CLS200 Series User's Guide

CLS200 Series User's Guide
CLS200 Series
User’s Guide
Watlow
1241 Bundy Boulevard
Winona, MN 55987
Customer Service:
Phone........1-800-414-4299
Fax.............1-800-445-8992
Technical Support:
Phone........+1 (507) 494-5656
Fax ............+1 (507) 452-4507
Email [email protected]
Part No. 0600-3050-2000 Rev. A
November 2008
Copyright © 1998-2003, Watlow Anafaze
Information in this manual is subject to change without notice. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form
without written permission from Watlow Anafaze.
Warranty
Watlow Anafaze, Incorporated warrants that the products furnished under this Agreement will be free from defects in material and workmanship for a period of three years
from the date of shipment. The Customer shall provide notice of any defect to Watlow
Anafaze, Incorporated within one week after the Customer's discovery of such defect.
The sole obligation and liability of Watlow Anafaze, Incorporated under this warranty
shall be to repair or replace, at its option and without cost to the Customer, the defective product or part.
Upon request by Watlow Anafaze, Incorporated, the product or part claimed to be
defective shall immediately be returned at the Customer's expense to Watlow Anafaze,
Incorporated. Replaced or repaired products or parts will be shipped to the Customer
at the expense of Watlow Anafaze, Incorporated.
There shall be no warranty or liability for any products or parts that have been subject to misuse, accident, negligence, failure of electric power or modification by the
Customer without the written approval of Watlow Anafaze, Incorporated. Final determination of warranty eligibility shall be made by Watlow Anafaze, Incorporated. If a
warranty claim is considered invalid for any reason, the Customer will be charged for
services performed and expenses incurred by Watlow Anafaze, Incorporated in handling and shipping the returned unit.
If replacement parts are supplied or repairs made during the original warranty
period, the warranty period for the replacement or repaired part shall terminate with
the termination of the warranty period of the original product or part.
The foregoing warranty constitutes the sole liability of Watlow Anafaze, Incorporated
and the Customer's sole remedy with respect to the products. It is in lieu of all other
warranties, liabilities, and remedies. Except as thus provided, Watlow Anafaze, Inc.
disclaims all warranties, express or implied, including any warranty of merchantability or fitness for a particular purpose.
Please Note: External safety devices must be used with this equipment.
Table of Contents
List of Figures xi
List of Tables xv
1 System Overview 1
Manual Contents 1
Getting Started 2
Safety Symbols 2
Initial Inspection 2
Product Features 3
CLS200 Parts List 5
Technical Description 7
CLS200 7
TB50 8
CLS200 Cabling 9
Safety 9
External Safety Devices 9
Power-Fail Protection 10
2 Installation 11
Typical Installation 12
Mounting Controller Components 12
Recommended Tools 13
Mounting the Controller 13
Mounting the TB50 16
Mounting the Power Supply 18
Mounting the Dual DAC or Serial DAC Module 19
System Wiring 21
Wiring Recommendations 21
Noise Suppression 22
Ground Loops 24
Power Connections 25
Wiring the Power Supply 25
Connecting TB50 to CLS200 27
Testing Your System 28
TB50 or TB18 Test 28
Digital Output Test 28
Digital Input Test 29
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Sensor Wiring 29
Input Wiring Recommendations 30
Thermocouple Connections 31
RTD Input Connections 32
Reference Voltage Terminals 32
Voltage Input Connections 32
Current Input Connections 33
Pulse Input Connections 34
Wiring Control and Digital I/O 35
Output Wiring Recommendations 35
Cable Tie Wraps 35
Digital Outputs 35
Digital Inputs 38
TB18 Connections (CLS204 and CLS208 Only) 40
TB50 Connections 41
Analog Outputs 43
Wiring the Dual DAC 43
Wiring the Serial DAC 44
Serial Communications 45
EIA/TIA-232 Interface 45
EIA/TIA-485 Interface 47
EIA/TIA-485 Converters and Laptop Computers 49
3 Using the CLS200 51
Front Panel 52
Front Panel Keys 53
Displays 55
Bar Graph Display 55
Single Loop Display 57
Alarm Displays 58
System Alarms 60
Job Display 60
Changing the Setpoint 61
Selecting the Control Status 61
Manual and Automatic Control 61
Autotuning a Loop 62
Using Alarms 64
Alarm Delay 64
Failed Sensor Alarms 65
Process Alarms 66
Global Alarm 68
Ramp/Soak 69
4 Setup 71
How to Access the Setup Menus 71
How to Change a Parameter 72
Setup Global Parameters Menu 74
Load Setup From Job 75
Save Setup to Job 75
Job Select Digital Inputs 76
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Job Select Digital Inputs Active 77
Output Override Digital Input 77
Override Digital Input Active 77
Startup Alarm Delay 78
Keyboard Lock Status 78
Power Up Output Status 78
Process Power Digital Input 79
Controller Address 79
Communications Baud Rate 80
Communications Protocol 80
Communications Error Checking 80
AC Line Frequency 81
Digital Output Polarity on Alarm 81
EPROM Information 81
Setup Loop Input Menu 82
Input Type 83
Loop Name 84
Input Units 84
Input Reading Offset 84
Reversed T/C Detection 85
Input Pulse Sample Time 85
Linear Scaling Parameters 86
Input Filter 89
Setup Loop Control Parameters Menu 90
Heat or Cool Control PB 91
Heat or Cool Control TI 91
Heat or Cool Control TD 91
Heat or Cool Output Filter 91
Spread 92
Restore PID Digital Input 92
Setup Loop Outputs Menu 93
Enable or Disable Heat or Cool Outputs 94
Heat or Cool Output Type 94
Heat or Cool Cycle Time 95
SDAC Mode 95
SDAC Low Value 95
SDAC High Value 95
Heat or Cool Output Action 96
Heat or Cool Output Limit 96
Heat or Cool Output Limit Time 96
Sensor Fail Heat or Cool Output 97
Heat or Cool Thermocouple Break Output Average 97
Heat or Cool Linearity 98
Setup Loop Alarms Menu 99
High Process Alarm Setpoint 100
High Process Alarm Type 100
High Process Alarm Output Number 100
Deviation Alarm Value 100
High Deviation Alarm Type 101
High Deviation Alarm Output Number 101
Low Deviation Alarm Type 101
Low Deviation Alarm Output Number 101
Low Process Alarm Setpoint 102
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Low Process Alarm Type 102
Low Process Alarm Output Number 102
Alarm Deadband 102
Alarm Delay 103
Manual I/O Test 103
Digital Inputs 103
Test Digital Output 104
Digital Output Number 104
Keypad Test 105
Display Test 105
5 Extruder Control 107
Setup Loop Outputs Menu 107
Cool Output Nonlinear Output Curve 107
Defaults 108
Extruder Control Algorithm 110
6 Enhanced Features 111
Process Variable Retransmit 113
Setup Loop Process Variable Retransmit Menu 113
Process Variable Retransmit Example: Data Logging 115
Cascade Control 118
Setup Loop Cascade Menu 119
Cascade Control Example: Water Tank 121
Ratio Control 124
Setup Loop Ratio Control Menu 125
Ratio Control Example: Diluting KOH 126
Remote Analog Setpoint 129
Remote Analog Setpoint Example: Setting a Setpoint with a PLC 129
Differential Control 131
Differential Control Example: Thermoforming 131
7 Ramp/Soak 133
Features 134
Ramp/Soak Menus 136
Setup Global Parameters Menu 137
Ramp/Soak Time Base 137
Setup Ramp/Soak Profile Menu 137
Edit Ramp/Soak Profile 137
Copy Setup From Profile 138
Tolerance Alarm Time 138
Ready Segment Setpoint 138
Ready Segment Edit Events 139
External Reset Input Number 139
Edit Segment Number 140
Segment Time 140
Segment Setpoint 140
Edit Segment Events 141
Edit Segment Triggers 142
Segment Tolerance 143
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Table of Contents
Last Segment 144
Repeat Cycles 144
Setpoints and Tolerances for Various Input Types 144
Using Ramp/Soak 145
Ramp/Soak Displays 146
Assigning a Profile to a Loop 148
Running a Profile 148
Holding a Profile or Continuing from Hold 150
Responding to a Tolerance Alarm 151
Resetting a Profile 151
In Case of a Power Failure 152
8 Tuning and Control 153
Control Algorithms 153
On/Off Control 154
Proportional Control 154
Proportional and Integral Control 155
Proportional, Integral and Derivative Control 155
Heat and Cool Outputs 156
Control Outputs 157
Output Control Signals 157
Output Filter 158
Reverse and Direct Action 159
Setting Up and Tuning PID Loops 159
Proportional Band (PB) Settings 159
Integral Settings 160
Derivative Settings 160
General PID Constants by Application 161
Proportional Band Only (P) 161
Proportional with Integral (PI) 161
PI with Derivative (PID) 161
9 Troubleshooting and Reconfiguring 163
When There is a Problem 163
Returning Your Unit 164
Troubleshooting Controllers 164
Process and Deviation Alarms 164
Failed Sensor Alarms 166
System Alarms 166
Other Behaviors 167
Corrective and Diagnostic Procedures 168
Low Power 168
Battery Dead 168
Ambient Warning 168
H/W Ambient Failure 169
H/W Gain or Offset Failure 170
Keys Do Not Respond 170
Checking Analog Inputs 171
Earth Grounding 172
Checking Control Outputs 172
Testing Control Output Devices 173
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Testing the TB18 and TB50 173
Testing Control and Digital Outputs 173
Testing Digital Inputs 173
Additional Troubleshooting for Computer Supervised Systems 174
Computer Problems 174
Communications 175
Ground Loops 175
Software Problems 176
NO-Key Reset 176
Replacing the EPROM 176
Changing Communications 179
Installing Scaling Resistors 180
CLS204 and CLS208 Input Circuit 180
CLS204 and CLS208 Current Inputs 181
CLS204 and CLS208 Voltage Inputs 182
CLS204 and CLS208 RTDs and Thermistors 183
CLS216 Input Circuit 184
CLS216 Current Inputs 184
CLS216 Voltage Inputs 185
Scaling and Calibration 186
Configuring Dual DAC Outputs 186
Configuring Serial DAC Outputs 188
10 Linear Scaling Examples 189
Example 1: A 4-to-20 mA Sensor 189
Example 2: A 0-to-5VÎ (dc) Sensor 191
Example 3: A Pulse Encoder 192
11 Specifications 193
CLS200 System Specifications 193
CLS200 Processor Physical Specifications 194
TB50 Physical Specifications 196
Inputs 200
Outputs 202
CLS200 Power Supply 205
Dual DAC Specifications 207
Dual DAC Inputs 208
Dual DAC Analog Outputs 208
Serial DAC Specifications 209
Serial DAC Inputs 210
Serial DAC Analog Outputs 211
Glossary 213
Index 221
Menu Structure 233
Declaration of Conformity 234
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List of Figures
1 System Overview
Figure 1.1—CLS200 Part Numbering 5
Figure 1.2—CLS200 Special Inputs Parts List
Figure 1.3—CLS200 Rear Views 7
Figure 1.4—CLS200 Front Panel 8
Figure 1.5—TB50 8
6
2 Installation
Figure 2.1—CLS200 System Components 12
Figure 2.2—Clearance with Straight SCSI Cable 14
Figure 2.3—Clearance with Right-Angle SCSI Cable 14
Figure 2.4—Wiring Clearances 15
Figure 2.5—Mounting Bracket 16
Figure 2.6—Mounting the TB50 16
Figure 2.7—TB50 Mounted on a DIN Rail (Front) 17
Figure 2.8—TB50 Mounted on DIN Rail (Side) 17
Figure 2.9—Mounting a TB50 with Standoffs 18
Figure 2.10—CLS200 Power Supply Mounting Bracket 19
Figure 2.11—Dual DAC and Serial DAC Dimensions 20
Figure 2.12—CLS200 Series Controller with TB18 25
Figure 2.13—CLS200 Series Controller with TB50 25
Figure 2.14—Power Connections with the CLS200 Power Supply 27
Figure 2.15—CLS200 Connector Locations 30
Figure 2.16—Thermocouple Connections 31
Figure 2.17—RTD Connections to CLS204 or CLS208 32
Figure 2.18—Linear Voltage Signal Connections 33
Figure 2.19—Linear Current Signal Connections 33
Figure 2.20—Encoder with 5VÎ (dc) TTL Signal 34
Figure 2.21—Encoder Input with Voltage Divider 34
Figure 2.22—Digital Output Wiring 36
Figure 2.23—Sample Heat, Cool and Alarm Output Connections 37
Figure 2.24—Output Connections Using External Power Supply 38
Figure 2.25—TB50 Watchdog Timer Output 38
Figure 2.26—TB18 Watchdog Timer Output 38
Figure 2.27—Wiring Digital Inputs 39
Figure 2.28—Dual DAC with Current Output 43
Figure 2.29—Dual DAC with Voltage Output 44
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List of Figures
CLS200 Series User’s Guide
Figure 2.30—Single/Multiple Serial DACs 45
Figure 2.31—Connecting One CLS200 to a Computer Using EIA/TIA-232
Figure 2.32—EIA/TIA-485 Wiring 47
Figure 2.33—Recommended System Connections 48
46
3 Using the CLS200
Figure 3.1—Operator Displays 51
Figure 3.2—CLS200 Front Panel 52
Figure 3.3—Bar Graph Display 55
Figure 3.4—Single Loop Display 57
Figure 3.5—Single Loop Display, Heat and Cool Outputs Enabled
Figure 3.6—Single Loop Display with a Process Alarm 58
Figure 3.7—Failed Sensor Alarm in the Single Loop Display 58
Figure 3.8—Alarm Symbols in the Bar Graph Display 58
Figure 3.9—Activation and Deactivation of Process Alarms 68
57
4 Setup
Figure 4.1—CLS200 Menu Tree 73
Figure 4.2—Two Points Determine Process Variable Conversion 86
Figure 4.3—Process Variable Limited by Input Reading Range 87
Figure 4.4—Linear and Nonlinear Outputs 98
Figure 4.5—Digital Inputs Screen 104
5 Extruder Control
Figure 5.1—Cool Output Nonlinear Output Curve
108
6 Enhanced Features
Figure 6.1—Enhanced Features Option Menus 112
Figure 6.2—Linear Scaling of Process Variable for Retransmit 115
Figure 6.3—Application Using Process Variable Retransmit 116
Figure 6.4—Relationship Between the Primary Loop’s Output and the Secondary
Loop’s Setpoint 119
Figure 6.5—Application Using Cascade Control 121
Figure 6.6—Secondary Loop Setpoint Related to Primary Loop Output 123
Figure 6.7—Relationship Between the Master Loop’s Process Variable and the Ratio
Loop’s Setpoint 124
Figure 6.8—Application Using Ratio Control 127
7 Ramp/Soak
Figure 7.1—Sample Ramp/Soak Profile 133
Figure 7.2—Setup Ramp/Soak Profiles Menu 136
Figure 7.3—Positive and Negative Tolerances 143
Figure 7.4—Ramp/Soak Screens 145
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List of Figures
8 Tuning and Control
Figure 8.1—On/Off Control 154
Figure 8.2—Proportional Control 155
Figure 8.3—Proportional and Integral Control 155
Figure 8.4—Proportional, Integral and Derivative Control 156
Figure 8.5—Time Proportioning and Distributed Zero Crossing Waveforms
157
9 Troubleshooting and Reconfiguring
Figure 9.1—Removal of Electronics Assembly from Case 177
Figure 9.2—Screws Locations on PC Board 178
Figure 9.3—EPROM Location 178
Figure 9.4—Remove EPROM 178
Figure 9.5—Jumper Configurations 179
Figure 9.6—CLS204 and CLS208 Input Circuit 181
Figure 9.7—CLS216 Input Circuit 184
Figure 9.8—Dual DAC 187
Figure 9.9—Serial DAC Voltage/Current Jumper Positions 188
11 Specifications
Figure 11.1—CLS200 Processor Module Dimensions 194
Figure 11.2—CLS200 Clearances with Straight SCSI Cable 195
Figure 11.3—CLS200 Clearances with Right-Angle SCSI Cable 195
Figure 11.4—TB50 Dimensions 197
Figure 11.5—TB50 Dimensions with Straight SCSI Cable 198
Figure 11.6—TB50 Dimensions with Right-Angle SCSI Cable 199
Figure 11.7—Power Supply Dimensions (Bottom View) 206
Figure 11.8—Dual DAC Dimensions 207
Figure 11.9—Serial DAC Dimensions 209
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List of Tables
2 Installation
Table 2.1—Cable Recommendations 22
Table 2.2—Power Connections 26
Table 2.3—Digital Output States and Values Stored in the Controller 36
Table 2.4—Digital Inputs States and Values Stored in the Controller 39
Table 2.5—TB18 Connections 40
Table 2.6—TB50 Connections for CLS204 and CLS208 41
Table 2.7—TB50 Connections for CLS216 42
Table 2.8—EIA/TIA-232 Connections 46
Table 2.9—RTS/CTS Pins in DB-9 and DB-25 Connectors 46
3 Using the CLS200
Table 3.1—Bar Graph Display Symbols 55
Table 3.2—Control Status Symbols on the Bar Graph and Single Loop Displays
Table 3.3—Alarm Type and Symbols 59
56
4 Setup
Table 4.1—Global Parameters 74
Table 4.2—Job Select Inputs 76
Table 4.3—Job Selected for Various Input States 76
Table 4.4—Firmware Option Codes 81
Table 4.5—Setup Loop Input 82
Table 4.6—CLS200 Input Types and Ranges 83
Table 4.7—Input Character Sets 84
Table 4.8—Input Reading Offset 85
Table 4.9—Display Formats 87
Table 4.10—Setup Loop Control Parameters 90
Table 4.11—Setup Loop Outputs 93
Table 4.12—Heat / Cool Output Types 94
Table 4.13—Setup Loop Alarms 99
Table 4.14—Manual I/O Test 103
5 Extruder Control
Table 5.1—Default Control Parameters for Fan Cool Output 109
Table 5.2—Default Control Parameters for Oil Cool Output 109
Table 5.3—Default Control Parameters for H2O Cool Output 109
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List of Tables
CLS200 Series User’s Guide
6 Enhanced Features
Table 6.1—Application Example: Setting Up Process Variable Retransmit
Table 6.2—Application Example: Setting Up Cascade Control 122
Table 6.3—Application Example: Setting Up Ratio Control 128
Table 6.4—Application Example: Setting Up Remote Setpoint 130
Table 6.5—Application Example: Setting Up Differential Control 132
117
7 Ramp/Soak
Table 7.1—Ramp/Soak Specifications 135
Table 7.2—Trigger Latch Logic 143
Table 7.3—Display Formats 145
Table 7.4—Ramp/Soak Single Loop Display 146
Table 7.5—Ramp/Soak Control Status Symbols 147
Table 7.6—Ramp/Soak Profile Modes 150
8 Tuning and Control
Table 8.1—Proportional Band Settings 159
Table 8.2—Integral Term and Reset Settings 160
Table 8.3—Derivative Term Versus Rate 160
Table 8.4—General PID Constants 162
9 Troubleshooting and Reconfiguring
Table 9.1—Controller Alarm Codes for Process and Deviation Alarms 164
Table 9.2—Operator Response to Alarms 165
Table 9.3—Failed Sensor Alarm Codes 166
Table 9.4—Hardware Error Messages 166
Table 9.5—Other Symptoms 167
Table 9.6—Resistor Values for CLS204 and CLS208 Current Inputs 181
Table 9.7—Resistor Locations for CLS204 and CLS208 Current Inputs 181
Table 9.8—Resistor Values for CLS204 and CLS208 Voltage Inputs 182
Table 9.9—Resistor Locations for CLS204 and CLS208 Voltage Inputs 182
Table 9.10—Resistor Values for CLS204/208 RTD and Thermistor Inputs 183
Table 9.11—Resistor Locations for CLS204/208 RTD and Thermistor Inputs 183
Table 9.12—Resistor Values for CLS216 Current Inputs 184
Table 9.13—Resistor Locations for CLS216 Current Inputs 185
Table 9.14—Resistor Values for CLS216 Voltage Inputs 185
Table 9.15—Resistor Locations for CLS216 Voltage Inputs 186
Table 9.16—Dual DAC Jumper Settings 187
10 Linear Scaling Examples
Table 10.1—Input Readings 190
Table 10.2—Scaling Values 190
Table 10.3—Input Readings and Calculations
Table 10.4—Scaling Values 191
Table 10.5—Scaling Values 192
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List of Tables
11 Specifications
Table 11.1—Agency Approvals / Compliance 193
Table 11.2—Environmental Specifications 194
Table 11.3—Physical Dimensions 194
Table 11.4—Processor with Straight SCSI 195
Table 11.5—Processor with Right Angle SCSI 195
Table 11.6—Processor Connections 196
Table 11.7—TB50 Physical Dimensions 196
Table 11.8—TB50 Connections 197
Table 11.9—TB50 with Straight SCSI 198
Table 11.10—TB50 with Right Angle SCSI 199
Table 11.11—Analog Inputs 200
Table 11.12—Pulse Inputs 201
Table 11.13—Thermocouple Range and Resolution 201
Table 11.14—RTD Range and Resolution 201
Table 11.15—Input Resistance for Voltage Inputs 202
Table 11.16—Digital Inputs 202
Table 11.17—Digital Outputs Control / Alarm 203
Table 11.18—CPU Watchdog Output 203
Table 11.19—5VÎ (dc) Output (Power to Operate Solid-State Relays) 204
Table 11.20—Reference Voltage Output (Power to Operate Bridge Circuit
Sensors) 204
Table 11.21—Processor Serial Interface 204
Table 11.22—Processor Power Requirements 204
Table 11.23—Power Supply Environmental Specifications 205
Table 11.24—Power Supply Agency Approvals / Compliance 205
Table 11.25—Power Supply Physical Specifications 205
Table 11.26—Power Supply with Mounting Bracket 205
Table 11.27—Power Supply Inputs 206
Table 11.28—Power Supply Outputs 206
Table 11.29—Dual DAC Environmental Specifications 207
Table 11.30—Dual DAC Physical Specifications 207
Table 11.31—Dual DAC Power Requirements 208
Table 11.32—Dual DAC Specifications by Output Range 208
Table 11.33—Serial DAC Environmental Specifications 209
Table 11.34—Serial DAC Physical Specifications 209
Table 11.35—Serial DAC Agency Approvals / Compliance 210
Table 11.36—Serial DAC Inputs 210
Table 11.37—Serial DAC Power Requirements 210
Table 11.38—Serial DAC Analog Output Specifications 211
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1
System Overview
Manual Contents
This manual describes how to install, set up, and operate a
CLS204, CLS208 or CLS216 controller. Each chapter covers a different aspect of your control system and may apply
to different users:
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Doc.# 0600-3050-2000
Chapter 1: System Overview provides a component
list and summary of features for the CLS200 series
controllers.
Chapter 2: Installation provides detailed instructions on installing the CLS200 series controller and its
peripherals.
Chapter 3: Using the CLS200 provides an overview
of operator displays used for system monitoring and
job selection.
Chapter 4: Setup provides detailed descriptions of
all menus and parameters for controller setup.
Chapter 5: Extruder Control explains the additional features of a CLS200 controller equipped with Extruder Control Firmware.
Chapter 6: Enhanced Features describes process
variable retransmit, ratio, differential and cascade
control features available with the enhanced features
option.
Chapter 7: Ramp/Soak explains how to set up and
use the features of the ramp/soak option.
Chapter 8: Tuning and Control describes available
control algorithms and provides suggestions for applications.
Chapter 9: Troubleshooting and Reconfiguring
includes troubleshooting, upgrading and reconfiguring procedures for technical personnel.
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Chapter 1: System Overview
CLS200 Series User’s Guide
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Chapter 10: Linear Scaling Examples provides an
example configuring a pressure sensor, a flow sensor,
and an encoder using linear scaling.
Chapter 11: Specifications lists detailed specifications of the controller and optional components.
Getting Started
The following sections provide information regarding product features, technical descriptions, safety requirements,
and preparation for operation.
Safety Symbols
These symbols are used throughout this manual:
WARNING! Indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury.
CAUTION!
NOTE!
Indicates a potentially hazardous situation
which, if not avoided, could result in minor or
moderate injury or property damage.
Indicates pertinent information or an item
that may be useful to document or label for
later reference.
Initial Inspection
Accessories may or may not be shipped in the same container as the CLS200, depending upon their size. Check the
shipping invoice carefully against the contents received in
all boxes.
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CLS200 Series User’s Guide
Chapter 1: System Overview
Product Features
The CLS200 series controllers provide 4, 8 or 16 fully independent control loops. When used as a stand-alone controller, you may operate the CLS200 via the two-line 16character display and touch keypad. You can also use it as
the key element in a computer-supervised data acquisition
and control system; the CLS200 can be locally or remotely
controlled via an EIA/TIA-232 or EIA/TIA-485 serial communications interface.
The CLS200 features include:
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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, process variable offset calibration to correct for
sensor inaccuracies, detection of broken, shorted or reversed thermocouples, and a choice of Fahrenheit or
Celsius display.
Accepts Resistive Temperature Detectors
(RTDs): Use 3-wire, 100 Ω, platinum, 0.00385-curve
sensors with two choices for range and precision of
measurements. (To use this input, order a CLS204 or
CLS208 controller with scaling resistors.)
Automatic Scaling for Linear Analog Inputs: The
CLS200 series automatically scales linear inputs used
with industrial process sensors. Enter two points, and
all input values are automatically scaled in your units.
Scaling resistors must be installed.
Dual Outputs: The CLS200 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: You can 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.
Control Outputs: Set high/low deviation and high/
low process limits to operate digital outputs as on/off
control functions or alarms.
Flexible Alarm Outputs: Independently set high/
low process alarms and a high/low deviation band
alarm for each loop. Alarms can activate a digital output by themselves, or they can be grouped with other
alarms to activate an output.
Global Alarm Output: When any alarm is triggered,
the global alarm output is also triggered, and it stays
on until you acknowledge it.
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Chapter 1: System Overview
CLS200 Series User’s Guide
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CPU Watchdog: The CLS200 series CPU watchdog
timer output notifies you of system failure. Use it to
hold a relay closed while the controller is running, so
you are notified if the microprocessor shuts down.
Front Panel or Computer Operation: Set up and
run the controller from the front panel or from a local
or remote computer. Watlow Anafaze offers WatView,
a Windows® compatible Human Machine Interface
(HMI) software package that includes data logging
and graphing features in addition to process monitoring and parameter setup screens.
Modbus RTU Protocol, EIA/TIA-232 and 485
Communications: Connect to PLCs, operator interface terminals and third-party software packages using the widely supported Modbus RTU protocol.
Multiple Job Storage: Store up to eight jobs in memory, and access them locally by entering a single job
number or remotely via digital inputs. Each job is a set
of operating conditions, including setpoints and
alarms.
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 CLS200 internal expert system table finds the correct PID parameters for
your process.
Pulse Counter Input: Use the pulse counter input
for precise control of motor or belt speed.
Low Power Shutdown: The controller shuts down
and turns off all outputs when it detects the input voltage drop below the minimum safe operating level.
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CLS200 Series User’s Guide
Chapter 1: System Overview
CLS200 Parts List
You may have received one or more of the following components. See Figure 2.1 on page 12 for CLS200 configuration
information.
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CLS200 series controller
Controller mounting kit
TB50 with 50-pin SCSI cable
EIA/TIA-232 or EIA/TIA-485 communications cable
Power supply with mounting bracket and screws
Serial DAC (digital-to-analog converter)
Special input resistors (installed in CLS200)
User’s guide
2_ _–_ _ _ _ _ _ ___
Number of Loops
04 = 4 loops
08 = 8 loops
16 = 16 loops
Controller Type
1 = Standard EPROM
2 = Extruder applications
3 = Ramp/soak option
4 = Enhanced features option (includes cascade, PV retransmit, ratio, remote setpoint)
Terminal Board
0 = No terminal board accessory
1 = 18-terminal block mounted on unit, no SCSI cable required
2 = 50-pin terminal board, includes 3 ft. SCSI cable
Power Supply
0 = No power supply
2 = 120/240VÅ (ac), 50/60Hz panel mount power supply adapter
(5VÎ [dc] @ 4A, 15VÎ [dc] @ 1.2A) CE approved
SCSI Cables (for use with 50-pin terminal board)
0 = No special SCSI cable (3 ft. cable is included with 50-pin terminal board)
1 = 6 ft. SCSI cable
2 = 3 ft. right angle SCSI cable
3 = 6 ft. right angle SCSI cable )
Communications Cables (For EIA/TIA-232 communications with computer)
0 = No communications cable
1 = 10 ft. (3.0 m) communications cable, DB-9 female/bare wire
2 = 25 ft. (7.6 m) communications cable, DB-9 female/bare wire
3 = 50 ft. (15.2 m) communications cable, DB-9 female/bare wire
Serial Communications Jumper Settings
0 = EIA/TIA-232
1 = EIA/TIA-485
2 = EIA/TIA-485 terminated
Special Inputs (one or two digits)
(Standard unit is conf gured for thermocouples and -10 to 60mV linear inputs.
For other sensors, special inputs are required.
00 = Thermocouples and -10 to 60mV inputs only
XX = Number of current and voltage inputs. RTDs are not available on the CLS216. Include
leading zero as needed.
Figure 1.1
Doc.# 0600-3050-2000
CLS200 Part Numbering
Watlow Anafaze
5
Chapter 1: System Overview
CLS200 Series User’s Guide
CLSSI _ _–_ _–_ _
If special inputs are ordered in the
controller part number, the following
is specified in the pa t description.
Special Input Type (Not required for thermocouple sensor inputs)
20 = RTD1: 0.1°, -100.0 to 275.0° C (-148.0 to 572.0° F) (Not available on CLS216)
21 = RTD2: 1°, -120.0 to 840.0° C (-184.0 to 1544.0° F) (Not available on CLS216)
43 = 0 to 10 mAÎ (dc)
44 = 0 to 20mAÎ (dc)/4 to 20mAÎ (dc)
50 = 0 to 100mVÎ (dc)
52 = 0 to 500mVÎ (dc)
53 = 0 to 1VÎ (dc)
55 = 0 to 5VÎ (dc)
56 = 0 to 10VÎ (dc)
57 = 0 to 12VÎ (dc)
Start Channel
XX = Channel number XX
End Channel
XX = Channel number XX
Note:
Make sure the number of special inputs specif ed is equal to
the number of special inputs in the controller part number.
Uninstalled kits are available.
Figure 1.2
6
CLS200 Special Inputs Parts List
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 1: System Overview
Technical Description
This section contains a technical description of each component of your CLS200 series controller.
CLS200
The CLS200 is housed in an 1/8-DIN panel mount package.
It contains the CPU, RAM with a built-in battery, EPROM,
serial communications, digital I/O, analog inputs, the
screen and touch keypad.
CLS200 Series
with SCSI Connector
CLS204 or CLS208
with TB18 Connector
Figure 1.3
CLS200 Rear Views
The CLS200 has the following features:
•
•
Keypad and 2-line 16-character display.
Screw terminals for the power and analog inputs and
communications.
•
Input power is 12 to 24VÎ (dc) at 1 Amp.
•
A 50-pin SCSI cable connects the digital inputs and
outputs to the 50-terminal block (TB50). The CLS204
and CLS208 are available with an 18-terminal block
(TB18) in place of the SCSI connector, as shown in Figure 1.3.
The firmware resides in an EPROM. See Replacing the
EPROM on page 176 for information on removing and replacing the EPROM.
The operating parameters are stored in battery-backed
RAM. If there is a power loss the operating parameters are
unchanged. The battery has a ten-year shelf life, and it is
not used when the unit is on.
The microprocessor performs all calculations for input signal linearization, PID control, alarms and communications.
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Chapter 1: System Overview
CLS200 Series User’s Guide
Front Panel Description
The display and touch keypad provide an intelligent way to
operate the controller. The display has 16 alphanumeric or
graphic characters per line. The 8-key keypad allows you to
change the operating parameters, controller functions, and
displays.
The information-packed displays show process variables,
setpoints, and output levels for each loop. A bar graph display, single loop display, scanning display and an alarm
display offer a real-time view of process conditions. Two access levels allow operator changes and supervisor changes.
WATLOW ANAFAZE CLS200
Figure 1.4
CLS200 Front Panel
TB50
The TB50 is a screw-terminal interface for control wiring
which allows you to connect relays, encoders and discrete I/
O devices to the CLS200. The screw terminal blocks accept
wires as large as 18 AWG (0.75 mm2). A 50-pin SCSI cable
connects the TB50 to the CLS200.
Figure 1.5
8
TB50
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 1: System Overview
CLS200 Cabling
Watlow Anafaze provides cables required to install your
CLS200. A 50-pin SCSI cable connects the TB50 to the
CLS200.
The optional cable used to connect the CLS200 to a computer using EIA/TIA-232 communications has a DB9 or DB25
connector for the computer and bare wires for connecting to
the CLS200.
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
The CLS200 controller may fail full-on (100% output power) or full-off (0% output power), or may remain full-on if an
undetected sensor failure occurs. For more information
about failed sensor alarms, see Failed Sensor Alarms on
page 65.
Design your system to be safe even if the controller sends a
0% or 100% output power signal at any time. Install independent, external safety devices that will shut down the
system if a failure occurs.
Typically, a shutdown device consists of an FM-approved
high/low process limit controller that operates a shutdown
device such as an mechanical contactor. The limit controller monitors for a hazardous condition such as an undertemperature 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% or 100% power
output state. To prevent death, personal injury, equipment damage or property damage,
install external safety shutdown devices. If
death or injury may occur, you must install
FM-approved safety shutdown devices that
operate independently from the process control equipment.
With proper approval and installation, thermal fuses may
be used in some processes.
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Watlow Anafaze
9
Chapter 1: System Overview
CLS200 Series User’s Guide
Power-Fail Protection
In the occurrence of a sudden loss of power, this controller
can be programmed to reset the control outputs to off (this
is the default). Typically, when power is re-started, the controller restarts to data stored in memory. If you have programmed the controller to restart with control outputs on,
the memory-based restart might create an unsafe process
condition for some installations. Therefore, you should only
set the restart with outputs on if you are certain your system will safely restart. (See the Process Power Digital Input on page 79).
When using a computer or host device, you can program the
software to automatically reload desired operating constants or process values on power-up. Keep in mind that
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.
10
Watlow Anafaze
Doc.# 0600-3050-2000
2
Installation
This chapter describes how to install the CLS200 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 (EIA/TIA-232 or EIA/TIA485)
Output wiring
WARNING! Risk of electric shock. Shut off power to your
entire process before you begin installation
of the controller.
WARNING! The controller may fail in a 0% or 100% power
output state. To prevent death, personal injury, equipment damage or property damage,
install external safety shutdown devices. If
failure may cause death or injury, you must
install FM-approved safety shutdown devices that operate independently from the process control equipment.
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11
Chapter 2: Installation
CLS200 Series 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 Figures 2.2 to 2.11.)
We recommend that you read this entire chapter first before beginning the installation procedure. This will help
you to carefully plan and assess the installation.
CLS200 with TB50
SCSI Cable
8 Digital Inputs,
35 Digital Outputs
(Control/Alarm)
Pulse Input
Signal Inputs
CLS200
Power supply
CLS200 with TB18
Signal Inputs
11 Digital Outputs (Control/Alarm)
2 Digital Inputs, 1 Digital/Pulse Input
Figure 2.1
CLS200
Power supply
CLS200 System Components
Mounting Controller Components
Install the controller in a location free from excessive heat
(more than 50º C [122° F]), dust, and unauthorized handling. Electromagnetic and radio frequency interference
can induce noise on sensor wiring. Select locations for the
CLS200 and TB50 such that wiring can be routed clear of
sources of interference such as high voltage wires, power
switching devices and motors.
NOTE!
12
For indoor use only.
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 2: Installation
WARNING! To reduce the risk of fire or electric shock, install the CLS200 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 in. (3 mm) flathead screwdriver for wiring
Multimeter
Mounting the Controller
Mount the controller before you mount the terminal block
or do any wiring. The controller’s placement affects placement and wiring considerations for the other components
of your system.
Ensure there is enough clearance for mounting brackets,
terminal blocks, and cable and wire connections; the controller extends up to 7.0 inches (178 mm) behind the panel
face and the screw brackets extend 0.5 inch (13 mm) above
and below it. If using a straight SCSI cable, allow for an additional 1.6 inches (41 mm) beyond the terminal block. If
using a right-angle SCSI cable, allow an additional 0.6 inch
(15 mm). (See Figure 2.2 and Figure 2.3.)
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13
Chapter 2: Installation
1.0 inch
(25 mm)
CLS200 Series User’s Guide
7.0 inches
(178 mm)
Figure 2.2
1.0 inch
(25 mm)
14
Clearance with Straight SCSI Cable
7.0 inches
(178 mm)
Figure 2.3
1.6 inch
(41 mm)
0.6 inch
(41 mm)
Clearance with Right-Angle SCSI
Cable
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 2: Installation
Maximum Panel Thickness
0.2 inch (5 mm)
1.80 ± 0.020 inch
(45.7 ± 0.5 mm)
3.63 ± 0.020 inches
(92.2 ± 0.5 mm)
Figure 2.4
Wiring Clearances
We recommend you mount the controller in a panel not
more than 0.2 in. (5 mm) thick.
Doc.# 0600-3050-2000
1.
Choose a panel location free from excessive heat (more
than 50° C [122° F]), dust, and unauthorized handling.
(Make sure there is adequate clearance for the mounting hardware, terminal blocks, and cables. The controller extends 7.40 in. (178 mm) behind the panel.
Allow for an additional 0.60 to 1.60 in. (15 to 41 mm)
beyond the connectors.)
2.
Temporarily cover any slots in the metal housing so
that dirt, metal filings, and pieces of wire do not enter
the housing and lodge in the electronics.
3.
Cut a hole in the panel 1.80 in. (46 mm) by 3.63 in. (92
mm) as shown below. (This picture is NOT a template;
it is for illustration only.) Use caution; the dimensions
given here have 0.02 in. (1 mm) tolerances.
4.
Remove the brackets and collar from the processor
module, if they are already in place.
5.
Slide the processor module into the panel cutout.
6.
Slide the mounting collar over the back of the processor module, making sure the mounting screw indentations face toward the back of the processor module.
Watlow Anafaze
15
CLS200 Series User’s Guide
Bracket (top and bottom)
24
22
20
18
16
14
12
10
8
6
4
2
Panel
26
Chapter 2: Installation
25
23
21
19
17
15
13
11
9
7
5
3
1
+
Bezel
Figure 2.5
Mounting Collar
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 processor module).
Push each bracket backward then to the side to secure
it to the processor module case.
8.
Make sure the case is seated properly. Tighten the 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.
Mounting the TB50
There are two ways you can mount the TB50: Use the preinstalled DIN rail mounting brackets or use the plastic
standoffs. Follow the corresponding procedures to mount
the board.
TB50
Mounted
with Standoffs
TB50
Mounted to
DIN Rail
Figure 2.6
16
Mounting the TB50
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 2: Installation
DIN Rail Mounting
Snap the TB50 on to the DIN rail by placing the hook side
on the rail first, then pushing the snap latch side in place.
(See Figure 2.7.)
Figure 2.7
TB50 Mounted on a DIN Rail (Front)
To remove the TB50 from the rail, use a flathead screwdriver to unsnap the bracket from the rail. (See Figure 2.8.)
Removal
catch for
screwdriver
DIN Rail
snap latch
Hook side
Figure 2.8
Doc.# 0600-3050-2000
TB50 Mounted on DIN Rail (Side)
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Chapter 2: Installation
CLS200 Series User’s Guide
Mounting with Standoffs
1.
Remove the DIN rail mounting brackets from the
TB50.
2.
Select a location with enough clearance to remove the
TB50, its SCSI cable and the controller itself.
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.
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)
0.7 in
(18 mm)
4 holes for
#6 (3.5 mm)
screws or bolts
3.4 in
(86 mm)
SCSI Connector
0.2 in
(5 mm)
Figure 2.9
3.6 in
(91 mm)
0.2 in
(5 mm)
Mounting a TB50 with Standoffs
Mounting the Power Supply
If you use your own power supply for the CLS200, refer to
the power supply manufacturer’s instructions for mounting
information. Choose a Class 2 power supply that supplies
an isolated regulated 12 to 24VÎ (dc) at 1 A.
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CLS200 Series User’s Guide
Chapter 2: Installation
Mounting Environment
Leave enough clearance around the power supply so that it
can be removed.
Two holes for #10 (5.0 mm) screws or bolts
0.3 inch
(8 mm)
1.4 inch
(36 mm)
7.5 inches
(191 mm)
8.1 inches
(206 mm)
0.7 inch
(18 mm)
Figure 2.10 CLS200 Power Supply Mounting
Bracket
Mounting Steps
CAUTION!
Use 6-32, 1/4-inch screws only. Longer
screws may extend too far into the power
supply and short to components, damaging
the power supply.
1.
Attach the bracket to the power supply using the
bracket’s two center holes.
2.
Select a location with enough clearance to remove the
power supply and bracket. (See Figure 2.10.)
3.
When a location has been determined for the power
supply, mark the bracket’s two outer holes for mounting.
4.
Drill and tap the two mounting holes. (The bracket
holes accept up to #10 [5.0 mm] screws.)
5.
Mount the power supply on the panel.
6.
Tighten the screws.
Mounting the Dual DAC or Serial DAC Module
This section describes how to install the optional Dual DAC
and Serial DAC digital-to-analog converters.
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Chapter 2: Installation
CLS200 Series User’s Guide
Installation
Installation of the Dual DAC and Serial DAC is essentially
the same. The main differences are in the dimensions and
the wiring. Follow this procedure to correctly install these
devices.
Jumpers
The output signal range of the Dual DAC and Serial DAC
modules is configured with jumpers. See Configuring Dual
DAC Outputs on page 186 and Configuring Serial DAC
Outputs on page 188 for information on setting these jumpers.
Mounting
1.
Select 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
accommodate #8 (4.0 mm) size screws. See Figure 2.11
for screw locations. Install the unit with the four
screws.
Serial DAC
Dual DAC
4 holes for #8 (4.0 mm)
screws or bolts
3.62 in
(91 mm)
Electrical
connections
3.7 in
(94 mm)
0.3 in
(8 mm)
3.00 in
(76 mm)
0.3 in
(8 mm)
4 holes for #8 (4.0 mm)
screws or bolts
3.62 in
(91 mm)
0.37 in
(9 mm)
Electrical
connections
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
connections
0.65 in
(17 mm)
1.75 in
(44 mm)
Electrical
connections
4.40 in
(112 mm)
5.40 in
(137 mm)
Figure 2.11 Dual DAC and Serial DAC
Dimensions
20
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 2: Installation
System Wiring
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 CLS200
hardware. If possible, install high-voltage ac
power circuits in a separate panel.
Wiring Recommendations
Follow these guidelines for selecting wires and cables:
•
•
•
•
Doc.# 0600-3050-2000
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 mm2) 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 CLS200 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.
Watlow Anafaze
21
Chapter 2: Installation
CLS200 Series User’s Guide
Table 2.1
Function
Mfr. P/N
Cable Recommendations
No. of
Wires
AWG
mm2
Analog Inputs
Belden 9154
Belden 8451
2
2
20
22
0.5
0.5
RTD Inputs
Belden 8772
Belden 9770
3
3
20
22
0.5
0.5
Thermocouple Inputs
T/C Ext. Wire
2
20
0.5
Control Outputs and
Digital I/O
Belden 9539
Belden 9542
Ribbon Cable
9
20
50
24
24
22 to 14
0.2
0.2
0.5 to 2.5
Analog Outputs
Belden 9154
Belden 8451
2
2
20
22
0.5
0.5
Computer Communication: EIA/TIA-232, 422
or 485, or 20 mA
Belden 9729
Belden 9730
Belden 9842
Belden 9843
Belden 9184
4
6
4
6
4
24
24
24
24
22
0.2
0.2
0.2
0.2
0.5
Maximum
Length
4,000 ft. (1,219 m)
4,000 ft. (1,219 m)
6,000 ft. (1,829 m)
Noise Suppression
The CLS200’s outputs are typically used to drive solid state
relays. These relays may in turn operate more inductive
types of loads such as electromechanical relays, alarm
horns and motor starters. Such devices may generate 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 CLS200 case.
Symptoms of RFI/EMI
If your controller displays the following symptoms, suspect
EMI:
•
•
The controller’s display blanks out and then reenergizes as if power had been turned off for a moment.
The process variable does not display correctly.
EMI may also damage the digital output circuit—so digital
outputs will not turn on. If the digital output circuit is damaged, return the controller to Watlow Anafaze for repair.
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CLS200 Series User’s Guide
Chapter 2: Installation
Avoiding RFI/EMI
•
•
To avoid or eliminate most RFI/EMI noise problems:
Connect the CLS200 case to earth ground. The
CLS200 system includes noise suppression circuitry.
This circuitry requires proper grounding.
•
Separate the 120 or 240VÅ (ac) power leads from the
low-level input and output leads connected to the
CLS200 series controller. Do not run the digital I/O or
control output leads in bundles with ac wires.
Where possible, use solid-state relays (SSRs) instead
of electromechanical relays. If you must use electromechanical relays, try to avoid mounting them in the
same panel as the CLS200 series equipment.
If you must use electromechanical relays and you
must place them in a panel with CLS200 series equipment, use a 0.01 microfarad capacitor rated at
1000VÅ (ac) (or higher) in series with a 47 Ω, 0.5 watt
resistor across the N.O. contacts of the relay load. This
is known as a snubber network and can reduce the
amount of electrical noise.
You can use other voltage suppression devices, but
they are not usually required. For instance, you can
place a metal oxide varistor (MOV) rated at 130VÅ for
120VÅ (ac) control circuits across the load, which limits the peak ac voltage to about 180VÅ (ac) (Watlow
Anafaze part number 26-130210-00). You can also
place a transorb (back-to-back zener diodes) across the
digital output, which limits the digital output voltage.
•
•
•
Additional Recommendations for a Noise Immune System
It is strongly recommended that you:
•
•
•
•
Doc.# 0600-3050-2000
Isolate outputs through solid-state relays, where 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.
If you are using EIA/TIA-232 from a non-isolated host,
either (1) do not connect any other power common
point to earth ground, or (2) use an optical isolator in
the communications line.
Watlow Anafaze
23
Chapter 2: Installation
CLS200 Series User’s Guide
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 communications port.
From a sensor to the dc power supply.
The best way to avoid ground loops is to minimize unnecessary connections to ground. Do not connect any of the following terminals to each other or to earth ground:
•
•
•
Power supply dc common
TB1, terminals 5, 6, 11, 12 (analog common)
TB1, terminal 17 (reference voltage common)
•
•
TB1, terminals 23, 24 (communications common)
TB2, terminal 2 (dc power common)
Special Precautions for the CLS216
The CLS216 has single-ended inputs. All the negative sensor leads are tied to the analog common. That means there
is no sensor-to-sensor isolation. Proper grounding is critical
for this unit. Take these additional precautions with a
CLS216:
•
•
•
•
Use all ungrounded or all well-grounded thermocouples, not a mix.
If using a mixture of thermocouples or low-voltage inputs (<500 mV) and current inputs, connect the negative leads of the current transmitters to terminal 17
(Ref Com) on TB1.
If using voltage transmitters, use only sourcing models or configuration. Sinking configurations will not
work.
Isolate the controller’s communication port (if used) by
using an optically isolated 232-to-485 converter.
Personal Computers and Ground Loops
Many PC communications ports connect the communications common to chassis ground. When such a PC is connected to the controller, this can provide a path to ground
for current from the process that can enter the controller
through a sensor (such as a thermocouple). This creates a
ground loop that can affect communications and other controller functions. To eliminate a ground loop, either use an
optically isolated communications adapter or take measures to ensure that sensors and all other connections to
the controller are isolated and not conducting current into
the unit.
24
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Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 2: Installation
Power Connections
This section covers making the power connections to the
CLS200 and connecting the TB50.
TB1
(to signal
inputs
TB2
(to power
supply)
TB18
(to digital
outputs)
Figure 2.12 CLS200 Series Controller with
TB18
TB1
(to signal
inputs
TB2
(to power
supply)
SCSI-2
(to TB50)
Figure 2.13 CLS200 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.
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25
Chapter 2: Installation
CLS200 Series User’s Guide
Table 2.2
Power Connections
Function
26
Power Supply
CLS200 TB2
DC Power
(Controller)
+12 to 24VÎ (dc)
+
DC Common
12 to 24VÎ (dc)
Common
-
Earth Ground
Ground
1.
Connect the dc common terminal on the power supply
to the dc common (-) terminal on CLS200 TB2.
2.
Connect the positive terminal on the power supply to
the dc positive (+) terminal on CLS200 TB2.
3.
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 CLS200 chassis and
must be connected to earth ground.
5.
Connect 120/240VÅ (ac) 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 inch-pound (0.5 to 0.6
Nm).
CAUTION!
Without proper grounding, the CLS200 may
not operate properly or may be damaged.
Watlow Anafaze
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CLS200 Series User’s Guide
Chapter 2: Installation
CAUTION!
NOTE!
To prevent damage from incorrect connections, do not turn on the ac power before testing the connections as explained in Testing
Your System on page 28.
Do not connect the controller’s dc common
(COM) to earth ground
. Doing so will defeat the noise protection circuitry, making
measurements less stable.
Power Supply
+V1 (5V)
0 (5V COM)
C G
V O N
+ M D
Add jumper *
+V2 (+15V)
COM (15V COM)
SSR
SSR
SSR
SSR
CLS200
**
-V2 (-15V)
(Ground)
ACL (AC Line)
ACN (AC Neutral)
120/240
Vı (ac)
Supply
N
H
G
1 2 3 4
+ C
5 O
M
Serial DAC
white
black
green
**
* If using 5VÎ (dc) for outputs, jumper 5V common to 15V common.
** Connect terminals to ac panel ground.
Figure 2.14 Power Connections with the
CLS200 Power Supply
Connecting TB50 to CLS200
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1.
Connect the SCSI cable to the controller.
2.
Connect the SCSI cable to the TB50.
Watlow Anafaze
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Chapter 2: Installation
CLS200 Series User’s Guide
Testing Your 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 CLS200. The display should read
CALCULATING CHECKSUM then show the bar graph
display. (See Figure 3.3.) If you do not see these displays, disconnect power and check wiring and power
supply output.
2.
Measure the +5VÎ (dc) supply at the TB50 or TB18:
a)
Connect the voltmeter’s common lead to TB50 or
TB18 terminal 3 or TB18 terminal 2.
b)
Connect the voltmeter’s positive lead to TB50 or
TB18 screw terminal 1. The voltage should be
+4.75 to +5.25VÎ (dc).
Digital Output Test
Use this procedure to test the controller’s outputs before
loads are connected. If using it at another time for troubleshooting, disconnect loads from outputs before testing.
NOTE!
28
1.
Connect a 500 Ω to 100 kΩ resistor between TB50 or
TB18 screw terminal 1 and a digital output terminal.
(See Table 2.5, TB18 Connections on page 40; Table
2.6, TB50 Connections for CLS204 and CLS208 on
page 41; or Table 2.7, TB50 Connections for CLS216 on
page 42.)
2.
Connect the voltmeter’s positive lead to screw terminal 1.
3.
Connect the common lead to the digital output terminal.
4.
Use the digital output test in the MANUAL I/O TEST
menu to turn the digital output on and off. (See Test
Digital Output on page 104 and Digital Output Number on page 104.) When the output is ON, the output
voltage should be less than 1V. When the output is
OFF, the output voltage should be between 4.75 and
5.25V.
By default, heat outputs are enabled. Only
disabled outputs may be turned on using the
manual I/O test. To test heat outputs, set the
corresponding loop to manual mode 100%
output. See Selecting the Control Status on
page 61.
Watlow Anafaze
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CLS200 Series User’s Guide
Chapter 2: Installation
Digital Input Test
Use the following procedure to test digital inputs before
connecting to field devices:
1.
Disconnect any system wiring from the input to be
tested.
2.
Go to the DIGITAL INPUTS test in the MANUAL I/O
TEST menu. (See Digital Inputs on page 103.) This test
shows whether the digital inputs are H (high, or open)
or L (low, or closed).
3.
Attach a wire to the terminal of the digital input you
want to test. See tables 2.5 to 2.7 on pages 40 to 42 for
connections.
a)
When the wire is connected only to the digital input terminal, the digital input test should show
that the input is H (high, or open).
b)
When you connect the other end of the wire to the
controller common (TB50 terminal 3 or TB18 terminal 2), the digital input test should show that
the input is L (low, or closed).
Sensor Wiring
This section describes how to properly connect thermocouples, RTDs, current and voltage inputs to your controller.
The controller can accept any mix of available input types.
Some input types require that special scaling resistors be
installed (generally done by Watlow Anafaze before the
controller is delivered).
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 the CLS200 series controllers.
CAUTION!
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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.
Watlow Anafaze
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Chapter 2: Installation
CLS200 Series User’s Guide
Figure 2.15 CLS200 Connector Locations
Input Wiring Recommendations
Use multicolored stranded shielded cable for analog inputs.
Watlow Anafaze recommends that you use 20 AWG wire
(0.5 mm2). If the sensor manufacturer requires it, you can
also use 24 or 22 AWG wiring (0.2 mm2). Most inputs use a
shielded twisted pair; some require a 3-wire input.
Follow the instructions pertaining to the type(s) of input(s)
you are installing.
The controller accepts the following inputs without any
special scaling resistors:
•
•
J, K, T, S, R, B and E thermocouples.
Linear inputs with ranges between -10 and 60 mV.
Any unused inputs should be set to SKIP or jumpered to
avoid thermocouple break alarms.
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Chapter 2: Installation
Thermocouple Connections
Connect the positive lead of any of the supported thermocouple types to the IN+ terminal for one of the loops and the
negative lead to the corresponding IN- terminal.
Use 18 or 20 AWG (0.5 or 0.75 mm2) for all the thermocouple inputs. Most thermocouple wire is solid, unshielded
wire. When using shielded wire, ground one end only.
CH IN+
*CH IN-
White
Type J
thermocouple
Red
Shield (if present)
*For CLS216 use Com
Earth Ground
at Process End
Figure 2.16 Thermocouple Connections
NOTE!
CAUTION!
When mixing current inputs with low-voltage
inputs (thermocouples or voltage inputs <1V)
to a CLS216, connect the current signal to the
IN+ and Ref Com terminals. If no low-voltage
sensors are used, connect current inputs to
the IN+ and Com terminals on TB1. For all inputs to a CLS204 or CLS208, connect the
sensors to the IN+ and Com terminals.
Ground loops and common mode noise can
damage the controller or disrupt measurements. To minimize ground loops and common mode noise:
• With a CLS216, use only ungrounded thermocouples with each thermocouple sheath
electrically connected to earth ground. The
negative sensor terminals on the CLS216 are
tied to analog common.
• With a CLS204 or CLS208, 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
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Chapter 2: Installation
CLS200 Series User’s Guide
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
CLS200 uses a floating analog common for
sensor measurements. The noise protection
circuits on the sensor inputs function correctly only when the controller is correctly installed. See Ground Loops on page 24.
RTD Input Connections
This input type requires scaling resistors. Watlow Anafaze
recommends that you use a 100 Ω, 3-wire platinum RTD to
prevent reading errors due to cable resistance. If you use a
2-wire RTD, jumper the negative input to common. If you
must use a 4-wire RTD, leave the fourth wire unconnected.
CH IN +
CH IN Com
100 Ω RTD
Figure 2.17 RTD Connections to CLS204 or
CLS208
Reference Voltage Terminals
The +5V Ref and Ref Com terminals are provided in order
to power external bridge circuits for special sensors. Do not
connect any other types of devices to these terminals.
Voltage Input Connections
This input type requires scaling 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.
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Chapter 2: Installation
CLS204 and CLS208
CH IN+
CH IN-
Device with
Voltage
Output
CLS216
CH IN+
Com
Device with
Voltage
Output
Figure 2.18 Linear Voltage Signal Connections
Current Input Connections
This input type requires scaling 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.
CLS204 and CLS208
CH IN+
CH IN-
Device with
Current
Output
CLS216
CH IN+
Com/Ref Com
Device with
Current
Output
Figure 2.19 Linear Current Signal Connections
NOTE!
Doc.# 0600-3050-2000
When mixing current inputs with low-voltage
inputs (thermocouples or voltage inputs <1V)
to a CLS216, connect the current signal to the
IN+ and Ref Com terminals. When no lowvoltage sensors are used, connect current inputs to the IN+ and Com terminals on TB1.
For all inputs to a CLS204 or CLS208, connect the sensors to the IN+ and Com terminals.
Watlow Anafaze
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Chapter 2: Installation
CLS200 Series User’s Guide
Pulse Input Connections
The CLS200 can accept a pulse input of up to 2000 Hz from
a device such as an encoder. The frequency of this input is
scaled with user-set parameters. See Setup Loop Input
Menu on page 82 and Chapter 9, Linear Scaling Examples.
This scaled value is the process variable for loop 5 on a
CLS204, loop 9 on a CLS208, or loop 17 on a CLS216.
The CLS200 can accommodate encoder signals up to 24VÎ
(dc) using a voltage divider or can power encoders with the
5VÎ (dc) from the TB50 or TB18. The following figures illustrate connecting encoders. A pull-up resistor in the
CLS200 allows open collector inputs to be used.
NOTE!
If the signal on the pulse input exceeds
10kHz the controller’s operation may be disrupted. Do not connect the pulse input to a
signal source that may exceed 10kHz.
CLS200 and TB50 or TB18
+5VÎ (dc)
10 kΩ
Pulse Input
Encoder
Com
Figure 2.20 Encoder with 5VÎ (dc) TTL Signal
CLS200 and TB50 or TB18
+5VÎ (dc)
10 kΩ
R1
Pulse Input
Com
R2
Encoder
Figure 2.21 Encoder Input with Voltage Divider
For encoders with signals greater than 5VÎ (dc), use a voltage divider to drop the voltage to 5 volts at the input. Use
appropriate values for R1 and R2 depending on the encoder
excitation voltage. Be sure not to exceed the specific current load on the encoder.
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CLS200 Series 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 CLS200 series controller.
NOTE!
Control outputs are connected to the
CLS200’s common when the control output
is on (low). Be careful when you connect external devices that may have a low side at a
voltage other than controller ground, since
you may create ground loops.
If you expect grounding problems, use isolated solid state relays and isolate the control
device inputs.
The CLS200 provides dual PID control outputs for each
loop. These outputs can be enabled or disabled, and are
connected via TB50 or TB18.
Output Wiring Recommendations
When wiring output devices, use multicolored, stranded,
shielded cable for analog outputs and digital outputs 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
Once you have wired outputs to the TB50, install the cable
tie wraps to reduce strain on the connectors.
Each row of terminals has a cable tie wrap hole at one end.
Thread the cable tie wrap through the cable tie wrap hole.
Then wrap the cable tie wrap around the wires attached to
that terminal block.
Digital Outputs
The CLS200 series provides dual control outputs for up to
16 loops. The controller’s default configuration has all heat
outputs enabled and all cool outputs disabled. Disabling a
heat output makes that output available to be used as a
control or an alarm output. See Enable or Disable Heat or
Cool Outputs on page 94. The CPU watchdog timer output
can be used to monitor the state of the controller with an
external circuit or device. See CPU Watchdog Timer on
page 38.
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Chapter 2: Installation
CLS200 Series User’s Guide
Table 2.3
Digital Output States and Values
Stored in the Controller
State Value
Description
Off
High
Open circuit
On
Low
Sinking current to common
The digital outputs sink current from the load to the controller common. The load may powered by the 5VÎ (dc)
supplied by the controller at the TB50. Alternately, an external power supply may be used to drive loads.
Keep in mind the following points when using an external
power supply:
•
The CLS200 power supply available from Watlow
Anafaze includes a 5VÎ (dc) supply. When using it to
supply output loads, connect the 5VÎ (dc) common to
the 15VÎ (dc) common at the power supply.
•
•
Do not exceed +24 volts.
If you tie the external load to earth ground, or if you
cannot connect it as shown in (See Figure 2.22), then
use a solid-state relay.
All digital outputs are sink outputs referenced to the
CLS200 series controller common supply. These outputs
are low (pulled to common) when they are on.
The outputs conduct current when they are low or on. The
maximum current sink capability is 60 mA at 24VÎ (dc).
They cannot “source” current to a load.
TB50 or TB18
+5VÎ (dc)
Loads
Digital Output 1
Digital Output 2
External
Power
Supply +
Do not connect
to earth ground or
equipment ground
TB50 or TB18
Using Internal Power Supply
Control Common
Loads
Digital Output 1
Digital Output 2
Using External Power Supply
Figure 2.22 Digital Output Wiring
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CLS200 Series User’s Guide
Chapter 2: Installation
Configuring Outputs
Keep in mind the following points as you choose outputs for
control and alarms:
•
•
•
•
•
•
You can enable or disable the control outputs. The default setting is heat outputs enabled, cool outputs 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 nonlatching.
Alarms can be suppressed during process start up and
for preprogrammed durations. See Alarm Delay on
page 103.
Alarm outputs can be configured as a group as normally on (low) or normally off (high). See Digital Output
Polarity on Alarm on page 81.
Control and Alarm Output Connections
Typically control and alarm outputs use external optically
isolated solid state relays (SSRs). SSRs accept a 3 to 32VÎ
(dc) input for control, and some can switch up to 100 Amps
at 480 VÅ (ac). For larger currents, use silicon control rectifier (SCR) power controllers up to 1000 Amps at 120 to
600VÅ (ac). You can also use SCRs and a Serial DAC for
phase-angle fired control.
The 34 control and alarm outputs are open collector outputs referenced to the CLS200’s common. Each output
sinks up to 60 mAÎ (dc) to the controller common when on.
NOTE!
Control outputs are SINK outputs. They are
Low when the output is ON. Connect them to
the negative side of solid state relays.
Figure 2.23 shows sample heat, cool and alarm output connections.
TB50 or TB18
Heat Output
Cool Output
Alarm Output
+5VÎ (dc)
SSR
-
+
SSR
-
+
SSR
-
+
Figure 2.23 Sample Heat, Cool and Alarm
Output Connections
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Chapter 2: Installation
CLS200 Series User’s Guide
Heat Output
Cool Output
Alarm Output
Common
SSR
SSR
TB50 or TB18
-
-
+
+
SSR
-
+
- PS +
Figure 2.24 Output Connections Using
External Power Supply
CPU Watchdog Timer
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 in order to determine if the controller
is powered and operational. Do not exceed 5VÎ (dc), 10
mAÎ (dc) rating for the watchdog output. The output is low
(on) when the microprocessor is operating; when it stops
operating, the output goes high (off).
Figure 2.25 and Figure 2.26 show the recommended circuit
for the watchdog timer output for the TB50 and the TB18.
TB50
+ 5VÎ (dc)
(Terminal 1)
+
Watchdog Timer
(Terminal 6)
-
SSR
Figure 2.25 TB50 Watchdog Timer Output
TB18
+ 5VÎ (dc)
(Terminal 1)
+
Watchdog Timer
(Terminal 3)
-
SSR
Figure 2.26 TB18 Watchdog Timer Output
Digital Inputs
All digital inputs are transistor-transistor logic (TTL) level
inputs referenced to control common and the internal +5V
power supply of the CLS200.
When an input is connected to the controller common, the
input is considered on. Otherwise, the input is considered
38
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CLS200 Series User’s Guide
Chapter 2: Installation
off. Most features that use the digital inputs can be userconfigured to activate when an input is either on or off.
In the off state, internal 10 k resistors pull the digital inputs high to 5VÎ (dc) with respect to the controller common.
Table 2.4
Digital Inputs States and Values
Stored in the Controller
State
Value
Description
Off
High
Open circuit
On
Low
Digital Input connected to
controller common
External Switching Devices
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 off, the swiching device must provide an impedance
of at least 11 kΩ to ensure that the voltage will rise to
greater than 3.7VÎ (dc). When on, the switch must provide
not more than 1 kΩ impedance to ensure the voltage drops
below 1.3VÎ (dc).
To install a switch as a digital input, connect one lead to the
common terminal on the TB50 (terminals 3 and 4) or TB18
(terminal 2). Connect the other lead to the desired digital
input terminal on the TB50 (terminals 43 to 50) or TB18
(terminals 16 to 18).
Functions Activated by Digital Inputs
Use digital inputs to activate the following functions:
•
•
•
•
Load a job that is stored in controller memory. See Job
Select Digital Inputs on page 76.
Change all loops to manual mode at specified output
levels. See Output Override Digital Input on page 77.
Enable thermocouple short detection. See Process
Power Digital Input on page 79.
Restore control automatically after a failed sensor has
been repaired. See Restore PID Digital Input on page 92.
TB50
Input
External
Switching
Device
Control Com
Figure 2.27 Wiring Digital Inputs
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Chapter 2: Installation
CLS200 Series User’s Guide
TB18 Connections (CLS204 and CLS208 Only)
Table 2.5
TB18 Connections
Control Output1
Terminal
Function
CLS204
CLS208
1
+5VÎ (dc)
2
CTRL COM
3
Watchdog timer
4
Global alarm
5
Output 1
Loop 1 heat
Loop 1 heat
6
Output 2
Loop 2 heat
Loop 2 heat
7
Output 3
Loop 3 heat
Loop 3 heat
8
Output 4
Loop 4 heat
Loop 4 heat
9
Output 5
Pulse loop heat
Loop 5 heat
10
Output 6
Loop 1 cool
Loop 6 heat
11
Output 7
Loop 2 cool
Loop 7 heat
12
Output 8
Loop 3 cool
Loop 8 heat
13
Output 9
Loop 4 cool
Pulse loop heat
14
Output 10
Pulse loop cool
Loop 1 cool
15
Output 342
Serial DAC clock
Serial DAC clock
16
Input 1
17
Input 2
18
Input 3/Pulse input
1 The indicated outputs are dedicated for control when enabled in
the loop setup. If one or both of a loop’s outputs are disabled, the
corresponding digital outputs become available for alarms or
ramp/soak events.
2 If you install a Watlow Anafaze Serial DAC, the CLS200 series
controller uses digital output 34 for a clock line. You cannot use
output 34 for anything else when you have a Serial DAC installed.
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Chapter 2: Installation
TB50 Connections
Table 2.6
TB50 Connections for CLS204 and
CLS208
Control Output1
Terminal
Function
CLS208
CLS204
Control Output1
Terminal
Function
1
+5VÎ (dc)
2
+5VÎ (dc)
3
CTRL COM
4
CTRL COM
5
Not Used
6
Watchdog
Timer
7
Pulse Input
8
Global Alarm
9
Output 1
Loop 1 heat
Loop 1 heat
10
Output 342
11
Output 2
Loop 2 heat
Loop 2 heat
12
Output 33
13
Output 3
Loop 3 heat
Loop 3 heat
14
Output 32
15
Output 4
Loop 4 heat
Loop 4 heat
16
Output 31
17
Output 5
Loop 5 heat
Pulse loop heat
18
Output 30
19
Output 6
Loop 6 heat
Loop 1 cool
20
Output 29
21
Output 7
Loop 7 heat
Loop 2 cool
22
Output 28
23
Output 8
Loop 8 heat
Loop 3 cool
24
Output 27
25
Output 9
Pulse loop
heat
Loop 4 cool
26
Output 26
27
Output 10
Loop 1 cool
Pulse loop cool
28
Output 25
29
Output 11
Loop 2 cool
30
Output 24
31
Output 12
Loop 3 cool
32
Output 23
33
Output 13
Loop 4 cool
34
Output 22
35
Output 14
Loop 5 cool
36
Output 21
37
Output 15
Loop 6 cool
38
Output 20
39
Output 16
Loop 7 cool
40
Output 19
41
Output 17
Loop 8 cool
42
Output 18
43
Input 1
44
Input 2
45
Input 3
46
Input 4
47
Input 5
48
Input 6
49
Input 7
50
Input 8
CLS208
CLS204
Pulse
loop cool
1 The indicated outputs are dedicated for control when enabled in
the loop setup. If one or both of a loop’s outputs are disabled, the
corresponding digital outputs become available for alarms or
ramp/soak events.
2 If you install a Watlow Anafaze Serial DAC, the controller uses
digital output 34 (terminal 10) for a clock line. You cannot use output 34 for anything else when you have a Serial DAC installed.
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Chapter 2: Installation
CLS200 Series User’s Guide
Table 2.7
Terminal
Function
CLS216
Control Output1
TB50 Connections for CLS216
Terminal
Function
CLS216
Control Output1
1
+5VÎ (dc)
2
+5VÎ (dc)
3
CTRL COM
4
CTRL COM
5
Not Used
6
Watchdog Timer
7
Pulse Input
8
Global Alarm
9
Output 1
Loop 1 heat
10
Output 342
Pulse loop cool
11
Output 2
Loop 2 heat
12
Output 33
Loop 16 cool
13
Output 3
Loop 3 heat
14
Output 32
Loop 15 cool
15
Output 4
Loop 4 heat
16
Output 31
Loop 14 cool
17
Output 5
Loop 5 heat
18
Output 30
Loop 13 cool
19
Output 6
Loop 6 heat
20
Output 29
Loop 12 cool
21
Output 7
Loop 7 heat
22
Output 28
Loop 11 cool
23
Output 8
Loop 8 heat
24
Output 27
Loop 10 cool
25
Output 9
Loop 9 heat
26
Output 26
Loop 9 cool
27
Output 10
Loop 10 heat
28
Output 25
Loop 8 cool
29
Output 11
Loop 11 heat
30
Output 24
Loop 7 cool
31
Output 12
Loop 12 heat
32
Output 23
Loop 6 cool
33
Output 13
Loop 13 heat
34
Output 22
Loop 5 cool
35
Output 14
Loop 14 heat
36
Output 21
Loop 4 cool
37
Output 15
Loop 15 heat
38
Output 20
Loop 3 cool
39
Output 16
Loop 16 heat
40
Output 19
Loop 2 cool
41
Output 17
Pulse loop heat
42
Output 18
Loop 1 cool
43
Input 1
44
Input 2
45
Input 3
46
Input 4
47
Input 5
48
Input 6
49
Input 7
50
Input 8
1 The indicated outputs are dedicated for control when enabled in
the loop setup. If one or both of a loop’s outputs are disabled, the
corresponding digital outputs become available for alarms or
ramp/soak events.
2 If you install a Watlow Anafaze Serial DAC, the controller uses
digital output 34 (terminal 10) for a clock line. You cannot use output 34 for anything else when you have a Serial DAC installed.
42
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 2: Installation
Analog Outputs
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.
Wiring the Dual DAC
A Dual DAC module includes two identical circuits. Each
can convert a distributed zero-cross (DZC) signal from the
controller to a voltage or current signal. Watlow Anafaze
strongly recommends using a power supply separate from
the controller supply to power the Dual DAC. Using a 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
Dual DAC
+5VÎ (dc)
Control Output
mA Load
1
+5V CTRL Supply
2
DZC CTRL PID Output
3
+
4
+12/24VÎ (dc) External
Power Supply
+VÎ (dc) Load Connection
-
5
-mAÎ (dc) Load Connection
6
-External Power
Supply/ VÎ (dc) Load
Connection
+ 12 to 24VÎ (dc) Power Supply
Figure 2.28 Dual DAC with Current Output
Doc.# 0600-3050-2000
Watlow Anafaze
43
Chapter 2: Installation
CLS200 Series User’s Guide
Dual DAC
TB50 or TB18
+5VÎ (dc) 1
1
+5VÎ (dc) CTRL
PID Loop Output
2
DZC CTRL PID Output
3
4
+12/24VÎ (dc) External Power Supply
+VÎ (dc) Load Conn.
5
-mAÎ (dc) Load Conn.
6
-External Power
Supply/ VÎ (dc) Load
Conn.
VÎ (dc) Load
+
-
+ 12 to 24VÎ (dc) Power Supply
Figure 2.29 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 2.30 for wiring. The Serial DAC is user-configurable
for voltage or current output through firmware configuration. See Configuring Serial DAC Outputs on page 188.
The Serial DAC optically isolates the controller’s control
output from the load. When a single Serial DAC is used, it
may be powered by the 5VÎ (dc) found on the TB50, or by
an external supply referenced to the controller's power supply. When using multiple Serial DACs, the controller cannot provide sufficient current; use the 5VÎ (dc) output from
the CLS200 power supply
44
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 2: Installation
Controller
Power Supply
Daisy chain up to
16 Serial DACs
Serial DAC
1
+5V In
5V Common
2
COM In
15V Common
3
CLK In
4
Data In
5
+ Out
6
- Out
+5V
TB50 or TB18
Serial DAC Clock
Control Output
Load
+
Figure 2.30 Single/Multiple Serial DACs
Serial Communications
The CLS200 series controllers are factory-configured for
EIA/TIA-232 communications unless otherwise specified
when purchased. However, the communications are jumper-selectable, so you can switch between EIA/TIA-232 and
EIA/TIA-485. See Changing Communications on page 179.
EIA/TIA-232 Interface
EIA/TIA-232 provides communication to the serial port of
an IBM PC or compatible computer. It is used for singlecontroller installations where the cable length does not exceed 50 feet (15.2 m).
The EIA/TIA-232 interface is a standard three-wire interface. See the table below for connection information.
If you are using EIA/TIA-232 communications with
grounded thermocouples, use an optical isolator between
the controller and the computer to prevent ground loops.
Table 2.8 shows EIA/TIA-232 connections for 25-pin and 9pin connectors or cables that are supplied by the factory.
EIA/TIA-232 may be used to connect a computer through a
232/485 converter, to an EIA/TIA-485 communications network with up to 32 CLS200 controllers.
Doc.# 0600-3050-2000
Watlow Anafaze
45
Chapter 2: Installation
CLS200 Series User’s Guide
Table 2.8
Wire
Color
EIA/TIA-232 Connections
CLS200
TB1
DB 9
Connector
DB 25
Connector
White
TX Pin 26
RX Pin 2
RX Pin 3
Red
RX Pin 25
TX Pin 3
TX Pin 2
Black
GND Pin 23
GND Pin 5
GND Pin 7
Green
GND Pin 24
N/U Pin 9
N/U Pin 22
Shield
N/C
GND Pin 5
GND Pin 7
Jumpers in EIA/TIA-232 Connectors
Some software programs and some operator interface terminals require a Clear to Send (CTS) signal in response to
their Request to Send (RTS) signal, or a Data Set Ready
(DSR) in response to their Data Terminal Ready (DTR).
The CLS200 is not configured to receive or transmit these
signals. To use such software with the CLS200, jumper the
RTS to the CTS and the DTR to the DSR in the DB connector. Table 2.9 lists the standard pin assignments for DB-9
and DB-25 connectors.
Table 2.9
RTS/CTS Pins in DB-9 and DB-25
Connectors
RTS
CTS
DTR
DSR
DB-9
DB-25
7
8
4
6
4
5
20
6
Cables manufactured by Watlow Anafaze for EIA/TIA-232
communications include these jumpers. Neither AnaWin
nor Anasoft software requires these jumpers.
EIA/TIA-232
cable
W
LO
WAT
E
AZ
AF
AN
00
S2
CL
RM
ALA
%
OUT
TUS
STA
NT
POI
SET
MP
RAAK
SO
RM
ALAK
AC
TS
UNI
S
CES
PRO
P
LOO
R
ENTE
K
BAC
NO
YES
NG
CH
SP
N
MATO
AU
Figure 2.31 Connecting One CLS200 to a Computer Using EIA/TIA-232
46
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 2: Installation
EIA/TIA-485 Interface
To communicate with more than one CLS200 series controller on a controller network, or to use communication cable lengths greater than 50 feet (15.2 m) from PC to
controller, you must use EIA/TIA-485 communications.
When using EIA/TIA-485 communications, you must attach an optically isolated EIA/TIA-232 to EIA/TIA-485 converter to the computer.
Figure 2.32 and Figure 2.33 show the recommended system
wiring. To avoid ground loops, use an optically isolated
EIA/TIA-232 to EIA/TIA-485 converter between the computer and the EIA/TIA-485 network.
EIA/TIA-485 Converter
TXA/TDA/TXPersonal Computer
First CLS200
JU1
A
RXA 25
B
Last CLS200
JU1
A
RXA 25
B
TXB/TDB/TX+
RXB 23
RXB 23
RXA/RDA/RX-
TXA 26
TXA 26
RXB/RDB/RX+
TXB 24
Do not
connect
shield to
CLS200
TXB 24
Figure 2.32 EIA/TIA-485 Wiring
Cable Recommendations
Watlow Anafaze recommends Belden 9843 cable or its
equivalent. This cable includes three 24 AWG (0.2 mm2)
shielded, twisted pairs. It should carry signals of up to
19.2k baud with no more than acceptable losses for up to
4,000 feet (1,220 m).
EIA/TIA-485 Network Connections
Walow Anafaze recommends that you use a single daisy
chain configuration rather than spurs. Run a twisted-pair
cable from the host or the converter to the first CLS200,
and from that point run a second cable to the next CLS200,
and so on. (See Figure 2.33.)
If necessary for servicing, instead of connecting each controller directly into the next, install a terminal strip or connector as close as possible to each CLS200, run a
communications cable from one terminal strip to the next
and connect the controllers to the bus with short lengths of
cable.
Doc.# 0600-3050-2000
Watlow Anafaze
47
Chapter 2: Installation
CLS200 Series User’s Guide
To avoid unacceptable interference, use less than 10 feet
(3 m) of cable from the terminal or connector to the CLS200
serial port.
Some systems may experience problems with sensor signal
reading if the commons of multiple controllers are connected. See Signal Common on page 48.
Refer to Termination on page 48 for more on terminating
resistors.
Connect the shield drain to earth ground only at computer
or host end.
.
232 Communications
485 Communications
Serial Port
Optically
Isolating
232 to 485
Converter
Shielded Twisted Pair Cable
E
AZ
AF
AN
00
S2
CL
P
RAMK
SOA
M
ALAR
ACK
00
UNITS
ESS
OW
WATL
OUT%
S2
ENTER
PROC
S
LOOP
E
AZ
AF
BACK
STATU
AN
NO
OINT
SETP
M
ALAR
CL
P
RAMK
SOA
00
S2
RM
ALA
ACK
E
UNITS
ESS
OUT%
AZ
AF
AN
ENTER
PROC
OW
WATL
YES
G
CHN
SP
US
STAT
LOOP
WATL
CL
P
RAMK
SOA
RM
ALA
ACK
UNITS
ESS
OUT%
ENTER
PROC
OW
BACK
NO
US
STAT
LOOP
BACK
NO
OINT
OINT
SETP
MAN
O
AUT
SETP
M
ALAR
YES
M
G
CHN
SP
ALAR
MAN
O
AUT
First CLS200
Second CLS200
YES
G
CHN
SP
MAN
O
AUT
Last CLS200
Figure 2.33 Recommended System
Connections
Signal Common
For usual installations, do not connect the dc commons of
the controllers together or to the converter or host device.
Use an optically isolating EIA/TIA-232-to-485 converter to
prevent problems with sensor readings.
Termination
In order for EIA/TIA-485 signals to be transmitted properly, each pair must be properly terminated. The value of the
termination resistor should be equal to the impedance of
the communications cable used. Values are typically 150 to
200 Ω.
The receive lines at the converter or host device should be
terminated in the converter, the connector to the host device or the device itself. Typically the converter documentation provides instructions for termination.
Use a terminating resistor on the receive lines on the last
controller on the 485 line. Set JU1 inside the CLS200 in position B to connect a 200 Ω resistor across the receive lines.
Refer to Changing Communications on page 179.
48
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 2: Installation
EIA/TIA-485 Converters and Laptop Computers
In order for an EIA/TIA-232-to-485 converter to optically
isolate the computer from the 485 network, the 232 and 485
sides must be powered independently. Many 232-to-485
converters can be powered by the computer’s communications port. Some computers, laptops in particular, do not
automatically provide the appropriate voltages. These computer/converter combinations can usually be used by connecting an external power supply to the 232 side of the
converter. Not all converters have power inputs for the 232
side, however.
NOTE!
Doc.# 0600-3050-2000
When using Anasoft with a laptop computer,
choose a converter with an external 232 power input. AnaWin and Watview works with all
tested converters without an external 232 input.
Watlow Anafaze
49
Chapter 2: Installation
50
CLS200 Series User’s Guide
Watlow Anafaze
Doc.# 0600-3050-2000
3
Using the CLS200
This chapter explains how to use the keypad and display to
operate the controller. Figure 3.1 shows the operator
menus and displays accessible from the front panel.
To change global parameters, loop inputs, control parameters, outputs, and alarms using the setup menus, see Chapter 4, Setup.
BACK
Power
on
Bar Graph
Display
ENTER
ENTER
Any
Key
Scanning
Bar Graph
Display
BACK
ENTER
ENTER
CHNG
SP
Any
Key
Scanning
Single Loop
Display
Job
Display
BACK
Change
Setpoint
RAMP
SOAK
MAN
AUTO
BACK
Manual,
Automatic
or Autotune
Mode
Ramp/Soak
Figure 3.1
Doc.# 0600-3050-2000
BACK
Single Loop
Display
BACK
ENTER
(Manual)
Heat/Cool
Output
Percentage
BACK
(Manual
mode only)
Operator Displays
Watlow Anafaze
51
Chapter 3: Using the CLS200
CLS200 Series User’s Guide
Front Panel
The CLS200 front panel provides a convenient interface
with the controller. You can use the front panel keys to program and operate the CLS200.
RAMP
SOAK
WATLOW ANAFAZE CLS200
• Assigns and
monitors profile
ALARM
ACK
MAN
AUTO
• Acknowledges
alarms
• Changes loop output
control from automatic
to manual or tune
• Assigns output power
level of manual loops
CHNG
SP
• Changes process
setpoint
ENTER
BACK
YES
• Cancels editing
and returns to a
previous menu
• Selects a menu
or parameter
• Answers YES to
YES/NO prompts
• Increases a
value or choice
• Stores data or settings
and advances to the next
parameter
• Starts scanning mode
(if pressed twice)
NO
• Skips a menu or parameter
• Answers NO to YES/NO
prompts
• Decreases a value or choice
Figure 3.2
52
CLS200 Front Panel
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 3: Using the CLS200
Front Panel Keys
YES (up)
Press YES to:
•
•
•
•
Select a menu or parameter
Answer YES to the flashing ? prompts
Increase a value or choice when editing
Stop scanning mode
NO (down)
Press NO to:
NOTE!
•
Skip a menu or parameter when the prompt is blinking
•
•
•
•
Answer NO to the flashing ? prompts
Decrease a value or choice when editing
Stop scanning mode
Perform a NO-key reset
Pressing the NO key on power up performs a
NO-key reset. This procedure clears the RAM
and sets the controller’s parameters to their
default values. See NO-Key Reset on page
176.
BACK
Press BACK to:
•
•
•
•
Cancel editing
Return to a previous menu
Switch between bar graph, single loop and job displays
Stop scanning mode
ENTER
Press ENTER to:
•
•
Doc.# 0600-3050-2000
Store data or a parameter choice after editing and go
to the next parameter
Start scanning mode (if pressed twice)
Watlow Anafaze
53
Chapter 3: Using the CLS200
CLS200 Series User’s Guide
CHNG
SP
Press CHNG SP to change the loop setpoint
MAN
AUTO
Press MAN/AUTO to:
•
•
•
Toggle a loop between manual and automatic control
Adjust the output power level of manual loops
Automatically tune the loop
RAMP
SOAK
If your controller has the ramp/soak option, press RAMP/
SOAK to:
•
•
•
Assign a ramp/soak profile to the current loop
Select the ramp/soak mode
See the status of a running profile
Your controller may not have the ramp/soak option. If it
does not, pressing the RAMP/SOAK key displays the message
OPTION UNAVAILABLE.
ALARM
ACK
Press ALARM ACK to:
•
•
54
Acknowledge an alarm condition
Reset the global alarm output
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 3: Using the CLS200
Displays
This section discusses the controller’s main displays: bar
graph, single loop and job.
Bar Graph Display
On power up, the controller displays general symbolic information for up to eight loops. This screen is called the bar
graph display. The diagram below shows the symbols used
in the bar graph display.
Symbol
Loop Number
or Name
Control Status
Figure 3.3
01> >
AAAA
< < 08
MAMA
ALARM
Bar Graph Display
Table 3.1 explains the symbols you see on the top line of
the bar graph display. These symbols appear when the controller is in dual output mode (heat and cool outputs enabled) and single output mode (heat or cool outputs
enabled, but not both).
Table 3.1
Bar Graph Display Symbols
Symbol
Description
<
Loop is in low process or low deviation alarm.
>
Loop is in high process or high deviation alarm.
Loop is above setpoint. If you enable the high
or low deviation alarm, this symbol is scaled to
it. If you do not enable these alarms, these
symbols are scaled to the setpoint +5% of the
sensor’s range.
Loop is at setpoint. If you enable the high or
low deviation alarm, this symbol is scaled to it.
If you do not enable these alarms, these symbols are scaled to the setpoint +5% of the sensor’s range.
Loop is below setpoint. If you enable the high
or low deviation alarm, this symbol is scaled to
it. If you do not enable these alarms, these
symbols are scaled to the setpoint +5% of the
sensor’s range.
(blank)
F
Doc.# 0600-3050-2000
Loop’s input type is set to SKIP.
Open thermocouple (T/C), shorted T/C,
reversed T/C, open RTD or shorted RTD.
Watlow Anafaze
55
Chapter 3: Using the CLS200
CLS200 Series User’s Guide
Table 3.2 explains the control status symbols on the bottom line of bar graph display. Additional symbols may appear with the ramp/soak option. See Bar Graph Display on
page 146.
Table 3.2
Control Status Symbols on the Bar
Graph and Single Loop Displays
Bar Graph
Display
Symbol
Single
Loop
Display
Symbol
M
MAN
One or both outputs are
enabled. Loop is in manual control.
A
AUTO
Only one output (heat or cool) is
enabled. Loop is in automatic
control.
T
TUNE
The loop is in autotune mode.
H
T
HEAT
Both heat and cool outputs are
enabled. Loop is in automatic
control and heating.
C
L
COOL
Both heat and cool outputs are
enabled. Loop is in automatic
control and cooling.
(blank)
(blank)
Description
Both outputs disabled, or input
type is set to SKIP.
Navigating in Bar Graph Display
When the bar graph display is visible:
•
•
•
•
56
Press the YES (up) or NO (down) key to see a new group
of loops.
Press ENTER twice to scan all groups of loops. The
groups will display sequentially for three seconds
each. This is called scanning mode.
Press any key to stop scanning.
Press BACK once to go to the job display, if enabled, or
the single loop display.
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 3: Using the CLS200
Single Loop Display
The single loop display shows detailed information for one
loop at a time.
Process Variable
Loop Number
or Name
02
160˚F
180AUTO100
ALARM
Setpoint
Figure 3.4
Control Status
Engineering
Units
Output
Percentage
Single Loop Display
The control status indicator shows MAN, AUTO or TUNE
modes.
If both control outputs for a loop are enabled and the loop
is in automatic control, then the single loop display shows
HEAT or COOL as the control status:
Process Variable
Loop Number
or Name
02
Engineering Units
160˚F
0
180HEAT100
ALARM
Setpoint
Figure 3.5
Control Status
Cool Output
Percentage
Heat Output
Percentage
Single Loop Display, Heat and Cool
Outputs Enabled
Navigating the Single Loop Display
In the single loop display:
•
•
•
•
•
Doc.# 0600-3050-2000
Press YES to go to the next loop.
Press NO to go to the previous loop.
Press BACK once to go to the job display (if enabled) or
bar graph display.
Press ENTER twice to start the single loop scanning display. The single loop scanning display shows information for each loop in sequence. Data for each loop
displays for one second.
Press any key to stop scanning.
Watlow Anafaze
57
Chapter 3: Using the CLS200
CLS200 Series User’s Guide
Alarm Displays
If a process, deviation, failed or system sensor alarm occurs, the controller switches from any Single Loop display
or Bar Graph display to the Single Loop display for the loop
with the alarm. The global alarm output turns on and a
two-character alarm code appears in the lower left corner
of the Single Loop display. If the alarm is for a failed sensor, a short message appears in place of the process variable and units. Control outputs associated with failed
sensors are set to the value of the SENSOR FAIL HT/CL
OUTPUT % parameter (default, 0%). The alarm code blinks
and displays cannot be changed until the alarm has been
acknowledged. Once the alarm is acknowledged, the alarm
code stops blinking. When the condition that caused the
alarm is corrected, the alarm messages disappear.
02
LP
Loop Number
°F
180
180AUTO
ALARM
Alarm Code
Figure 3.6
03
FS
Single Loop Display with a Process
Alarm
T/C BREAK
25MAN
0
Failed Sensor
Description
ALARM
Alarm Code
Figure 3.7
Failed Sensor Alarm in the Single
Loop Display
Alarms that still exist but have been acknowledged are displayed on the Bar Graph display. A letter or symbol indicates the alarm condition. See Table 3.3 on page 59 for a
full list of alarm codes, failed sensor messages and alarm
symbols.
Open
Thermocouple
on Loop 1
01 F
AAAA
08
Low Process
or Low Deviation
on Loop 5
MAMA
ALARM
Figure 3.8
58
Alarm Symbols in the Bar Graph
Display
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 3: Using the CLS200
Table 3.3 shows the symbols used in each form of the alarm
display.
Table 3.3
Alarm Type and Symbols
Alarm
Code
Bar Graph
Symbol
Alarm
Message
Alarm
Description
FS
F
T/C BREAK
Failed Sensor: Break detected
in thermocouple circuit.
RO
F
RTD OPEN
RTD Open: Break detected in
RTD circuit.
RS
F
RTD SHORTED
RTD Short: Short detected in
RTD circuit.
REVERSED TC
Reversed Thermocouple:
Reversed polarity detected in
thermocouple circuit.
T/C SHORTED
Shorted Thermocouple: Short
detected in thermocouple circuit.
No message
High Process Alarm: Process
variable has risen above the
set limit.
No message
High Deviation Alarm: Process
variable has risen above the
setpoint plus the deviation
alarm value.
No message
Low Process Alarm:
Process variable has dropped
below the set limit.
No message
Low Deviation Alarm: Process
variable has dropped below the
setpoint minus the deviation
alarm value.
No message
Ambient Warning: Controller's
ambient temperature has
exceeded operating limits by
less than 5° C.
RT
ST
HP
HD
LP
LD
AW
F
F
>
>
<
<
*
Acknowledging an Alarm
Press ALARM ACK to acknowledge the alarm. If there are
other loops with alarm conditions, the Alarm display
switches to the next loop in alarm. Acknowledge all alarms
to clear the global alarm digital output (the keypad and display won't work for anything else until you acknowledge
each alarm). The alarm symbols are displayed as long as
the alarm condition is valid.
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59
Chapter 3: Using the CLS200
CLS200 Series User’s Guide
System Alarms
When a system alarm occurs, the global alarm output turns
on and an alarm message appears on the display. The message continues to be displayed until the error condition is
removed and the alarm is acknowledged. The CLS200 can
display the following system alarms:
•
•
•
•
•
•
BATTERY DEAD
See Battery Dead on page 168.
LOW POWER
See Low Power on page 168.
AW
See Ambient Warning on page 168.
H/W FAILURE: AMBIENT
See H/W Ambient Failure on page 169.
H/W FAILURE: GAIN
See H/W Gain or Offset Failure on page 170.
H/W FAILURE: OFFSET
See H/W Gain or Offset Failure on page 170.
Job Display
The job display appears only if:
You have enabled JOB SELECT DIG INPUTS. (See
Load Setup From Job on page 75.)
– and –
•
You have selected a job from the job load menu.
After loading a job using the LOAD SETUP FROM JOB
menu, the job display shows you the following screen:
•
JOB 3 RUNNING
ALARM
If parameters are modified while the job is running, this
screen will display:
JOB 3 RUNNING
DATA MODIFIED
ALARM
If the job was loaded using digital inputs, the display
shows:
JOB 3 RUNNING
REMOTELY LOADED
ALARM
60
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 3: Using the CLS200
Changing the Setpoint
Select the single loop display for the loop you want to
change. Press CHNG SP. This display appears:
01
SETPOINT ?
25 ° F
ALARM
Press YES to change the setpoint.
•
Press the up or down keys (YES or NO) to increase or decrease the setpoint value.
Press ENTER to save your changes and return to single
loop display.
– or –
Press NO or BACK (without pressing ENTER) to return to
single loop display without saving the new setpoint.
•
Selecting the Control Status
If you set the control status to AUTO, the controller automatically controls the process according to the configuration information you give it.
If you set the control status to MAN, you need to set the output level.
If you set the control status to TUNE, the controller performs
an autotune and chooses PID parameters.
NOTE!
If the loop outputs are disabled, you cannot
toggle between manual and automatic control. If you try it, the screen shows an error
message telling you that the outputs are disabled, as shown below. Use the SETUP
LOOPS OUTPUT menu to enable the outputs.
See Setup Loop Outputs Menu on page 93.
MAN/AUTO CONTROL
OUTPUTS DISABLED
ALARM
Manual and Automatic Control
Doc.# 0600-3050-2000
1.
Switch to the single loop display for the loop.
2.
Press MAN/AUTO.
3.
Press YES to change the mode
– or –
if the mode is MAN, press NO to set the output power.
Watlow Anafaze
61
Chapter 3: Using the CLS200
CLS200 Series User’s Guide
Go to the next subsection, Manual Output Levels.
– or –
press NO if in AUTO to cancel and remain in AUTO mode.
4.
Select a mode by pressing the up or down key (YES or
NO) to scroll through the modes.
5.
Press ENTER to make the mode change
– or –
press BACK to return to the single loop display without
saving the new mode setting.
6.
If you set the loop to manual, you are prompted for the
output power. Go to Manual Output Levels below.
Manual Output Levels
If the loop to is set to manual control, the controller
prompts for output levels for the enabled control outputs.
Use this menu to set the manual heat and cool output levels. You should see a display like this:
01
SET HEAT
OUTPUT? 90%
ALARM
1.
Press YES to change the output power level. (If the heat
outputs are enabled, you will be able to change the
heat output power level. If only the cool outputs are
enabled, you will be able to change only the cool output
power level.)
– or –
Press NO to go to the cool output, if available, and then
press YES to change the cool output.
2.
Press up or down (YES or NO) to select a new output
power level.
3.
Press ENTER to store your changes
– or –
press BACK to discard your changes and return to single loop display.
4.
Repeat from Step 1 for the cool output, if available.
5.
Press BACK at any time to discard your changes and
return to single loop display.
Autotuning a Loop
Autotuning is a process by which a controller determines
the correct PID parameters for optimum control. This section explains how to autotune the CLS200.
Prerequisites
Before autotuning the controller, it must be installed with
control and sensor circuitry and the thermal load in place.
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It must be safe to operate the thermal system, and the approximate desired operating temperature (setpoint) must
be known.
The technician or engineer performing the autotune should
know how to use the controller front panel or MMI software
interface (e.g., AnaWin or Anasoft) to do the following:
1.
Select a loop to operate and monitor.
2.
Set a loop’s setpoint.
3.
Change a loop’s control status (MAN, TUNE, AUTO).
4.
Read and change the controller’s global and loop setup
parameters.
Background
Autotuning is performed at the maximum allowed output.
If you have set an output limit, autotuning occurs at that
value. Otherwise, the control output is set to 100% during
the autotune. Only the heat output (output 1) of a loop may
be autotuned.
The PID constants are calculated according to process’s response to the output. The loop need not reach or cross setpoint to successfully determine the PID parameters. While
autotuning the controller looks at the delay between when
power is applied and when the system responds in order to
determine the proportional band (PB). The controller then
looks for the slope of the rising temperature to become constant in order to determine the integral term (TI). The derivative term (TD) is derived mathematically from the TI.
When the controller has finished autotuning, the loop’s
control status switches to AUTO. If the process reaches 75%
of the setpoint or the autotuning time exceeds ten minutes,
the controller switches to AUTO and applies the PID constants it has calculated up to that point.
The Watlow Anafaze autotune is started at ambient temperature or at a temperature above ambient. However, the
temperature must be stable and there must be sufficient
time for the controller to determine the new PID parameters.
Performing an Autotune
NOTE!
A loop must be stable at a temperature well
below the setpoint in order to successfully
autotune. The controller will not complete
tuning if the temperature exceeds 75% of setpoint before the new parameters are found.
The following procedure explains how to autotune a loop:
1.
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Select the single loop display of the loop to be tuned.
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2.
Ensure the loop’s process variable is stable and the
loop is in MAN control status.
3.
Set the setpoint to a value as near the normal operating temperature as is safe for the system.
WARNING! During autotuning, the controller will set the
output to 100% until the process variable rises
near the setpoint. Set the setpoint within the
safe operating limits of your system.
4.
Use the three-key sequence (ENTER, ALARM ACK, CHNG
SP) to access the setup menus. In the SETUP LOOP
INPUT menu, locate the INPUT FILTER parameter.
Note the setting and then change it to 0 SCANS.
5.
Press the BACK key until the single loop display appears.
6.
Press the MAN/AUTO key.
7.
Press the NO key to toggle to the TUNE mode.
8.
Press the ENTER key to begin tuning the loop. TUNE
flashes throughout the tuning process. When tuning is
completed the control status indicator changes to AUTO.
9.
Adjust the setpoint to the desired temperature.
10. Restore the INPUT FILTER parameter to its original value.
Using Alarms
The CLS200 has three main types of alarms:
•
•
•
Failed sensor alarms
Process alarms
System alarms
Alarm Delay
You can set the controller to delay normal alarm detection
and alarm reporting. There are two kinds of alarm delay:
•
•
Start-up alarm delay delays process alarms (but not
failed sensor alarms) for all loops for a time period you
set at the STARTUP ALARM DELAY parameter in the
SETUP GLOBAL PARAMETERS menu.
Loop alarm delay delays failed sensor alarms and process alarms for one loop until the alarm condition is
continuously present for longer than the loop alarm
delay time you set.
Failed sensor alarms are affected by the loop alarm delay
even during the start-up alarm delay time period.
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Failed Sensor Alarms
Failed sensor alarms alert you if one of the following conditions occurs:
•
•
•
•
•
Thermocouple open
Thermocouple shorted (must be enabled)
Thermocouple reversed (must be enabled)
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 HT OUTPUT and
SENSOR FAIL CL OUTPUT parameters in the SETUP
LOOP OUTPUTS menu. (The output power may be different for a thermocouple open alarm; see Thermocouple Open Alarm on page 65.)
The controller displays an alarm code and alarm message on the display. See Alarm Displays on page 58.
The global alarm output is activated.
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 HEAT/COOL T/C BRK OUT parameter in the
SETUP LOOP OUTPUTS menu is set to ON, then the controller sets the output power to an average of the recent output.
If the HEAT/COOL T/C BRK OUT AVG parameter is set
to OFF, then the controller sets the output to the level
indicated by the SENSOR FAIL HT/CL OUTPUT parameter in the SETUP LOOP OUTPUTS 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 disabled by default. To
enable this alarm, set the REVERSED T/C DETECT parameter in the SETUP LOOP INPUTS menu to ON. It may be disabled if false alarms occur in your application.
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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 PROCESS POWER DIGIN
parameter in the SETUP GLOBAL PARAMETERS menu.
Connect the digital input to a device that connects the
input to controller common when the process power is
on.
RTD Open or RTD Shorted Alarm
The RTD open alarm occurs if the controller detects that the
positive or negative RTD lead is broken or disconnected.
The RTD shorted alarm occurs if the controller detects that
the positive and negative RTD leads are shorted.
You do not have to set any parameters for the RTD alarms.
Restore Automatic Control After a Sensor Failure
This feature returns a loop to automatic control after a
failed sensor is repaired. To enable this feature:
•
•
Choose a digital input for the RESTORE PID DIGIN
parameter in the SETUP LOOP CONTROL PARAMS
menu.
Connect the digital input to the dc common terminal
on the controller.
Process Alarms
The CLS200 has four process alarms, each of which you can
configure separately for each loop:
•
•
•
•
Low process alarm
High process alarm
Low deviation alarm
High deviation alarm
Setting Up Alarms
To set up an alarm:
•
•
•
•
•
Set the alarm setpoint (limit)
Set the alarm type
Choose an output, if desired
Set the alarm deadband
Set an alarm delay, if desired
The setpoints, deviation alarm values, and deadband all
use the same decimal format as the loop’s process variable.
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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 58.) .
Activates the global alarm output. (See Global Alarm
on page 68.)
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 deadband. 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 DIG
OUT POLARITY ON ALARM setting in the SETUP GLOBAL
PARAMETERS.
Alarm Type: Control or Alarm
You can configure each process alarm as either a control or
alarm.
•
•
Alarm configuration 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 userspecified non-latching alarm output.
Control configuration provides on/off control output
using the alarm setpoints. 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.
High and Low Process Alarms
A high process alarm occurs if the process variable rises
above a user-specified value. A low process alarm occurs if
the process variable drops below a separate user-specified
value. See Figure 3.9.
Enter the alarm high and low process setpoints at the HI
PROC ALARM SETPT and LO PROC ALARM SETPT parameters in the SETUP LOOP ALARMS menu.
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High process alarm on
High process alarm off
High process alarm set point
Setpoint + Deviation alarm value
} Deadband
High deviation
alarm on
High deviation
alarm off
Setpoint
} Deadband
Low deviation
alarm off
Setpoint - Deviation alarm value
Low deviation
alarm on
Low process alarm setpoint
Low process alarm on
Figure 3.9
} Deadband
} Deadband
Low process alarm off
Activation and Deactivation of
Process Alarms
Deviation Alarms
A deviation alarm occurs if the process deviates from setpoint by more than a user-specified amount. (See Figure
3.9.) Set the deviation with the DEV ALARM VALUE parameter in the SETUP LOOP ALARMS menu.
Upon power up or when the setpoint changes, the behavior
of the deviation alarms depends upon the alarm function:
•
•
If the alarm type parameter is set to ALARM, 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 type parameter is set to CONTROL, then
the deviation output switches on whenever the setpoint 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 setpoint
changes.
Global Alarm
The CLS200 comes equipped with a global alarm output.
The global output is activated if one or more of the following conditions occurs:
•
•
68
A system alarm occurs, or
A failed sensor alarm occurs and is unacknowledged,
or
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•
A process alarm occurs and is unacknowledged. The
global alarm occurs only if the alarm type is set to
ALARM in the SETUP LOOP ALARMS menu. (The global
alarm does not occur if the alarm function is set to
CONTROL.)
The global alarm output stays active until all alarms have
been acknowledged.
When the global alarm output is active, it conducts current
to the controller’s 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 DIG OUT
POLARITY ON ALARM polarity parameter in the
SETUP GLOBAL PARAMETERS menu.
Ramp/Soak
If you have a controller without the Ramp/Soak option,
pressing the RAMP/SOAK key has no effect.
If you have a controller with this option installed, see
Chapter 7, Ramp/Soak.
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4
Setup
The setup menus let you change detailed configuration information. This section describes how to set up the controller from menus in the controller firmware. The following
information is included in this chapter:
•
•
•
Accessing the setup menus
Changing parameter settings
Description of controller parameters
If you have not set up a CLS200 series controller before, or
if you do not know what values to enter, please read Chapter 8, Tuning and Control, which contains PID tuning constants and useful starting values.
How to Access the Setup Menus
Use the three-key sequence to enter the setup menus:
1.
Select the single loop display for the loop you wish to
edit.
2.
Press ENTER then ALARM A CK then CHNG SP to access
the setup menus. Do not press these keys at the same
time; press them one at a time.
3.
The first setup menu appears.
To prevent unauthorized personnel from accessing setup
parameters, the controller reverts to the single loop display
if you do not press any keys for three minutes.
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How to Change a Parameter
To change a parameter, first select the appropriate menu,
then the parameter.
When you enter the setup menus, the first menu is SETUP
GLOBAL PARAMETERS. Refer to Figure 4.1 for a listing of
all top level menus and their related parameters.
1.
Select the single loop display for the loop to set up.
2.
Enter the three-key sequence. (See How to Access the
Setup Menus on page 71.) The first menu is displayed:
SETUP GLOBAL PARAMETERS.
3.
To select the appropriate menu:
•
•
4.
To select the parameter to be edited:
•
•
5.
Press NO to move from one menu to the next. The
menus wrap around; pressing NO continuously
advances through the top level menus.
Press YES to enter the displayed menu.
Press NO to advance from one parameter to the
next. Parameters do not wrap around.
Press YES to edit the displayed parameter.
To edit the parameter setting:
•
•
Press up or down (YES or NO) to scroll to the value
or choice you want to select.
Press ENTER to accept the change
- or press BACK to cancel the change without saving.
6.
Select another parameter and repeat from step 4, or
press BACK to return to the top level menu.
7.
Select another menu and repeat from step 3,
- or press BACK to exit the setup menus.
The following sections tell more about the parameters for
each of the six top level menus. Each display illustration
contains the default value for that specific parameter. If
you have a controller with the enhanced features option,
there will be additional menus. (See Chapter 6, Enhanced
Features.)
Figure 4.1 shows the top level menus accessible from the
single loop display.
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Chapter 4: Setup
SETUP GLOBAL
PARAMETERS?
SETUP LOOP
INPUT?
SETUP LOOP
CONTROL PARAMS?
SETUP LOOP
OUTPUTS?
SETUP LOOP
ALARMS?
MANUAL I/O
TEST
LOAD SETUP
FROM JOB?
INPUT TYPE?
HEAT CONTROL PB?
HEAT CONTROL
OUTPUT?
HI PROC ALARM
SETPT?
DIGITAL INPUTS
SAVE SETUP
TO JOB?
LOOP NAME?
HEAT CONTROL TI?
HEAT OUTPUT TYPE?
HI PROC ALARM
TYPE?
TEST DIGITAL
OUTPUT?
JOB SELECT
DIG INPUTS?
INPUT UNITS?
HEAT CONTROL TD?
HEAT OUTPUT
CYCLE TIME? (TP)
HI PROC ALARM
OUTPUT?
DIGITAL OUTPUT
NUMBER XX
JOB SEL DIG INS
ACTIVE?
INPUT READING
OFFSET
HEAT CONTROL
FILTER?
(SDAC)
SDAC PARAMETERS
DEV ALARM
VALUE?
KEYPAD TEST
OUTPUT OVERRIDE
DIG INPUT?
REVERSED T/C
DETECT?
COOL CONTROL PB?
HEAT OUTPUT
ACTION?
HI DEV ALARM
TYPE?
DISPLAY TEST
OVERRIDE DIG
IN ACTIVE?
INPUT PULSE
SAMPLE TIME?
COOL CONTROL TI?
HEAT OUTPUT
LIMIT?
HI DEV ALARM
OUTPUT?
STARTUP ALARM
DELAY?
COOL CONTROL TD?
DISP FORMAT?
HEAT OUTPUT
LIMIT TIME?
LO DEV ALARM
TYPE?
COOL CONTROL
FILTER?
SENSOR FAIL
HT OUTPUT?
LO DEV ALARM
OUTPUT?
SPREAD?
HEAT T/C BRK
OUT AVG?
LO PROC ALARM
SETPT?
RESTORE PID
DIGIN?
HEAT OUTPUT?
LO PROC ALARM
TYPE?
COOL CONTROL
OUTPUT?
LO PROC ALARM
OUTPUT?
INPUT SCALING
LO RDG?
COOL OUTPUT TYPE?
ALARM DEADBAND?
INPUT FILTER?
COOL OUTPUT
CYCLE TIME?
ALARM DELAY?
(Pulse input)
RAMP/SOAK
TIME BASE?
(Ramp/soak)
KEYBOARD LOCK
STATUS?
POWER UP
OUTPUT STATUS?
PROCESS POWER
DIGIN?
CONTROLLER
ADDRESS?
COMMUNICATIONS
BAUD RATE?
(Linear and pulse)
INPUT SCALING
HI PV?
(Linear and pulse)
INPUT SCALING
HI RDG?
(Linear and pulse)
INPUT SCALING
LO PV?
(Linear and pulse)
(Linear and pulse)
(TP)
SDAC PARAMETERS
COMMUNICATIONS
PROTOCOL?
(SDAC)
COMMUNICATIONS
COMMUNICATIONS
ERR CHECK?
COOL OUTPUT
ACTION?
AC LINE FREQ?
COOL OUTPUT
LIMIT?
DIG OUT POLARITY
ON ALARM?
COOL OUTPUT
LIMIT TIME?
CLS 200
[FIRMWARE INFO]
SENSOR FAIL
CL OUTPUT?
If the enhanced features option or ramp/soak
feature is installed, refer to Chapter 6, Enhanced Features, or Chapter 7, Ramp/Soak
for additional menus.
Figure 4.1
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COOL T/C BRK
OUT AVG?
COOL OUTPUT?
CLS200 Menu Tree
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Setup Global Parameters Menu
SETUP GLOBAL
PARAMETERS
ALARM
Table 4.1 shows the parameters available in this menu.
Table 4.1
Global Parameters
Parameter
Default Value
LOAD SETUP FROM JOB?
1
SAVE SETUP TO JOB?
1
JOB SELECT DIG INPUTS?
NONE
JOB SEL DIG INS ACTIVE?
LOW
OUTPUT OVERRIDE DIG INPUT?
NONE
OVERRIDE DIG IN ACTIVE?
LOW
STARTUP ALARM DELAY?
0 MINS
RAMP/SOAK TIME BASE?*
HOURS/MINS
KEYBOARD LOCK STATUS?
OFF
POWER UP OUTPUT STATUS?
OFF
PROCESS POWER DIGIN?
NONE
CONTROLLER ADDRESS?
1
COMMUNICATIONS BAUD RATE?
9600
COMMUNICATIONS PROTOCOL?
ANA
COMMUNICATIONS ERR CHECK?
BCC
AC LINE FREQ?
60 HERTZ
DIG OUT POLARITY ON ALARM?
LOW
CLS200 [model no., fi mware rev.]
* The RAMP/SOAK TIME BASE parameter appears only if the ramp/soak
feature is installed.
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Load Setup From Job
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.
Load any one of eight jobs saved in battery-backed RAM.
LOAD SETUP
FROM JOB? 1
ALARM
Selectable values: 1 to 8
The following parameters are loaded for each loop as part
of a job:
•
•
•
PID constants, filter settings, setpoints and spread
values.
Loop control status (automatic or manual) and output
values (if the loop is in manual control)
Alarm function (off, alarm control) setpoints, high/low
process setpoints, high/low deviation setpoints and
deadband settings, and loop alarm delay.
If you have enabled the remote job select function (see Job
Select Digital Inputs on page 76), you will not be able to
load a job. If you try, you will see this message:
CANNOT LOAD JOB
REMOTE SELECT ON
ALARM
Save Setup to Job
Save the job information for every loop to one of eight jobs
in the battery-backed RAM.
SAVE SETUP
TO JOB? 1
ALARM
Selectable values: 1 to 8
If you have enabled the remote job select function (see Job
Select Digital Inputs on page 76), you will not be able to
save a job. If you try, you will see this message:
CANNOT SAVE JOB
REMOTE SELECT ON
ALARM
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Job Select Digital Inputs
Set the number of job select inputs. The controller uses
these inputs as a binary code that specifies the job number
to run. The number of inputs you choose in this parameter
controls the number of jobs you can select remotely.
If you select NONE, digital inputs do not affect job selection.
Jobs may be loaded and saved using the LOAD SETUP FROM
JOB and SAVE SETUP TO JOB parameters.
JOB SELECT
DIG INPUTS? NONE
ALARM
Selectable values: 1, 2 or 3 inputs, or NONE. These choices
have the following effect:
Table 4.2
Job Select Inputs
Setting
Enables
1
Jobs 1-2
2
Jobs 1-4
3
Jobs 1-8
NONE
Disables remote job selection
Table 4.3 shows which input states select which jobs. When
nothing is connected, the inputs are all false and job 1 is selected.
Table 4.3
76
Job Selected for Various Input
States
Digital Input 3
Digital Input 2
Digital Input 1
Job
No.
F
F
F
1
F
F
T
2
F
T
F
3
F
T
T
4
T
F
F
5
T
F
T
6
T
T
F
7
T
T
T
8
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Chapter 4: Setup
Job Select Digital Inputs Active
Specify which state is considered “true” for the digital inputs used for job selection. Default is LOW, meaning that an
input must be pulled low to be considered true. If HIGH is
selected, an input will be considered true unless it is pulled
low.
JOB SEL DIG INS
ACTIVE ? LOW
ALARM
Selectable values: HIGH or LOW.
Changing this setting has the effect of reversing the order
of the jobs in Table 4.3.
Output Override Digital Input
To enable the output override feature, select a digital input. When the specified input is activated, the controller
sets all loops to manual mode at the output levels specified
at the SENSOR FAIL HT OUTPUT and SENSOR FAIL CL
OUTPUT parameters in the SETUP LOOP OUTPUTS menu.
OUTPUT OVERRIDE
DIG INPUT? NONE
ALARM
Selectable values: NONE or input number 1 to 8.
Use the next parameter, OVERRIDE DIG IN ACTIVE, to set
the signal state that activates the output override feature.
WARNING! Do not rely solely on the output override fea-
ture to shut down your process. Install external safety devices or over-temperature
devices for emergency shutdowns.
Override Digital Input Active
Specify whether a low or high signal activates the output
override feature (see OUTPUT OVERRIDE DIG INPUT
above).
OVERRIDE DIG IN
ACTIVE ? LOW
ALARM
Selectable values: HIGH or LOW.
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You can set the input to be active when low or active when
high. When the input selected for OUTPUT OVERRIDE DIG
INPUT changes to the specified state, all the loop’s outputs
are set to their sensor fail levels.
Startup Alarm Delay
Set a startup delay for process and deviation alarms for all
loops. The controller does not report these alarm conditions
for the specified number of minutes after the controller
powers up. This feature does not delay failed sensor
alarms.
STARTUP ALARM
DELAY ? 0 MINS
ALARM
Selectable values: 0 to 60 minutes.
Keyboard Lock Status
Set this parameter to ON to disable the CHNG SP, MAN/AUTO,
and RAMP/SOAK keys on the keypad. If the keys are disabled, pressing them has no effect. If you want to use these
functions, turn off the keyboard lock.
KEYBOARD LOCK
STATUS ? OFF
ALARM
Selectable values: ON or OFF.
Power Up Output Status
WARNING! Do not set the controller to start from memo-
ry if it may be unsafe for your process to have
outputs on upon power-up.
Set the initial power-up state of the control outputs. If you
choose OFF, all loops are initially set to manual mode at 0%
output. If you choose MEMORY, the loops are restored to the
control status and output value prior to powering down.
See In Case of a Power Failure on page 152 for information
about how this feature affects ramp/soak profiles.
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POWER UP OUTPUT
STATUS ? OFF
ALARM
Selectable values: OFF or MEMORY.
Process Power Digital Input
To enable the thermocouple short detection feature, select
a digital input (1 to 8). Connect the specified input to a device that pulls the input low when the process power is on.
A short is indicated when the process power is on and the
temperature does not rise as expected.
If the controller determines that there is a thermocouple
short, it sets the loop to manual mode at the power level set
for the SENSOR FAIL HT OUTPUT or SENSOR FAIL CL
OUTPUT parameter in the SETUP LOOP OUTPUTS menu.
PROCESS POWER
DIGIN ? NONE
ALARM
Selectable values: 1 to 8, or NONE.
Controller Address
Set the communications address for the controller. On an
EIA/TIA-485 communication loop, each controller must
have a unique address. Begin with address 1 for the first
controller and assign each subsequent controller the next
higher address.
CONTROLLER
ADDRESS ?
1
ALARM
Selectable values: 1 to 247. When using one controller
with Anasoft, select address 1. When using multiple controllers with Anasoft, use consecutive addresses from 1 to
16 only.
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Communications Baud Rate
Set the communications baud rate.
COMMUNICATIONS
BAUD RATE ? 9600
ALARM
Selectable values: 9600, 2400 or 19200.
NOTE!
Set the baud rate to the same speed in both
the controller and the HMI software or panel.
Communications Protocol
Set the communications protocol. Choose the correct protocol for the software or device with which the controller will
communicate. You must switch power to the controller off,
then back on, to make a change to this parameter take effect.
COMMUNICATIONS
PROTOCOL ? ANA
ALARM
Selectable values: MOD (Modbus RTU), ANA (Anafaze), AB
(Allen Bradley).
Communications Error Checking
If you selected the ANA or AB communications protocol, set
the data check algorithm for CLS200 communications.
CRC (Cyclic Redundancy Check) is a more secure error
checking algorithm than BCC, but it requires more calculation time and slows communications. BCC (Block Check
Character) ensures a high degree of communications integrity. We recommend BCC unless your application requires
CRC.
COMMUNICATIONS
ERR CHECK ? BCC
ALARM
Selectable values: BCC or CRC.
NOTE!
80
If you are using Anasoft, configure it with
ANAINSTL for the same error checking method and baud rate set in the controller.
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Chapter 4: Setup
AC Line Frequency
Specify the ac line frequency. Since the controller reduces
the effect of power line noise on the analog measurement by
integrating the signal over the period of the ac line frequency, the controller must know the frequency of power in use.
You must switch power to the controller off, then back on,
to make a change to this parameter take effect.
AC LINE FREQ
60 HERTZ
?
ALARM
Selectable values: 50 or 60 Hz.
Digital Output Polarity on Alarm
Set the polarity of all digital outputs used for alarms. If LOW
is selected, if an alarm occurs the outputs sink to analog
common. If HIGH is selected, the outputs sink to common
when no alarm is active and go high when an alarm occurs.
DIG OUT POLARITY ON
ALARM ? LOW
ALARM
Selectable values: HIGH or LOW.
This parameter does not affect the Global Alarm output or
the Watchdog Alarm output.
EPROM Information
The display shows the controller type, firmware options,
the firmware version and the EPROM checksum. Table 4.4
lists the available firmware options.
Firmware Option
Controller Model
Firmware Version
CLS208-RS
V03.13
CS=ED74
EPROM Checksum
ALARM
Table 4.4
Firmware Option Codes
Firmware Option
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Description
(none)
Standard Firmware
-EF
Enhanced Features Option
-RS
Ramp/Soak Option
-EX
Extruder Option
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NOTE!
If the EPROM information does not match
this description, the EPROM probably contains a custom program. Custom programs
may not work as described in this manual. If
that is the case, contact your dealer for more
information about the firmware.
Setup Loop Input Menu
SETUP LOOP 01
INPUT ?
ALARM
The SETUP LOOP INPUT menu includes parameters
related to the loop input:
•
•
•
•
Input type
Input units
Input scaling and calibration
Input filtering
Table 4.5
Setup Loop Input
Parameter
Default Value
INPUT TYPE?
J
LOOP NAME?
01
INPUT UNITS?
°F
INPUT READING OFFSET?
0° F
REVERSED T/C DETECT?3
OFF
INPUT PULSE SAMPLE TIME?1
DISP FORMAT?2
1
-999 TO 3000
INPUT SCALING HI PV?2
1000
INPUT SCALING HI RDG?2
100.0% FS
INPUT SCALING LO PV?2
0
INPUT SCALING LO RDG?2
0.0% FS
INPUT FILTER?
3 SCANS
1 This parameter is available only for the pulse loop (loop 5 on
CLS204, loop 9 on CLS208, loop 17 on CLS216).
2 These parameters are available only if LINEAR is selected for
INPUT TYPE.
3 These parameter is available only if INPUT TYPE is set to one of
the thermocouple or RTD options.
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Input Type
Specify the type of input sensor used on this loop:
•
•
•
•
•
Thermocouple type J, K, T, S, R, B or E.
RTD 1 or RTD 2.
Linear input.
Skip (an input type available for unused loops).
Alarms are not detected, and the scanning display
does not show loops that are set to SKIP.
Pulse input (available only for loop 5 on CLS204, loop
9 on CLS208 or loop 17 on CLS216).
01 INPUT
TYPE ? J T/C
ALARM
Selectable values: See Table 4.6.
Table 4.6
CLS200 Input Types and Ranges
Input
Type
J T/C
-350 to +1,400° F (-212 to +760° C)
K T/C
-450 to +2,500° F (-268 to +1,371° C)
T T/C
-450 to +750° F (-268 to +399° C)
S T/C
0 to +3,200° F (-18 to +1,760° C)
R T/C
0 to +3,210° F (-18 to +1,766° C)
B T/C
+150 to 3,200° F (+66 to 1,760° C)
E T/C
+150 to 3,200° F (+66 to 1,760° C)
RTD1
-148.0 to +572.0° F (-100.0 to +275.0° C)
RTD2
-184 to +1,544° F (-120 to +840° C)
PULSE
0 to 2 kHz
SKIP
LINEAR
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Input Range
Loop not used.
See Linear Scaling Parameters on page 86.
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Loop Name
Assign a two-character name to the loop. This name is shown
on the single loop display in place of the loop number.
01 LOOP
NAME ?
01
ALARM
Selectable values: 0 to 9, A to Z, %, /, ° (degree symbol).
Input Units
For loops with temperature sensor input types, choose a
temperature scale: Fahrenheit or Celsius. For a linear or
pulse loop, choose a three-character description of the
loop’s engineering units.
01 INPUT
UNITS ?
°F
ALARM
Selectable values: The table below shows the character
set for input units.
Table 4.7
Input Character Sets
Input
Character Sets for Units
Thermocouple
or RTD
°F or °C
Linear or Pulse
0 to 9, A to Z,%, /, °, space
Input Reading Offset
If the input type is a thermocouple or RTD, specify the offset to correct for signal inaccuracy at a given point. For example, at temperatures below 400˚ F, a type J
thermocouple may be inaccurate or “offset” by several degrees. Use an independent thermocouple or your own calibration equipment to find the offset for your equipment.
A positive value increases the reading and a negative value
decreases it.
01 INPUT READING
OFFSET ? 0˚F
ALARM
Selectable values: See Table 4.8.
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Table 4.8
Input Reading Offset
Offset Range
Type of Sensor
°F
°C
RTD2
J
K
T
-300 to +300
-300 to +300
RTD1
-300.0 to +300.0
-300.0 to +300.0
B
S
-300 to +76
-300 to +300
R
-300 to +66
-300 to +300
Reversed T/C Detection
Set this parameter to ON to enable polarity checking for
thermocouples. If a reversed thermocouple is detected, the
controller sets the loop to manual control at the SENSOR
FAIL HT OUTPUT or SENSOR FAIL CL OUTPUT power level
and displays the alarm.
01 REVERSED T/C
DETECT ?
OFF
ALARM
Selectable values: ON or OFF.
Input Pulse Sample Time
You can connect a digital pulse signal of up to 2 kHz to the
pulse input. Use this parameter to set the time over which
pulses are counted. The controller counts pulses for the
amount of time you set here before calculating the frequncy. The controller scales this frequency and uses the resulting value as the process variable for the pulse loop.
Generally, the longer the pulse sample time, the more stable the process variable, but the slower the response of the
pulse loop.
This parameter is available only for loop 5 on the CLS204,
loop 9 on the CLS208 or loop 17 on the CLS216.
17 INPUT PULSE
SAMPLE TIME ? 1S
ALARM
Selectable values: 1 to 20 seconds.
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Linear Scaling Parameters
The following parameters are only available if the input
type is LINEAR or PULSE. These parameters let you scale
the raw input readings (in millivolts or Hertz) to the engineering units of the process variable.
For linear inputs, the input reading is in percent (0 to
100%) representing the 0 to 60mV input range of the controller. For pulse inputs, the input reading is in Hertz (cycles per second.)
The scaling function is defined by two points on a conversion line. This line relates the process variable (PV) to the
input signal. The engineering units of the process variable
can be any units—the graph in Figure 4.2 shows PSI as an
example.
High Process
Variable
Low Process
Variable
Low
Reading
Figure 4.2
Input Reading
High
Reading
Two Points Determine Process
Variable Conversion
Before you enter the values determining the two points for
the conversion line, you must choose an appropriate display format. The controller has six characters available for
process display; select the setting with the desired number
of decimal places. Use a display format that matches the
range of the process variable and resolution of the sensor.
The display format you choose is used for the process variable setpoint, alarms limits, deadband, spread and proportional band.
The process variable range for the scaled input is between
the process variable values that correspond to the 0% and
100% input readings. For the pulse input, it is between the
0 Hz and 2000 Hz readings. The process variable range defines the limits for the setpoint and alarms. See Figure 4.3.
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Chapter 4: Setup
High Process
Variabale
Process Variable
Low Process
Variabale
Low
Reading
Figure 4.3
Input Reading
High
Reading
Process Variable Limited by Input
Reading Range
Display Format
Select a display format for a linear or pulse input. Choose
a format appropriate for the input range and sensor accuracy.
01 DISP FORMAT ?
-999 TO 3000
ALARM
Selectable values: The controller has several available
display formats, as shown in Table 4.9. The table also
shows the maximum and minimum process variable for
each display format.
Table 4.9
Display Formats
Maximum
Process
Variable
Minimum
Process
Variable
-9999 TO +30000
30,000
-9,999
-999 TO +3000
3,000
-999
-999.9 TO +3000.0
3,000.0
-999.9
-99.99 TO +300.00
300.00
-99.99
-9.999 TO +30.000
30.000
-9.999
-.9999 TO +3.0000
3.0000
-0.9999
Display Format
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High Process Variable
Set a high process variable for input scaling purposes. The
high process variable and the high reading (HI RDG) together define one of the points on the linear scaling function’s conversion line. Set HI PV to the value you want
displayed when the signal is at the level set for the high
reading (HI RDG).
01 INPUT SCALING
HI PV ? 1000
ALARM
Selectable values: Any value between the low process
variable (LO PV) and the maximum process variable for the
selected display format. See Table 4.9.
High Reading
Enter the input signal level that corresponds to the high
process variable (HI PV) you entered in the previous parameter.
01 INPUT SCALING
HI RDG? 100.0%FS
ALARM
Selectable values: For linear inputs, any value between
-99.9% and 999.9% of full scale, where 100% corresponds
to 60mV and 0% corresponds to 0mV. For pulse inputs, any
value between 0 and 2000 HZ. The high reading must be
greater than the low reading (LO RDG).
Low Process Variable
Set a low process variable for input scaling purposes. The
low process variable and the low reading (LO RDG) together
define one of the points on the linear scaling function’s conversion line. Set LO PV to the value you want displayed
when the signal is at the level set for the low reading (LO
RDG).
01 INPUT SCALING
LO PV ? 0
ALARM
Selectable values: Any value between the minimum process variable and the high process variable for the selected
display format. See Table 4.9 on page 87.
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Low Reading
Enter the input signal level that corresponds to the low
process variable (LO PV) you entered in the previous parameter.
01 INPUT SCALING
LO RDG?
0.0%FS
ALARM
Selectable values: For linear inputs, any value between
-99.9% and 999.9% percent of full scale, where 100% corresponds to 60mV and 0% corresponds to 0mV. For pulse
inputs, any value between 0 and 2000 HZ. The low reading
must be less than the high reading (HI RDG).
Input Filter
The controller has two types of input filtering:
•
•
The rejection filter ignores sensor readings outside the
acceptance band when subsequent readings are within
the band. For temperature sensors, the band is ±5˚
about the last accepted reading. For linear inputs the
band is ±0.5% of the input range. This filter is not adjustable.
A simulated resistor-capacitor (RC) filter damps the
input response if inputs change unrealistically or
change faster than the system can respond. If the input filter is enabled, the process variable responds to
a step change by going to 2/3 of the actual value within
the number of scans you set.
01 INPUT FILTER?
3
SCANS
ALARM
Selectable values: 0 to 255 scans. 0 disables the filter.
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Setup Loop Control Parameters Menu
Use the SETUP LOOP CONTROL PARAMS menu to adjust
heat and cool control parameters, including:
•
•
•
Proportional band (PB, or gain), integral (TI or reset),
and derivative (TD, or rate) settings
Output filter
Spread between heat and cool outputs
The controller has separate PID and filter settings for heat
and cool outputs. The screens used to set these parameters
are nearly identical. In this section, only the heat screens
are shown and explained. The heat and cool parameters appear only if the corresponding output is enabled.
See Setup Loop Outputs Menu on page 93 for help enabling
and disabling heat and cool outputs.
SETUP LOOP 01
CONTROL PARAMS?
ALARM
Table 4.10 shows the parameters available in the SETUP
LOOP CONTROL PARAMS menu.
Table 4.10
Setup Loop Control Parameters
Parameter
Default Value
HEAT CONTROL PB?
Depends upon the INPUT TYPE setting; 50 for J-type thermocouple.
HEAT CONTROL TI?
Depends upon the INPUT TYPE setting; 180 SEC/R for J-type thermocouple.
HEAT CONTROL TD?
0
HEAT CONTROL FILTER?
3
COOL CONTROL PB
50
COOL CONTROL TI?
Depends upon the INPUT TYPE setting; 60 SEC/R for J-type thermocouple.
COOL CONTROL TD?
Depends upon the INPUT TYPE setting; 0 SECONDS for J-type thermocouple.
COOL CONTROL FILTER?
3
SPREAD?
5
RESTORE PID DIGIN?
NONE
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Heat or Cool Control PB
Set the proportional band (also known as gain). A larger
value yields less proportional action for a given deviation
from setpoint.
01 HEAT CONTROL
PB ?
50
ALARM
Selectable values: Dependent upon sensor type.
The controller internally represents the proportional band
(PB) as a gain value. When you edit the proportional band,
you will see the values change in predefined steps; small
steps for narrow proportional band values and large steps
for wide proportional band values.
The controller calculates the default proportional band for
each input type according to the following equation:
(High Range - Low Range)
Default PB = ----------------------------------------------------------------------Gain
Heat or Cool Control TI
Set the integral term (also known as reset). A larger value
yields less integral action.
01 HEAT CONTROL
TI ? 180 SEC/R
ALARM
Selectable values: 0 (off) to 6000 seconds.
Heat or Cool Control TD
Set the derivative constant. A larger value yields greater
derivative action.
01 HEAT CONTROL
TD ?
0
ALARM
Selectable values: 0 to 255 seconds.
Heat or Cool Output Filter
Dampen the response of the heat or cool output. The output
responds to a step change by going to approximately 2/3 of
its final value within the number of scans you set here. A
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larger value results in a slower, or more dampened, response to changes in the process variable.
01 HEAT CONTROL
FILTER ?
3
ALARM
Selectable values: 0 to 255. 0 disables the output filter.
Spread
For a loop using on/off control, the spread is the control hysteresis. This determines the difference between the point at
which a heat output turns off as the temperature rises, and
the point at which it turns back on as the temperature falls.
For a loop using PID control, the spread determines how
far the process variable must be from the setpoint before
the controller can switch from heating to cooling. A loop
will not switch from heat to cool or vice versa unless the
process variable deviates from setpoint by more than the
spread.
When the loop is using PID control and the spread is set to
0, the PID calculation alone determines when the heat or
cool output should be on.
01
SPREAD ?
5
ALARM
Selectable values: 0 to 255, 25.5, 2.55, .255, or.0255,
depending upon the DISP FORMAT setting.
Restore PID Digital Input
To enable the sensor failure recovery feature, select a digital input at this parameter. If the specified input is held
low when the sensor fails, the loop returns to automatic
control after a failed sensor is corrected.
01 RESTORE PID
DIGIN ? NONE
ALARM
Selectable range: NONE (disable the sensor failure recovery feature), 1 to 8.
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Setup Loop Outputs Menu
Use the SETUP LOOP OUTPUTS menu to:
•
•
•
•
•
•
•
•
Enable or disable outputs
Set output type
Set cycle time for time proportioning outputs
Enter Serial DAC parameters (for Serial DAC outputs)
Select control action
Set output level limit and limit time
Select sensor fail output (output override)
Select a nonlinear output curve
SETUP LOOP 01
OUTPUTS ?
ALARM
Table 4.11 shows the parameters available in the SETUP
LOOP OUTPUTS menu. Both heat and cool outputs have the
same parameters; only one of each parameter is shown.
Table 4.11
Setup Loop Outputs
Parameter
Default Value
HEAT CONTROL OUTPUT?
ENABLED
HEAT OUTPUT TYPE?
TP
HEAT OUTPUT CYCLE TIME?
10S
SDAC MODE?*
VOLTAGE
SDAC LO VALUE?*
0.00 VDC
SDAC HI VALUE?*
10.00 VDC
HEAT OUTPUT ACTION?
REVERSE
HEAT OUTPUT LIMIT?
100%
HEAT OUTPUT LIMIT TIME?
CONT
SENSOR FAIL HT OUTPUT?
0%
HEAT T/C BRK OUT AVG?
OFF
HEAT OUTPUT?
LINEAR
COOL CONTROL OUTPUT?
DISABLED
* The SDAC parameters are available only if you select SDAC as
the output type. Use these parameters to configure the Serial
DAC signal output.
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Enable or Disable Heat or Cool Outputs
Enable or disable the heat or cool output for the loop. If you
want the loop to have a control output, you must enable at
least one output. You can also disable a heat or cool control
output and use the output for something else, such as an
alarm.
01 HEAT CONTROL
OUTPUT ? ENABLED
ALARM
Selectable values: ENABLED or DISABLED.
Heat or Cool Output Type
Select the output type.
01
HEAT OUTPUT
TYPE ? TP
ALARM
Selectable values: TP, DZC, SDAC, ON/OFF, 3P DZC. See
Table 4.12 for a description of the output types.
NOTE!
The controller assigns digital output 34 as a
clock line for the Serial DAC. You will not be
able to assign another function to output 34
if any loop’s output is set to SDAC.
Table 4.12
Display
Code
Heat / Cool Output Types
Output Type
Definition
TP
Time Proportioning
Percent output converted to a percent duty
cycle over the user-selected, fi ed time base.
DZC
Distributed Zero
Crossing
Output on/off state calculated for every ac line
cycle. Use with Dual DAC.
SDAC
Serial DAC
Use with Serial DAC.
ON/OFF
On/Off
Output either full on or full off.
3P DZC
3-Phase Distributed
Zero Crossing
Use with 3-phase heaters when wired in delta
configu ation. (For grounded Y configu ation,
use DZC instead.)
For an expanded description of these output types, see
Chapter 8, Tuning and Control.
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Heat or Cool Cycle Time
Set the cycle time for time proportioning outputs.
01 HEAT OUTPUT
CYCLE TIME? 10S
ALARM
This parameter appears only if the heat or cool output type
for the loop is set to time proportioning (TP).
Selectable values: 1 to 255 seconds.
SDAC Mode
Select the Serial DAC output signal.
01
SDAC MODE?
VOLTAGE
ALARM
Selectable values: CURRENT or VOLTAGE.
SDAC Low Value
Set the low output signal level for the Serial DAC. The Serial DAC converts 0% output from the controller to the value set here.
Set the high and low values to match the input range of the
output device. For instance, if the output device has a 0.0010.00 V range, set the SDAC LO VALUE to 0.00 VDC and
set the SDAC HI VALUE to 10.00 VDC.
01 SDAC LO VALUE?
0.00 VDC
ALARM
Selectable values: 0.00 to 9.00 VDC or 0.0 to 19.90
MA. This value must be less than the SDAC HI VALUE.
SDAC High Value
Set the high output signal level for the Serial DAC. The Serial DAC converts 100% output from the controller to the
value set here.
Set the high and low values to match the range of the output device. For instance, if the output device has a 4 to 20
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mA range, set the SDAC HI VALUE to 20.00 MA and the
SDAC LO VALUE to 4.00 MA.
01 SDAC HI VALUE?
10.00 VDC
ALARM
Selectable values: 0.10 to 10.00 VDC or 0.10 to 20.00
mA. This value must be greater than the SDAC LO VALUE.
Heat or Cool Output Action
Select the control action for the output. Normally, heat outputs are set to reverse action and cool outputs are set to direct action. When output action is set to REVERSE, the
output goes up when the process variable goes down. When
set to DIRECT, the output goes up when the process variable goes up.
01 HEAT OUTPUT
ACTION? REVERSE
ALARM
Selectable values: REVERSE or DIRECT.
Heat or Cool Output Limit
This parameter limits the maximum PID control output for
a loop’s heat or cool output. This limit may be continuous,
or it or it may be in effect for a specified number of seconds
(see the next parameter). If you choose a timed limit, the
output limit time restarts when the controller powers up
and whenever the loop goes from manual to automatic control. The output limit only affects loops under automatic
control. It does not affect loops under manual control.
01 HEAT OUTPUT
LIMIT ? 100%
ALARM
Selectable values: 0 to 100%.
Heat or Cool Output Limit Time
Set a time limit for the output limit set at the previous parameter.
01 HEAT OUTPUT
LIMIT TIME? CONT
ALARM
Selectable values: 1 to 999 seconds, or to CONT (continuous).
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Sensor Fail Heat or Cool Output
When a sensor fail alarm occurs or when the OUTPUT
OVERRIDE DIG INPUT (page 77) becomes active on a loop
that is in automatic control, that loop goes to manual control at the percent power output set here.
01 SENSOR FAIL
HT OUTPUT ? 0%
ALARM
Selectable values: 0 to 100%.
NOTE!
When a sensor fails or the override input is
detected, both the heat and cool outputs are
set to their fail settings. In most applications,
SENSOR FAIL HT OUTPUT and SENSOR
FAIL CL OUTPUT should be set to 0%.
WARNING! Do not rely solely on the sensor fail alarm to
adjust the output in the event of a sensor failure. If the loop is in manual control when a
failed sensor alarm occurs, the output is not
adjusted. Install independent external safety
devices that will shut down the system if a
failure occurs.
Heat or Cool Thermocouple Break Output Average
If you set this parameter to ON and a thermocouple break
occurs, a loop set to automatic control status will go to manual mode at a percentage equal to the average output prior
to the break.
01 HEAT T/C BRK
OUT AVG ?
OFF
ALARM
Selectable range: ON or OFF
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Heat or Cool Linearity
Select an output curve. For a nonlinear process, select
CURVE 1 or CURVE 2.
01 HEAT OUTPUT?
LINEAR
ALARM
Selectable values: CURVE 1, CURVE 2, or LINEAR. Refer
to Figure 4.4.
100
90
80
80
79
Actual Output
70
62
60
60
Linear
40
40
50
48
Curve 1
36
30
20
20
10
3
19
8
2
4
44
Curve 2
29
27
13
66
19
12
7
0
PID Calculation
Figure 4.4
Linear and Nonlinear Outputs
If curve 1 or 2 is selected, a PID calculation results in a lower actual output level than the linear output requires. One
of the nonlinear curves may be used when the response of
the system to the output device is nonlinear.
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Setup Loop Alarms Menu
Use the SETUP LOOP ALARMS menu to set:
•
•
•
•
•
High and low process and deviation alarm limits
Alarm outputs
Alarm/control behavior
Alarm deadband
Alarm delay
SETUP LOOP 01
ALARMS ?
ALARM
Table 4.13 shows the parameters available in the SETUP
LOOP ALARMS menu.
Table 4.13
Setup Loop Alarms
Parameter
HI PROC ALARM SETPT?
1000
HI PROC ALARM TYPE?
OFF
HI PROC ALARM OUTPUT?
NONE
DEV ALARM VALUE?
5
HI DEV ALARM TYPE?
OFF
HI DEV ALARM OUTPUT?
NONE
LO DEV ALARM TYPE?
OFF
LO DEV ALARM OUTPUT?
NONE
LO PROC ALARM SETPT?
0
LO PROC ALARM TYPE?
OFF
LO PROC ALARM OUTPUT?
NONE
ALARM DEADBAND?
ALARM DELAY?
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Value
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High Process Alarm Setpoint
Set the value at which the high process alarm activates.
01 HI PROC ALARM
SETPT ? 1000
ALARM
Selectable values: Any point within the scaled sensor
range.
High Process Alarm Type
Select an alarm type for the high process alarm.
01 HI PROC ALARM
TYPE ? OFF
ALARM
Selectable values: OFF, ALARM, or CONTROL.
High Process Alarm Output Number
Choose a digital output to activate when the high process
alarm occurs, if desired.
01 HI PROC ALARM
OUTPUT? NONE
ALARM
Selectable values: NONE, or any output from 1 to 34 not
enabled for closed-loop control or for the Serial DAC clock.
Deviation Alarm Value
Set the deviation from setpoint at which the high and low
deviation alarms occur.
01 DEV ALARM
VALUE ?
5
ALARM
Selectable values: 0 to 255, 25.5, 2.55, .255 or.0255,
depending on the INPUT TYPE and DISP FORMAT settings.
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Chapter 4: Setup
High Deviation Alarm Type
Select an alarm type for the high deviation alarm.
01 HI DEV ALARM
TYPE ? OFF
ALARM
Selectable values: ALARM, CONTROL or OFF
High Deviation Alarm Output Number
Choose a digital output to activate when the high deviation
alarm occurs, if desired.
01 HI DEV ALARM
OUTPUT ? NONE
ALARM
Selectable values: NONE, or any output from 1 to 34 not
enabled for closed-loop control or for the Serial DAC clock.
Low Deviation Alarm Type
Select an alarm type for the low deviation alarm.
01 LO DEV ALARM
TYPE ? OFF
ALARM
Selectable values: ALARM, CONTROL or OFF.
Low Deviation Alarm Output Number
Choose a digital output to activate when the low deviation
alarm occurs, if desired.
01 LO DEV ALARM
OUTPUT ? NONE
ALARM
Selectable values: NONE, or any output from 1 to 34 not
enabled for closed-loop control or for the Serial DAC clock.
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Low Process Alarm Setpoint
Set a low process alarm setpoint. See Process Alarms on
page 66.
01 LO PROC ALARM
SETPT?
0
ALARM
Selectable values: Any value within the input sensor’s
range.
Low Process Alarm Type
Select an alarm type for the low process alarm.
01 LO PROC ALARM
TYPE ? OFF
ALARM
Selectable values: ALARM, CONTROL or OFF.
Low Process Alarm Output Number
Choose a digital output to activate when the low process
alarm occurs, if desired.
01 LO PROC ALARM
OUTPUT ? NONE
ALARM
Selectable values: NONE, or any output from 1 to 34 not
enabled for closed-loop control or for the Serial DAC clock.
Alarm Deadband
Set an alarm deadband. This deadband value applies to the
high process, low process, high deviation and low deviation
alarms for the loop. Use the alarm deadband to avoid repeated alarms as the process variable cycles around an
alarm value.
01 ALARM DEADBAND ?
2
ALARM
Selectable values: 0 to 255, 25.5, 2.55, .255 or .0255,
depending on the INPUT TYPE and DISP FORMAT settings.
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Alarm Delay
Set a loop alarm delay. This parameter delays failed sensor
and process alarms until the alarm condition has been continuously present for longer than the alarm delay time.
01 ALARM DELAY ?
0 SECONDS
ALARM
Selectable range: 0 to 255 seconds.
Manual I/O Test
This menu facilitates testing of:
•
•
•
Digital inputs
Digital outputs
The keypad buttons
MANUAL I/O
TEST ?
ALARM
Table 4.14 shows the screens available in the
MANUAL I/O TEST menu.
Table 4.14
Manual I/O Test
Parameter
NOTE!
Default
Value
DIGITAL INPUTS
HHHHHHHH
TEST DIGITAL OUTPUT?
1: IN USE
DIGITAL OUTPUT NUMBER XX?
OFF
KEYPAD TEST
N/A
The DIGITAL OUTPUT NUMBER screen appears only if an unassigned output has been
selected in the TEST DIGITAL OUTPUT
screen.
Digital Inputs
View the logic state of the eight digital inputs as H (high)
meaning the input is not pulled low, or L (low) meaning the
input is connected to the controller common.
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This screen shows the state of inputs 1 to 8 from left to
right. See Figure 4.5. Since inputs are pulled high when
they are not connected, test an input by shorting it to controller common and making sure this screen shows the correct state for that input.
Input 8
DIGITAL INPUTS
HHHHHHHH
Input 1
ALARM
Figure 4.5
Digital Inputs Screen
When you are done testing digital inputs, press YES or NO
to advance to the next screen, or press BACK to return to the
MANUAL I/O TEST menu.
Test Digital Output
Select one of the digital alarm outputs to test. You will test
the output on the next screen.
You cannot force the state of an output enabled for control.
TEST DIGITAL
OUTPUT? 1:IN USE
ALARM
Selectable values: Any output from 1 to 34 that is not enabled for closed-loop control or for the Serial DAC clock and
GA, the global alarm output.
Digital Output Number
This screen appears only if you selected an output that is
not in use for control at the TEST DIGITAL OUTPUT screen.
Use this parameter to manually toggle a digital output on
or off to test it. Toggling an output ON sinks current from
the output to the controller common. Toggling the output
OFF stops current flow. All tested outputs are set to OFF
when you exit the MANUAL I/O TEST menu.
You cannot toggle outputs enabled for control. To test a
control loop output, first disable it using the SETUP LOOP
OUTPUTS menu.
DIGITAL OUTPUT
NUMBER XX ? OFF
ALARM
Selectable values: ON or OFF.
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Keypad Test
Test the keypad. The test begins automatically when the
screen appears.
KEYPAD TEST
QUIT = "NO"+"NO"
ALARM
•
•
Press any key to test the keypad. The controller will
display the name of the key you have pressed.
Press NO twice to end the test and return to the top of
the MANUAL I/O TEST menu.
Display Test
Use this function to test the display.
DISPLAY TEST?
ALARM
Press YES to enter the test and display the instruction
screen.
TO TEST DISPLAY
Y-TOGGLE N-QUIT
ALARM
Press YES to begin the display of a discernable pixel pattern.
•
•
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Press YES to toggle the pixel pattern.
Press NO to end the test and return to the top of
the MANUAL I/O TEST menu.
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5
Extruder Control
This chapter explains the additional features for the
CLS200 series controller equipped with Extruder Control
Firmware. Except for setup, default and control algorithm
differences described below, the Extruder Control Firmware operates the same as the standard control firmware.
Setup Loop Outputs Menu
The SETUP LOOP OUTPUTS menu contains a parameter
with descriptors for the selections that are different than
those in the standard control firmware.
SETUP LOOP 01
OUTPUTS ?
ALARM
Cool Output Nonlinear Output Curve
Select linear or nonlinear output curves for the cool output.
01 COOL OUTPUT
FAN
ALARM
Selectable Values: FAN, OIL or H2O. See Figure 5.1.
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100
100
90
80
80
Fan
70
66
62
60
Output
60
50
40
Oil
79
48
44
40
36
30
20
20
10
0
0
3
Figure 5.1
19
19
13
8
4
2
29
27
12
7
H2O
Calculated by PID
Cool Output Nonlinear Output
Curve
The COOL OUTPUT parameter is located in the SETUP
LOOP OUTPUTS menu. Select one of three nonlinear or linear output curves for cooling.
Defaults
The Extruder Control Firmware uses different defaults for
some parameters in the SETUP LOOP CONTROL
PARAMS menu. Furthermore, a unique set of control defaults are asserted whenever the COOL OUTPUT parameter on the SETUP LOOP OUTPUTS menu is changed.
Table 5.1 through Table 5.3 on page 109 list the default parameter settings for each cool output curve.
NOTE!
108
Changing the cool output curve parameter
will change control parameter settings to defaults for that particular cool output curve.
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Chapter 5: Extruder
Table 5.1 Default Control Parameters for Fan Cool Output
Parameter
Default Value
HEAT CONTROL PB?
50 (for J-type thermocouple) depends on Input Type setting
HEAT CONTROL TI?
500 sec/repeat
HEAT CONTROL TD?
125 sec
HEAT CONTROL FILTER
6
COOL CONTROL PB?
10 (for J-type thermocouple) depends on Input Type setting
COOL CONTROL TI?
0 sec/repeat
COOL CONTROL TD?
0 sec
COOL CONTROL FILTER?
4
Table 5.2 Default Control Parameters for Oil Cool Output
Parameter
Default Value
HEAT CONTROL PB?
50 (for J-type thermocouple) depends on Input Type setting
HEAT CONTROL TI?
500 sec/repeat
HEAT CONTROL TD?
125 sec
HEAT CONTROL FILTER
6
COOL CONTROL PB?
35 (for J-type thermocouple) depends on Input Type setting
COOL CONTROL TI?
300 sec/repeat
COOL CONTROL TD?
60 sec
COOL CONTROL FILTER?
3
Table 5.3 Default Control Parameters for H2O Cool Output
Parameter
Default Value
HEAT CONTROL PB?
50 (for J-type thermocouple) depends on Input Type setting
HEAT CONTRO TI?
500 sec/repeat
HEAT CONTROL TD?
125 sec
HEAT CONTROL FILTER
6
COOL CONTROL PB?
70 (for J-type thermocouple) depends on Input Type setting
COOL CONTROL TI?
500 sec/repeat
COOL CONTROL TD?
90 sec
COOL CONTROL FILTER?
2
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Extruder Control Algorithm
The Extruder Control Firmware uses a control algorithm
that has been optimized for controlling temperature loops
in plastic extruder equipment. Typically, overshoot is undesirable and ambient cooling is not sufficient to dampen
the effects of self heating that are inherent in the extrusion
process. This control method uses both heat and cool outputs. Under some conditions both heat and cool outputs
may be on at the same time.
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6
Enhanced Features
This chapter explains five additional features for the
CLS200 controller when enabled with enhanced features
option firmware:
•
•
•
•
•
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Process variable retransmit
Cascade control
Ratio control
Remote analog setpoint
Differential control
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Chapter 6: Enhanced Features
SETUP
GLOBAL
PARAMETERS
SETUP
LOOP
INPUTS
CLS200 Series User’s Guide
SETUP
LOOP CONTROL
PARAMETERS
SETUP
LOOP
OUTPUTS
SETUP
LOOP PV
RETRANSMIT
SETUP
LOOP
CASCADE
YES
YES
HEAT OUTPUT
RETRANS PV?
SETUP
LOOP RATIO
CONTROL
SETUP
LOOP
ALARMS
MANUAL
I/O
TEST
YES
CASCADE
PRIM. LOOP?
RATIO CONTROL
MSTR LOOP?
HEAT RETRANS
MIN INP?
CASCADE
BASE SP?
RATIO CONTROL
MIN SP?
HEAT RETRANS
MIN OUT%?
CASCADE
MIN SP?
RATIO CONTROL
MAX SP?
HEAT RETRANS
MAX INP?
CASCADE
MAX SP?
RATIO CONTROL
CTRL RATIO?
CASCADE
HT SPAN?
RATIO CONTROL
SP DIFF?
Enter 1-9
Enter
NONE
or NO
Enter
NONE
or NO
HEAT RETRANS
MAX OUT%?
COOL OUTPUT
RETRANS PV?
CASCADE
CL SPAN?
Enter 1-9
COOL RETRANS
MIN INP?
COOL RETRANS
MIN OUT%?
COOL RETRANS
MAX INP?
COOL RETRANS
MAX OUT%?
Figure 6.1
112
Enhanced Features Option Menus
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Chapter 6: Enhanced Features
Process Variable Retransmit
The process variable retransmit feature retransmits the
process signal of one loop (primary) via the control output
of another loop (secondary). This signal is linear and proportional to the engineering units of the primary loop input.
Typical uses include data logging to analog recording systems and long distance transmission of the primary signal
to avoid degradation of the primary signal. The signal can
also be used as an input to other types of control systems
such as a PLC.
Any available output (heat or cool) may be used as a retransmit output. Any process variable (including the same
loop number input) may be retransmitted.
The controller output signal must be connected to a Dual
DAC or Serial DAC converter to get a 4 to 20 mAÎ (dc) or
0 to 5VÎ (dc) signal. The choice of converter depends on application requirements.
The process variable retransmit feature is included in both
the ramp/soak and enhanced features options.
NOTE!
If an output is defined as a process variable
retransmit, it cannot be used for PID control.
Setup Loop Process Variable Retransmit Menu
The setup parameters for the process variable retransmit
feature appear in the SETUP LOOP PV RETRANSMIT menu.
SETUP LOOP 02
PV RETRANSMIT?
ALARM
Press YES to view the process variable retransmit parameters.
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Retransmit Process Variable
Enter the number of the loop that provides the process
variable for the retransmit calculation.
02 HEAT OUTPUT
RETRANS PV? 02
ALARM
If you set this parameter NONE and press NO, the controller
skips to the COOL OUTPUT RETRANS PV screen. The COOL
parameter is set up the same way as the HEAT parameter.
Selectable values: Any loop or NONE.
Minimum Input
Enter the lowest value of the process variable to be retransmitted. This value is expressed in the same engineering
units as the input loop.
02 HEAT RETRANS
MIN INP? 1000
ALARM
If the process variable falls below the minimum, the output
will stay at the minimum value.
Selectable values: Any value in the input loop’s range.
Minimum Output
Enter the output value (0 to 100%) that corresponds to the
minimum input.
02 HEAT RETRANS
MIN OUT%? 0%
ALARM
Selectable values: 0 to 100%
If you select a minimum output value other than 0%, the
output will never drop below MIN OUT, even if the process
variable drops below the MIN INP that you specified.
Maximum Input
Enter the highest value of the process variable to be retransmitted. This value is expressed in the same engineering units as the input loop.
02 HEAT RETRANS
MAX INP? 10000
ALARM
If the process variable goes above the maximum, the output
will stay at the maximum value.
Selectable values: Any value in the input loop’s range.
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By adjusting the maximum and minimum inputs, you can
scale the output appropriately. See Figure 6.2.
Output Power (%)
100%
Maximum
Output
Minimum
Output
0%
Minimum
Input
Maximum
Input
Input Process Variable
Figure 6.2
Linear Scaling of Process Variable
for Retransmit
Maximum Output
Enter the output value (0 to 100%) which corresponds to
the maximum input.
02 HEAT RETRANS
MAX OUT%? 100%
ALARM
The output will never go above the this maximum output
percentage, regardless of how high the process variable
goes.
Selectable values: 0 to 100%
Process Variable Retransmit Example: Data Logging
The CLS200 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 input
is a linear 4 to 20 mAÎ (dc) signal representing a process
variable range of 0 to 1000˚ F.
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Loop 1
Input
Process
Variable
Loop 1 PID Output
Loop 2 PID Output
Furnace
CLS200
Heater
Serial
DAC
Power
Controller
Figure 6.3
To Data
Logger
Application Using Process Variable Retransmit
To set up this application, you would do the following:
116
1.
First, set up the standard control loop parameters according to the furnace application, in this case on loop
1.
2.
Select another unused PID output for retransmitting
the thermocouple value (for example, loop 2 heat output).
3.
Change the display to loop 2, and then enter the threekey sequence (ENTER, then ALARM ACK, then CHNG SP)
and go to the first screen in Table 6.1.
4.
Follow the steps in Table 6.1 to configure the process
variable retransmit option.
5.
After following the steps in Table 6.1, press BACK several times until the normal loop display appears. The
controller will now produce an output on loop 2 which
is linear and proportional to the loop 1 process variable.
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Chapter 6: Enhanced Features
Table 6.1
Application Example: Setting Up
Process Variable Retransmit
Display
SETUP LOOP 02
PV RETRANSMIT
User Input
Press YES.
ALARM
02 HEAT OUTPUT
RETRANS PV? 01
Enter 01 for loop 1 process variable. Press ENTER.
ALARM
02 HEAT RETRANS
MIN INP? 0
Enter the minimum input value, which corresponds to the minimum
output percentage. For a range of 0 to 1000° F, set the minimum
input value to 0° F. Press ENTER.
ALARM
02 HEAT RETRANS
MIN OUT%? 0
Enter the minimum output percentage, from 0 to 100%. For this
example we will assume a full span with a minimum of 0%. Press
ENTER.
ALARM
02 HEAT RETRANS
MAX INP? 1000
Enter the maximum input value, which corresponds to the maximum output percentage. For a range of 0 to 1000° F, set the maximum input value to 1000° F. Press ENTER.
ALARM
02 HEAT RETRANS
MAX OUT%? 100
ALARM
02 COOL OUTPUT
RETRANS PV? NONE
Enter the maximum output percentage, from 0 to 100%. For this
example we will assume a full span with a maximum of 100%.
Press ENTER.
The process variable retransmit section of the controller programming is now completed. We are not using the cool output of loop 2
to retransmit a process variable, so choose NONE. Press ENTER.
ALARM
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Notes about this application:
•
•
•
This is not a thermocouple curve type of signal and requires a linear input range in the recorder.
To complete this configuration, the loop 2 output must
be enabled and tailored to meet the requirements of
the data-application. In this example, the data logger
requires an analog input of 4 to 20 mA.
The CLS200 Series controllers must be used with a
Watlow Anafaze Serial DAC.
Consult Chapter 4, Setup for information on setting up the
other options of the controller.
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 setpoint of the second (secondary)
loop. The secondary loop normally executes the actual control.
The cascade control feature allows the output percentage of
one control loop to determine the setpoint of a second control loop. By adjusting the setpoint (SP) parameters, the
user can adjust the influence that the primary loop has on
the setpoint of the secondary loop. See Figure 6.4.
Some applications, such as aluminum casting, use twozone cascade control where the primary output is used for
the primary heat control and the cascaded output is used
for boost heat. The CLS200 allows you to use the primary
heat output for both control and for determining the setpoint of the secondary loop.
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Secondary Loop’s Setpoint
CLS200 Series User’s Guide
Maximum SP
Base SP
an
Sp
l
oo n
* C t Spa
|
r
e
a
ow He
t P r| *
u
utp owe
l O ut P
o
Co tp
+ | t Ou
P
a
e S |He
as
Minimum SP
+
B
100%
Cool
0%
Heat
100%
Primary Loop’s Output (%)
Calculation of new secondary loop setpoint:
SP2 = Base SP + |Cool Output Power| * Cool Span + |Heat Output Power| * Heat Span
Figure 6.4
NOTE!
Relationship Between the Primary
Loop’s Output and the Secondary
Loop’s Setpoint
Cascade control cannot be used on the same
control loop as ratio control. However, both
features may be used in the same multiloop
controller.
Setup Loop Cascade Menu
The setup parameters for cascade control appear under the
SETUP LOOP CASCADE menu.
SETUP LOOP 02
CASCADE?
ALARM
Press YES to set up the cascade parameters. The loop currently displayed (loop 02 in this case) will be the secondary
control loop, which performs the actual control.
Primary Loop
Enter the primary loop number. The output percentage of
this loop will control the setpoint of the secondary loop.
02 CASCADE
PRIM. LOOP? 03
ALARM
Selectable values: Any loop except the secondary loop.
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Base Setpoint
Enter the setpoint that corresponds to 0% (heat and cool)
output from the primary loop (PRIM. LOOP). This value is
expressed in the same engineering units as the secondary
loop’s process variable.
02 CASCADE
BASE SP? 25
ALARM
Selectable values: Any value from the secondary loop’s
minimum process variable to its maximum process variable.
Minimum Setpoint
Enter the lowest value of the secondary loop setpoint. This
minimum setpoint overrides any calculation caused by the
primary loop calling for a lower setpoint. This value is expressed in the same engineering units as the secondary
loop’s process variable.
02 CASCADE
MIN SP? 25
ALARM
Selectable values: Any value from the secondary loop’s
minimum process variable to its maximum process variable.
Maximum Setpoint
Enter the highest value of the secondary loop setpoint. This
maximum setpoint overrides any calculation caused by the
primary loop calling for a higher setpoint. This value is expressed in the same engineering units as the secondary
loop’s process variable.
02 CASCADE
MAX SP? 180
ALARM
Selectable values: Any value from the secondary loop’s
minimum process variable to its maximum process variable.
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Chapter 6: Enhanced Features
Heat Span
Enter the multiplier to apply to the primary loop heat output percentage.
02 CASCADE
HT SPAN? +9999
ALARM
Selectable values: -9999 to +9999.
Cool Span
Enter the multiplier to apply to the primary loop cool output percentage.
02 CASCADE
CL SPAN? +9999
ALARM
Selectable values: -9999 to +9999.
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 with a setpoint range of 150 to 190˚ F.
Loop 1: Primary Cascade Loop
Loop 2: Secondary Cascade Loop
Water
150°
Loop 1 Input
Process Variable
Outer
Thermocouple
Loop 2 PID Output
Loop 2 Input
Process Variable
CLS200
Heater
Inner Thermocouple
Power
Controller
Figure 6.5
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Application Using Cascade
Control
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To set up this application, you would do the following:
1.
Change the display to loop 2, which will be the secondary loop, and then enter the three-key sequence (ENTER, then ALARM ACK, then CHNG SP) and go to the first
screen in Table 6.2.
2.
Follow the steps in Table 6.2 to configure cascade control.
Table 6.2
Application Example: Setting Up
Cascade Control
Display
SETUP LOOP 02
CASCADE?
User Input
Press YES to set up the cascade parameters with loop 2 as the secondary loop.
ALARM
02 CASCADE
PRIM. LOOP? 01
Enter 01 to make loop 1 the primary loop. Press ENTER.
ALARM
02 CASCADE
BASE SP? 150
ALARM
02 CASCADE
MIN SP? -350
The base setpoint corresponds to the 0% level output of the primary
loop. Enter the base setpoint of the secondary loop. For this example, we will assume a base setpoint of 150° F, which is the desired
water temperature. Press ENTER.
Enter the minimum setpoint of the secondary loop. For this example,
we will use a minimum setpoint of -350° F. Press ENTER.
ALARM
02 CASCADE
MAX SP? 1400
Enter the maximum setpoint of the secondary loop. For this example, we will use a maximum setpoint of 1400° F. Press ENTER.
ALARM
02 CASCADE
HT SPAN? 40
ALARM
02 CASCADE
CL SPAN? 0
Enter the heat span of the secondary loop. This is the span over
which the primary output from 0 to 100% is used to change the setpoint. The desired setpoint range is 150 to 190° F. We will assume
a linear rise in setpoint, so the heat span is 40° F. Press ENTER.
Enter the cool span of the secondary loop. For this example we will
assume no low-side adjustment to the setpoint, so the cool span is
0° F. Press ENTER.
ALARM
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3.
Press BACK several times until the normal loop display
appears. The output percentage of loop 1 will now control the setpoint of loop 2.
To verify that cascade is working as expected, you would
follow these steps:
1.
Set loop 1 to MANUAL and the OUTPUT to 0%. Loop 2 setpoint should equal 150 (BASE SP).
2.
Adjust loop 1 MANUAL OUTPUT to 50%. Loop 2 setpoint
should equal 170 (BASE SP + 50% of HT SPAN)
3.
Adjust loop 1 MANUAL OUTPUT to 100%. Loop 2 setpoint should equal 190 (BASE SP + HT SPAN).
4.
To complete the cascade setup, both loop 1 and loop 2
must be configured for inputs, outputs, and alarms.
In addition, the PID parameters of loop 1 must be tuned to
produce the desired effect for the application on the setpoint of loop 2. For a cascade control application that uses
the secondary loop for PID control, loop 1 typically uses
only proportional mode. This must be set for the amount of
change in the process variable to cause a 100% change in
the output level.
Secondary Loop Setpoint
(eng. units)
The proportional band is selected so the setpoint of the secondary loop has the desired relationship to the process
variable of the primary loop. In this application, the proportional band (PB) of the primary loop is set to 10˚ F and
the integral and derivative are turned off.
(BASE SP + HT SPAN) 190°F
170°F
(BASE SP) 150°F
SP: Setpoint
PB: Proportional Band
0%
50%
100%
Heat Output (%)
150°F
145°F
140°F
Process Variable 1
(eng. units)
(SP1-PB1)
(SP1)
Primary Loop Output
Figure 6.6
Secondary Loop Setpoint Related
to Primary Loop Output
As the temperature of loop 1 drops, the output of loop 1 goes
up proportionally and the setpoint of loop 2 goes up proportionally. Thus heat is added to the system at the element
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even though the temperature near the element may have
been at setpoint (150˚ F).
With proportional control, when loop 1 is at setpoint, its
output is 0%, and the setpoint of loop 2 is equal to the base
setpoint (150˚ F). If the temperature of loop 1 drops to 149˚
F, the deviation results in a proportional output of 10%.
This times the span of 40˚ F results in an increase in setpoint for loop 2 of 4˚ F. The loop 2 setpoint increases to 154˚
F. For every degree that loop 1 drops, loop 2 increases by 4˚
F until the output of loop 1 is 100% and the loop 2 setpoint
is 190˚ F. Any further drop in the loop 1 process variable
does not affect loop 2.
The PID parameters of loop 2 must be tuned to perform efficient control.
For two-zone cascade control systems, the PID settings for
both loops, the primary plus the secondary, must be optimized for good temperature control.
See Chapter 4, Setup for information on tuning PID loops.
Ratio Control
Ratio control allows the process variable of one loop (master loop), multiplied by a ratio, to be the setpoint of another
loop (ratio loop). You can assign any process variable to determine the setpoint of a ratio loop.
By adjusting the ratio control parameters, you can adjust
the influence that the master loop process variable has on
the setpoint of the ratio loop.
Ratio Loop Setpoint
Maximum SP
l
tia
r
ste
Minimum SP
PV
*C
on
l
tro
tio
Ra
P
+S
en
fer
f
Di
Ma
SP Differential
Maximum
PV
Minimum
PV
Master Loop Process Variable
SP: Setpoint
PV: Process Variable
Figure 6.7
124
Relationship Between the Master
Loop’s Process Variable and the
Ratio Loop’s Setpoint
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Chapter 6: Enhanced Features
NOTE!
Ratio control cannot be used on the same
control loop as cascade control. However,
both features may be used in the same multiloop controller.
Setup Loop Ratio Control Menu
The ratio control parameters appear in the SETUP LOOP
RATIO CONTROL menu.
SETUP LOOP 02
RATIO CONTROL?
ALARM
Press YES to set up the ratio control parameters with loop
number 2 as the ratio loop.
Master Loop
Enter the master loop which will provide the output to the
internal controller setpoint calculation for the ratio loop
setpoint.
02 RATIO CONTROL
MSTR LOOP? NONE
ALARM
Selectable values: Any loop except the loop currently selected (in this case, loop 02). Choose NONE for no ratio control.
Minimum Setpoint
Enter the lowest allowable setpoint for the ratio loop. This
minimum setpoint overrides any ratio calculation calling
for a lower setpoint. This value is expressed in the same engineering units as the ratio loop’s process variable.
02 RATIO CONTROL
MIN SP? 25
ALARM
Selectable values: Any value from the minimum value of
the ratio loop’s process variable to its maximum value.
Maximum Setpoint
Enter the highest allowable setpoint for the ratio loop. This
maximum setpoint overrides any ratio calculation calling
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for a higher setpoint. This value is expressed in the same
engineering units as the ratio loop’s process variable.
02 RATIO CONTROL
MAX SP? 25
ALARM
Selectable values: Any value from the minimum value of
the ratio loop’s process variable to its maximum value.
Control Ratio
Enter the multiplier to apply to the master loop’s process
variable.
02 RATIO CONTROL
CTRL RATIO? 1.0
ALARM
Selectable values: 0.1 to 999.9.
Setpoint Differential
Enter the value to add or subtract from the ratio loop setpoint calculation before using it as the setpoint. This value
is expressed in the same engineering units as the ratio
loop’s process variable.
02 RATIO CONTROL
SP DIFF? 0
ALARM
Selectable values: -9999 to 9999 with the decimal
placement determined by the DISP FORMAT setting for the
ratio loop.
Ratio Control Example: Diluting KOH
A chemical process requires a formula of two parts water
(H2O) to one part potassium hydroxide (KOH) to produce
diluted potassium hydroxide. The desired flow of H2O is 10
gallons per second (gps), so the KOH should flow at 5 gps.
Separate pipes for each chemical feed a common pipe. The
flow rate of each feeder pipe is measured by a CLS200, with
H2O flow as process variable 1 and KOH flow as process
variable 2. The outputs of loops 1 and 2 adjust motorized
valves.
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Chapter 6: Enhanced Features
KOH Input
Water Input
Loop 1: Water Flow Control Loop
Loop 2: KOH Flow Control Loop
Loop 1 Input
Process Variable
Flow
Transducer
Loop 1 PID Output
Loop 2 Input
CLS200
Loop 2 PID Output
Process Variable
Motorized Control Valve 2
Motorized
Control
Valve 1
Serial
DAC
Serial
DAC
Mixture Output
Figure 6.8
Application Using Ratio Control
To set up this application, you would do the following:
Doc.# 0600-3050-2000
1.
Adjust and tune loop 1 (H2O) for optimal performance
before implementing the ratio setup.
2.
Switch the controller to display loop 2 (KOH), and
then enter the three-key sequence (ENTER, then ALARM
ACK, then CHNG SP ) and go to the first screen in
Table 6.3.
3.
Follow the steps in Table 6.3 to configure ratio control.
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Table 6.3
Application Example: Setting Up
Ratio Control
Display
SETUP LOOP 02
RATIO CONTROL?
User Input
Press YES to set up the ratio control parameters for loop 02.
ALARM
02 RATIO CONTROL
MSTR LOOP? 01
Assign loop 01 as the master loop. Press ENTER.
ALARM
02 RATIO CONTROL
MIN SP? 0.0
Enter the minimum ratio loop setpoint. For this example, we will use
0.0 gallons per second as a minimum. Press ENTER.
ALARM
02 RATIO CONTROL
MAX SP? 7.0
Enter the maximum ratio loop setpoint. For this example, we will use
7.0 gallons per second as a maximum. Press ENTER.
ALARM
02 RATIO CONTROL
CTRL RATIO? 0.5
ALARM
02 RATIO CONTROL
SP DIFF.? 0
Enter the control ratio, which is the multiple applied to the master.
The H2O fl w rate is multiplied by 0.5 to obtain the KOH fl w rate
setpoint. Press ENTER.
Enter the setpoint differential (or offset). For this example we have
no offset requirement and will use 0. Press ENTER.
ALARM
128
4.
Press BACK several times until the normal loop display
appears. The setpoint of loop 2 will now be equal to one
half of the process variable of loop 2.
5.
To complete the ratio setup, configure both loops 1 and
2 for inputs, outputs, and alarms. See Chapter 4, Setup
for information on loop setup.
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Chapter 6: Enhanced Features
Remote Analog Setpoint
The remote analog setpoint is set up identically to ratio
control. To provide a setpoint remotely, typically a voltage
or current source is connected to an analog input on the
controller. This input is configured as a linear input type
and the master loop for ratio control. All other input types
are also usable as remote analog setpoint inputs.
Specify the loop to which the analog input is connected as
the master loop and setup the rest of the ratio control parameters as outlined in Setup Loop Ratio Control Menu on
page 125.
Remote Analog Setpoint Example: Setting a Setpoint with a PLC
Remote analog setpoint allows external equipment, such as
a PLC or other control system, to change the setpoint of a
loop.
Both the remote analog setpoint feature and the process
variable retransmit feature can be used with PLC systems
as the link between multiloop PID control systems and
PLC systems.
For example, a 0 to 5 VÎ (dc) signal representing 0 to 300˚
F will be used as a remote setpoint input to the CLS200.
The input signal will be received on loop 1 with the control
being performed on loop 2. Note that proper scaling resistors must be installed on the input of loop 1 to allow it to
accept a 0 to 5 VÎ (dc) input.
To set up this application, you would do the following:
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1.
In the loop 1 SETUP LOOP INPUT menu, set the INPUT
TYPE to LINEAR, set HI PV to 300, set LO PV to 0, set
HI RDG to 100.0% and set LO RDG to 0.0%.
2.
Change the display to loop 2, and then enter the setup
parameters. Go to the first screen in Table 6.4.
3.
Follow the steps in Table 6.4 to configure the process
variable retransmit option.
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Table 6.4
Application Example: Setting Up
Remote Setpoint
Display
SETUP LOOP 02
RATIO CONTROL?
User Input
Press YES to set up the ratio control parameters for loop 2.
ALARM
02 RATIO CONTROL
MSTR LOOP? 01
Assign loop 01 to be the master loop. Press ENTER.
ALARM
02 RATIO CONTROL
MIN SP? 0
Enter the minimum ratio loop setpoint. For this example, we will
use 0° F. Press ENTER.
ALARM
02 RATIO CONTROL
MAX SP? 300.0
Enter the maximum ratio loop setpoint. For this example, we will
use 300.0° F as a maximum. Press ENTER.
ALARM
02 RATIO CONTROL
CTRL RATIO? 1.0
Enter the control ratio, which is the multiple applied to the master
process variable. In this example the ratio is 1.0. Press ENTER.
ALARM
02 RATIO CONTROL
SP DIFF.? 0
Enter the setpoint differential (or offset). For this example we have
no offset requirement and will use 0. Press ENTER.
ALARM
130
4.
Press BACK several times until the normal loop display
appears. The setpoint of loop 2 will now be equal to the
process variable of loop 1.
5.
To complete the remote analog setpoint setup, loop 1
may be configured for outputs and alarms. Likewise,
loop 2 must be configured for inputs, outputs, and
alarms. See Chapter 4, Setup for information on loop
setup.
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Chapter 6: Enhanced Features
Differential Control
Differential control is a simple application of the ratio control option, used to control one process (ratio loop) at a differential, or offset, to another (master loop). To use
differential control, set the ratio value to 1.0 to provide the
desired offset.
Differential Control Example: Thermoforming
A thermal forming application requires that the outside
heaters operate at a higher temperature than the center
heaters. The differential control point is determined by the
master loop which is using infrared (IR) sensors for temperature feedback. Secondary loops use thermocouples for
feedback.
The loop using the IR sensor as an input is assigned to the
master loop in the SETUP LOOP RATIO CONTROL menu.
The secondary loop is the differential control loop. Setting
the setpoint differential (SP DIFF) to the desired offset will
produce the desired offset between the secondary and master loops.
For example, the master loop can be controlled at 325º F
and the secondary loop at 375º F by using a differential of
50º F.
Loop 1 must be set up for PID control of the setpoint at
325º F.
To set up this application, you would do the following:
Doc.# 0600-3050-2000
1.
Change the display to loop 2, and then enter the setup
parameters. Go to the first screen in Table 6.5.
2.
Follow the steps in Table 6.5 to configure the process
variable retransmit option.
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Table 6.5
Application Example: Setting Up
Differential Control
Display
SETUP LOOP 02
RATIO CONTROL?
User Input
Press YES to setup the ratio control parameters for loop 2.
ALARM
02 RATIO CONTROL
MSTR LOOP? 01
Assign loop 01 to be the master loop. Press ENTER.
ALARM
02 RATIO CONTROL
MIN SP? 300.0
Enter the minimum ratio loop setpoint. For this example, we will
use 300.0° F. Press ENTER.
ALARM
02 RATIO CONTROL
MAX SP? 400.0
Enter the maximum ratio loop setpoint. For this example, we will
use 400.0° F. Press ENTER.
ALARM
02 RATIO CONTROL
CTRL RATIO? 1.0
Enter the control ratio, which is the multiple applied to the master
process variable. In this example the ratio is 1.0. Press ENTER.
ALARM
02 RATIO CONTROL
SP DIFF.? 50
Enter the setpoint differential (or offset). For this example, we have
an offset of +50. Press ENTER.
ALARM
132
3.
Press BACK several times until the normal loop display
appears. The setpoint of loop 2 will now be equal to
process variable of loop 1 plus 50˚ F.
4.
To complete the differential control setup, loop 1 and
loop 2 must be configured for inputs, outputs, and
alarms. See Chapter 4, Setup for information on loop
setup.
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7
Ramp/Soak
This chapter covers setup and operation of ramp/soak profiles in CLS200 series controllers.
These features are available in controllers that have the
optional ramp/soak firmware installed.
The ramp/soak feature turns your controller into a powerful and flexible batch controller. Ramp/soak lets you program the controller to change a process setpoint in a preset
pattern over time. This preset pattern, or temperature
profile, consists of several segments. During a segment,
the temperature goes from the previous segment’s setpoint
to the current segment’s setpoint.
•
•
If the current segment’s setpoint is higher or lower
than the previous segment’s setpoint, it is called a
ramp segment.
If the current segment’s setpoint is the same as the
previous segment’s setpoint, it is called a soak segment.
p
Soak
Ra
m
p
Figure 7.1
m
Segment 1
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Ra
Process Variable
Profile
Segment 2
Segment 3
Sample Ramp/Soak Profile
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Features
Ramp/soak in the CLS200 includes the following features:
•
•
•
•
•
•
•
•
•
•
•
Ready segment sets loop up for profile: Ready
segment can control at setpoint until profile needs to
run. Ready segment events set all available event outputs to desired states before profile starts.
Up to 20 segments per profile: The controller can
store up to 17 profiles, each with up to 20 segments.
Multiple profiles run independently: Each loop
can run a different profile or the same profile can be
run independently on more than one loop.
Up to two triggers per segment: Triggers are digital inputs that can be programmed to start and hold
segments based on the trigger’s digital state. You can
use any one of the eight digital inputs for triggers. You
can also use the same trigger for more than one segment or more than one profile.
Up to four events per segment: Digital outputs controlled by the ramp/soak profile. Events outputs are
set at the end of a segment. You can use any of the digital outputs that are not used for control or for the Serial DAC clock.
Tolerance hold ensures time at temperature: Set
a limit on how far the process variable can vary above
or below setpoint. The profile clock only runs when the
process variable is within the limit.
Tolerance alarm indicates process not tracking
setpoint: Set a maximum amount of time for the tolerance hold to wait for a process deviation before notifying the operator. The operator can acknowledge the
alarm and proceed if desired.
User-configurable time base: Program profiles to
run for hours and minutes or for minutes and seconds.
Repeatable profiles: Set any profile to repeat from 1
to 99 times or continuously.
Fast setup for similar profiles: Set up one profile,
then copy it and alter it to set up the rest.
External reset: Select a digital input you can use to
hold a profile in the “start” state and restart it.
Table 7.1 summarizes the ramp/soak features of the
CLS200.
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Chapter 7: Ramp/Soak
Table 7.1
Ramp/Soak Specifications
Number of possible profile
Number of times to repeat a profil
1 to 99 or
Continuous
Number of segments per profil
1 to 20
Number of triggers per segment
Up to 2
Type of triggers
Number of possible inputs for triggers
Number of events per segment
Number of possible outputs for events
(At least one of these outputs must be
used for control)
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On,
On Latched, Off,
Off Latched
8
Up to 4
34
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Ramp/Soak Menus
The SETUP R/S PROFILES menu appears between the
SETUP LOOP ALARMS and MANUAL I/O TEST menus. Figure 7.2 shows the ramp/soak setup menu tree.
SETUP
GLOBAL
PARAMETERS
SETUP
LOOP
INPUTS
SETUP
LOOP CONTROL
PARAMETERS
YES
SETUP
SETUP
LOOP PV
LOOP
RETRANSMIT* OUTPUTS
SETUP
LOOP
ALARMS
MANUAL
I/O
TEST
SETUP
RAMP/SOAK
PROFILE
YES
RAMP/SOAK TIME BASE
EDIT RAMP & SOAK
PROFILE?
* See Process Variable Retransmit on page 113.
COPY SETUP FROM
PROFILE?
OUT-OF-TOLRNCE
ALARM TIME?
READY SEGMENT
SETPOINT?
READY SEGMENT
EDIT EVENTS?
READY EVENT
OUTPUT
YES
BACK
EXTERNAL RESET
INPUT NUMBER?
EDIT SEGMENT
NUMBER?
SEGMENT ##
SEG TIME?
ENTER
SEGMENT ##
SEG SETPT?
SEGMENT ##
EDIT SEG EVENTS?
YES
BACK
SEG ## EVENT #
OUTPUT?
SEG ## EV# DO##
ACTIVE STATE?
SEGMENT ##
EDIT SEG TRGGRS?
YES
BACK
SEG ## TRIG #
INPUT NR?
SEG ## TR# DI##
ACTIVE STATE?
SEGMENT ##
SEG TOLERANCE?
ENTER
SEG ## TR# DI##
TRIG?
SEGMENT ##
LAST SEGMENT?
REPEAT CYCLES?
Figure 7.2
136
Setup Ramp/Soak Profiles Menu
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Chapter 7: Ramp/Soak
Setup Global Parameters Menu
With the Ramp and Soak option an additional menu appears on the Setup Global Parameters Menu
Ramp/Soak Time Base
The RAMP/SOAK TIME BASE parameter is in the SETUP
GLOBAL PARAMETERS menu.
Use this parameter to set the time base in all your ramp/
soak profiles. When set to HOURS/MINS, the setpoint is updated once every minute. When set to MINS/SECS, the setpoint is updated once every second.
RAMP/SOAK TIME
BASE? HOURS/MINS
ALARM
Selectable values: HOURS/MINS (hours/minutes) or
MINS/SECS (minutes/seconds).
Setup Ramp/Soak Profile Menu
The SETUP RAMP/SOAK PROFILE menu is located between the SETUP LOOP ALARMS and the MANUAL I/O
TEST menus if the ramp/soak option is installed.
SETUP RAMP/SOAK
PROFILE?
ALARM
Press YES to set up or edit ramp/soak profiles.
Edit Ramp/Soak Profile
Choose a profile to set up or edit.
EDIT RAMP & SOAK
PROFILE? A
ALARM
Selectable values: A to Q (17 profiles).
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Copy Setup From Profile
Set up similar profiles quickly by copying the setup of an
existing profile.
COPY SETUP
FROM PROFILE ? Q
ALARM
Selectable values: A to Q.
Tolerance Alarm Time
Set a limit on how long the process variable can be outside
the tolerance set for the segment before the tolerance
alarm occurs.
A OUT-OF-TOLRNCE
ALARM TIME? 1:00
ALARM
If the process variable does not return within the tolerance,
the tolerance alarm will recur after the tolerance alarm
time elapses again.
If the alarm persists, you may want to reset the profile.
Selectable values: 0:00 to 99:59 (minutes or hours, depending on the time base setting).
Ready Segment Setpoint
When you assign a profile to a loop, the profile does not
start immediately. Instead, it goes to the ready segment
(segment 0) and stays there until you put the profile in run
mode.
You can set a setpoint, assign events, and set event states
for the ready segment. Use this parameter to set the ready
segment setpoint. Setting the setpoint to OFF ensures that
control outputs for the loop running the profile will not
come on.
A READY SEGMENT
SETPOINT? OFF
ALARM
Selectable values: -999 to 9999, or OFF. See Setpoints
and Tolerances for Various Input Types on page 144.
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Ready Segment Edit Events
Press YES to set or edit the ready state for all outputs that
are not used for control or for the Serial DAC clock. When
you assign a profile, the controller starts the ready segment: it goes to the setpoint and puts all the outputs in the
state you set here. The outputs stay in the states they are
set to until their states are changed at the end of subsequent segments.
A READY SEGMENT
EDIT EVENTS ?
ALARM
Press NO to advance to EXTERNAL RESET INPUT NUMBER.
Ready Event Output
Press NO to increment the output number. Press YES to set
the event state to ON or OFF.
This parameter appears only if you answered YES to READY
SEGMENT EDIT EVENTS?.
A READY EVENT
OUTPUT 15? OFF
ALARM
Selectable values: ON or OFF.
When you are done, press BACK to return to READY SEGMENT EDIT EVENTS, then press NO to go to the next parameter.
External Reset Input Number
Select one of the eight digital inputs as an external reset.
When the reset input is on, the profile is set to RUN mode at
the beginning of the first segment. As long as the reset input is on, the profile is held at the beginning of the first segment. Once the reset input turns off the profile begins to
run.
A EXTERNAL RESET
INPUT NUMBER? N
ALARM
Selectable values: 1 to 8, or N (for no external reset).
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Edit Segment Number
Each profile is made up of several segments (up to 20).
Choose the segment to edit.
A EDIT SEGMENT
NUMBER? 15
ALARM
Selectable values: 1 to 20.
The first time you use this parameter, it defaults to segment 1. When you finish editing a segment, the controller
goes to the next segment. This loop continues until you
make a segment the last segment of a profile.
Segment Time
Enter the duration of the segment.
A SEGMENT 11
SEG TIME? 000:00
ALARM
Selectable values: 0:00 to 999:59 (hours and minutes or
minutes and seconds, depending on the selected time base).
Segment Setpoint
Enter the ending setpoint for the segment you are editing.
For a ramp, the setpoint changes steadily over the segment
time from the end setpoint of the previous segment to the
value set here. For a soak, set the value here equal to the
end setpoint of the previous segment.
C SEGMENT 5
SEG SETPT? OFF
ALARM
Selectable values: -999 to 3276, or OFF (no output during segment). See Setpoints and Tolerances for Various Input Types on page 144.
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Edit Segment Events
You can assign up to four digital outputs, or events, to each
segment. When the segment ends, the outputs you select
are set to the state you specify. Press YES to select outputs
and specify their states.
A SEGMENT 5
EDIT SEG EVENTS?
ALARM
Press NO to advance to the EDIT SEG TRGGRS parameter.
NOTE!
Events are set at the end of segments. If you
want a segment to start with an event, program the event in the previous segment. You
can also create a segment with zero time preceding the segment during which you want
the event on.
Segment Event Output
Select a digital output for the event. Use a digital output
that is not being used for PID control or for Serial DAC
clock.
This parameter appears only if you answered YES to EDIT
SEG EVENTS?
A SEG 20 EVENT 3
OUTPUT? 30
ALARM
Selectable values: Any digital output from 1 to 34, except
those in use, or NONE (no event).
When you are done setting segment events, press BACK to
return to EDIT SEG EVENTS, then press NO to go to the
next parameter.
Segment Events Output States
Assign a state to the event. At the end of the segment, the
output goes to the state you assign here.
This parameter appears only if you answered YES to EDIT
SEG EVENTS?
A SEG20 EV3 DO 30
ACTIVE STATE? OFF
ALARM
Selectable values: OFF (high) or ON (low).
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Edit Segment Triggers
Each segment may have up to two triggers (digital inputs).
Both triggers must be true in order for the segment to run.
If a trigger is not true, the profile goes into the trigger wait
state.
A SEGMENT 15
EDIT SEG TRGGRS?
ALARM
Press YES to edit triggers for the current segment, or NO
to advance to the SEGMENT TOLERANCE parameter.
Trigger Input Number
Assign a digital input to a segment trigger. You can assign
any digital input to any trigger. You can also assign the
same digital input as a trigger in more than one segment
and more than one profile.
This parameter appears only if you answered YES to EDIT
SEG TRGGRS?
A SEG 15 TRIG 1
INPUT NR ? NONE
ALARM
Selectable values: Any digital input from 1 to 8, or NONE
(disable trigger).
When you are done editing segment triggers, press BACK
to return to EDIT SEG TRGGRS.
Trigger Active State
Choose the state that will satisfy the trigger condition. A
trigger input is ON when pulled low by an external device.
A trigger input is OFF when the digital input is high.
This parameter appears only if you answered YES to EDIT
SEG TRGGRS?
A SEG01 TR1 DIO8
ACTIVE STATE?OFF
ALARM
Selectable values: OFF or ON.
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Trigger Latch Status
Choose whether the trigger is latched or unlatched.
•
A latched trigger is checked once, at the beginning of a
segment.
An unlatched trigger is checked constantly while a
segment is running. If an unlatched trigger becomes
false, the segment timer stops and the loop goes into
trigger wait state.
•
When using two triggers with a segment, the following logic applies:
Table 7.2
Trigger Latch Logic
Trigger Settings
Trigger Logic
Both Triggers Latched
ORed Trigger starts a segment
Both Triggers Unlatched
ANDed Triggers start/continue a segment
One Trigger Latched,
One Trigger Unlatched
• The unlatched trigger starts/continues a segment.
• The latched trigger has no effect.
This parameter appears only if you answered YES to EDIT
SEG TRGGRS?
A SEG01 TR1 DI08
TRIG? UNLATCHED
ALARM
Selectable values: LATCHED or UNLATCHED.
Segment Tolerance
Set a positive or negative tolerance value for each segment.
Tolerance works as shown in Figure 7.3.
Positive Tolerance Value
Negative Tolerance Value
Out of Tolerance
} Tolerance
Setting
Setpoint
Within Tolerance
Setpoint
Within Tolerance
} Tolerance
Setting
Out of Tolerance
Figure 7.3
Positive and Negative Tolerances
If you enter a positive tolerance, the process is out of tolerance when the process variable goes above the setpoint
plus the tolerance.
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If you enter a negative tolerance, the process goes out of tolerance when the process variable goes below the setpoint
minus the tolerance.
A SEGMENT 01
SEG TOLERNCE? OFF
ALARM
Selectable values: -99 to 99, or OFF (no tolerance limit).
See Setpoints and Tolerances for Various Input Types on
page 144.
Last Segment
Specify whether the current segment is the last one in the
profile.
A SEGMENT 01
LAST SEGMENT? NO
ALARM
Selectable values: NO or YES.
Repeat Cycles
Set the number of times you want a profile to repeat or cycle.
The profile returns to START mode after completing the
number of cycles specified here.
A REPEAT CYCLES
? 1
ALARM
Selectable values: 1 to 99, or C (continuous cycling).
Setpoints and Tolerances for Various Input Types
Setpoints and tolerances are set in segments before the
profile is assigned to a particular loop. When the profile is
used with a loop, the INPUT TYPE and DISP FORMATS settings are applied to the following parameters:
•
•
•
Ready setpoint
Segment setpoint
Segment tolerance
Refer to Table 7.3 to determine how these parameters are
affected for the various INPUT TYPE and DISP FORMAT
settings.
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Table 7.3
Input Type
Display Format
Thermocouples
and RTDs
N/A
Linear
Display Formats
Effect on Parameter
No decimal shift
-999 to 3000
No decimal shift
-9999 to 30000
Setting multiplied by 10
-999.9 to 3000.0
No decimal shift; additional tenth in display
-99.99 to 300.00
Settings divided by 10
-9.999 to 30.000
Settings divided by 100
-0.9999 to 3.0000
Settings divided by 1,000
Using Ramp/Soak
This section explains how to assign a profile to a loop, how
to put a profile in RUN or HOLD mode, how to reset a profile,
and how to display profile statistics. Figure 7.4 shows the
ramp/soak screens:
Single
Loop
Display
No
Profile
RAMP/ Assigned
SOAK
Profile
Assigned
BACK
ASSIGN R/S
PROFILE
TIME REMAINING
BACK
RAMP/
SOAK
YES ENTER
CYCLE NUMBER
BACK
BACK
RAMP/
SOAK
SET MODE
BACK
NO
NO
Figure 7.4
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RESET
Ramp/Soak Screens
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Ramp/Soak Displays
The single loop and bar graph displays show additional
codes when ramp/soak firmware is installed.
Single Loop Display
When the controller is running a profile, the single loop display shows the ramp/soak mode where it would usually
show MAN or AUTO. Table 7.4 describes the modes.
Table 7.4
Ramp/Soak Single Loop Display
Ramp/Soak
Mode
Description
STRT
The profile is in the ready segment
RUN
The profile is unning.
HOLD
The user has put the profile in hold mod .
TOHO
The profile is in tole ance hold.
WAIT
The profile is in t igger wait state.
This is the single loop display when a profile is running. If
a tolerance alarm occurs, the controller displays a flashing
T in the alarm symbol position.
Process Variable
Loop Number
Alarm Symbol
02
T
Engineering Units
347 ˚F
180TOHO50
Output Percentage
ALARM
Setpoint
Ramp/Soak Mode
Bar Graph Display
The ramp/soak mode is also displayed on the bar graph display.
Symbol
Loop Number
Ramp/Soak Mode
01> >
RSHS
< < 08
ROMA
ALARM
Table 7.5 describes the control status symbols used for
loops with ramp/soak profiles assigned.
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Table 7.5
Ramp/Soak Control Status Symbols
Ramp/Soak
Symbol
Description
R
A profile is unning.
H
A profile is holding
S
A profile is in ready stat .
O
A profile is in tole ance hold.
W
A profile is in t igger wait.
Time Remaining Display
From the single loop display, press the RAMP/SOAK key
once.
This screen shows how much time remains to complete the
profile. All screens that are accessed by pressing RAMP/
SOAK key have the same information on the top line.
Profile Letter
Current Segment
Loop Number
04 A SEG10/20 R
TIM REM= 32:11
ALARM
Number of Segments
in Profile
Ramp/Soak Mode
Time Remaining
Cycle Number Display
From the single loop display, press the RAMP/SOAK key
twice. This screen displays the number of times the profile
has run out of the total number of cycles. In this example,
the ramp/soak profile is on the 10th of 15 cycles to be performed.
04 A SEG10/20 R
CYCLE NR= 10/15
ALARM
Set Mode Display
From the single loop display, press the RAMP/SOAK key
three times. The SET MODE parameter allows you to
change the ramp/soak mode.
01 A SEG01/05 R
SET MODE? START
ALARM
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See Running a Profile on page 148 and Holding a Profile or
Continuing from Hold on page 150 for instructions on
changing the ramp/soak mode.
Assigning a Profile to a Loop
Use this parameter to assign a profile to a loop.
01 ASSIGN R/S
PROFILE? A
ALARM
Selectable Values: A to Q or NONE
Assigning a Profile the First Time
To assign a profile to a loop that does not have a profile currently assigned:
1.
In the single loop display, switch to the loop you want
to assign a profile to.
2.
Press the RAMP/SOAK key. The ASSIGN R/S PROFILE parameter appears.
3.
Choose one of the available profiles and press ENTER
- or press BACK to return to single loop display without
sending profile data to the controller.
Assigning, Changing and Unassigning a Profile
To assign a new profile to a loop that already has one assigned:
1.
In the single loop display, switch to the loop in which
you want to change or unassign the profile.
2.
Press the RAMP/SOAK key three times.
3.
Press the NO key. You will see the RESET PROFILE
parameter. See Resetting a Profile on page 151.
4.
Press YES then ENTER to reset the profile. You will
see the ASSIGN PROFILE parameter. See Assigning a
Profile to a Loop on page 148.
5.
Choose one of the available profiles or NONE (to
unassign) and press ENTER.
6.
To return to the single loop display without changing
the profile assignments, press BACK.
Running a Profile
When you assign a profile, it does not start running immediately. Instead, the loop is in the START mode and the
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READY segment (segment 0). Use the SET MODE parameter
to start a profile (put it in RUN mode).
01 A SEG01/05 R
SET MODE? RUN
ALARM
Starting a Profile
You can start a profile only when it is in the READY segment.
1.
In the single loop display, switch to the loop you want
to start.
2.
Press the RAMP/SOAK key three times. The SET
MODE parameter appears.
3.
Press YES and ENTER to start the profile. While the
profile is in START mode, the only mode available is
the RUN mode.
Running Several Profiles Simultaneously
To run several profiles simultaneously, follow these steps:
1.
Set up the profiles so that segment 1 of each profile
has the same latched trigger.
2.
Assign the profiles to the appropriate loops. The loops
will go to the READY segment of each profile.
3.
Set each profile to RUN mode.
4.
Trip the trigger.
Editing a Profile While It Is Running
You can edit a profile while it is running. Changes made to
segments after the current segment will take effect when
the segment is reached. Changes made to the segments
that have already been completed will take effect the next
time the profile is run. Do not edit the current segment.
Changes to the current segment can have unexpected consequences.
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Holding a Profile or Continuing from Hold
Use the SET MODE parameter to select the ramp/soak profile mode. Table 7.6 shows the available modes.
Table 7.6
Current
Mode
Available
Mode
START
RUN
HOLD
CONT
Ramp/Soak Profile Modes
Description
Begin running the assigned profil .
Continue from user-selected hold. The profile uns from the point when you put the profile in HOLD mode. (You cannot continue from
a tolerance hold or a trigger wait.)
After you choose this mode, the controller
switches back to RUN mode.
RUN
HOLD
Hold the profil .
Holding a Profile
In HOLD mode, all loop parameters stay at their current settings until you change the mode or reset the profile. To put
a profile into HOLD mode, follow these steps:
1.
In the single loop display, switch to the loop you want
to hold.
2.
Press the RAMP/SOAK key three times to see the SET
MODE parameter:
01 A SEG01/05 R
SET MODE? HOLD
ALARM
3.
Press YES to set the mode. While the profile is running, the only mode you will be able select is HOLD.
4.
Press ENTER to hold the profile.
Continuing a Profile
To resume or continue a profile that is holding:
150
1.
In the single loop display, switch to the loop you want
to run.
2.
Press the RAMP/SOAK key three times. The SET
MODE parameter appears.
3.
Press YES to set the mode. While the profile is holding,
the only mode you will be able select is CONT (continue).
4.
Press ENTER to run the profile.
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Responding to a Tolerance Alarm
A tolerance can be set for each segment. The following occurs when the process variable goes outside this tolerance:
•
•
•
•
The profile goes into tolerance hold
The segment timer holds
The loop’s single loop display shows TOHO
The tolerance alarm timer starts
If the process variable returns within the segment tolerance before the tolerance alarm time elapses, the profile returns to RUN mode and the tolerance alarm timer resets.
The following occurs if the profile remains out of tolerance
for longer than the tolerance alarm time:
•
•
The controller displays the single loop display with the
tolerance alarm (a flashing T)
The global alarm output turns on
Press ALARM ACK to:
•
•
•
Turn off the global alarm output
Reset the tolerance alarm timer
Clear the tolerance alarm
If the process variable does not return within the tolerance,
the tolerance alarm will recur after the tolerance alarm
time elapses again.
If the alarm persists you may want to reset the profile.
Resetting a Profile
To reset a profile, follow these steps:
1.
In the single loop display, switch to the loop you want
to reset.
2.
Press the RAMP/SOAK key three times to see the
SET MODE parameter.
3.
Press the NO key. The following screen will display:
01 A SEG01/05 R
SET MODE? RESET
ALARM
4.
Press YES to reset the profile, and then ENTER to confirm your choice.
When you reset a profile, the following happens:
•
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The profile returns to the ready segment. The setpoint
goes to the ready setpoint, and the event outputs go to
the states you specified for the READY EVENT OUTPUT
parameter in the READY SEGMENT EDIT EVENTS submenu (See Ready Segment Edit Events on page 139.)
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•
The controller shows you the ASSIGN R/S PROFILE
screen in case you would like to assign a different profile to the loop or select NONE to unassign the profile.
In Case of a Power Failure
If the power fails or the controller is otherwise powered
down while running a ramp/soak profile, by default the profile is set to the START mode when power is restored.
If the POWER UP OUTPUT STATUS parameter in the SETUP
GLOBAL PARAMETERS menu is set to MEMORY, then after a
power failure the profile will resume operation at the
elapsed time of the segment that was active when the power failure occurred.
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8
Tuning and Control
This chapter describes the different methods of control
available with the CLS200. This chapter covers control algorithms, control methods, PID control, starting PID values and tuning instructions to help appropriately set
control parameters in the CLS200 system. For more information on 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 setpoint varies.
NOTE!
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For any of these control statuses to function,
the loop must be in automatic mode.
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On/Off Control
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 setpoint. This limit
is adjustable; Watlow Anafaze controllers use an adjustable spread.
For example, if the setpoint is 1,000˚ F and the spread is
20˚ F, the heat output switches on when the process variable drops below 980˚ F and off when the process rises
above 1,000˚ F. A process using on/off control cycles around
the setpoint. Figure 8.1 illustrates this example.
Heat Off
Heat Off
Process
Variable
Heat On
On
Output
Setpoint
1,000° F
Setpoint - Spread
980° F
Off
Figure 8.1
On/Off Control
Proportional Control
Proportional control eliminates cycling by increasing or decreasing the output proportionally with the process variable’s deviation from the setpoint.
The magnitude of proportional response is defined by the
proportional band. Outside this band, the output is either
100% or 0%. Within the proportional band the output power is proportional to the process variable’s deviation from
the setpoint.
For example, if the setpoint is 1,000˚ F and the proportional
band is 20˚ F, the output is:
•
•
•
•
0% when the process variable is 1,000˚ F or above
50% when the process variable is 990˚ F
75% when the process variable is 985˚ F
100% when the process variable is 980˚ F or below
However, a process which uses only proportional control
settles at a point above or below the setpoint; it never
reaches the setpoint by itself. This behavior is known as offset or droop.
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Setpoint
Offset
Proportional
Band
Process Variable
Figure 8.2
Proportional Control
Proportional and Integral Control
With proportional and integral control, the integral term
corrects for offset by repeating the proportional band’s error correction until there is no error. For example, if a process tends to settle about 5˚ F below the setpoint,
appropriate integral control brings it to the desired setting
by gradually increasing the output until there is no deviation.
Setpoint
Overshoot
Proportional
Band
Process Variable
Figure 8.3
Proportional and Integral Control
Proportional and integral action working together can
bring a process to setpoint and stabilize it. However, with
some processes the user may be faced with choosing between parameters that make the process very slow to reach
setpoint and parameters that make the controller respond
quickly, but introduce some transient oscillations when the
setpoint or load changes. The extent to which these oscillations of the process variable exceed the setpoint is called
overshoot.
Proportional, Integral and Derivative Control
Derivative control corrects for overshoot by anticipating
the behavior of the process variable and adjusting the output appropriately. For example, if the process variable is
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rapidly approaching the setpoint from below, derivative
control reduces the output, anticipating that the process
variable will reach setpoint. Use it to reduce overshoot and
oscillation of the process variable common to PI control.
Figure 8.4 shows a process under full PID control.
Setpoint
Proportional
Band
Process Variable
Figure 8.4
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 SPREAD parameter to prevent such oscillations (see Spread on page 92). When PID control is used for
one or both loop outputs, both the SPREAD parameter and
PID parameters determine when control switches between
heating and cooling.
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Control Outputs
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 VÎ (dc), 0 to 10 VÎ (dc) or 4 to 20 mA
control signals to operate field output devices.
Output Control Signals
The following sections explain the different control output
signals available.
On/Off
When on/off control is used, the output is on or off depending on the difference between the setpoint and the process
variable. PID algorithms are not used with on/off control.
The output variable is always off or on (0% or 100%).
Time Proportioning (TP)
With time proportioning outputs, the PID algorithm calculates an output between 0 and 100%, 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% and the cycle time is 10 seconds, then the output will be on for 3 seconds and off for 7
seconds. Figure 8.5 shows examples of time proportioning
and distributed zero crossing (DZC) waveforms.
Distributed Zero
Crossing (33%)
Time Proportioning (30%)
On
Off
0
3
10
Seconds
Cycle Time set to 10
Figure 8.5
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0
1
3
4
6
AC Cycle
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%, 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%. This percentage of the analog output
range can be applied to an output device via a Dual DAC or
a Serial DAC.
Output Filter
The output filter digitally smooths PID control output signals. It has a range of 0 to 255 scans, which gives a time
constant of 0 to 170 seconds for a CLS216, 0 to 85 seconds
for a CLS208 or 0 to 43 seconds for a CLS204. Use the 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.
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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.
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 (PB) Settings
Table 8.1 shows proportional band settings for various
temperatures in degrees Fahrenheit or Celsius.
Table 8.1
Proportional Band Settings
Temperature
Setpoint
PB
Temperature
Setpoint
PB
Temperature
Setpoint
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
1000 to 1099
20
20
30
35
40
45
50
55
60
65
70
1100 to 1199
1200 to 1299
1300 to 1399
1400 to 1499
1500 to 1599
1600 to 1699
1700 to 1799
1800 to 1899
1900 to 1999
2000 to 2099
2100 to 2199
75
80
85
90
95
100
105
110
120
125
130
2200 to 2299
2300 to 2399
2400 to 2499
2500 to 2599
2600 to 2699
2700 to 2799
2800 to 2899
2900 to 2999
3000 to 3099
3100 to 3199
3200 to 3299
135
140
145
150
155
160
165
170
175
180
185
As a general rule, set the proportional band to 10% of the
setpoint below 1000˚ and 5% of the setpoint above 1000˚.
This setting is useful as a starting value.
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Integral Settings
The controller’s integral parameter (TI) is set in seconds
per repeat. Some other products use an integral term called
reset, in units of repeats per minute. Table 8.2 shows integral settings versus reset settings.
Table 8.2
Integral Term and Reset Settings
Integral
(Seconds/Repeat)
Reset
(Repeats/Minute)
Integral
(Seconds/Repeat)
Reset
(Repeats/Minute)
30
45
60
90
120
150
180
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 (TD) is programmed
in seconds. Some other products use a derivative term
called rate programmed in minutes. Use the table or the
formula to convert parameters from one form to the other.
Table 8.3 shows derivative versus rate. Rate = Derivative/
60.
Table 8.3
Derivative Term Versus Rate
Derivative
(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% of integral as a
starting value.
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NOTE!
While the basic PID algorithm is well defined
and widely recognized, various controllers
implement it differently. Parameters may not
be taken from one controller and applied to
another with optimum results even if the
above unit conversions are performed.
General PID Constants by Application
This section gives PID values for many applications. They
are useful as control values or as starting points for PID
tuning.
Proportional Band Only (P)
Set the proportional band to 7% of the setpoint.
(Example: Setpoint set to 450, proportional band set to 31).
Proportional with Integral (PI)
•
•
•
•
Set the proportional band to 10% of setpoint.
(Example: Setpoint set to 450, proportional band set to
45).
Set integral to 60.
Set derivative to Off.
Set the output filter to 2.
PI with Derivative (PID)
•
•
•
•
Set the proportional band to 10% of the setpoint.
(Example: Setpoint set to 450, proportional band set to
45).
Set the integral to 60.
Set the derivative to 15% of the integral.
(Example: Integral set to 60, derivative set to 9).
Set the output filter to 2.
Table 8.4 on page 162 shows general PID constants by application.
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Table 8.4
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
Setpoint>1200
162
General PID Constants
Proportional
Band
Integral
Derivative
Filter
Output
Type
Cycle
Time
Action
50°
60
15
4
DZC
-
Reverse
50°
60
15
6
TP
20
Reverse
70°
500
90
4
TP
10
Direct
10°
Off
10
4
TP
10
Direct
30°
20
Off
4
DZC
-
Reverse
60°
120
25
8
Analog
-
Reverse
100°
240
40
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9
Troubleshooting and Reconfiguring
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:
•
•
NOTE!
Controller is installed correctly. (See Chapter 2, Installation for help.)
Sensors, such as thermocouples and RTDs, are installed correctly and working.
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 Application Engineering
for additional troubleshooting help. If you need to return
the unit to Watlow Anafaze for testing and repair, Customer Service will issue you an RMA number. See Returning
Your Unit on page 164.
CAUTION!
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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.
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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.
Returning Your Unit
Before returning a controller, contact your supplier or call
Watlow for technical support.
Controllers purchased as part of a piece of equipment must
be serviced or returned through the equipment manufacturer. Equipment manufacturers and authorized distributors should call customer service 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 Controllers
A problem may be indicated by one or more of several types
of symptoms:
•
•
•
•
A process or deviation 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.
Process and Deviation Alarms
When a process or deviation alarm occurs, the controller
switches to the single loop display for the loop with the
alarm and displays the alarm code on the screen. Software
such as AnaWin or WatView displays a message on the
alarm screen and logs the alarm in the event log.
Table 9.1
Code
164
Controller Alarm Codes for
Process and Deviation Alarms
Alarm
Description
HP
High Process
Process variable has risen above the high process alarm setpoint.
HD
High Deviation
Process variable has risen above the setpoint by more than the deviation alarm value.
LD
Low Deviation
Process variable has dropped below the setpoint by more than the
deviation alarm value.
LP
Low Process
Process variable has dropped below the low process alarm setpoint.
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Responding to Process and Deviation Alarms
In a heating application, a low process or low deviation
alarm may indicate one of the following:
•
•
•
•
•
•
•
NOTE!
The heater has not had time to raise the temperature.
The load has increased and the temperature has fallen.
The control status is set to manual instead of automatic.
The heaters are not working due to a hardware failure.
The sensor is not placed correctly and is not measuring
the load’s temperature.
The deviation limit is too narrow.
The system is so poorly tuned that the temperature is
cycling about setpoint by more than the alarm limit.
In cooling applications, similar issues cause
high process and high deviation alarms.
In a heating application, a high process alarm or high deviation alarm may indicate one of the following:
•
•
•
•
•
The setpoint and high process limit have been lowered
and the system has not had time to cool to within the
new alarm limit.
The control status is set to manual and the heat output is greater than 0%.
The load has decreased such that the temperature has
risen.
The heater is full-on due to a hardware failure.
The system is so poorly tuned that the temperature is
cycling about setpoint by more than the alarm limit.
Resetting a Process or Deviation Alarm
Your response to an alarm depends upon the alarm type
setting, as explained in Table 9.2 below.
Table 9.2
Operator Response to Alarms
Alarm
Type
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Operator Response
Control
The operator does not need to do anything.
The alarm clears automatically when the process variable returns within limits.
Alarm
Acknowledge the alarm by pressing ALARM
ACK on the controller or by using software.
The alarm clears after the process variable
returns within the limits and the operator has
acknowledged it.
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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 on the screen. AnaWin or WatView
displays a message on the alarm screen and logs the alarm
in the event log.
Table 9.3
Failed Sensor Alarm Codes
Alarm
Code
Description
FS
Failed Sensor
Open thermocouple.
RT
Reversed
Thermocouple
Temperature changed in the opposite direction than expected.
ST
Shorted
Thermocouple
Temperature failed to change as expected.
RO
RTD Open
Positive or negative lead is broken or disconnected.
RS
RTD Shorted
Positive and negative leads are shorted.
A failed sensor alarm clears once it has been acknowledged
and the sensor is repaired.
System Alarms
If the controller detects a hardware problem, it displays a
message. The message persists until the condition is corrected.
Table 9.4
Message
Hardware Error Messages
Possible Cause
Recommended Action
LOW POWER
Power supply failed.
See Low Power on page 168.
BATTERY DEAD
RAM battery is dead.
See Battery Dead on page 168.
AW
Ambient warning. Ambient temperature exceeds operating limits by less than 5° C (9° F).
See Ambient Warning on page
168.
Ambient temperature exceeds
operating limits by 5° C (9° F).
H/W AMBIENT FAILURE
Reference voltage (5VÎ [dc])
shorted to common.
See H/W Ambient Failure on
page 169.
Hardware failed due to excessive voltage on inputs.
H/W GAIN FAILURE
Hardware failed due to excessive voltage on inputs.
See H/W Gain or Offset Failure
on page 170.
H/W OFFSET FAILURE
Hardware failed due to excessive voltage on inputs.
See H/W Gain or Offset Failure
on page 170.
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Other Behaviors
The following table indicates potential problems with the
system or controller and recommends corrective actions.
Table 9.5
Symptom
Indicated temperature not as expected
CLS 200 display is
not lit
CLS200 display is lit,
but keys do not work
Control status of one
or more loops
changes from automatic to manual
Other Symptoms
Possible Causes
Recommended Action
Controller not communicating
Sensor wiring incorrect
See Checking Analog Inputs on page 171.
Noise
Power connection incorrect
Check wiring and service. See Wiring the
Power Supply on page 25.
No EPROM or bad EPROM
Replace the EPROM. See Replacing the
EPROM on page 176.
CLS200 damaged or failed
Return the CLS200 for repair. See Returning Your Unit on page 164.
Keypad is locked
See Keys Do Not Respond on page 170.
CLS200 damaged or failed
Return the CLS200 for repair. See Returning Your Unit on page 164.
Failed sensor
Check the display or software for a failed
sensor message.
Digital job select feature is
enabled and has changed
jobs
Set JOB SELECT DIG INPUTS to NONE.
This parameter is only accessible using the
controller’s keypad and display. See Job
Select Digital Inputs on page 76.
Check wiring and service. See Wiring the
Power Supply on page 25.
Use a separate dc supply for the controller.
Power is intermittent
Set POWER UP OUTPUT STATUS to MEMORY. See Power Up Output Status on page
78.
All loops are set to
manual 0%
Controller does not
behave as expected
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Provide backup power (UPS).
Analog reference voltage is
overloaded
Disconnect any wiring from the +5V Ref
connection on TB1.
Hardware failure
Check the controller front panel for a hardware alarm. See System Alarms on page
166.
Corrupt or incorrect values in
RAM
Perform a NO-key reset. See NO-Key
Reset on page 176.
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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.
Acknowledge the alarm.
2.
If the error message remains, turn the power to the
controller off, then on again.
3.
If the error message returns, check that the power
supplied to the controller is at least 12.0VÎ (dc) @ 1 A.
See Wiring the Power Supply on page 25.
4.
If the error message returns again, make a record of
the settings if possible (using software). Then, perform
a NO-key reset (see NO-Key Reset on page 176).
5.
If the error is not cleared, contact your supplier for further troubleshooting guidance. See Returning Your
Unit on page 164.
Battery Dead
The dead battery alarm indicates that the CLS200 battery
is not functioning correctly or has low power or no power. If
this alarm occurs, parameters have reset to the factory default settings.
NOTE!
The controller will retain its settings when
powered. The battery is required to keep the
settings in memory only when the controller
is powered down.
If the controller displays BATTERY DEAD:
1.
Acknowledge the alarm.
2.
If the error message remains, turn the power to the
controller off, then on again.
3.
If the error message returns when power is restored,
perform a NO-key reset. See NO-Key Reset on page 176.
4.
If the error is not cleared, contact your supplier for further troubleshooting guidelines. See Returning Your
Unit on page 164.
Ambient Warning
The ambient warning alarm indicates that the ambient
temperature of the controller is too hot or too cold. Ambient
warning occurs when the controller’s temperature is in the
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range of 23 to 32° F or 122 to 131° F (-5 to 0° C or 50 to
55° C). The operating limits are 32 to 122° F (0 to 50° C).
If the controller displays AW in the lower left corner of the
display:
1.
Acknowledge the alarm.
2.
If the error message remains, check the ambient air
temperature near the controller. Adjust ventilation,
cooling or heating to ensure that the temperature
around the controller is 32 to 122° F (0 to 50° C). If the
unit is functioning correctly, the error will clear when
the ambient temperature is within range and the
alarm has been acknowledged.
3.
If the ambient temperature is within range and the error persists:
a)
Turn the power to the controller off.
b)
Remove the boards from the CLS200 housing.
See Replacing the EPROM on page 176.
c)
Reseat the boards and turn the power on.
4.
If the error persists, make a record of the settings then
perform a NO-key reset. See NO-Key Reset on page 176.
5.
If the error is not cleared, contact your supplier for further troubleshooting guidelines. See Returning Your
Unit on page 164.
H/W Ambient Failure
The hardware ambient failure alarm indicates that the ambient sensor in the CLS200 is reporting that the temperature around the controller is outside of the acceptable
range of 0 to 50° C. This error can also occur when there is
a hardware failure.
If the controller displays H/W AMBIENT FAILURE:
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1.
Acknowledge the alarm.
2.
If the error message remains, check the ambient air
temperature near the controller. Adjust ventilation,
cooling or heating to ensure that the temperature
around the controller is 0 to 50° C. If the unit is functioning correctly, the error will clear automatically
when the ambient temperature is within range and
the alarm has been acknowledged.
3.
Remove any connections to the 5VÎ (dc) reference
(TB1-18) on the back of the controller. If this corrects
the problem, there was an error in the wiring. You
may need to consult technical support to determine
the correct wiring.
4.
If the ambient temperature is within range and the error persists:
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NOTE!
CLS200 Series User’s Guide
a)
Turn the power to the controller off.
b)
Remove the boards from the CLS200 housing.
c)
Reseat the boards and turn power on.
5.
If the error persists, make a record of the settings,
then perform a NO-key reset. See NO-Key Reset on
page 176.
6.
If the error is not cleared, contact your supplier for further troubleshooting guidelines. See Returning Your
Unit on page 164.
If the controller has failed, it is likely that it
was damaged by excessive voltage or noise.
Before replacing the controller, troubleshoot
for noise and ground loops.
H/W Gain or Offset Failure
If the controller displays H/W GAIN FAILURE or
H/W OFFSET FAILURE:
NOTE!
1.
Acknowledge the alarm.
2.
If the error message remains, turn the power to the
controller off, then on again.
3.
If the H/W Gain error is reported, remove any connections to the 5VÎ (dc) reference (TB1-18) on the back of
the controller. If this corrects the problem, there was
an error in the wiring. You may need to consult technical support to determine the correct wiring.
4.
If the error persists, make a record of the settings (using software), then perform a NO-key reset. See NOKey Reset on page 176.
5.
If the error is not cleared, contact your supplier for further troubleshooting guidelines. See Returning Your
Unit on page 164.
If the controller has failed, it is likely that it
was damaged by excessive voltage or noise.
Before replacing the controller, troubleshoot
for noise and ground loops.
Keys Do Not Respond
If the CLS200 seems to function but the MAN/AUTO, CHNG
SP, ALARM ACK, and RAMP/SOAK keys do not respond when
you press them, the keypad is probably locked. Unlock the
keypad according to the instructions in Keyboard Lock Status on page 78.
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Checking Analog Inputs
If the process variable displayed in the software and on the
controller do not agree:
1.
Verify that the controller is communicating.
2.
If the process variable indicated on the controller display is incorrect:
3.
NOTE!
a)
Verify that you have selected the correct input
type for the affected loops.
b)
Verify that sensors are properly connected.
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 Your Unit on page 164.
Noise in excess of 1V Å (ac) should be eliminated by correctly grounding the CLS200.
See Wiring the Power Supply on page 25.
4.
Verify the sensors:
•
•
5.
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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.
To verify that the controller hardware is working correctly, check any input (except the pulse input or an
RTD) as follows:
a)
Disconnect the sensor wiring.
b)
Set the INPUT TYPE to J T/C in the SETUP LOOP
INPUT menu.
c)
Place a short across the input. The controller
should indicate the ambient temperature on the
channel you are testing.
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Earth Grounding
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 above 2VÅ (ac) is observed, 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 2VÅ (ac) may indicate problems with
the ac ground circuit.
Check for ac voltage on thermocouples with the heater
power on. A control output providing power to the
heaters will increase the ac voltage if there is heater
leakage and an improper grounding circuit. Measure
from either positive or negative thermocouple lead to
ac ground. AC voltage above 2VÅ (ac) may indicate the
ground lead is not connected to the CLS200 TB2
ground terminal.
If the above tests indicate proper ac grounding but the controller is indicating incorrect temperatures or process readings:
•
•
•
•
•
Verify which type of sensor is installed and that the
INPUT TYPE parameter is set accordingly.
For an RTD or linear voltage or current input, check
that the correct input scaling resistors are installed
(page 180) and check the input scaling parameter settings (page 86).
If readings are erratic, look for sources of electrical
noise. See Noise Suppression on page 22.
Eliminate possible ground loops. See Ground Loops on
page 24.
Contact your supplier for further troubleshooting
guidance. See Returning Your Unit on page 164.
Checking Control Outputs
To check control outputs:
•
•
•
Set the loop you want to check to manual mode.
Set the output power percentage to the desired level.
Set the output type to ON/OFF or TP (see Chapter 4,
Setup).
If the control output is not connected to an output device
like an SSR, connect an LED in series with a 1 kΩ resistor
from +5V to the output. (Tie the anode of the LED to +5V.)
The LED should be off when the output is 0% and on when
the output is 100%.
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Testing Control Output Devices
Connect the solid state relay (SSR) control terminals to the
CLS200 control output and connect a light bulb (or other
load that can easily be verified) to the output terminals on
the SSR. Put the loop in manual mode and set the output
to 100%. The ac load should turn on.
Do not attempt to measure ac voltage at the SSR’s output
terminals. Without a load connected, the SSR’s output 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 +5VÎ (dc) supply at the TB18 or TB50.
The voltage should be +4.75 to +5.25VÎ (dc):
a)
Connect the voltmeter’s common lead to the TB18
screw terminal 2 or TB50 screw terminal 3.
b)
Connect the voltmeter’s positive lead to the TB18
or TB50 screw terminal 1.
Testing Control and Digital Outputs
1.
Turn off power to the controller.
2.
Disconnect any process output wiring on the output to
be tested.
3.
Connect a 500 Ω to 100 kΩ resistor between the
+5V terminal (TB18 or TB50 screw terminal 1) and the
output terminal you want to test.
4.
Connect the voltmeter’s common lead to the output
terminal, and connect the voltmeter’s positive lead to
the +5V terminal.
5.
Restore power to the controller.
6.
If you are testing a PID control output, use the MAN/
AUTO key to turn the output on (100%) and off (0%).
When the output is off, the output voltage should be
less than 1V. When the output is on, the output voltage should be between +3.75 and +5.25V.
7.
If you are testing a digital output not used for control,
use the MANUAL I/O TEST menu to turn the output on
and off. See Manual I/O Test on page 103.
1.
Turn off power to the controller.
2.
Disconnect any system wiring from the input to be
tested.
Testing Digital Inputs
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3.
Restore power to the controller.
4.
Go to the DIGITAL INPUTS parameter in the MANUAL
I/O TEST menu. This parameter shows whether the
digital inputs are H (high, or open) or L (low, or closed).
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 H (high). 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 L (low).
Additional Troubleshooting for Computer
Supervised Systems
These four elements must work properly in a computer-supervised system:
•
•
•
•
The controller
The computer and its EIA/TIA-232 or EIA/TIA-485 serial interface
The EIA/TIA-232 or EIA/TIA-485 communication lines
The computer software
For troubleshooting, disconnect the communications line
from the computer and follow the troubleshooting steps in
the first section of this chapter. The next few sections explain troubleshooting for the other elements of computer
supervised systems.
Computer Problems
If you are having computer or serial interface problems,
check the following:
•
•
•
•
174
Check your software manual and make sure your computer meets the software and system requirements.
Check the communications interface, cables, and connections. Make sure the serial interface is set according to the manufacturer’s instructions.
To test an EIA/TIA-232 interface, purchase an EIA/
TIA-232 tester with LED indicators. Attach the tester
between the controller and the computer. When the
computer sends data to the controller, the tester’s TX
LED should blink. When the computer receives data
from the controller, the RX LED should blink.
You can also connect an oscilloscope to the transmit or
receive line to see whether data is being sent or received. If the serial port does not appear to be working,
the software setup may need to be modified or the
hardware may need to be repaired or replaced.
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Communications
Most communications problems are due to incorrect wiring
or incorrectly set communications parameters. Therefore,
when there is a problem, check the wiring and communications settings first. Verify the following:
•
•
•
•
•
•
•
•
Communications port: Software must be configured to
use the communications port to which the controller is
connected.
Software protocol: Set the controller to MOD (Modbus)
for AnaWin or WatView, ANA (Anafaze) for Anasoft or
Anascan.
Controller address: Configure software to look for the
controller at the correct address. In a multiple-controller installation, each controller must have a unique
address.
Baud rate: Software and controller must be set the
same.
Error checking (ANA protocol only): Software and controller must be set the same (CRC or BCC).
Hardware protocol: PC and controller must use the
same protocol, or a converter must be used. The controller is typically configured for EIA/TIA-232 when it
is shipped. See Changing Communications on page
179 to change between EIA/TIA-232 and EIA/TIA-485.
To communicate with more than one controller, or
when more than 50 feet of cable is required, use EIA/
TIA-485. Even for a single controller, you may use
EIA/TIA-485 and an optically isolating converter to
eliminate ground loops.
Converter: Make sure that the EIA/TIA-232-to-485
converter is powered, configured and wired correctly.
Cables: Check continuity by placing a resistor across
each pair of wires and measuring the resistance with
an ohmmeter at the other end.
Ground Loops
Many PC communications ports have their common wires
connected to chassis ground. Once connected to the controller, this can provide a path to ground for current from the
process that can enter the controller through a sensor (such
as a thermocouple). This creates a ground loop that can affect communications and other controller functions. To
eliminate a ground loop, either use an optically isolated
communications adapter or take measures to ensure that
sensors and all other connections to the controller are isolated and not conducting current into the unit.
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Software Problems
If the controller and serial communications connections
seem to be working correctly, but you are still not getting
the result you expect, consult the resources you have available for the software program you are using.
WatView, AnaWin or Anasoft
Consult the AnaWin or Anasoft User’s Guide for help with
the user interface. WatView comes with a context-sensitive
help explaining operation of the software. Context-sensitive means that you can press the F1 key to get help related
to the part of the program you are using.
User-Written Software
You can request a communications specification from Watlow Anafaze if you want to write your own software. Watlow Anafaze will answer technical questions that arise
during your software development process, but does not
otherwise support user-developed or third-party software
in any way.
NO-Key Reset
Performing a NO-key reset returns all controller settings to
their defaults. All recipes are also cleared.
To perform a NO-key reset:
1.
Make a record of the controller’s settings.
2.
Turn off power to the unit.
3.
Press and hold the NO key on the keypad.
4.
Turn on power to the controller still holding the NO
key.
5.
When prompted RESET WITH DEFAULTS?, release the
NO key and press the YES key.
6.
If you do not see the RESET WITH DEFAULTS? prompt
or do not get a chance to press YES, repeat the procedure.
7.
Restore the controller settings.
If you have a stand-alone system, there is no way to recover
your original parameters. If you have a computer-supervised system with AnaWin or Anasoft, a copy of your parameters can be saved to a job file.
Replacing the EPROM
Replacing the EPROM involves minor mechanical disassembly and reassembly of the controller. You will need a
Phillips screwdriver and a small flathead screwdriver.
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CAUTION!
The EPROM 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 EPROM with another version
results in full erasure of RAM. Make a record
of all parameters before changing the
EPROM.
1.
Make a record of system parameters.
2.
Power down the controller.
3.
Remove the four screws from the sides of the controller
front panel.
4.
Remove the electronics assembly from the case, as
shown in Figure 9.1.
WA
TL
OW
AN
AF
AZ
EC
LS
WA
20
0
TL
OW
AN
AF
AZ
EC
LS
Figure 9.1
5.
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20
0
Removal of Electronics Assembly
from Case
Unscrew the four screws at the corners of the top
board and carefully unplug this board to access the
bottom board (processor board). Figure 9.2 shows the
screws to remove:
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WA
TL
OW
AN
AF
AZ
EC
LS
Figure 9.2
6.
20
0
Screws Locations on PC Board
Locate the EPROM on the circuit board. The EPROM
is a 32-pin socketed chip that is labeled with the model, version and checksum.
EPROM Detail
EPROM
U2
Pin 1
MP
SRAM
Notch
Figure 9.3
7.
EPROM Location
Remove the existing EPROM from its socket with an
IC extraction tool or a jeweler’s flathead screwdriver.
Figure 9.4
Remove EPROM
8.
Carefully insert the new EPROM into the EPROM
socket. Make sure that the chip is oriented so that its
notch fits in the corresponding corner of the socket.
9.
Reverse steps 2 through 4 to reassemble the unit.
10. Power up the controller.
11. Re-enter parameters.
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Changing Communications
To switch between EIA/TIA-232 and EIA/TIA-485, change
the jumpers as shown in Figure 9.5.
JU1
JU2
JU3
JU4
JU5
A
A
B
Configured for
EIA/TIA-232
Figure 9.5
A
B
Configured for
EIA/TIA-485
B
Last controller in
system configured
for EIA/TIA-485
Jumper Configurations
You will need tweezers and a Phillips head screwdriver to
switch between EIA/TIA-232 and EIA/TIA-485. Follow
these steps:
Doc.# 0600-3050-2000
1.
Power down the unit.
2.
Remove the controller’s metal casing. See Replacing
the EPROM on page 176 for step-by-step instructions.
3.
Find jumpers JU2, JU3, JU4, and JU5 on the board.
4.
Use tweezers to carefully grasp the jumpers and gently slide them off the pins.
5.
Use tweezers to gently slide jumpers JU2, JU3, JU4
and JU5 onto the correct pins (see Figure 9.5).
6.
If you are configuring the controller as the last device
on an EIA/TIA-485 network, move JU1 to the B position.
7.
Reassemble the controller.
Watlow Anafaze
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Chapter 9: Troubleshooting and Reconfiguring
CLS200 Series User’s Guide
Installing Scaling Resistors
Resistors are installed for all inputs on the CLS200. 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.
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.
CLS204 and CLS208 Input Circuit
The CLS204 and CLS208 can accept differential thermocouple, mVÎ (dc), VÎ (dc), mAÎ (dc) and RTD inputs. Unless ordered with special inputs these controller accept only
signals within the standard range -10 to 60mVÎ (dc).
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.
Figure 9.6 shows the input circuit for one differential, analog input. See CLS204 and CLS208 Current Inputs on page
181 through CLS204 and CLS208 RTDs and Thermistors
on page 183 for specific instructions and resistor values for
voltage, current and RTD inputs.
NOTE!
180
When adding your own scaling resistors to
the controller, for voltage and RTD inputs
you will have to carefully remove one of the
RC resistors in order to install the resistor
listed in the table.
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 9:Troubleshooting and Reconfiguring
RC (Voltage)
+
IN+
RP
Internal
+5VÎ (dc)
Reference
Analog
Input
Terminal
RD
RC (RTD)
IN-
RP
To CLS200
Circuitry
-
Com
Figure 9.6
CLS204 and CLS208 Input Circuit
CLS204 and CLS208 Current Inputs
For each current input on a CLS204 or CLS208 controller
you must install a resistor. The value of the resistor must
be correct for the expected input range. Install the resistor
in the listed resistor pack (RP) location. Note the resistor
pack locations have three through holes. Install the resistor as shown in the illustration below.
Table 9.6
Resistor Values for CLS204 and
CLS208 Current Inputs
Input Range
Resistor Value RD
0 to 10 mA
6.0 Ω
0 to 20 mA
3.0 Ω
Resistor tolerance: ±0.1%
RP#
RD
Table 9.7
Doc.# 0600-3050-2000
Resistor Locations for CLS204 and
CLS208 Current Inputs
Loop
Resistor
Location RD
Loop
Resistor
Location RD
1
RP1
5
RP5
2
RP2
6
RP6
3
RP3
7
RP7
4
RP4
8
RP8
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Chapter 9: Troubleshooting and Reconfiguring
CLS200 Series User’s Guide
CLS204 and CLS208 Voltage Inputs
For each voltage input on a CLS204 and CLS208 controller
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 9.8
Resistor Values for CLS204 and
CLS208 Voltage Inputs
Resistor Values
Input Range
RC
RD
0 to100mVÎ (dc)
499 Ω
750 Ω
0 to 500mVÎ (dc)
5.49 kΩ
750 Ω
0 to 1VÎ (dc)
6.91 kΩ
442.0 Ω
0 to 5VÎ (dc)
39.2 kΩ
475.0 Ω
0 to 10VÎ (dc)
49.9 kΩ
301.0 Ω
0 to 12VÎ (dc)
84.5 kΩ
422.0 Ω
Resistor tolerance: ±0.1%
RP#
RD
Table 9.9
Resistor Locations for CLS204 and
CLS208 Voltage Inputs
Resistor Locations
182
Loop
RC
RD
1
R58
RP1
2
R56
RP2
3
R54
RP3
4
R52
RP4
5
R50
RP5
6
R48
RP6
7
R46
RP7
8
R44
RP8
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 9:Troubleshooting and Reconfiguring
CLS204 and CLS208 RTDs and Thermistors
For each RTD or thermistor input on a CLS204 or CLS208
controller, you must install three resistors: RA, RB, and
RC. The resistance must be correct for the expected input
range. RA and RB are a matched pair of resistors. Install
them in the resistor pack (RP) locations as shown in the illustration below.
Table 9.10
Resistor Values for CLS204/208
RTD and Thermistor Inputs
Resistor Values
Input
RA/RB
RC
RTD1
10.0 kΩ
80 Ω
RTD2
25.0 kΩ
100 Ω
Resistor tolerances: RA/RB matched to 0.02% (2 ppm/˚C)
and absolute tolerance is 0.1% (10 ppm/˚C) RC accurate to
0.05%.
RP#
RA RB
Table 9.11
Resistor Locations for CLS204/208
RTD and Thermistor Inputs
Resistor Locations
Doc.# 0600-3050-2000
Loop
RA/RB
RC
1
RP1
R57
2
RP2
R55
3
RP3
R53
4
RP4
R51
5
RP5
R49
6
RP6
R47
7
RP7
R45
8
RP8
R43
Watlow Anafaze
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Chapter 9: Troubleshooting and Reconfiguring
CLS200 Series User’s Guide
CLS216 Input Circuit
The CLS216 can accept single-ended thermocouple, mVÎ
(dc), VÎ (dc) and mAÎ (dc) inputs. Unless ordered with
special inputs, the controller accepts only signals within
the standard range of -10 to 60mVÎ (dc).
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
milliamp current signals or voltage signals outside the
standard range, resistors are added or replaced to scale the
signals to the standard range. These resistors can be installed by Watlow Anafaze or by a qualified electronics
technician using scaling resistors supplied by Watlow
Anafaze.
Figure 9.7 shows the schematic for one single-ended sensor
input to the CLS216. See CLS216 Current Inputs on page
184 and CLS216 Voltage Inputs on page 185 for specific instructions and resistor values for voltage and current inputs.
(Voltage only)
To CLS200
IN +
Measurement
Analog
Circuitry
RC
Input
RD (Voltage and Current)
Terminals
Com
Figure 9.7
CLS216 Input Circuit
CLS216 Current Inputs
For each current input on a CLS216 controller, you must
install one resistor. The value of the resistor must be correct for the expected input range. Install the resistor in the
listed resistor location.
Table 9.12
Resistor Values for CLS216 Current Inputs
Input Range
Resistor Value RD
0 to 10 mA
6.0 Ω
0 to 20 mA
3.0 Ω
Resistor tolerance: ±0.1%
184
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 9:Troubleshooting and Reconfiguring
Table 9.13
Resistor Locations for CLS216
Current Inputs
Loop
Resistor
Location
RD
Loop
Resistor
Location
RD
1
R42
9
R41
2
R40
10
R39
3
R38
11
R37
4
R36
12
R35
5
R34
13
R33
6
R32
14
R31
7
R30
15
R29
8
R28
16
R27
CLS216 Voltage Inputs
For each voltage input on a CLS216 controller, you must install two resistors. The resistance must be correct for the
expected input range. Install the resistors in the listed locations.
Table 9.14
Resistor Values for CLS216
Voltage Inputs
Resistor Values
Input Range
RC
RD
0 to 100mVÎ (dc)
499 Ω
750 Ω
0 to 500mVÎ (dc)
5.49 kΩ
750 Ω
0 to 1VÎ (dc)
6.91 kΩ
442.0 Ω
0 to 5VÎ (dc)
39.2 kΩ
475.0 Ω
0 to 10VÎ (dc)
49.9 kΩ
301.0 Ω
0 to 12VÎ (dc)
84.5 kΩ
422.0 Ω
Resistor tolerance: ±0.1%
Doc.# 0600-3050-2000
Watlow Anafaze
185
Chapter 9: Troubleshooting and Reconfiguring
CLS200 Series User’s Guide
Table 9.15
Resistor Locations for CLS216
Voltage Inputs
Resistor Locations
Resistor Locations
Loop
RC
RD
Loop
RC
RD
1
R58
R42
9
R57
R41
2
R56
R40
10
R55
R39
3
R54
R38
11
R53
R37
4
R52
R36
12
R51
R35
5
R50
R34
13
R49
R33
6
R48
R32
14
R47
R31
7
R46
R30
15
R45
R29
8
R44
R28
16
R43
R27
Scaling and Calibration
The controller provides offset calibration for thermocouple,
RTD, and other fixed ranges, and offset and span (gain) calibration for linear and pulse inputs. In order to scale linear
input signals, you must:
1.
Install appropriate scaling resistors. (Contact Watlow
Anafaze’s Customer Service Department for more information about installing scaling resistors.)
2.
Select the display format. The smallest possible range
is -.9999 to +3.0000; the largest possible range is
-9,999 to 30,000.
3.
Enter the appropriate scaling values for your process.
Configuring Dual DAC Outputs
Dual DAC modules ship with both outputs configured for
the signal type and span ordered. The module contains two
independent circuits (DAC1 and DAC2). These circuits can
be configured for different output types. Remove the board
from the housing and set the jumpers. The odd numbered
jumpers determine the signal from DAC1; the even numbered jumpers determine the output from DAC2.
186
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Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 9:Troubleshooting and Reconfiguring
A
N
A
FA
D
L
+5V IN
DZC IN
+10-24V IN
V OUT
I SINK
OUT COM
1
C
A
D
ZE
A
U
C
A
D
1
C
A
D
2
3
4
+5V IN
DZC IN
+10-24V IN
V OUT
I SINK
OUT COM
6
2
5
1
2
3
4
5
6
Figure 9.8
Dual DAC
Table 9.16
Dual DAC Jumper Settings
Jumper Settings
Output
Type
1/2
3/4
5/6
7/8
9/10
11/12
13/14
0 to 5VÎ (dc)
B
A
A
O
B
A
O
0 to 10VÎ (dc)
B
A
A
O
B
O
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.
Doc.# 0600-3050-2000
1.
Power down the system (if the Dual DAC is already installed and wired).
2.
Ensure the DAC1 and DAC2 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.
Watlow Anafaze
187
Chapter 9: Troubleshooting and Reconfiguring
CLS200 Series User’s Guide
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
Table 9.16.
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 DAC1 and
DAC2 connectors.
10. Replace the end plate, end plate screws and, if necessary, mounting screws.
11. Check the wire connections to the DAC1 and DAC2
terminal blocks.
12. If necessary, change the wiring connections to the correct configuration for the new output type. See Wiring
the Dual DAC on page 43.
13. Restore system power.
Configuring Serial DAC Outputs
The Serial DAC’s voltage and current output is jumper selectable. Refer to Figure 9.9. Configure the jumpers as indicated on the Serial DAC label.
ZE
FA
+5
C V
O
C M IN
DA LK IN
FL TA IN
=R AS IN
U HI
N N
N G
IN
G
3
4
OU
TP
UT
VO
SE
EN
LT
LE
T
AG
CT
E
CU
RR
{
{
5
+
- OU
O T
U
T
2
C
A
D
1
L
IA
R
SE
PI
N:
6
Jumper
Figure 9.9
188
Serial DAC Voltage/Current Jumper Positions
Watlow Anafaze
Doc.# 0600-3050-2000
10
Linear Scaling Examples
This chapter provides three linear scaling examples. The
examples describe:
•
•
•
A pressure sensor generating a 4 to 20 mA signal
A flow sensor generating a 0 to 5V signal
A pulse encoder generating 900 pulses per inch of
movement
Example 1: A 4-to-20 mA Sensor
Situation
A pressure sensor that generates a 4 to 20 mA signal is connected to the controller. The specifications of the sensor
state it generates 4 mA at 0.0 pounds per square inch (PSI)
and 20 mA at 50.0 PSI.
Setup
The sensor is connected to a loop input set up with a resistor scaling network producing 60mV at 20 mA.
The INPUT TYPE for the loop is set to LINEAR. The sensor
measures PSI in tenths, so the DISP FORMAT is set to
-999.9 TO +3000.0.
Doc.# 0600-3050-2000
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Chapter 10: Linear Scaling Examples
CLS200 Series User’s Guide
Table 10.1
Input Readings
Process
Variable
Displayed
Sensor
Input
Reading, Percent of
Full Scale (%FS)
50.0 PSI
20 mA
100%FS
0.0 PSI
4 mA
100% x (4 mA/20 mA) = 20%FS
The scaling values setup in the SETUP LOOP INPUT menu
are shown in Table 10.2 .
Table 10.2
Scaling Values
Parameter
190
Prompt
Value
High Process Variable
HIGH PV
50.0 PSI
High Sensor Reading
HIGH RDG
100.0%FS
Low Process Variable
LO PV
Low Sensor Reading
LO RDG
Watlow Anafaze
0.0 PSI
20.0%FS
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 10: Linear Scaling Examples
Example 2: A 0-to-5VÎ (dc) Sensor
Situation
A flow sensor connected to the controller measures the flow
in a pipe. The sensor generates a 0 to 5V signal. The sensor’s output depends on its installation. Independent calibration measurements of the flow in the pipe indicate that
the sensor generates 0.5V at three gallons per minute
(GPM) and 4.75V at 65 GPM. The calibration instruments
are accurate to within 1 gallon per minute.
Setup
The sensor is connected to a loop input set up with a resistor voltage divider network producing 60mV at 5V.
The INPUT TYPE for the loop is set to LINEAR. The calibrating instrument is precise to ±1 GPM, so the DISP FORMAT
is set to -999 to +3000.
This table shows the input readings and the percentage
calculation from the 60mV full scale input.
Table 10.3
Input Readings and Calculations
Process
Variable
Displayed
Sensor
Input
Reading, Percent of
Full Scale (%FS)
65 GPM
4.75
(4.75V / 5.00V) x 100%=95%FS
3 GPM
0.5
(0.5V / 5.00V) x 100%=10%FS
Table 10.4
Scaling Values
Parameter
Doc.# 0600-3050-2000
Prompt
Value
High Process Variable
HIGH PV
65 GPM
High Sensor Reading
HIGH RDG
95.0%FS
Low Process Variable
LO PV
0.0 GPM
Low Sensor Reading
LO RDG
10.0%FS
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Chapter 10: Linear Scaling Examples
CLS200 Series User’s Guide
Example 3: A Pulse Encoder
Situation
A pulse encoder which measures the movement of a conveyor is connected to the controller. The encoder generates 900
pulses for every inch the conveyor moves. You want to measure conveyor speed in feet per minute (FPM).
Setup
The encoder input is connected to the controller’s pulse input. The INPUT TYPE for the loop is set to PULSE. A onesecond sample time gives adequate resolution of the conveyor’s speed. The resolution is:
1 pulse 60 seconds
1 inch
1 foot
-------------------------- x --------------------------------- x ------------------------------- x --------------------------- = 0.006 FPM
1 second 1 minute 900 pulses 12 inches
A DISP FORMAT of -99.99 TO +300.00 is appropriate.
The input readings are as follows:
•
•
At 0 Hz, the input reading will be 0.00 FPM.
At the maximum pulse rate of the CLS200 (2000 Hz):
2000 pulses 60 seconds
1 inch
1 foot
---------------------------------- x --------------------------------- x ------------------------------- x --------------------------- = 11.11 FPM
1 second
1 minute 900 pulses 12 inches
Table 10.5
Scaling Values
Parameter
192
Prompt
Value
High Process Variable
HIGH PV
11.11 FPM
High Sensor Reading
HIGH RDG
2000 Hz
Low Process Variable
LO PV
0 FPM
Low Sensor Reading
LO RDG
0 Hz
Watlow Anafaze
Doc.# 0600-3050-2000
11
Specifications
This chapter contains specifications for the CLS200 series
controllers, TB50 terminal board, Dual DAC module, Serial
DAC module and the CLS200 power supply.
CLS200 System Specifications
This section contains CLS200 series controller specifications for environmental specifications and physical dimensions, inputs, outputs, the serial interface and system
power requirements.
The controller described consists of a processor module and
a 50-terminal block (TB50).
Table 11.1
Doc.# 0600-3050-2000
Agency Approvals / Compliance
CE Directive
Electromagnetic Compatibility (EMC)
Directive 89/336/EEC
UL and C-UL
UL 916, Standard for Energy Management Equipment File E177240
Watlow Anafaze
193
Chapter 11: Specifications
CLS200 Series User’s Guide
CLS200 Processor Physical Specifications
Table 11.2
Environmental Specifications
Storage Temperature
-20 to 60° C
Operating Temperature
0 to 50° C
Humidity
10 to 95% non-condensing
Environment
The controller is for indoor
use only
Table 11.3
Physical Dimensions
Weight
1.98 lbs
0.9 kg
Length*
8.0 inches
203 mm
Width
3.78 inches
96 mm
Height
1.96 inches
50 mm
* Without SCSI connector or with TB18 option.
3.78 in.
(96 mm)
1.96 in.
(50 mm)
1.76 in.
(45 mm)
6.12 in.
(155 mm)
3.55 in.
(90 mm)
8.0 in.
(203 mm)
Figure 11.1 CLS200 Processor Module
Dimensions
194
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 11: Specifications
Table 11.4
Processor with Straight SCSI
Length
9.6 inches
244 mm
Width
3.78 inches
96 mm
Height
1.96 inches
50 mm
1.0 in.
7.0 in.
(178 mm)
(25 mm)
1.6 in.
(41 mm)
1.96 in.
(50 mm)
Figure 11.2 CLS200 Clearances with
Straight SCSI Cable
Table 11.5
1.0 in.
(25 mm)
Processor with Right Angle SCSI
Length
8.6 inches
218 mm
Width
3.78 inches
96 mm
Height
1.96 inches
50 mm
7.0 in.
(178 mm)
0.60 in.
(15 mm)
1.96 in.
(50 mm)
Figure 11.3 CLS200 Clearances with
Right-Angle SCSI Cable
Doc.# 0600-3050-2000
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195
Chapter 11: Specifications
CLS200 Series User’s Guide
Table 11.6
Processor Connections
Power Terminals (TB2)
Captive screw cage clamp
Power Wire Gauge (TB2)
22 to 18 AWG (0.5 to 0.75 mm2)
Power Terminal Torque (TB2)
4.4 to 5.3 in-lb. (0.5 to 0.6 Nm)
Sensor Terminals (TB1)
Captive screw cage clamp
Sensor Wire Gauge (TB1)
Thermocouples: 20 AWG (0.5 mm2)
Linear: 22 to 20 AWG (0.5 mm2)
Communications: 24 AWG (0.2 mm2)
Sensor Terminal Torque (TB1)
4.4 to 5.3 in-lb. (0.5 to 0.6 Nm)
Output Terminals (TB18)
Captive screw cage clamp
Output Wire Gauge (TB18)
Multiconductor cables: 24 AWG (0.2 mm2)
Single-wire: 22 to 18 AWG (0.5 to 0.75 mm2)
Output Terminal Torque (TB18)
4.4 to 5.3 in-lb. (0.5 to 0.6 Nm)
SCSI Connector
SCSI-2 female
TB50 Physical Specifications
Table 11.7
196
TB50 Physical Dimensions
Weight
0.32 lb.
0.15 kg
Length
4.1 inches
104 mm
Width
4.0 inches
102 mm
Height
1.5 inches
37 mm
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 11: Specifications
4.1 in.
(104 mm)
4.0 in.
(102 mm)
1.5 in.
(37 mm)
Figure 11.4 TB50 Dimensions
Table 11.8
TB50 Connections
Screw Terminal Torque
4.4 to 5.3 in-lb. (0.5 to 0.6 Nm)
SCSI Connector on
Board
SCSI-2 female
Output Terminals
Captive screw cage clamp
Output Wire Gauge
Output Terminal Torque
Doc.# 0600-3050-2000
Watlow Anafaze
Multiconductor cables: 24 AWG
(0.2 mm2)
Single-wire: 22 to 18 AWG
(0.5 to 0.75 mm2)
4.4 to 5.3 in-lb. (0.5 to 0.6 Nm)
197
Chapter 11: Specifications
CLS200 Series User’s Guide
Table 11.9
TB50 with Straight SCSI
Length
6.4 inches
163 mm
Width
4.0 inches
102 mm
Height
1.5 inches
37 mm
6.4 in.
(163 mm)
4.0 in.
(102 mm)
1.5 in.
(37 mm)
Figure 11.5 TB50 Dimensions with Straight
SCSI Cable
198
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CLS200 Series User’s Guide
Chapter 11: Specifications
Table 11.10 TB50 with Right Angle SCSI
Length
5.4 inches
137 mm
Width
4.0 inches
102 mm
Height
1.5 inches
37 mm
5.4 in.
(137 mm)
4.0 in.
(102 mm)
1.5 in.
(37 mm)
Figure 11.6 TB50 Dimensions with Right-Angle
SCSI Cable
Doc.# 0600-3050-2000
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Chapter 11: Specifications
CLS200 Series User’s Guide
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 11.11 Analog Inputs
Parameter
Description
Number of Control Loops
CLS204: 5; CLS208: 9; CLS216: 17
Number of Analog Inputs
CLS204: 4 with full range of input types, plus one pulse
CLS208: 8 with full range of input types, plus one pulse
CLS216: 16 with full range of input types, plus one pulse
Input Switching
CLS204 and CLS208: Differential solid state multiplexer
CLS216: Single-ended, solid state multiplexer
Input Sampling Rate
CLS204: 6 Hz (167 ms) at 60 Hz; 5 Hz (200 ms) at 50 Hz.
CLS208: 3 Hz (333 ms) at 60 Hz; 2.5 Hz (400 ms) at 50 Hz.
CLS216:1.5 Hz (667 ms) at 60 Hz; 1.25 Hz (800 ms) at 50 Hz
Analog Over Voltage Protection
±20V referenced to digital ground.
Maximum Common Mode Voltage
5V input to input or input to analog common (CLS204 and CLS208)
Common Mode
Rejection (CMR)
For inputs that do not exceed ±5V, >60 dB dc to 1 kHz, and
120 dB at selected line frequency.
A/D Converter
Integrates voltage to frequency
Input Range
-10 to +60mV, or 0 to 25V with scaling resistors
Resolution
0.006%, greater than 14 bits (internal)
Accuracy
0.03% of full scale (60mV) at 25° C
0.08% of full scale (60mV) at 0 to 50° C
Calibration
Automatic zero and full scale
DC Common to Frame Ground
Maximum Potential
20V
Thermocouple Break Detection
Pulse type for upscale break detection
Milliampere Inputs
0 to 20 mA (3 Ω resistance) or 0 to 10 mA (6 Ω resistance),
with scaling resistors
Linear Voltage Input Ranges Available
0 to12V, 0 to 10V, 0 to 5V, 0 to 1V, 0 to 500 mV, 0 to 100 mV
with scaling resistors.
Source Impedance
200
For 60mV thermocouple, measurements are within specifica
tion with up to 500 Ω source resistance
For other types of analog signals, the maximum source impedance is 5,000 Ω
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Chapter 11: Specifications
Table 11.12 Pulse Inputs
Parameter
Description
Number
1
Frequency Range
0 to 2,000 Hz
Input Voltage Protection
Diodes to supply and common
Voltage Levels
<1.3V: Low
>3.7V: High (TTL)
Maximum Switch Resistance to
Pull Input Low
2 kΩ
Minimum Switch Off Resistance
30 kΩ
Table 11.13 Thermocouple Range and
Resolution
Thermocouple
Type
Range
in °F
Accuracy* at
0 to 50°C
Ambient
Accuracy* at
25°C Ambient
Range
in °C
°F
°C
°F
°C
J
-350 to 1,400
-212 to 760
±2.2
±1.2
±3.3
±1.8
K
-450 to 2,500
-268 to 1371
±2.4
±1.3
±3.8
±2.1
T
-450 to 750
-268 to 399
±2.9
±1.6
±5.8
±3.2
S
0 to 3,200
-18 to 1,760
±5.0
±2.8
±8.8
±4.9
R
0 to 3,210
-18 to 1,766
±5.0
±2.8
±8.8
±4.9
B
150 to 3,200
66 to 1,760
±7.2
±4.0
±22.1
±12.3
E
-328 to 1,448
-200 to 787
±1.8
±1.0
±2.9
±1.6
* True for 10% to 100% of span except type B, which is specified for 800˚ F to 3200˚ F.
Table 11.14 RTD Range and Resolution
Name
Range
in °F
Range
in °C
Resolution
in °C
RTD1
-148.0 to
527.0
-100.0 to
275.0
0.023
RTD2
-184 to
1544
-120 to 840
0.023
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Measurement
Temperature
in °C
Watlow Anafaze
Accuracy
at 25°C
Ambient
Accuracy at
0 to 50°C
Ambient
°F
°C
°F
°C
25
±0.7
±0.4
±1.0
±0.6
275
±1.9
±1.1
±2.8
±1.6
25
±2.5
±1.4
±5.9
±3.3
840
±2.9
±1.6
±8.6
±4.8
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Chapter 11: Specifications
CLS200 Series User’s Guide
Table 11.15 Input Resistance for Voltage Inputs
Range
Input Resistance
0 to 12V
85 kΩ
0 to 10V
50 kΩ
0 to 5V
40 kΩ
0 to 1V
7.4 kΩ
0 to 500mV
6.2 kΩ
0 to 100mV
1.2 kΩ
Table 11.16 Digital Inputs
Parameter
Description
Number
8
Configu ation
8 selectable for output override, remote job
selection
Input Voltage Protection
Diodes to supply and common. Source must
limit current to 10 mA for override conditions
Voltage Levels
<1.3V: Low
>3.7V: High (TTL)
5V maximum, 0V minimum
Maximum Switch Resistance to Pull Input Low
1 kΩ
Minimum Switch Off Resistance
11 kΩ
Update Rate
6 Hz
Outputs
The controller directly accommodates switched dc and
open-collector outputs only. These outputs can be used to
control a wide variety of loads. They are typically used to
control SSRs or other power switching devices which in
turn control, for example, heaters. They may also be used
to signal another device of an alarm condition in the 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 may monitor the CPU state.
202
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CLS200 Series User’s Guide
Chapter 11: Specifications
Analog Outputs
No direct analog outputs are provided.
The digital outputs may be used in conjunction with Dual
DAC or Serial DAC modules to provide analog signals. See
Dual DAC Specifications on page 207 and Serial DAC Specifications on page 209.
Digital Outputs
Table 11.17 Digital Outputs Control / Alarm
Parameter
Description
Number
35
Operation
Open collector output; ON state sinks to logic common
Function
34 Outputs selectable as closed-loop control or alarm/control.
1 global alarm output
Number of Control Outputs per
PID Loop
2 (maximum)
Control Output Types
Time proportioning, distributed zero crossing, Serial DAC or
on/off. All independently selectable for each output. Heat and
cool control outputs can be individually disabled for use as
alarm outputs
Time Proportioning Cycle Time
1 to 255 seconds, programmable for each output
Control Action
Reverse (heat) or direct (cool), independently selectable for
each output
Off State Leakage Current
<0.01 mA to dc common
Maximum Current
60 mA for each output. 5V power supply (from the processor
module) can supply up to 350 mA total to all outputs
Maximum Voltage Switched
24VÎ (dc)
Table 11.18 CPU Watchdog Output
Parameter
Description
Number
1
Operation
Open collector output; ON state sinks to logic common
Function
Monitors the processor module microprocessor
Maximum Current
10 mA (5V power supply in the processor module can supply
up to 350 mA total to all outputs)
Maximum Voltage Switched
5VÎ (dc)
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Chapter 11: Specifications
CLS200 Series User’s Guide
Table 11.19 5VÎ (dc) Output (Power to Operate
Solid-State Relays)
Parameter
Description
Voltage
5VÎ (dc)
Maximum Current
350 mA
Table 11.20 Reference Voltage Output (Power
to Operate Bridge Circuit Sensors)
Parameter
Description
Voltage
5VÎ (dc)
Maximum Current
100 mA
Table 11.21 Processor Serial Interface
Parameter
Description
Type
EIA/TIA-232 3-wire or EIA/TIA-485 4-wire
Isolation
None
Baud Rate
2,400, 9,600 or 19,200 user selectable
Error Check
BCC or CRC, user selectable
Number of Controllers
1 with EIA/TIA-232 communications; up to 32 with EIA/
TIA-485 communications, depending upon protocol
Protocol
Form of ANSI X3.28-1976 (D1, F1), compatible with Allen Bradley PLC, full duplex or Modbus RTU
Table 11.22 Processor Power Requirements
Parameter
Description
Voltage
15 to 24VÎ (dc) +/- 3VÎ (dc)
Maximum Current
1A
204
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CLS200 Series User’s Guide
Chapter 11: Specifications
CLS200 Power Supply
Complete specifications for the CLS200 power supply
are available at www.watlow.com. See the links on the
CLS200 page.
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205
Chapter 11: Specifications
CLS200 Series User’s Guide
0.7 inch
(18 mm)
8.1 inches with mounting bracket
(206 mm)
7.5 inches
(191 mm)
3.9 inches
(99 mm)
0.3 inch
(8 mm)
1.4 in
(36 mm)
6.9 inches
(175 mm)
0.19 (3/16) inch diameter
(5 mm)
Figure 11.7 Power Supply Dimensions (Bottom
View)
Table 11.27 Power Supply Inputs
Voltage
120/240Vı (ac) at 0.75 A, 50/60 Hz
Table 11.28 Power Supply Outputs
206
Voltage V1
5VÎ (dc) @ 4 A
Voltage V2
15 VÎ (dc) @ 1.2 A
Watlow Anafaze
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CLS200 Series User’s Guide
Chapter 11: Specifications
Dual DAC Specifications
The Watlow Anafaze Dual DAC (digital-to-analog converter) is an optional module for the CLS200 series controller.
The Dual DAC converts a distributed zero crossing (DZC)
output signal to an analog process control signal. Watlow
Anafaze provides the following version of the Dual DAC:
•
4 to 20 mA dc
•
0 to 5VÎ (dc)
•
0 to 10VÎ (dc)
Table 11.29 Dual DAC Environmental Specifications
Storage Temperature
-20 to 60° C
Operating Temperature
0 to 50° C
Humidity
10 to 95% non-condensing
Table 11.30 Dual DAC Physical Specifications
Weight
0.42 lb.
0.19 kg
Length
4.4 inches
112 mm
Width
3.6 inches
91 mm
Height
1.8 inches
44 mm
+5V IN
DZC IN
+10-24V IN
V OUT
I SINK
OUT COM
ZE
1
C
A
D
C
A
D
L
A
U
D
FA
A
N
A
0.162 in. diameter
(4 mm)
1
C
A
D
2
3
4
+5V IN
DZC IN
+10-24V IN
V OUT
I SINK
OUT COM
6
2
5
1.8 in.
(44 mm)
1
2
3
4
5
6
3.7 in.
(94 mm)
3.0 in.
(76 mm)
4.4 in.
(112 mm)
3.6 in.
(91 mm)
0.3 in. 0.4 in.
(8 mm) (10 mm)
Figure 11.8 Dual DAC Dimensions
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Chapter 11: Specifications
CLS200 Series User’s Guide
Dual DAC Inputs
The Dual DAC accepts an open-collector signal from the
CLS200 controller and the power from an external power
supply. See Table 11.31.
Table 11.31 Dual DAC Power Requirements
Parameter
Description
Voltage
12 to 24VÎ (dc)
Current
100 mA @ 15VÎ (dc)
Dual DAC Analog Outputs
Table 11.32 Dual DAC Specifications by Output
Range
Version
4-20 mA
0-5 V
±6
±6
± 0.75
± 0.75
± 0.75
% of full scale
range
1.6
1.6
1.6
% of full scale
range
Time Constant
2
2
2
seconds
Maximum Current Output
20
10
10
mA dc
Load Resistance (12V)
250 maximum
500 minimum
1000 minimum
Ω
Load Resistance (24V)
850 maximum
n/a
n/a
Ω
Gain Accuracy
Output Offset
Ripple
208
Watlow Anafaze
0-10 V
±
Units
6
%
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CLS200 Series User’s Guide
Chapter 11: Specifications
Serial DAC Specifications
Watlow Anafaze offers a Serial DAC for precision open-loop
analog outputs. The Serial DAC is jumper-selectable for a
0 to 10VÎ (dc) or 4 to 20 mA output. Multiple Serial DAC
modules can be used with one CLS200. The Serial DAC carries a CE mark.
Table 11.33 Serial DAC Environmental Specifications
Storage Temperature
-20 to 60° C
Operating Temperature
0 to 70° C
Humidity
10 to 95% non-condensing
Table 11.34 Serial DAC Physical Specifications
Weight
0.76 lb.
0.34 kg
Length
5.4 inches
137 mm
Width
3.6 inches
91 mm
Height
1.8 inches
44 mm
FA
A
N
A
+5
C V
C OM IN
L
D K IN
FL ATA IN
=R AS IN
U HI
N N
N G
IN
G
2
3
4
OU
TP
CU
UT
RR
VO
SE
EN
LT
LE
T
AG
CT
E
{
1.8 in.
(44 mm)
{
5
+
- OU
O T
U
T
1
C
A
D
PI
N:
L
IA
R
ZE
SE
0.162 in. diameter
(4 mm)
6
4.7 in.
(119 mm)
3.0 in.
(76 mm)
3.6 in.
(91 mm)
5.4 in.
(137 mm)
0.3 in.
0.4 in.
(8 mm) (10 mm)
Figure 11.9 Serial DAC Dimensions
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Chapter 11: Specifications
CLS200 Series User’s Guide
Table 11.35 Serial DAC Agency Approvals /
Compliance
CE Directive
Electromagnetic Compatibility (EMC)
directive 89/336/EEC
UL and C-UL
UL 916 Standard for Energy Management Equipment File E177240
Serial DAC Inputs
The Serial DAC requires a proprietary serial data signal
and the clock signal from the CLS200 via the TB50. Any
control output can be configured to provide the data signal.
The Serial DAC also requires a 5VÎ (dc) power input.
Table 11.36 Serial DAC Inputs
Parameter
Description
Data
4 mA maximum to DC COM
Open collector or HC CMOS logic levels
Clock
0.5 mA maximum to DC COM
Open collector or HC CMOS logic levels
Table 11.37 Serial DAC Power Requirements
Parameter
Description
Voltage
4.75 to 5.25VÎ (dc) @ 300 mA maximum
Current
210 mA typical @ 20VÎ (dc) out
210
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Chapter 11: Specifications
Serial DAC Analog Outputs
Table 11.38 Serial DAC Analog Output Specifications
Parameter
Description
Absolute Maximum Common
Mode Voltage
Measured between output terminals and controller common:
1,000V
Resolution
15 bits (plus polarity bit for voltage outputs)
(0.305mV for 10V output range)
(0.00061 mA for 20 mA output range)
Accuracy (Calibrated for Voltage
Output)
For voltage output: ± 0.005V (0.05% at full scale)
Temperature coefficien
440 ppm/ °C typical
Isolation Breakdown Voltage
1,000V between input power and signals
Current
0 to 20 mA (500 Ω load max.)
Voltage
0 to 10VÎ (dc) with 10 mA source capability
Output Response Time
1 ms typical
For current output: ± 0.1 mA (0.5% at full scale)
Once per controller A/D cycle nominal. Twice per second maximum for 60 Hz clock rate.
Update Rate
Doc.# 0600-3050-2000
Output changes are step changes due to the fast time constant. All Serial DAC loop outputs are updated at the same
time.
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Chapter 11: Specifications
212
CLS200 Series User’s Guide
Watlow Anafaze
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CLS200 Series User’s Guide
Glossary
Glossary
system.
American Wire Gauge (AWG)
A standard of the dimensional characteristics
of wire used to conduct electrical current or
signals. AWG is identical to the Brown and
Sharpe (B&S) wire gauge.
A
AC
See Alternating Current.
AC Line Frequency
The frequency of the AC power line measured
in Hertz (Hz), usually 50 or 60 Hz.
Accuracy
Closeness between the value indicated by a
measuring instrument and a physical constant
or known standards.
Action
The response of an output when the process
variable is changed. See also Direct Action,
Reverse Action.
Address
A numerical identifier for a controller when
used in computer communications.
Alarm
A signal that indicates that the process has
exceeded or fallen below a certain range
around the setpoint. For example, an alarm
may indicate that a process is too hot or too
cold. See also:
Deviation Alarm
Failed Sensor Alarm
Global Alarm
High Deviation Alarm
High Process Alarm
Loop Alarm
Low Deviation Alarm
Low Process Alarm
Alarm Delay
The lag time before an alarm is activated.
Alternating Current (AC)
An electric current that reverses at regular
intervals, and alternates positive and negative
values.
Ambient Temperature
The temperature of the air or other medium
that surrounds the components of a thermal
Doc.# 0600-3050-2000
Ammeter
An instrument that measures the magnitude
of an electric current.
Ampere (Amp)
A unit that defines the rate of flow of electricity (current) in the circuit. Units are one coulomb (6.25 x 1018 electrons) per second.
Analog Output
A continuously variable signal that is used to
represent a value, such as the process value or
setpoint value. Typical hardware configurations
are 0 to 20mA, 4 to 20mA or 0 to 5 VÎ (dc).
Automatic Mode
A feature that allows the controller to set PID
control outputs in response to the Process
Variable (PV) and the setpoint.
Autotune
A feature that automatically sets temperature
control PID values to match a particular thermal system.
AWG
See American Wire Gauge.
B
Baud Rate
The rate of information transfer in serial communications, measured in bits per second.
Block Check Character (BCC)
A serial communications error checking
method. An acceptable method for most applications, BCC is the default method. See also
Cyclic Redundancy Check.
Bumpless Transfer
A smooth transition from automatic (closed
loop) to manual (open loop) operation. The control output does not change during the transfer.
Watlow Anafaze
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Glossary
CLS200 Series User’s Guide
C
Calibration
The comparison of a measuring device (an
unknown) against an equal or better standard.
Celsius (Centigrade)
Formerly known as Centigrade. A temperature
scale in which water freezes at 0˚C and boils at
100˚C at standard atmospheric pressure. The
formula for conversion to the Fahrenheit scale:
˚F = (1.8 x ˚C) + 32.
Central Processing Unit (CPU)
The unit of a computing system that includes
the circuits controlling the interpretation of
instructions and their execution.
Circuit
Any closed path for electrical current. A configuration of electrically or electromagneticallyconnected components or devices.
Closed Loop
A control system that uses a sensor to measure
a process variable and makes decisions based
on that feedback.
Cold Junction
Connection point between thermocouple metals and the electronic instrument.
Common Mode Rejection Ratio
The ability of an instrument to reject electrical
noise, with relation to ground, from a common
voltage. Usually expressed in decibels (dB).
Communications
The use of digital computer messages to link
components. See also Serial Communications,
Baud Rate.
Control Action
The response of the PID control output relative
to the error between the process variable and
the setpoint. For reverse action (usually heating), as the process decreases below the setpoint the output increases. For direct action
(usually cooling), as the process increases
above the setpoint, the output increases.
Control Status
The type of action that a controller uses. For
example, on/off, time proportioning, PID, automatic or manual, and combinations of these.
214
Current
The rate of flow 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 on-off-on cycle. It is usually expressed in
seconds.
Cyclic Redundancy Check (CRC)
An error checking method in communications.
It provides a high level of data security but is
more difficult to implement than Block Check
Character (BCC). See also Block Check Character.
D
DAC
See Digital-to-Analog Converter.
Data Logging
A method of recording a process variable over
a period of time. Used to review process performance.
DC
See Direct Current.
Deadband
The range through which a variation of the
input produces no noticeable change in the
output. In the deadband, specific conditions
can be placed on control output actions. Operators select the deadband. It is usually above
the heating proportional band and below the
cooling proportional band.
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 anticipated the rate of change of the process, and compensates to minimize overshoot
and undershoot. Derivative control is an
instantaneous change of the control output in
the same direction as the proportional error.
This is caused by a change in the process variable (PV) that decreases over the time of the
derivative (TD). The TD is in units of seconds.
Deutsche Industrial Norms (DIN)
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Glossary
A set of technical, scientific and dimensional
standards developed in Germany. Many DIN
standards have worldwide recognition.
Deviation Alarm
Warns that a process has exceeded or fallen
below a certain range around the setpoint.
Digital-to-Analog Converter (DAC)
A device that converts a numerical input signal to a signal that is proportional to the input
in some way.
body at the same temperature.
Engineering Units
Selectable units of measure, such as degrees
Celsius and Fahrenheit, pounds per square
inch, newtons per meter, gallons per minute,
liters per minute, cubic feet per minute or
cubic meters per minute.
EPROM
Erasable Programmable, Read-Only Memory
inside the controller.
Direct Action
An output control action in which an increase
in the process variable, causes an increase in
the output. Cooling applications usually use
direct action.
Error
The difference between the correct or desired
value and the actual value.
Direct Current (DC)
An electric current that flows in one direction.
Fahrenheit
The temperature scale that sets the freezing
point of water at 32˚ F and its boiling point at
212˚ F at standard atmospheric pressure. The
formula for conversion to Celsius: ˚C = 5/9 (˚F 32).
Distributed Zero Crossing (DZC)
A form of digital output control in which the
output on/off state is calculated for every ac
line cycle. Power is switched at the zero cross,
which reduces electrical noise. See also Zero
Cross.
E
Earth Ground
A metal rod, usually copper, that provides an
electrical path to the earth, to prevent or
reduce the risk of electrical shock.
EIA/TIA
See Serial Communications.
Failed Sensor Alarm
Warns that an input sensor no longer produces
a valid signal. For example, when there are
thermocouple breaks, infrared problems or
resistance temperature detector (RTD) open or
short failures.
Filter
Filters are used to handle various electrical
noise problems.
Digital Filter (DF) — A filter that allows the
response of a system when inputs change
unrealistically or too fast. Equivalent to a
standard resistor-capacitor (RC) filter
Electrical Noise
See Noise.
Electromagnetic Interference (EMI)
Electrical and magnetic noise imposed on a
system. There are many possible causes, such
as switching ac power on inside the sine wave.
EMI can interfere with the operation of controls and other devices.
Electrical-Mechanical Relays
See Relay, Electromechanical.
Emissivity
The ratio of radiation emitted from a surface
compared to radiation emitted from a blackDoc.# 0600-3050-2000
F
Digital Adaptive Filter — A filter that
rejects high frequency input signal noise (noise
spikes).
Heat/Cool Output Filter — A filter that
slows the change in the response of the heat or
cool output. The output responds to a step
change by going to approximately 2/3 its final
value within the numbers of scans that are set.
Frequency
The number of cycles over a specified period of
Watlow Anafaze
215
Glossary
CLS200 Series User’s Guide
time, usually measured in cycles per second.
Also referred to as Hertz (Hz). The reciprocal
is called the period.
G
Gain
The amount of amplification used in an electrical circuit. Gain can also refer to the Proportional (P) mode of PID.
Global Alarm
Alarm associated with a global digital output
that is cleared directly from a controller or
through a user interface.
Global Digital Outputs
A pre-selected digital output for each specific
alarm that alerts the operator to shut down
critical processes when an alarm condition
occurs.
Ground
An electrical line with the same electrical
potential as the surrounding earth. Electrical
systems are usually grounded to protect people
and equipment from shocks due to malfunctions. Also referred to a “safety ground”.
H
Hertz (Hz)
Frequency, measured in cycles per second.
process value. For linear inputs, the high reading is a percentage of the full scale input
range. For pulse inputs, the high reading is
expressed in cycles per second (Hz).
I
Infrared (IR)
A region of the electromagnetic spectrum with
wavelengths ranging from one to 1,000
microns. These wavelengths are most suited
for radiant heating and infrared (noncontact)
temperature sensing.
Input
Process variable information that is supplied
to the instrument.
Input Scaling
The ability to scale input readings (readings in
percent of full scale) to the engineering units of
the process variable.
Input Type
The signal type that is connected to an input,
such as thermocouple, RTD, linear or process.
Integral Control (I)
Control action that automatically eliminates
offset, or droop, between setpoint and actual
process temperature.
J
High Deviation Alarm
Warns that the process is above setpoint, but
below the high process variable. It can be used
as either an alarm or control function.
Job
A set of operating conditions for a process that
can be stored and recalled in a controller’s
memory. also called a recipe.
High Power
(As defined by Watlow Anafaze) Any voltage
above 24 Vac or Vdc and any current level
above 50 mAac or mAdc.
Junction
The point where two dissimilar metal conductors join to form a thermocouple.
High Process Alarm
A signal that is tied to a set maximum value
that can be used as either an alarm or control
function.
High Process Variable
See Process Variable (PV).
High Reading
An input level that corresponds to the high
216
L
Lag
The delay between the output of a signal and
the response of the instrument to which the
signal is sent.
Linear Input
A process input that represents a straight line
function.
Watlow Anafaze
Doc.# 0600-3050-2000
CLS200 Series User’s Guide
Glossary
Linearity
The deviation in response from an expected or
theoretical straight line value for instruments
and transducers. also called linearity error.
Liquid Crystal Display (LCD)
A type of digital display made of a material
that changes reflectance or transmittance
when an electrical field is applied to it.
Load
The electrical demand of a process, expressed
in power (watts), current (amps) or resistance
(ohms). The item or substance that is to be
heated or cooled.
Loop Alarm
Any alarm system that includes high and low
process, deviation band, deadband, digital outputs, and auxiliary control outputs.
Low Deviation Alarm
Warns that the process is below the setpoint,
but above the low process variable. It can be
used as either an alarm or control function.
Low Process Alarm
A signal that is tied to a set minimum value
that can be used as either an alarm or control
function.
Low Reading
An input level corresponding to the low process value. For linear inputs, the low reading is
a percentage of the full scale input range. For
pulse inputs, the low reading is expressed in
cycles per second (Hz).
M
Manual Mode
A selectable mode that has no automatic control aspects. The operator sets output levels.
Manual Reset
See Reset.
Milliampere (mA)
One thousandth of an ampere.
MMI
Man-machine interface.
N
Doc.# 0600-3050-2000
NO-Key Reset
A method for resetting the controller’s memory
(for instance, after an EPROM change).
Noise
Unwanted electrical signals that usually produce signal interference in sensors and sensor
circuits. See also Electromagnetic Interference.
Noise Suppression
The use of components to reduce electrical
interference that is caused by making or
breaking electrical contact, or by inductors.
Nonlinear
Through Anafaze software, the Nonlinear field
sets the system to linear control, or to one of
two nonlinear control options. Input 0 for linear, 1 or 2 for nonlinear.
O
Offset
The difference in temperature between the setpoint and the actual process temperature. Offset is the error in the process variable that is
typical of proportional-only control.
On/Off Control
A method of control that turns the output full
on until setpoint is reached, and then off until
the process error exceeds the hysteresis.
Open Loop
A control system with no sensory feedback.
Operator Menus
The menus accessible from the front panel of a
controller. These menus allow operators to set
or change various control actions or features.
Optical Isolation
Two electronic networks that are connected
through an LED (Light Emitting Diode) and a
photoelectric receiver. There is no electrical
continuity between the two networks.
Output
Control signal action in response to the difference between setpoint and process variable.
Output Type
The form of PID control output, such as time
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217
Glossary
CLS200 Series User’s Guide
proportioning, distributed zero crossing, Serial
DAC or analog. Also the description of the electrical hardware that makes up the output.
Overshoot
The amount by which a process variable
exceeds the setpoint before it stabilizes.
R
Ramp
A programmed increase in the temperature of
a setpoint system.
P
Range
The area between two limits in which a quantity or value is measured. It is usually
described in terms of lower and upper limits.
Panel Lock
A feature that prevents operation of the front
panel by unauthorized people.
Recipe
See Job.
PID
Proportional, Integral, Derivative. A control
status with three functions: Proportional
action dampens the system response, integral
corrects for droops, and derivative prevents
overshoot and undershoot.
Polarity
The electrical quality of having two opposite
poles, one positive and one negative. Polarity
determines the direction in which a current
tends to flow.
Process Variable (PV)
The parameter that is controlled or measured.
Typical examples are temperature, relative
humidity, pressure, flow, fluid level, events, etc.
The high process variable is the highest value
of the process range, expressed in engineering
units. The low process variable is the lowest
value of the process range.
Proportional (P)
Output effort proportional to the error from
setpoint. For example, if the proportional band
is 20˚ and the process is 10˚ below the setpoint,
the heat proportioned effort is 50%. The lower
the PB value, the higher the gain.
Proportional Band (PB)
A range in which the proportioning function of
the control is active. Expressed in units,
degrees or percent of span. See also PID.
Proportional Control
A control using only the P (proportional) value
of PID control.
Pulse Input
Digital pulse signals from devices, such as
optical encoders.
218
Reflection Compensation Mode
A control feature that automatically corrects
the reading from a sensor.
Relay
A switching device.
Electromechanical Relay — A power
switching device that completes or interrupts a circuit by physically moving electrical contacts into contact with each other.
Not recommended for PID control.
Solid State Relay (SSR) — A switching
device with no moving parts that completes
or interrupts a circuit electrically.
Reset
Control action that automatically eliminates
offset or droop between setpoint and actual
process temperature. See also Integral.
Automatic Reset — The integral function
of a PI or PID temperature controller that
adjusts the process temperature to the setpoint after the system stabilizes. The
inverse of integral.
Resistance
Opposition to the flow of electric current, measured in ohms.
Resistance Temperature Detector (RTD)
A sensor that uses the resistance temperature
characteristic to measure temperature. There
are two basic types of RTDs: the wire RTD,
which is usually made of platinum, and the
thermistor which is made of a semiconductor
material. The wire RTD is a positive temperature coefficient sensor only, while the thermistor can have either a negative or positive
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Glossary
limits of a range expressed in the same units
as the range.
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.
Stability
The ability of a device to maintain a constant
output with the application of a constant
input.
RTD
See Resistance Temperature Detector.
S
Serial Communications
A method of transmitting information between
devices by sending all bits serially over a single communication channel.
EIA/TIA-232—An Electronics Industries of
America (EIA) 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—An Electronics Industries of
America (EIA) standard for electrical characteristics of generators and receivers for use in
balanced digital multipoint systems. This is
usually used to communicate with multiple
devices over a common cable or where distances over 50 feet (15 m) are required.
Setpoint (SP)
The desired value programmed into a controller. For example, the temperature at which a
system is to be maintained.
Shield
A metallic foil or braided wire layer surrounding conductors that is designed to prevent 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
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Spread
In heat/cool applications, the +/- difference
between heat and cool. Also known as process
deadband. See also Deadband.
T
T/C 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.
TD (Timed Derivative)
The derivative function.
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 they are
also available with positive temperature coefficients.
Thermocouple (T/C)
A temperature sensing device made by joining
two dissimilar metals. This junction produces
an electrical voltage in proportion to the difference in temperature between the hot junction
(sensing junction) and the lead wire connection
to the instrument (cold junction).
TI (Timed Integral)
The Integral term.
Transmitter
A device that transmits temperature data from
either a thermocouple or RTD by way of a twowire loop. The loop has an external power 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.
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Glossary
CLS200 Series User’s Guide
U
Upscale Break Protection
A form of break detection for burned-out thermocouples. Signals the operator that the thermocouple has burned out.
Undershoot
The amount by which a process variable falls
below the setpoint before it stabilizes.
V
Volt (V)
The unit of measure for electrical potential,
voltage or electromotive force (EMF). See also
Voltage.
Voltage (V)
The difference in electrical potential between
two points in a circuit. It’s the push or pressure behind current flow through a circuit.
One volt (V) is the difference in potential
required to move one coulomb of charge
between two points in a circuit, consuming one
joule of energy. In other words, one volt (V) is
equal to one ampere of current (I) flowing
through one ohm of resistance (R), or V = IR.
Z
Zero Cross
Action that provides output switching only at
or near the zero-voltage crossing points of the
ac sine wave.
220
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Index
A
A control status symbol 56
AC LINE FREQ
default value 74
description 81
location 73, 233
agency compliance
controller 193
power supply 205
Serial DAC 210
ALARM ACK key
acknowledging alarms 59–60
description 54
does not work 170
ALARM DEADBAND
default value 99
description 102
location 73, 233
ALARM DELAY
default value 99
description 103
location 73, 233
location of 64
Alarm High SP parameter 67
Alarm Low SP parameter 67
alarms
acknowledging 59–60
alarm high, see process alarms
alarm low, see process alarms
codes 164, 166
deadband 102
delaying 64, 100, 103
deviation 164
deviation, see process alarms
digital output polarity 81
disabling control on alarm outputs 94
displays 58
failed sensor 65, 166
global 99
global alarm output 68
high deviation alarm settings 100–101
high process alarm settings 100
hysteresis 68
loop delay 64
low deviation alarm settings 100–101
low process alarm settings 102
messages 166
process 164
resetting 165
restoring control after sensor failure 92
reversed thermocouple 85
RTD, see failed sensor alarms
SCRs 37
sensor fail percent output power 97
setting up 66–69
setup parameters 99–103
solid state relays 37
startup delay 64, 78
system 60, 166
T/C BREAK, switching to manual mode 97
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Index
thermocouple, see failed sensor alarms
tolerance 138, 151
troubleshooting 164, 166
wiring 37
ambient temperature
H/W AMBIENT FAILURE message 169
operating range 12
AMBIENT WARNING 168
ANAINSTL 80
analog inputs, see sensor inputs
analog output 158
see also Dual DAC or Serial DAC
ASSIGN R/S PROFILE 148
AUTO 56, 61
automatic control, selecting 61
automatic mode
restoring after failed sensor repair 66
autotuning 62–64
B
BACK key 53
bar graph display 55–56
control status symbols 56
navigating in 56
ramp/soak symbols 147
symbols 55, 58
when running ramp/soak profile 146
battery 7
BATTERY DEAD 166
baud rate 80
BCC, see block check character
block check character 80
boost output 67
bridge circuit 32
C
cables
communications 9, 47
SCSI 7, 9
tie wrapping 35
troubleshooting 175
CALCULATING CHECKSUM 28
CANNOT LOAD JOB 75
CANNOT SAVE JOB 75
CASCADE BASE SP
description 120
location 112, 233
CASCADE CL SPAN
description 121
location 112, 233
cascade control 118–124
application example 121
relationship of secondary setpoint to primary
output 123
setting up, example 122
setup parameters 119–121
testing setup, example 123
CASCADE HT SPAN
description 121
location 112, 233
CASCADE MAX SP
description 120
location 112, 233
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Index
CLS200 Series User’s Guide
CASCADE MIN SP
description 120
location 112, 233
CASCADE PRIM. LOOP
description 119
location 112, 233
case, removing 177
CE, see agency compliance
CHNG SP key
changing the setpoint 61
description 54
does not work 170
locking and unlocking 78
clearance, see installation
communications
baud rate 80
cable 9, 47
controller address 79
error checking algorithm 80
ground loops 24, 175
installation 45–49
jumper configurations 179
protocol 80
software problems 176
specifications 204
troubleshooting 174–176
wire sizes and lengths 22
see also EIA/TIA
COMMUNICATIONS BAUD RATE
default value 74
description 80
location 73, 233
COMMUNICATIONS ERR CHECK
default value 74
description 80
location 73, 233
COMMUNICATIONS PROTOCOL
default value 74
description 80
location 73, 233
computer, see communications 174
control algorithms 153–156
on/off 154
proportional (P) 154, 161
proportional with integral (PI) 155, 161
proportional, integral and derivative (PID) 155,
161
control outputs 157–162
action 96
automatic control, see automatic control
cascade control, see cascade control
control algoritms, see control algorithms
control status, see control status
curve 98
cycle time 95
direct action 96, 159
disabling 94
distributed zero crossing 94, 158
Dual DAC, see Dual DAC
enabling 94
filter 91, 158
limit 96
manual control, see manual control
on/off 94, 157
222
process variable retransmit 113
ratio control, see ratio control
reverse action 96, 159
SCRs 37
Serial DAC, see Serial DAC
solid state relays 37
spread 92
status on power up 78
time proportioning 94, 157
troubleshooting 172–173
wiring 37
control parameters 90–92
control status 61–64
symbols on display 56
unexpected switches from automatic to
manual 167
controller
agency compliance 193
clearance 13, 195
connecting to TB50 27
dimensions 194
environment 194
input specifications 200–202
mounting 13–16
output specifications 202–204
specifications 193–196
terminal specifications 196
troubleshooting, see troubleshooting
wire sizes 196
CONTROLLER ADDRESS
default value 74
description 79
location 73, 233
COOL 56
COOL CONTROL FILTER
default value 90
description 91
location 73, 233
COOL CONTROL OUTPUT
default value 93
description 94
location 73, 233
COOL CONTROL PB
default value 90
description 91
location 73, 233
COOL CONTROL TD
default value 90
description 91
location 73, 233
COOL CONTROL TI
default value 90
description 91
location 73, 233
COOL OUTPUT
curves 98
description 98
location 73, 233
COOL OUTPUT ACTION
description 96
location 73, 233
COOL OUTPUT CYCLE TIME
description 95
location 73, 233
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COOL OUTPUT LIMIT
description 96
location 73, 233
COOL OUTPUT LIMIT TIME
description 96
location 73, 233
COOL OUTPUT RETRANS PV
description 114
location 112, 233
COOL OUTPUT TYPE
description 94
location 73, 233
cool output, see control outputs
COOL RETRANS MAX INP
description 114
location 112, 233
COOL RETRANS MAX OUT%
description 115
location 112, 233
COOL RETRANS MIN INP
description 114
location 112, 233
COOL RETRANS MIN OUT%
description 114
location 112, 233
COOL T/C BRK OUT AVG
description 97
location 73, 233
COPY SETUP FROM PROFILE
description 138
location 136, 233
CPU watchdog timer 38, 203
CRC, see cyclic redundancy check
C-UL, see agency compliance
current inputs
scaling resistors 33, 181, 184
wiring 33
CYCLE NR= 147
cycle time 95
cyclic redundancy check 80
D
D/O alarm polarity parameter 68
DAC, see Dual DAC or Serial DAC
data logging 113, 115
derivative
description 155
guidelines for setting 160–162
setting a value 91
settings from other controllers 161
term versus rate settings 160
DEV ALARM VALUE
default value 99
description 100
location 73, 233
deviation alarms, see process alarms
differential control, see ratio control 131
DIG OUT POLARITY ON ALARM
default value 74
description 81
location 73, 233
DIGITAL INPUTS
default value 103
description 103
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Index
location 73, 233
using for testing 29
digital inputs
external switching devices 39
functions activated 39
output override 77
ramp/soak external reset 139
ramp/soak triggers 142
remote job selection 76–77
restoring control after sensor failure 92
specifications 202
technical information 38
testing 29, 103
thermocouple short detection 79
troubleshooting 173
wiring 38
DIGITAL OUTPUT NUMBER
default value 103
description 104
location 73, 233
digital outputs
polarity for alarms 81
ramp/soak events 141
specifications 203
testing 28, 104
troubleshooting 173
will not turn on 22
wiring 35–36
dimensions
controller 194
Dual DAC 20, 207
power supply 205–206
power supply bracket 19
Serial DAC 20, 209
TB50 196–199
direct action, see control outputs
DISP FORMAT
default value 82
description 87
effect on ramp/soak parameters 144
location 73, 233
scaling parameters 86
values 87
display
bar graph, see bar graph display
does not work 167
job display 60
process variable not correct 167, 171
single loop, see single loop display
distributed zero crossing 94, 158
down-arrow key 53
Dual DAC
configuring outputs 186–188
dimensions 20, 207
environment 207
input specifications 208
jumper settings 187
mounting 19–20
output specifications 208
process variable retransmit 113, 118
specifications 207–208
wiring 43–44
dust 12
DZC, see distributed zero crossing
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Index
CLS200 Series User’s Guide
E
earth, see ground
EDIT RAMP & SOAK PROFILE
description 137
location 136, 233
EDIT SEGMENT NUMBER
description 140
location 136, 233
EIA/TIA-232 45–46
connections 46
jumper configurations 179
jumpers in connectors 46
specifications 204
troubleshooting 174–175
see also communications
EIA/TIA-485 47–49
EIA/TIA-232-to-485 converter 47, 49
jumper configurations 179
network connections 47–48
signal common 48
specifications 204
termination 48
troubleshooting 175
see also communications
electrostatic discharge 177
EMI, see noise
encoders 34
enhanced features option 111–132
cascade control, see cascade control
firmware code shown on display 81
menu tree 112
process variable restransmit, see process variable
retransmit
ENTER key 53
environment 12
controller 194
Dual DAC 207
power supply 205
Serial DAC 209
EPROM
checksum 81
replacing 176–178
error checking 80
ESD, see electrostatic discharge
external bridge circuit 32
EXTERNAL RESET INPUT NUMBER
description 139
location 136, 233
external safety devices 9
external switching devices 39
extruder control 107–110
extruder control algorithm 110
extruder firmware option code 81
F
failed sensor alarms
restoring automatic control after sensor repair 66
RTD open 66
RTD shorted 66
setting up 65–66
thermocouple open 65
thermocouple short 66
224
filter
output 91, 158
sensor input 89
firmware
custom 82
version 81
frequency 81
front panel 8
navigation 51
overview 52
FS alarm code 166
functions activated by digital inputs 39
G
gain, see proportional band
ground loops 24
communications 47
isolation 35
paths 24
and personal computers 24
and thermocouples 31
troubleshooting 172, 175
grounding, troubleshooting 172
H
H/W AMBIENT FAILURE 166, 169
H/W GAIN FAILURE 166, 170
H/W OFFSET FAILURE 166, 170
HD alarm code 164
HEAT 56
HEAT CONTROL FILTER
default value 90
description 91
location 73, 233
HEAT CONTROL OUTPUT
default value 93
description 94
location 73, 233
HEAT CONTROL PB
default value 90
description 91
location 73, 233
HEAT CONTROL TD
default value 90
description 91
location 73, 233
HEAT CONTROL TI
default value 90
description 91
location 73, 233
HEAT OUTPUT
curves 98
default value 93
description 98
location 73, 233
HEAT OUTPUT ACTION
default value 93
description 96
location 73, 233
HEAT OUTPUT CYCLE TIME
default value 93
description 95
location 73, 233
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HEAT OUTPUT LIMIT
default value 93
description 96
location 73, 233
HEAT OUTPUT LIMIT TIME
default value 93
description 96
location 73, 233
HEAT OUTPUT RETRANS PV
description 114
location 112, 233
HEAT OUTPUT TYPE
default value 93
description 94
location 73, 233
heat output, see control outputs
HEAT RETRANS MAX INP
description 114
location 112, 233
HEAT RETRANS MAX OUT%
description 115
location 112, 233
HEAT RETRANS MIN INP
description 114
location 112, 233
HEAT RETRANS MIN OUT%
description 114
location 112, 233
HEAT T/C BRK OUT AVG
default value 93
description 97
location 73, 233
HEAT/COOL SPREAD
location 233
Heat/Cool Thermocouple Break Out 65
HI DEV ALARM OUTPUT
default value 99
description 101
location 73, 233
HI DEV ALARM TYPE
default value 99
description 101
location 73, 233
HI PROC ALARM OUTPUT
default value 99
description 100
location 73, 233
HI PROC ALARM SETPT
default value 99
description 100
location 73, 233
HI PROC ALARM TYPE
default value 99
description 100
location 73, 233
high deviation alarm, see process alarms
HP alarm code 164
humidity
controller 194
Dual DAC 207
power supply 205
Serial DAC 209
hysteresis
alarm 68
hysteresis, see spread
Doc.# 0600-3050-2000
Index
I
INPUT FILTER
default value 82
description 89
location 73, 233
setting before autotuning 64
input power, see power supply
INPUT PULSE SAMPLE TIME
default value 82
description 85
location 73, 233
INPUT READING OFFSET
default value 82
description 84
location 73, 233
values 85
INPUT SCALING HI PV
default value 82
description 88
location 73, 233
scaling parameters 86
INPUT SCALING HI RDG
default value 82
description 88
location 73, 233
scaling parameters 86
INPUT SCALING LO PV
default value 82
description 88
location 73, 233
scaling parameters 86
INPUT SCALING LO RDG
default value 82
description 89
location 73, 233
scaling parameters 86
INPUT TYPE
default value 82
description 83
effect on ramp/soak parameters 144
location 73, 233
values 83
INPUT UNITS
default value 82
description 84
location 73, 233
inputs
analog, see sensor inputs
current, see current inputs
digital, see digital inputs
filter 89
pulse, see pulse inputs
RTD, see RTD
scaling resistors 180–186
sensor, see sensor inputs
setup parameters 82–89
specifications 200–202
thermocouple, see thermocouples
voltage, see voltage inputs
wiring, see installation
installation 11–49
alarm wiring 37
clearance 13–15, 195
communications 45–49
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Index
control output wiring 37
controller 13–16
CPU watchdog timer 38
digital output wiring 35–36
Dual DAC 19–20
environment 12
ground loops, see ground loops
location 12
noise suppression, see noise
overview 11
panel hole dimensions 15
panel thickness 15
power supply 18–19, 25–27
reference voltage terminals 32
sensor input wiring 29–34
Serial DAC 19–20
TB50 16–18, 27
testing 28–29
tie-wrapping cables 35
tools 13
torque for screw terminals 26
typical 12
wire recommendations 21, 30, 35, 47
wire sizes 22
wiring 21–27, 29–49
integral
description 155
guidelines for setting 160–162
setting a value 91
settings from other controllers 161
term versus reset settings 160
J
JOB RUNNING 60
JOB RUNNING DATA MODIFIED 60
JOB RUNNING REMOTELY LOADED 60
JOB SEL DIG INS ACTIVE
default value 74
description 77
location 73, 233
JOB SELECT DIG INPUTS
default value 74
description 76
location 73, 233
jobs
loading from memory 75
remote selection 76–77
saving to memory 75
jumpers
Dual DAC 187
EIA/TIA-232 179
EIA/TIA-485 179
in EIA/TIA-232 connectors 46
power supply common 27
Serial DAC 188
unused inputs 30
when using 2-wire RTD 32
K
KEYBOARD LOCK STATUS
default value 74
description 78
location 73, 233
226
CLS200 Series User’s Guide
keypad
ALARM ACK, see ALARM ACK key
BACK, see BACK key
CHNG SP, see CHNG SP key
ENTER, see ENTER key
keys do not work 167, 170
locking 78
MAN/AUTO, see MAN/AUTO key
NO, see NO key
overview 52
RAMP/SOAK, see RAMP/SOAK key
testing 105
unlocking 78
YES, see YES key
KEYPAD TEST
description 105
how to quit 105
location 73, 233
L
LD alarm code 164
limit controller 9
limit, output 96
linear inputs
decimal shift in ramp/soak parameters 145
display format 87
engineering units 84
scaling and calibration 186
scaling examples 189–192
scaling parameters 86–89
LO DEV ALARM OUTPUT
default value 99
description 101
location 73, 233
LO DEV ALARM TYPE
default value 99
description 101
location 73, 233
LO PROC ALARM OUTPUT
default value 99
description 102
location 73, 233
LO PROC ALARM SETPT
default value 99
description 102
location 73, 233
LO PROC ALARM TYPE
default value 99
description 102
location 73, 233
LOAD SETUP FROM JOB
CANNOT LOAD JOB 75
default value 74
description 75
job display 60
location 73, 233
locking the keypad 78
LOOP NAME
default value 82
description 84
location 73, 233
loops
autotuning, see autotuning
naming 84
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Index
number available 200
ramp/soak profiles, see ramp/soak 148
single loop display, see single loop display
tuning 159–161
low deviation alarm, see process alarms
LOW POWER 166, 168
LP alarm code 164
M
M control status symbol 56
MAN 56, 61
MAN/AUTO CONTROL OUTPUTS DISABLED 61
MAN/AUTO key 54
does not work 170
locking and unlocking 78
switching control statuses 61
manual control
selecting 61
setting the output level 62
MANUAL I/O TEST 103
location 73, 233
parameters in menu 103
menu tree
all setup menus 233
enhanced features 112
ramp/soak profiles 136
standard setup menus 73
menus
accessing 71
global parameters 74
loop alarms 99
loop control 90
loop input 82
loop outputs 93
manual I/O test 103
menu tree, see menu tree
process variable retransmit 113
ramp/soak profile 137
model information
accessing through display 81
location in firmware 73
model number description 5
mounting, see installation
N
NO key
description 53
NO-key reset 176
noise
eliminating problems with 23
isolation 23
reducing with zero-cross switching 158
suppression 22–23
symptoms 22
O
on/off control
control signal 157
description 154
selecting 94
spread 92
operator displays 51
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OUT-OF-TOLRNCE ALARM TIME
description 138
location 136, 233
output override 77, 97
OUTPUT OVERRIDE DIG INPUT
default value 74
description 77
location 73, 233
outputs
5 Vdc output power 204
alarm, see alarms
analog, see Dual DAC or Serial DAC
boost output 67
control, see control outputs
CPU watchdog timer, see CPU watchdog timer
digital, see digital outputs
filter 91
process variable retransmit, see process variable
retransmit
ramp/soak ready state 139
reference voltage, see reference voltage
setup parameters 93–98
solid state relays 37
specifications 202–204
wiring, see installation
OVERRIDE DIG IN ACTIVE
default value 74
description 77
location 73, 233
over-temperature shutdown devices 9
P
panel, see installation
parameters
accessing 71
alarm 99–103
changing values 72
control 90–92
global 74–82
input 82–89
menu tree, see menu tree
output 93–98
process variable retransmit 113
ramp/soak profile 137–143
storage of in RAM 7
test 103
parts list 5
personal computer, see communications 174
PID
autotuning, see autotuning
derivative constant, see derivative
integral term, see integral
proportional band, see proportional band
settings for various applications 162
settings from other controllers 161
tuning 159–161
PLC
transmitting process data to 113
using to set a setpoint, example 129
see also communications
power failure 10
output status upon restart 78
ramp/soak profile upon restart 152
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Index
CLS200 Series User’s Guide
power supply
dimensions 205–206
dimensions of mounting bracket 19
for Dual DAC 43
inputs 206
mounting 18–19
outputs 206
powering loads with 36
requirements 18
specifications 205–206
wiring 25–27
POWER UP OUTPUT STATUS
default value 74
description 78
effect on ramp/soak profiles 152
location 73, 233
process alarms
alarm high 67
alarm low 67
boost output 67
function 67
high deviation 68
low deviation 68
outputs 67
setting up 66
PROCESS POWER DIGIN
default value 74
description 79
location 73, 233
process variable
not displayed correctly 22, 167, 171
retransmit, see process variable retransmit
process variable retransmit 113–118
application example 115
scaling the output 115
setting up, example 116
setup parameters 113
profile, see ramp/soak
proportional band
and cascade control 123
description 154
guidelines for setting 159, 161–162
setting a value 91
settings for various temperature ranges 159
settings from other controllers 161
protocol 80
pulse inputs
display format 87
encoder signals 34
engineering units 84
loops available on 34
sample time 85
scaling and calibration 186
scaling parameters 86–89
specifications 201
technical information 34
wiring 34
PV, see process variable
R
RAM 7, 177
ramp/soak 133–152
assigning profiles to loops 148
continuing from hold 150
228
cycle number 147
decimal shift 145
editing a profile while it is running 149
events 141
firmware option code 81
holding a profile 150
mode symbols on display 146–147
mode, setting 147
overview 133–135
power failure while running profile 152
process variable retransmit, see process variable
retransmit
profile setup parameters 137–143
resetting a profile 151
running a profile 148
screens for RAMP/SOAK key 145
specifications 135
time base 137
time remaining 147
tolerance 143
tolerance alarm, see alarms, tolerance
triggers 142
RAMP/SOAK key 54
assigning profiles 148
cycle number 147
does not work 64, 69, 170
locking and unlocking 78
screens accessed by pressing 145
set mode 147
time remaining 147
unassigning profiles 148
RAMP/SOAK TIME BASE
default value 74
description 137
location 73, 136, 233
ratio control 124–132
application example 126, 129, 131
differential control 131
remote analog setpoint 129
setting up, example 127, 129, 131
setup parameters 125–126
RATIO CONTROL CTRL RATIO
description 126
location 112, 233
RATIO CONTROL MAX SP
description 125
location 112, 233
RATIO CONTROL MIN SP
description 125
location 112, 233
RATIO CONTROL MSTR LOOP
description 125
location 112, 233
RATIO CONTROL SP DIFF
description 126
location 112, 233
READY EVENT OUTPUT
description 139
location 136, 233
READY SEGMENT EDIT EVENTS
description 139
location 136, 233
READY SEGMENT SETPOINT
description 138
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CLS200 Series User’s Guide
Index
location 136, 233
Ref terminals, see reference voltage
reference voltage 32, 204
remote analog setpoint, see ratio control
repair, returning controller for 164
REPEAT CYCLES
description 144
location 136, 233
reset
external 139
integral, see integral
NO-key reset 176
RESET PROFILE 148
RESET WITH DEFAULTS 176
RESTORE PID DIGIN
default value 90
description 92
location 73, 233
RestoreAuto parameter 66
retransmit, see process variable retransmit
returning the controller 164
reverse action, see control outputs
REVERSED T/C DETECT
default value 82
description 85
location 73, 233
RFI, see noise
RMA number 164
RO alarm code 166
RS alarm code 166
RS-232, see EIA/TIA-232
RS-485, see EIA/TIA-485
RT alarm code 166
RTD
accuracy 201
offset 84
range 201
recommended type 32
resolution 201
scaling resistors 32, 183
troubleshooting 171
wiring 32
RTD open alarm 66
RTD shorted alarm 66
S
safety
external safety devices 9
output status on power up 10
symbols and signal words in this manual 2
SAVE SETUP TO JOB
CANNOT SAVE JOB 75
default value 74
description 75
location 73, 233
scaling parameters
example settings, flow sensor with 0-5 Vdc
signal 191
example settings, pressure sensor with 4-20mA
signal 190
example settings, pulse encoder 192
linear inputs 86–89
process variable retransmit 114–115
pulse inputs 86–89
Doc.# 0600-3050-2000
scaling resistors
CLS204 and CLS208 input circuit 180
CLS216 input circuit 184
for current inputs 33, 181, 184
for RTD inputs 32, 183
for thermistor inputs 183
for voltage inputs 32, 182, 185
installing 180–186
SCSI cable 7, 9
clearance 13–14, 195
installing 27
SDAC HI VALUE
default value 93
description 95
location 233
SDAC LO VALUE
default value 93
description 95
location 233
SDAC MODE
default value 93
description 95
location 233
SEG ## EV# DO## ACTIVE STATE
description 141
location 136, 233
SEG ## EVENT # OUTPUT
description 141
location 136, 233
SEG ## TR# DI## ACTIVE STATE
description 142
location 136, 233
SEG ## TR# DI## TRIG
description 143
location 136, 233
SEG ## TRIG # INPUT NR
description 142
location 136, 233
SEGMENT ## EDIT SEG EVENTS
description 141
location 136, 233
SEGMENT ## EDIT SEG TRGGRS
description 142
location 136, 233
SEGMENT ## LAST SEGMENT
description 144
location 136, 233
SEGMENT ## SEG SETPT
description 140
location 136, 233
SEGMENT ## SEG TIME
description 140
location 136, 233
SEGMENT ## SEG TOLERANCE
description 143
location 136, 233
SENSOR FAIL CL OUTPUT
and output override feature 77
and reversed thermocouple detection 85
and thermocouple short detection 79
description 97
location 73, 233
values 97
Sensor Fail Cool Output parameter
and failed sensor alarm 65
Watlow Anafaze
229
Index
Sensor Fail Heat Output parameter
and failed sensor alarm 65
SENSOR FAIL HT OUTPUT
and output override feature 77
and reversed thermocouple detection 85
and thermocouple short detection 79
default value 93
description 97
location 73, 233
values 97
sensor inputs
engineering units 84
failed sensor alarms 166
filter 89
offset 84
ranges 83
specifications 200
troubleshooting 171
type, setting 83
wiring 29–34
Serial DAC
agency compliance 210
clock input 210
configuring outputs 188
configuring the controller output 94
dimensions 20, 209
environment 209
input specifications 210
jumper positions 188
mounting 19–20
output specifications 211
process variable retransmit 113, 118
specifications 209–211
wiring 44–45
SET COOL OUTPUT 62
SET HEAT OUTPUT 62
SET MODE 147–148
SETPOINT 61
setpoint
changing 61
ramp/soak ready setpoint 138
using cascade control to set 118
using PLC to set, example 129
using ratio control to set 124
SETUP GLOBAL PARAMETERS 74
location 73, 233
parameters in menu 74
SETUP LOOP ALARMS 99
location 73, 233
parameters in menu 99
SETUP LOOP CASCADE 119
location 112, 233
SETUP LOOP CONTROL PARAMS 90
location 73, 233
parameters in menu 90
SETUP LOOP INPUT 82
location 73, 233
parameters in menu 82
SETUP LOOP OUTPUTS 93
location 73, 233
parameters in menu 93
SETUP LOOP PV RETRANSMIT
description 113
location 112, 233
230
CLS200 Series User’s Guide
SETUP LOOP RATIO CONTROL
description 125
location 112, 233
SETUP RAMP/SOAK PROFILE 137
location 136, 233
shutdown devices 9
single loop display 56
control status symbols 56
navigating 57
ramp/soak symbols 146
when running ramp/soak profile 146
solid state relays
5 Vdc power from controller 204
distributed zero crossing 158
troubleshooting controller connections 173
specifications 193–211
communications 204
controller 204
controller inputs 200–202
controller outputs 202–204
CPU watchdog timer 203
Dual DAC 207–208
power supply 205–206
Serial DAC 209–211
TB50 196
SPREAD
default value 90
description 92, 156
location 73
spread 92
ST alarm code 166
STARTUP ALARM DELAY
default value 74
description 78
location 73, 233
T
T control status symbol 56
TB18
alarm outputs 37–38
connections 40
CPU watchdog timer output 38
digital output wiring 36
testing after installation 28
to power encoders 34
troubleshooting 173
TB50
alarm outputs 37–38
connecting to controller 27
connections for CLS204 41
connections for CLS208 41
connections for CLS216 42
CPU watchdog timer output 38
digital output wiring 36
dimensions 196–199
for powering Serial DAC 44
mounting on DIN rail 17
mounting with standoffs 18
specifications 196
technical description 8
terminal specifications 197
testing after installation 28
to power encoders 34
troubleshooting 173
Watlow Anafaze
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CLS200 Series User’s Guide
Index
TD, see derivative
temperature
incorrect on display 167, 171
operating 194, 205, 207, 209
storage 194, 205, 207, 209
terminal specifications
controller 196
TB50 197
TEST DIGITAL OUTPUT
default value 103
description 104
location 73, 233
testing
TB18 after installation 28
TB50 after installation 28
see also troubleshooting
thermistor inputs, scaling resistors for 183
Thermocouple Short Alarm parameter 66
thermocouples
accuracy 201
ground loops 31
manual mode if break occurs 97
offset 84
polarity checking 85
range 201
resolution 201
reversed detection 85
short detection 79
troubleshooting 171
types supported 83
wiring 31–32
thermoforming example 131
three-key sequence 71
TI, see integral
tie wraps 35
TIM REM= 147
time proportioning 94
cycle time 95
description 157
TOHO 151
torque, see terminal specifications
triggers, ramp/soak 142
troubleshooting 163–176
alarms 164, 166
all loops are set to manual 0% 167
AMBIENT WARNING 168
check these things first 163
communications 174–176
control outputs 172–173
control status switches unexpectedly 167
digital inputs 29, 103, 173
digital outputs 28, 104, 173
display does not work 167
grounding problems 172, 175
H/W AMBIENT FAILURE 169
H/W GAIN FAILURE 170
H/W OFFSET FAILURE 170
keypad 105, 167, 170
LOW POWER 168
process variable incorrect on display 167, 171
sensor inputs 171
software 176
TB18 173
TB50 173
Doc.# 0600-3050-2000
tolerance alarms 151
unexpected behavior 167
TUNE 56, 61, 64
tuning control loops 159–161
U
UL, see agency compliance
under-temperature shutdown devices 9
unlocking the keypad 78
up-arrow key 53
V
voltage inputs
ranges 202
resistance 202
scaling resistors 32, 182, 185
wiring 32
W
weight
controller 194
Dual DAC 207
power supply 205
Serial DAC 209
TB50 196
wire sizes
controller 196
wiring, see installation
Y
YES key 53
Watlow Anafaze
231
Index
232
CLS200 Series User’s Guide
Watlow Anafaze
Doc.# 0600-3050-2000
Menu Structure
SETUP GLOBAL PARAMETERS (p. 74)
SETUP LOOP INPUT (p. 82)
SETUP LOOP CONTROL PARAMS (p. 90)
SETUP LOOP OUTPUTS (p. 93)
SETUP LOOP ALARMS (p. 99)
MANUAL I/O TEST (p. 103)
LOAD SETUP FROM JOB
SAVE SETUP TO JOB
JOB SELECT DIG INPUTS
JOB SEL DIG INS ACTIVE
OUTPUT OVERRIDE DIG INPUT
OVERRIDE DIG IN ACTIVE
STARTUP ALARM DELAY
RAMP/SOAK TIME BASE
KEYBOARD LOCK STATUS
POWER UP OUTPUT STATUS
PROCESS POWER DIGIN
CONTROLLER ADDRESS
COMMUNICATIONS BAUD RATE
COMMUNICATIONS PROTOCOL
COMMUNICATIONS ERR CHECK
AC LINE FREQ
DIG OUT POLARITY ON ALARM
CLS200 [FIRMWARE INFO.]
INPUT TYPE
LOOP NAME
INPUT UNITS
INPUT READING OFFSET
REVERSED T/C DETECT
INPUT PULSE SAMPLE TIME
DISP FORMAT
INPUT SCALING HI PV
INPUT SCALING HI RDG
INPUT SCALING LO PV
INPUT SCALING LO RDG
INPUT FILTER
HEAT CONTROL PB
HEAT CONTROL TI
HEAT CONTROL TD
HEAT CONTROL FILTER
COOL CONTROL PB
COOL CONTROL TI
COOL CONTROL TD
COOL CONTROL FILTER
SPREAD
RESTORE PID DIGIN
HEAT CONTROL OUTPUT
HEAT OUTPUT TYPE
HEAT OUTPUT CYCLE TIME
SDAC MODE
SDAC LO VALUE
SDAC HI VALUE
HEAT OUTPUT ACTION
HEAT OUTPUT LIMIT
HEAT OUTPUT LIMIT TIME
SENSOR FAIL HT OUTPUT
HEAT T/C BRK OUT AVG
HEAT OUTPUT
COOL CONTROL OUTPUT
COOL OUTPUT TYPE
COOL OUTPUT CYCLE TIME
SDAC PARAMETERS
COOL OUTPUT ACTION
COOL OUTPUT LIMIT
COOL OUTPUT LIMIT TIME
SENSOR FAIL CL OUTPUT
COOL T/C BRK OUT AVG
COOL OUTPUT
HI PROC ALARM SETPT
HI PROC ALARM TYPE
HI PROC ALARM OUTPUT
DEV ALARM VALUE
HI DEV ALARM TYPE
HI DEV ALARM OUTPUT
LO DEV ALARM TYPE
LO DEV ALARM OUTPUT
LO PROC ALARM SETPT
LO PROC ALARM TYPE
LO PROC ALARM OUTPUT
ALARM DEADBAND
ALARM DELAY
DIGITAL INPUTS
TEST DIGITAL OUTPUT
DIGITAL OUTPUT NUMBER XX
KEYPAD TEST
TEST DISPLAY
Additional Enhanced Features Option Menus
Additional Ramp/Soak Option Menus
SETUP LOOP PV RETRANSMIT
SETUP LOOP CASCADE (p. 119)
SETUP LOOP RATIO CONTROL (p. 125)
SETUP LOOP PV RETRANSMIT
SETUP RAMP/SOAK PROFILE (p. 137)
HEAT OUTPUT RETRANS PV
HEAT RETRANS MIN INP
HEAT RETRANS MIN OUT%
HEAT RETRANS MAX INP
HEAT RETRANS MAX OUT%
COOL OUTPUT RETRANS PV
COOL RETRANS MIN INP
COOL RETRANS MIN OUT%
COOL RETRANS MAX INP
COOL RETRANS MAX OUT%
CASCADE PRIM. LOOP
CASCADE BASE SP
CASCADE MIN SP
CASCADE MAX SP
CASCADE HT SPAN
CASCADE CL SPAN
RATIO CONTROL MSTR LOOP
RATIO CONTROL MIN SP
RATIO CONTROL MAX SP
RATIO CONTROL CTRL RATIO
RATIO CONTROL SP DIFF
HEAT OUTPUT RETRANS PV
HEAT RETRANS MIN INP
HEAT RETRANS MIN OUT%
HEAT RETRANS MAX INP
HEAT RETRANS MAX OUT%
COOL OUTPUT RETRANS PV
COOL RETRANS MIN INP
COOL RETRANS MIN OUT%
COOL RETRANS MAX INP
COOL RETRANS MAX OUT%
EDIT RAMP & SOAK PROFILE
COPY SETUP FROM PROFILE
OUT-OF-TOLRNCE ALARM TIME
READY SEGMENT SETPOINT
READY SEGMENT EDIT EVENTS
READY EVENT OUTPUT
EXTERNAL RESET INPUT NUMBER
EDIT SEGMENT NUMBER
SEGMENT ## SEG TIME
SEGMENT ## SEG SETPT
SEGMENT ## EDIT SEG EVENTS
SEG ## EVENT # OUTPUT
SEG ## EV# DO## ACTIVE STATE
SEGMENT ## EDIT SEG TRGGRS
SEG ## TRIG # INPUT NR
SEG ## TR# DI## ACTIVE STATE
SEG ## TR# DI## TRIG
SEGMENT ## SEG TOLERANCE
SEGMENT ## LAST SEGMENT
REPEAT CYCLES
Declaration of Conformity
Declaration of Conformity
CLS200 Series
WATLOW ANAFAZE
314 Westridge Drive
Watsonville, California 95076 USA
Declares that the following product:
English
Designation:
CLS200 Series
Model Number(s):
2 (04, 08 or 16) - (1,2,3 or 4) (0,1 or 2) (0 or 2)
(0,1,2 or 3) (0,1,2 or 3) (0,1, or 2)
(1 or 2 letters or numbers)
Classification:
Installation Category II, Pollution Degree II
Rated Voltage:
15 to 24 VDC
Rated Current:
610mA maximum
Meets the essential requirements of the following European Union Directive(s) using the relevant
section(s) of the normalized standards and related documents shown:
89/336/EEC Electromagnetic Compatibility Directive
EN 61326:
1997
EN 61000-3-2:
EN 61000-3-3:
EN 61000-4-2:
EN 61000-4-3:
EN 61000-4-4:
EN 61000-4-5:
EN 61000-4-6:
EN 61000-4-11:
1995
1995
1995
1997
1995
1995
1994
1994
ENV 50204:
1995
Déclare que le produit suivant :
Désignation :
Numéro(s) de modèle(s):
Electrical equipment for measurement, control and
laboratory use - EMC requirements (Class A)
Limits for harmonic current
Limitations of voltage fluctuations and flicker
Electrostatic discharge
Radiated immunity
Electrical fast transients
Surge immunity
Conducted immunity
Voltage dips, short interruptions and
voltage variations immunity
Cellular phone
Français
Série CLS200
2 - (04, 08 ou 16) - (1, 2, 3 ou 4) (0,1 ou 2)
(0, 1 ou 2) (0, 1, 2 ou 3) (0, 1, 2 ou 3) (0, 1 ou 2)
(1 ou 2 lettres ou chiffren)
Classification :
Installation catégorie II, degré de pollution II
Tension nominale :
15 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
EN 61000-3-2 :
EN 61000-3-3 :
EN 61000-4-2 :
EN 61000-4-3:
EN 61000-4-4 :
EN 61000-4-5 :
EN 61000-4-6:
EN 61000-4-11 :
1995
1995
1995
1997
1995
1995
1996
1994
ENV 50204 :
1995
Appareillage électrique pour la mesure, la commande
et l’usage de laboratoire –— Prescriptions relatives
à la Compatilité Electro Magnétique (Classe A)
Limites d’émission de courant harmon ique
Limites de fluctuation de tension
Décharge électrostatique
Insensibilité à l’énergie rayonnée
Courants électriques transitoires rapides
Insensibi lité aux surtensions
Insensibilité à l’énergie par conduction
Insensibilité aux chutes subites, aux courtes
interruptions et aux variations de tension
Téléphone cellulaire
Erklärt, daß das folgende Produkt:
Deutsch
Beschreibung:
Serie CLS200
Modellnummer(n):
2 (04, 08 oder 16) - (1, 2, 3 oder 4) (0,1 oder 2)
(0,1 oder 2) (0,1,2 oder 3) (0,1,2 oder 3) (0,1 oder 2)
(1 oder 2 Buchstabe oder Ziffern)
Klassifikation:
Installationskategorie II, Emissionsgrad II
Nennspannung:
15 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 Übereinstimmungsanw
EN 61326:
1997
EN 61000-3-2:
EN 61000-3-3:
EN 61000-4-2:
EN 61000-4-3:
EN 61000-4-4:
EN 61000-4-5:
EN 61000-4-6:
EN 61000-4-11:
1995
1995
1995
1997
1995
1995
1994
1994
ENV 50204:
1995
Elektrogeräte zur Messung, Regelung und zum
Laboreinsatz EMC - Richtlinien (Klasse A)
Grenzen der Oberwellenstromemissionen
Grenzen der Spannungsschwankungen
Elektrostatische Entladung
Strahlungsimmunität
Elektrische schnelle Stöße
Spannungsstoßimmunität
Störimmunität
Immunität gegen Spannungsgefälle, kurze
Unterbrechungen und Spannungsabweichungen
Mobiltelefon
Declara que el producto siguiente:
Español
Designación:
Serie CLS200
Números de modelo:
2 - (04, 08 ó 16) - (1, 2, 3 ó 4) (0,1 ó 2)
(0,1 ó 2) (0,1,2 ó 3) (0,1,2 ó 3) (0,1 ó 2)
(1 ó 2 letras ó numeros)
Clasificación:
Categoría de instalación II, grado de contaminación
ambiental II
Tensión nominal:
15 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 Electromagn
EN 61326:
1997
EN 61000-3-2
EN 61000-3-3
EN 61000-4-2:
EN 61000-4-3:
EN 61000-4-4:
EN 61000-4-5:
EN 61000-4-6:
EN 61000-4-11:
1995
1995
1995
1997
1995
1995
1994
1994
ENV 50204:
1995
Equipo elétrico para medición control y uso en
laboratorios - Requisitos de compatibilidad
electromagnética (Clase A)
Límites para emisiones de corriente armónica
Limitaciones de fluctuaciones del voltaje
Descarga electrostática
Inmunidad radiada
Perturbaciones transitorias eléctricas rápidas
Sobretensión
Inmunidad conducida
Caídas de tensión, interrupciones breves y variaciones
de tensión
Teléfono portátil
Sean Wilkinson
Name of Authorized Representative
Watsonville, California. USA
Place of Issue
Manager
Title of Authorized Representative
Feb 28, 2003
Date of Issue
________________________________
Signature of Authorized Representative
30590-00 REV E
e
é
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