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List of Figures
1 System Overview
Figure 1.1—D8 Standard Parts List 5
Figure 1.2—D8 Special Inputs Parts List 6
2 Installation
Figure 2.1—D8 System Components 12
Figure 2.2—Module Dimensions and Clearance 14
Figure 2.3—Wiring Clearances 14
Figure 2.4—Mounting Bracket 15
Figure 2.5—Mounting the TB50 16
Figure 2.6—TB50 Mounted on a DIN Rail (Front) 16
Figure 2.7—TB50 Mounted on DIN Rail (Side) 17
Figure 2.8—Mounting a TB50 with Standoffs 17
Figure 2.9—D8 Power Supply Mounting Bracket 18
Figure 2.10—Dual DAC and Serial DAC Dimensions 19
Figure 2.11—D8 Series Controller with TB50 23
Figure 2.12—Power Connections with the D8 Power Supply 25
Figure 2.13—Thermocouple Connections 29
Figure 2.14—RTD Connections 30
Figure 2.15—Voltage Signal Connections 30
Figure 2.16—Current Signal Connections 30
Figure 2.17—Digital Output Wiring 32
Figure 2.18—Sample Heat, Cool and Alarm Output Connections 33
Figure 2.19—Output Connections Using External Power Supply 34
Figure 2.20—TB50 Watchdog Timer Output 34
Figure 2.21—TB18 Watchdog Timer Output 34
Figure 2.22—Wiring Digital Inputs 35
Figure 2.23—Dual DAC with Current Output 38
Figure 2.24—Dual DAC with Voltage Output 39
Figure 2.25—Single/Multiple Serial DACs 40
Figure 2.26—DeviceNet Connector 40
Figure 2.27—DeviceNet Connector 41
Figure 2.29—D8 Side with Rotary Switches 43
0600-3120-2000 Watlow Anafaze ix
x
List of Figures Series D8 User’s Guide
3 Communicating by DeviceNet
Figure 3.1—RSNetWorx On-line with Found Devices 47
Figure 3.2—The D8 Registered in RSNetWorx 48
Figure 3.3—D8 Properties in RSNetWorx 49
Figure 3.5—Adding the D8 to the Scanlist 51
Figure 3.6—Scanner Input Properties 52
Figure 3.7—Advanced Mapping Dialog Box 53
Figure 3.8—Using Scanned Data in Logic 54
Figure 3.9—Contents of the PLC Memory 55
Figure 3.10—Explicit Write in Ladder 56
Figure 3.11—Explicit Read in Ladder 58
Figure 3.12—D84 Produced Static Input 65
Figure 3.13— D84 Consumed Static Output 65
Figure 3.14—D88 Produced Static Input 65
Figure 3.15—D88 Consumed Static Output 66
4 Operation and Setup
Figure 4.1—General Navigation Map 78
Figure 4.2—Keypad Navigation 79
Figure 4.4—Loop Display with Alarm Code 81
Figure 4.5—Display for Failed Sensor Alarm 81
Figure 4.7—Activation and Deactivation of Process Alarms 96
Figure 4.8—Application Using Process Variable Retransmit 99
Figure 4.9—Secondary Set Point When Primary Loop Has Heat and Cool Outputs
Figure 4.10—Secondary Set Point When Primary Loop Has Heat Output Only 101
Figure 4.11—Example Application Using Cascade Control 103
Figure 4.12—Relationship of Secondary Loop Set Point to Primary Loop Process
Variable in Cascade Example 104
Figure 4.13—Relationship Between the Process Variable on the Master Loop and the
Set Point of the Ratio Loop 105
Figure 4.14—Application Using Ratio Control 106
5 Tuning and Control
Figure 5.2—Proportional Control 113
Figure 5.3—Proportional and Integral Control 113
Figure 5.4—Proportional, Integral and Derivative Control 114
Figure 5.5—Time Proportioning and Distributed Zero Crossing Waveforms 118
6 Menu and Parameter Reference
Figure 6.1—Operator Parameter Navigation 121
Figure 6.2—Setup Menus and Parameters 124
Figure 6.3—Linear and Nonlinear Outputs 143
Watlow Anafaze Doc. 0600-3120-2000
Series D8 User’s Guide
7 Troubleshooting and Reconfiguring
Figure 7.1—Removal of Electronics Assembly from Case 170
Figure 7.2—Screw Locations on PC Board 171
Figure 7.3—Location of Flash Memory Chip 171
Figure 7.5—Serial DAC Voltage and Current Jumper Positions 176
8 Specifications
Figure 8.1—D8 Module Dimensions 180
Figure 8.2—Module Dimensions and Clearance 181
Figure 8.3—TB50 Dimensions 182
Figure 8.4—TB50 Dimensions with Straight SCSI Cable 183
Figure 8.5—TB50 Dimensions with Right-Angle SCSI Cable 184
Figure 8.6—Power Supply Dimensions (Bottom View) 190
Figure 8.7—Dual DAC Dimensions 191
Figure 8.8—Serial DAC Dimensions 193
Glossary
Index
Menu Structure
List of Figures
Doc. 0600-3120-2000 Watlow Anafaze xi
List of Figures Series D8 User’s Guide xii Watlow Anafaze Doc. 0600-3120-2000
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Table of contents
- 1 Cover
- 2 Warranty
- 3 Table of Contents
- 11 List of Figures
- 15 List of Tables
- 19 System Overview
- 19 Manual Contents
- 20 Getting Started
- 20 Safety Symbols
- 20 Initial Inspection
- 20 Product Features
- 23 D8 Parts List
- 24 Technical Description
- 24 D8
- 26 TB50
- 26 D8 Cabling
- 26 Safety
- 26 External Safety Devices
- 27 Power-Fail Protection
- 29 Installation
- 30 Typical Installation
- 30 Mounting Controller Components
- 31 Recommended Tools
- 31 Mounting the Controller
- 34 Mounting the TB50
- 36 Mounting the Power Supply
- 37 Mounting the Dual DAC or Serial DAC Module
- 38 System Wiring
- 38 Wiring Recommendations
- 39 Noise Suppression
- 40 Ground Loops
- 41 Power Connections
- 41 Wiring the Power Supply
- 43 Connecting the TB50 to the D8
- 44 Testing the System
- 44 TB50 or TB18 Test
- 44 Digital Output Test
- 45 Digital Input Test
- 45 Sensor Wiring
- 46 Input Wiring Recommendations
- 47 Thermocouple Connections
- 48 RTD Input Connections
- 48 Voltage Input Connections
- 48 Current Input Connections
- 49 Wiring Control and Digital I/O
- 49 Output Wiring Recommendations
- 49 Cable Tie Wraps
- 49 Digital Outputs
- 53 Digital Inputs
- 54 TB18 Connections
- 55 TB50 Connections
- 56 Analog Outputs
- 56 Wiring the Dual DAC
- 57 Wiring the Serial DAC
- 58 Connecting the D8 to a DeviceNet Network
- 58 Connector Type
- 59 Pinout
- 60 Network Length
- 60 Baud Rate (Data Rate)
- 60 Node Address (MAC ID)
- 61 Status Indicators
- 63 Communicating by DeviceNet
- 63 Accessing Data with a DeviceNet Master
- 63 Software
- 64 About The Electronic Data Sheet (EDS)
- 64 Configuring a D8 Using RSNetWorx
- 65 Registering the D8 without an EDS File
- 66 Registering the D8 with the Watlow EDS File
- 68 Mapping Polled I/O Data
- 68 Adding the D8 to the Master's Scanlist
- 69 Assigning PLC Addresses
- 71 Sample Ladder Logic
- 71 Accessing Polled I/O Data
- 73 Setting a Value with an Explicit Message
- 75 Reading a Value with an Explicit Message
- 76 Setting Parameters via DeviceNet
- 76 Non-Numeric Settings
- 77 Bit-Wise Values
- 77 Decimal Placement for Numeric Values
- 78 Decimal Placement for Percentage Values
- 78 D8 DeviceNet Overview
- 78 Master/Slave Connections
- 79 Addressing
- 79 Data Types
- 79 DeviceNet Objects
- 79 Identity Object
- 80 Message Router Object
- 81 DeviceNet Object
- 81 Assembly Object
- 84 Connection Object
- 85 Input Object
- 86 Output Object
- 88 Control Object
- 89 Alarm Object
- 90 PV Retransmit Object
- 91 Ratio Object
- 92 Cascade Object
- 93 Global Object
- 95 Operation and Setup
- 95 General Navigation Map
- 97 Keypad
- 98 Displays
- 98 Loop Display
- 99 Alarm Displays
- 101 Job Display
- 102 Changing the Set Point
- 102 How to Manually Change the Set Point
- 102 Other Methods of Changing the Set Point
- 103 Changing the Control Mode and Output Power
- 104 Accessing and Navigating the Setup Menus
- 104 How to Access the Setup Menus
- 104 How to Edit a Setup Parameter
- 105 Setting Up Closed-Loop Control
- 105 Feedback
- 105 Control Algorithm
- 105 Control Output Signal Forms
- 105 Heat and Cool Outputs
- 106 How to Set Up Closed-Loop Control
- 106 Setting Up a Process Input
- 106 Input Scaling
- 107 Input Scaling Example: 4 to 20 mA Sensor
- 108 Input Scaling Example: 0 to 5 Vdc Sensor
- 109 Autotuning
- 109 How Does Autotuning Work?
- 110 Prerequisites
- 110 How to Autotune a Loop
- 111 Setting Up Alarms
- 111 Failed Sensor Alarms
- 113 Process Alarms
- 115 Global Alarm
- 115 Setting Up Process Variable Retransmit
- 116 How to Set Up Process Variable Retransmit
- 116 Process Variable Retransmit Example: Data Logging
- 118 Setting Up Cascade Control
- 118 How the Secondary Set Point is Determined
- 119 Proportional-Only Control on the Primary Loop
- 120 How To Set Up Cascade Control
- 120 Cascade Control Example: Water Tank
- 122 Setting Up Ratio Control
- 123 How to Set Up Ratio Control
- 123 Ratio Control Example: Diluting KOH
- 124 Setting Up Differential Control
- 125 How to Set Up Differential Control
- 125 Differential Control Example: Thermoforming
- 125 Setting Up Remote Analog Set Point
- 126 How to Set Up a Remote Analog Set Point
- 126 Remote Analog Set Point Example: Changing a Set Point with a PLC
- 129 Tuning and Control
- 129 Control Algorithms
- 130 On/Off Control
- 130 Proportional Control (P)
- 131 Proportional and Integral Control (PI)
- 132 Proportional, Integral and Derivative Control (PID)
- 132 Heat and Cool Outputs
- 133 Setting Up and Tuning PID Loops
- 133 Proportional Band Settings
- 133 Integral Settings
- 134 Derivative Settings
- 135 General PID Constants by Application
- 135 Proportional Band Only (P)
- 135 Proportional with Integral (PI)
- 135 Proportional and Integral with Derivative (PID)
- 136 Control Outputs
- 136 Output Control Signals
- 138 Output Filter
- 138 Reverse and Direct Action
- 139 Menu and Parameter Reference
- 139 Operator Parameters
- 140 Set Point
- 140 Mode
- 140 Heat/Cool Output
- 141 Process Variable
- 141 Overview of the Setup Menus
- 143 Global Setup Menu
- 143 Load Setup From Job
- 143 Save Setup As Job
- 144 BCD Job Load
- 144 BCD Job Load Logic
- 145 Mode Override
- 146 Mode Override Digital Input Active
- 146 Power Up Alarm Delay
- 146 Power Up Loop Mode
- 147 Keypad Lock
- 147 Thermocouple Short Alarm
- 147 AC Line Frequency
- 147 Digital Output Alarm Polarity
- 148 MAC ID
- 148 Baud Rate
- 148 Module LED
- 148 Network LED
- 148 Bus Off Count
- 149 Model and Firmware Version
- 149 Input Menu
- 149 Input Type
- 150 Loop Name
- 150 Input Units
- 150 Calibration Offset
- 151 Reversed Thermocouple Detection
- 151 Display Format
- 152 Input Range High
- 152 Input High Signal
- 153 Input Range Low
- 153 Input Low Signal
- 153 Input Filter
- 154 Control Menu
- 154 Heat/Cool Proportional Band
- 155 Heat/Cool Integral
- 155 Heat/Cool Derivative
- 155 Heat/Cool Manual Reset
- 155 Heat/Cool Filter
- 156 Hysteresis
- 156 Restore Automatic Mode
- 157 Output Menu
- 157 Heat/Cool Output Type
- 158 Heat/Cool Cycle Time
- 158 Heat/Cool SDAC Signal
- 158 Heat/Cool SDAC Low Signal
- 158 Heat/Cool SDAC High Signal
- 159 Heat/Cool Action
- 159 Heat/Cool Power Limit
- 159 Heat/Cool Power Limit Time
- 160 Sensor Fail Heat/Cool Output
- 160 Open Thermocouple Heat/Cool Output Average
- 161 Heat/Cool Output Curve
- 161 Alarms Menu
- 161 Alarm High Set Point
- 162 Alarm High Function
- 162 Alarm High Output
- 163 High Deviation Value
- 163 High Deviation Function
- 163 High Deviation Output
- 163 Low Deviation Value
- 163 Low Deviation Function
- 164 Low Deviation Output
- 164 Alarm Low Set Point
- 164 Alarm Low Function
- 164 Alarm Low Output
- 165 Alarm Hysteresis
- 165 Alarm Delay
- 166 Process Variable Retransmit Menu
- 166 Heat/Cool Output Retransmit
- 166 Heat/Cool Retransmit Low Process Variable
- 166 Heat/Cool Retransmit High Process Variable
- 167 Cascade Menu
- 167 Cascade Primary Loop
- 167 Cascade Low Set Point
- 167 Cascade High Set Point
- 168 Ratio Menu
- 168 Ratio Master Loop
- 168 Ratio Low Set Point
- 169 Ratio High Set Point
- 169 Control Ratio
- 169 Ratio Set Point Differential
- 169 I/O Tests Menu
- 170 Digital Inputs
- 170 Keypad Test
- 170 Display Test
- 171 Test Digital Output 1 to 20
- 171 Parameters Only Available via Communications
- 171 Alarm Acknowledge
- 171 Alarm Enable
- 172 Alarm Function
- 172 Alarm Status
- 173 Ambient Sensor Reading
- 174 Heat/Cool Output Action for Watchdog Inactivity Fault
- 175 Troubleshooting and Reconfiguring
- 175 When There is a Problem
- 176 Returning a Unit
- 176 Troubleshooting the Controller
- 177 Process Alarms
- 178 Ambient Warning
- 178 Failed Sensor Alarms
- 178 System Alarms
- 179 Other Behaviors
- 180 Reading the DeviceNet Indicator Lights
- 181 Corrective and Diagnostic Procedures
- 181 Low Power
- 181 Battery Dead
- 182 H/W Error: Gain or Offset
- 183 H/W Error: Ambient
- 184 Keys Do Not Work
- 184 Checking Analog Inputs
- 185 Earth Grounding
- 186 Testing Control Output Devices
- 186 Testing the TB18 and TB50
- 186 Testing Control and Digital Outputs
- 187 Testing Digital Inputs
- 187 Clearing the RAM
- 188 Replacing the Flash Memory Chip
- 190 Installing Scaling Resistors
- 190 Input Circuit
- 191 Current Inputs
- 192 Voltage Inputs
- 193 RTD Inputs
- 194 Scaling and Calibration
- 194 Configuring Serial DAC Outputs
- 195 Configuring Dual DAC Outputs
- 197 Specifications
- 197 System Specifications
- 197 Physical Specifications
- 203 Inputs
- 205 Outputs
- 207 Power Supply
- 209 Dual DAC Specifications
- 210 Dual DAC Inputs
- 210 Dual DAC Analog Outputs
- 211 Serial DAC Specifications
- 212 Serial DAC Inputs
- 213 Serial DAC Analog Outputs
- 215 Glossary
- 223 Index
- 231 Menu Structure