anafaze.
Anafaze is a re gistered trademark of Watlow Electric Manuf acturing Compan y. DeviceNet is a trademark of the Open DeviceNet Vendor Association, Inc. UL is a registered trademark of Underwriters Laboratories, Inc. All other trademarks are the property of their respective owners.
RSNetWorx, RSLinx and RSLogix are trademarks of Rockwell Software Inc.
DeviceNet is a trademark of the Open DeviceNet Vendors Association.
Warranty
Watlow Anafaze, Incorporated w arrants that the products furnished under this Agreement will be free from defects in material and w orkmanship 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 disco very of such defect. The sole obligation and liability of Watlow
Anafaze, Incorporated under this w arranty shall be to repair or replace, at its option and without cost to the Customer, the defective product or part.
Upon request by Watlow Anafaze, Incorporated, the product or part claimed to be defecti ve shall immediately be returned at the Customer's e xpense to Watlow Anafaze, Incorporated. Replaced or repaired products or parts will be shipped to the Customer at the e xpense of Watlow Anafaze,
Incorporated.
There shall be no w arranty or liability for an y products or parts that ha ve been subject to misuse, accident, negligence, failure of electric power or modification by the Customer without the writte approval of Watlow Anafaze, Incorporated. Final determination of w arranty eligibility shall be made by Watlow Anafaze, Incorporated. If a w arranty claim is considered in valid for any reason, the Customer will be char ged for services performed and e xpenses incurred by Watlow Anafaze,
Incorporated in handling and shipping the returned unit.
If replacement parts are supplied or repairs made during the original w arranty period, the warranty period for the replacement or repaired part shall terminate with the termination of the w arranty 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 w arranties, liabilities, and remedies. Except as thus pro vided, Watlow Anafaze, Inc., disclaims all w arranties, e xpress or implied, including any warranty of merchantability or fitness for a particular purpose
Please Note
: External safety devices must be used with this equipment.
Table of Contents
List of Figures ix
List of Tables xiii
1 System Overview 1
2 Installation 11
Mounting Controller Components 12
Mounting the Dual DAC or Serial DAC Module 19
Connecting the TB50 to the D8 25
Input Wiring Recommendations 28
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Table of Contents ii
Wiring Control and Digital I/O 31
Output Wiring Recommendations 31
Connecting the D8 to a DeviceNet Network 40
3 Communicating by DeviceNet 45
Accessing Data with a DeviceNet Master 45
About The Electronic Data Sheet (EDS) 46
Configuring a D8 Using RSNetWorx 46
Registering the D8 without an EDS File 47
Registering the D8 with the Watlow EDS File 48
Adding the D8 to the Master's Scanlist 50
Setting a Value with an Explicit Message 55
Reading a Value with an Explicit Message 57
Setting Parameters via DeviceNet 58
Decimal Placement for Numeric Values 59
Decimal Placement for Percentage Values 60
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4 Operation and Setup 77
How to Manually Change the Set Point 84
Other Methods of Changing the Set Point 84
Changing the Control Mode and Output Power 85
Accessing and Navigating the Setup Menus 86
How to Access the Setup Menus 86
How to Edit a Setup Parameter 86
Setting Up Closed-Loop Control 87
Control Output Signal Forms 87
How to Set Up Closed-Loop Control 88
Input Scaling Example: 4 to 20 mA Sensor 89
Input Scaling Example: 0 to 5 Vdc Sensor 90
Setting Up Process Variable Retransmit 97
How to Set Up Process Variable Retransmit 98
Process Variable Retransmit Example: Data Logging 98
Setting Up Cascade Control 100
How the Secondary Set Point is Determined 100
Proportional-Only Control on the Primary Loop 101
How To Set Up Cascade Control 102
Cascade Control Example: Water Tank 102
How to Set Up Ratio Control 105
Ratio Control Example: Diluting KOH 105
Setting Up Differential Control 106
How to Set Up Differential Control 107
Differential Control Example: Thermoforming 107
Setting Up Remote Analog Set Point 107
How to Set Up a Remote Analog Set Point 108
Remote Analog Set Point Example: Changing a Set Point with a PLC 108
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Table of Contents
5 Tuning and Control 111
Proportional and Integral Control (PI) 113
Proportional, Integral and Derivative Control (PID) 114
Setting Up and Tuning PID Loops 115
Proportional Band Settings 115
General PID Constants by Application 117
Proportional Band Only (P) 117
Proportional with Integral (PI) 117
Proportional and Integral with Derivative (PID) 117
6 Menu and Parameter Reference 121
Overview of the Setup Menus 123
Mode Override Digital Input Active 128
Digital Output Alarm Polarity 129
Model and Firmware Version 131
Reversed Thermocouple Detection 133
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Heat/Cool Proportional Band 136
Heat/Cool SDAC High Signal 140
Heat/Cool Power Limit Time 141
Sensor Fail Heat/Cool Output 142
Open Thermocouple Heat/Cool Output Average 142
Process Variable Retransmit Menu 148
Heat/Cool Output Retransmit 148
Heat/Cool Retransmit Low Process Variable 148
Heat/Cool Retransmit High Process Variable 148
Ratio Set Point Differential 151
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Table of Contents
Test Digital Output 1 to 20 153
Parameters Only Available via Communications 153
Heat/Cool Output Action for Watchdog Inactivity Fault 156
7 Troubleshooting and Reconfiguring 157
Troubleshooting the Controller 158
Reading the DeviceNet Indicator Lights 162
Corrective and Diagnostic Procedures 163
Testing Control Output Devices 168
Testing Control and Digital Outputs 168
Replacing the Flash Memory Chip 170
Installing Scaling Resistors 172
Configuring Serial DAC Outputs 176
Configuring Dual DAC Outputs 177
8 Specifications 179
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Glossary 197
Index 205
Menu Structure 213
Table of Contents
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List of Figures
1 System Overview
Figure 1.1—D8 Standard Parts List 5
Figure 1.2—D8 Special Inputs Parts List 6
2 Installation
Figure 2.1—D8 System Components 12
Figure 2.2—Module Dimensions and Clearance 14
Figure 2.3—Wiring Clearances 14
Figure 2.4—Mounting Bracket 15
Figure 2.5—Mounting the TB50 16
Figure 2.6—TB50 Mounted on a DIN Rail (Front) 16
Figure 2.7—TB50 Mounted on DIN Rail (Side) 17
Figure 2.8—Mounting a TB50 with Standoffs 17
Figure 2.9—D8 Power Supply Mounting Bracket 18
Figure 2.10—Dual DAC and Serial DAC Dimensions 19
Figure 2.11—D8 Series Controller with TB50 23
Figure 2.12—Power Connections with the D8 Power Supply 25
Figure 2.13—Thermocouple Connections 29
Figure 2.14—RTD Connections 30
Figure 2.15—Voltage Signal Connections 30
Figure 2.16—Current Signal Connections 30
Figure 2.17—Digital Output Wiring 32
Figure 2.18—Sample Heat, Cool and Alarm Output Connections 33
Figure 2.19—Output Connections Using External Power Supply 34
Figure 2.20—TB50 Watchdog Timer Output 34
Figure 2.21—TB18 Watchdog Timer Output 34
Figure 2.22—Wiring Digital Inputs 35
Figure 2.23—Dual DAC with Current Output 38
Figure 2.24—Dual DAC with Voltage Output 39
Figure 2.25—Single/Multiple Serial DACs 40
Figure 2.26—DeviceNet Connector 40
Figure 2.27—DeviceNet Connector 41
Figure 2.29—D8 Side with Rotary Switches 43
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List of Figures Series D8 User’s Guide
3 Communicating by DeviceNet
Figure 3.1—RSNetWorx On-line with Found Devices 47
Figure 3.2—The D8 Registered in RSNetWorx 48
Figure 3.3—D8 Properties in RSNetWorx 49
Figure 3.5—Adding the D8 to the Scanlist 51
Figure 3.6—Scanner Input Properties 52
Figure 3.7—Advanced Mapping Dialog Box 53
Figure 3.8—Using Scanned Data in Logic 54
Figure 3.9—Contents of the PLC Memory 55
Figure 3.10—Explicit Write in Ladder 56
Figure 3.11—Explicit Read in Ladder 58
Figure 3.12—D84 Produced Static Input 65
Figure 3.13— D84 Consumed Static Output 65
Figure 3.14—D88 Produced Static Input 65
Figure 3.15—D88 Consumed Static Output 66
4 Operation and Setup
Figure 4.1—General Navigation Map 78
Figure 4.2—Keypad Navigation 79
Figure 4.4—Loop Display with Alarm Code 81
Figure 4.5—Display for Failed Sensor Alarm 81
Figure 4.7—Activation and Deactivation of Process Alarms 96
Figure 4.8—Application Using Process Variable Retransmit 99
Figure 4.9—Secondary Set Point When Primary Loop Has Heat and Cool Outputs
Figure 4.10—Secondary Set Point When Primary Loop Has Heat Output Only 101
Figure 4.11—Example Application Using Cascade Control 103
Figure 4.12—Relationship of Secondary Loop Set Point to Primary Loop Process
Variable in Cascade Example 104
Figure 4.13—Relationship Between the Process Variable on the Master Loop and the
Set Point of the Ratio Loop 105
Figure 4.14—Application Using Ratio Control 106
5 Tuning and Control
Figure 5.2—Proportional Control 113
Figure 5.3—Proportional and Integral Control 113
Figure 5.4—Proportional, Integral and Derivative Control 114
Figure 5.5—Time Proportioning and Distributed Zero Crossing Waveforms 118
6 Menu and Parameter Reference
Figure 6.1—Operator Parameter Navigation 121
Figure 6.2—Setup Menus and Parameters 124
Figure 6.3—Linear and Nonlinear Outputs 143
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7 Troubleshooting and Reconfiguring
Figure 7.1—Removal of Electronics Assembly from Case 170
Figure 7.2—Screw Locations on PC Board 171
Figure 7.3—Location of Flash Memory Chip 171
Figure 7.5—Serial DAC Voltage and Current Jumper Positions 176
8 Specifications
Figure 8.1—D8 Module Dimensions 180
Figure 8.2—Module Dimensions and Clearance 181
Figure 8.3—TB50 Dimensions 182
Figure 8.4—TB50 Dimensions with Straight SCSI Cable 183
Figure 8.5—TB50 Dimensions with Right-Angle SCSI Cable 184
Figure 8.6—Power Supply Dimensions (Bottom View) 190
Figure 8.7—Dual DAC Dimensions 191
Figure 8.8—Serial DAC Dimensions 193
Glossary
Index
Menu Structure
List of Figures
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List of Tables
2 Installation
Table 2.1—Cable Recommendations 21
Table 2.2—Power Connections 24
Table 2.4—Digital Output States and Values Stored in the Controller 32
Table 2.5—Digital Input States and Values Stored in the Controller 35
Table 2.8—DeviceNet Connector 41
Table 2.9—Maximum Network Speed 42
Table 2.10—Module Status Indicator Light 44
Table 2.11—Network Status Indicator Light 44
3 Communicating by DeviceNet
Table 3.2—Outbound Transaction Header 57
Table 3.3—Explicit Message Body 57
Table 3.4—Number of Decimal Places for Numeric Values via Logic 59
Table 3.5—Address Components 61
Table 3.6—Elementary Data Types 61
Table 3.7—Identity Class and Services 62
Table 3.8—Identity Instance Attributes 62
Table 3.9—Message Router Class and Services 62
Table 3.10—Message Router Instance Attributes 62
Table 3.11—DeviceNet Class and Services 63
Table 3.12—DeviceNet Class Attributes 63
Table 3.13—DeviceNet Instance Attributes 63
Table 3.14—Assembly Class and Services 64
Table 3.15—Assembly Instance Attributes 64
Table 3.16—Connection Class and Services 66
Table 3.17—Connection Instance Attributes 66
Table 3.18—Input Class and Services 67
Table 3.19—Input Class Attributes (Instance 0) 67
Table 3.20—Input Instance Attributes (Instances 1 to 4 or 8) 68
Table 3.21—Output Class and Services 68
Table 3.22—Output Class Attributes (Instance 0) 69
Table 3.23—Output Instance Attributes (Instances 1 to 4 or 8) 69
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List of Tables Series D8 User’s Guide
Table 3.24—Control Class and Services 70
Table 3.25—Control Class Attributes (Instance 0) 70
Table 3.26—Control Instance Attributes (Instances 1 to 4 or 8) 70
Table 3.27—Alarm Class and Services 71
Table 3.28—Alarm Class Attributes (Instance 0) 71
Table 3.29—Alarm Instance Attributes (Instances 1 to 4 or 8) 71
Table 3.30—PV Retransmit Class and Services 72
Table 3.31—PV Retransmit Class Attributes (Instance 0) 72
Table 3.32—PV Retransmit Instance Attributes (Instances 1 to 4 or 8) 73
Table 3.33—Ratio Class and Services 73
Table 3.34—Ratio Class Attributes (Instance 0) 73
Table 3.35—Ratio Instance Attributes (Instances 1 to 4 or 8) 74
Table 3.36—Cascade Class and Services 74
Table 3.37—Cascade Class Attributes (Instance 0) 74
Table 3.38—Cascade Instance Attributes (Instances 1 to 4 or 8) 75
Table 3.39—Global Class and Services 75
Table 3.40—Global Class Attributes (Instance 0) 75
Table 3.41—Global Instance Attributes (Instance 1) 76
4 Operation and Setup
Table 4.2—Alarm Codes and Messages for Process and Failed Sensor Alarms 82
Table 4.3—System Alarm Messages 83
Table 4.6—Input Readings and Calculations 91
Table 4.8—Parameters Settings for Process Variable Retransmit Example 99
Table 4.9—Parameter Settings for the Primary Loop in the Cascade Example 103
Table 4.10—Parameter Settings for the Secondary Loop in the Cascade Example
Table 4.11—Ratio Control Settings for the Ratio Loop (Loop 2) in the Example 106
Table 4.12—Parameter Settings for the Ratio Loop (Loop 2) for the Example 107
Table 4.13—Parameters Settings for the Master Loop (Loop 1) in the Example 108
Table 4.14—Parameter Settings for the Ratio Loop (Loop 2) in the Example 109
5 Tuning and Control
Table 5.1—Proportional Band Settings 115
Table 5.2—Integral Term and Reset Settings 116
Table 5.3—Derivative Term Versus Rate 116
Table 5.4—General PID Constants 117
6 Menu and Parameter Reference
Table 6.3—Values for BCD Job Load 126
Table 6.4—Digital Input States Required to Load Each Job 127
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Series D8 User’s Guide List of Tables
Table 6.5—Power Up Loop Modes 128
Table 6.6—Digital Output Alarm Polarity 130
Table 6.7—Input Types and Ranges 131
Table 6.8—Characters for the Loop Name and Input Units Parameters 132
Table 6.9—Calibration Offset Ranges 133
Table 6.10—Display Formats 134
Table 6.11—Proportional Band Values 136
Table 6.12—Values for the Control Hysteresis and Deviation Alarm Parameters 138
Table 6.13—Heat and Cool Output Types 139
Table 6.14—Alarm Functions 144
Table 6.15—Values for Alarm Hysteresis 147
Table 6.16—Bit Positions for Alarm Enable and Alarm Function 154
Table 6.17—Bit Positions for Alarm Status and Alarm Acknowledge 155
Table 6.18—System Status Bits 155
Table 6.19—DeviceNet Value for Watchdog Inactivity Fault 156
7 Troubleshooting and Reconfiguring
Table 7.1—Operator Response to Process Alarms 160
Table 7.3—Module Status Indicator States and Descriptions 162
Table 7.4—Network Status Indicator Light 163
Table 7.5—Resistor Values for Current Inputs 173
Table 7.6—Resistor Locations for Current Inputs 173
Table 7.7—Resistor Values for Voltage Inputs 174
Table 7.8—Resistor Locations for Voltage Inputs 174
Table 7.9—Resistor Locations for RTD Inputs 175
Table 7.10—Dual DAC Jumper Settings 177
8 Specifications
Table 8.1— Agency Approvals / Compliance 179
Table 8.2—Environmental Specifications 179
Table 8.3—D8 with Straight SCSI 180
Table 8.5—TB50 Physical Dimensions 181
Table 8.6—TB50 Connections 182
Table 8.7—TB50 with Straight SCSI 182
Table 8.8—TB50 with Right Angle SCSI 183
Table 8.10—Thermocouple Range and Resolution 186
Table 8.11—RTD Range and Resolution 186
Table 8.12—Input Resistance for Voltage Inputs 186
Table 8.14—Digital Outputs Control / Alarm 188
Table 8.15—5 Vdc Output (Power to Operate Solid-State Relays) 188
Table 8.17—D8 Power Requirements 188
Table 8.18—Power Supply Environmental Specifications 189
Table 8.19—Power Supply Agency Approvals / Compliance 189
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List of Tables
Table 8.20—Power Supply Physical Specifications 189
Table 8.21—Power Supply with Mounting Bracket 189
Table 8.22—Power Supply Inputs and Outputs 190
Table 8.23—Dual DAC Environmental Specifications 191
Table 8.24—Dual DAC Physical Specifications 191
Table 8.25—Dual DAC Power Requirements 192
Table 8.26—Dual DAC Specifications by Output Range 192
Table 8.27—Serial DAC Environmental Specifications 193
Table 8.28—Serial DAC Physical Specifications 193
Table 8.29—Serial DAC Agency Approvals / Compliance 194
Table 8.30—Serial DAC Inputs 194
Table 8.31—Serial DAC Power Requirements 194
Table 8.32—Serial DAC Analog Output Specifications 195
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1
System Overview
Manual Contents
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This manual describes how to install, set up, and operate a D8 series controller. Each chapter covers 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 D8 series controllers.
Chapter 2: Installation
provides detailed instructions on installing the D8 series controller and its peripherals.
Chapter 3: Communicating via DeviceNet
explains how to add the D8 controller to a network and how to access controller data via DeviceNet.
Chapter 4: Operation and Setup provides instructions about operating and setting up the D8.
Chapter 5: Tuning and Control
describes available control algorithms and provides suggestions for applications.
Chapter 6: Menu and Parameter Reference
provides detailed descriptions of all menus and parameters for controller setup.
Chapter 7: Troubleshooting and Reconfiguring
includes troubleshooting, upgrading and reconfiguring procedures for technical personnel.
Chapter 8: Specifications
lists detailed specifications of the controller and optional components.
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Chapter 1: System Overview
Getting Started
Safety Symbols
Series D8 User’s Guide
These symbols are used throughout this manual:
WARNING!
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
2
Initial Inspection
CAUTION!
Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury or property damage.
NOTE!
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 container as the D8, depending upon their size. Check the shipping invoice against the contents received in all boxes. If you are uncertain whether you have received all of the items you ordered, contact your vendor or Watlow Anafaze.
Product Features
D8 series controllers offer high-performance closed-loop control.
The D8 provides four or eight independent control loops with analog inputs — thermocouples, RTDs and process — and features DeviceNet communications.
When used as a stand-alone controller, you may operate the
D8 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 D8 can be locally or remotely controlled via its DeviceNet communications interface.
D8 features include:
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Chapter 1: System Overview
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Direct Connection of Mixed Thermocouple Sensors:
Connect most thermocouples to the controller with no hardware modifications. Thermocouple inputs feature reference junction compensation, linearization, offset calibration to correct for sensor inaccuracies, detection of open, shorted or reversed thermocouples, and a choice of
Fahrenheit or Celsius display.
Accepts Resistive Temperature Detectors (RTDs):
Use three-wire, 100 Ω , platinum, 0.00385-curve sensors.
Special inputs must be installed.
Automatic Scaling for Process Analog Inputs:
The D8 series automatically scales process inputs used with industrial process sensors. Enter two points, and all input values are automatically scaled. Special inputs must be installed.
Dual Outputs:
The D8 series includes both heat and cool control outputs for each loop. Independent control parameters are provided for each output.
Independently Selectable Control and Output
Modes:
Set each control output to on/off, time proportioning, Serial DAC (digital-to-analog converter) or distributed zero crossing mode. Set up to two outputs per loop for on/off, P, PI or PID control with reverse or direct action.
Boost Output Function:
Set digital outputs to function as boost on/off control in association with any alarm.
Flexible Alarms:
Independently set high and low alarms and high and low deviation alarms for each loop. Alarms can activate a digital output by themselves, or they can be grouped with other alarms to activate an output.
Global Alarm Output:
Any alarm event activates the global alarm output.
CPU Watchdog:
The CPU watchdog timer output notifies you of system failure.
Keypad or DeviceNet Operation:
Set up and run the controller from the keypad or via the DeviceNet interface.
DeviceNet Communications:
Connect software, programmable logic controllers and other master devices using the widely supported DeviceNet protocol. The D8 is compliant with both the ODVA DeviceNet specification and the Interface Guidelines for DeviceNet on Semiconductor Manufacturing Tools.
Multiple Job Storage:
Store up to eight jobs in the controller’s battery-backed memory. Load a job through the keypad, digital inputs or software. Each job is a set of operating conditions, including set points and alarm limits.
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Chapter 1: System Overview Series D8 User’s Guide
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Nonlinear Output Curves:
Select either of two nonlinear output curves for each control output.
Autotuning:
Use the autotune feature to set up your system quickly and easily. The internal expert system table finds the correct PID parameters for your process.
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Low Power Shutdown:
The controller shuts down and turns off all outputs when it detects the input voltage drop below the minimum safe operating level.
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Process Variable Retransmit:
Scale a temperature or process and convert it to an analog output for external devices such as chart recorders.
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Two-Zone Cascade Control:
Control thermal systems with long lag times, which cannot be accurately controlled with a single loop.
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Ratio or Offset Control:
Control one process as a ratio or offset of another process.
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Remote Analog Set Point:
Scale an external voltage or current source to provide a set point for a loop.
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Series D8 User’s Guide
D8 Parts List
Chapter 1: System Overview
Number of Loops
4 = 4-loop controller
8 = 8-loop controller
Digital I/O Termination
0 = TB18
1 = SCSI connector, no terminal board or cable
2 = SCSI connector, TB50 and 3-foot cable
3 = SCSI connector, TB50 and 6-foot cable
4 = SCSI connector, TB50 and 3-foot right angle cable
5 = SCSI connector, TB50 and 6-foot right angle cable
Power Supply
0 = No power supply
1 = CE Power Supply
2 = Wall mount power supply
Special Inputs
0 = Thermocouples and -10 to 60mV inputs only
X = Number of current, voltage and RTD inputs
You may have received one or more of the following compo-
nents. See Figure 2.1 on page 12 for D8 configuration infor-
mation.
• D8 series controller with mounting collar and brackets
• TB50 with 50-pin SCSI cable
• Power supply with mounting bracket and screws
• Serial DAC (digital-to-analog converter)
• Special input resistors (installed in D8)
• User’s guide
D8x0-0000-xx0x
Figure 1.1
D8 Standard Parts List
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6
Chapter 1: System Overview Series D8 User’s Guide
D8SI _ _ - _ _ - _ _
Special/Process Input Type
(Not required for thermocouple sensor inputs)
23 = RTD
43 = 0 to 10 mA dc
44 = 0 to 20 mA dc or 4 to 20 mA dc
50 = 0 to 100 mV dc
52 = 0 to 500 mV dc
53 = 0 to 1 Vdc
55 = 0 to 5 Vdc
56 = 0 to 10 Vdc
57 = 0 to 12 Vdc
Start Loop
XX = Loop number XX
End Loop
XX = Loop number XX
Figure 1.2
D8 Special Inputs Parts List
Technical Description
This section contains a technical description of each component of the D8 series controller.
D8
The D8 is housed in a 1/8-DIN panel mount package. It contains the central processing unit (CPU), random access memory (RAM) with a built-in battery, flash memory, communications, digital I/O, analog inputs, display and touch keypad.
DeviceNet
Connector
Network LED
Indicator Light
Module LED
Indicator Light
Series D8 with SCSI Connector.
Series D8 with TB18 Connector.
Figure 1.3
D8 Rear Views
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Series D8 User’s Guide
Front Panel Description
Chapter 1: System Overview
The D8 has the following features:
• Keypad and two-line, 16-character display.
• Screw terminals for the power and analog inputs.
• Micro-style connector for DeviceNet.
• Input power of 12 to 24 Vdc at 1 Amp.
• 50-pin SCSI cable to connect the digital inputs and outputs to the 50-terminal block (TB50). The D8 is available with an 18-terminal block (TB18) in place of the SCSI
connector, as shown in Figure 1.3 on page 6.
• Nonvolatile flash memory for storage of firmware and programmable logic.
• Battery-backed storage of operating parameters. If a power loss occurs, the operating parameters are stored in memory. The battery has a ten-year shelf life, and it is not used when the controller is on.
• Microprocessor control of all calculations for input signal linearization, PID control, alarms, and communications.
The display and keypad provide an intelligent way to operate the controller. The display has 16 alphanumeric or graphic characters per line. The eight-key keypad allows you to change the operating parameters, controller functions and displays.
The displays show process variables, set points and output levels for each loop. A single-loop display, scanning display and alarm display offer a real-time view of process conditions.
For useful tips, help and menu information, press i screen.
from any
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Figure 1.4
D8 Front Panel
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Chapter 1: System Overview
TB50
Series D8 User’s Guide
The TB50 is a screw-terminal interface for control wiring. It allows you to connect power controllers and other discrete I/O devices to the D8. The screw terminal blocks accept wires as large as 18 AWG (0.75 mm the TB50 to the D8.
2 ). A 50-pin SCSI cable connects
Figure 1.5
TB50
D8 Cabling
Watlow Anafaze provides cables required to install the D8. A
50-pin SCSI cable connects the TB50 to the D8.
Safety
Watlow Anafaze has made every effort to ensure the reliability and safety of this product. In addition, we have provided recommendations that will allow you to safely install and maintain this controller.
External Safety Devices
8
The D8 controller may fail full-on (100 percent output power) or full-off (0 percent output power), or may remain full-on if an undetected sensor failure occurs.
Design your system to be safe even if the controller sends a 0 percent or 100 percent output power signal at any time Install independent, external safety devices such as the Watlow
Anafaze TLM-8 that will shut down the system if a failure occurs.
Typically, a shutdown device consists of an agency-approved high/low process limit controller that operates a shutdown de-
Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 1: System Overview vice such as an mechanical contactor. The limit controller monitors for a hazardous condition such as an under-temperature or over-temperature fault. If a hazardous condition 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 equipment.
WARNING!
The controller may fail in a 0 percent or 100 percent output power state. To prevent death, personal injury, equipment damage or property damage, install external safety shutdown devices that operate independently from the process control equipment.
With proper approval and installation, thermal fuses may be used in some processes.
Power-Fail Protection
In the occurrence of a sudden loss of power, the D8 controller can be programmed to reset the control outputs to off (this is the default). The controller can also be configured to restart to data stored in memory.
A memory-based restart might create an unsafe process condition for some installations. Use a memory-based restart only
if you are certain your system will safely restart. See Power
When using the controller with a computer or other master device, you can program the software to automatically reload desired operating constants or process values on powerup.
These convenience features do not eliminate the need for independent safety devices.
Contact Watlow Anafaze immediately if you have any questions about system safety or system operation.
Doc. 0600-3120-2000 Watlow Anafaze 9
Chapter 1: System Overview Series D8 User’s Guide
10 Watlow Anafaze Doc. 0600-3120-2000
Doc. 0600-3120-2000
2
Installation
This chapter describes how to install the D8 series controller and its peripherals. Installation of the controller involves the following procedures:
• Determining the best location for the controller
• Mounting the controller and TB50
• Power connection
• Input wiring
• Communications wiring
• Output wiring
WARNING!
Risk of electric shock. Shut off power to your entire process before you begin installing the controller.
WARNING!
The controller may fail in a 0 percent or 100 percent power output state. To prevent death, personal injury, equipment damage or property damage, install external safety shutdown devices that operate independently from the process control equipment.
Watlow Anafaze 11
Chapter 2: Installation Series D8 User’s Guide
Typical Installation
Figure 2.1 shows typical installations of the controller with
the TB50 and the TB18 terminal blocks. The type of terminal block you use greatly impacts the layout and wiring of your
installation site. See Figure 2.2 to Figure 2.10 to determine po-
tential space requirements.
We recommend that you read this entire chapter before beginning the installation procedure. This will help you to carefully plan and assess the installation.
D8 with TB50
SCSI Cable
8 Digital Inputs
20 Digital Outputs
(Control Alarm,
Watchdog)
Signal Inputs
D8
Power Supply
D8 with TB18
Signal Inputs
3 Digital Inputs
D8
Power Supply
11 Digital Outputs (Control, Alarm, Watchdog)
Figure 2.1
D8 System Components
Mounting Controller Components
Install the controller in a location free from excessive heat
(>50º C), dust and unauthorized handling. Electromagnetic and radio frequency interference can induce noise on sensor wiring. Choose locations for the D8 and TB50 such that wiring can be routed clear of sources of interference such as high voltage wires, power switching devices and motors.
NOTE!
For indoor use only.
12 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 2: Installation
WARNING!
To reduce the risk of fire or electric shock, install the D8 in a controlled environment, relatively free of contaminants.
Recommended Tools
Use any of the following tools to cut a hole of the appropriate size in the panel.
• Jigsaw and metal file, for stainless steel and heavyweight panel doors.
• Greenlee 1/8-DIN rectangular punch (Greenlee part number 600-68), for most panel materials and thicknesses.
• Nibbler and metal file, for aluminum and lightweight panel doors.
You will also need these tools:
• Phillips head screwdriver
• 1/8-inch (3 mm) flathead screwdriver for wiring
• Multimeter
Mounting the Controller
Mount the controller before you mount the other components, such as the power supply or TB50, or do any wiring. The controller’s placement affects placement and wiring considerations for the other components of your system.
Ensure that there is enough clearance for mounting brackets, terminal blocks, and cable and wire connections. The controller extends 191 mm (7.5 inches) behind the panel face and the collar and brackets extend 7 mm (9/32 inches) on the sides and
12 mm (15/32 inches) above and below it. Allow an additional
Doc. 0600-3120-2000 Watlow Anafaze 13
Chapter 2: Installation Series D8 User’s Guide
41 mm (1.6 inches) for a right-angle DeviceNet connector and
SCSI connector. Refer to Figure 2.2.
188 mm (7.4 in)
41 mm to 54 mm
(1.6 in to 2.1 in) for cables and clearance
25 mm
(1.0 in)
Figure 2.2
Module Dimensions and Clearance
Maximum Panel Thickness
0.2 inch (5 mm)
14
1.80 ± 0.020 inch
(45.7 ± 0.5 mm)
3.63 ± 0.020 inches
(92.2 ± 0.5 mm)
Figure 2.3
Wiring Clearances
We recommend you mount the controller in a panel not more than 0.2 inch (5 mm) thick.
1. Choose a panel location free from excessive heat (more than 50°C), dust, and unauthorized handling. (Make sure there is adequate clearance for the mounting hardware,
Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide
Doc. 0600-3120-2000
Chapter 2: Installation terminal blocks, and cables. The controller extends 188 mm (7.4 in.) behind the panel. Allow for an additional 41 to 54 mm (1.6 to 2.1 in.) 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. Cut a hole in the panel 46 mm (1.80 in.) by 92 mm (3.63
in.) as shown below. (This picture is NOT a template; it is for illustration only.) Use caution; the dimensions given here have 1 mm (0.02 in.) tolerances.
4. Remove the brackets and collar from the controller, if they are already in place.
5. Slide the controller into the panel cutout.
6. Slide the mounting collar over the back of the controller, making sure the mounting screw indentations face toward the back of the controller.
Bracket (top and bottom)
Panel
19
17
21
25
23
13
11
15
7
5
9
3
1
24
22
26
18
16
20
12
10
14
6
4
2
8
+
Bezel Mounting Collar
Figure 2.4
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 (head of the screw facing the back of the controller). Push each bracket backward then to the side to secure it to the controller case.
8. Make sure the case is seated properly. Tighten the installation 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.
Watlow Anafaze 15
Chapter 2: Installation
Mounting the TB50
DIN Rail Mounting
Series D8 User’s Guide
There are two ways to mount the TB50: Use the pre-installed
DIN rail mounting brackets or use the plastic standoffs.
TB50
Mounted with Standoffs
TB50
Mounted to
DIN Rail
Figure 2.5
Mounting the TB50
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 2.6.
16
Figure 2.6
TB50 Mounted on a DIN Rail (Front)
Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 2: Installation
To remove the TB50 from the rail, use a flathead screw driver
to unsnap the bracket from the rail. See Figure 2.7.
Removal
Screwdriver
DIN Rail
Snap Latch
Hook Side
Figure 2.7
TB50 Mounted on DIN Rail (Side)
Mounting with Standoffs
Doc. 0600-3120-2000
1. Remove the DIN rail mounting brackets from the TB50.
2. Choose a location with enough clearance to remove the
TB50, its SCSI cable and the controller itself.
3. 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 or bolts.
There are four smaller holes on the terminal board. Use these holes to secure wiring to the terminal block with tie wraps.
0.2 in
(5 mm)
2.6 in
(66 mm)
4 Holes for
#6 (3.5 mm)
Bolts or Screws
3.4 in
(86 mm)
SCSI Connector
0.2 in
(5 mm)
0.2 in
(5 mm)
Figure 2.8
Mounting a TB50 with Standoffs
Watlow Anafaze 17
Chapter 2: Installation Series D8 User’s Guide
Mounting the Power Supply
If you use your own power supply for the D8, refer to the power supply manufacturer’s instructions for mounting information. Choose a Class 2 power supply that supplies an isolated, regulated 12 to 24 Vdc at 1 A.
Mounting Environment
Leave enough clearance around the power supply so that it can be removed.
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Series D8 User’s Guide Chapter 2: Installation
Mounting the Dual DAC or Serial DAC Module
This section describes how to mount the optional Dual DAC and Serial DAC digital-to-analog converters.
Mounting of the Dual DAC and Serial DAC is essentially the same, except that the dimensions differ.
Jumpers
The output signal range of the Dual DAC and Serial DAC
modules is configured with jumpers. See Configuring Dual
DAC Outputs on page 177 and Configuring Serial DAC Out-
puts on page 176 for information about setting these jumpers.
Mounting
Dual DAC
4 Holes for #8 (3.5 mm)
Screws or Bolts
1. Choose a location. The unit is designed for wall mounting. Install it as close to the controller as possible.
2. Mark and drill four holes for screw mounting. Holes ac-
commodate #8 (3.5 mm) screws. See Figure 2.10 for
screw locations. Install the unit with the four screws.
0.3 in
(8 mm) 4 Holes for #8 (3.5 mm)
Screws or Bolts
Serial DAC
0.3 in
(8 mm)
3.62 in
(91 mm)
Electrical
Connectors
3.7 in
(94 mm)
Electrical
Connectors
4.40 in
(112 mm)
3.00 in
(76 mm)
3.62 in
(91 mm)
Electrical
Connectors
3.00 in
(76 mm)
0.37 in
(9 mm)
4.7 in
(119 mm)
0.65 in
(17 mm)
1.75 in
(44 mm)
Electrical
Connectors
5.40 in
(137 mm)
Figure 2.10 Dual DAC and Serial DAC
Dimensions
0.37 in
(9 mm)
0.65 in
(17 mm)
1.75 in
(44 mm)
Doc. 0600-3120-2000 Watlow Anafaze 19
Chapter 2: Installation
System Wiring
Series D8 User’s Guide
Successful installation and operation of the control system can depend on placement of the components and on selection of the proper cables, sensors and peripheral components.
Routing and shielding of sensor wires and proper grounding of components can insure a robust control system. This section includes wiring recommendations, instructions for proper grounding and noise suppression, and considerations for avoiding ground loops.
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.
CAUTION!
Do not wire bundles of low-voltage signal and control circuits next to bundles of highvoltage ac wiring. High voltage may be inductively 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 D8 hardware. If possible, install high-voltage ac power circuits in a separate panel.
Wiring Recommendations
Follow these guidelines for selecting wires and cables:
• Use stranded wire. (Solid wire can be used for fixed service; it makes intermittent connections when you move it for maintenance.)
• Use 20 AWG (0.5 mm
2
) thermocouple extension wire.
Larger or smaller sizes may be difficult to install, may break easily or may cause intermittent connections.
• Use shielded wire. The electrical shield protects the signals and the D8 from electrical noise. Connect one end of the input and output wiring shield to earth ground.
• Use copper wire for all connections other than thermocouple sensor inputs.
20 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 2: Installation
Function
Analog Inputs
RTD Inputs
Table 2.1
Cable Recommendations
Thermocouple Inputs
Control Outputs and
Digital I/O
Analog Outputs
Mfr. P/N
Belden 9154
Belden 8451
Belden 8772
Belden 9770 thermocouple
Ext. Wire
Belden 9539
Belden 9542
Ribbon Cable
Belden 9154
Belden 8451
2
9
20
50
2
2
No. of
Wires
3
3
2
2
AWG
20
22
20
22
20
24
24
22 to 14
20
22
mm
2
0.5
0.5
0.5
0.5
0.5
0.2
0.2
0.5 to 2.5
0.5
0.5
Noise Suppression
The D8 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 electromagnetic interference (EMI, or noise). If the controller is placed close to sources of EMI, it may not function correctly. Below are some tips on how to recognize and avoid problems 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 D8 case.
Symptoms of Noise
If your controller displays the following symptoms, suspect noise:
• The display screen blanks out and then reenergizes as if power had been turned off for a moment.
• The process variable value is incorrect on the controller display.
Noise may also damage the digital output circuit such that the digital outputs will not turn on. If the digital output circuit is damaged, return the controller to Watlow Anafaze for repair.
Avoiding Noise
To avoid or eliminate most RFI/EMI noise problems:
Doc. 0600-3120-2000 Watlow Anafaze 21
Chapter 2: Installation Series D8 User’s Guide
• Connect the D8 case to earth ground. The D8 system includes noise suppression circuitry. This circuitry requires proper grounding.
• Separate the 120 Vac and higher power leads from the low-level input and output leads connected to the D8 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 electromechanical relays, avoid mounting them in the same panel as the D8 series equipment.
• If you must use electromechanical relays and you must place them in a panel with D8 series equipment, use a
0.01 microfarad capacitor rated at 1000 Vac (or higher) in series with a 47 Ω , 0.5 watt resistor across the normally-open 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 130 Vac for 120 Vac control circuits across the load, which limits the peak ac voltage to about 180 Vac (Watlow Anafaze part number
26-130210-00). You can also place a transorb (back-toback zener diodes) across the digital output, which limits the digital output voltage.
Additional Recommendations for a Noise Immune System
We strongly recommended the following:
• Isolate outputs through solid state relays, where possible.
• 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 digital input is the only connection to earth ground other than the chassis ground.
Ground Loops
Ground loops occur when current passes from the process through the controller to ground. This can cause instrument errors or malfunctions.
A ground loop may follow one of these paths, among others:
• From one sensor to another.
• From a sensor to the dc power supply.
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Series D8 User’s Guide Chapter 2: Installation
The best way to avoid ground loops is to minimize unnecessary connections to ground. Do not connect any of the following terminals to earth ground:
• Power supply dc common
• TB1 terminals 9, 10, 19 (analog common)
• TB2 terminal 2 (dc power common)
Do not connect the analog common terminals to the other terminals listed above.
Power Connections
This section explains how to make power connections to the
D8 and the TB50.
DEVICENET
CONNECTOR
NETWORK LED
INDICATOR LIGHT
MODULE LED
INDICATOR LIGHT
Figure 2.11 D8 Series Controller with TB50
Wiring the Power Supply
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 connections,
This allows you to ensure that the controller is working before any time is taken installing inputs and outputs.
Doc. 0600-3120-2000 Watlow Anafaze 23
Chapter 2: Installation Series D8 User’s Guide
Table 2.2
Power Connections
Function
DC Power
(Controller)
DC Common
Power Supply
+12 to 24 Vdc
12 to 24 Vdc
Common
Ground
D8 TB2
+
-
Earth Ground
1. Connect the dc common terminal on the power supply to the dc common (-) terminal on D8 TB2.
2. Connect the positive terminal on the power supply to the dc positive (+) terminal on D8 TB2.
3. If using an isolated dc output or another power supply to power the loads, connect the dc common of the supply 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 D8 chassis and must be connected to earth ground.
5. Connect 120/240 Vac power to the power supply.
NOTE!
Connect the dc common of the power supply used for loads to the dc common of the supply powering the controller. If the supplies are not referenced to one another, the controller’s outputs will not be able to switch the loads.
NOTE!
When making screw terminal connections, tighten to 4.5 to 5.4 in.-lb. (0.5 to 0.6 Nm).
CAUTION!
Without proper grounding, the D8 may not operate properly or may be damaged.
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Series D8 User’s Guide Chapter 2: Installation
CAUTION!
To prevent damage from incorrect connections, do not turn on the heater power or other output power before testing the
connections as explained in Testing the System on page 26.
NOTE!
Do not connect the controller’s dc common
(COM) to earth ground . Doing so will defeat the noise protection circuitry, making measurements less stable.
+5V
5V COM
+15V
15V COM
-15V
Ground
AC Line
AC Neutral green add jumper solid-state relay (ssr)
-
+ ssr
+
ssr
-
+ ssr
-
+
V+ common ground
D8
Controller
1 2 3 4
Serial digital-to-analog converter black
L1 white
120/240V Å (ac)
L2
Figure 2.12 Power Connections with the D8
Power Supply
Connecting the TB50 to the D8
1. Connect the SCSI cable to the controller.
2. Connect the SCSI cable to the TB50.
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Chapter 2: Installation Series D8 User’s Guide
Testing the System
This section explains how to test the controller after installation and prior to making field wiring connections.
TB50 or TB18 Test
Use this procedure to verify that the TB50 or TB18 is properly connected and supplied with power:
1. Turn on power to the D8. The display should first show
Calculating checksum
, and then show the single-loop display. If you do not see these displays, disconnect power and check wiring and power supply output.
2. Measure the +5 Vdc supply at the TB50 or TB18: a) Connect the voltmeter’s common lead to TB50 terminal 3 or TB18 terminal 2.
b) Connect the voltmeter’s positive lead to TB50 or
TB18 terminal 1. The voltage should be +4.75 to
+5.25 Vdc.
Digital Output Test
Use this procedure to test the controller outputs before loads are connected. If using it at another time for troubleshooting, disconnect loads from outputs before testing.
1. Connect a 500 Ω to 100 k Ω resistor between TB50 or
TB18 terminal 1 and a digital output terminal. See
Table 2.6 on page 36 for TB18 connections or Table 2.7
on page 37 for TB 50 connections.
2. Connect the voltmeter’s positive lead to terminal 1 on the
TB50 or TB18.
3. Connect the voltmeter’s common lead to the digital output terminal.
4. Use the digital output test in the I/O tests menu to turn the
should be less than 1 V. When the output is on, the output voltage should be between 4.75 and 5.25 V.
26
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 per-
cent output. See Changing the Control Mode and Output Power on page 85.
Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide
Digital Input Test
Chapter 2: Installation
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. Go to the Digital inputs test in the I/O tests menu. This test shows whether the digital inputs are off (open) or on
(closed).
3. Attach a wire to the terminal of the digital input you want
to test. See Table 2.6 on page 36 for TB 18 connections
or Table 2.7 on page 37 for TB50 connections.
a) When the wire is connected only to the digital input terminal, the digital input test should show that the input is off (open).
b) When you connect the other end of the wire to the controller common (TB50 terminal 3 or TB18 terminal 2), the digital input test should show that the input is on (closed).
Sensor Wiring
This section describes how to properly connect thermocouples, RTDs, current and voltage inputs to the 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).
All inputs are installed at the “CH” input connectors (TB1) at the back of the controller. The illustrations below show the connector locations for all D8 series controllers.
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 measurement and control.
Doc. 0600-3120-2000 Watlow Anafaze 27
Chapter 2: Installation Series D8 User’s Guide
Terminal Number
15
16
17
18
19
7
8
5
6
3
4
1
2
9
10
11
12
13
14
Label
CH 1 IN+
CH 1 IN-
CH 2 IN+
CH 2 IN-
CH 3 IN+
CH 3 IN-
CH 4 IN+
CH 4 IN-
Com
Com
CH 5 IN+
CH 5 IN-
CH 6 IN+
CH 6 IN-
CH 7 IN+
CH 7 IN-
CH 8 IN+
CH 8 IN-
Com
Table 2.3
TB1 Connections
Function
Channel 1 positive input
Channel 1 negative input
Channel 2 positive input
Channel 2 negative input
Channel 3 positive input
Channel 3 negative input
Channel 4 positive input
Channel 4 negative input
Analog Common
Analog Common
Channel 5 positive input 1
Channel 5 negative input 1
Channel 6 positive input 1
Channel 6 negative input 1
Channel 7 positive input 1
Channel 7 negative input 1
Channel 8 positive input 1
Channel 8 negative input 1
Analog Common
NOTE!
1
Terminals 11 to 18 are not used with a 4-channel controller.
Input Wiring Recommendations
Use multicolored stranded shielded cable for analog inputs.
Watlow Anafaze recommends that you use 20 AWG wire (0.5 mm 2 ). If the sensor manufacturer requires it, you can also use
24 or 22 AWG wiring (0.2 mm 2 ). Most inputs use a shielded twisted pair; some require a three-wire input.
The controller accepts the following inputs without any special scaling resistors:
• J, K, T, S, R, B and E thermocouples.
• Process inputs with ranges between -10 and 60 mV.
To avoid thermocouple open alarms on unused inputs, either set the Input type parameter to skip or jumper the input.
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Series D8 User’s Guide Chapter 2: Installation
Thermocouple Connections
Connect the positive lead of the thermocouple to the IN+ terminal for one of the loops, and connect the negative lead to the corresponding IN- terminal.
Use 18 or 20 AWG (0.5 or 0.75 mm 2 ) for all thermocouple inputs. Most thermocouple wire is solid, unshielded wire. When using shielded wire, ground one end only.
CH IN+
CH IN-
White
Red
Type J thermocouple
Shield (if present)
Earth Ground at Process End
Figure 2.13 Thermocouple Connections
CAUTION!
Ground loops and common mode noise can damage the controller or disrupt measurements. To minimize ground loops and common mode noise:
• Do not mix grounded and ungrounded thermocouples. If any thermocouple connected to the controller is of grounded construction, all thermocouples should be of grounded construction and each should be connected to ground at the process end.
• Connect the earth ground terminal on TB2 to a good earth ground, but do not connect the analog common to earth ground. The D8 uses a floating analog common for sensor measurements. The noise protection circuits on the sensor inputs function correctly only if the controller is correctly installed. See
Doc. 0600-3120-2000 Watlow Anafaze 29
Chapter 2: Installation
RTD Input Connections
Series D8 User’s Guide
RTD inputs require accessory resistors. Watlow Anafaze recommends that you use a 100 Ω , three-wire platinum RTD to prevent reading errors due to cable resistance. If you use a two-wire RTD, jumper the negative input to common. If you must use a four-wire RTD, leave the fourth wire unconnected.
CH IN +
CH IN -
Com
Figure 2.14 RTD Connections
100 Ω RTD
Voltage Input Connections
Voltage inputs with ranges greater than -10 to 60 mV require accessory resistors. Special input resistors installed at Watlow
Anafaze divide analog input voltages such that the controller sees a -10 to 60 mV signal on the loop.
CH IN+
CH IN-
Device with
Voltage
Output
Figure 2.15 Voltage Signal Connections
Current Input Connections
Current inputs require accessory resistors. Special input resistors installed at Watlow Anafaze for analog current signals are such that the controller sees a -10 to 60 mV signal across its inputs for the loop.
CH IN+
CH IN-
Device with
Current
Output
Figure 2.16 Current Signal Connections
30 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 2: Installation
Wiring Control and Digital I/O
This section describes how to wire and configure the control outputs for the D8 series controller. The D8 provides dual control outputs for each loop. These outputs can be enabled or disabled, and are connected through a TB50 or TB18.
NOTE!
Control outputs are connected to controller common when the control output is on. If you connect external devices that may have a low side at a voltage other than controller ground, you may create ground loops. To prevent ground loops, use isolated solid state relays and isolate the control device inputs.
Output Wiring Recommendations
When wiring output devices, use multicolored, stranded, shielded cable for analog outputs and digital outputs connected to panel-mounted solid state relays.
• Analog outputs usually use a twisted pair.
• Digital outputs usually have 9 to 20 conductors, depending on wiring technique.
Cable Tie Wraps
After you wire 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 D8 provides dual control outputs for up to eight loops. By default, heat outputs are enabled and cool outputs are disabled. If the heat or cool output is disabled for a loop, then the output is available for alarms or programmable logic. The
CPU watchdog timer output can be used to monitor the state
of the controller; see CPU Watchdog Timer on page 34.
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Chapter 2: Installation Series D8 User’s Guide
Table 2.4
Digital Output States and Values
Stored in the Controller
State Value
1 Description
Off
On
0
1
Open circuit
Sinking current to controller common
1
Read and write these values through communications.
All digital outputs sink current to controller common when on. The load may powered by the 5 Vdc supplied by the controller at the TB50, or by an external power supply. When using an external power supply, bear in mind:
• The D8 power supply available from Watlow Anafaze includes a 5 Vdc supply. When using it to supply output loads, connect the 5 Vdc common to the 15 Vdc common at the power supply.
• Do not exceed +24 volts.
• If you connect the external load to earth ground, or if you
cannot connect it as shown in Figure 2.17, then use a sol-
id state relay.
The outputs conduct current when they are on. The maximum current sink capability is 60 mA at 24 Vdc. The outputs cannot
“source” current to a load.
Using Internal Power Supply
TB50 or TB18
+5 Vdc
Loads
Digital Output 1
Digital Output 2
Using External Power Supply
External
Power
Supply +
-
Do not connect to earth ground or equipment ground
TB50 or TB18
Control Common
Loads
Digital Output 1
Digital Output 2
Figure 2.17 Digital Output Wiring
32 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 2: Installation
Configuring Outputs
As you choose outputs for control and alarms, bear in mind the following points:
• You can enable or disable the control outputs. By default, heat outputs are enabled and cool outputs are disabled.
• You can program each control output individually for on/ off, time proportioning, distributed zero-crossing or Serial DAC control.
• You can individually program each control output for direct or reverse action.
• Alarm outputs other than the global alarm are non-latch-
ing. See Global Alarm on page 97.
• Alarms can be suppressed during process start up and for
preprogrammed durations. See Power Up Alarm Delay on page 128.
• Alarm outputs can be configured, as a group, to sink to output during an alarm or stop current flow during an
alarm. See Digital Output Alarm Polarity on page 129.
Control and Alarm Output Connections
Typically control and alarm outputs use external opticallyisolated solid state relays (SSRs). SSRs accept a 3 to 32 Vdc input for control, and some can switch up to 100 Amps at 480
Vac. For larger currents, use silicon control rectifier (SCR) power controllers up to 1000 Amps at 120 to 600 Vac. You can also use SCRs and a Serial DAC for phase-angle fired control.
The control and alarm outputs are open collector outputs referenced in the D8’s common. Each output sinks up to 60 mAdc to the controller common when on.
Doc. 0600-3120-2000
NOTE!
Control outputs are sink outputs. They sink current when the output is on. Connect them to the negative side of solid state relays.
Figure 2.18 shows sample heat, cool and alarm output connec-
tions.
TB50 or TB18
Heat Output
Cool Output
Alarm Output
+5 Vdc
-
SSR
+ -
SSR
+ -
SSR
+
Figure 2.18 Sample Heat, Cool and Alarm
Output Connections
Watlow Anafaze 33
Chapter 2: Installation
CPU Watchdog Timer
Series D8 User’s Guide
TB50 or TB18
Heat Output
Cool Output
Alarm Output
Common
-
SSR
- PS +
+ -
SSR
+
Figure 2.19 Output Connections Using
External Power Supply
-
SSR
+
The CPU watchdog timer constantly monitors the microprocessor. It is a sink output located on TB50 terminal 6 or TB18 terminal 3. The output can be connected to an external circuit or device to monitor whether the controller is powered and operational. The output is on (low) when the microprocessor is operating; when it stops operating, the output goes off (high).
Figure 2.20 and Figure 2.21 show the recommended circuit
for the watchdog timer output for the TB50 and the TB18.
TB50
+ 5 Vdc
(Terminal 1)
Watchdog Timer
(Terminal 6)
+
-
SSR
Figure 2.20 TB50 Watchdog Timer Output
TB18
Watchdog Timer
(Terminal 3)
+
-
SSR
Figure 2.21 TB18 Watchdog Timer Output
34 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide
Digital Inputs
Chapter 2: Installation
External Switching Device
All digital inputs are transistor-transistor logic (TTL) level inputs referenced to controller common and the internal +5 V power supply of the D8.
When an input is connected to the controller common, the input is considered on. Otherwise, the input is considered 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 4.7 k Ω resistors pull the digital inputs high to 5 Vdc with respect to the controller common.
Table 2.5
Digital Input States and Values
Stored in the Controller
State Value
1 Description
Off
On
0
1
Open circuit
Digital input connected to controller common
1
Read and write these values through communications.
To ensure that the inputs are reliably switched, 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 open, the switching device must provide an impedance of at least 14 k Ω to ensure that the voltage will rise to greater than 3.7 Vdc. When closed, the switch must provide not more than 1.7 k Ω impedance to ensure the voltage drops below 1.3
Vdc.
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).
TB50
Input
External
Switching
Device
Control Com
Figure 2.22 Wiring Digital Inputs
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Chapter 2: Installation Series D8 User’s Guide
Functions Activated by Digital Inputs
Use digital inputs to activate the following functions:
•
Load a job that is stored in controller memory. See BCD
• Change all loops to manual mode at specified output lev-
els. See Mode Override on page 127.
•
Enable thermocouple short detection. See Thermocouple
• Restore automatic control after a failed sensor has been
repaired. See Restore Automatic Mode on page 138.
TB18 Connections
Terminal
15
16
17
18
9
10
11
12
13
14
7
8
5
6
3
4
1
2
Table 2.6
TB18 Connections
Control Output
1
Function D84 _ - _ _ _ _ - _ _ _ _ D88 _ - _ _ _ _ - _ _ _ _
+5 Vdc
CTRL COM
Watchdog timer
Global alarm
Output 1
Output 2
Output 3
Output 4
Output 5
Output 6
Output 7
Output 8
Output 9
Output 10
Output 18 2
Input 1
Input 2
Input 3
Loop 1 heat
Loop 2 heat
Loop 3 heat
Loop 4 heat
Loop 1 cool
Loop 2 cool
Loop 3 cool
Loop 4 cool
Serial DAC clock
Loop 1 heat
Loop 2 heat
Loop 3 heat
Loop 4 heat
Loop 5 heat
Loop 6 heat
Loop 7 heat
Loop 8 heat
Loop 1 cool
Loop 2 cool
Serial DAC clock
1
The indicated outputs are dedicated for control when enabled in the loop setup. If one or both of the outputs are disabled for a loop, then the corresponding digital outputs become available for alarms.
2
If you install a Watlow Anafaze Serial DAC, the D8 series controller uses digital output 18 (terminal 15) for a clock line. You cannot use output 18 for anything else if a Serial DAC is installed.
36 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 2: Installation
TB50 Connections
Table 2.7
TB50 Connections
Control Output
1
Control Output
1
33
35
37
39
41
25
27
29
31
17
19
21
23
11
13
15
7
9
43
45
47
49
Terminal
1
3
5
Function
+5 Vdc
CTRL COM
Not used
Not used
Output 1
Output 2
Output 3
Output 4
Output 5
Output 6
Output 7
Output 8
Output 9
Output 10
Output 11
Output 12
Output 13
Output 14
Output 15
Output 16
Output 17
Input 1
Input 3
Input 5
Input 7
D88
Loop 1 heat
Loop 2 heat
Loop 3 heat
Loop 4 heat
Loop 5 heat
Loop 6 heat
Loop 7 heat
Loop 8 heat
Loop 1 cool
Loop 2 cool
Loop 3 cool
Loop 4 cool
Loop 5 cool
Loop 6 cool
Loop 7 cool
Loop 8 cool
D84
Terminal
Function D88 D84
Loop 2 heat
Loop 3 heat
Loop 4 heat
Loop 1 cool
Loop 2 cool
Loop 3 cool
Loop 4 cool
2
4
6
+5 Vdc
CTRL COM
Watchdog
Timer
Global Alarm
Loop 1 heat
8
10
34
36
38
40
42
26
28
30
32
18
20
22
24
12
14
16
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Output 18 2 Serial
DAC clock
44
46
48
50
Input 2
Input 4
Input 6
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 alarms or programmable logic.
2
If you install a Watlow Anafaze Serial DAC, the D8 uses digital output
18 (terminal 42) for a clock line. You cannot use output 18 for anything else if a Serial DAC is installed.
Doc. 0600-3120-2000 Watlow Anafaze 37
Chapter 2: Installation
Analog Outputs
Series D8 User’s Guide
Wiring the Dual DAC
Analog outputs can be provided by using a Dual DAC or Serial 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 controller 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 strong- ly
recommends using a power supply separate from the controller supply to power the Dual DAC. Using a separate power supply isolates the controller’s digital logic circuits 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 approvals as the Serial DAC.
TB50 or TB18
+5V 1
Control Output mA Load
-
+
2
3
5
6
Dual DAC
1 +5V CTRL Supply
4
DZC CTRL PID Output
+12/24 Vdc External
Power Supply
+Vdc Load Connection
-mAdc Load Connection
-External Power
Supply/ Vdc Load
Connection
+ -
12 to 24 Vdc Power Supply
Figure 2.23 Dual DAC with Current Output
38 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 2: Installation
TB50 or TB18
+5V 1
PID Loop Output
Vdc Load
+
-
Dual DAC
1 +5V CTRL Supply
2
3
4
5
6
DZC CTRL PID Output
+12/24 Vdc External
Power Supply
+Vdc Load Connection
-mAdc Load Connection
-External Power
Supply/ Vdc Load
Connection
+ -
12 to 24 Vdc Power Supply
Figure 2.24 Dual DAC with Voltage Output
Wiring the Serial DAC
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 2.25
for wiring. The Serial DAC is user-configurable for voltage or
current output through firmware configuration. See Configuring Serial DAC Outputs on page 176.
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 5 Vdc found on the TB50 or by an external power supply referenced to the controller’s power supply.
When using multiple Serial DACs, the controller cannot provide sufficient current; use the 5 Vdc output from the D8 power supply.
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Chapter 2: Installation Series D8 User’s Guide
Controller
Power Supply
+5 V
5 V Common
15 V Common
Daisy chain up to
16 Serial DACs
Serial DAC
1 +5V In
2
3
COM In
CLK In
TB50 or TB18
Serial DAC Clock
Control Output
4
5
6
Data In
+ Out
- Out
Load
+
-
Figure 2.25 Single/Multiple Serial DACs
Connecting the D8 to a DeviceNet Network
Connector Type
Connect the D8 to the DeviceNet network using a female, sealed, micro-style, quick disconnect connector with five conductors. The DeviceNet connector is in the back of the controller.
J4
DeviceNet
Connector
Network LED
Indicator Light
Module LED
Indicator Light
40
Figure 2.26 DeviceNet Connector
Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 2: Installation
J4
DeviceNet
Connector
Network LED
Indicator Light
Module LED
Indicator Light
Pinout
Doc. 0600-3120-2000
Figure 2.27 DeviceNet Connector
2
3
5
4
Figure 2.28 Pinout
Pin
3
4
1
2 V+
5
Table 2.8
DeviceNet Connector
Signal
Shield
V-
CAN+
CAN-
Function
Shield interconnect
DeviceNet power
DeviceNet power return
Positive side of the DeviceNet bus
Negative side of DeviceNet bus
1
Watlow Anafaze 41
Chapter 2: Installation Series D8 User’s Guide
Network Length
The network speed is limited by the end-to-end network distance. The longer the network, the slower the baud rate setting
Table 2.9
Maximum Network Speed
Distance
100 m (328 ft)
250 m (820 ft)
500 m (1,640 ft)
Baud Rate
500 Kbps
250 Kbps
125 Kbps
Baud Rate (Data Rate)
DeviceNet communications can use three different baud rates
(data rates) 125k, 250k, and 500k baud. When the switch is set to the PGM position, the unit's baud rate is determined by a software setting. If the switch is set to PGM you must set the data rate using the controller’s front panel or network-configuration software. As long as the switch is set to PGM, the controller will always come back up on the network with the last software-configured baud rate stored in the controller's memory.
As an example, assume the controller's baud rate switch is set to PGM, and it is programmed at 500k baud. Assume too, that the DeviceNet network experiences a power loss. When power is restored, the controller will come back up with a baud rate of 500k baud. If on the other hand, the baud rate switch was changed to 250k baud before the network power had been restored, the controller will attempt to come back on the network at 250k baud.
NOTE!
When changing the baud rate via the software or by manually changing the switch position, you will need to cycle power on the network for the change to take effect.
Node Address (MAC ID)
Valid node addresses on a DeviceNet network range from 0 to
63 decimal. When the switch is set to the PGM position, the unit's node address is determined by a software setting. If the switch is set to “PGM” you must set the node address using the controller’s front panel or network-configuration software. As long as the switch setting remains set for software
42 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 2: Installation selection, the controller will always come back up on the network with the last software configured node address stored in the controller's memory.
Set the controller’s MAC ID with the two rotary switches on the side of the case. Set the most significant digit (MSD) with the left switch and the least significant digit (LSD) with the right switch. For example, to set the address to 23, set the
MSD to 2 and the LSD to 3.
NOTE!
If the node address is changed with the switch, the D8 controller’s power must be cycled before the change takes effect. If the node address is changed using software, the change takes effect immediately.
Status Indicators
Figure 2.29 D8 Side with Rotary Switches
The D8 controller has two indicator lights on the back, one labeled “NET” (Network) and the other labeled “MOD” (Module). On power-up the controller performs a self-test. The indicator light identified as "MOD" displays the result of this test as either pass (green) or fail (red). Also, under normal operation the indicator lights indicate the health of the module and the network. In the event that an indicator light should go from green to red either on power up or afterwards, consult ta-
bles Table 2.10 and Table 2.11 below for basic troubleshoot-
ing.
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Chapter 2: Installation Series D8 User’s Guide
Indicator Light
Off
Green
Red
Flashing Green
Flashing Red
Table 2.10
Module Status Indicator Light
Indicator Light
Off
Flashing Green-Red
Green
Red
Description
No power is applied to the device.
The device is performing a Self-Test.
The device is operating normally
The device has detected an unrecoverable fault.
Table 2.11
Network Status Indicator Light
Description
The device is not online.
The device has not completed the duplicate MAC ID test yet.
The device may not be powered. Look at Table 2.10 ,Module Status
Indicator Light.
The device is online and has connections in the established state.
For a Group 2 Only device it means that the device is allocated to a
Master.
Failed communication device.
The device has detected an error that has rendered it incapable of communicating on the network (Duplicate MAC ID, or Bus-off).
The device is online, but no connection has been allocated or an explicit connection has timed out.
A poll connection has timed out.
44 Watlow Anafaze Doc. 0600-3120-2000
3
Communicating by DeviceNet
This chapter explains how to add a D8 series controller to a
DeviceNet network and how to access and manipulate the controller's data over a network using a Programmable Logic
Controller or other device with a DeviceNet scanner. The chapter also includes descriptions of the D8's objects and attributes that are accessible via the DeviceNet protocol.
Accessing Data with a DeviceNet Master
Figure 3.12 to Figure 3.15 starting on page 65 illustrate the in-
puts and outputs in the D8 controller's polled I/O messages.
These messages are typically used to get the controller's data in and out of a master on a DeviceNet network. To use this data in a Programmable Logic Controller (PLC) these parameters must be mapped through the master (scanner) to memory locations accessible to the PLC or other control devices.
When configuring the number of input bytes, it is important to note that the first input byte, the Exception Status Byte is not currently used. When configuring the D8 with DeviceNet network software such as RSNetWorx™, you must offset the
polled input data by one byte. See the example in Mapping
Software
More than one software package is available to configure devices such as the D8 on a DeviceNet network. This chapter provides step-by-step examples of configuring the D8 controller using Rockwell Software’s RSNetWorx. The methodology used to accomplish this task will be different in other software, but the key steps and the end result, a valid stream
Doc. 0600-3120-2000 Watlow Anafaze 45
Chapter 3: Communicating by DeviceNet Series D8 User’s Guide of data from the D8 to the PLC or other device, will be the same.
About The Electronic Data Sheet (EDS)
Most, if not all, vendors supply an EDS file with their DeviceNet products. The EDS file allows for faster and easier configuration with the network software, but it is not required to make the device work. The examples cover commissioning the D8 on a network both with and without the EDS file. EDS files for the D8 are available on the Watlow web site and upon request from Watlow technical support.
NOTE!
There are several versions of the EDS file.
You must use the correct file for the number of loops in the controller (D84, 4-loop, or D88,
8-loop) and the controller firmware revision.
This information is included in the file description on Watlow's web site.
Configuring a D8 Using RSNetWorx
Complete the following steps prior to configuring the DeviceNet network software:
• The physical layer of the DeviceNet network is built.
• At least the D8 controller, a DeviceNet master, and a computer interface are connected to the network.
• Each device has a unique node addresses and the same baud rate setting.
Once all the devices are connected and power is applied to the network:
1. With RSLinx™ select and configure the appropriate communications driver for your hardware.
2. Open RSNetWorx and go online.
46 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 3: Communicating by DeviceNet
Figure 3.1
RSNetWorx On-line with
Found Devices
Figure 3.1 shows node address 1 with a question mark on its
icon, indicating that this device has not yet been registered in
RSNetWorx. At this point the user may register an existing
EDS file or create one. Both options are addressed in the following sections.
Registering the D8 without an EDS File
This section assumes the user does not have an EDS file from
Watlow for the D8 controller but needs to get the unit up and running anyway.
To register the device without the Watlow EDS file:
1. Double-click the device with a question mark.
2. Proceed through the prompts to create an EDS file.
3. Select the polled method (Master/Slave) and then enter
the number of input and output bytes. See Table 3.1.
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Chapter 3: Communicating by DeviceNet Series D8 User’s Guide
Table 3.1
Number of Bytes
Controller Input Bytes Output Bytes
D84 (4-loop) 41
D88 (8-loop) 81
12
24
Figure 3.2
The D8 Registered in RSNetWorx
Registering the D8 with the Watlow EDS File
There are important differences between the results of registering the D8 controller with and without the Watlow-supplied EDS file, though these differences are not readily visible
Double-clicking node address 1 (D8 controller) in the RSNet-
Worx graph of the network opens the dialog box shown at the
left in Figure 3.3. When the controller is registered with the
Watlow EDS, the same dialog box has an additional tab labeled Parameters as shown at the right in the figure.
48 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 3: Communicating by DeviceNet
A. Registered without the Watlow EDS B. Registered with the Watlow EDS
Figure 3.3
D8 Properties in RSNetWorx
The Parameters tab provides access to all of the D8 control-
ler's parameters. See Figure 3.4. Some of these parameters
have read-only access and some have read-and-write access.
This tab can be a valuable tool for configuring the D8. Without the Watlow EDS file all configuration must be done through the front panel of the controller or via explicit messages initiated through a PLC or other device passed through a scanner (DeviceNet master).
Doc. 0600-3120-2000 Watlow Anafaze 49
Chapter 3: Communicating by DeviceNet Series D8 User’s Guide
Figure 3.4
Parameters Tab
Mapping Polled I/O Data
Once the D8 controller is registered, the master must be configured to communicate with it. Once the master is configured it is possible to map the polled I/O data from the D8 to the
PLC. The next sections address these steps.
Adding the D8 to the Master's Scanlist
This section describes configuring the DeviceNet scanner so that it will copy data between the scanner's memory and the
D8 controller.
To add the D8 controller to the scanlist:
dialog lists the Available Devices and displays the scan-
ner's Scanlist (see Figure 3.5 on page 51). The Scanlist
shows the devices that are mapped into the scanner's memory, the Available Devices list displays the devices that are on the network.
2. Uncheck the Automap on Add option. (When checked the software automatically assigns addresses to data from the
50 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 3: Communicating by DeviceNet device starting at the next available byte in the PLC memory. When not checked the user controls how the bytes are arranged.)
3. Select 01 Watlow D84/D88 by clicking it in the Available
Devices list.
4. Click the right-arrow button to put the D8 on the Scanlist.
Figure 3.5
Adding the D8 to the Scanlist
Assigning PLC Addresses
Once the device has been added to the Scanlist, it is possible to map the polled bytes to any available contiguous memory location for both inputs and outputs.
The Allen-Bradley 1747-SDN scanner module in this example consumes the first 32 words of the input and output files corresponding to the slot in which it is inserted. For example, when the module is inserted in slot 3 of the PLC, the scanner uses addresses in the input file I:3.0 through I:3.31. This provides only 32 words of memory. Because the D88 controller supplies 81 bytes or 40.5 words of input, it is necessary to map the incoming polled data to the scanner's M1 file instead.
The following procedure maps the D88's input bytes to the scanner's M1 file. Actually only 40 words or 80 bytes of input data will be mapped because the Exception Status Byte, which is currently unused, is excluded.
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Chapter 3: Communicating by DeviceNet Series D8 User’s Guide
The Node list in Figure 3.6 indicates that the scanner will
communicate with the D8 via Polled messages. The scanner expects to find 81 bytes, but no data is currently mapped. The figure also shows four other devices on the network and their corresponding communications and data mapping configurations.
52
Figure 3.6
Scanner Input Properties
To map the D8's data:
1. Select the D8 by clicking 01, Watlow D84/D88 in the
Node list on the Input tab.
2. Click the Advanced button to open the Advanced Map- ping
dialog box. See Figure 3.7 on page 53.
3. In the Map From group, for Message, select Polled, and set Byte to 1. (This excludes the first byte.)
4. In the Map To group, for Memory, select M File.
5. Set Bit Length to 640. (80 bytes times 8 bits per byte is
640 bits, the Exception Status Byte is excluded.)
6. Click Apply Mapping.
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Series D8 User’s Guide Chapter 3: Communicating by DeviceNet
Figure 3.7
Advanced Mapping Dialog Box
The D8's polled input data is now mapped to the scanner's M1 file.
The scanner's M0 file may similarly be used to map the DeviceNet output data. The output data is easier to map because
Sample Ladder Logic
The following sections give examples of using information from the polled I/O and using explicit messages to read and write data between the D8 controller and a PLC.
Accessing Polled I/O Data
For a better understanding of the ladder logic examples in this
section, refer to Figure 3.14 and Figure 3.15 starting on page
65. These figures illustrate the polled input and output mes-
sages. Because the first byte of the input data, the Exception
Status Byte was excluded, the first word mapped is loop 1's
Process Variable, and it is stored in the scanner's memory at
M1:1.0. The Process Variables for subsequent loops are in the next seven memory locations (M1:1.1 to M1:1.7).
All ladder logic examples that follow were made using an
Allen-Bradley SLC 5/04. Although there are different instruc-
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Chapter 3: Communicating by DeviceNet Series D8 User’s Guide tions from one PLC manufacturer to another, the same concepts apply.
NOTE!
The contents of the scanner's M1 file cannot be monitored directly in RSLogix™, the logic-programming environment used in the following examples. For ease of demonstration and troubleshooting, the relevant registers are copied from the scanner's M1 file to the
PLC's N14 file.
54
Figure 3.8
Using Scanned Data in Logic
For programming convenience the ladder program in
Figure 3.8 copies the portion of the scanner's memory to
which the D8's inputs are mapped into an integer file, N14:0.
This information is automatically polled so it does not require special communication instructions to update values between the D8 and the PLC. During every PLC scan the DeviceNet scanner is queried for the latest values stored in its memory.
The D8 controller stores and communicates Process Variables
function scales the scanned value into whole degrees. The
DIV function block divides the value in N14:0 (923) by 10 and places the temperature (92° F) into N14:43. This value can be used elsewhere in logic, and the programmer will know that the value is in degrees.
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Series D8 User’s Guide Chapter 3: Communicating by DeviceNet
Figure 3.8 also shows the power level for loop 1 being scaled.
The scanned value is also in tenths, so 1000 means 100%
power (see Heat/Cool Output on page 122).
According to Figure 3.14 on page 65, M1:1.8 will hold the Set
Point for loop 1. This value is copied by the ladder logic to
N14:8. The 8 words after the set points, starting at M1:1.16 copied to N14:16 contain the Heat Output power for loops 1
to 8. Figure 3.9 shows the copied values for loop 1 to 8's Pro-
cess Variables and Set Points and the Heat Outputs for loops
1 to 4.
Figure 3.9
Contents of the PLC Memory
Setting a Value with an Explicit Message
The Allen-Bradley 1747-SDN scanner module provides dedicated memory for explicit messages. In this model M0:1.224 is the first of 32 words that may be used for an explicit message (see Allen-Bradley Publication 1747-IN058C-EN-P -
May 2002).
In the first rung of ladder logic in Figure 3.10 on page 56
when the Enable Power Out Write (B17:0/6) is on, the PLC writes to the scanner. At the first off-to-on transition of
B17:0/6 the copy instruction (COP) sends an explicit message to the scanner. In this example, the message changes the Heat
Output for loop 1 to the value specified in N14:56.
NOTE!
The Heat Output can only be set via DeviceNet when the loop is in the Manual Mode.
If the loop's Mode is Off, Tune or Auto, the controller sets the Heat Output.
The copy instruction in the second rung of logic is executed only when a response to a previously sent explicit message is available to be read and interpreted by the ladder program
(I:1/15). If communications is successful with the D8, the copy instruction returns an echo of N14:50 and places it in
N14:60. If this echo occurs, the MVM instruction deletes the transaction from the response queue. If communications is not successful, an error code is returned via N14:60. For all error code definitions, see the Allen-Bradley publication mentioned above.
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Chapter 3: Communicating by DeviceNet Series D8 User’s Guide
56
Figure 3.10 Explicit Write in Ladder
NOTE!
The numbers shown above in N14:50 through N14:56 and N14:60 through N14:66 are in hexadecimal.
The explicit messages in the example are 7 words long. The outbound transaction header is defined in the first 3 words of the copy instruction. In the figure the header for the first mes-
sage is N14:50, 51, and 52. Table 3.2 lists and describes the
parts of the message header.
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Table 3.2
Outbound Transaction Header
Memory Location
N14:50 MSB
N14:50 LSB
N14:51 MSB
N14:51 LSB
N14:52 MSB
N14:52 LSB
Description Example Value Note
Transaction ID
(TXID)
Command
Port
Data Size (in bytes) 8 hex
Service
MAC ID
1 hex
1 hex
0 hex
10 hex
Unique number for message in the queue
Execute the transmission block
The DeviceNet port
Size of the message body: 8 bytes or 4 words
Get Attribute Single
The D8's address 1 hex
Up to 32 words are allocated for an explicit message in the scanner used in the example. The header used 3, leaving 29 for the message body. In this example only 4 words are used in the message body. The first 3 words of the body contain the class, instance and attribute to be accessed. The final word is the data, in this case the new power level sent to the D8.
Table 3.3 lists and describes the parts of the message body.
Table 3.3
Explicit Message Body
Memory Location Description Example Value
N14:53
N14:54
N14:55
N14:55
Class
Instance
Attribute
Data
65 hex
1 hex
64 hex
0 hex
Note
Output Object (See Table 3.21)
Loop 1
Sets the Heat Output to 0%
As another example, if you wanted to change the Heat Output for loop 6, the body of the message would be the same except that the Instance would be 6 hex.
Reading a Value with an Explicit Message
The logic in Figure 3.11 on page 58 initiates an explicit mes-
sage from the PLC to the D8. This message specifies the Get
Attribute Single service (0E hex) rather than the Set Attribute
Single service (10 hex) used in the previous example.
With the class, instance and attribute specified, the PLC gets back the current setting for loop 1's Proportional Band. In this explicit read example you can see not much has changed in the ladder logic. In fact, the logic could be duplicated from the previous example with the only change being the contents of
N14:92.
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Figure 3.11 Explicit Read in Ladder
When I:1/15 comes on, indicating there is a response available to a previously sent message, the controller's loop 1 Proportional Band value is copied to N14:103. Again, if N14:100 comes back as an echo of N14:90 (transaction completed successfully) the MVM instruction deletes the transaction from the response queue.
Setting Parameters via DeviceNet
All values stored in the D8 are bits, integers or strings. Some integers represent settings that appear as text in the controller interface. Some integers represent numeric settings.
This section describes how to interpret values found in the DeviceNet objects.
Non-Numeric Settings
58
With the exceptions of the Loop Name and Units parameters, when the controller interface displays the setting as a word, a
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mation in Chapter 6, Menu and Parameter Reference. The in-
teger value appears in parentheses following each option. Use that integer value when you set or interpret the value of the parameter via DeviceNet.
Bit-Wise Values
Some settings, such as those that enable alarms, are stored as bits within words. To examine the value of just one bit, you can “and” the value with a mask word to extract the particular bit in which you are interested. To set or clear the bit, add or subtract the appropriate value to change the value of the word.
For example, to extract the fourth bit from a value in a bit-wise parameter, you would “and” it with a word that is all zeros except the fourth bit (0000000000001000, or 8 in decimal). To set the bit, add 8 to the value. To clear the bit, subtract 8 from the value.
NOTE!
Throughout this manual, we refer to the least significant bit as the rightmost bit.
Decimal Placement for Numeric Values
Numeric values that are in the loop’s engineering units are stored as integers. The number of decimal places that are assumed when a parameter value is stored in the controller depends upon the Input type and Disp format parameter values
Table 3.4
Number of Decimal Places for
Numeric Values via Logic
Input Type
Any thermocouple
RTD
Process
Display Format
-999 to 3000
-999.9 to 3000.0
-999 to 3000
-9999 to 30000
-999.9 to 3000.0
-99.99 to 300.00
-9.999 to 30.000
-0.9999 to 3.0000
Decimal
Places
3
4
1
2
1
0
1
1
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To determine the integer value to set in the controller, move the decimal to the right the number of places specified.
For example:
• If a loop has a process input with a display format of
-99.99 to 300.00, values are stored with two decimal places. If you read a value in the set point register of
2500, you should interpret that value as 25.00.
• If a loop has a thermocouple input and you want to set the
Alarm High SP
parameter to 355 through logic, you should set a value of 3550.
Decimal Placement for Percentage Values
Percentage values are stored internally in tenths of a percent, such that 1000 corresponds to 100.0 percent. Divide values by ten when reading, and multiply values by ten before writing.
D8 DeviceNet Overview
The D8 controller is configured as a Group 2 Only Slave device using the Predefined Master/Slave Connection Set.
The D8's DeviceNet interface includes objects in two main categories, DeviceNet Objects and Application Objects. DeviceNet objects handle what is necessary for networking and communications. Application Objects provide access to the
D8 controller's parameters and data.
Master/Slave Connections
The D8 supports the Predefined Master/Slave Connection Set, which calls for the utilization of an Explicit Messaging Connection to manually create and configure Connection Objects within each connection end-point. These Connections are referred to collectively as the Predefined Master/Slave Connec- tion Set
.
The master is the device that gathers and distributes I/O data for the process controller. Slaves are the devices from which the master gathers I/O data and to which the master distributes
I/O data. The master “owns” the slaves whose node addresses appear in its scan list. To determine which slaves it will communicate with, the master examines its scan list and sends commands accordingly. Except for the Duplicate MAC ID
Check, a slave cannot initiate any communication before being told by the master to do so.
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Addressing
Chapter 3: Communicating by DeviceNet
All data is referenced using a four-part definition: Node
(MAC ID) + Class + Instance + Attribute.
Table 3.5
Address Components
Address Component
Node Address (MAC ID)
Class ID
Instance ID
Attribute ID
Range
[0 to 63]
[1 to 255]
[0 to 255]
[1 to 255]
Data Types
The descriptions of attributes in the following sections include
the data type for each. Table 3.6 lists and describes these data
types.
Table 3.6
Elementary Data Types
Type
BOOL
BYTE
EPATH
INT
SHORT_STRING
UDINT
UINT
USINT
WORD
Description
Logical Boolean (TRUE or FALSE)
Bit string (8 bits)
DeviceNet path segments
Signed integer (16 bits)
Character string (1 byte per character, 1 byte length indicator)
Unsigned double integer (32 bits)
Unsigned integer (16 bits)
Unsigned short integer (8 bits)
Bit string (16 bits)
DeviceNet Objects
The following sections describe the standard DeviceNet objects and the D8-specific application objects. Tables in each section identify the class, available services, and the object's class and instance attributes.
Identity Object
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The Identity object provides identification information for the device. This includes the device manufacturer, product name, product type, serial number and revision.
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Table 3.7
Identity Class and Services
Class Code
Class Services
Instance Services
01 hex
None
01 hex Get Attribute All
05 hex Reset (O,1)
0E hex Get Attribute Single
Table 3.8
Identity Instance Attributes
Attribute Access
1 (1 hex) Get
2 (2 hex) Get
3 (3 hex) Get
4 (4 hex) Get
5 (5 hex) Get
6 (6 hex) Get
7 (7 hex) Get
Name Type
Vendor ID UINT
Product
Type
Product
Code
Revision
UINT
UINT
STRUCT of: 2 USINT
WORD Status
Serial
Number
Product
Name
UDINT
SHORT_
STRING
Description
Identification of each vendor by number.
Watlow has vendor ID 153
Identification of general type of product for vender. The D8 has type 0.
Specific product code: D88 (1); D84 (2).
Revision of the item the Identity Object represents
Summary status of device
Serial number of device
Human readable ID: "WATLOW D88" or
"WATLOW D84"
Message Router Object
The Message Router object provides a messaging connection point through which a client may address a service to any object class or instance residing in the physical device.
Table 3.9
Message Router Class and Services
Class Code
Class Services
Instance Services
02 hex
None
04 hex Get Attribute Single
Table 3.10 Message Router Instance Attributes
Attribute Access Name
2 (2 hex) Get
3 (3 hex) Get
Type
Number
Available
Number
Active
UINT
UINT
Description
Maximum number of connections supported. The D8 supports up to 3 connections.
Number of connections currently used by the system components.
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DeviceNet Object
The DeviceNet object is used to provide the configuration and status of a physical attachment to DeviceNet.
Table 3.11 DeviceNet Class and Services
Class Code
Class Services
Instance Services
03 hex
0E hex Get Attribute Single
10 hex Set Attribute Single
0E hex Get Attribute Single
08 hex Create
09 hex Delete
Table 3.12 DeviceNet Class Attributes
Attribute Access Name
1 (1 hex) Get
Type Description
Revision UINT Revision of this object
Table 3.13 DeviceNet Instance Attributes
Attribute Access Name Type Description
1 (1 hex) Get/Set 1 MAC ID
2 (2 hex) Get/Set 2 Baud Rate
4 (3 hex)
5 (4 hex)
Get
Get
USINT
USINT
Node Address (0 to 63)
Baud Rate (0 to 2)
Bus-Off Counter
Allocation Info.
USINT
Number of times CAN went to the bus-off state (0 to 255)
STRUCT of: Allocation Information
BYTE Allocation Choice Byte
USINT MAC ID of Master (0 to 63, 255)
1 If the Node Address (MAC ID) rotary switches are set to a value from 0 to 63, the MAC ID attribute has only Get access. If the rotary switches are set to the programmable mode, the MAC ID attribute has both Get and Set ac-
2 cess.
If the Baud Rate (data rate) rotary switch is set to 125, 250 or 500k baud, the Baud Rate attribute has only Get access. If the rotary switches are set to the software programmable mode, the Baud Rate has both Get and Set access.
Assembly Object
The Assembly object binds attributes of multiple objects, which allows data to or from each object to be sent or received over a single connection.
There are several instances of the Assembly object and each has an attribute 3 with controller parameter values for each loop concatenated. For example, an explicit get of instance
100, attribute 3 to a D84 controller returns the four set-point values in one message. This simplifies access to these frequently used parameters.
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Table 3.14 Assembly Class and Services
Class Code
Class Services
Instance Services
04 hex
None
0E hex Get Attribute Single
10 hex Set Attribute Single
Table 3.15 Assembly Instance Attributes
Instance Attribute Access Name Type Description
100 (64 hex) 3 (3 hex) Get/Set Set Points array 1 of INTs
Set Point of each loop
101 (65 hex) 3 (3 hex)
102 (66 hex) 3 (3 hex)
103 (67 hex) 3 (3 hex)
Get/Set
Get
Get
Modes
Process
Variables array 1 of USINTs Mode of each loop array
Heat Outputs array
1
1
of INTs
of UINTs
Process Variable of each loop
Heat Output of each loop
104 (68 hex) 3 (3 hex)
105 (69 hex) 3 (3 hex)
Get
Get
Cool Outputs
Alarm Status array array
1
1
of UINTs
of UINTs
Cool Output of each loop
Alarm status of each loop
106
(6A hex)
107
(6B hex)
3 (3 hex)
3 (3 hex)
Get/Set
Get
Poll Out
Poll In array array
1
1
of INTs+
of USINTs
BYTE + array array
2
3
of INTs +
of UINTs
Consumed Static
Output
Consumed Static
Input
1
2
3
Array size is equal to the number of loops in the controller (4 in a D84 and 8 in a D88).
Array size is equal to the two times the number of loops in the controller (8 in a D84 and 16 in a D88).
Array size is equal to the three times the number of loops in the controller (12 in a D84 and 24 in a D88).
Poll Connection
The poll connection allows the master to write all set points and control modes in one connection. It also allows the reading of all process variables, set points, heat and cool outputs, and alarm status for all of the loops.
Figure 3.12 to Figure 3.15 illustrate the contents of the polled
I/O messages for the D84 (4-loop) and D88 (8-loop) controllers. The Produced Static Input message is produced by the controller as input to the DeviceNet bus. It is, therefore, output from the controller. The Consumed Static Output message is consumed by the controller. It is, therefore, input to the controller.
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Byte Byte
Exception
Status
1 byte
Loop 1 Process Variable
INT (2 bytes)
Loop 1 Set Point
INT (2 bytes)
Loop 1 Heat Output
UINT (2 bytes)
Loop 1 Cool Output
UINT (2 bytes)
Loop 1 Alarm Status
UINT (2 bytes)
Byte Byte Byte Byte Byte Byte
Loop 2 Process Variable
INT (2 bytes)
Loop 2 Set Point
INT (2 bytes)
Loop 2 Heat Output
UINT (2 bytes)
Loop 2 Cool Output
UINT (2 bytes)
Loop 2 Alarm Status
UINT (2 bytes)
Loop 3 Process Variable
INT (2 bytes)
Loop 3 Set Point
INT (2 bytes)
Loop 3 Heat Output
UINT (2 bytes)
Loop 3 Cool Output
UINT (2 bytes)
Loop 3 Alarm Status
UINT (2 bytes)
Loop 4 Process Variable
INT (2 bytes)
Loop 4 Set Point
INT (2 bytes)
Loop 4 Heat Output
UINT (2 bytes)
Loop 4 Cool Output
UINT (2 bytes)
Loop 4 Alarm Status
UINT (2 bytes)
Figure 3.12 D84 Produced Static Input
Byte Byte
Loop 1 Set Point
INT (2 bytes)
Loop 1 Control
Mode
USINT (1 byte)
Loop 2 Control
Mode
USINT (1 byte)
Byte Byte
Loop 2 Set Point
INT (2 bytes)
Loop 3 Control
Mode
USINT (1 byte)
Loop 4 Control
Mode
USINT (1 byte)
Byte
Loop 3 Set Point
INT (2 bytes)
Byte Byte
Loop 4 Set Point
INT (2 bytes)
Byte
Figure 3.13 D84 Consumed Static Output
Byte Byte
Exception
Status
1 byte
Loop 1 Process Variable
INT (2 bytes)
Loop 5 Process Variable
INT (2 bytes)
Loop 1 Set Point
INT (2 bytes)
Loop 5 Set Point
INT (2 bytes)
Loop 1 Heat Output
UINT (2 bytes)
Loop 5 Heat Output
UINT (2 bytes)
Loop 1 Cool Output
UINT (2 bytes)
Loop 5 Cool Output
UINT (2 bytes)
Loop 1 Alarm Status
UINT (2 bytes)
Loop 5 Alarm Status
UINT (2 bytes)
Byte Byte
Loop 2 Process Variable
INT (2 bytes)
Loop 6 Process Variable
INT (2 bytes)
Loop 2 Set Point
INT (2 bytes)
Loop 6 Set Point
INT (2 bytes)
Loop 2 Heat Output
UINT (2 bytes)
Loop 6 Heat Output
UINT (2 bytes)
Loop 2 Cool Output
UINT (2 bytes)
Loop 6 Cool Output
UINT (2 bytes)
Loop 2 Alarm Status
UINT (2 bytes)
Loop 6 Alarm Status
UINT (2 bytes)
Byte Byte
Loop 3 Process Variable
INT (2 bytes)
Loop 7 Process Variable
INT (2 bytes)
Loop 3 Set Point
INT (2 bytes)
Loop 7 Set Point
INT (2 bytes)
Loop 3 Heat Output
UINT (2 bytes)
Loop 7 Heat Output
UINT (2 bytes)
Loop 3 Cool Output
UINT (2 bytes)
Loop 7 Cool Output
UINT (2 bytes)
Loop 3 Alarm Status
UINT (2 bytes)
Loop 7 Alarm Status
UINT (2 bytes)
Byte
Loop 4 Process Variable
INT (2 bytes)
Loop 8 Process Variable
INT (2 bytes)
Loop 4 Set Point
INT (2 bytes)
Loop 8 Set Point
INT (2 bytes)
Loop 4 Heat Output
UINT (2 bytes)
Loop 8 Heat Output
UINT (2 bytes)
Loop 4 Cool Output
UINT (2 bytes)
Loop 8 Cool Output
UINT (2 bytes)
Loop 4 Alarm Status
UINT (2 bytes)
Loop 8 Alarm Status
UINT (2 bytes)
Figure 3.14 D88 Produced Static Input
Byte
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Byte Byte Byte Byte Byte Byte
Loop 1 Set Point
INT (2 bytes)
Loop 5 Set Point
INT (2 bytes)
Loop 1 Control
Mode
USINT (1 byte)
Loop 2 Control
Mode
USINT (1 byte)
Loop 2 Set Point
INT (2 bytes)
Loop 6 Set Point
INT (2 bytes)
Loop 3 Control
Mode
USINT (1 byte)
Loop 4 Control
Mode
USINT (1 byte)
Loop 3 Set Point
INT (2 bytes)
Loop 7 Set Point
INT (2 bytes)
Loop 5 Control
Mode
USINT (1 byte)
Loop 6 Control
Mode
USINT (1 byte)
Byte Byte
Loop 4 Set Point
INT (2 bytes)
Loop 8 Set Point
INT (2 bytes)
Loop 7 Control
Mode
USINT (1 byte)
Loop 8 Control
Mode
USINT (1 byte)
Figure 3.15 D88 Consumed Static Output
Connection Object
The Connection Object allocates and manages the internal resources associated with both polled I/O and explicit messaging connections. The specific instance generated by the
Connection Class is referred to as a Connection Instance or a
Connection Object.
Table 3.16 Connection Class and Services
Class Code
Class Services
Instance Services
05 hex
None
0E hex Get Attribute Single
10 hex Set Attribute Single
Table 3.17 Connection Instance Attributes
Attribute Access
1 (1 hex)
2 (2 hex)
3 (3 hex)
Get
Get
Get
4 (4 hex)
5 (5 hex)
6 (6 hex)
7 (7 hex)
8 (8 hex)
9 (9 hex)
Get
Get
Get
Get
Get
Get/Set
Name Type Description
State USINT State of the object
Instance Type USINT Indicates either I/O or Messaging
Transport Class
Trigger
BYTE Defines behavior of the Connection
Produced
Connection ID UINT
Consumed
Connection ID UINT
Initial Comm
Characteristics BYTE
UINT
Placed in CAN Identifier Field when the Connection transmits
CAN Identifier Field value that denotes message to be received
Defines the Message Group(s) across which productions and consumption associated with this Connection when it occurs
Maximum number of bytes transmitted across this Connection
Produced Connection Size
Consumed
Connection
Size
Expected
Packet Rate
UINT
UINT
Maximum number of bytes received across this Connection
Defines timing associated with this Connection
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Attribute Access
12 (C hex) Get/Set
13 (D hex) Get
14 (E hex) Get
15 (F hex) Get
16 (10 hex) Get
Name Type
Watchdog
Timeout Action USINT
Produced Connection Path
Length
UINT
Produced Connection Path
Consumed
Connection
Path Length
Consumed
Connection
Path
EPATH
UINT
EPATH
Description
Defines how to handle inactivity or watchdog timeouts; Auto Delete (1), Deferred Delete (3)
Number of bytes in the Produced Connection
Path Attribute
Specifies the Application Object(s) whose data is to be produced by this Connection
Object.
Number of bytes in the Consumed Connection Path Length
Specifies the Application Object(s) that are to receive data consumed by this Connection
Object.
Input Object
Attribute Access
1 (1 hex) Get
2 (2 hex) Get
3 (3 hex) Get
Name
Revision
Max Instance
Number of
Instances
The Input Object provides read/write access to all input parameters. Instance 0 of this object contains the class attributes
listed in Table 3.19. The four-loop controller has four addi-
tional instances, and the eight-loop controller has eight additional instances, each containing the attributes listed in
Table 3.20. Instance 1 corresponds to loop 1, instance 2 cor-
responds to loop 2, and so on.
Table 3.18 Input Class and Services
Class Code
Class Services
Instance Services
64 hex
0E hex Get Attribute Single
0E hex Get Attribute Single
10 hex Set Attribute Single
Table 3.19 Input Class Attributes (Instance 0)
Type Description
UINT Revision of this object
UINT Maximum instances of this object (8)
UINT Number of object instances
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Attribute
100 (64 hex)
101 (65 hex)
102 (66 hex)
103 (67 hex)
104 (68 hex)
105 (69 hex)
106 (6A hex)
107 (6B hex)
108 (6C hex)
109 (6D hex)
110 (6E hex)
111 (6F hex)
112 (70 hex)
Access
Get/Set
Get
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Table 3.20 Input Instance Attributes
(Instances 1 to 4 or 8)
Name Type Description
Set Point INT
Process Variable INT
Input Type
Loop Name
SHORT_STRING
SHORT_STRING
Input Units
Array of 3 USINT See page 132.
Calibration Offset INT
Reverse Thermocouple Detection
BOOL
Display Format USINT
Input Range High INT
Input Range Low INT
Input High Signal INT
Input Low Signal
Input Filter
INT
USINT
NOTE!
All successful explicit message responses from a Set service will contain no data. The response will be a two-byte message containing the requester’s node address and service code (with R/R bit set).
Output Object
The Output Object provides read/write access to all output parameters. Instance 0 of this object contains the class attributes
listed in Table 3.22. The four-loop controller has four addi-
tional instances, and the eight-loop controller has eight additional instances, each containing the attributes listed in
Table 3.23. Instance 1 corresponds to loop 1, instance 2 cor-
responds to loop 2, and so on.
Table 3.21 Output Class and Services
Class Code
Class Services
Instance Services
65 hex
0E hex Get Attribute Single
0E hex Get Attribute Single
10 hex Set Attribute Single
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Attribute
100 (64 hex)
101 (65 hex)
102 (66 hex)
103 (67 hex)
104 (68 hex)
105 (69 hex)
106 (6A hex)
107 (6B hex)
108 (6C hex)
109 (6D hex)
110 (6E hex)
111 (6F hex)
112 (70 hex)
113 (71 hex)
114 (72 hex)
115 (73 hex)
116 (74 hex)
117 (75 hex)
118 (76 hex)
119 (77 hex)
120 (78 hex)
121 (79 hex)
122 (7A hex)
123 (7B hex)
124 (7C hex)
Table 3.22 Output Class Attributes (Instance 0)
Attribute Access
1 (1 hex)
2 (2 hex)
Get
Get
3 (3 hex) Get
Name Type
Revision UINT
Max Instance UINT
Number of
Instances
UINT
Description
Revision of this object
Maximum instances of this object (8)
Number of object instances
Table 3.23 Output Instance Attributes
(Instances 1 to 4 or 8)
Access
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Name
Heat Output
Cool Output
Heat Output Type
Cool Output Type
Heat Action
Cool Action
Heat Cycle Time
Cool Cycle Time
Heat Power Limit
Cool Power Limit
Heat Power Limit Time
Cool Power Limit Time
Sensor Fail Heat Output
Sensor Fail Cool Output
Open Thermocouple Heat
Output Average
Open Thermocouple Cool
Output Average
Heat Output Curve
Cool Output Curve
Heat SDAC Signal
Cool SDAC Signal
Heat SDAC Low Signal
Cool SDAC Low Signal
Heat SDAC High Signal
Cool SDAC High Signal
Heat/Cool Output Action for
Watchdog Inactivity Fault
BOOL
USINT
USINT
BOOL
BOOL
UINT
UINT
UINT
UINT
BOOL
Type
UINT
UINT
UINT
UINT
UINT
UINT
UINT
UINT
USINT
USINT
BOOL
BOOL
USINT
USINT
BOOL
Description
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NOTE!
All successful explicit message responses from a Set service will contain no data. The response will be a two-byte message containing the requester’s node address and service code (with R/R bit set).
Control Object
The Control Object provides read/write access to all control parameters. Instance 0 of this object contains the class at-
tributes listed in Table 3.25. The four-loop controller has four
additional instances, and the eight-loop controller has eight additional instances, each containing the attributes listed in
Table 3.26. Instance 1 corresponds to loop 1, instance 2 cor-
responds to loop 2, and so on.
Table 3.24 Control Class and Services
Class Code
Class Services
Instance Services
66 hex
0E hex Get Attribute Single
0E hex Get Attribute Single
10 hex Set Attribute Single
Table 3.25 Control Class Attributes (Instance 0)
Attribute Access
1 (1 hex)
2 (2 hex)
Get
Get
3 (3 hex) Get
Name Type
Revision UINT
Max Instance UINT
Number of
Instances
UINT
Description
Revision of this object
Maximum instances of this object (8)
Number of object instances
Attribute
100 (64 hex)
101 (65 hex)
102 (66 hex)
103 (67 hex)
104 (68 hex)
105 (69 hex)
106 (6A hex)
107 (6B hex)
108 (6C hex)
Table 3.26 Control Instance Attributes
(Instances 1 to 4 or 8)
Access
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Name
Heat Proportional Band
Cool Proportional Band
Heat Integral
Cool Integral
Heat Derivative
Cool Derivative
Heat Manual Reset
Cool Manual Reset
Heat Filter
Type
UINT
UINT
UINT
UINT
USINT
USINT
UINT
UINT
USINT
Description
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Attribute
109 (6D hex)
110 (6E hex)
111 (6F hex)
112 (70 hex)
Access
Get/Set
Get/Set
Get/Set
Get/Set
Name
Cool Filter
Hysteresis
Restore Automatic Mode
Mode
Type
USINT
UINT
USINT
USINT
Description
NOTE!
All successful explicit message responses from a Set service will contain no data. The response will be a two-byte message containing the requester’s node address and service code (with R/R bit set).
Alarm Object
The Alarm Object provides read/write access to all alarm parameters. Instance 0 of this object contains the class attributes
listed in Table 3.28. The four-loop controller has four addi-
tional instances, and the eight-loop controller has eight additional instances, each containing the attributes listed in
Table 3.29. Instance 1 corresponds to loop 1, instance 2 cor-
responds to loop 2, and so on.
Table 3.27 Alarm Class and Services
Class Code
Class Services
Instance Services
67 hex
0E hex Get Attribute Single
0E hex Get Attribute Single
10 hex Set Attribute Single
Table 3.28 Alarm Class Attributes (Instance 0)
Attribute Access
1 (1 hex) Get
2 (2 hex) Get
3 (3 hex) Get
Name Type Description
Revision
Max Instance
UINT
UINT
Revision of this object
Maximum instances of this object (8)
Number of Instances UINT Number of object instances
Table 3.29 Alarm Instance Attributes
(Instances 1 to 4 or 8)
Attribute Access Name
100 (64 hex) Get/Set Alarm High Set Point
101 (65 hex) Get/Set Alarm Low Set Point
102 (66 hex) Get/Set High Deviation Value
103 (67 hex) Get/Set Low Deviation Value
Type Description
INT
INT
UINT
UINT
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Attribute Access Name Type Description
104 (68 hex) Get/Set Alarm Hysteresis
105 (69 hex) Get/Set Alarm High Output
UINT
USINT
106 (6A hex) Get/Set Alarm Low Output USINT
107 (6B hex) Get/Set High Deviation Output USINT
108 (6C hex) Get/Set Low Deviation Output
109 (6D hex) Get/Set Alarm Delay
110 (6E hex) Get Alarm Status
111 (6F hex) Get/Set Alarm Enable
112 (70 hex) Get/Set Alarm Function
113 (71 hex) Get/Set Alarm Acknowledge
USINT
UINT
UINT
UINT
UINT
UINT
NOTE!
All successful explicit message responses from a Set service will contain no data. the response will be a two-byte message containing the requester’s node address and service code (with R/R bit set).
PV Retransmit Object
The PV Retransmit Object provides read/write access to all process variable retransmit parameters. Instance 0 of this ob-
ject contains the class attributes listed in Table 3.31. The four-
loop controller has four additional instances, and the eightloop controller has eight additional instances, each containing
the attributes listed in Table 3.32. Instance 1 corresponds to
loop 1, instance 2 corresponds to loop 2, and so on.
Table 3.30 PV Retransmit Class and Services
Class Code
Class Services
Instance Services
68 hex
0E hex Get Attribute Single
0E hex Get Attribute Single
10 hex Set Attribute Single
Table 3.31 PV Retransmit Class Attributes
(Instance 0)
Attribute Access
1 (1 hex)
2 (2 hex)
Get
Get
3 (3 hex) Get
Name Type
Revision UINT
Max Instance UINT
Number of
Instances
UINT
Description
Revision of this object
Maximum instances of this object (8)
Number of object instances
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Table 3.32 PV Retransmit Instance Attributes
(Instances 1 to 4 or 8)
Attribute Access Name
100 (64 hex) Get/Set Heat Output Retransmit
101 (65 hex) Get/Set Cool Output Retransmit
102 (66 hex) Get/Set Heat Retransmit Low Process Variable
103 (67 hex) Get/Set Cool Retransmit Low Process Variable
104 (68 hex) Get/Set Heat Retransmit High Process Variable
105 (69 hex) Get/Set Cool Retransmit High Process Variable
Type Description
INT
INT
INT
INT
NOTE!
All successful explicit message responses from a Set service will contain no data. The response will be a two-byte message containing the requester’s node address and service code (with R/R bit set).
Ratio Object
The Ratio Object provides read/write access to all ratio parameters. Instance 0 of this object contains the class attributes
listed in Table 3.34. The four-loop controller has four addi-
tional instances, and the eight-loop controller has eight additional instances, each containing the attributes listed in
Table 3.35. Instance 1 corresponds to loop 1, instance 2 cor-
responds to loop 2, and so on.
Table 3.33 Ratio Class and Services
Class Code
Class Services
Instance Services
69 hex
0E hex Get Attribute Single
0E hex Get Attribute Single
10 hex Set Attribute Single
Table 3.34 Ratio Class Attributes (Instance 0)
Attribute Access
1 (1 hex) Get
2 (2 hex) Get
3 (3 hex) Get
Name
Revision
Max
Instance
Number of
Instances
Type
UINT
UINT
UINT
Description
Revision of this object
Maximum instances of this object (8)
Number of object instances
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Attribute
100 (64 hex)
101 (65 hex)
102 (66 hex)
103 (67 hex)
104 (68 hex)
Table 3.35 Ratio Instance Attributes
(Instances 1 to 4 or 8)
Access
Get/Set
Get/Set
Get/Set
Get/Set
Get/Set
Name
Ratio Master Loop
Ratio Low Set Point
Ratio High Set Point
Control Ratio
Ratio Set Point Differential
Type
USINT
INT
INT
UINT
INT
Description
NOTE!
All successful explicit message responses from a Set service will contain no data. The response will be a two-byte message containing the requester’s node address and service code (with R/R bit set).
Cascade Object
The Cascade Object provides read/write access to all cascade parameters. Instance 0 of this object contains the class at-
tributes listed in Table 3.37. The four-loop controller has four
additional instances, and the eight-loop controller has eight additional instances, each containing the attributes listed in
Table 3.38. Instance 1 corresponds to loop 1, instance 2 cor-
responds to loop 2, and so on.
Table 3.36 Cascade Class and Services
Class Code
Class Services
Instance Services
6A hex
0E hex Get Attribute Single
0E hex Get Attribute Single
10 hex Set Attribute Single
Table 3.37 Cascade Class Attributes
(Instance 0)
Attribute Access
1 (1 hex) Get
2 (2 hex) Get
3 (3 hex) Get
Name
Revision
Max
Instance
Number of
Instances
Type
UINT
UINT
UINT
Description
Revision of this object
Maximum instances of this object (8)
Number of object instances
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Attribute
100 (64 hex)
101 (65 hex)
102 (66 hex)
Table 3.38 Cascade Instance Attributes
(Instances 1 to 4 or 8)
Access
Get/Set
Get/Set
Get/Set
Name
Cascade Primary Loop
Cascade Low Set Point
Cascade High Set Point
Type
USINT
INT
INT
Description
NOTE!
All successful explicit message responses from a Set service will contain no data. The response will be a two-byte message containing the requester’s node address and service code (with R/R bit set).
Global Object
The Global Object provides read/write access to all global parameters. Instance 0 contains the class attributes listed in
Table 3.40. Instance 1 contains the attributes listed in
Table 3.39 Global Class and Services
Class Code
Class Services
Instance Services
6B hex
0E hex Get Attribute Single
0E hex Get Attribute Single
10 hex Set Attribute Single
Table 3.40 Global Class Attributes (Instance 0)
Attribute Access
1 (1 hex)
2 (2 hex)
Get
Get
3 (3 hex) Get
Name Type
Revision UINT
Max Instance UINT
Number of
Instances
UINT
Description
Revision of this object
Maximum instances of this object (1)
Number of object instances (1)
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Table 3.41 Global Instance Attributes
(Instance 1)
Attribute Access Name Type Description
100 (64 hex) Get/Set
101 (65 hex) Get/Set
102 (66 hex) Get/Set
103 (67 hex) Get/Set
104 (68 hex) Get/Set
105 (69 hex) Get/Set
106 (6A hex) Get/Set
107 (6B hex) Get/Set
108 (6C hex) Get/Set
109 (6D hex) Get/Set
110 (6E hex) Get/Set
111 (6F hex) Get/Set
112 (70 hex) Get
113 (71 hex) Get/Set
114 (72 hex) Get/Set
115 (73 hex) Get/Set
116 (74 hex) Get
117 (75 hex) Get
118 (76 hex) Get
119 (77 hex) Get
120 (78 hex) Get
Load Setup From Job
Save Setup As Job
BCD Job Load
BCD Job Load Logic
Mode Override
Mode Override Digital Input Active BOOL
Power Up Alarm Delay
Power Up Loop Mode
Keypad Lock
Thermocouple Short Alarm
AC Line Frequency
Digital Output Alarm Polarity
Ambient Sensor
Battery Status
HW Ambient Status
HW Offset Status
HW Gain Status
USINT
USINT
USINT
BOOL
USINT
USINT
BOOL
BOOL
BOOL
INT
BOOL
BOOL
BOOL
BOOL
* Least significant bit (LSB) is digital input 1, most significant bit (MSB) is digital input 8.
BOOL
USINT
Digital Inputs 1 (LSB) to 8 (MSB)* USINT
Digital Outputs 1 (LSB) to 8 (MSB) USINT
Digital Outputs 9 (LSB) to 16 (MSB) USINT
Digital Outputs 17 (LSB) to 18 USINT
OK = 0; Fault = 1
OK = 0; Fault = 1
OK = 0; Fault = 1
OK = 0; Fault = 1
NOTE!
All successful explicit message responses from a Set service will contain no data. The response will be a two-byte message containing the requester’s node address and service code (with R/R bit set).
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4
Operation and Setup
This chapter explains how to use the keypad and display to operate the controller. This chapter also explains the basic concepts that you need to understand to set up and operate the controller.
General Navigation Map
The normal display on the D8 is the loop display. Figure 4.1
shows how to navigate from the loop display to other displays, menus and parameters.
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Chapter 4: Operation and Setup Series D8 User’s Guide
Loop Display
01 925 ∞C
1000auto100
Hold 3 seconds
Scanning Loop Display
01 925 ∞C
02 1025∞C
03 1050∞C
1050auto 0
><
Job Display (if a job is loaded)
Job 1 running
Hold 3 seconds
Setup Menus lGlobal setup r
Other menus b
LOOP
Same Screen on the
Next or Previous Loop
02 1025∞C
1050auto100
.
Operator Parameters l01 Set point r l01 Mode r
^manual l01 Heat out r
% l01 Cool out r
b 0 %
Figure 4.1
General Navigation Map
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Series D8 User’s Guide
Keypad
Chapter 4: Operation and Setup l01 Set point r
b 1000ËšC
Key x
>
<
Description
Access the setup menus (press and hold for 3 seconds).
Cancel a change without saving.
Escape from a parameter to a top-level setup menu.
Escape from a setup menu to the loop display or job display.
Acknowledge an alarm.
Toggle between the loop display and job display (if a job is loaded).
Edit a parameter value.
Scroll through the top-level setup menus.
Toggle between the loop display and job display (if a job is loaded).
Edit a parameter value.
Scroll through the top-level setup menus.
Clear RAM and set all parameters to defaults (hold during power up).
Save a change and go to the previous parameter.
,
.
Access the operator parameters (from the loop display).
Save a change and go to the next parameter.
p
Go to a different loop.
Save a change and go to a different loop.
Go to the scanning loop display (hold + for 3 seconds).
i Get more information about the current screen.
Figure 4.2
Keypad Navigation
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Chapter 4: Operation and Setup
Displays
Loop Display
80
Series D8 User’s Guide
The loop display shows detailed information about a loop.
Process
Variable
Engineering
Units
Loop Name
01 925 ËšCc 0
1000manh100
Cool and
Heat Output
Power
Set Point
Figure 4.3
Loop Display
The control modes are described in Table 4.1.
Table 4.1
Control Modes
Control
Mode
Description off man auto heat cool tun
(blank)
The loop is set to off. One or both outputs are enabled but both outputs are at 0%.
The loop is in manual control. One or both outputs are enabled.
The loop is in automatic control. Only one output (heat or cool) is enabled.
The heat and cool outputs are enabled. The loop is in automatic control and heating.
The heat and cool outputs are enabled. Loop is in automatic control and cooling.
The loop is in autotune mode.
The heat and cool outputs are both disabled.
NOTE!
If the input type for a loop is set to “skip,” the loop display will be blank for that loop.
The scanning loop display sequentially displays the information for each loop. The data for each loop displays for one second. To activate the scanning loop display, go to the loop display, then press and hold the + side of the p key for three seconds. To exit the scanning mode, press any key.
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Alarm Displays
If an alarm condition occurs, the controller displays an alarm code or alarm message.
Two-Character Alarm Codes
If a process, deviation, ambient warning or failed sensor alarm occurs, a two-character alarm code appears in the lower left corner of the loop display.
The alarm code blinks and you cannot change the display until the alarm has been acknowledged. After the alarm is acknowledged, the alarm code stops blinking. The alarm code remains on the display until the condition that caused the alarm is corrected.
Alarm Code
01 925 ËšCc 0
TO 1000manh100
Figure 4.4
Loop Display with Alarm Code
For more information about alarms, see Setting Up Alarms on page 93 and Process Alarms on page 95.
Failed Sensor Alarm Messages
If the alarm is for a failed sensor, an alarm message appears in
the first line of the loop display, as shown in Figure 4.5.
Alarm Message
Alarm Code
01 T/C open c 0
TO 1000manh 0
Figure 4.5
Display for Failed Sensor Alarm
Table 4.2 describes the alarm codes and messages for process
alarms and failed sensor alarms.
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Chapter 4: Operation and Setup Series D8 User’s Guide
Table 4.2
Alarm Codes and Messages for
Process and Failed Sensor Alarms
AH
AL
HD
LD
Alarm
Code
AW
TO
TR
TS
RO
RF
Alarm
Message
Description
(No message)
(No message)
RTD open
RTD fail
Alarm high. See Alarm High and Alarm Low on page 96.
Alarm low. See Alarm High and Alarm Low on page 96.
(No message)
(No message)
(No message)
T/C open
T/C reversed
High deviation alarm. See Deviation Alarms on page 96.
Low deviation alarm. See Deviation Alarms on page 96.
Ambient Warning: The controller is within 5°C of its operating temper-
ature limits. See Ambient Warning on page 160.
Thermocouple open. See Thermocouple Open Alarm on page 94.
Thermocouple reversed. See Thermocouple Reversed Alarm on page 94.
T/C shorted
Thermocouple shorted. See Thermocouple Short Alarm on page 94.
RTD open. See RTD Open and RTD Fail Alarms on page 94.
RTD open or shorted. See RTD Open and RTD Fail Alarms on page
For details about the condition that causes each alarm, see Setting Up Alarms on page 93.
How to Acknowledge an Alarm
To acknowledge a process alarm, failed sensor alarm or system alarm, press x. If there are other loops with alarm conditions, the alarm display switches to the next loop that has an alarm. Acknowledge all alarms to clear the global alarm digital output.
The keypad and display will not work for anything else until you acknowledge each alarm. The alarm code or message persists as long as the alarm condition exists.
System Alarm Messages
If a system alarm occurs, the alarm message replaces the entire display. The message persists until the condition is corrected and the alarm is acknowledged.
Table 4.3 describes system alarm messages. For more infor-
mation, see the Troubleshooting and Reconfiguring chapter.
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Message
Low power
Battery dead
H/W error:
Ambient
H/W error:
Gain
H/W error:
Offset
Job Display
Chapter 4: Operation and Setup
Table 4.3
System Alarm Messages
Description
The power supply has failed. See Low Power on page 163.
The RAM battery in the D8 is not functioning correctly, and stored data
has been corrupted. See Battery Dead on page 163.
The temperature around the controller is outside of the acceptable range
of -5 to 55°C. See H/W Error: Ambient on page 165.
Hardware failed because of excessive voltage on inputs. See H/W Error:
The job display appears if you load a job from memory. If you load a job using the Load setup from job parameter, the job display shows the following screen:
Job 1 running
Doc. 0600-3120-2000
If the job was loaded using digital inputs, the display shows this screen:
Job 1 running remotely loaded
If parameters are modified while the job is running, the display shows this screen:
Job 1 running
Data modified
To toggle between the job display and the loop display, press
> or <.
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Chapter 4: Operation and Setup Series D8 User’s Guide
Changing the Set Point
How to Manually Change the Set Point
Start at the loop display and follow these steps:
1. Press p to choose the appropriate loop.
2. Press .. The Set point parameter should appear. If noth-
ing happens, the keypad may be locked; see Keypad
Lock on page 129. Also, the Set point parameter is not
available if cascade control or ratio control is enabled on the loop.
3. Press > or < to adjust the set point value.
4. Press , to save the value and return to the loop display, or
press p to save the value and switch to the set point for another loop, or press x to cancel changes.
5. On the loop display, the new set point value is shown on the second line.
Set Point
01 925 ËšCc 0
1000manh100
Other Methods of Changing the Set Point
You can use other methods to change the set point:
•
Cascade Control:
Use the output of one loop to adjust
the set point of another loop. See Setting Up Cascade
•
Ratio Control:
Use the process variable of one loop, multiplied by a ratio, as the set point of another loop. See
Setting Up Ratio Control on page 104.
•
Differential Control:
Use the process variable of one loop, plus an offset value, as the set point of another loop.
See Setting Up Differential Control on page 106.
•
Remote Analog Set Point:
Use an external device such
as a PLC to control the set point. See Setting Up Remote
•
Communications:
Use a computer program or operator
interface panel to change the set point. See Chapter 3:
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Series D8 User’s Guide Chapter 4: Operation and Setup
Changing the Control Mode and Output Power
The D8 has four control modes:
•
Off:
Outputs are at 0%.
•
Automatic:
The controller automatically adjusts the output power according to the set point, process variables and other control parameters.
•
Manual:
You set the output power level.
•
Autotune:
The controller calculates the best PID settings
for optimum control. For more information, see Autotuning on page 91.
To change the control mode and output power level, start at the loop display and do the following:
1. Press p to choose the appropriate loop.
2. Press . twice. The Mode parameter should appear. (If
nothing happens, the keypad may be locked; see Keypad
NOTE!
If the heat and cool outputs are disabled on this loop, the Mode parameter is not available. Instead, this message appears:
l01 Mode r outputs disabled
3. Press > or < to choose a control mode. If you make a change and want to cancel it, press x.
4. Press . to save the new value.
5. If you chose manual mode, then the next parameter is the
Heat output
or Cool output parameter. Use these parameters to set the heat and cool output power levels, then press . to save.
6. You should be back at the loop display. The control mode is shown on the second line of the loop display; see
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Chapter 4: Operation and Setup Series D8 User’s Guide
Accessing and Navigating the Setup Menus
Use the setup menus to configure the controller. For a list of
all setup menus and parameters, refer to Figure 6.2 on page
How to Access the Setup Menus
To access the setup menus, press and hold x for three seconds, until the Global setup menu appears.
To prevent unauthorized personnel from accessing setup parameters, the controller reverts to the regular display if you do not press any keys for three minutes.
How to Edit a Setup Parameter
To edit a setup parameter, go to the appropriate setup menu, go to the parameter, then edit the value:
1. Press and hold x for three seconds to access the setup menus.
2. Press < to go to the appropriate a menu.
3. If applicable, press p to choose the loop that you want to edit.
4. Press . to go to the parameter that you want to edit.
5. To edit a parameter:
• Press < or > to choose a value.
• Press . to save the new value and go to the next parameter.
• Press x to cancel a change without saving.
6. Repeat from step 4 to edit another parameter in the current menu.
7. Press x to return to the top-level menus.
8. Repeat from step 2 to go to another menu, or press x to exit the setup menus.
For information about setting parameters through communications, see Appendix A, DeviceNet Interface.
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Setting Up Closed-Loop Control
Closed-loop control is used to control an output based on feedback from a sensor or other signal.
Feedback
The controller receives electrical signals, or feedback, from a sensor or other device. The input parameters determine how the controller interprets the signal. The controller interprets or scales the input signal in engineering units such as °C or °F.
Control Algorithm
Control Output Signal Forms
The output level calculated by the controller is represented by a percentage (0 to 100 percent) of power to be applied. That value is applied on a digital or analog output according to the
able.
Heat and Cool Outputs
When the controller is in automatic control mode and a set point is supplied, the controller determines the appropriate output signal.
The controller calculates the output signal based on the feedback and the control algorithm. Each loop may use either on/off control or any combination of proportional, integral and derivative (PID) control. See the Tuning and Control chapter for information about these control modes.
In some applications, two outputs may be controlled according to one input. For example, a loop with both heat and cooling water flow might be controlled according to feedback from one thermocouple.
In such systems, the control algorithm includes provisions to avoid switching too frequently between the heat and cool outputs. The on/off algorithm uses a hysteresis parameter. The
PID algorithms use both a hysteresis parameter and the PID parameters to determine when control switches between heating and cooling.
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Chapter 4: Operation and Setup Series D8 User’s Guide
How to Set Up Closed-Loop Control
To set up closed-loop control:
• Use the Input menu to specify the type of input signal and, if necessary, how to scale that signal.
• Use the Control menu to specify PID parameters and the control hysteresis.
• Use the Output menu to enable the heat and cool outputs and to specify other output parameters.
• Provide a set point:
• To use cascade control to adjust the set point of the loop, set up the Cascade menu.
• To use ratio control, differential control, or remote analog set point, set up the Ratio menu.
• To manually adjust the set point of the loop, use the
Set point
parameter to enter the set point. See
Changing the Set Point on page 84.
•
Put the controller in automatic mode. See Changing the
Control Mode and Output Power on page 85.
For more information about the setup menus and parameters, see the Menu and Parameter Reference chapter.
Setting Up a Process Input
If you use a process input signal, you must set up scaling parameters in the Input menu to scale the raw input signals to the engineering units of the process.
Input Scaling
To scale the input, you enter values that represent two points on a conversion line. Each point indicates an input signal level and the corresponding process value.
The input signal is expressed as percent of full range. For example, for a 0 to 20 mA process input, 0 mA is 0 percent, 10 mA is 50 percent, and so on.
The conversion line scales the input signal to the engineering
units of the process. For example, in Figure 4.6, a 20 percent
input signal corresponds to 8 pounds per square inch (PSI), and a 100 percent signal corresponds to 28 PSI.
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28
8
0% 20%
Input Signal
Figure 4.6
Input Scaling
100%
The range for set points and alarms is bound by the process variables that correspond to the 0 percent and 100 percent input signals. Bear in mind that the range for set points and alarms is not bound by the low and high process variable ranges that you enter in the scaling parameters.
Input Scaling Example: 4 to 20 mA Sensor
Situation
Suppose the controller has a 0 to 20 mA process input that is connected to a pressure sensor. The pressure sensor has a range of 4 to 20 mA, representing 0.0 to 50.0 pounds per square inch (PSI).
Setup
Set the scaling parameters in the Input menu as follows:
• For the Input type parameter, choose process.
• For the Disp format parameter, choose -999.9to 3000.0, because the sensor measures PSI in tenths.
• For the Input signal low and Input signal high parameters, use the minimum and maximum range of the sensor.
In this case, the sensor range is 4 to 20 mA. The range must be expressed in percent of full scale. To determine the percentages, divide the minimum and maximum sensor range (4 mA and 20 mA) by the maximum signal that the controller can accept (20 mA):
•
Input signal low
= 4 mA/20 mA = 0.2 = 20%
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Chapter 4: Operation and Setup Series D8 User’s Guide
•
Input signal high
= 20 mA/20 mA = 1.0 = 100%
• For the Input range low and Input range high parameters, enter the process values that correspond to the low and high signals. In this case, a 20 percent (4 mA) signal represents 0.0 PSI. A 100 percent (20 mA) signal represents
50.0 PSI.
Table 4.4
Input Readings
Process
Variable
Displayed
50.0 PSI
.0 PSI
Sensor
Input
20 mA
4 mA
Reading in
Percent of Full Scale
100%
100% x (4 mA/20 mA) = 20%
Table 4.5
Scaling Values
Parameter
Input range high
Input high signal
Input range low
Input low signal
Value
50.0 PSI
100.0%
.0 PSI
20.0%
Input Scaling Example: 0 to 5 Vdc Sensor
Situation
A flow sensor connected to the controller measures the flow in a pipe. The sensor generates a 0 to 5 Vdc signal. Independent calibration measurements of the flow in the pipe indicate that the sensor generates 0.5 V at 3 gallons per minute (GPM) and 4.75 V at 65 GPM. The calibration instrument is accurate
±1 GPM.
Setup
For the Disp format parameter in the Input menu, choose
-999to 3000
, because the calibrating instrument is precise to
±1 GPM.
The tables below show the minimum and maximum input signals and their corresponding process variables, and the resulting values for the scaling parameters.
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Table 4.6
Input Readings and Calculations
Process
Variable
Displayed
65 GPM
3 GPM
Sensor
Input
Reading in
Percent of Full Scale
4.75 V (4.75 V / 5.00 V) x 100% = 95%
0.5 V (0.5 V / 5.00 V) x 100% = 10%
Table 4.7
Scaling Values
Parameter
Input range high
Input high signal
Input range low
Input low signal
Value
65 GPM
95.0%
3 GPM
10.0%
Autotuning
Autotuning is a process by which a controller calculates the correct PID parameters for optimum control. Only the heat output of a loop may be autotuned.
How Does Autotuning Work?
Autotuning is performed at the maximum allowed output. If an output limit has been set, then autotuning occurs at that value. Otherwise, the control output is set to 100 percent.
The PID constants are calculated according to process response to the output. The loop need not reach or cross the set point to successfully determine the PID parameters.
The controller looks at the delay between when power is applied and when the system responds and uses this information to determine the proportional band. The controller then looks for the slope of the rising temperature to become constant to determine the integral term. The controller mathematically derives the derivative term from the integral term.
When the controller finishes autotuning a loop, it switches the loop to automatic mode. If the process reaches 80 percent of the set point or the autotuning time exceeds 30 minutes, the controller switches the loop to automatic mode and applies the
PID constants it has calculated up to that point.
Autotuning is started at ambient temperature or at a temperature above ambient. However, the temperature must be stable
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Chapter 4: Operation and Setup Series D8 User’s Guide and there must be sufficient time for the controller to determine the new PID parameters.
Prerequisites
Before autotuning, the controller must be installed with control and sensor circuitry and the thermal load in place. It must be safe to operate the thermal system, and the approximate desired operating temperature (set point) must be known.
The technician or engineer performing the autotune should know how to use the controller keypad or HMI software interface to do the following:
• Select a loop.
• Change the set point.
• Change the control mode (manual, automatic, off or tune).
• Read and change the setup parameters.
How to Autotune a Loop
NOTE!
The loop must be stable at a temperature well below the set point in order to successfully autotune. The controller will not complete tuning if the temperature exceeds 80 percent of set point before the new parameters are found.
To autotune a loop:
1. Go to the loop display (see Loop Display on page 80) and
press p to choose the loop to autotune.
2. Verify that process is stable.
3. Put the loop into manual control mode (see page 85).
4. Enter a set point value as near the normal operating tem-
perature as is safe for the system (see page 84).
WARNING!
During autotuning, the controller sets the output to 100 percent until the process variable rises to 80 percent of set point. Enter a set point that is within the safe operating limits of your system.
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5. Access the setup menus (see page 86). Go to the Input fil-
ter
parameter in the Input menu. Write down the value, and then change it to 0 scans. Press . to save the new setting.
6. Press x twice to return to the loop display.
7. Set the Mode parameter to tune (see page 85).
8. The controller will automatically return to the loop display. The word tun flashes throughout the tuning process.
When tuning is complete, the control mode indicator changes to auto.
9. Adjust the set point to the desired operating temperature
10. Restore the Input filter parameter to its original value.
Setting Up Alarms
The D8 has three main types of alarms:
• Failed sensor alarms
• Process alarms
• System alarms
Failed Sensor Alarms
Failed sensor alarms alert you if one of the following conditions occurs:
• Thermocouple open
• Thermocouple shorted (must be enabled)
• Thermocouple reversed (enabled by default)
• RTD open positive input or open negative input
• RTD short between the positive and negative inputs
What Happens if a Failed Sensor Alarm Occurs?
If a failed sensor alarm occurs:
• The controller switches to manual mode at the output power indicated by the Sensor fail heat output and Sen- sor fail cool output
parameters in the Output menu. (The output power may be different for a thermocouple open
alarm; see Thermocouple Open Alarm below.)
• The controller displays an alarm code and alarm message
on the display. See Alarm Displays on page 81.
• The global alarm output is activated.
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Thermocouple Open Alarm
The thermocouple open alarm occurs if the controller detects a break in a thermocouple or its leads.
If a thermocouple open alarm occurs, the controller switches to manual mode. The output level is determined as follows:
• If the Open T/C ht/cl out average parameter in the Output menu is set to on, then the controller sets the output power to an average of the recent output.
• If the Open T/C ht/cl out average parameter is set to off, then the controller sets the output to the level indicated by the Sensor fail heat/cool output parameter in the Out- put
menu.
Thermocouple Reversed Alarm
The thermocouple reversed alarm occurs if the temperature 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 enabled by default. If false alarms occur in your application, you can disable the alarm by setting the Reversed T/C detect parameter to off. See
Reversed Thermocouple Detection on page 133.
Thermocouple Short Alarm
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:
• Choose a digital input for the TC short alarm parameter in the Global setup menu.
• Connect the digital input to a device that connects the input to controller common when the process power is on.
RTD Open and RTD Fail Alarms
The RTD open alarm occurs if the controller detects that the positive RTD lead is broken or disconnected.
The RTD fail alarm occurs if the controller detects any of the following conditions:
• negative lead is broken or disconnected
• common lead is broken or disconnected
• positive and negative leads are shorted
• positive and common leads are shorted
• positive, negative and common leads are shorted
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The RTD alarms are enabled on any channel with Input Type set to RTD.
Restore Automatic Control After a Sensor Failure
This feature returns a loop to automatic control after a failed sensor is repaired. To enable this feature:
• Choose a digital input for the RestoreAuto parameter in the Control menu.
• Connect the digital input to the dc common terminal on the controller.
Process Alarms
The D8 has four process alarms, each of which you can configure separately for each loop:
• Alarm low
• Alarm high
• Low deviation alarm
• High deviation alarm
What Happens if a Process Alarm Occurs?
If a process alarm occurs, the controller does the following:
•
Shows an alarm code on the display. See Alarm Displays on page 81.
•
Activates the global alarm output. See Global Alarm on page 97.
• Activates the digital output that is assigned to the process alarm (if applicable). The digital output remains active until the process variable returns within the corresponding limit and hysteresis. The alarm output deactivates when the process returns to normal.
Process Alarm Outputs
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-latching—that is, the output is deactivated when the process returns to normal, whether or not the alarm has been acknowledged.
Specify the active state of process alarm outputs at the D/O alarm polarity
setting in the Global setup menu.
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Alarm Function: Standard Alarm or Boost Output
You can configure each process alarm as either a standard alarm or a boost alarm:
• A standard alarm provides traditional alarm functionality: 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 nonlatching alarm output.
• A boost alarm provides on/off control output using the alarm set points. For example, you could configure 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.
Alarm High and Alarm Low
An alarm high occurs if the process variable rises above a user-specified value. An alarm low occurs if the process vari-
able drops below a separate user-specified value. See Figure
Enter the alarm high and low set points at the Alarm high SP and Alarm low SP parameters in the Alarms menu.
Alarm high on
Alarm high SP
Set point + HiDeviation value
High deviation alarm on
Alarm high off
High deviation alarm off
} Hysteresis
} Hysteresis
Set point
Set point - HiDeviation value
Alarm low SP
Low deviation alarm on
Alarm low on
Low deviation alarm off
} Hysteresis
Alarm low off
} Hysteresis
Figure 4.7
Activation and Deactivation of
Process Alarms
Deviation Alarms
96
A deviation alarm occurs if the process deviates from set point
by more than a user-specified amount; see Figure 4.7. You can
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and LoDeviation value parameters in the Alarms menu.
Upon power up or when the set point changes, the behavior of the deviation alarms depends upon the alarm function:
• If the alarm function parameter is set to standard, then deviation alarms do not activate until the after the process variable has first come within the deviation alarm band. This prevents nuisance alarms.
• If the alarm function parameter is set to boost, then the deviation output switches on whenever the set point and process variable differ by more than the deviation setting, regardless of whether the process variable has been within the deviation band. This allows you to use boost control upon power up and set point changes.
Global Alarm
The D8 comes equipped with a global alarm output. The global output is activated if one or more of the following conditions occurs:
• A system alarm occurs, or
• A failed sensor alarm occurs and is unacknowledged, or
• A process alarm occurs and is unacknowledged. The global alarm occurs only if the alarm function is set to stan- dard
in the Alarms menu. (The global alarm does not occur if the alarm function is set to boost.)
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 dc common. When the global alarm output is not active, it does not conduct current.
NOTE!
You cannot configure any parameters for the global alarm. The active state of the global
alarm output is NOT affected by the D/O alarm polarity parameter in the Global setup menu.
Setting Up Process Variable Retransmit
The process variable retransmit feature retransmits the process variable of one loop (primary) via the control output of another loop (secondary). This signal is linear and proportional to the engineering units of the primary loop input.
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Typical uses include data logging to analog recording systems, and long distance transmission of the primary signal to avoid signal degradation. The retransmitted signal can also be used as an input to other types of control systems such as a
PLC.
Any available heat or cool output may be used as a retransmit output. Any process variable may be retransmitted, including the input from the same loop.
To get a 4 to 20 mA or 0 to 5 Vdc signal, the controller output signal must be connected to a Serial DAC.
How to Set Up Process Variable Retransmit
1. Configure all of the setup parameters for the primary loop (the loop whose input signal will be retransmitted).
2. Choose an unused control output to retransmit the input signal. This output may be on the primary loop or on a different loop.
3. On the secondary loop (the loop whose output will retransmit the signal):
• Set up the parameters in the PV retrans menu. See
Process Variable Retransmit Menu on page 148.
• Enable the loop’s output and configure it to meet the requirements of the application.
4. If the signal is being retransmitted to another controller, configure the input of that controller to accept the linear output signal produced by the retransmit output.
Process Variable Retransmit Example: Data Logging
The D8 controls the temperature of a furnace. The thermocouple in one of the zones is connected to the controller and is used for closed-loop PID control. An analog recorder data logging system is also in place, and a recording of the process temperature is required. The recorder requires a linear 4 to 20 mA input signal, which represents a process variable range of
0 to 1000° F.
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Furnace
Heater
Loop 1
Input
Process
Variable
D8
Loop 1 PID Output
Loop 2 PID Output
Serial
DAC
Power
Controller
To Data
Logger
Figure 4.8
Application Using Process
Variable Retransmit
Table 4.8 shows the parameter setup for this example.
Table 4.8
Parameters Settings for Process
Variable Retransmit Example
Menu Parameter Value Comment
PV retrans
PV retrans
Ht retrans
LowPV
PV retrans
Ht retrans
HighPV
PV retrans
Ht output retrans
Cl output retrans
PV 1
0ËšF
1000ËšF none
Choose to retransmit the loop 1 process variable.
This is the input value represented by a 0 percent output signal. The recorder input is a linear 4 to 20 mA signal representing a range of 0° F to 1000° F, so we will use a 0 percent output signal to represent
0° F.
This is the input value represented by a 100 percent output signal. The recorder input is a linear 4 to 20 mA signal representing a range of 0° F to 1000° F, so we will use a 100 percent output signal to represent 1000° F.
Not using the cool output of loop 2 to retransmit a process variable.
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To complete this configuration, the output for loop 2 must be configured to provide the 4 to 20 mA analog signal (via the
Serial DAC) that is required by the data logger.
When setup is completed, the controller will produce an output on loop 2 which is linear and proportional to the loop 1 process variable.
Setting Up Cascade Control
Cascade control is used to control thermal systems with long lag times, which cannot be as accurately controlled with a single control loop. The output of the first (primary) loop is used to adjust the set point of the second (secondary) loop. The secondary loop normally executes the actual control.
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. You can use the primary heat output for both control and for determining the set point of the secondary loop.
How the Secondary Set Point is Determined
The set point of the secondary loop is determined according to the heat and cool output values from the primary loop and user-specified cascade parameters:
• If the primary loop has both heat and cool outputs, then the set point of the secondary loop is equal to the Cas- cade low SP
parameter when the cool output is at 100 percent, and is equal to the Cascade high SP when the
heat output is at 100 percent. See Figure 4.9.
• If the primary loop has only a heat output, then the set point of the secondary loop is equal to the Cascade low
SP
parameter when the heat output is at 0 percent, and is equal to the Cascade high SP parameter when the heat
output is at 100 percent. See Figure 4.10.
• If the primary loop has only a cool output, then the set point of the secondary loop is equal to the Cascade low
SP
parameter when the cool output is at 100 percent, and is equal to the Cascade high SP parameter when the cool output is at 0 percent.
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High Set Point
Low Set Point
-100% 100%
Output of Primary Loop (Percent of Full Scale)
Figure 4.9
Secondary Set Point When Primary
Loop Has Heat and Cool Outputs
High Set Point
Low Set Point
0% 100%
Output of Primary Loop (Percent of Full Scale)
Figure 4.10 Secondary Set Point When Primary
Loop Has Heat Output Only
Proportional-Only Control on the Primary Loop
The PID parameters of the primary loop must be tuned to produce the desired effect on the set point of the secondary loop.
The primary loop typically uses proportional-only control.
Disabling the integral and derivative components of PID makes the secondary set point a predictable function of the primary loop’s process variable.
The proportional band is selected so that the set point of the secondary loop has the desired relationship to the process
variable of the primary loop. For an example, see Cascade
Control Example: Water Tank on page 102.
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How To Set Up Cascade Control
1. For the primary cascade loop:
• Configure proportional-only control. For an exam-
ple, see Cascade Control Example: Water Tank on page 102.
•
Enter the desired set point. See Changing the Set
2. For the secondary cascade loop:
• Set up PID control as you would for a standard closed-loop application.
• Set up the parameters in the Cascade menu. See
NOTE!
Cascade control cannot be used on the same control loop as ratio control.
Cascade Control Example: Water Tank
A tank of water has an inner and outer thermocouple. The outer thermocouple is located in the center of the water. The inner thermocouple is located near the heating element. The desired temperature of the water is 150° F, which is measured at the outer thermocouple.
Using cascade 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 controlled by loop 2.
As the temperature of the outer thermocouple drops from 150°
F to 140° F, the set point of the secondary loop should rise from 150 to 190° F.
Table 4.9 and Table 4.10 show the setup for this application.
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Water
Outer T/C
Loop 1 Input
Process Variable
Loop 1: Primary Cascade Loop
Loop 2: Secondary Cascade Loop
Loop 2 PID Output
Loop 2 Input
Process Variable D8
Heater
Inner T/C
Power
Controller
Figure 4.11 Example Application Using
Cascade Control
Menu
(none)
Control
Control
Control
Menu
Cascade
Cascade
Cascade
Table 4.9
Parameter Settings for the Primary
Loop in the Cascade Example
Parameter Value Comment
Set point
Ht prop band
Ht integral
Ht derivative
150ËšF
Desired temperature at the inner thermocouple.
10
0
0
As the input drops 10° F, the output increases to
100 percent.
Only proportional control is used.
Only proportional control is used.
Table 4.10
Parameter Settings for the Secondary Loop in the Cascade Example
Parameter Value Comment
Cascade prim loop
Cascade low SP
Cascade high SP
1
150ËšF
190ËšF
Loop 1 is the primary loop.
When the primary loop’s output is 0 percent, the secondary loop’s set point is 150° F.
When the primary loop output is 100 percent, the secondary channel set point is 190° F.
As the temperature in the middle of the tank (loop 1) drops, the output goes up proportionally and the set point of loop 2 goes up proportionally. Thus heat is added to the system at the element even though the temperature near the element may have been at the desired temperature.
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With proportional control, when loop 1 is at set point, its output is 0 percent, and the set point of loop 2 is equal to the desired temperature 150º F. If the temperature of the loop 1 drops below 149º F, the deviation results in a proportional output of 10 percent. This results in an increase to the set point for loop 2 equal to 10 percent of the set point range. In this case the range is 40º F (190º F - 150º F = 40º F), and 10 percent of 40º F is 4º F.
So when the temperature at loop 1 drops 1º F, the set point of loop 2 increases by 4º F until the output of loop 1 is 100 percent and the set point of loop 2 is 190º F. At this point, further decreases of the loop 1 process variable have no additional af-
fect on loop 2. Figure 4.12 illustrates this relationship.
190º F
170º F
150º F
0%
50%
Heat Output of Primary Loop
(Percent of Full Scale)
100%
150º F 145º F 140º F
Process Variable of Primary Loop (ºF)
Figure 4.12 Relationship of Secondary Loop
Set Point to Primary Loop Process
Variable in Cascade Example
Setting Up Ratio Control
Ratio control allows the process variable of one loop (master loop), multiplied by a ratio, to be the set point of another loop
(ratio loop). You can assign any process variable to determine the set point of a ratio loop.
By adjusting the ratio control parameters, you can adjust the influence that the master loop process variable has on the set point of the ratio loop.
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High SP erential
Low SP
Master PV * Control Ratio + SP Diff
SP Differential
Input Range
Low
Master Loop Process Variable
Input Range
High
SP = Set Point
PV = Process Variable
Figure 4.13 Relationship Between the Process
Variable on the Master Loop and the Set Point of the Ratio Loop
NOTE!
Ratio control cannot be used on the same control loop as cascade control.
How to Set Up Ratio Control
1. Adjust and tune the master loop for optimal performance before implementing the ratio setup.
2. For the ratio loop, set the parameters in the Ratio menu.
3. Configure both the master loop and the ratio loop for inputs, outputs, and alarms
Ratio Control Example: Diluting KOH
A chemical process requires a formula of two parts water
(H
2
O) to one part potassium hydroxide (KOH) to produce di-
2
O 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 D8, with H
2
O flow measured on loop 1 and KOH flow measured on loop 2.
The outputs of loops 1 and 2 adjust motorized valves.
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Water Input
Flow
Transducer
Series D8 User’s Guide
KOH Input
Loop 1 Input
Process Variable
Loop 2 Input
Process Variable
Loop 1: Water Flow Control Loop
Loop 2: KOH Flow Control Loop
D8
Loop 1 PID Output
Loop 2 PID Output
Motorized
Control
Valve 1
Motorized Control Valve 2
Mixture Output
Figure 4.14 Application Using Ratio Control
Menu
Ratio
Ratio
Ratio
Ratio
Ratio
Ratio low SP
Ratio high SP
Control ratio
Ratio SP diff
Table 4.11
Ratio Control Settings for the Ratio
Loop (Loop 2) in the Example
Parameter Value
Ratio master loop 01
0.0
7.0
0.5
0
Comment
Loop 1 is the master loop.
The minimum ratio loop set point is 0.0 gallons per second (gps).
The maximum ratio loop set point is 7.0 gps.
The H
2
0 flow rate (10 gps) is multiplied by 0.5 to obtain the KOH flow rate (5 gps).
For this example, there is no set point differential.
Setting Up Differential Control
Differential control is a simple application of ratio control, used to control one process (ratio loop) at a differential, or offset, to another process (master loop).
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How to Set Up Differential Control
Set up differential control as you would set up ratio control.
Set the Control ratio parameter to 1.0, and enter the desired set point differential (offset) at the Ratio SP diff parameter.
Differential Control Example: Thermoforming
A thermal forming application requires that the outer heaters operate at temperature 50º F hotter than the center heaters.
The center heaters use infrared (IR) sensors for temperature feedback. The outer heaters use thermocouples for feedback.
We can use differential control to control the outer heaters at a 50º F differential to the central heaters. For example, if the set point for the center heaters is 325º F, the set point of the outer heaters will be 375º F.
In this application, the center heaters will be controlled by the master loop (on loop 1), and the outer heaters will be controlled by the ratio loop (on loop 2).
To set up this application, first set up the master loop (loop 1) for PID control with a set point of 325º F. Then, for the ratio loop (loop 2), set the parameters in the Ratio menu as shown
Table 4.12
Parameter Settings for the Ratio
Loop (Loop 2) for the Example
Menu
Ratio
Ratio
Ratio
Ratio
Ratio
Parameter Value Comment
Ratio master loop
Ratio low SP
Ratio high SP
Control ratio
Ratio SP diff
01
300.0ËšF
400.0ËšF
1.0
Loop 1 is the master loop.
The lowest allowable set point for the ratio loop. For this example, we’ll use 300.0.
The highest allowable set point for the ratio loop. For this example, we’ll use 400.0.
For differential control, always set this parameter to 1.0.
50ËšF
The set point differential, or offset.
To complete the differential control setup, loop 1 and loop 2 must be configured for inputs, outputs and alarms.
Setting Up Remote Analog Set Point
Remote analog set point allows external equipment, such as a
PLC or other control system, to change the set point of a loop.
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Typically, a voltage or current source is connected to an analog input on the controller, and this input is configured as the master loop for ratio control.
Proper scaling resistors must be installed on the input to allow it to accept the analog input signal.
How to Set Up a Remote Analog Set Point
1. For the master loop (the loop that accepts the input signal from the external device), set the parameters in the Input menu.
2. For the ratio loop (the one whose set point is controlled by the external device), set the parameters in the Ratio menu. Specify the loop that accepts the input signal as the master loop.
Remote Analog Set Point Example: Changing a Set Point with a PLC
A PLC provides a 0 to 5 Vdc signal representing 0 to 300° F as a remote set point input to the D8. The input signal is received on loop 1, and control is performed on loop 2. The D8 is equipped with the proper scaling resistors to allow it to accept a 0 to 5 Vdc input.
Table 4.13 and Table 4.14 show the parameter settings for this
application.
Table 4.13
Parameters Settings for the Master
Loop (Loop 1) in the Example
Menu Parameter Value Comment
Input
Input
Input
Input
Input
Input type
Input range high
Input high signal
Input range low
Input low signal process
A 0 to 5 Vdc input signal is a process input.
300ËšF
100.0%
0ËšF
0.0%
The 5 Vdc input signal represents 300° F.
The controller is equipped with a 0 to 5 Vdc input, and the input signal is 0 to 5 Vdc, so the signal covers the full scale of 0 to 100 percent.
The 0 Vdc input signal represents 0° F.
The controller is equipped with a 0 to 5 Vdc input, and the input signal is 0 to 5 Vdc, so the signal covers the full scale of 0 to 100 percent.
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Menu
Ratio
Ratio
Ratio
Ratio
Ratio
Parameter
Ratio master loop
Ratio low SP
Ratio high SP
Control ratio
Ratio SP diff
Table 4.14
Parameter Settings for the Ratio
Loop (Loop 2) in the Example
Value Comment
01
0ËšF
300ËšF
1.0
Loop 1 is the master loop (receives the input signal from the external device).
For this example, we will assume that the process can be set safely over the entire range of
0 to 300° F. If desired, we could set a more restrictive range for the ratio loop.
For this example, we want to retain the original input value, so we will multiply it times 1.0.
0
For this example, we want to retain the original value, so we will add 0.
To complete the setup, loop 2 must be configured for inputs, outputs, and alarms. In addition, loop 1 may be configured for outputs and alarms.
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5
Tuning and Control
This chapter describes the different methods of control available with the D8. This chapter covers control algorithms, control methods, PID control, starting PID values and tuning instructions to help appropriately set control parameters in the
D8 system.
For more information about PID control, consult the Watlow
Anafaze Practical Guide to PID
.
Control Algorithms
This section explains the algorithms available for controlling 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 dc voltage).
There are several control algorithms available:
• On/off
• Proportional (P)
• Proportional and integral (PI)
• Proportional with derivative (PD)
• Proportional with integral and derivative (PID)
P, PI or PID control is necessary when process variable cycling is unacceptable or if the load or set point varies.
NOTE!
For any of these control algorithms to function, the loop must be in automatic mode.
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On/Off Control
Series D8 User’s Guide
Process
Variable
On/off control is the simplest way to control a process. The controller turns an output on or off when the process variable reaches limits around the desired set point. This limit is adjustable.
For example, if the set point is 1000° F and the control hysteresis is 20° F, the heat output switches on when the process variable drops below 980° F and off when the process rises above 1000° F. A process using on/off control cycles around
the set point. Figure 5.1 illustrates this example.
Heat Off Heat Off
On Output
Heat On
Set Point
1000
°
F
Set Point - Hysteresis
980
°
F
Off
Figure 5.1
On/Off Control
Proportional Control (P)
Proportional control eliminates cycling by increasing or decreasing the output proportionally with the process variable’s deviation from the set point.
The magnitude of proportional response is defined by the proportional band. Outside this band, the output is either 100 percent or 0 percent. Within the proportional band the output power is proportional to the process variable’s deviation from the set point.
For example, if the set point is 1000° F and the proportional band is 20° F, the output power is as follows:
• 0 percent when the process variable is 1000° F or above
• 50 percent when the process variable is 990° F
• 75 percent when the process variable is 985° F
• 100 percent when the process variable is 980° F or below
However, a process that uses only proportional control settles at a point above or below the set point; it never reaches the set point. This behavior is known as offset or droop. When using proportional control, configure the manual reset parameter for the power level required to maintain set point.
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Set Point
Proportional
Band
Process Variable
Figure 5.2
Proportional Control
Offset
Proportional and Integral Control (PI)
With proportional and integral control, the integral term corrects for offset by repeating the proportional band’s error correction until there is no error. For example, if a process tends to settle about 5° F below the set point, appropriate integral control brings it to the desired setting by gradually increasing the output until there is no deviation.
Set Point
Overshoot
Proportional
Band
Process Variable
Figure 5.3
Proportional and Integral Control
Proportional and integral action working together can bring a process to set point and stabilize it. However, with some processes the user may be faced with choosing between parameters that make the process very slow to reach set point and parameters that make the controller respond quickly, but introduce some transient oscillations when the set point or load changes. The extent to which these oscillations cause the process variable to exceed the set point is called overshoot.
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Proportional, Integral and Derivative Control (PID)
Derivative control corrects for overshoot by anticipating the behavior of the process variable and adjusting the output appropriately. For example, if the process variable is rapidly approaching the set point from below, derivative control reduces the output, anticipating that the process variable will reach set point. Use derivative control to reduce the overshoot and oscillation of the process variable that is common to PI control.
Figure 5.4 shows a process under full PID control.
Set Point
Proportional
Band
Process Variable
Figure 5.4
Proportional, Integral and Derivative Control
Heat and Cool Outputs
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 thermocouple.
In such systems, the control algorithm avoids switching too frequently between heat and cool outputs. The on/off algorithm uses the control hysteresis parameter to prevent such os-
cillations (see Hysteresis on page 138). When PID control is
used for one or both loop outputs, both the hysteresis parameter and PID parameters determine when control switches between heating and cooling.
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Setting Up and Tuning PID Loops
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 process.
This section gives PID values for a variety of heating and cooling applications.
NOTE!
Tuning is a slow process. After adjusting a loop, allow about 20 minutes for the change to take effect.
Proportional Band Settings
Table 5.1 shows proportional band settings for various tem-
peratures in degrees Fahrenheit or Celsius.
Table 5.1
Proportional Band Settings
Temperature
Set Point
PB
Temperature
Set Point
PB
Temperature
Set Point
PB
-100 to 99
100 to 199
200 to 299
300 to 399
400 to 499
500 to 599
600 to 699
700 to 799
800 to 899
900 to 999
60
65
1000 to 1099 70
40
45
50
55
20
20
30
35
1100 to 1199 75
1200 to 1299 80
1300 to 1399 85
1400 to 1499 90
1500 to 1599 95
1600 to 1699 100
1700 to 1799 105
1800 to 1899 110
1900 to 1999 120
2000 to 2099 125
2100 to 2199 130
2200 to 2299 135
2300 to 2399 140
2400 to 2499 145
2500 to 2599 150
2600 to 2699 155
2700 to 2799 160
2800 to 2899 165
2900 to 2999 170
3000 to 3099 175
3100 to 3199 180
3200 to 3299 185
As a general rule, set the proportional band to ten percent of the set point below 1000 above 1000
°
°
and five percent of the set point
. This setting is useful as a starting value.
Integral Settings
The controller’s integral parameter is set in seconds per repeat. Some other products use an integral term called reset, in
units of repeats per minute. Table 5.2 shows integral settings
versus reset settings.
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Integral
(Seconds/Repeat)
30
45
60
90
120
150
180
Table 5.2
Integral Term and Reset Settings
Reset
(Repeats/Minute)
Integral
(Seconds/Repeat)
Reset
(Repeats/Minute)
2.0
1.3
1.0
0.66
0.50
0.40
0.33
210
240
270
300
400
500
600
0.28
0.25
0.22
0.20
0.15
0.12
0.10
As a general rule, use 60, 120, 180 or 240 as a starting value for the integral.
Derivative Settings
The controller’s derivative parameter is programmed in seconds. Some other products use a derivative term called rate programmed in minutes. Use the table or the formula to con-
vert parameters from one form to the other. Table 5.3 shows
derivative versus rate. Rate = Derivative/60.
Table 5.3
Derivative Term Versus Rate
Derivative
(seconds)
Rate
(minutes)
Derivative
(seconds)
Rate
(minutes)
5
10
15
20
25
30
0.08
0.16
0.25
0.33
0.41
0.50
35
40
45
50
55
60
0.58
0.66
0.75
0.83
0.91
1.0
As a general rule, set the derivative to 15 percent of integral as a starting value.
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.
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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 seven percent of the set point.
(Example: Set point = 450, proportional band = 31).
Proportional with Integral (PI)
• Set the proportional band to ten percent of set point.
(Example: Set point = 450, proportional band = 45).
• Set integral to 60.
• Set derivative off.
• Set the output filter to 2.
Proportional and Integral with Derivative (PID)
• Set the proportional band to ten percent of the set point.
(Example: Set point = 450, proportional band = 45).
• Set the integral to 60.
• Set the derivative to 15 percent of the integral.
(Example: Integral = 60, derivative = 9).
• Set the output filter to 2.
Table 5.4 shows general PID constants by application.
Application
Electrical heat with solid state relays
Electrical heat with electromechanical relays
Cool with solenoid valve
Cool with fans
Electric heat with open heat coils
Gas heat with motorized valves
Set Point>1200
Table 5.4
General PID Constants
Proportional
Band
Integral Derivative Filter
Output
Type
Cycle
Time
50
50
70
°
10
°
30
60
100
°
°
°
°
°
60
60
500
Off
20
120
240
15
15
90
10
Off
25
40
4
6
4
4
4
8
DZC
TP
TP
TP
DZC
Analog
10
10
-
-
-
20
Action
Reverse
Reverse
Direct
Direct
Reverse
Reverse
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Chapter 5: Tuning and Control
Control Outputs
Series D8 User’s Guide
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 Vdc, 0 to 10 Vdc or 4 to 20 mA control signals to operate field output devices.
Output Control Signals
On/Off
Time Proportioning (TP)
The following sections explain the different control output signals available.
When on/off control is used, the output is on or off depending on the difference between the set point and the process variable. PID algorithms are not used with on/off control. The output variable is always off or on (0 or 100 percent).
With time proportioning outputs, the PID algorithm calculates an output between 0 and 100 percent, which is represented by turning on an output for that percent of a fixed, user-selected time base or cycle time.
The cycle time is the time over which the output is proportioned, and it can be any value from 1 to 255 seconds. For example, if the output is 30 percent and the cycle time is ten seconds, then the output will be on for three seconds and off
for seven seconds. Figure 5.5 shows examples of time propor-
tioning and distributed zero crossing (DZC) waveforms.
Distributed Zero
Crossing (33%)
On
Time Proportioning (30%)
Off
0 3
Seconds
(Cycle Time = 10)
10 0 1 3 4
AC Cycle
6
Figure 5.5
Time Proportioning and Distributed Zero Crossing Waveforms
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Distributed Zero Crossing (DZC)
With DZC outputs, the PID algorithm calculates an output between 0 and 100 percent, but the output is distributed on a variable time base. For each ac line cycle, the controller decides whether the power should be on or off. There is no fixed cycle time since the decision is made for each line cycle.
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 electrical 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-angle firing does.
Three-Phase Distributed Zero Crossing (3P DZC)
This output type performs exactly the 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 percent. This percentage of the analog output range can be applied to an output device via a Dual DAC or a
Serial DAC.
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Chapter 5: Tuning and Control Series D8 User’s Guide
Output Filter
The output filter digitally smooths PID control output signals.
It has a range of 0 to 255 scans, which gives a time constant of 0 to 85 seconds for a CPC408 or 0 to 43 seconds for a
CPC404. Use the output filter if you need to filter out erratic output swings due to extremely sensitive input signals, like a turbine flow signal or an open air thermocouple in a dry air gas oven.
The output filter can also enhance PID control. Some processes are very sensitive and would otherwise require a large proportional band, making normal control methods ineffective.
Using the output filter allows a smaller proportional 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.
Reverse and Direct Action
With reverse action an increase in the process variable causes a decrease in the output. Conversely, with direct action 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.
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6
Menu and Parameter Reference
The D8 has operator and setup parameters that let you change the configuration of the controller. This section contains the following information for each operator and setup parameter:
• Description
• Values
• Default value
• Information for addressing controller parameters via
DeviceNet.
For information about how to access the operator and setup
parameters, see the Operation and Setup chapter.
Operator Parameters
Use the operator parameters to change the set point, control mode or output power level.
.
><
, p x
Access the operator parameters (from the loop display).
Save a value and go to the next parameter.
Edit parameter values.
Save a value and go to the previous parameter.
Save a value and go to the next or previous loop.
Cancel a change without saving.
Escape to the loop display.
Figure 6.1
Operator Parameter Navigation
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Chapter 6: Menu and Parameter Reference Series D8 User’s Guide
Set Point l01 Set point r
b 25 ËšC
Enter the desired value for the process variable. The new set point will take effect immediately when you save the new value. The Set point parameter is not available if ratio control or cascade control is enabled for the loop.
Values:
For thermocouples and RTD inputs, same as the input
range (see Table 6.7 ). For process and pulse inputs, any value
between the Input range low and Input range high parameters in the Input menu.
Default:
25
Decimal Placement for DeviceNet:
See Decimal Placement for Numeric Values on page 59.
DeviceNet Object
: Assembly (04 hex), Input (64 hex)
Mode l01 Mode r
bmanual
Display
Value manual auto tune
Off
DeviceNet
Value
0
1
2
3
Heat/Cool Output l01 Heat outputr
b 0%
Choose the control mode for this loop.
Values:
Default:
off (3)
DeviceNet Object
: Assembly (04 hex), Control (66 hex)
Table 6.1
Control Modes
Description
The operator manually sets the output power for the loop.
The controller automatically controls the outputs according to the controller configuration.
The controller calculates PID parameters for the loop. After tuning, the controller switches to automatic mode.
Outputs are at 0%
Choose the manual output power level for this loop. This parameter is available only for the manual control mode.
Values:
0 to 100% (0 to 1000). Values in parentheses are for communications.
Default:
0% (0)
Decimal Placement for DeviceNet:
See Decimal Placement for Percentage Values on page 60.
DeviceNet Object
: Assembly (04 hex), Output (65 hex)
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Process Variable
01 925 ËšF 0
1000man 100
Indicates the value measured by the sensor after filtering and scaling. This parameter is read-only.
Values:
For thermocouples and RTD inputs, same as the input
range (see Table 6.7 on page 131). For process and pulse in-
puts, any value between the Input range low and Input range high
parameters in the Input menu.
Decimal Placement for DeviceNet:
See Decimal Placement for Numeric Values on page 59.
DeviceNet Object:
Assembly (04 hex), Input (64 hex)
Overview of the Setup Menus
The D8 has nine setup menus. Table 6.2 provides a brief de-
scription of each menu. Figure 6.2 lists all of the menus and
parameters in the same order that they appear in the controller.
Table 6.2
D8 Setup Menus
Menu
Global setup
Input
Control
Output
Alarms
PV retrans
Cascade
Ratio
I/O test
Description
Configure global settings, which affect all loops.
Configure the input for each loop.
Configure PID control for each loop.
Configure heat and cool outputs for each loop.
Configure alarms for each loop.
Configure process variable retransmit.
Configure cascade control.
Configure ratio control.
Perform tests of the digital inputs, digital outputs and keypad.
Page
Number
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Chapter 6: Menu and Parameter Reference Series D8 User’s Guide
Global setup
Load setup from job
Save setup as job
BCD job load
BCD job load logic
Mode override
Mode override D/I active
Power up alarm delay
Power up loop mode
Keypad lock
TC short alarm
AC line freq
D/O alarm polarity
MAC ID
Baud rate
Module LED
Network LED
Bus off count
WATLOW D8x Vx.xx cs=xxxx
Input
Input type
Loop name
Input units
Input pulse sample
Calibration offset
Reversed T/C detect
Disp format
Input range high
Input high signal
Input range low
Input low signal
Input filter
Control
Heat prop band
Heat integral
Heat derivative
Heat manual reset
Heat filter
Cool prop band
Cool integral
Cool derivative
Cool manual reset
Cool filter
Hysteresis
RestoreAuto
Navigation for the Setup Menus x
><
,.
Alarms
Access the setup menus (press and hold for 3 seconds)
Cancel a change without saving.
Escape from a parameter to a menu.
Escape from a menu to the loop display.
Go to the next or previous menu.
Edit a parameter value.
Save a value and go to the next or previous parameter.
p
Save a value and go to the next or previous loop.
Output
Heat output type
Heat cycle time
Heat SDAC signal
Ht SDAC low signal
Ht SDAC hi signal
Heat action
Heat power limit
HtPwr limit time
Sensor fail heat output
Open T/C ht out average
Heat output curve
Cool output type
Cool cycle time
Cool SDAC signal
Cl SDAC low signal
Cl SDAC hi signal
Cool action
Cool power limit
ClPwr limit time
Sensor fail cool output
Open T/C cl out average
Cool output curve
Alarm high SP
Alarm high func
Alarm high output
HiDeviation value
HiDeviation func
HiDeviation output
LoDeviation value
LoDeviation func
LoDeviation output
Alarm low SP
Alarm low func
Alarm low output
Alarm hysteresis
Alarm delay
PV retrans
Heat output retrans PV
Ht retrans LowPV
Ht retrans HighPV
Cool output retrans PV
Cl retrans LowPV
Cl retrans HighPV
Cascade
Cascade prim loop
Cascade low SP
Cascade hi SP
Ratio
Ratio master loop
Ratio low SP
Ratio high SP
Control ratio
Ratio SP diff
I/O tests
Digital inputs
Keypad test
Display test
Test D/O 1
...
Test D/O 20
124
Figure 6.2
Setup Menus and Parameters
Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 6: Menu and Parameter Reference
Global Setup Menu
lGlobal setup r
Other menus b
Use the Global setup menu to set parameters that affect all loops.
Load Setup From Job lLoad setup r from job bnone
Load one of the jobs stored in battery-backed RAM. The following parameters are loaded for each loop as part of a job:
• PID constants, filter settings, set points and hysteresis.
• Control mode (automatic or manual) and output power levels (if the loop is in manual control)
• Alarm functions, set points, hysteresis and delay settings.
not be able to use the controller keypad to load a job.
lLoad setup r not available
Save Setup As Job lSave setup as r job bnone
NOTE!
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.
Values:
1 to 8 (1 to 8) or none (0). Values in parentheses are for communications.
Default:
none (0)
DeviceNet Object
: Global (6B hex)
Save the current settings as one of eight jobs in the batterybacked RAM. The following parameters are saved for each loop as part of a job:
• PID constants, filter settings, set points and hysteresis.
• Control mode (automatic, tune, off or manual) and output power levels (if the loop is in manual control)
• Alarm functions, set points, hysteresis and delay settings.
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Chapter 6: Menu and Parameter Reference Series D8 User’s Guide
not be able to use the controller keypad to save a job.
lSave setup as r not available
Values:
1 to 8 (1 to 8) or none (0). Values in parentheses are for communications.
Default:
none (0)
DeviceNet Object:
Global (6B hex)
BCD Job Load lBCD job load r
bdisabled
Choose the digital input(s) to use for remote job selection. The controller uses the states of the selected inputs as a binary
code that specifies which job number to run (see Table 6.3).
To save jobs into memory, use the Save setup as job parameter.
Values:
Default:
disabled (0)
DeviceNet Object
: Global (6B hex)
Table 6.3
Values for BCD Job Load
Display
Value use D/I 1 use D/I 1-2 use D/I 1-3 disabled
DeviceNet
Value
1
2
3
0
Description
Use digital input 1 for remote selection of jobs 1 and 2.
Use digital inputs 1 and 2 for remote selection of jobs 1 to 4.
Use digital inputs 1 to 3 for remote selection of jobs 1 to 8.
Disable remote job selection
BCD Job Load Logic lBCD job load r logic b1=true
Choose which state is considered “true” for the digital inputs that are used for remote job selection.
• If 1=true is selected, then an input is true if connected to controller common, and false for an open circuit.
• If 0=true is selected, then an input is true for an open circuit, and false if connected to controller common.
Table 6.4 shows which combinations of input states are re-
quired to load each job.
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Mode Override lMode override r bdisabled
Chapter 6: Menu and Parameter Reference
Values:
1=true (0) or 0=true (1). Values in parentheses are for communications.
Default:
1=true (0)
DeviceNet Object:
Global (6B hex)
Table 6.4
Digital Input States Required to
Load Each Job
Job
7
8
5
6
3
4
1
2
1
F
T
F
T
F
T
F
T
Digital Input
2
T
T
F
F
T
T
F
F
3
T
T
T
T
F
F
F
F
Choose the digital input to use for the mode override feature.
When the input is activated, the controller sets all loops to manual mode at the output levels specified at the Sensor fail heat output
and Sensor fail cool output parameters in the Out- put
menu.
Use the Mode override D/I active parameter to choose which signal state activates the mode override feature.
Values:
enabled by D/I1 to enabled by D/I8 (1 to 8) or dis- abled
(0). Values in parentheses are for communications.
Default:
disabled (0)
DeviceNet Object
: Global (6B hex)
WARNING!
Do not rely solely on the mode override feature to shut down your process. Install external safety devices or overtemperature devices for emergency shutdowns.
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Chapter 6: Menu and Parameter Reference Series D8 User’s Guide
Mode Override Digital Input Active lMode override r
D/I active bon
Choose whether the on state (connected to controller common) or off state (open circuit) activates the mode override feature.
Use the Mode override parameter to enable the mode override feature and select the digital input.
Values:
on (0) or off (1). Values in parentheses are for communications.
Default:
on (0)
DeviceNet Object:
Global (6B hex)
Power Up Alarm Delay lPower up alarmr delay b 0 min
Specify how long to delay high, low and deviation alarms on all loops during powerup. This feature does not delay failed sensor alarms.
Values:
0 to 60 minutes
Default:
0
DeviceNet Object:
Global (6B hex)
Power Up Loop Mode lPower up loop r modebmanual 0%
Choose the power-up state of the control outputs.
Values:
Default:
off (0)
DeviceNet Object
: Global (6B hex)
Display
Value off from memory
WARNING!
Do not set the controller to start from memory if it might be unsafe for the control outputs to be on upon power up.
Table 6.5
Power Up Loop Modes
DeviceNet
Value
Description
0
1
Upon powerup, all loops are set to manual mode at 0 percent output.
Upon powerup, all loops are restored to the previous control mode and output power level.
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Keypad Lock lKeypad lock r
boff
Thermocouple Short Alarm lTC short alarmr bdisabled
Choose a digital input to enable for thermocouple short detection. Install a device that connects the input to controller common when the process power is on. A thermocouple short is detected if the process power is on but the temperature does not rise as expected.
If a thermocouple short is detected, the controller puts the loop in manual mode at the output power level specified by the
Sensor fail heat
output or Sensor fail cool output parameter in the Output menu.
Values:
enabled by D/I1 to enabled by D/I8 (1 to 8) or dis- abled
(0). Values in parentheses are for communications.
Default:
disabled (0)
DeviceNet Object
: Global (6B hex)
AC Line Frequency
Set this parameter to on to disable the . key on the keypad.
This restricts access to the operator parameters from the controller keypad.
Values:
on (1) or off (0). Values in parentheses are for communications, and are stored as the second bit of the system command word, so set or read only that bit.
Default:
off (0)
DeviceNet Object:
Global (6B hex)
lAC line freq r
b60 Hz
Specify the ac line frequency. The controller uses this information for correct timing of distributed zero-crossing (DZC) output signals and for optimum filtering of analog inputs.
If you edit this parameter, you must switch power to the controller off, then back on, in order for the change take effect.
Values:
50 (1) or 60 (0) Hz. Values in parentheses are for communications.
Default:
60 Hz (0)
DeviceNet Object:
Global (6B hex)
Digital Output Alarm Polarity lD/O alarm r polarity bon
Choose the polarity of all digital outputs used for alarms.
This setting does not apply to the global alarm output or the
CPU watchdog output.
Values:
Default:
on (0)
DeviceNet Object:
Global (6B hex)
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Chapter 6: Menu and Parameter Reference Series D8 User’s Guide
Table 6.6
Digital Output Alarm Polarity
Display Value DeviceNet Value on off
0
1
Description
Digital alarm outputs sink current to analog common when an alarm occurs.
Digital alarm outputs stop sinking current to analog common when an alarm occurs.
MAC ID lMAC ID r
b63
The node address for the controller. This value is set with the
Address rotary switches. See Connecting the D8 to a DeviceNet Network on page 40.
Values
: 00 to 63
DeviceNet Object
: DeviceNet (03 hex)
Baud Rate lBaud rate r
b500
Indicates the baud rate for communications. This value is set
with the Data Rate rotary switch. See Connecting the D8 to a
Values
: 125, 250, 500K
DeviceNet Object
: DeviceNet (03 hex)
Module LED l<Module LED r
green
Indicates the status of the Module LED
Values
: off, green, red, flashing red, flashing green ( see Module Status Indicator Light on page 44).
DeviceNet Object
: N/A
Network LED lNetwork LED r
green
Indicates the status of the Network LED
Values:
off, flashing green, green, flashing red, red, (see Network Status Indicator Light on page 44).
DeviceNet Object:
N/A
Bus Off Count
130
lBus off count r
0
Indicates the number of times the controller has gone to the bus-off state.
Values
: 0 (indicates the controller has not had a bus off error since the last power cycle) or 1 (indicates the controller has gone bus off since the last power cycle)
DeviceNet Object
: DeviceNet (03 hex)
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Model and Firmware Version lWATLOW D84 r
V1.00 cs=1234
The last parameter in the Global setup menu shows the controller model (WATLOW D84 or WATLOW D88), the firmware version (Vxx.xx), and the flash-memory checksum
(CS=xxxx).
DeviceNet Objects
: Model: Identity (01 hex), Firmware Version: N/A, Checksum: N/A.
Input Menu
l01 Input r
Other menus b
Use the Input menu to configure the process input:
• Input type
• Engineering units
• Scaling, calibration and filtering.
Input Type l01 Input type r
bJ T/C
Choose the type of sensor that is connected to the analog input.
Values:
Default:
J thermocouple (1)
DeviceNet Object
: Input (64 hex)
Table 6.7
Input Types and Ranges
J t/c
K t/c
T t/c
S v
R t/c
B t/c
E t/c
RTD
Display
Value process skip
DeviceNet
Value
20
8
5
6
3
4
1
2
0
10
Description Input Range
Type J thermocouple
Type K thermocouple
Type T thermocouple
Type S thermocouple
Type R thermocouple
Type B thermocouple
Type E thermocouple
RTD
Voltage or current signal, depending upon the hardware
configuration. See Figure 1.2 on page 6.
Loop is not used for control, does not report alarms, and is not shown on the scanning display.
-350 to 1400°F (-212 to 760°C)
-450 to 2500° F (-268 to 1371°C)
-450 to 750°F (-268 to 399°C)
0 to 3200°F (-18 to 1760°C)
0 to 3210°F (-18 to 1766°C)
150 to 3200°F (66 to 1760°C)
-328 to 1448°F (-200 to 787°C)
-328.0 to 1150.0°F (-200.0 to 621.1°C)
User defined. See Setting Up Process Variable Retransmit on page
(none)
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Loop Name l01 Loop name r
b01
Series D8 User’s Guide
Enter a two-character name for the loop. This name is shown on the controller display in place of the loop number.
Values:
Default:
The loop number (01, 02, 03, and so on.)
DeviceNet Object
: Input (64 hex)
Table 6.8
Characters for the Loop Name and
Input Units Parameters
Character
A to Z
0 to 9
Degree symbol
Percent sign
Forward slash
Space
Pound sign
Display Values ASCII Values
A to Z
0 to 9
Ëš
%
/
.
#
65 to 90
48 to 57
223
37
47
32
35
Input Units l01 Input unitsr
b ËšF
For a thermocouple or RTD input, choose the temperature scale. For a process input, enter a three-character description of the engineering units.
Values:
For a process input, see Table 6.8. For a thermocou-
ple or RTD input, ËšF or ËšC. When setting the units for a thermocouple or RTD input through communications, you must set the first character as a space (32), the second character as the degree symbol (223) and the third character as “C” (67) or
“F” (70).
Default:
ËšC for a thermocouple or RTD input, three spaces for a process input
DeviceNet Object
: Input (64 hex)
Calibration Offset l01 Calibrationr offsetb 0 ËšF
132
For a thermocouple or RTD input, enter the offset to correct for signal inaccuracy. A positive value increases the reading and a negative value decreases it. Use an independent sensor or your own calibration equipment to find the offset for your system.
Values:
Default:
0 or 0.0
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Series D8 User’s Guide Chapter 6: Menu and Parameter Reference
Decimal Placement for DeviceNet:
See Decimal Placement for Numeric Values on page 59.
DeviceNet Object
: Input (64 hex)
Table 6.9
Calibration Offset Ranges
Offset Range
Type of Sensor
ËšF ËšC
RTD
J Thermocouple
K Thermocouple
T Thermocouple
-300.0 to 300.0
-300 to 300
B Thermocouple
S Thermocouple
-300 to 76
R Thermocouple -300 to 66
-300.0 to 300.0
-300 to 300
-300 to 300
-300 to 300
Reversed Thermocouple Detection l01 Reversed r
T/C detect b on
Choose whether to enable polarity checking for thermocouples. If the controller detects a reversed thermocouple, it activates an alarm and sets the loop to manual mode at the power level indicated by the Sensor fail heat output or Sensor fail cool output
parameter in the Output menu.
Values:
on (1) or off (0). Values in parentheses are for communications.
Default:
on (1)
DeviceNet Object:
Input (64 hex)
Display Format l01 Disp formatr b -999to 3000
For a process input, choose the range and the number of decimal places for the process variable and related parameters.
Choose a precision appropriate for the range and accuracy of the sensor.
Values:
Default:
-999 to 3000 for a process input.
DeviceNet Object
: Input (64 hex)
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Chapter 6: Menu and Parameter Reference Series D8 User’s Guide
Input Range High
Table 6.10
Display Formats
Display Value
-999 to 3000
-9999 to 30000
-999.9 to 3000.0
-99.99 to 300.00
-9.999 to 30.000
-.9999 to 3.0000
DeviceNet
Value
255
0
1
2
3
4
Minimum
Process
Variable
-999
-9999
-999.9
-99.99
-9.999
-0.9999
Maximum
Process
Variable
3000
30000
3000.0
300.00
30.000
3.0000
l01 Input ranger high b 1000 ËšF
For a process input, enter the high process variable for input scaling purposes. This value will be displayed when the input signal is at the level set for Input high signal.
This parameter and the Input high signal parameter together define a point on the conversion line for the scaling function.
See Setting Up a Process Input on page 88.
Values:
Any value between Input range low and the maximum process variable for the selected display format (see
Default:
1000. Decimal placement depends upon the value of the Disp format parameter.
Decimal Placement for DeviceNet:
See Decimal Placement for Numeric Values on page 59.
DeviceNet Object:
Input (64 hex)
Input High Signal l01 Input high r signal b100.0%
For a process input, enter the input signal level that corresponds to the value for the Input range high parameter. The high signal is a percentage of the full scale input range.
Values:
-99.8 to 999.9 (-998 to 9999) percent of full scale.
This value must be greater than the value for Input low signal.
Values in parentheses are for communications.
Default:
100.0% (1000)
Decimal Placement for DeviceNet:
See Decimal Placement for Percentage Values on page 60.
DeviceNet Object:
Input (64 hex)
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Series D8 User’s Guide
Input Range Low l01 Input ranger low b 0
Input Low Signal l01 Input low r signal b .0%
Input Filter l01 Input r filter b 3scans
Chapter 6: Menu and Parameter Reference
For a process input, enter the low process variable for input scaling purposes. This value will be displayed when the input signal is at the level set for Input low signal.
This value and the value for Input low signal together define one of the points on the scaling function’s conversion line. See
Setting Up a Process Input on page 88.
Values:
Any value between the minimum process variable for
the selected display format (see Table 6.10 on page 134) and
the value for Input range high.
Default:
0
Decimal Placement for DeviceNet
: See Decimal Placement for Numeric Values on page 59.
DeviceNet Object:
Input (64 hex)
For a process input, enter the input signal level that corresponds to the low process variable you entered for the Input range low
parameter. The low signal is a percentage of the full scale input range.
Values:
-99.9 to 999.8 (-999 to 9998) percent of full scale.
This value must be less than the value for Input high signal.
Values in parenthesis are for communications.
Default:
0
Decimal Placement for DeviceNet :
See Decimal Placement for Percentage Values on page 60.
DeviceNet Object:
Input (64 hex)
Choose the amount of filtering to apply to the process variable before the value is logged, displayed or used in the control calculation. The input filter simulates a resistor-capacitor (RC) filter. Use it to keep the process variable from varying unrealistically.
When enabled, the process variable responds to a step change by going to two-thirds of the actual value within the specified number of scans. One scan is 0.17 seconds for a four-loop controller and 0.33 seconds for a eight-loop controller.
Values:
0 (off) to 255
Default:
3
DeviceNet Object:
Input (64 hex)
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Chapter 6: Menu and Parameter Reference Series D8 User’s Guide
Control Menu
l01 Control r
Other menus b
Use the Control menu to adjust heat and cool control parameters, including:
• Proportional band, integral and derivative
• Output filter
• Control hysteresis
The controller has separate PID and filter settings for heat and cool outputs. In this section, only the heat screens are shown, but the explanations apply to both the heat and cool parameters.
If you have not set up a Series D8 controller before, or if you
starting values.
Heat/Cool Proportional Band l01 Heat prop r band b 40 ËšF
Enter the proportional band. A larger value yields less proportional action for a given deviation from set point.
Values:
For a thermocouple or RTD input, see Table 6.11.
For a process input, 1 to the span of the input range (Input range high
- Input range low).
Default:
50 for a thermocouple, RTD or process input.
Decimal Placement for DeviceNet:
See Decimal Placement for Numeric Values on page 59.
DeviceNet Object:
Control (66 hex)
Table 6.11
Proportional Band Values
Type of Sensor
J Thermocouple
K Thermocouple
T Thermocouple
S Thermocouple
R Thermocouple
B Thermocouple
E Thermocouple
RTD
Values in ËšF
1 to 1750
1 to 2950
1 to 1200
1 to 3200
1 to 3210
1 to 3350
1 to 1776
0.1 to 1478.0
Values in ËšC
1 to 972
1 to 1639
1 to 667
1 to 1778
1 to 1784
1 to 1694
1 to 987
0.1 to 821.1
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Heat/Cool Integral l01 Heat inte- r gral b 180 sec/R
Enter the integral constant. A larger value yields less integral action.
Values:
0 (off) to 6000 seconds per repeat
Default:
For the Heat integral parameter, 180. For the Cool integral
parameter, 60.
DeviceNet Object:
Control (66 hex)
Heat/Cool Derivative l01 Heat de- r rivativeb 0 sec
Heat/Cool Manual Reset l01 Heat manualr reset b 0%
A process that uses only proportional control settles at a point above or below the set point; it never reaches the set point.
This is known as offset or droop. At this parameter, enter the power level required to maintain set point to compensate for this offset.
Values:
0 to 100% (0 to 1000). Values in parentheses are for communications.
Default:
0% (0)
Decimal Placement for DeviceNet:
See Decimal Placement for Percentage Values on page 60.
DeviceNet Object:
Control (66 hex)
Heat/Cool Filter
Enter the derivative constant. A larger value yields greater derivative action.
Values:
0 to 255 seconds
Default:
0
DeviceNet Object:
Control (66 hex)
l01 Heat filterr
b 3 scans
Use this parameter to dampen the response of the heat or cool output. The output responds to a change by going to approximately two-thirds of its final value within the specified number of scans. A larger value results in a slower response to changes in the process variable.
Values:
0 (off) to 255
Default:
3
DeviceNet Object:
Control (66 hex)
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Chapter 6: Menu and Parameter Reference Series D8 User’s Guide
Hysteresis l01 Hysteresis r
b 5 ËšC
Input Type
Thermocouple
RTD
Process
Display Format n/a n/a
-999 to 3000
-9999 to 30000
-999.9 to 3000.0
-99.99 to 300.00
-9.999 to 30.000
-0.9999 to 3.0000
Specify how much the process variable must deviate from set point before the output can switch between on and off (for on/ off control) or switch between heating and cooling (for heat/ cool control).
Values:
See Table 6.12 for values and decimal placement.
For communications the value is always 0 to 5000, see
Table 6.12 for implied decimal location.
Default:
DeviceNet Object:
Control (66 hex)
Table 6.12
Values for the Control Hysteresis and Deviation Alarm Parameters
Values
0 to 500
0 to 500.0
0 to 500
0 to 5000
0.0 to 500.0
0.00 to 50.00
0.000 to 5.000
0.0000 to 0.5000
Default
5
5.0
5
50
5.0
0.50
0.050
0.0050
Restore Automatic Mode l01 RestoreAutor bdisabled
Choose a digital input. If the input is connected to controller common, the loop returns to automatic control mode after a failed sensor is repaired (if it was in automatic mode when the sensor failure occurred).
Values:
enabled by D/I1 to enabled by D/I8 (1 to 8) or dis- abled
(0). Values in parentheses are for communications.
Default:
disabled (0)
DeviceNet Object:
Control (66 hex)
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Output Menu
l01 Output r
Other menus b
Chapter 6: Menu and Parameter Reference
Use the Output menu to enable and configure heat and cool outputs.
Heat/Cool Output Type l01 Heat outputr type bTP
Output Type
Display
Value
Choose the output type, or disable the heat or cool output. For more information about each output type, see the Tuning and
Control chapter. (If an output is used for process variable retransmit, the disabled option is not available. To disable the output, first disable process variable retransmit for the output.
See Heat/Cool Output Retransmit on page 148.)
Values:
Default:
TP (2) for heat, disabled (0) for cool
DeviceNet Object:
Output (65 hex)
Table 6.13
Heat and Cool Output Types
DeviceNet
Value
Description
Time
Proportioning
On/Off
None
Three-Phase
Distributed
Zero Crossing
Serial DAC
Distributed
Zero Crossing
TP on/off disabled
3P DZC
SDAC
DZC
2
1
0
5
4
3
The output is switched on and off once during a user-selected cycle time. Within each cycle, the duration of on versus off time is proportional to the percent output power.
The output is either full on or full off.
The output is not used for control and is available for another use, such as an alarm output.
Same as DZC, but for three-phase heaters wired in delta configuration. For grounded Y configuration, use DZC instead.
Use this option if a Serial DAC is connected to the output. If you set the output type to SDAC, the controller assigns digital output 34 as a clock line for the Serial DAC.
The output on/off state is calculated for every ac line cycle, which means that the output turns on and off multiple times per second. Use DZC with solid state output devices or a Dual DAC. Not recommended for use with electromechanical relays.
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Chapter 6: Menu and Parameter Reference Series D8 User’s Guide
Heat/Cool Cycle Time l01 Heat cycle r
time b 10sec
For a time-proportioning output, enter the cycle time in sec-
onds. For more information about cycle time, see Time Proportioning (TP) on page 118.
Values:
1 to 255 seconds
Default:
10
DeviceNet Object:
Output (65 hex)
Heat/Cool SDAC Signal l01 Heat SDAC r signal bvoltage
For a Serial DAC output, choose the type of output signal that the Serial DAC will provide.
Values:
voltage (0) or current (1). Values in parentheses are for communications.
Default:
voltage (0)
DeviceNet Object:
Output (65 hex)
Heat/Cool SDAC Low Signal l01 Ht SDAC lowr signal b .00vdc
For a Serial DAC output, enter the low output signal level for the Serial DAC. The Serial DAC converts 0 percent output from the controller to this value.
Enter high and low values that match the input range of the output device. For instance, if the output device has a 0 to 10
Vdc input range, then set SDAC low signal to .00 Vdc and set
SDAC hi signal
to 10.00 Vdc.
Values:
.00 to 9.90 Vdc (0 to 990) or 0.00 to 19.90 mA
(0 to 1990). This value must be less than the value of SDAC hi signal
. Values in parentheses are for communications.
Default:
.00 Vdc (0) or 4.00 mA (400)
DeviceNet Object:
Output (65 hex)
Heat/Cool SDAC High Signal l01 Ht SDAC hi r signal b10.00vdc
For a Serial DAC output, enter the high output signal level for the Serial DAC. The Serial DAC converts 100 percent output from the controller to the value set here.
Enter the high and low values that match the input range of the output device. For instance, if the output device has a 4 to 20 mA input range, then set SDAC hi signal to 20 mA and set
SDAC low signal
to 4 mA.
Values:
0.10 to 10.00 Vdc (10 to 1000) or 0.10 to 20.00 mA
(10 to 2000) This value must be greater than the value of
SDAC low signal
. Values in parentheses are for communications.
Default:
10.00 Vdc (1000) or 20.00 mA (2000)
DeviceNet Object:
Output (65 hex)
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Heat/Cool Action
Chapter 6: Menu and Parameter Reference
l01 Heat actionr
breverse
Choose the control action for the output. When the action is set to reverse, the output goes up when the process variable goes down. When the action is set to direct, the output goes down when the process variable goes down. Normally, heat outputs are set to reverse action and cool outputs are set to direct action.
Values:
reverse (0) or direct (1). Values in parentheses are for communications.
Default:
reverse (0) for heat outputs, direct (1) for cool outputs
DeviceNet Object:
Output (65 hex)
Heat/Cool Power Limit l01 Heat power r limit b100%
Use this parameter to limit the output power for a heat or cool output. This limit may be continuous, or it may be in effect for the number of minutes specified at the next parameter.
The power limit only affects loops in automatic mode. It does not affect loops in manual mode.
Values:
0 to 100% (0 to 1000). Values in parentheses are for communications.
Default:
100% (1000)
Decimal Placement for DeviceNet:
See Decimal Placement for Percentage Values on page 60.
DeviceNet Object:
Output (65 hex)
Heat/Cool Power Limit Time l01 HtPwr limitr time bcontinuous
Enter the duration of the power limit set at the previous parameter, or choose continuous to keep the limit in effect at all times.
If you choose a timed limit, the limit timer restarts whenever the controller powers up and whenever the loop switches from manual to automatic mode.
Values:
1 to 999 minutes (1 to 999) or continuous (0). Values in parentheses are for communications.
Default:
continuous (0)
DeviceNet Object:
Output (65 hex)
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Chapter 6: Menu and Parameter Reference Series D8 User’s Guide
Sensor Fail Heat/Cool Output l01 Sensor failr heat outputb 0%
A loop will switch to manual mode at the specified output power if one of the following conditions occurs while in automatic mode:
• A failed sensor alarm occurs, or
•
The mode override input becomes active (see Mode
• DeviceNet connection becomes inactive unexpectedly.
For most applications, this parameter should be set to 0% for both heat and cool outputs.
Values:
0 to 100% (0 to 1000). Values in parentheses are for communications.
Default:
0% (0)
Decimal Placement for DeviceNet:
See Decimal Placement for Percentage Values on page 60.
DeviceNet Object:
Output (65 hex)
WARNING!
Do not rely solely on the failed sensor alarm to adjust the output in the event of a sensor failure. If the loop is in manual mode when a failed sensor alarm occurs, the output is not adjusted. Install independent external safety devices to shut down the system if a failure occurs.
Open Thermocouple Heat/Cool Output Average l01 Open T/C htr out average boff
If you set this parameter to on and a thermocouple open alarm occurs, a loop set to automatic control mode will switch to manual mode at the average output prior to the alarm.
Values:
on (1) or off (0). Values in parentheses are for communications.
DeviceNet Object:
Output (65 hex)
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Heat/Cool Output Curve l01 Heat outputr curve blinear
Choose an output curve. If curve 1 or 2 is selected, a PID calculation results in a lower actual output level than the linear output requires. Use curve 1 or 2 if the system has a nonlinear response to the output device.
Values:
linear (0), curve 1 (1) or curve 2 (2). Values in parentheses are for communications.
Default:
linear (0)
DeviceNet Object:
Output (65 hex)
100
90
80
80 79
70
66
60
60
62
40
20
10
3
20
8
2
30
Linear
40
50
Curve 1
48
36
27
29
19 19
13
4
7
12
44
Curve 2
0
Figure 6.3
Linear and Nonlinear Outputs
Alarms Menu
l01 Alarms r
Other menus
Use the Alarms menu to configure high alarms, low alarms, and deviation alarms, including:
• Alarm set points
• Alarm outputs
• Alarm behavior
• Alarm hysteresis
• Alarm delay
Alarm High Set Point l01 Alarm high r
SP b 760 ËšC
Enter the set point at which the high alarm activates. The high alarm activates if the process variable rises above this value.
For more information about the high alarm, see Alarm High and Alarm Low on page 96.
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Chapter 6: Menu and Parameter Reference Series D8 User’s Guide
Values:
For a thermocouple or RTD input, any value within
the input range (see Table 6.7 ). For a process or pulse input,
any value between the Input range low and Input range high parameters.
Default:
760. Decimal placement depends upon the Input type
and Disp format settings.
Decimal Placement for DeviceNet:
See Decimal Placement for Numeric Values on page 59.
DeviceNet Object:
Alarm (67 hex)
Alarm High Function l01 Alarm high r func boff
Choose whether the high alarm functions as an alarm or as a boost output, or disable the alarm.
Values:
Default:
off
DeviceNet Object:
See Alarm Acknowledge on page 153 and
Table 6.14
Alarm Functions
Value off standard boost
Description
No alarm function.
Alarm is indicated and logged.
Latching global alarm is activated.
Alarm must be acknowledged to clear.
Optional non-latching alarm output is activated.
Alarm message on controller display only.
Alarm does not require acknowledgement.
Non-latching alarm output is activated. Use the alarm set points to control this output for boost control.
Alarm High Output l01 Alarm high r outputbnone
Choose a digital output to activate when the high alarm occurs. You cannot choose an output that is in use for closedloop control or for the Serial DAC clock.
Values:
none (0) or output 1 to 18 (1 to 18). Values in parentheses are for communications.
Default:
none (0)
DeviceNet Object
: Alarm (67 hex)
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High Deviation Value l01 HiDeviationr value b 5 ËšC
High Deviation Function l01 HiDeviationr func boff
Choose whether the alarm functions as an alarm or as a boost output, or disable the alarm.
Values:
Default:
off
DeviceNet Object:
See Alarm Enable on page 153 and Alarm
High Deviation Output
Enter the amount by which the process variable must rise above the set point for the high deviation alarm to occur. For
more information, see Deviation Alarms on page 96.
Values:
See Table 6.12 on page 138 for values and decimal
placement.
Default:
DeviceNet Object:
Alarm (67 hex)
l01 HiDeviationr outputbnone
Choose a digital output to activate when the high deviation alarm occurs. You cannot choose an output that is in use for closed-loop control or for the Serial DAC clock.
Values:
none (0) or output 1 to 18 (1 to 18). Values in parentheses are for communications.
Default:
none (0)
DeviceNet Object:
Alarm (67 hex)
Low Deviation Value l01 LoDeviationr value b 5 ËšC
Enter the amount by which the process variable must fall below the set point for the low deviation alarm to occur. For
more information, see Process Alarms on page 95.
Values:
See Table 6.12 on page 138 for values and decimal
placement.
Default:
DeviceNet Object:
Alarm (67 hex)
Low Deviation Function l01 LoDeviationr func boff
Choose whether the alarm functions as an alarm or as a boost output, or disable the alarm.
Values:
Default:
off
DeviceNet Object:
See Alarm Enable on page 153 and Alarm
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Chapter 6: Menu and Parameter Reference
Low Deviation Output l01 LoDeviationr outputbnone
Series D8 User’s Guide
Choose a digital output to activate when the low deviation alarm occurs. You cannot choose an output that is in use for closed-loop control or for the Serial DAC clock.
Values:
none (0) or output 1 to 18 (1 to 18). Values in parentheses are for communications.
Default:
none (0)
DeviceNet Object:
Alarm (67 hex)
Alarm Low Set Point l01 Alarm low r
SP b 0°C
Enter the set point at which the low alarm activates. The low alarm activates if the process variable drops below this value.
For more information, see Process Alarms on page 95.
Values:
For a thermocouple or RTD input, any value within
the input range (see Table 6.7 on page 131). For a process or
pulse input, any value between the Input range low and Input range high
parameters.
Default:
0
Decimal Placement for DeviceNet:
See Decimal Placement for Numeric Values on page 59.
DeviceNet Object:
Alarm (67 hex)
Alarm Low Function l01 Alarm low r func boff
Choose whether the alarm functions as an alarm or as a boost output, or disable the alarm.
Values:
Default:
off
DeviceNet Object:
See Alarm Acknowledge on page 153 and
Alarm Low Output l01 Alarm low r outputbnone
Choose a digital output to activate when the low alarm occurs.
You cannot choose an output that is in use for closed-loop control or for the Serial DAC clock.
Values:
none (0) or output 1 to 18 (1 to 18). Values in parentheses are for communications.
Default:
none (0)
DeviceNet Object:
Alarm (67 hex)
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Alarm Hysteresis l01 Alarm hys- r teresisb 2 ËšC
Input Type
Thermocouple
RTD
Process
Display Format n/a n/a
-999 to 3000
-9999 to 30000
-999.9 to 3000.0
-99.99 to 300.00
-9.999 to 30.000
-0.9999 to 3.0000
Enter the amount by which the process variable must return within the alarm limit before a high alarm, low alarm or deviation alarm clears. Use the alarm hysteresis to prevent repeated alarms as the process variable cycles around an alarm limit.
Values:
See Table 6.15 on page 147 for values and decimal
placement. For communications the value is always 0 to 5000.
Default:
DeviceNet Object:
Alarm (67 hex)
Table 6.15
Values for Alarm Hysteresis
Values
Values via
Communications
0 to 500
0 to 500.0
0 to 500
0 to 5000
0 to 5000
0 to 5000
0 to 5000
0 to 5000
0.0 to 500.0
0.00 to 50.00
0 to 5000
0 to 5000
0.000 to 5.000
0 to 5000
0.0000 to 0.5000
0 to 5000
Default
2
2.0
2
20
2.0
0.20
0.020
0.0020
Alarm Delay l01 Alarm delayr
b 0 sec
Use this parameter to delay a failed sensor or process alarm until the alarm condition has been continuously present for longer than the delay time.
To delay alarms on powerup only, see Power Up Alarm Delay on page 128.
Values:
0 to 255 seconds.
Default:
0
DeviceNet Object:
Alarm (67 hex)
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Chapter 6: Menu and Parameter Reference Series D8 User’s Guide
Process Variable Retransmit Menu
l01 PV retrans r
Other menus b
Use the PV retrans menu to configure an output so that it will retransmit the process variable from another loop. For details,
see Setting Up Process Variable Retransmit on page 97.
This menu contains parameters for both heat and cool outputs.
The sample screens in this section show the heat parameters, but the descriptions apply to both the heat and cool parameters.
Heat/Cool Output Retransmit l01 Heat outputr retrans PV b 2
Choose the loop that provides the process variable to be retransmitted. For example, in the sample display at left, the heat output from loop 1 (01) will retransmit the process variable from loop 2.
Values:
none (0), or loop 1 to 4 (1 to 4) for a four-loop controller or loop 1 to 8 (1 to 8) for an eight-loop controller. Values in parentheses are for communications.
Default:
none (0)
DeviceNet Object:
Retransmit (68 hex)
Heat/Cool Retransmit Low Process Variable l01 Ht retrans r
LowPV b 0 ËšC
Enter the value of the process variable to retransmit as a 0 percent output signal. If the process variable falls below this value, the output will stay at 0 percent.
Values:
Any value within the input sensor range; see
Default:
The minimum value in the input sensor range
Decimal Placement for DeviceNet:
See Decimal Placement for Numeric Values on page 59.
DeviceNet Object:
Retransmit (68 hex)
Heat/Cool Retransmit High Process Variable l01 Ht retrans r
HighPVb 0 ËšC
Enter the value of the process variable to retransmit as a 100 percent output signal. If the process variable rises above this value, the output will stay at 100 percent.
Values:
Any value within the input sensor range; see
Default:
The maximum value in the input sensor range
Decimal Placement for DeviceNet:
See Decimal Placement for Numeric Values on page 59.
DeviceNet Object:
Retransmit (68 hex).
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Cascade Menu
l01 Cascade r
Other menus b
Use the cascade menu to configure cascade control. Use cascade control to calculate the set point of the current loop (the secondary, or outer, loop) based upon the output of another loop (the primary, or inner, loop).
For more information about cascade control, see Setting Up
Cascade Primary Loop l01 Cascade r prim loop bnone
Choose the primary loop. The controller uses the output of the primary loop to calculate the set point of the current loop.
Values:
none (0), or loop 1 to 4 (1 to 4) for a four loop-controller or 1 to 8 (1 to 8) for an eight-loop controller. You cannot choose the current loop. Values in parentheses are for communications.
Default:
none (0)
DeviceNet Object:
Cascade (6A hex)
Cascade Low Set Point l01 Cascade lowr
SP b 25 ËšC
Enter the set point to use for the current loop when the output of the primary loop is at its minimum value. The set point will never drop below this value.
• If the primary loop has only the heat output enabled, then this value is the set point when the heat output of the primary loop is 0 percent.
• If the primary loop has only the cool output enabled or has the heat and cool outputs enabled, then this value is the set point when the cool output is 100 percent.
Values:
For a thermocouple or RTD input, any value within
the input range (see Table 6.7 ). For a process input, any value
between the Input range low and Input range high parameters.
This value must be less than the Cascade hi SP parameter.
Default:
25 for a thermocouple, RTD or process input.
Decimal Placement for DeviceNet:
See Decimal Placement for Numeric Values on page 59.
DeviceNet Object:
Cascade (6A hex)
Cascade High Set Point l01 Cascade hi r
SP b 25 ËšC
Enter the set point to use for the current loop when the output of primary loop is at its maximum value. The set point will never exceed this value.
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• If the primary loop has only the heat output enabled, or has the heat and cool outputs enabled, this value is the set point when the output of the primary loop is 100 percent.
• If the primary loop has only the cool output enabled, then this value is the set point when the output of the primary loop is 0 percent.
Values:
For a thermocouple or RTD input, any value within
the input range (see Table 6.7 on page 131). For a process in-
put, any value between the Input range low and Input range high
parameters. This value must be greater than the Cascade low SP
parameter.
Default:
25 for a thermocouple, RTD or process input.
Decimal Placement for DeviceNet:
See Decimal Placement for Numeric Values on page 59.
DeviceNet Object:
Cascade (6A hex)
Ratio Menu
l01 Ratio r
Other menus b
Use the ratio menu to configure ratio control, differential control or remote analog set point. Use these control methods to calculate the set point of the current loop (the ratio loop) based upon the process variable of another loop (the master loop).
For more information about ratio control, see Setting Up Ratio
Control on page 104, Setting Up Differential Control on page
106 and Setting Up Remote Analog Set Point on page 107.
Ratio Master Loop l01 Ratio r master loopbnone
Choose the master loop. The controller uses the process variable of the master loop to calculate the set point of the current loop.
Values:
none (0), or loop 1 to 4 (1 to 4) for a four-loop controller or 1 to 8 (1 to 8) for an eight-loop controller. You cannot choose the current loop.
Default:
none (0)
DeviceNet Object:
Ratio (69 hex)
Ratio Low Set Point
150
l01 Ratio low r
SP b 25 ËšC
Enter the lowest allowable set point for the current loop. The set point will never drop below this value, regardless of the result of the ratio calculation.
Values:
For a thermocouple or RTD input, any value within
the input range (see Table 6.7 ). For a process, any value be-
tween the Input range low and Input range high parameters.
This value must be less than the Ratio high SP parameter.
Default:
25
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Decimal Placement for DeviceNet:
See Decimal Placement for Numeric Values on page 59.
DeviceNet Object:
Ratio (69 hex)
Ratio High Set Point l01 Ratio high r
SP b 25 ËšC
Enter the highest allowable set point for the current loop. The set point will never exceed this value, regardless of the result of the ratio calculation.
Values:
For a thermocouple or RTD input, any value in the in-
put sensor range; see Table 6.7 on page 131. For a process in-
put, any value from Input range low to Input range high. This value must be greater than the Ratio low SP parameter.
Default:
25
Decimal Placement for DeviceNet:
See Decimal Placement for Numeric Values on page 59.
DeviceNet Object:
Ratio (69 hex)
Control Ratio l01 Control r ratio b 1.0
Enter the factor by which to multiply the process variable of the master loop to calculate the set point of the ratio loop.
Values:
.1 to 999.9 (1 to 9999). Values in parentheses are for communications (values are in tenths).
Default:
1.0 (10) for a thermocouple, RTD or process input.
DeviceNet Object:
Ratio (69 hex)
Ratio Set Point Differential l01 Ratio SP r diff b 0 ËšC
Enter the value to add to the ratio calculation before using it as the set point.
Values:
-9999 to 9999. Decimal placement depends upon the
Input type
and Disp format values in the Input menu.
Default:
0
Decimal Placement for DeviceNet:
See Decimal Placement for Numeric Values on page 59.
DeviceNet Object
: Ratio (69 hex)
I/O Tests Menu
lI/O tests r
Other menus b
Use the I/O tests menu to test the following:
• Digital inputs
• Digital outputs
• Keypad
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Digital Inputs lDigital inputsr
00000000 1=on
Series D8 User’s Guide
This parameter indicates the states of the eight digital inputs.
A 1 indicates that the input is connected to controller common
(on). A 0 indicates an open circuit (off).
To test an input, short it to controller common. When the input is shorted, its input state should be 1. For detailed instructions,
see Digital Input Test on page 27.
The controller display shows the states of digital inputs 1 to 8 from left to right.
Values:
0 if the input is off, 1 if the input is on
DeviceNet Object:
Global (6B hex)
Keypad Test lKeypad test r press d to begin
To test the keypad, press <. This screen will appear:
uu Ends test key pressed=
To test a key, press it. If the key is working properly, an icon for that key appears.
When you are done testing the keypad, press >> to return to the Keypad test parameter.
DeviceNet Object:
None
Display Test lDisplay test r
Press d to begin
Displays two screens with alternate pixels lit. Press < to enter test, press > or < to switch pattern. Press x
to end the test.
DeviceNet Object:
None
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Test Digital Output 1 to 20 lTest D/O 1 r
boff
Use the Test D/O parameter to manually toggle a digital output on and off. Choose on to sink the current from the output to the controller common. Choose off to stop the current flow.
For instructions, see Digital Output Test on page 26. You can-
not toggle an output that is enabled for control.
Values:
off (0) or on (1)
Default:
off (0)
DeviceNet Object:
Global (6B hex)
NOTE!
When you exit the I/O tests menu, all outputs that were forced on are turned off.
Parameters Only Available via Communications
These parameters are available only via communications.
They are not accessible through the controller keypad.
Alarm Acknowledge
Indicates whether an alarm has been acknowledged. To ac-
This parameter is available only via communications.
Values:
Unacknowledged (1) or acknowledged (0)
DeviceNet Object:
Alarm (67 hex)
Alarm Enable
Enable or disable an alarm. Table 6.16 on page 154 shows the
bit to set or read for each alarm. This parameter is available only via communications.
Values:
Disabled (0) or enabled (1)
Default:
Disabled (0)
DeviceNet Object:
Alarm (67 hex)
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Table 6.16
Bit Positions for Alarm Enable and
Alarm Function
Alarm
Low Deviation Alarm
High Deviation Alarm
Alarm Low
Alarm High
Bit
Third
Fourth
Fifth
Sixth
NOTE!
All other bits, 1, 2, and 7 to 16 are always 0.
You must transmit a complete 2-byte word to set any alarm parameter for a channel. You may want to read the alarm settings before constructing the word to set an alarm parameter.
NOTE!
The least significant bit is considered the first bit and the most significant is consid-
ered the sixteenth bit. See Bit-Wise Values on page 59.
Alarm Function
Choose whether an alarm behaves as a standard alarm or as a boost output. For descriptions of the standard and boost func-
tions, see Table 6.14 on page 144. Table 6.16 on page 154
shows the bit to read for each alarm.
This parameter is available only via communications.
Values:
Standard alarm (0) or boost output (1)
Default:
Standard alarm (0)
DeviceNet Object:
Alarm (67 hex)
Alarm Status
Indicates whether an alarm is active. Table 6.17 shows the bit
to read for each alarm. This parameter is available only via communications.
Values:
Not active (0) or active (1)
DeviceNet Object:
Alarm (67 hex)
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Table 6.17
Bit Positions for Alarm Status and
Alarm Acknowledge
Alarm
Low Deviation Alarm
High Deviation Alarm
Alarm Low
Alarm High
Thermocouple Reversed
Thermocouple Shorted
Thermocouple Open
RTD Open
RTD Fail
Bit
Third
Fourth
Fifth
Sixth
Seventh
Eighth
Ninth
Tenth
Eleventh
Ambient Sensor Reading
Parameter
This read-only parameter indicates the temperature measured by the cold-junction compensation sensor located near the analog input terminal block.
This parameter is available only for communications programs.
Values:
Temperature in tenths of a degree Fahrenheit. To convert to Celsius, use the formula °C = 5/9 (°F - 32).
DeviceNet Object:
Global (6 hex)
Table 6.18
System Status Bits
Description Values
DeviceNet
Object
Battery Status
Hardware
Ambient Status
Hardware Offset
Status
Hardware Gain
Status
Indicates whether the values in RAM have been corrupted while the power has been off.
Indicates whether the full scale self-calibration measurement falls within acceptable limits.
0: No corruption detected
1: Data corrupted
Indicates whether the ambient temperature is within the controller’s operating range. If the ambient is out of range, the controller sets all loops to manual mode at 0 percent power.
Indicates whether the zero self-calibration measurement falls within acceptable limits.
0: Within range
1: Outside of range
0: In calibration
1: Out of calibration
0: In calibration
1: Out of calibration
Global (6)
Global (6)
Global (6)
Global (6)
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Heat/Cool Output Action for Watchdog Inactivity Fault
Action on heat and cool outputs when a DeviceNet Watchdog
Inactivity Timeout is detected.
Values:
Default:
0
DeviceNet Object:
Output (65 hex)
Table 6.19
DeviceNet Value for Watchdog
Inactivity Fault
0
1
DeviceNet Value Description
If not in Manual Mode will then put in Manual Mode, with output set to value in Sensor Fail Heat and Cool Output.
Do Nothing (continue operating output).
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7
Troubleshooting and Reconfiguring
This chapter explains how to troubleshoot and reconfigure the controller.
When There is a Problem
The controller is only one part of your control system. Often, what appears to be a problem with the controller is really a problem with other equipment, so check these things first:
•
The controller is installed correctly. (See the Installation
chapter.)
• Sensors, such as thermocouples and RTDs, are installed correctly and working.
NOTE!
If you suspect your controller has been damaged, 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 Watlow technical support (see
page 1). If you need to return the unit to Watlow Anafaze for
testing and repair, Customer Service will issue you an RMA
number (see Returning a Unit on page 158).
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Returning a Unit
CAUTION!
Before trying to troubleshoot a problem by replacing your controller with another one, first check the installation. If you have shorted 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.
If you are certain the installation is correct, you can try replacing the controller. If the second unit works correctly, then the problem is specific to the controller you replaced.
Before returning a controller, contact your supplier or call
Watlow (see page 1) for technical support.
Controllers purchased as part of a piece of equipment must be serviced or returned through the equipment manufacturer.
Equipment manufacturers and authorized distributors should call customer service at Watlow to obtain a return materials authorization (RMA) number. Shipments without an RMA will not be accepted. Other users should contact their suppliers for instructions on returning products for repair.
Troubleshooting the Controller
A problem may be indicated by one or more of several types of symptoms:
• A process alarm
• A failed sensor alarm
• A system alarm
• Unexpected or undesired behavior
The following sections list symptoms in each of these categories and suggest possible causes and corrective actions.
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Process Alarms
When a process alarm occurs, the controller switches to the single-loop display for the loop with the alarm and displays
the alarm code (see Alarm Displays on page 81).
Possible Causes of a Process Alarm
In a heating application, a low alarm or low deviation alarm may indicate one of the following:
• The heater has not had time to raise the temperature.
• The load has increased and the temperature has fallen.
• The control mode is set to manual instead of automatic.
• The heaters are not working because of a hardware failure.
• The sensor is not placed correctly and is not measuring the load’s temperature.
• The alarm settings are too tight. The process variable varies by more than the alarm limits because of load changes, lag or other system conditions.
• The system is so poorly tuned that the temperature is cycling about set point by more than the alarm set point.
NOTE!
In cooling applications, similar issues cause high alarms.
In a heating application, a high alarm or high deviation alarm may indicate one of the following:
• The process set point and high alarm set point have been lowered and the system has not had time to cool to within the new alarm setting.
• The controller is in manual mode and the heat output is greater than 0 percent.
• The load has decreased such that the temperature has risen.
• The heater is full-on because of a hardware failure.
• The system is so poorly tuned that the temperature is cycling about set point by more than the alarm set point.
NOTE!
In cooling applications, similar issues cause low alarms.
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Responding to a Process Alarm
Your response to an alarm depends upon the alarm function
setting, as explained in Table 7.1.
Table 7.1
Operator Response to Process
Alarms
Alarm
Function
Operator Response
Boost
Standard
The operator does not need to acknowledge the alarm. The alarm clears automatically when the process variable returns within limits.
Acknowledge the alarm by pressing x on the keypad or via communications. The alarm clears after the operator acknowledges it and the process variable returns within the limits.
Ambient Warning
The Ambient Warning indicates that the controller is within
5°C of its operating temperature limits. If an Ambient Warning occurs, the alarm code AW (flashing) is displayed, and the global alarm output is turned on. Acknowledging the alarm turns off the global alarm output. The error clears when the condition no longer exists and the alarm has been acknowledged.
If the controller displays the AW alarm code:
1. Acknowledge the alarm.
2. Adjust the ambient temperature to a more appropriate level.
Failed Sensor Alarms
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 (see Alarm Displays on page 81).
A failed sensor alarm clears once it has been acknowledged and the sensor is repaired. For more information about the
causes of failed sensor alarms, see Failed Sensor Alarms on page 93.
System Alarms
If the controller detects a hardware problem, it displays an alarm message, and with the exception of the Low Power
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The D8 displays the following system alarm messages:
•
Low power
•
Battery dead
: See Battery Dead on page 163.
•
H/W error: Ambient
: See H/W Error: Ambient on page
•
H/W error: Gain
: H/W Error: Gain or Offset on page
•
H/W error: Offset
: See H/W Error: Gain or Offset on page 164.
Other Behaviors
Table 7.2 indicates potential problems with the system or con-
troller and recommends corrective actions.
Table 7.2
Other Symptoms
Symptom
Indicated temperature not as expected
Possible Causes
Controller not communicating
Sensor wiring incorrect
Noise
Power connection incorrect
D8 display is not lit
D8 display is lit, but keys do not work
Failed flash memory chip
D8 damaged or failed
Keypad locked
Unacknowledged alarm
D8 damaged or failed
Recommended Action
See Checking Analog Inputs on page 166.
Check wiring and service. See Wiring the
Replace the flash memory chip. See
Replacing the Flash Memory Chip on page
Return the D8 for repair. See Returning a
See Keys Do Not Work on page 166.
An alarm condition exists and has not been
acknowledged. See How to Acknowledge an Alarm on page 82.
Return the D8 for repair. See Returning a
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Symptom
All loops are in manual mode at 0 percent power
Intermittent power
Controller does not behave as expected
Possible Causes
Failed sensor
Control mode of one or more loops changes from automatic to manual
BCD job selection feature loaded a different job
Hardware failure
Corrupt or incorrect values in
RAM
Recommended Action
Check the display or HMI software for a failed sensor message.
Check whether the new job was supposed to be loaded. If not, check the BCD job load setup:
Check the settings of the BCD job load parameters in the Global setup menu.
Use the Digital inputs parameter in the I/O tests
menu to test the BCD job load input(s).
Check the device that is used to activate job selection.
Check wiring and service. See Wiring the
Use a separate dc supply for the controller.
Provide backup power (uninterruptible power system).
In the Global menu, set the Power up loop mode
parameter to from memory if safe for
your application. See Power Up Loop
Check the controller display for a hardware
alarm. See System Alarms on page 160.
Clear the RAM. See Clearing the RAM on page 169.
Reading the DeviceNet Indicator Lights
The Module Status Indicator Light indicates whether or not the device has power and is operating properly. The following chart is the definition of valid states available to this indicator:
Table 7.3
Module Status Indicator States and
Descriptions
Device State
Power Off
Device Self-Test
Device Operational
Unrecoverable Fault
Indicator Light State
Off
Flashing Green-Red
Green
Red
Description
No power applied to device.
Device is in Self-Test.
Device is operating normally.
Device has detected an unrecoverable fault. All module level faults are considered unrecoverable.
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Indicator Light
Off
Green
Red
Flashing Green
Flashing Red
Table 7.4
Network Status Indicator Light
Description
The device is not online.
The device has not completed the duplicate MAC ID test yet.
The device may not be powered. Look at Table 2.10, Module Status
The device is online and has connections in the established state.
For a Group 2 Only device it means that the device is allocated to a
Master.
Failed communication device.
The device has detected an error that has rendered it incapable of communicating on the network (Duplicate MAC ID, or Bus-off).
The device is online, but no connection has been allocated or an explicit connection has timed out.
A poll connection has timed out.
Corrective and Diagnostic Procedures
The following sections detail procedures you may use to diagnose and correct problems with the controller.
Low Power
If the controller displays Low power or the display is not lit:
1. Turn the power to the controller off, then on again.
2. If the Low power alarm message returns, check that the power supplied to the controller is at least 12.0 Vdc at
1 A. See Wiring the Power Supply on page 23.
3. If power is correct and the alarm message persists, make a record of all controller settings. Then, clear the RAM.
See Clearing the RAM on page 169.
4. If the alarm is not cleared, contact your supplier for fur-
ther troubleshooting guidance. See Returning a Unit on page 158.
Battery Dead
The Battery dead alarm indicates that the battery is not functioning correctly. This alarm occurs upon powerup only. The alarm indicates that values stored in memory may have been corrupted because of battery failure and should be restored to factory defaults.
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If the Battery Dead alarm occurs, the controller displays an alarm message and the global alarm output turns on. Acknowledging the alarm restores all settings to factory defaults and turns off the global alarm output.
CAUTION!
Acknowledging this alarm restores all setting to factory defaults.
NOTE!
The controller retains its settings when powered. The battery is required to keep the settings in memory only while the controller is not powered.
If a replacement controller is available:
1. Replace the controller.
2. Enter the parameter settings into the new controller.
If you must use the controller with the failed battery:
1. Acknowledge the Battery Dead alarm. This restores all setting to factory defaults.
2. Using your record of controller settings, re-enter your settings.
H/W Error: Gain or Offset
Gain and Offset alarms indicate that a hardware error is preventing accurate measurements. If a Gain or Offset alarm occurs, the control outputs are turned off, an alarm message is displayed and the global alarm output turns on. Acknowledging the alarm turns off the global alarm output. The error clears when the condition no longer exists and the alarm has been acknowledged.
If the controller displays H/W error: Gain or H/W error: Off- set
:
1. Switch the power to the controller off, then on again.
2. If the alarm persists, make a record of all controller set-
tings, then clear the RAM. See Clearing the RAM on page 169.
3. If the alarm is not cleared, contact your supplier for fur-
ther troubleshooting guidelines. See Returning a Unit on page 158.
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NOTE!
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.
H/W Error: Ambient
The H/W error: Ambient alarm indicates that the ambient sensor in the D8 is reporting that the temperature around the controller is outside of the acceptable range of 0 to 50° C. This alarm can also occur if there is a hardware failure.
If an H/W Error: Ambient alarm occurs, the control outputs are turned off, an alarm message is displayed with the ambient temperature and the global alarm output turns on. Acknowledging the alarm turns off the global alarm output. The error clears when the condition no longer exists and the alarm has been acknowledged.
If the controller displays H/W error: Ambient:
1. Acknowledge the alarm and check the ambient air temperature near the controller. Adjust ventilation, cooling or heating so that the temperature around the controller is
0 to 50° C. If the unit is functioning correctly, the alarm will clear automatically when the ambient temperature is within range.
2. If the ambient temperature is within range and the alarm persists, reseat the board assembly: a) Switch off power to the controller.
b) Remove the board assembly from the D8 housing.
See Replacing the Flash Memory Chip on page 170,
steps 2 to 5.
c) Reseat the board assembly and reassemble the controller. Reverse the steps refered to above to reseat.
d) Switch on power to the controller.
3. If the alarm persists, make a record of all controller set-
tings, then clear the RAM. See Clearing the RAM on page 169.
4. If the alarm is not cleared, contact your supplier for fur-
ther troubleshooting guidelines. See Returning a Unit on page 158.
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Keys Do Not Work
NOTE!
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 D8 seems to function but one or more keys do not work, check the following:
• If the . key does not work, but other keys work, then the keypad is probably locked. Unlock the keypad according
to the instructions in Keypad Lock on page 129.
• Check whether there is an unacknowledged alarm. The keys will not work for anything else until all alarms are acknowledged. To acknowledge an alarm, press x.
Checking Analog Inputs
1. If the process variable read via communications does not agree with the process variable on the controller display, verify that the controller is communicating. See Reading the DeviceNet LEDs on page 148.
2. If the process variable indicated on the controller display is incorrect: a) Verify that you have selected the correct input type for the affected loops.
b) Verify that sensors are properly connected.
3. If the sensors are correctly connected, with power on to the heaters check for high common mode voltage: a) Set a 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 connections. The process variable should indicate ambient temperature. If it does not, contact your supplier to return
the unit for repair. See Returning a Unit on page
NOTE!
Noise in excess of 1 Vac should be eliminat-
ed by correctly grounding the D8. See Wiring the Power Supply on page 23.
4. Verify the sensors:
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Earth Grounding
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• 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 Ω is normal. Readings in excess of 200 Ω indicate a problem with the sensor.
• For RTDs, measure between the IN+ and IN- terminals of TB1. RTD inputs should read between 20 and 250 Ω .
5. To verify that the controller hardware is working correctly, check any input (except an RTD) as follows: a) Disconnect the sensor wiring.
b) In the Input menu, set the Input type parameter to
J thermocouple
.
c) Place a short across the input. On the loop that you are testing, the controller should indicate the ambient temperature.
If you suspect a problem with the ac ground or a ground loop:
• Measure for ac voltage between ac neutral and panel chassis ground. If ac voltage is above 2 Vac, then there may be a problem with the ac power wiring. This should be corrected per local electrical codes.
• With ac power on, measure for ac voltage that may be present between control panels’ chassis grounds. Any ac voltage above 2 Vac may indicate problems with the ac ground circuit.
• With the heater power on, check for ac voltage on thermocouples. 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 2 Vac may indicate the ground lead is not connected to the D8 TB2 ground terminal.
If the above tests indicate proper ac grounding but the controller is indicating incorrect temperatures or process readings:
• Verify which type of sensor is installed and that the Input type
parameter in the Input menu is set accordingly.
• For an RTD or process input, check that the correct input
ter settings (see Setting Up a Process Input on page 88).
• If readings are erratic, look for sources of electrical
noise. See Noise Suppression on page 21.
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•
Eliminate possible ground loops. See Ground Loops on page 22.
• Contact your supplier for further troubleshooting guidance.
Testing Control Output Devices
Connect the solid-state relay (SSR) control terminals to the
D8 control output and connect a light bulb (or other load that can easily be verified) to be switched by the SSR's outputs.
Put the loop in manual mode and set the output to 100 percent.
The ac load should turn on.
Do not attempt to measure ac voltage at the output terminals of the SSR. Without a load connected, the SSR output terminals do not turn off. This makes it difficult to determine whether the SSR is actually working. Measure the voltage across a load or use a load that can be visually verified, such as a light bulb.
Testing the TB18 and TB50
1. Turn on power to the controller.
2. Measure the +5 Vdc supply at the TB18 or TB50. The voltage should be +4.75 to +5.25 Vdc: a) Connect the voltmeter’s common lead to TB18 terminal 2 or TB50 terminal 3.
b) Connect the voltmeter’s positive lead to the TB18 or
TB50 terminal 1.
Testing Control and Digital Outputs
1. Switch off power to the controller.
2. Disconnect any output wiring on the output to be tested.
3. Connect a 500 Ω to 100 k Ω resistor between the
+5V terminal (TB18 or TB50 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.
5. Restore power to the controller.
6. If you are testing a control output, turn the output on and off by setting the loop to 100 percent and 0 percent out-
put power (see Changing the Control Mode and Output
Power on page 85). When the output is off (0 percent),
the output voltage should be less than 1V. When the out-
168 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 7: Troubleshooting and Reconfiguring put is on (100 percent), the output voltage should be between +4.75 and +5.25V.
7. If you are testing a digital output not used for control, use
the I/O tests menu to turn the output on and off. See Test
Digital Output 1 to 20 on page 153.
Testing Digital Inputs
1. Switch off power to the controller.
2. Disconnect any system wiring from the input to be tested.
3. Restore power to the controller.
4. Go to the Digital inputs parameter in the I/O tests menu.
5. Attach a wire to the terminal of the digital input to test.
When the wire is connected only to the digital input terminal, the Digital inputs parameter should show that the input is off ( 0). When you connect the other end of the wire to controller common (TB50 terminal 3), the Digital inputs
parameter should show that the input is on (1).
Clearing the RAM
Clearing the random access memory (RAM) returns all controller settings to their defaults. All stored jobs are also cleared from controller memory.
To clear the RAM:
1. Make a record of all controller settings.
2. Switch off power to the controller.
3. Press and hold <.
4. Switch on power to the controller while still holding <.
5. When you see the prompt Clear RAM?, release < and press ..
6. Restore the controller settings.
NOTE!
If your controller does not have a keypad and display, you can clear the RAM by powering the controller up with pins 1 and 6 on the keypad header (J3 on the bottom circuit card) shorted. After clearing the RAM, power down the controller and remove the jumper wire from the keypad header before putting the controller back in service.
Doc. 0600-3120-2000 Watlow Anafaze 169
Chapter 7: Troubleshooting and Reconfiguring Series D8 User’s Guide
Replacing the Flash Memory Chip
This procedure requires a 32-pin PLCC IC extraction tool.
CAUTION!
The flash memory chip and other components are sensitive to damage from electrostatic discharge (ESD). To prevent ESD damage, use an ESD wrist strap or other antistatic device.
NOTE!
Replacing the flash memory chip results in full erasure of RAM. Make a record of all parameters before changing the flash memory chip.
1. Make a record of controller parameters.
2. Switch off power to the controller.
3. Disconnect input power to the controller.
4. Remove the four screws from the sides of the controller front bezel.
5. Remove the electronics assembly from the case, as
D8
170
D8
Figure 7.1
Removal of Electronics Assembly from Case
Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 7: Troubleshooting and Reconfiguring
6. Unscrew the four screws at the corners of the top board and carefully unplug this board to access the bottom
board. Figure 7.2 shows the screws to remove:
D8
Figure 7.2
Screw Locations on PC Board
7. Locate the flash memory chip on the circuit board. The flash memory chip is a 32-pin socketed chip that is labeled with the model, version and checksum.
Doc. 0600-3120-2000
Figure 7.3
Location of Flash Memory Chip
8. Remove the existing flash memory chip from its socket with an IC extraction tool.
9. Carefully insert the new flash memory chip into the socket. Make sure that the chip is oriented so that its notch fits in the corresponding corner of the socket.
10. Reverse steps 2 through 6 to reassemble the unit.
11. Power up the controller.
12. Re-enter parameters.
Watlow Anafaze 171
Chapter 7: Troubleshooting and Reconfiguring Series D8 User’s Guide
Installing Scaling Resistors
Resistors are installed for all inputs on the D8. Inputs with signal ranges between -10 and +60 mV use 0 Ω resistors in the
RC position only. All other input signals require special input scaling resistors.
Input Circuit
CAUTION!
Scaling resistors are soldered to the circuit board. Only qualified technicians should attempt 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.
The D8 can accept thermocouple, mVdc, Vdc, mAdc and
RTD inputs. Unless ordered with special inputs these controller accept only signals within the standard range -10 to 60 mVdc.
To accommodate other signals, the input circuit must be modified. When configured for thermocouple inputs, 0 Ω resistors are installed in all RC locations. To accommodate voltage signals outside the standard range, milliamp current 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.
page 175 for specific instructions and resistor values for volt-
age, current and RTD inputs.
NOTE!
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.
172 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide
Current Inputs
Doc. 0600-3120-2000
Chapter 7: Troubleshooting and Reconfiguring
RC (Voltage)
IN+
Input
Terminal
IN-
Com
Internal
+5 Vdc
Reference
RC (RTD)
RP
RP
Figure 7.4
Input Circuit
RD
+
To D8
Circuitry
-
For each current input, 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 resistor as shown in the illustration below.
Table 7.5
Resistor Values for Current Inputs
Input Range
0 to 10 mA
0 to 20 mA
Resistor tolerance:
±
0.1%
RP#
Resistor Value RD
6.0 Ω
3.0 Ω
RD
Table 7.6
Resistor Locations for Current Inputs
3
4
1
2
Loop
Resistor
Location RD
RP1
RP2
RP3
RP4
Loop
7
8
5
6
Resistor
Location RD
RP5
RP6
RP7
RP8
Watlow Anafaze 173
Chapter 7: Troubleshooting and Reconfiguring
Voltage Inputs
Series D8 User’s Guide
For each voltage input, you must install two resistors. The resistances must be correct for the expected input range. Note the resistor pack (RP) locations have three through-holes. Install the RD resistor as indicated in the illustration below.
Table 7.7
Resistor Values for Voltage Inputs
Resistor Values
Input Range
RC
0 to 100 mVdc
0 to 500 mVdc
0 to 1 Vdc
0 to 5 Vdc
0 to 10 Vdc
499 Ω
5.49 k Ω
6.91 k Ω
39.2 k Ω
49.9 k Ω
0 to 12 Vdc
Resistor tolerance:
±
0.1%
84.5 k Ω
RP#
RD
750 Ω
750 Ω
442 .
0 Ω
475.0 Ω
301.0 Ω
422.0 Ω
RD
7
8
5
6
3
4
1
2
Table 7.8
Resistor Locations for Voltage Inputs
Resistor Locations
Loop
RC
R50
R48
R46
R44
R58
R56
R54
R52
RD
RP5
RP6
RP7
RP8
RP1
RP2
RP3
RP4
174 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide
RTD Inputs
Chapter 7: Troubleshooting and Reconfiguring
For each RTD input, 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 illustration below.
Resistor values:
• RA/RB: 25 k Ω
• RC: 18.2 Ω
Resistor tolerances:
• RA/RB: Matched to 0.02% ( tolerance of 0.1% (
±
5 ppm/°C) with absolute
±
25 ppm/°C)
• RC: Accurate to 0.05% (
±
5ppm/°C)
RP#
RA RB
7
8
5
6
3
4
1
2
Table 7.9
Resistor Locations for RTD Inputs
Loop
Resistor Values
RA/RB
RP4
RP5
RP6
RP7
RP1
RP2
RP3
RP3
RC
R49
R47
R45
R43
R57
R55
R53
R51
Doc. 0600-3120-2000 Watlow Anafaze 175
Chapter 7: Troubleshooting and Reconfiguring Series D8 User’s Guide
Scaling and Calibration
The controller provides offset calibration for thermocouple,
RTD, and other fixed ranges, and offset and span (gain) calibration for process inputs. In order to scale the input signal, you must:
1. Install appropriate scaling resistors.
2. Enter the input range at the Disp format parameter in the
Input
menu. The smallest possible range is -.9999 to
3.0000; the largest possible range is -9999 to 30000.
3. Enter the appropriate scaling values for your process. See
Setting Up a Process Input on page 88.
Configuring Serial DAC Outputs
On the Serial DAC, the voltage and current output is jumper-
selectable. Refer to Figure 7.5. Configure the jumpers as indi-
cated on the Serial DAC label.
SERIAL
NA
FAZE
PIN
: 1
+5V IN
DAT
A IN
FLASHING
VOL
OUTPUT
CURRENT
SELECT
TAGE
{
{
5 6
DAC
Jumper
Figure 7.5
Serial DAC Voltage and Current
Jumper Positions
176 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 7: Troubleshooting and Reconfiguring
Configuring Dual DAC Outputs
Dual DAC modules ship with both of the outputs configured for the signal type and span that were ordered. The module contains two independent circuits (DAC 1 and DAC 2). 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 DAC 1; the evennumbered jumpers determine the output from DAC 2.
DAC 1
I SINK OUT
ANAF
DUAL
DAC
AZE
DAC 2
+5V IN DZC IN
+10-24V IN V OUT
I SINK OUT
Figure 7.6
Dual DAC
Table 7.10
Dual DAC Jumper Settings
Jumper Settings
Output
Type
1/2 3/4 5/6 7/8 9/10 11/12 13/14
0 to 5 Vdc B
0 to 10 Vdc B
A
A
A
A
O
O
B
B
A
O
4 to 20 mA O A B A A O A
A = Load jumper in the “A” position, or load jumper if header has only two pins.
B = Load jumper in the “B” position.
O = Open. Do not load jumper.
O
O
Doc. 0600-3120-2000 Watlow Anafaze 177
Chapter 7: Troubleshooting and Reconfiguring Series D8 User’s Guide
1. Power down the system (if the Dual DAC is already installed and wired).
2. Ensure the DAC 1 and DAC 2 terminal blocks or associated wires are labeled such that you will know which terminal block connects to which side of the board if the module is already installed and wired.
3. Unplug the two terminal blocks.
4. Depending on the installation, you may need to unmount the Dual DAC module before proceeding. Remove the four screws from the end plate on the opposite side of the module from the terminal blocks.
5. If necessary, remove the two mounting screws holding the loosened end plate in place.
6. Slide the board out of the housing.
7. Set the jumpers for the two outputs as desired. See
8. Replace the board such that the connectors extend through the opposite end plate. The board fits in the third slot from the bottom.
9. Reconnect the two terminal blocks to the DAC 1 and
DAC 2 connectors.
10. Replace the end plate, end plate screws and, if necessary, mounting screws.
11. Check the wire connections to the DAC 1 and DAC 2 terminal blocks.
12. If necessary, change the wiring connections to the correct
configuration for the new output type. See Wiring the
13. Restore system power.
178 Watlow Anafaze Doc. 0600-3120-2000
8
Specifications
This chapter contains specifications for the D8 series controllers, TB50 terminal board, Dual DAC module, Serial DAC module and the D8 power supply.
System Specifications
This section contains D8 series controller specifications for environmental specifications and physical dimensions, inputs, outputs, the serial interface and system power requirements.
The controller consists of a processor module with a 50-terminal block (TB50) or a processor module with an 18-terminal block (TB18).
CE Directive
UL and C-UL
ODVA
Table 8.1
Agency Approvals / Compliance
Electromagnetic Compatibility (EMC) Directive 89/336/EEC
UL 916, Standard for Energy Management Equipment File E177240
DeviceNet and Semiconductor SIG
Physical Specifications
Table 8.2
Environmental Specifications
Storage Temperature
Operating Temperature
Humidity
Environment
-20 to 60° C
0 to 50° C
10 to 95% non-condensing
The controller is for indoor use only
Doc. 0600-3120-2000 Watlow Anafaze 179
Chapter 8: Specifications
96 mm (3.78 in)
Series D8 User’s Guide
45 mm
(1.76 in)
90 mm
(3.55 in)
50 mm
(1.96 in)
213 mm
(8.4 in)
188 mm
(7.4 in)
Figure 8.1
D8 Module Dimensions
Table 8.3
D8 with Straight SCSI
Length*
Width
Height
10.0 to 10.5 in.
3.78 inches
1.96 inches
254 to 267 mm
96 mm
50 mm
*Exact requirement depends on usage and choice of cables.
180 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 8: Specifications
188 mm (7.4 in)
41 mm to 54 mm
(1.6 in to 2.1 in) for cables and clearance
25 mm
(1.0 in)
Figure 8.2
Module Dimensions and Clearance
Power Terminals (TB2)
Power Wire Gauge (TB2)
Power Terminal Torque (TB2)
Sensor Terminals (TB1)
Sensor Wire Gauge (TB1)
Sensor Terminal Torque (TB1)
Output Terminals (TB18)
Output Wire Gauge (TB18)
Output Terminal Torque (TB18)
SCSI Connector
DeviceNet Connector
Doc. 0600-3120-2000
Table 8.4
D8 Connections
Captive screw cage clamp
22 to 18 AWG (0.5 to 0.75 mm 2 )
4.4 to 5.3 in.-lb. (0.5 to 0.6 Nm)
Captive screw cage clamp
Thermocouple: 20 AWG (0.5 mm 2 )
Process: 22 to 20 AWG (0.5 mm 2 )
Communications: 24 AWG (0.2 mm 2 )
4.4 to 5.3 in.-lb. (0.5 to 0.6 Nm)
Captive screw cage clamp
Multiconductor cables: 24 AWG (0.2 mm 2 )
Single-wire: 22 to 18 AWG (0.5 to 0.75 mm 2 )
4.4 to 5.3 in.-lb. (0.5 to 0.6 Nm)
SCSI-2 female
Male, sealed, micro-style, quick disconnect DeviceNet connector
Table 8.5
TB50 Physical Dimensions
Weight
Length
Width
Height
0.32 lb.
4.1 inches
4.0 inches
1.5 inches
0.15 kg
104 mm
102 mm
37 mm
Watlow Anafaze 181
Chapter 8: Specifications
182
Series D8 User’s Guide
4.1 in.
(104 mm)
4.0 in.
(102 mm)
Figure 8.3
TB50 Dimensions
1.5 in.
(37 mm)
Table 8.6
TB50 Connections
Screw Terminal Torque 4.4 to 5.3 in.-lb. (0.5 to 0.6 Nm)
SCSI Connector on
Board
Output Terminals
SCSI-2 female
Captive screw cage clamp
Output Wire Gauge
Multiconductor cables: 24 AWG
(0.2 mm 2 )
Single-wire: 22 to 18 AWG
(0.5 to 0.75 mm 2 )
Output Terminal Torque 4.4 to 5.3 in.-lb. (0.5 to 0.6 Nm)
Table 8.7
TB50 with Straight SCSI
Length
Width
Height
6.4 inches
4.0 inches
1.5 inches
163 mm
102 mm
37 mm
Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 8: Specifications
6.4 in.
(163 mm)
4.0 in.
(102 mm)
1.5 in.
(37 mm)
Figure 8.4
TB50 Dimensions with Straight
SCSI Cable
Table 8.8
TB50 with Right Angle SCSI
Length
Width
Height
5.4 inches
4.0 inches
1.5 inches
137 mm
102 mm
37 mm
Doc. 0600-3120-2000 Watlow Anafaze 183
Chapter 8: Specifications Series D8 User’s Guide
5.4 in.
(137 mm)
4.0 in.
(102 mm) 1.5 in.
(37 mm)
Figure 8.5
TB50 Dimensions with Right-Angle
SCSI Cable
184 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 8: Specifications
Inputs
The controller accepts analog sensor inputs which are measured 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 8.9
Analog Inputs
Number of Control Loops
Number of Analog Inputs
Input Switching
Input Sampling Rate
Milliampere Inputs
Voltage Input Ranges Available
Source Impedance
D84_- _ _ _ _ - _ _ _ _ : 4 loops
D88_- _ _ _ _ - _ _ _ _ : 8 loops
D84_- _ _ _ _ - _ _ _ _: 4 loops with full range of input types
D88_- _ _ _ _ - _ _ _ _: 8 loops with full range of input types
Differential, solid-state multiplexer
D84_- _ _ _ _ - _ _ _ _: 6 Hz (167 ms) at 60 Hz; 5 Hz (200 ms) at 50 Hz
D88_- _ _ _ _ - _ _ _ _: 3 Hz (333 ms) at 60 Hz; 2.5 Hz (400 ms) at 50 Hz
0 to 20 mA (3 Ω resistance) or 0 to 10 mA (6 Ω resistance), with scaling resistors
0 to 12 V, 0 to 10 V, 0 to 5 V, 0 to 1 V, 0 to 500 mV, 0 to 100 mV with scaling resistors
For 60 mV thermocouple, measurements are within specification with up to 500 Ω source resistance
For other types of analog signals, the maximum source impedance is 5000 Ω
-10 to +60 mV, or 0 to 25 V with scaling resistors
0.006%, greater than 14 bits (internal)
Input Range
Resolution
Accuracy
0.03% of full scale (60 mV) at 25° C
0.08% of full scale (60 mV) at 0 to 50° C
Analog Over Voltage
Protection
± 20 V referenced to digital ground.
Maximum Common Mode Voltage 5 V input to input or input to analog common
Common Mode
Rejection (CMR)
Calibration
Analog Ground to Frame Ground
Maximum
DC Common to Frame Ground
Maximum Potential
Open Thermocouple Detection
For inputs that do not exceed ± 5 V, >60 dB dc to 1 kHz, and
120 dB at selected line frequency.
Automatic zero and full scale
40 V
40 V
Pulse type for upscale break detection
Doc. 0600-3120-2000 Watlow Anafaze 185
Chapter 8: Specifications Series D8 User’s Guide
Table 8.10
Thermocouple Range and
Resolution
Thermocouple
Type
R
B
E
T
S
J
K
Accuracy* at
25ËšC Ambient
Accuracy* at
0 to 50ËšC Ambient
Range in ËšF Range in ËšC
ËšF ËšC ËšF ËšC
-350 to 1400 -212 to 760
-450 to 2500 -268 to 1371
-450 to 750
0 to 3200
-268 to 399
-18 to 1760
0 to 3210
150 to 3200
-328 to 1448
-18 to 1766
66 to 1760
±2.2
±2.4
±2.9
±5.0
±5.0
±7.2
±1.2
±1.3
±1.6
±2.8
±2.8
±4.0
±3.3
±3.8
±5.8
±8.8
±8.8
±22.1
±1.8
±2.1
±3.2
±4.9
±4.9
±12.3
-200 to 787 ±1.8
±1.0
±2.9
±1.6
* True for 10 percent to 100 percent of span except type B, which is specified for 800° F to 3200° F.
Range in ËšF
Range in ËšC
Resolution in ËšC
Measurement
Temperature in ËšC
-328.0 to
1150.0
-200.0 to
621.1
0.07
Table 8.11
RTD Range and Resolution
25
400
Accuracy at
25ËšC Ambient
ËšF
0.9
2.7
ËšC
0.5
1.5
Accuracy at
0 to 50ËšC Ambient
ËšF
1.2
4.1
ËšC
0.5
2.2
Table 8.12
Input Resistance for Voltage Inputs
Range
0 to 12 V
0 to 10 V
0 to 5 V
0 to 1 V
0 to 500 mV
0 to 100 mV
Input Resistance
85 k Ω
50 k Ω
40 k Ω
7.4 k Ω
6.2 k Ω
1.2 k Ω
186 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 8: Specifications
Number
Function
Input Voltage Protection
Voltage Levels
Response Time
Table 8.13
Digital Inputs
Maximum Switch Resistance to Pull Input Low
Minimum Switch Off Resistance
With TB50: 8
With TB18: 3
Selectable for output override or remote job selection
Diodes to supply and common. Source must limit current to 10 mA for override conditions
<1.3 V = Low
>3.7 V = High (TTL)
5 V maximum, 0 V minimum
1.7 k Ω
1.4 k Ω
50 ms (AC line frequency set to 60 Hz)
60 ms (AC line frequency set to 50 Hz)
Outputs
The controller directly accommodates switched dc and opencollector outputs only. These outputs can be used to control a wide variety of loads. They are typically used to control solid state relays or other power switching devices which, in turn, control devices such as heaters. They may also be used to signal another device of an alarm condition in the controller.
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 can monitor the CPU state.
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 191 and Serial DAC Spec-
Doc. 0600-3120-2000 Watlow Anafaze 187
Chapter 8: Specifications Series D8 User’s Guide
Digital Outputs
Number
Operation
Function
Number of Control Outputs per
PID Loop
Control Output Types
Time Proportioning Cycle Time
Control Action
Off State Leakage Current
Maximum Current
Maximum Voltage Switched
Table 8.14
Digital Outputs Control / Alarm
20 with TB50 option or 13 with TB18 option
Open collector output; ON state sinks to logic common
1 Global alarm output
1 CPU watchdog output
Balance selectable as closed-loop control or alarms
2 (maximum)
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
1 to 255 seconds, programmable for each output
Reverse (heat) or direct (cool), independently selectable for each output
<0.01 mA to dc common
60 mA for each output. 5V power supply (from the processor module) can supply up to 350 mA total to all outputs
24 Vdc
Voltage
Maximum Current
Minimum Time Between
Polled I/O Requests
Voltage
Maximum Current
Table 8.15
5 Vdc Output (Power to Operate
Solid-State Relays)
5 Vdc
350 mA
Table 8.16
Communications
20 ms
Table 8.17
D8 Power Requirements
15 to 24 +/-3 Vdc
1 A
188 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide
Power Supply
Chapter 8: Specifications
Specifications for the D8 power supply are available at www.watlow.com. See the links on the D8 page.
Doc. 0600-3120-2000 Watlow Anafaze 189
Chapter 8: Specifications Series D8 User’s Guide
190 Watlow Anafaze
7.5 inches
(191 mm)
Doc. 0600-3120-2000
1.4 in
(36 mm)
0.19 (3/16) inch diameter
0.3 inch
(8 mm)
(5 mm)
Series D8 User’s Guide Chapter 8: Specifications
Dual DAC Specifications
The Watlow Anafaze Dual DAC (digital-to-analog converter) is an optional module for the D8 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:
• 4 to 20 mAdc
• 0 to 5 Vdc
• 0 to 10 Vdc
Table 8.23
Dual DAC Environmental Specifications
Storage Temperature
Operating Temperature
Humidity
-20 to 60° C
0 to 50° C
10 to 95% non-condensing
Table 8.24
Dual DAC Physical Specifications
Weight
Length
Width
Height
0.42 lb.
4.4 inches
3.6 inches
1.8 inches
0.19 kg
112 mm
91 mm
44 mm
0.162 in. diameter
(4 mm)
DAC 1
1.8 in.
44 mm
3.6 in.
91 mm
ANAF
DUAL
DAC
AZE
DAC 2
I SINK OUT
+5V IN DZC IN
+10-24V IN V OUT
I SINK OUT
3.0 in.
76 mm
3.7 in.
94 mm
0.3 in. 0.4 in.
8 mm 10 mm
Figure 8.7
Dual DAC Dimensions
4.4 in.
112 mm
Doc. 0600-3120-2000 Watlow Anafaze 191
Chapter 8: Specifications Series D8 User’s Guide
Dual DAC Inputs
The Dual DAC accepts an open-collector signal from the D8 controller and the power from an external power supply. See
Table 8.25
Dual DAC Power Requirements
Voltage
Current
Parameter Description
12 to 24 Vdc
100 mA @ 15 Vdc
Dual DAC Analog Outputs
Version
Gain Accuracy
Output Offset
Table 8.26
Dual DAC Specifications by Output
Range
4 to 20 mA
± 6
± 0.75
0 to 5 V
± 6
± 0.75
0 to 10 V
± 6
± 0.75
Ripple
Time Constant
Maximum Current Output
Load Resistance (12 V)
Load Resistance (24 V)
1.6
1.6
1.6
2
20
2
10
2
10
250 maximum 500 minimum 1000 minimum
850 maximum n/a n/a
Units percent percent of full scale range percent of full scale range seconds mAdc
Ohms
Ohms
192 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 8: 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
10 Vdc or 4 to 20 mA output. Multiple Serial DAC modules can be used with one D8. The Serial DAC carries a CE mark.
Table 8.27
Serial DAC Environmental Specifications
Storage Temperature
Operating Temperature
Humidity
-20 to 60° C
0 to 50° C
10 to 95% non-condensing
Table 8.28
Serial DAC Physical Specifications
Weight
Length
Width
Height
0.76 lb.
5.4 inches
3.6 inches
1.8 inches
0.34 kg
137 mm
91 mm
44 mm
ANAF
AZE
0.2 in. diameter
4 mm
1.8 in.
44 mm
SERIAL D
PIN
: 1
2 +5V IN
CLK IN
IN
FLASHING
OUTPUT SELECT
CURRENT
VO
LTAG
E
{
{
5 6
AC
3.0 in.
76 mm
4.7 in.
119 mm
5.5 in.
138 mm
3.6 in.
91 mm
0.3 in.
8 mm
0.4 in.
10 mm
Figure 8.8
Serial DAC Dimensions
Doc. 0600-3120-2000 Watlow Anafaze 193
Chapter 8: Specifications
Serial DAC Inputs
Series D8 User’s Guide
Table 8.29
Serial DAC Agency Approvals /
Compliance
CE Directive
UL and C-UL
Electromagnetic Compatibility (EMC) directive 89/336/EEC
UL 916 Standard for Energy Management Equipment File E177240
The Serial DAC requires a proprietary serial data signal and the clock signal from the D8 via the TB50. Any control output can be configured to provide the data signal. The Serial DAC also requires a 5 Vdc power input.
Table 8.30
Serial DAC Inputs
Data
Clock
4 mA maximum to DC COM
Open collector or HC CMOS logic levels
0.5 mA maximum to DC COM
Open collector or HC CMOS logic levels
Table 8.31
Serial DAC Power Requirements
Voltage 4.75 to 5.25 Vdc @ 300 mA maximum
194 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Chapter 8: Specifications
Serial DAC Analog Outputs
Absolute Maximum Common
Mode Voltage
Resolution
Accuracy (Calibrated for Voltage
Output)
Temperature coefficient
Isolation Breakdown Voltage
Current
Voltage
Output Response Time
Update Rate
Table 8.32
Serial DAC Analog Output Specifications
Measured between output terminals and controller common:
1000 V
15 bits (plus polarity bit for voltage outputs)
(0.305 mV for 10 V output range)
(0.00061 mA for 20 mA output range)
For voltage output: ± 0.005 V (0.05% at full scale)
For current output: ± 0.1 mA (0.5% at full scale)
440 ppm/ °C typical
1000 V between input power and signals
0 to 20 mA with 10 V minimum compliance (500 Ω load)
0 to 10 Vdc with 10 mA source capability
1 ms typical
Once per controller A/D cycle nominal. Twice per second maximum for 60 Hz clock rate.
Output changes are step changes due to the fast time constant. All Serial DAC loop outputs are updated at the same time.
Doc. 0600-3120-2000 Watlow Anafaze 195
Chapter 8: Specifications Series D8 User’s Guide
Declaration of Conformity
D8 Series
WATLOW ANAFAZE
314 Westridge Drive
Watsonville, California 95076 USA
Declares that the following product:
Designation: D8 Series
Model Number(s):
Classification:
English
D8(4 or 8)(any digit or letter)-(any 4 digits or letters) -
(any 4 digits or letters)
Installation Category II, Pollution Degree II
Rated Voltage: 12 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)
1995 Electrostatic discharge EN 61000-4-2:
EN 61000-4-3:
EN 61000-4-4:
EN 61000-4-5:
EN 61000-4-6:
1997 Radiated immunity
1995 Electrical fast transients
1995
1994
Surge immunity
Conducted immunity
EN 61000-4-11: 1994 Voltage dips, short interruptions and voltage variations immunity
Déclare que le produit suivant :
Désignation : Série D8
Français
Numéro(s) de modèle(s): D8(4 ou 8)(Tout caractère ou lettre)-(tout groupe de
4 caractères ou lettres)-(tout groupe de 4 caractères ou lettres)
Classification :
Tension nominale :
Installation catégorie II, degré de pollution II
12 à 24V c.c.
Courant nominal : 610 mA maximum
Conforme aux exigences de la (ou des) directive(s) suivante(s) de l’Union
Européenne figurant aux sections correspondantes des normes et documents associés ci-dessous :
89/336/EEC Directive de compatibilité électromagnétique
EN 61326: 1995 Appareillage électrique pour la mesure, la commande et l’usage de laboratoire –—
Prescriptions relatives à la Compatilité Electro
Magnétique (Classe A)
EN 61000-4-2 : 1995 Décharge électrostatique
EN 61000-4-3: 1997 Insensibilité à l’énergie rayonnée
EN 61000-4-4 : 1995 Courants électriques transitoires rapides
EN 61000-4-5 : 1995 Insensibilité aux surtensions
EN 61000-4-6: 1996 Insensibilité à l’énergie par conduction
EN 61000-4-11 : 1994 Insensibilité aux chutes subites, aux courtes interruptions et aux variations de tension
Erklärt, daß das folgende Produkt:
Beschreibung: Serie D8
Deutsch
Modellnummer(n):
Klassifikation:
Nennspannung:
D8(4 oder 8)(jede Zahl oder Buchstabe)(4 beliebige
Buchstaben oder Ziffern )(4 beliebige Buchstaben oder Ziffern)
Installationskategorie II, Emissionsgrad II
12 bis 24 Vdc
Nominaler
Stromverbrauch: max. 610 mA
Erfüllt die wichtigsten Normen der folgenden Anweisung(en) der Europäischen Union unter Verwendung des wichtigsten Abschnitts bzw. der wichtigsten Abschnitte der normalisierten Spezifikationen und der untenstehenden einschlägigen Dokumente:
89/336/EEC Elektromagnetische Übereinstimmungsanweisung
EN 61326: 1997 Elektrog erät e zur Messun g, Regelu ng u nd zum
Lab oreinsatz EMC - Rich tlinien ( Klasse A)
1995 Elektrostatische Entladung EN 61000-4-2:
EN 61000-4-3:
EN 61000-4-4:
EN 61000-4-5:
EN 61000-4-6:
1997 Strahlungsimmunität
1995 Elektrische schnelle Stöße
1995
1994
Spannungsstoßimmunität
Störimmunität
EN 61000-4-11: 1994 Immunität gegen Spannungsgefälle, kurze
Unterbrechungen und Spannungsabweichungen
Declara que el producto siguiente:
Designación: Serie D8
Español
Números de modelo:
Clasificación:
D8(4 ó 8)(qualquier citra ó letra)-(cualquier 4 citras ó letras)-
(cualquier 4 citras ó letras)
Categoría de instalación II, grado de contaminación ambiental II
Tensión nominal: 12 a 24Vcc
Consumo nominal
de energía: 610 mA máximo
Cumple con los requisitos esenciales de las siguientes Directivas de la Unión
Europea, usando las secciones pertinentes de las reglas normalizadas y los documentos relacionados que se muestran:
89/336/EEC - Directiva de Compatibilidad Electromagnética
EN 61326:
EN 61000-4-2:
EN 61000-4-3:
EN 61000-4-4:
1997 Equipo elétrico para medición control y uso en laboratorios - Requisitos de compatibilidad electromagnética (Clase A)
1995 Descarga electrostática
1997
1995
Inmunidad radiada
Perturbaciones transitorias eléc tricas rápidas
EN 61000-4-5:
EN 61000-4-6:
1995
1994
Sobretensión
Inmunidad conducida
EN 61000-4-11: 1994 Caídas de tensión, interrupciones breves y variaciones de tensión
Dean Hoffman
Name of Authorized Representative
Controls Product Group Leader
Title of Authorized Representative
Watsonville, California. USA
Place of Issue
September 12, 2002
Date of Issue
________________________________
Signature of Authorized Representative
25950-00 REV A
196 Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Glossary
Glossary
A
AC
See Alternating Current.
AC Line Frequency
The frequency of the ac line power measured in Hertz
(Hz), usually 50 or 60 Hz.
Accuracy
Closeness between the value indicated by a measuring instrument and a physical constant or kno wn standards.
Action
The response of an output when the process v ariable is changed. See also Direct Action, Reverse Action.
Address
A numerical identifier for a controller when used i computer communications.
Alarm
A signal that indicates that the process has e xceeded or fallen below a certain range around the set point.
For example, an alarm may indicate that a process is too hot or too cold. See also Failed Sensor Alarm,
Global Alarm, High De viation Alarm, High Alarm,
Loop Alarm, Low Deviation Alarm, Low Alarm.
Alarm Delay
The lag time before an alarm is activated.
Alternating Current (AC)
An electric current that re verses at re gular intervals, and alternates positive and negative values.
Ambient Temperature
The temperature of the air or other medium that sur rounds the components of a thermal system.
American Wire Gauge (AWG)
A standard of the dimensional characteristics of wire used to conduct electrical current or signals. AWG is identical to the Brown and Sharpe (B&S) wire gauge.
Ammeter
An instrument that measures the magnitude of an electric current.
Ampere (Amp, A)
A unit that defines the rate of f w of electricity (current) in the circuit. Units are one coulomb (6.25 x
1018 electrons) per second.
Analog Output
A continuously v ariable signal that is used to represent a v alue, such as the process v alue or set point value. Typical hardw are configurations are 0 t
20mA, 4 to 20mA or 0 to 5 Vdc.
Automatic Mode
A feature in which the controller sets PID control outputs in response to the process v ariable and the set point.
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.
Autotune
A feature that automatically sets temperature control
PID values to match a particular thermal system.
AWG
See American Wire Gauge.
B
Baud Rate
The rate of information transfer in serial communications, measured in bits per second.
BCD
Binary coded decimal. F or BCD job loading, the binary states of three digital inputs are decoded as decimal numbers 1 to 8.
Bumpless Transfer
A smooth transition from automatic (closed loop) to manual (open loop) operation. The control output does not change during the transfer.
C
Calibration
The comparison of a measuring de vice (an unknown) against an equal or better standard.
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Glossary Series D8 User’s Guide
Celsius
A temperature scale in which w ater freezes at 0° C and boils at 100° C at standard atmospheric pressure.
The formula for conversion to the F ahrenheit scale is
°F = (1.8 x °C) + 32. Formerly known as Centigrade.
Central Processing Unit (CPU)
The unit of a computing system that includes the cir cuits controlling the interpretation of instructions and their execution.
Circuit
Any closed path for electrical current. A configuratio of electrically or electromagnetically-connected components or devices.
Class
The model for a software object. Objects of a class are similar to one another. DeviceNet classes define wha attributes and services objects of that type have. Class services are used to e xamine and change class attributes.
Closed Loop
A control system that uses a sensor to measure a process variable and makes decisions based on that feedback.
Cold Junction
Connection point between thermocouple metals and the electronic instrument.
Common Mode Rejection Ratio
The ability of an instrument to reject electrical noise, with relation to ground, from a common voltage. Usually expressed in decibels (dB).
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 relati ve to the difference between the process v ariable and the set point. See also Direct Action, Reverse Action.
Current
The rate of fl w of electricity. The unit of measure is the Ampere (A). 1 Ampere = 1 coulomb per second.
Cycle Time
The time required for a controller to complete one onoff-on cycle. It is usually expressed in seconds.
Cyclic Redundancy Check (CRC)
An error checking method in communications that provides a high level of data security.
D
DAC
See Digital-to-Analog Converter.
Data Logging
A method of recording a process v ariable o ver a period of time. Used to review process performance.
DC
See Direct Current.
Default Parameters
The programmed instructions that are permanently stored in the microprocessor software.
Derivative Control (D)
The last term in the PID algorithm. Action that anticipates the rate of change of the process and compensates to minimize o vershoot and undershoot.
Derivative control is an instantaneous change of the control output in the same direction as the propor tional error. This is caused by a change in the process variable that decreases over the time of the derivative.
The derivative is expressed in seconds.
Deutsche Industrial Norms (DIN)
A set of technical, scientific and dimensional stan dards de veloped in German y. Man y DIN standards have worldwide recognition.
Deviation Alarm
See High Deviation Alarm, Low Deviation Alarm.
DeviceNet
DeviceNet is a netw ork that connects industrial devices. De viceNet is designed to pro vide a costeffective and rob ust solution to de vice netw orking.
DeviceNet is designed to transport control-oriented information associated with lo w-level de vices and other information related to the system being controlled, such as configuration parameters
Digital-to-Analog Converter (DAC)
A device that con verts a numerical input signal to a signal that is proportional to the input in some way.
DIN
See Deutsche Industrial Norms.
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Series D8 User’s Guide Glossary
Direct Action
An output control action in which an increase in the process variable causes an increase in the output. Usually used with cooling applications.
Direct Current (DC)
An electric current that fl ws in one direction.
Distributed Zero Crossing (DZC)
A form of digital output control in which the output on/off state is calculated for e very ac line c ycle.
Power is switched at the zero cross, which reduces electrical noise. See also Zero Cross.
DZC
See Distributed Zero Crossing.
Emissivity
The ratio of radiation emitted from a surf ace compared to radiation emitted from a blackbody at the same temperature.
Engineering Units
Selectable units of measure, such as de grees Celsius or F ahrenheit, pounds per square inch, ne wtons per meter, gallons per minute, liters per minute, cubic feet per minute or cubic meters per minute.
E
Earth Ground
A metal rod, usually copper , that provides an electrical path to the earth, to pre vent or reduce the risk of electrical shock.
EIA/TIA
Electronic Industries Alliance (EIA) and Telecommunications Industry Association (TIA). See also Serial
Communications.
EIA/TIA-232
—
A standard for interface between data terminal equipment and data communications equipment for serial binary data interchange. This is usually for communications over a short distance
(50 feet [15 m] or less) and to a single device.
EIA/TIA-485
—
A standard for electrical characteristics of generators and recei vers for use in balanced digital multipoint systems. This is usually used to communicate with multiple de vices over a common cable or where distances o ver 50 feet (15 m) are required.
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 inside the sine w ave. EMI can interfere with the operation of controllers and other devices.
Electrical-Mechanical Relays
See Relay, Electromechanical.
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 con version to Celsius is °C = 5/9 (°F - 32).
Failed Sensor Alarm
Warns that an input sensor no longer produces a v alid signal.
Filter
Filters are used to handle v arious electrical noise problems.
Digital Filter
—
A filter that sl ws the response of a system when inputs change unrealistically or too fast. Equi valent to a standard resistor -capacitor
(RC) filte
Digital Adaptive Filter
—
A filter that reject high frequency input signal noise (noise spikes).
Heat/Cool Filter
—
A filter that sl ws 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 alue within the numbers of scans that are set.
Frequency
The number of cycles over a specified period of time usually measured in c ycles per second. Also referred to as Hertz (Hz).
G
Gain
The amount of amplification used in an electrical ci cuit. Gain can also refer to the proportional (P) mode of PID.
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Glossary Series D8 User’s Guide
Global Alarm
Warns that one or more alarm conditions exist by activating a digital output.
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 malfunctions. Also referred to as
“safety ground.”
Input Scaling
The con verting of input signals to the engineering units of the process variable.
Input Type
The signal type that is connected to an input, such as thermocouple, RTD or process.
H
Hertz (Hz)
Frequency, measured in cycles per second.
Instance
An object that is an occurance of a class. Each instance of a DeviceNet object can have unique values for its attrib utes and can be e xamined or changed using the instance services. Class services are used to examine and change class attrib utes, which af fect all instances. Instance services are used to e xamine and change instance attributes which affect only that par ticular instance.
High Deviation Alarm
Warns that the process has risen more than a certain amount abo ve set point. It can be used as either an alarm or control function.
Integral Control (I)
Control action that automatically eliminates of fset, or droop, between set point and actual process temperature.
High Power
(As defined by Watlow Anafaze) Any voltage above
24 Vac or Vdc and any current level above 50 mAac or mAdc.
High Alarm
A signal that is associated with a set maximum v alue that can be used as either an alarm or boost control function.
HMI
Human-machine interface.
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 conductors join to form a thermocouple.
Hysteresis
Control Hysteresis
—
The range through which a variation of the input produces no noticeable change in the output. In the hysteresis, specific con ditions can be placed on control output actions.
Operators select the hysteresis. It is usually abo ve the heating proportional band and belo w the cooling proportional band.
Process Hysteresis
—
In heat/cool applications, the +/- dif ference between heat and cool. Also known as process deadband.
K
Keypad Lock
A feature that pre vents operation of the k eypad by unauthorized people.
L
Lag
The delay between the output of a signal and the response of the instrument to which the signal is sent.
I
Input
Analog Input
— An input that accepts process variable information.
Digital Input
— An input that accepts on and of f signals.
200 Watlow Anafaze
Linearity
The deviation in response from an e xpected or theoretical straight line v alue for instruments and transducers. Also called linearity error.
Load
The electrical demand of a process, e xpressed in power (Watts), current (Amps) or resistance (Ohms).
Doc. 0600-3120-2000
Series D8 User’s Guide Glossary
The item or substance that is to be heated or cooled.
Low Deviation Alarm
Warns that the process has dropped more than a cer tain amount belo w set point. It can be used as either an alarm or control function.
On/Off Control
A method of control that turns the output full on until set point is reached, and then off until the process differs from the set point by more than the hysteresis.
Open Loop
A control system with no sensory feedback.
Low Alarm
A signal that is associated with a set minimum v alue that can be used as either an alarm or boost control function.
M
Manual Mode
A selectable mode that has no automatic control aspects. The operator sets output levels.
Optical Isolation
Two electronic netw orks 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 dif ference between set point and process variable.
Manual Reset
A parameter that allows the user to eliminate offset or droop between set point and actual process temperature. See also Integral.
Output Type
The form of control output, such as time proportioning, distributed zero crossing, Serial D AC or analog.
Also the description of the electrical hardw are that makes up the output.
Milliampere (mA)
One thousandth of an ampere.
Overshoot
The amount by which a process v ariable exceeds the set point before it stabilizes.
N
Noise
Unwanted electrical signals that usually produce signal interference in sensors and sensor circuits. See also Electromagnetic Interference.
P
PID
Proportional, Inte gral, Deri vative. A control mode with three functions: Proportional action dampens the system response, inte gral corrects for droops, and derivative prevents overshoot and undershoot.
Noise Suppression
The use of components to reduce electrical interfer ence that is caused by making or breaking electrical contact, or by inductors.
Polarity
The electrical quality of ha ving tw o opposite poles, one positive and one negative. Polarity determines the direction in which a current tends to fl w.
O
Object
An object is a softw are programming concept in which data and functionality are associated with vir tual objects. DeviceNet objects consists of data called attributes and functions called services. Services are used to examine or change attribute values.
Process Input
A v oltage or current input that represents a straight line function.
Process Variable (PV)
The parameter that is controlled or measured. Typical examples are temperature, relative humidity, pressure, fl w, fluid l vel, events, etc.
Offset
The difference between the set point and the actual value of the process variable. Offset is the error in the process v ariable that is typical of proportional-only control.
Doc. 0600-3120-2000
Proportional (P)
Output effort proportional to the error from set point.
For example, if the proportional band is 20° and the process is 10° belo w the set point, the heat propor tioned effort is 50 percent. The lower the PB v alue, the higher the gain.
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Glossary Series D8 User’s Guide
Proportional Band (PB)
A range in which the proportioning function of the control is acti ve. Expressed in units, de grees or per cent of span. See also PID.
Proportional Control
A control using only the P (proportional) value of PID control.
Pulse Input
Digital pulse signals from de vices, such as optical encoders.
PV
See Process Variable.
R
Ramp
A programmed increase in the temperature of a set point system.
Range
The area between tw o limits in which a quantity or value is measured. It is usually described in terms of lower and upper limits.
Recipe
See Job.
Relay
A switching device.
Electromechanical Relay
—
A power switching device that completes or interrupts a circuit by physically mo ving electrical contacts into contact with each other. Not recommended for PID control.
Solid State Relay (SSR)
— A switching de vice with no moving parts that completes or interrupts a circuit electrically.
Reset
See Automatic Reset, Manual Reset.
Resistance
Opposition to the fl w of electric current, measured in
Ohms.
Resistance Temperature Detector (RTD)
A sensor that uses the resistance temperature characteristic to measure temperature. There are tw o 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 R TD is a positi ve temperature coef ficient sensor onl , while the ther mistor can have either a negative or positive temperature coefficient
Reverse Action
An output control action in which an increase in the process variable causes a decrease in the 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 o ver a single communication channel.
Set Point (SP)
The desired v alue of the process v ariable. For example, the temperature at which a system is to be maintained.
Shield
A metallic foil or braided wire layer surrounding conductors that is designed to pre vent electrostatic 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 limits of a range expressed in the same units as the range.
Stability
The ability of a de vice to maintain a constant output with the application of a constant input.
T
Thermistor
A temperature-sensing device made of semiconductor material that exhibits a large change in resistance for a small change in temperature. Thermistors usually have negative temperature coefficients, although th y are also a vailable with positi ve temperature coef fi cients.
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Series D8 User’s Guide
Thermocouple (T/C)
A temperature sensing de vice made by joining tw o dissimilar metals. This junction produces an electrical voltage in proportion to the dif ference in temperature between the hot junction (sensing junction) and the lead wire connection to the instrument (cold junction).
Thermocouple Extension Wire
A grade of wire used between the measuring junction and the reference junction of a thermocouple. Extension wire and thermocouple wire have similar properties, but extension wire is less costly.
Transmitter
A device that transmits temperature data from either a thermocouple or RTD by way of a two-wire loop. The loop has an e xternal po wer supply . The transmitter acts as a variable resistor with respect to its input signal. Transmitters are desirable when long lead or extension wires produce unacceptable signal degradation.
U
Undershoot
The amount by which a process v ariable falls below the set point before it stabilizes.
V
Volt (V)
The unit of measure for electrical potential, voltage or electromotive force (EMF). See also Voltage.
Voltage (V)
The dif ference in electrical potential between tw o points in a circuit. It is the push or pressure behind current fl w through a circuit. One volt (V) is the difference in potential required to mo ve one coulomb of charge between two points in a circuit, consuming one joule of energy. In other w ords, one volt (V) is equal to one ampere of current (I) fl wing 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.
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Glossary
203
Glossary Series D8 User’s Guide
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Series D8 User’s Guide
Index
A
Address 61 see also Node Address
agency compliance
Alarm High Set Point 71, 96, 143
Alarm Low Set Point 71, 96, 146
alarms
alarm high, see process alarms alarm low, see process alarms
deadband, see alarms:hysteresis
failed sensor, see failed sensor alarms
global alarm output 36, 37, 97
messages 82 process, see process alarms
status through communications 154
thermocouple, see failed sensor alarms
ambient temperature
Ambient Sensor Reading 76, 155
H/W failure: Ambient alarm 165
analog inputs, see sensor inputs
analog output 119 see also Dual DAC or Serial DAC
auto message on loop display 80
automatic mode
restoring after failed sensor repair 95
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Index
setting 85 autotuning 85, 91–93, 122
B battery
C cables
Cascade High Set Point 75, 149
Clear RAM? message 169 clearing RAM 169
communications
on/off 112 proportional (P) 112, 117
proportional with integral (PI) 113, 117
proportional, integral and derivative (PID) 114, 117
control mode
unexpected switch from automatic to manual 162
control algorithms, see control algorithms
distributed zero crossing 119, 139
Watlow Anafaze 205
Index Series D8 User’s Guide
controller
troubleshooting, see troubleshooting
cool message on loop display 80
Cool Output Retransmit 73, 148
cool output, see control outputs
Cool Proportional Band 70, 136
Cool Retransmit High Process Variable 73, 148
Cool Retransmit Low Process Variable 73, 148
current inputs
scaling resistors 30, 173 wiring 30 see also process inputs
D
D/O alarm polarity parameter 76, 97, 129
DAC, see Dual DAC or Serial DAC
Data rate swtich, see also
default settings, restoring 169
derivative
guidelines for setting 116–117
settings from other controllers 116 term versus rate settings 116
deviation alarms, see process alarms
DeviceNet 40–44, 45–76, 121–156, 179
206
differential control, see ratio control
digital inputs
restoring automatic control after sensor failure 138
Digital Output Alarm Polarity 129
digital outputs
dimensions
direct action, see control outputs
display 80–83 control modes 80
process variable not correct 161, 166
toggling between loop and job displays 83
distributed zero crossing 119, 139
Dual DAC
specification 191–192 weight 191
DZC, see distributed zero crossing
E
Electronic Data Sheet, see EDS
Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Index
ESD, see electrostatic discharge
explicit messages 53, 55–58, 66, 68
F
failed sensor alarms
output power if sensor alarm occurs 142
restoring automatic control after sensor repair 95, 138
thermocouple open 94, 142 thermocouple reversed 94, 133 thermocouple short 94
filte
firm are
flash memor , replacing 170–171
G
Global object 125–129, 152, 153
troubleshooting 167 grounding, troubleshooting 167
H
heat message on loop display 80
Heat Output Retransmit 73, 148
heat output, see control outputs
Heat Proportional Band 70, 136
Heat Retransmit High Process Variable 73, 148
Heat Retransmit Low Process Variable 73, 148
Doc. 0600-3120-2000
Heat/Cool Output Action for Watchdog Inactivity Fault 69
high deviation alarm, see process alarms
High Deviation Value 71, 97, 145
humidity specificatio
hysteresis
I
input data 45, 51, 52, 53, 64, 65
inputs
scaling 88–91 scaling parameters 88–91, 134, 135
sensor inputs wiring 27–30 sensor, see sensor inputs
thermocouple, see thermocouples
ground loops, see ground loops
panel hole dimensions 14 panel thickness 14
Watlow Anafaze 207
Index
wire sizes
instance 57, 61, 67, 68, 70, 71, 72, 73, 74, 75
integral
guidelines for setting 116–117
settings from other controllers 116
term versus reset settings 115
J
jobs
jumpers
K keypad
L
loops
low deviation alarm, see process alarms
Low Deviation Value 71, 97, 145
M
MAC ID (see also
man message on loop display 80
manual mode
during a failed sensor alarm 142 during a mode override 142 during a thermocouple open alarm 142
if ambient temperature is out of range 155
208
Series D8 User’s Guide
menus
Mode Override Digital Input Active 76, 127–128
Model and Firmware Version parameter 131
model number
Module LED parameter (see also Module status indicator) 130
Module Status Indicator 6, 23, 40, 41, 44, 130, 162
N
Network LED parameter (see also Network status indicator) 130
Network Status Indicator 6, 23, 40, 41, 44, 130
noise
reducing with zero-cross switching 119
O on/off control
Open Thermocouple Cool Output Average 69
Open Thermocouple Heat Output Average 69, 94, 142
output power
outputs
analog, see Dual DAC or Serial DAC
Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide Index
process variable retransmit, see process variable retransmit
reference voltage, see reference voltage
over-temperature shutdown devices 8
P
parameters
editing
process variable retransmit 148
restoring all default settings 169
PID
derivative constant, see derivative integral term, see integral
proportional band, see proportional band
settings for various applications 117
settings from other controllers 116
transmitting process data to 98
polled I/O 45, 47, 50, 51–53, 54, 64, 66
power supply
dimensions of mounting bracket 18
specification 189–190 weight 189
Predefined Master/Sl ve Connection Set 60
alarm high 96 alarm low 96 boost output 96
function 96 high deviation 96 low deviation 96
process inputs
Doc. 0600-3120-2000 Watlow Anafaze
process variable
not displayed correctly 21, 161, 166
retransmit, see process variable retransmit process variable retransmit 97–100
Programmable Logic Controller, see PLC
proportional band
guidelines for setting 115–117
settings for various temperature ranges 115
settings from other controllers 116
R
RAM
erasure of during flash memory replacemen 170
application example
remote analog set point 107–109
Ratio Set Point Differential 74, 151
Ref terminals, see reference voltage reference voltage 30
remote analog set point, see ratio control
repair, returning controller for 158
Restore Automatic Mode 71, 95, 138
retransmit, see process variable retransmit
reverse action, see control outputs
Reverse Thermocouple Detection 68
Reversed Thermocouple Detect 94, 133
RTD
209
Index
S safety
symbols and signal words in this manual 2
scaling resistors
for current inputs 30, 173 for RTD inputs 30, 175
scanner 49, 50, 51, 52, 53, 54, 55, 57
Sensor Fail Cool Output 69, 142
reversed thermocouple detection 133
Sensor Fail Heat Output 69, 142
reversed thermocouple detection 133
sensor inputs
calibration offset 132 engineering units 132
Serial DAC
agency compliance 194 clock input 194
configuring the controller outpu 139
process variable retransmit 98
specification 193–195 weight 193
set point
remote analog set point 107–109
using cascade control to set 100–104
using differential control to set 106–107
using ratio control to set 104–109
solid-state relays
5 Vdc power from controller 188
troubleshooting controller connections 168
210
Series D8 User’s Guide
system alarms
T
TB18
temperature
operating 179, 189, 191, 193 storage 179, 189, 191, 193
terminal specification
testing
TB50 after installation 26 see also troubleshooting
thermistor inputs, scaling resistors for 175
Thermocouple Short Alarm 76, 94, 129
thermocouples
manual mode if break occurs 142
torque, see terminal specification
Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide
all loops are set to manual 0% 162
control mode switches unexpectedly 162
H/W failure: Ambient alarm 165
process variable incorrect on display 161, 166
tun message on loop display 80, 93
U
under-temperature shutdown devices 8
V voltage inputs
scaling resistors 30, 174 wiring 30
W
weight
Z
Doc. 0600-3120-2000 Watlow Anafaze
Index
211
Index Series D8 User’s Guide
212 Watlow Anafaze Doc. 0600-3120-2000
Menu Structure
Global setup
Load setup from job
Save setup as job
BCD job load
BCD job load logic
Mode override
Mode override D/I active
Power up alarm delay
Power up loop mode
Keypad lock
TC short alarm
AC line freq
D/O alarm polarity
MAC ID
Baud rate
Module LED
Network LED
Bus off count
WATLOW D8x Vx.xx cs=xxxx
Input
Input type
Loop name
Input units
Input pulse sample
Calibration offset
Reversed T/C detect
Disp format
Input range high
Input high signal
Input range low
Input low signal
Input filter
Control
Heat prop band
Heat integral
Heat derivative
Heat manual reset
Heat filter
Cool prop band
Cool integral
Cool derivative
Cool manual reset
Cool filter
Hysteresis
RestoreAuto
Output
Heat output type
Heat cycle time
Heat SDAC signal
Ht SDAC low signal
Ht SDAC hi signal
Heat action
Heat power limit
HtPwr limit time
Sensor fail heat output
Open T/C ht out average
Heat output curve
Cool output type
Cool cycle time
Cool SDAC signal
Cl SDAC low signal
Cl SDAC hi signal
Cool action
Cool power limit
ClPwr limit time
Sensor fail cool output
Open T/C cl out average
Cool output curve
Alarms
Alarm high SP
Alarm high func
Alarm high output
HiDeviation value
HiDeviation func
HiDeviation output
LoDeviation value
LoDeviation func
LoDeviation output
Alarm low SP
Alarm low func
Alarm low output
Alarm hysteresis
Alarm delay
PV retrans
Heat output retrans PV
Ht retrans LowPV
Ht retrans HighPV
Cool output retrans PV
Cl retrans LowPV
Cl retrans HighPV
Cascade
Cascade prim loop
Cascade low SP
Cascade hi SP
Ratio
Ratio master loop
Ratio low SP
Ratio high SP
Control ratio
Ratio SP diff
I/O tests
Digital inputs
Keypad test
Display test
Test D/O 1
...
Test D/O 20
Doc. 0600-3120-2000 Watlow Anafaze 213
214 Watlow Anafaze Doc. 0600-3120-2000
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