Series D8 User’s Guide Watlow Anafaze 1241 Bundy Blvd. Winona, MN 55987 Customer Service: Phone....... 1-800-414-4299 Fax ........... 1-800-445-8992 Technical Support: Phone....... (507) 494-5656 Fax ........... (507) 452-4507 Email ........ wintechsupport@watlow.com Part No. 0600-3120-2000 Rev.
Copyright © 2005, Watlow Anafaze, Incorporated Information in this manual is subject to change without notice. No part of this publication may be reproduced, stored in a retrie val system, or transmitted in an y form without written permission from Watlow Anafaze. Anafaze is a re gistered trademark of Watlow Electric Manuf acturing Compan y. De viceNet is a trademark of the Open DeviceNet Vendor Association, Inc. UL is a registered trademark of Underwriters Laboratories, Inc.
Table of Contents List of Figures ix List of Tables xiii 1 System Overview 1 Manual Contents 1 Getting Started 2 Safety Symbols 2 Initial Inspection 2 Product Features 2 D8 Parts List 5 Technical Description 6 D8 6 TB50 8 D8 Cabling 8 Safety 8 External Safety Devices 8 Power-Fail Protection 9 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 Mo
Table of Contents Series D8 User’s Guide RTD Input Connections 30 Voltage Input Connections 30 Current Input Connections 30 Wiring Control and Digital I/O 31 Output Wiring Recommendations 31 Cable Tie Wraps 31 Digital Outputs 31 Digital Inputs 35 TB18 Connections 36 TB50 Connections 37 Analog Outputs 38 Wiring the Dual DAC 38 Wiring the Serial DAC 39 Connecting the D8 to a DeviceNet Network 40 Connector Type 40 Pinout 41 Network Length 42 Baud Rate (Data Rate) 42 Node Address (MAC ID) 42 Status Indic
Series D8 User’s Guide Table of Contents PV Retransmit Object 72 Ratio Object 73 Cascade Object 74 Global Object 75 4 Operation and Setup 77 General Navigation Map 77 Keypad 79 Displays 80 Loop Display 80 Alarm Displays 81 Job Display 83 Changing the Set Point 84 How to Manually Change the Set Point 84 Other Methods of Changing the Set Point 84 Changing the Control Mode and Output Power 85 Accessing and Navigating the Setup Menus 86 How to Access the Setup Menus 86 How to Edit a Setup Parameter 86 Se
Table of Contents Series D8 User’s Guide 5 Tuning and Control 111 Control Algorithms 111 On/Off Control 112 Proportional Control (P) 112 Proportional and Integral Control (PI) 113 Proportional, Integral and Derivative Control (PID) 114 Heat and Cool Outputs 114 Setting Up and Tuning PID Loops 115 Proportional Band Settings 115 Integral Settings 115 Derivative Settings 116 General PID Constants by Application 117 Proportional Band Only (P) 117 Proportional with Integral (PI) 117 Proportional and Integr
Series D8 User’s Guide Table of Contents Input High Signal 134 Input Range Low 135 Input Low Signal 135 Input Filter 135 Control Menu 136 Heat/Cool Proportional Band 136 Heat/Cool Integral 137 Heat/Cool Derivative 137 Heat/Cool Manual Reset 137 Heat/Cool Filter 137 Hysteresis 138 Restore Automatic Mode 138 Output Menu 139 Heat/Cool Output Type 139 Heat/Cool Cycle Time 140 Heat/Cool SDAC Signal 140 Heat/Cool SDAC Low Signal 140 Heat/Cool SDAC High Signal 140 Heat/Cool Action 141 Heat/Cool Power Limit 1
Table of Contents Series D8 User’s Guide Digital Inputs 152 Keypad Test 152 Display Test 152 Test Digital Output 1 to 20 153 Parameters Only Available via Communications 153 Alarm Acknowledge 153 Alarm Enable 153 Alarm Function 154 Alarm Status 154 Ambient Sensor Reading 155 Heat/Cool Output Action for Watchdog Inactivity Fault 156 7 Troubleshooting and Reconfiguring 157 When There is a Problem 157 Returning a Unit 158 Troubleshooting the Controller 158 Process Alarms 159 Ambient Warning 160 Failed Se
Series D8 User’s Guide Table of Contents Serial DAC Specifications 193 Serial DAC Inputs 194 Serial DAC Analog Outputs 195 Glossary 197 Index 205 Menu Structure 213 Doc.
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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 Figure 1.3—D8 Rear Views 6 Figure 1.4—D8 Front Panel 7 Figure 1.5—TB50 8 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.
List of Figures Series D8 User’s Guide 3 Communicating by DeviceNet Figure 3.1—RSNetWorx On-line with Found Devices Figure 3.2—The D8 Registered in RSNetWorx 48 Figure 3.3—D8 Properties in RSNetWorx 49 Figure 3.4—Parameters Tab 50 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.
Series D8 User’s Guide List of Figures 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 7.4—Input Circuit 173 Figure 7.5—Serial DAC Voltage and Current Jumper Positions 176 Figure 7.6—Dual DAC 177 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.
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List of Tables 2 Installation Table 2.1—Cable Recommendations 21 Table 2.2—Power Connections 24 Table 2.3—TB1 Connections 28 Table 2.4—Digital Output States and Values Stored in the Controller 32 Table 2.5—Digital Input States and Values Stored in the Controller 35 Table 2.6—TB18 Connections 36 Table 2.7—TB50 Connections 37 Table 2.8—DeviceNet Connector 41 Table 2.9—Maximum Network Speed 42 Table 2.10—Module Status Indicator Light 44 Table 2.
List of Tables Series D8 User’s Guide Table 3.24—Control Class and Services 70 Table 3.25—Control Class Attributes (Instance 0) 70 Table 3.26—Control Instance Attributes (Instances 1 to 4 or 8) 70 Table 3.27—Alarm Class and Services 71 Table 3.28—Alarm Class Attributes (Instance 0) 71 Table 3.29—Alarm Instance Attributes (Instances 1 to 4 or 8) 71 Table 3.30—PV Retransmit Class and Services 72 Table 3.31—PV Retransmit Class Attributes (Instance 0) 72 Table 3.
Series D8 User’s Guide List of Tables Table 6.5—Power Up Loop Modes 128 Table 6.6—Digital Output Alarm Polarity 130 Table 6.7—Input Types and Ranges 131 Table 6.8—Characters for the Loop Name and Input Units Parameters 132 Table 6.9—Calibration Offset Ranges 133 Table 6.10—Display Formats 134 Table 6.11—Proportional Band Values 136 Table 6.12—Values for the Control Hysteresis and Deviation Alarm Parameters Table 6.13—Heat and Cool Output Types 139 Table 6.14—Alarm Functions 144 Table 6.
List of Tables Series D8 User’s Guide Table 8.20—Power Supply Physical Specifications 189 Table 8.21—Power Supply with Mounting Bracket 189 Table 8.22—Power Supply Inputs and Outputs 190 Table 8.23—Dual DAC Environmental Specifications 191 Table 8.24—Dual DAC Physical Specifications 191 Table 8.25—Dual DAC Power Requirements 192 Table 8.26—Dual DAC Specifications by Output Range 192 Table 8.27—Serial DAC Environmental Specifications 193 Table 8.28—Serial DAC Physical Specifications 193 Table 8.
1 System Overview Manual Contents This manual describes how to install, set up, and operate a D8 series controller. Each chapter covers a different aspect of your control system and may apply to different users: • • • • • • • • Doc. 0600-3120-2000 Chapter 1: System Overview provides a component list and summary of features for the D8 series controllers. Chapter 2: Installation provides detailed instructions on installing the D8 series controller and its peripherals.
Chapter 1: System Overview Series D8 User’s Guide Getting Started 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! Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury or property damage. NOTE! Indicates pertinent information or an item that may be useful to document or label for later reference.
Series D8 User’s Guide Chapter 1: System Overview • • • • • • • • • • • • Doc. 0600-3120-2000 Direct Connection of Mixed Thermocouple Sensors: Connect most thermocouples to the controller with no hardware modifications. Thermocouple inputs feature reference junction compensation, linearization, offset calibration to correct for sensor inaccuracies, detection of open, shorted or reversed thermocouples, and a choice of Fahrenheit or Celsius display.
Chapter 1: System Overview Series D8 User’s Guide • • • • • • • 4 Nonlinear Output Curves: Select either of two nonlinear output curves for each control output. Autotuning: Use the autotune feature to set up your system quickly and easily. The internal expert system table finds the correct PID parameters for your process. 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.
Series D8 User’s Guide Chapter 1: System Overview D8 Parts List You may have received one or more of the following components. See Figure 2.1 on page 12 for D8 configuration information.
Chapter 1: System Overview Series D8 User’s Guide D8SI _ _ - _ _ - _ _ Special/Process Input Type (Not required for thermocouple sensor inputs) 23 = RTD 43 = 0 to 10 mA dc 44 = 0 to 20 mA dc or 4 to 20 mA dc 50 = 0 to 100 mV dc 52 = 0 to 500 mV dc 53 = 0 to 1 Vdc 55 = 0 to 5 Vdc 56 = 0 to 10 Vdc 57 = 0 to 12 Vdc Start Loop XX = Loop number XX End Loop XX = Loop number XX Figure 1.
Series D8 User’s Guide Chapter 1: System Overview The D8 has the following features: • • • • • • • • Keypad and two-line, 16-character display. Screw terminals for the power and analog inputs. Micro-style connector for DeviceNet. Input power of 12 to 24 Vdc at 1 Amp. 50-pin SCSI cable to connect the digital inputs and outputs to the 50-terminal block (TB50). The D8 is available with an 18-terminal block (TB18) in place of the SCSI connector, as shown in Figure 1.3 on page 6.
Chapter 1: System Overview Series D8 User’s Guide TB50 The TB50 is a screw-terminal interface for control wiring. It allows you to connect power controllers and other discrete I/O devices to the D8. The screw terminal blocks accept wires as large as 18 AWG (0.75 mm2). A 50-pin SCSI cable connects the TB50 to the D8. Figure 1.5 TB50 D8 Cabling Watlow Anafaze provides cables required to install the D8. A 50-pin SCSI cable connects the TB50 to the D8.
Series D8 User’s Guide Chapter 1: System Overview vice such as an mechanical contactor. The limit controller monitors for a hazardous condition such as an under-temperature or over-temperature fault. If a hazardous condition is detected, the limit controller sends a signal to open the contactor. The safety shutdown device (limit controller and contactor) must be independent from the process control equipment. WARNING! The controller may fail in a 0 percent or 100 percent output power state.
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2 Installation This chapter describes how to install the D8 series controller and its peripherals. Installation of the controller involves the following procedures: • • • • • • Determining the best location for the controller Mounting the controller and TB50 Power connection Input wiring Communications wiring Output wiring WARNING! Risk of electric shock. Shut off power to your entire process before you begin installing the controller.
Chapter 2: Installation Series D8 User’s Guide Typical Installation Figure 2.1 shows typical installations of the controller with the TB50 and the TB18 terminal blocks. The type of terminal block you use greatly impacts the layout and wiring of your installation site. See Figure 2.2 to Figure 2.10 to determine potential space requirements. We recommend that you read this entire chapter before beginning the installation procedure. This will help you to carefully plan and assess the installation.
Series D8 User’s Guide Chapter 2: Installation WARNING! To reduce the risk of fire or electric shock, install the D8 in a controlled environment, relatively free of contaminants. Recommended Tools Use any of the following tools to cut a hole of the appropriate size in the panel. • • • Jigsaw and metal file, for stainless steel and heavyweight panel doors. Greenlee 1/8-DIN rectangular punch (Greenlee part number 600-68), for most panel materials and thicknesses.
Chapter 2: Installation Series D8 User’s Guide 41 mm (1.6 inches) for a right-angle DeviceNet connector and SCSI connector. Refer to Figure 2.2. 188 mm (7.4 in) 25 mm (1.0 in) 41 mm to 54 mm (1.6 in to 2.1 in) for cables and clearance Figure 2.2 Module Dimensions and Clearance Maximum Panel Thickness 0.2 inch (5 mm) 1.80 ± 0.020 inch (45.7 ± 0.5 mm) Figure 2.3 3.63 ± 0.020 inches (92.2 ± 0.5 mm) Wiring Clearances We recommend you mount the controller in a panel not more than 0.
Series D8 User’s Guide Chapter 2: Installation terminal blocks, and cables. The controller extends 188 mm (7.4 in.) behind the panel. Allow for an additional 41 to 54 mm (1.6 to 2.1 in.) beyond the connectors. 2. Temporarily cover any slots in the metal housing so that dirt, metal filings, and pieces of wire do not enter the housing and lodge in the electronics. 3. Cut a hole in the panel 46 mm (1.80 in.) by 92 mm (3.63 in.) as shown below. (This picture is NOT a template; it is for illustration only.
Chapter 2: Installation Series D8 User’s Guide Mounting the TB50 There are two ways to mount the TB50: Use the pre-installed DIN rail mounting brackets or use the plastic standoffs. TB50 Mounted with Standoffs TB50 Mounted to DIN Rail Figure 2.5 Mounting the TB50 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 2.6. Figure 2.6 16 TB50 Mounted on a DIN Rail (Front) Watlow Anafaze Doc.
Series D8 User’s Guide Chapter 2: Installation To remove the TB50 from the rail, use a flathead screw driver to unsnap the bracket from the rail. See Figure 2.7. Removal Catch for Screwdriver DIN Rail Snap Latch Hook Side Figure 2.7 TB50 Mounted on DIN Rail (Side) Mounting with Standoffs 1. Remove the DIN rail mounting brackets from the TB50. 2. Choose a location with enough clearance to remove the TB50, its SCSI cable and the controller itself. 3. Mark the four mounting holes. 4.
Chapter 2: Installation Series D8 User’s Guide Mounting the Power Supply If you use your own power supply for the D8, refer to the power supply manufacturer’s instructions for mounting information. Choose a Class 2 power supply that supplies an isolated, regulated 12 to 24 Vdc at 1 A. Mounting Environment Leave enough clearance around the power supply so that it can be removed. 18 Watlow Anafaze Doc.
Series D8 User’s Guide Chapter 2: Installation Mounting the Dual DAC or Serial DAC Module This section describes how to mount the optional Dual DAC and Serial DAC digital-to-analog converters. Mounting of the Dual DAC and Serial DAC is essentially the same, except that the dimensions differ. Jumpers The output signal range of the Dual DAC and Serial DAC modules is configured with jumpers.
Chapter 2: Installation Series D8 User’s Guide 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.
Series D8 User’s Guide Chapter 2: Installation Table 2.1 Function Cable Recommendations Mfr. P/N 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 thermocouple 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.
Chapter 2: Installation Series D8 User’s Guide • • • • • Connect the D8 case to earth ground. The D8 system includes noise suppression circuitry. This circuitry requires proper grounding. Separate the 120 Vac and higher power leads from the low-level input and output leads connected to the D8 series controller. Do not run the digital I/O or control output leads in bundles with ac wires. Where possible, use solid state relays (SSRs) instead of electromechanical relays.
Series D8 User’s Guide Chapter 2: Installation The best way to avoid ground loops is to minimize unnecessary connections to ground. Do not connect any of the following terminals to earth ground: • • • Power supply dc common TB1 terminals 9, 10, 19 (analog common) TB2 terminal 2 (dc power common) Do not connect the analog common terminals to the other terminals listed above. Power Connections This section explains how to make power connections to the D8 and the TB50.
Chapter 2: Installation Series D8 User’s Guide Table 2.2 Power Connections Function 24 Power Supply D8 TB2 DC Power (Controller) +12 to 24 Vdc + DC Common 12 to 24 Vdc Common - Earth Ground Ground 1. Connect the dc common terminal on the power supply to the dc common (-) terminal on D8 TB2. 2. Connect the positive terminal on the power supply to the dc positive (+) terminal on D8 TB2. 3.
Series D8 User’s Guide Chapter 2: Installation CAUTION! To prevent damage from incorrect connections, do not turn on the heater power or other output power before testing the connections as explained in Testing the System on page 26. NOTE! Do not connect the controller’s dc common (COM) to earth ground . Doing so will defeat the noise protection circuitry, making measurements less stable.
Chapter 2: Installation Series D8 User’s Guide Testing the System This section explains how to test the controller after installation and prior to making field wiring connections. TB50 or TB18 Test Use this procedure to verify that the TB50 or TB18 is properly connected and supplied with power: 1. Turn on power to the D8. The display should first show Calculating checksum, and then show the single-loop display. If you do not see these displays, disconnect power and check wiring and power supply output.
Series D8 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 I/O tests menu. This test shows whether the digital inputs are off (open) or on (closed). 3. Attach a wire to the terminal of the digital input you want to test. See Table 2.6 on page 36 for TB 18 connections or Table 2.
Chapter 2: Installation Series D8 User’s Guide Table 2.
Series D8 User’s Guide Chapter 2: Installation Thermocouple Connections Connect the positive lead of the thermocouple to the IN+ terminal for one of the loops, and connect the negative lead to the corresponding IN- terminal. Use 18 or 20 AWG (0.5 or 0.75 mm2) for all 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) Earth Ground at Process End Figure 2.
Chapter 2: Installation Series D8 User’s Guide RTD Input Connections RTD inputs require accessory resistors. Watlow Anafaze recommends that you use a 100 Ω, three-wire platinum RTD to prevent reading errors due to cable resistance. If you use a two-wire RTD, jumper the negative input to common. If you must use a four-wire RTD, leave the fourth wire unconnected. CH IN + CH IN Com 100 Ω RTD Figure 2.
Series D8 User’s Guide Chapter 2: Installation Wiring Control and Digital I/O This section describes how to wire and configure the control outputs for the D8 series controller. The D8 provides dual control outputs for each loop. These outputs can be enabled or disabled, and are connected through a TB50 or TB18. NOTE! Control outputs are connected to controller common when the control output is on.
Chapter 2: Installation Series D8 User’s Guide Table 2.4 State 1 Digital Output States and Values Stored in the Controller Value1 Description Off 0 Open circuit On 1 Sinking current to controller common Read and write these values through communications. All digital outputs sink current to controller common when on. The load may powered by the 5 Vdc supplied by the controller at the TB50, or by an external power supply.
Series D8 User’s Guide Chapter 2: Installation Configuring Outputs As you choose outputs for control and alarms, bear in mind the following points: • • • • • • You can enable or disable the control outputs. By default, heat outputs are enabled and cool outputs are disabled. You can program each control output individually for on/ off, time proportioning, distributed zero-crossing or Serial DAC control. You can individually program each control output for direct or reverse action.
Chapter 2: Installation Series D8 User’s Guide Heat Output Cool Output Alarm Output Common SSR SSR TB50 or TB18 - - + + SSR - + - PS + Figure 2.19 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 to monitor whether the controller is powered and operational.
Series D8 User’s Guide Chapter 2: Installation Digital Inputs All digital inputs are transistor-transistor logic (TTL) level inputs referenced to controller common and the internal +5 V power supply of the D8. When an input is connected to the controller common, the input is considered on. Otherwise, the input is considered off. Most features that use the digital inputs can be user-configured to activate when an input is either on or off. In the off state, internal 4.
Chapter 2: Installation Series D8 User’s Guide Functions Activated by Digital Inputs Use digital inputs to activate the following functions: • Load a job that is stored in controller memory. See BCD Job Load on page 126. Change all loops to manual mode at specified output levels. See Mode Override on page 127. Enable thermocouple short detection. See Thermocouple Short Alarm on page 129. Restore automatic control after a failed sensor has been repaired. See Restore Automatic Mode on page 138.
Series D8 User’s Guide Chapter 2: Installation TB50 Connections Table 2.
Chapter 2: Installation Series D8 User’s Guide 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.
Series D8 User’s Guide Chapter 2: Installation Dual DAC TB50 or TB18 +5V 1 1 +5V CTRL Supply PID Loop Output 2 DZC CTRL PID Output 3 4 +12/24 Vdc External Power Supply +Vdc Load Connection 5 -mAdc Load Connection 6 -External Power Supply/ Vdc Load Connection Vdc Load + - + 12 to 24 Vdc Power Supply Figure 2.24 Dual DAC with Voltage Output Wiring the Serial DAC The Serial DAC provides a robust analog output signal.
Chapter 2: Installation Series D8 User’s Guide Daisy chain up to Controller 16 Serial DACs Power Supply Serial DAC +5 V 1 +5V In 5 V Common 2 COM In 15 V Common 3 CLK In 4 Data In 5 + Out 6 - Out TB50 or TB18 Serial DAC Clock Control Output Load + Figure 2.25 Single/Multiple Serial DACs Connecting the D8 to a DeviceNet Network Connector Type Connect the D8 to the DeviceNet network using a female, sealed, micro-style, quick disconnect connector with five conductors.
Series D8 User’s Guide Chapter 2: Installation J4 DeviceNet Connector Network LED Indicator Light Module LED Indicator Light Figure 2.27 DeviceNet Connector Pinout 2 1 3 5 4 Figure 2.28 Pinout Table 2.8 Pin 1 DeviceNet Connector Signal Shield 2 V+ Doc.
Chapter 2: Installation Series D8 User’s Guide Network Length The network speed is limited by the end-to-end network distance. The longer the network, the slower the baud rate setting must be. See Table 2.9 Table 2.9 Maximum Network Speed Distance Baud Rate 100 m (328 ft) 500 Kbps 250 m (820 ft) 250 Kbps 500 m (1,640 ft) 125 Kbps Baud Rate (Data Rate) DeviceNet communications can use three different baud rates (data rates) 125k, 250k, and 500k baud.
Series D8 User’s Guide Chapter 2: Installation selection, the controller will always come back up on the network with the last software configured node address stored in the controller's memory. Set the controller’s MAC ID with the two rotary switches on the side of the case. Set the most significant digit (MSD) with the left switch and the least significant digit (LSD) with the right switch. For example, to set the address to 23, set the MSD to 2 and the LSD to 3.
Chapter 2: Installation Series D8 User’s Guide Table 2.10 Module Status Indicator Light Indicator Light Description Off No power is applied to the device. Flashing Green-Red The device is performing a Self-Test. Green The device is operating normally Red The device has detected an unrecoverable fault. Table 2.11 Indicator Light Network Status Indicator Light Description The device is not online. Off The device has not completed the duplicate MAC ID test yet. The device may not be powered.
3 Communicating by DeviceNet This chapter explains how to add a D8 series controller to a DeviceNet network and how to access and manipulate the controller's data over a network using a Programmable Logic Controller or other device with a DeviceNet scanner. The chapter also includes descriptions of the D8's objects and attributes that are accessible via the DeviceNet protocol. Accessing Data with a DeviceNet Master Figure 3.12 to Figure 3.
Chapter 3: Communicating by DeviceNet Series D8 User’s Guide of data from the D8 to the PLC or other device, will be the same. About The Electronic Data Sheet (EDS) Most, if not all, vendors supply an EDS file with their DeviceNet products. The EDS file allows for faster and easier configuration with the network software, but it is not required to make the device work. The examples cover commissioning the D8 on a network both with and without the EDS file.
Series D8 User’s Guide Chapter 3: Communicating by DeviceNet Figure 3.1 RSNetWorx On-line with Found Devices Figure 3.1 shows node address 1 with a question mark on its icon, indicating that this device has not yet been registered in RSNetWorx. At this point the user may register an existing EDS file or create one. Both options are addressed in the following sections.
Chapter 3: Communicating by DeviceNet Series D8 User’s Guide Table 3.1 Number of Bytes Controller Input Bytes Output Bytes D84 (4-loop) 41 12 D88 (8-loop) 81 24 Figure 3.2 The D8 Registered in RSNetWorx Registering the D8 with the Watlow EDS File There are important differences between the results of registering the D8 controller with and without the Watlow-supplied EDS file, though these differences are not readily visible in Figure 3.2.
Series D8 User’s Guide Chapter 3: Communicating by DeviceNet A. Registered without the Watlow EDS Figure 3.3 B. Registered with the Watlow EDS D8 Properties in RSNetWorx The Parameters tab provides access to all of the D8 controller's parameters. See Figure 3.4. Some of these parameters have read-only access and some have read-and-write access. This tab can be a valuable tool for configuring the D8.
Chapter 3: Communicating by DeviceNet Series D8 User’s Guide Figure 3.4 Parameters Tab Mapping Polled I/O Data Once the D8 controller is registered, the master must be configured to communicate with it. Once the master is configured it is possible to map the polled I/O data from the D8 to the PLC. The next sections address these steps.
Series D8 User’s Guide Chapter 3: Communicating by DeviceNet device starting at the next available byte in the PLC memory. When not checked the user controls how the bytes are arranged.) 3. Select 01 Watlow D84/D88 by clicking it in theAvailable Devices list. 4. Click the right-arrow button to put the D8 on theScanlist. Figure 3.
Chapter 3: Communicating by DeviceNet Series D8 User’s Guide The Node list in Figure 3.6 indicates that the scanner will communicate with the D8 via Polled messages. The scanner expects to find 81 bytes, but no data is currently mapped. The figure also shows four other devices on the network and their corresponding communications and data mapping configurations. Figure 3.6 Scanner Input Properties To map the D8's data: 52 1.
Series D8 User’s Guide Chapter 3: Communicating by DeviceNet Figure 3.7 Advanced Mapping Dialog Box The D8's polled input data is now mapped to the scanner's M1 file. The scanner's M0 file may similarly be used to map the DeviceNet output data. The output data is easier to map because there is no Exception Status Byte to omit. See Poll Connection on page 64 for information on the output data.
Chapter 3: Communicating by DeviceNet Series D8 User’s Guide tions from one PLC manufacturer to another, the same concepts apply. NOTE! The contents of the scanner's M1 file cannot be monitored directly in RSLogix™, the logic-programming environment used in the following examples. For ease of demonstration and troubleshooting, the relevant registers are copied from the scanner's M1 file to the PLC's N14 file. Figure 3.
Series D8 User’s Guide Chapter 3: Communicating by DeviceNet Figure 3.8 also shows the power level for loop 1 being scaled. The scanned value is also in tenths, so 1000 means 100% power (see Heat/Cool Output on page 122). According to Figure 3.14 on page 65, M1:1.8 will hold the Set Point for loop 1. This value is copied by the ladder logic to N14:8. The 8 words after the set points, starting at M1:1.16 copied to N14:16 contain the Heat Output power for loops 1 to 8. Figure 3.
Chapter 3: Communicating by DeviceNet Series D8 User’s Guide Figure 3.10 Explicit Write in Ladder NOTE! The numbers shown above in N14:50 through N14:56 and N14:60 through N14:66 are in hexadecimal. The explicit messages in the example are 7 words long. The outbound transaction header is defined in the first 3 words of the copy instruction. In the figure the header for the first message is N14:50, 51, and 52. Table 3.2 lists and describes the parts of the message header. 56 Watlow Anafaze Doc.
Series D8 User’s Guide Chapter 3: Communicating by DeviceNet Table 3.2 Memory Location Description Outbound Transaction Header Example Value Note N14:50 MSB Transaction ID (TXID) 1 hex Unique number for message in the queue N14:50 LSB Command 1 hex Execute the transmission block N14:51 MSB Port 0 hex The DeviceNet port N14:51 LSB Data Size (in bytes) 8 hex Size of the message body: 8 bytes or 4 words N14:52 MSB Service 10 hex Get Attribute Single (See Table 3.
Chapter 3: Communicating by DeviceNet Series D8 User’s Guide Figure 3.11 Explicit Read in Ladder When I:1/15 comes on, indicating there is a response available to a previously sent message, the controller's loop 1 Proportional Band value is copied to N14:103. Again, if N14:100 comes back as an echo of N14:90 (transaction completed successfully) the MVM instruction deletes the transaction from the response queue. Setting Parameters via DeviceNet All values stored in the D8 are bits, integers or strings.
Series D8 User’s Guide Chapter 3: Communicating by DeviceNet phrase and in some cases a number, see the parameter information in Chapter 6, Menu and Parameter Reference. The integer value appears in parentheses following each option. Use that integer value when you set or interpret the value of the parameter via DeviceNet. Bit-Wise Values Some settings, such as those that enable alarms, are stored as bits within words.
Chapter 3: Communicating by DeviceNet Series D8 User’s Guide To determine the integer value to set in the controller, move the decimal to the right the number of places specified. For example: • If a loop has a process input with a display format of -99.99 to 300.00, values are stored with two decimal places. If you read a value in the set point register of 2500, you should interpret that value as 25.00.
Series D8 User’s Guide Chapter 3: Communicating by DeviceNet Addressing All data is referenced using a four-part definition: Node (MAC ID) + Class + Instance + Attribute. Table 3.5 Address Components Address Component Range Node Address (MAC ID) [0 to 63] Class ID [1 to 255] Instance ID [0 to 255] Attribute ID [1 to 255] Data Types The descriptions of attributes in the following sections include the data type for each. Table 3.6 lists and describes these data types. Table 3.
Chapter 3: Communicating by DeviceNet Series D8 User’s Guide Table 3.7 Identity Class and Services Class Code 01 hex Class Services None 01 hex Get Attribute All Instance Services 05 hex Reset (O,1) 0E hex Get Attribute Single Table 3.8 Name Identity Instance Attributes Attribute Access Type Description 1 (1 hex) Get Vendor ID UINT Identification of each vendor by number. Watlow has vendor ID 153 2 (2 hex) Get Product Type UINT Identification of general type of product for vender.
Series D8 User’s Guide Chapter 3: Communicating by DeviceNet DeviceNet Object The DeviceNet object is used to provide the configuration and status of a physical attachment to DeviceNet. Table 3.11 DeviceNet Class and Services Class Code 03 hex Class Services 0E hex Get Attribute Single 10 hex Set Attribute Single 0E hex Get Attribute Single Instance Services 08 hex Create 09 hex Delete Table 3.
Chapter 3: Communicating by DeviceNet Series D8 User’s Guide Table 3.14 Assembly Class and Services Class Code 04 hex Class Services None Instance Services 0E hex Get Attribute Single 10 hex Set Attribute Single Table 3.
Series D8 User’s Guide Byte Byte Chapter 3: Communicating by DeviceNet Byte Byte Byte Byte Byte Byte Exception Status 1 byte Loop 1 Process Variable INT (2 bytes) Loop 2 Process Variable INT (2 bytes) Loop 3 Process Variable INT (2 bytes) Loop 4 Process Variable INT (2 bytes) Loop 1 Set Point INT (2 bytes) Loop 2 Set Point INT (2 bytes) Loop 3 Set Point INT (2 bytes) Loop 4 Set Point INT (2 bytes) Loop 1 Heat Output UINT (2 bytes) Loop 2 Heat Output UINT (2 bytes) Loop 3 Heat Output UINT
Chapter 3: Communicating by DeviceNet Byte Byte Byte Series D8 User’s Guide Byte Byte Byte Byte Loop 1 Set Point INT (2 bytes) Loop 2 Set Point INT (2 bytes) Loop 3 Set Point INT (2 bytes) Loop 4 Set Point INT (2 bytes) Loop 5 Set Point INT (2 bytes) Loop 6 Set Point INT (2 bytes) Loop 7 Set Point INT (2 bytes) Loop 8 Set Point INT (2 bytes) Loop 1 Control Mode USINT (1 byte) Loop 2 Control Mode USINT (1 byte) Loop 3 Control Mode USINT (1 byte) Loop 4 Control Mode USINT (1 byte) Loop 5
Series D8 User’s Guide Attribute Access 12 (C hex) Get/Set 13 (D hex) Get 14 (E hex) Get 15 (F hex) Get 16 (10 hex) Get Chapter 3: Communicating by DeviceNet Name Watchdog Timeout Action Produced Connection Path Length Produced Connection Path Consumed Connection Path Length Consumed Connection Path Type Description USINT Defines how to handle inactivity or watchdog timeouts; Auto Delete (1), Deferred Delete (3) UINT Number of bytes in the Produced Connection Path Attribute EPATH Specif
Chapter 3: Communicating by DeviceNet Series D8 User’s Guide Table 3.20 Input Instance Attributes (Instances 1 to 4 or 8) Attribute Access Name Type Description 100 (64 hex) Get/Set Set Point INT See page 122. 101 (65 hex) Get Process Variable INT See page 123. 102 (66 hex) Get/Set Input Type SHORT_STRING See page 131. 103 (67 hex) Get/Set Loop Name SHORT_STRING See page 132. 104 (68 hex) Get/Set Input Units Array of 3 USINT See page 132.
Series D8 User’s Guide Chapter 3: Communicating by DeviceNet Table 3.22 Output Class Attributes (Instance 0) Attribute Access Name Type Description 1 (1 hex) Get Revision UINT Revision of this object 2 (2 hex) Get Max Instance UINT Maximum instances of this object (8) 3 (3 hex) Get Number of Instances UINT Number of object instances Table 3.
Chapter 3: Communicating by DeviceNet NOTE! Series D8 User’s Guide All successful explicit message responses from a Set service will contain no data. The response will be a two-byte message containing the requester’s node address and service code (with R/R bit set). Control Object The Control Object provides read/write access to all control parameters. Instance 0 of this object contains the class attributes listed in Table 3.25.
Series D8 User’s Guide Attribute Chapter 3: Communicating by DeviceNet Access Name Type Description 109 (6D hex) Get/Set Cool Filter USINT See page 137. 110 (6E hex) Get/Set Hysteresis UINT See page 138. 111 (6F hex) Get/Set Restore Automatic Mode USINT See page 138. 112 (70 hex) Get/Set Mode USINT See page 122. NOTE! All successful explicit message responses from a Set service will contain no data.
Chapter 3: Communicating by DeviceNet Attribute Series D8 User’s Guide Access Name Type Description 104 (68 hex) Get/Set Alarm Hysteresis UINT See page 147. 105 (69 hex) Get/Set Alarm High Output USINT See page 144. 106 (6A hex) Get/Set Alarm Low Output USINT See page 146. 107 (6B hex) Get/Set High Deviation Output USINT See page 145. 108 (6C hex) Get/Set Low Deviation Output USINT See page 146. 109 (6D hex) Get/Set Alarm Delay UINT See page 147.
Series D8 User’s Guide Chapter 3: Communicating by DeviceNet Table 3.32 PV Retransmit Instance Attributes (Instances 1 to 4 or 8) Attribute Access Name Type Description 100 (64 hex) Get/Set Heat Output Retransmit USINT See page 148. 101 (65 hex) Get/Set Cool Output Retransmit USINT See page 148. 102 (66 hex) Get/Set Heat Retransmit Low Process Variable INT See page 148. 103 (67 hex) Get/Set Cool Retransmit Low Process Variable INT See page 148.
Chapter 3: Communicating by DeviceNet Series D8 User’s Guide Table 3.35 Ratio Instance Attributes (Instances 1 to 4 or 8) Attribute Access Name Type Description 100 (64 hex) Get/Set Ratio Master Loop USINT See page 150. 101 (65 hex) Get/Set Ratio Low Set Point INT See page 150. 102 (66 hex) Get/Set Ratio High Set Point INT See page 151. 103 (67 hex) Get/Set Control Ratio UINT See page 151. 104 (68 hex) Get/Set Ratio Set Point Differential INT See page 151.
Series D8 User’s Guide Chapter 3: Communicating by DeviceNet Table 3.38 Cascade Instance Attributes (Instances 1 to 4 or 8) Attribute Access Name Type Description 100 (64 hex) Get/Set Cascade Primary Loop USINT See page 149. 101 (65 hex) Get/Set Cascade Low Set Point INT See page 149. 102 (66 hex) Get/Set Cascade High Set Point INT See page 149. NOTE! All successful explicit message responses from a Set service will contain no data.
Chapter 3: Communicating by DeviceNet Series D8 User’s Guide Table 3.41 Global Instance Attributes (Instance 1) Attribute Access Name Type Description 100 (64 hex) Get/Set Load Setup From Job USINT See page 125. 101 (65 hex) Get/Set Save Setup As Job USINT See page 125. 102 (66 hex) Get/Set BCD Job Load USINT See page 126. 103 (67 hex) Get/Set BCD Job Load Logic BOOL See page 126. 104 (68 hex) Get/Set Mode Override USINT See page 127.
4 Operation and Setup This chapter explains how to use the keypad and display to operate the controller. This chapter also explains the basic concepts that you need to understand to set up and operate the controller. General Navigation Map The normal display on the D8 is the loop display. Figure 4.1 shows how to navigate from the loop display to other displays, menus and parameters. Doc.
Chapter 4: Operation and Setup Loop Display 01 Series D8 User’s Guide Scanning Loop Display Hold 3 seconds 01 925 ∞C 1000auto100 925 ∞C 1000man100 02 1025∞C 1000man100 03 1050∞C 1050auto 0 Job Display (if a job is loaded) Job 1 running >< Hold 3 seconds Setup Menus lGlobal setup r Other menus b Operator Parameters . l01 Set point ^1000 l01 Mode ^manual l01 Heat out r r r ^0% l01 Cool out r b 0 % LOOP Same Screen on the Next or Previous Loop 02 1025∞C 1050auto100 Figure 4.
Series D8 User’s Guide Chapter 4: Operation and Setup Keypad l01 Set point r b 1000˚C Key x > < , . Description Access the setup menus (press and hold for 3 seconds). Cancel a change without saving. Escape from a parameter to a top-level setup menu. Escape from a setup menu to the loop display or job display. Acknowledge an alarm. Toggle between the loop display and job display (if a job is loaded). Edit a parameter value. Scroll through the top-level setup menus.
Chapter 4: Operation and Setup Series D8 User’s Guide Displays Loop Display The loop display shows detailed information about a loop. Process Variable Loop Name 01 Set Point Figure 4.3 Engineering Units 925 ˚Cc 0 1000manh100 Cool and Heat Output Power Control Mode (see Table 4.1) Loop Display The control modes are described in Table 4.1. Table 4.1 Control Modes Control Mode NOTE! Description off The loop is set to off. One or both outputs are enabled but both outputs are at 0%.
Series D8 User’s Guide Chapter 4: Operation and Setup Alarm Displays If an alarm condition occurs, the controller displays an alarm code or alarm message. Two-Character Alarm Codes If a process, deviation, ambient warning or failed sensor alarm occurs, a two-character alarm code appears in the lower left corner of the loop display. The alarm code blinks and you cannot change the display until the alarm has been acknowledged. After the alarm is acknowledged, the alarm code stops blinking.
Chapter 4: Operation and Setup Series D8 User’s Guide Table 4.2 Alarm Code Alarm Codes and Messages for Process and Failed Sensor Alarms Alarm Message Description AH (No message) Alarm high. See Alarm High and Alarm Low on page 96. AL (No message) Alarm low. See Alarm High and Alarm Low on page 96. HD (No message) High deviation alarm. See Deviation Alarms on page 96. LD (No message) Low deviation alarm. See Deviation Alarms on page 96.
Series D8 User’s Guide Chapter 4: Operation and Setup Table 4.3 Message System Alarm Messages Description Low power The power supply has failed. See Low Power on page 163. Battery dead The RAM battery in the D8 is not functioning correctly, and stored data has been corrupted. See Battery Dead on page 163. H/W error: Ambient The temperature around the controller is outside of the acceptable range of -5 to 55°C. See H/W Error: Ambient on page 165.
Chapter 4: Operation and Setup Series D8 User’s Guide Changing the Set Point How to Manually Change the Set Point Start at the loop display and follow these steps: 1. Press p to choose the appropriate loop. 2. Press .. The Set point parameter should appear. If nothing happens, the keypad may be locked; see Keypad Lock on page 129. Also, the Set point parameter is not available if cascade control or ratio control is enabled on the loop. 3. Press > or < to adjust the set point value. 4.
Series D8 User’s Guide Chapter 4: Operation and Setup Changing the Control Mode and Output Power The D8 has four control modes: • • • • Off: Outputs are at 0%. Automatic: The controller automatically adjusts the output power according to the set point, process variables and other control parameters. Manual: You set the output power level. Autotune: The controller calculates the best PID settings for optimum control. For more information, see Autotuning on page 91.
Chapter 4: Operation and Setup Series D8 User’s Guide Accessing and Navigating the Setup Menus Use the setup menus to configure the controller. For a list of all setup menus and parameters, refer to Figure 6.2 on page 124. How to Access the Setup Menus To access the setup menus, press and hold x for three seconds, until the Global setup menu appears.
Series D8 User’s Guide Chapter 4: Operation and Setup Setting Up Closed-Loop Control Closed-loop control is used to control an output based on feedback from a sensor or other signal. Feedback The controller receives electrical signals, or feedback, from a sensor or other device. The input parameters determine how the controller interprets the signal. The controller interprets or scales the input signal in engineering units such as °C or °F.
Chapter 4: Operation and Setup Series D8 User’s Guide How to Set Up Closed-Loop Control To set up closed-loop control: • • • • • Use the Input menu to specify the type of input signal and, if necessary, how to scale that signal. Use the Control menu to specify PID parameters and the control hysteresis. Use the Output menu to enable the heat and cool outputs and to specify other output parameters. Provide a set point: • To use cascade control to adjust the set point of the loop, set up the Cascade menu.
Series D8 User’s Guide Chapter 4: Operation and Setup Process Variable Range for set points and alarms 28 8 0% 20% 100% Input Signal Figure 4.6 Input Scaling The range for set points and alarms is bound by the process variables that correspond to the 0 percent and 100 percent input signals. Bear in mind that the range for set points and alarms is not bound by the low and high process variable ranges that you enter in the scaling parameters.
Chapter 4: Operation and Setup Series D8 User’s Guide • • Input signal high = 20 mA/20 mA = 1.0 = 100% For the Input range low and Input range high parameters, enter the process values that correspond to the low and high signals. In this case, a 20 percent (4 mA) signal represents 0.0 PSI. A 100 percent (20 mA) signal represents 50.0 PSI. Table 4.4 Input Readings Process Variable Displayed Sensor Input Reading in Percent of Full Scale 50.0 PSI 20 mA 100% .
Series D8 User’s Guide Chapter 4: Operation and Setup Table 4.6 Input Readings and Calculations Process Variable Displayed Sensor Input Reading in Percent of Full Scale 65 GPM 4.75 V (4.75 V / 5.00 V) x 100% = 95% 3 GPM 0.5 V (0.5 V / 5.00 V) x 100% = 10% Table 4.7 Scaling Values Parameter Value Input range high 65 GPM Input high signal 95.0% Input range low 3 GPM Input low signal 10.
Chapter 4: Operation and Setup Series D8 User’s Guide and there must be sufficient time for the controller to determine the new PID parameters. Prerequisites Before autotuning, the controller must be installed with control and sensor circuitry and the thermal load in place. It must be safe to operate the thermal system, and the approximate desired operating temperature (set point) must be known.
Series D8 User’s Guide Chapter 4: Operation and Setup 5. Access the setup menus (see page 86). Go to theInput filter parameter in the Input menu. Write down the value, and then change it to 0 scans. Press . to save the new setting. 6. Press x twice to return to the loop display. 7. Set the Mode parameter to tune (see page 85). 8. The controller will automatically return to the loop display. The word tun flashes throughout the tuning process.
Chapter 4: Operation and Setup Series D8 User’s Guide Thermocouple Open Alarm The thermocouple open alarm occurs if the controller detects a break in a thermocouple or its leads. If a thermocouple open alarm occurs, the controller switches to manual mode. The output level is determined as follows: • • If the Open T/C ht/cl out average parameter in theOutput menu is set to on, then the controller sets the output power to an average of the recent output.
Series D8 User’s Guide Chapter 4: Operation and Setup The RTD alarms are enabled on any channel with Input Type set to RTD. Restore Automatic Control After a Sensor Failure This feature returns a loop to automatic control after a failed sensor is repaired. To enable this feature: • • Choose a digital input for the RestoreAuto parameter in the Control menu. Connect the digital input to the dc common terminal on the controller.
Chapter 4: Operation and Setup Series D8 User’s Guide Alarm Function: Standard Alarm or Boost Output You can configure each process alarm as either a standard alarm or a boost alarm: • • A standard alarm provides traditional alarm functionality: The operator must acknowledge the alarm message on the controller display, a latching global alarm is activated, and the alarm can activate a user-specified nonlatching alarm output. A boost alarm provides on/off control output using the alarm set points.
Series D8 User’s Guide Chapter 4: Operation and Setup set separate high and low deviation values at the HiDeviation value and LoDeviation value parameters in the Alarms menu. Upon power up or when the set point changes, the behavior of the deviation alarms depends upon the alarm function: • • If the alarm function parameter is set to standard, then deviation alarms do not activate until the after the process variable has first come within the deviation alarm band. This prevents nuisance alarms.
Chapter 4: Operation and Setup Series D8 User’s Guide Typical uses include data logging to analog recording systems, and long distance transmission of the primary signal to avoid signal degradation. The retransmitted signal can also be used as an input to other types of control systems such as a PLC. Any available heat or cool output may be used as a retransmit output. Any process variable may be retransmitted, including the input from the same loop.
Series D8 User’s Guide Chapter 4: Operation and Setup Loop 1 Input Process Variable Loop 1 PID Output Loop 2 PID Output Furnace D8 Heater Serial DAC Power Controller Figure 4.8 To Data Logger Application Using Process Variable Retransmit Table 4.8 shows the parameter setup for this example. Table 4.
Chapter 4: Operation and Setup Series D8 User’s Guide To complete this configuration, the output for loop 2 must be configured to provide the 4 to 20 mA analog signal (via the Serial DAC) that is required by the data logger. When setup is completed, the controller will produce an output on loop 2 which is linear and proportional to the loop 1 process variable.
Chapter 4: Operation and Setup Set Point of Secondary Loop (Engineering Units) Series D8 User’s Guide High Set Point Low Set Point -100% 100% Output of Primary Loop (Percent of Full Scale) Set Point of the Secondary Loop (Engineering Units) Figure 4.9 Secondary Set Point When Primary Loop Has Heat and Cool Outputs High Set Point Low Set Point 0% 100% Output of Primary Loop (Percent of Full Scale) Figure 4.
Chapter 4: Operation and Setup Series D8 User’s Guide How To Set Up Cascade Control 1. For the primary cascade loop: • • 2. For the secondary cascade loop: • • NOTE! Configure proportional-only control. For an example, see Cascade Control Example: Water Tank on page 102. Enter the desired set point. See Changing the Set Point on page 84. Set up PID control as you would for a standard closed-loop application. Set up the parameters in the Cascade menu. See Cascade Menu on page 149.
Series D8 User’s Guide Chapter 4: Operation and Setup Loop 1: Primary Cascade Loop Loop 2: Secondary Cascade Loop Water Loop 1 Input Process Variable Outer T/C Loop 2 PID Output Loop 2 Input Process Variable D8 Heater Inner T/C Power Controller Figure 4.11 Example Application Using Cascade Control Table 4.9 Menu Parameter Parameter Settings for the Primary Loop in the Cascade Example Value Comment (none) Set point 150˚F Desired temperature at the inner thermocouple.
Chapter 4: Operation and Setup Series D8 User’s Guide With proportional control, when loop 1 is at set point, its output is 0 percent, and the set point of loop 2 is equal to the desired temperature 150º F. If the temperature of the loop 1 drops below 149º F, the deviation results in a proportional output of 10 percent. This results in an increase to the set point for loop 2 equal to 10 percent of the set point range.
Series D8 User’s Guide Chapter 4: Operation and Setup High SP l Ratio Loop Set Point tia P Low SP SP Differential Input Range Low V rP te as *C on l tro S o+ ren iffe D ti Ra M Input Range High Master Loop Process Variable SP = Set Point PV = Process Variable Figure 4.13 Relationship Between the Process Variable on the Master Loop and the Set Point of the Ratio Loop NOTE! Ratio control cannot be used on the same control loop as cascade control. How to Set Up Ratio Control 1.
Chapter 4: Operation and Setup Series D8 User’s Guide KOH Input Water Input Loop 1: Water Flow Control Loop Loop 2: KOH Flow Control Loop Loop 1 Input Process Variable Flow Transducer Loop 2 Input Process Variable Loop 1 PID Output D8 Loop 2 PID Output Motorized Control Valve 2 Motorized Control Valve 1 Mixture Output Figure 4.14 Application Using Ratio Control Table 4.
Series D8 User’s Guide Chapter 4: Operation and Setup How to Set Up Differential Control Set up differential control as you would set up ratio control. Set the Control ratio parameter to 1.0, and enter the desired set point differential (offset) at the Ratio SP diff parameter. Differential Control Example: Thermoforming A thermal forming application requires that the outer heaters operate at temperature 50º F hotter than the center heaters.
Chapter 4: Operation and Setup Series D8 User’s Guide Typically, a voltage or current source is connected to an analog input on the controller, and this input is configured as the master loop for ratio control. Proper scaling resistors must be installed on the input to allow it to accept the analog input signal. How to Set Up a Remote Analog Set Point 1. For the master loop (the loop that accepts the input signal from the external device), set the parameters in the Input menu. 2.
Series D8 User’s Guide Menu Chapter 4: Operation and Setup Table 4.14 Parameter Settings for the Ratio Loop (Loop 2) in the Example Value Comment Parameter Loop 1 is the master loop (receives the input signal from the external device). Ratio Ratio master loop 01 Ratio Ratio low SP 0˚F Ratio Ratio high SP 300˚F Ratio Control ratio 1.0 For this example, we want to retain the original input value, so we will multiply it times 1.0.
Chapter 4: Operation and Setup 110 Series D8 User’s Guide Watlow Anafaze Doc.
5 Tuning and Control This chapter describes the different methods of control available with the D8. This chapter covers control algorithms, control methods, PID control, starting PID values and tuning instructions to help appropriately set control parameters in the D8 system. For more information about PID control, consult the Watlow Anafaze Practical Guide to PID. Control Algorithms This section explains the algorithms available for controlling a loop.
Chapter 5: Tuning and Control Series D8 User’s Guide 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 set point. This limit is adjustable. For example, if the set point is 1000° F and the control hysteresis is 20° F, the heat output switches on when the process variable drops below 980° F and off when the process rises above 1000° F.
Series D8 User’s Guide Chapter 5: Tuning and Control Set Point Offset Proportional Band Process Variable Figure 5.2 Proportional Control Proportional and Integral Control (PI) With proportional and integral control, the integral term corrects for offset by repeating the proportional band’s error correction until there is no error.
Chapter 5: Tuning and Control Series D8 User’s Guide Proportional, Integral and Derivative Control (PID) Derivative control corrects for overshoot by anticipating the behavior of the process variable and adjusting the output appropriately. For example, if the process variable is rapidly approaching the set point from below, derivative control reduces the output, anticipating that the process variable will reach set point.
Series D8 User’s Guide Chapter 5: Tuning and Control Setting Up and Tuning PID Loops After installing your control system, tune each control loop and then set the loop to automatic control. When tuning a loop, choose PID parameters that will best control the process. This section gives PID values for a variety of heating and cooling applications. NOTE! Tuning is a slow process. After adjusting a loop, allow about 20 minutes for the change to take effect. Proportional Band Settings Table 5.
Chapter 5: Tuning and Control Series D8 User’s Guide Table 5.2 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 is programmed in seconds.
Series D8 User’s Guide Chapter 5: Tuning and Control General PID Constants by Application This section gives PID values for many applications. They are useful as control values or as starting points for PID tuning. Proportional Band Only (P) Set the proportional band to seven percent of the set point. (Example: Set point = 450, proportional band = 31). Proportional with Integral (PI) • Set the proportional band to ten percent of set point. (Example: Set point = 450, proportional band = 45).
Chapter 5: Tuning and Control Series D8 User’s Guide 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 Vdc, 0 to 10 Vdc or 4 to 20 mA control signals to operate field output devices.
Series D8 User’s Guide Chapter 5: Tuning and Control Distributed Zero Crossing (DZC) With DZC outputs, the PID algorithm calculates an output between 0 and 100 percent, but the output is distributed on a variable time base. For each ac line cycle, the controller decides whether the power should be on or off. There is no fixed cycle time since the decision is made for each line cycle.
Chapter 5: Tuning and Control Series D8 User’s Guide Output Filter The output filter digitally smooths PID control output signals. It has a range of 0 to 255 scans, which gives a time constant of 0 to 85 seconds for a CPC408 or 0 to 43 seconds for a CPC404. Use the output filter if you need to filter out erratic output swings due to extremely sensitive input signals, like a turbine flow signal or an open air thermocouple in a dry air gas oven. The output filter can also enhance PID control.
6 Menu and Parameter Reference The D8 has operator and setup parameters that let you change the configuration of the controller. This section contains the following information for each operator and setup parameter: • • • • Description Values Default value Information for addressing controller parameters via DeviceNet. For information about how to access the operator and setup parameters, see the Operation and Setup chapter.
Chapter 6: Menu and Parameter Reference Series D8 User’s Guide Set Point l01 Set point r b 25 ˚C Enter the desired value for the process variable. The new set point will take effect immediately when you save the new value. The Set point parameter is not available if ratio control or cascade control is enabled for the loop. Values: For thermocouples and RTD inputs, same as the input range (see Table 6.7 ).
Series D8 User’s Guide Chapter 6: Menu and Parameter Reference Process Variable 01 925 ˚F 0 1000man 100 Indicates the value measured by the sensor after filtering and scaling. This parameter is read-only. Values: For thermocouples and RTD inputs, same as the input range (see Table 6.7 on page 131). For process and pulse inputs, any value between the Input range low and Input range high parameters in the Input menu. Decimal Placement for DeviceNet: See Decimal Placement for Numeric Values on page 59.
Chapter 6: Menu and Parameter Reference Global setup Load setup from job Save setup as job BCD job load BCD job load logic Mode override Mode override D/I active Power up alarm delay Power up loop mode Keypad lock TC short alarm AC line freq D/O alarm polarity MAC ID Baud rate Module LED Network LED Bus off count WATLOW D8x Vx.
Series D8 User’s Guide Chapter 6: Menu and Parameter Reference Global Setup Menu lGlobal setup r Other menus b Use the Global setup menu to set parameters that affect all loops. Load Setup From Job Load one of the jobs stored in battery-backed RAM. The following parameters are loaded for each loop as part of a job: lLoad setup r from job bnone • • • PID constants, filter settings, set points and hysteresis.
Chapter 6: Menu and Parameter Reference Series D8 User’s Guide If you have enabled remote job selection (see BCD Job Load on page 126), you will see the message below, and you will not be able to use the controller keypad to save a job. lSave setup as r not available Values: 1 to 8 (1 to 8) or none (0). Values in parentheses are for communications. Default: none (0) DeviceNet Object: Global (6B hex) BCD Job Load lBCD job load bdisabled r Choose the digital input(s) to use for remote job selection.
Series D8 User’s Guide Chapter 6: Menu and Parameter Reference Values: 1=true (0) or 0=true (1). Values in parentheses are for communications. Default: 1=true (0) DeviceNet Object: Global (6B hex) Table 6.4 Digital Input States Required to Load Each Job Digital Input Job 1 2 3 1 F F F 2 T F F 3 F T F 4 T T F 5 F F T 6 T F T 7 F T T 8 T T T Mode Override lMode override r bdisabled Choose the digital input to use for the mode override feature.
Chapter 6: Menu and Parameter Reference Series D8 User’s Guide Mode Override Digital Input Active Choose whether the on state (connected to controller common) or off state (open circuit) activates the mode override feature. lMode override r D/I active bon Use the Mode override parameter to enable the mode override feature and select the digital input. Values: on (0) or off (1). Values in parentheses are for communications.
Series D8 User’s Guide Chapter 6: Menu and Parameter Reference Keypad Lock lKeypad lock r boff Set this parameter to on to disable the . key on the keypad. This restricts access to the operator parameters from the controller keypad. Values: on (1) or off (0). Values in parentheses are for communications, and are stored as the second bit of the system command word, so set or read only that bit.
Chapter 6: Menu and Parameter Reference Series D8 User’s Guide Table 6.6 Display Value Digital Output Alarm Polarity DeviceNet Value Description on 0 Digital alarm outputs sink current to analog common when an alarm occurs. off 1 Digital alarm outputs stop sinking current to analog common when an alarm occurs. MAC ID lMAC ID r b63 The node address for the controller. This value is set with the Address rotary switches. See Connecting the D8 to a DeviceNet Network on page 40.
Series D8 User’s Guide Chapter 6: Menu and Parameter Reference Model and Firmware Version The last parameter in the Global setup menu shows the controller model (WATLOW D84 or WATLOW D88), the firmware version (Vxx.xx), and the flash-memory checksum (CS=xxxx). lWATLOW D84 r V1.00 cs=1234 DeviceNet Objects: Model: Identity (01 hex), Firmware Version: N/A, Checksum: N/A.
Chapter 6: Menu and Parameter Reference Series D8 User’s Guide Loop Name l01 Loop name r b01 Enter a two-character name for the loop. This name is shown on the controller display in place of the loop number. Values: See Table 6.8. Default: The loop number (01, 02, 03, and so on.) DeviceNet Object: Input (64 hex) Table 6.
Series D8 User’s Guide Chapter 6: Menu and Parameter Reference Decimal Placement for DeviceNet: See Decimal Placement for Numeric Values on page 59. DeviceNet Object: Input (64 hex) Table 6.9 Calibration Offset Ranges Offset Range Type of Sensor ˚F RTD ˚C -300.0 to 300.0 -300.0 to 300.
Chapter 6: Menu and Parameter Reference Series D8 User’s Guide Table 6.10 Display Value -999 to 3000 Display Formats DeviceNet Value Minimum Process Variable Maximum Process Variable 255 -999 3000 -9999 to 30000 0 -9999 30000 -999.9 to 3000.0 1 -999.9 3000.0 -99.99 to 300.00 2 -99.99 300.00 -9.999 to 30.000 3 -9.999 30.000 -.9999 to 3.0000 4 -0.9999 3.
Series D8 User’s Guide Chapter 6: Menu and Parameter Reference Input Range Low l01 Input ranger low b 0 For a process input, enter the low process variable for input scaling purposes. This value will be displayed when the input signal is at the level set for Input low signal. This value and the value for Input low signal together define one of the points on the scaling function’s conversion line. See Setting Up a Process Input on page 88.
Chapter 6: Menu and Parameter Reference Series D8 User’s Guide Control Menu l01 Control Other menus r b Use the Control menu to adjust heat and cool control parameters, including: • • • Proportional band, integral and derivative Output filter Control hysteresis The controller has separate PID and filter settings for heat and cool outputs. In this section, only the heat screens are shown, but the explanations apply to both the heat and cool parameters.
Series D8 User’s Guide Chapter 6: Menu and Parameter Reference Heat/Cool Integral l01 Heat inte- r gral b 180 sec/R Enter the integral constant. A larger value yields less integral action. Values: 0 (off) to 6000 seconds per repeat Default: For the Heat integral parameter, 180. For the Cool integral parameter, 60. DeviceNet Object: Control (66 hex) Heat/Cool Derivative l01 Heat der rivativeb 0 sec Enter the derivative constant. A larger value yields greater derivative action.
Chapter 6: Menu and Parameter Reference Series D8 User’s Guide Hysteresis Specify how much the process variable must deviate from set point before the output can switch between on and off (for on/ off control) or switch between heating and cooling (for heat/ cool control). l01 Hysteresis r b 5 ˚C Values: See Table 6.12 for values and decimal placement. For communications the value is always 0 to 5000, see Table 6.12 for implied decimal location. Default: See Table 6.
Series D8 User’s Guide Chapter 6: Menu and Parameter Reference Output Menu l01 Output Other menus Use the Output menu to enable and configure heat and cool outputs. r b Heat/Cool Output Type l01 Heat outputr type bTP Choose the output type, or disable the heat or cool output. For more information about each output type, see the Tuning and Control chapter. (If an output is used for process variable retransmit, the disabled option is not available.
Chapter 6: Menu and Parameter Reference Series D8 User’s Guide Heat/Cool Cycle Time l01 Heat cycle r time b 10sec For a time-proportioning output, enter the cycle time in seconds. For more information about cycle time, see Time Proportioning (TP) on page 118. Values: 1 to 255 seconds Default: 10 DeviceNet Object: Output (65 hex) Heat/Cool SDAC Signal l01 Heat SDAC r signal bvoltage For a Serial DAC output, choose the type of output signal that the Serial DAC will provide.
Series D8 User’s Guide Chapter 6: Menu and Parameter Reference Heat/Cool Action l01 Heat actionr breverse Choose the control action for the output. When the action is set to reverse, the output goes up when the process variable goes down. When the action is set to direct, the output goes down when the process variable goes down. Normally, heat outputs are set to reverse action and cool outputs are set to direct action. Values: reverse (0) or direct (1). Values in parentheses are for communications.
Chapter 6: Menu and Parameter Reference Series D8 User’s Guide Sensor Fail Heat/Cool Output l01 Sensor failr heat outputb 0% A loop will switch to manual mode at the specified output power if one of the following conditions occurs while in automatic mode: • • • A failed sensor alarm occurs, or The mode override input becomes active (see Mode Override on page 127). DeviceNet connection becomes inactive unexpectedly.
Series D8 User’s Guide Chapter 6: Menu and Parameter Reference Heat/Cool Output Curve l01 Heat outputr curve blinear Choose an output curve. If curve 1 or 2 is selected, a PID calculation results in a lower actual output level than the linear output requires. Use curve 1 or 2 if the system has a nonlinear response to the output device. Values: linear (0), curve 1 (1) or curve 2 (2). Values in parentheses are for communications.
Chapter 6: Menu and Parameter Reference Series D8 User’s Guide Values: For a thermocouple or RTD input, any value within the input range (see Table 6.7 ). For a process or pulse input, any value between the Input range low and Input range high parameters. Default: 760. Decimal placement depends upon the Input type and Disp format settings. Decimal Placement for DeviceNet: See Decimal Placement for Numeric Values on page 59.
Series D8 User’s Guide Chapter 6: Menu and Parameter Reference High Deviation Value l01 HiDeviationr value b 5 ˚C Enter the amount by which the process variable must rise above the set point for the high deviation alarm to occur. For more information, see Deviation Alarms on page 96. Values: See Table 6.12 on page 138 for values and decimal placement. Default: See Table 6.12 .
Chapter 6: Menu and Parameter Reference Series D8 User’s Guide Low Deviation Output l01 LoDeviationr outputbnone Choose a digital output to activate when the low deviation alarm occurs. You cannot choose an output that is in use for closed-loop control or for the Serial DAC clock. Values: none (0) or output 1 to 18 (1 to 18). Values in parentheses are for communications.
Series D8 User’s Guide Chapter 6: Menu and Parameter Reference Alarm Hysteresis l01 Alarm hys- r teresisb 2 ˚C Enter the amount by which the process variable must return within the alarm limit before a high alarm, low alarm or deviation alarm clears. Use the alarm hysteresis to prevent repeated alarms as the process variable cycles around an alarm limit. Values: See Table 6.15 on page 147 for values and decimal placement. For communications the value is always 0 to 5000. Default: See Table 6.15.
Chapter 6: Menu and Parameter Reference Series D8 User’s Guide Process Variable Retransmit Menu l01 PV retrans r Other menus b Use the PV retrans menu to configure an output so that it will retransmit the process variable from another loop. For details, see Setting Up Process Variable Retransmit on page 97. This menu contains parameters for both heat and cool outputs. The sample screens in this section show the heat parameters, but the descriptions apply to both the heat and cool parameters.
Series D8 User’s Guide Chapter 6: Menu and Parameter Reference Cascade Menu l01 Cascade Other menus r b Use the cascade menu to configure cascade control. Use cascade control to calculate the set point of the current loop (the secondary, or outer, loop) based upon the output of another loop (the primary, or inner, loop). For more information about cascade control, see Setting Up Cascade Control on page 100. Cascade Primary Loop l01 Cascade r prim loop bnone Choose the primary loop.
Chapter 6: Menu and Parameter Reference Series D8 User’s Guide • • If the primary loop has only the heat output enabled, or has the heat and cool outputs enabled, this value is the set point when the output of the primary loop is 100 percent. If the primary loop has only the cool output enabled, then this value is the set point when the output of the primary loop is 0 percent. Values: For a thermocouple or RTD input, any value within the input range (see Table 6.7 on page 131).
Series D8 User’s Guide Chapter 6: Menu and Parameter Reference Decimal Placement for DeviceNet: See Decimal Placement for Numeric Values on page 59. DeviceNet Object: Ratio (69 hex) Ratio High Set Point l01 Ratio high r SP b 25 ˚C Enter the highest allowable set point for the current loop. The set point will never exceed this value, regardless of the result of the ratio calculation. Values: For a thermocouple or RTD input, any value in the input sensor range; see Table 6.7 on page 131.
Chapter 6: Menu and Parameter Reference Series D8 User’s Guide Digital Inputs lDigital inputsr 00000000 1=on This parameter indicates the states of the eight digital inputs. A 1 indicates that the input is connected to controller common (on). A 0 indicates an open circuit (off). To test an input, short it to controller common. When the input is shorted, its input state should be1. For detailed instructions, see Digital Input Test on page 27.
Series D8 User’s Guide Chapter 6: Menu and Parameter Reference Test Digital Output 1 to 20 lTest D/O 1 r boff Use the Test D/O parameter to manually toggle a digital output on and off. Choose on to sink the current from the output to the controller common. Choose off to stop the current flow. For instructions, see Digital Output Test on page 26. You cannot toggle an output that is enabled for control.
Chapter 6: Menu and Parameter Reference Series D8 User’s Guide Table 6.16 Bit Positions for Alarm Enable and Alarm Function Alarm Bit Low Deviation Alarm Third High Deviation Alarm Fourth Alarm Low Fifth Alarm High Sixth NOTE! All other bits, 1, 2, and 7 to 16 are always 0. You must transmit a complete 2-byte word to set any alarm parameter for a channel. You may want to read the alarm settings before constructing the word to set an alarm parameter.
Series D8 User’s Guide Chapter 6: Menu and Parameter Reference Table 6.
Chapter 6: Menu and Parameter Reference Series D8 User’s Guide Heat/Cool Output Action for Watchdog Inactivity Fault Action on heat and cool outputs when a DeviceNet Watchdog Inactivity Timeout is detected. Values: See Table 6.19 on page 156 Default: 0 DeviceNet Object: Output (65 hex) Table 6.19 DeviceNet Value for Watchdog Inactivity Fault DeviceNet Value 156 Description 0 If not in Manual Mode will then put in Manual Mode, with output set to value in Sensor Fail Heat and Cool Output.
7 Troubleshooting and Reconfiguring This chapter explains how to troubleshoot and reconfigure the controller. When There is a Problem The controller is only one part of your control system. Often, what appears to be a problem with the controller is really a problem with other equipment, so check these things first: • • NOTE! The controller is installed correctly. (See the Installation chapter.) Sensors, such as thermocouples and RTDs, are installed correctly and working.
Chapter 7: Troubleshooting and Reconfiguring CAUTION! Series D8 User’s Guide Before trying to troubleshoot a problem by replacing your controller with another one, first check the installation. If you have shorted sensor inputs to high voltage lines or a transformer is shorted out, and you replace the controller, you will risk damage to the new controller. If you are certain the installation is correct, you can try replacing the controller.
Series D8 User’s Guide Chapter 7: Troubleshooting and Reconfiguring Process Alarms When a process alarm occurs, the controller switches to the single-loop display for the loop with the alarm and displays the alarm code (see Alarm Displays on page 81). Possible Causes of a Process Alarm In a heating application, a low alarm or low deviation alarm may indicate one of the following: • • • • • • • NOTE! The heater has not had time to raise the temperature.
Chapter 7: Troubleshooting and Reconfiguring Series D8 User’s Guide Responding to a Process Alarm Your response to an alarm depends upon the alarm function setting, as explained in Table 7.1. Table 7.1 Operator Response to Process Alarms Alarm Function Operator Response Boost The operator does not need to acknowledge the alarm. The alarm clears automatically when the process variable returns within limits. Standard Acknowledge the alarm by pressing x on the keypad or via communications.
Series D8 User’s Guide Chapter 7: Troubleshooting and Reconfiguring alarm, turns on the global alarm output. The global alarm remains on until the alarm is acknowledged. The message persists until the condition is corrected and the alarm is acknowledged. The D8 displays the following system alarm messages: • • • • • Low power: See Low Power on page 163. Battery dead: See Battery Dead on page 163. H/W error: Ambient: See H/W Error: Ambient on page 165.
Chapter 7: Troubleshooting and Reconfiguring Symptom Series D8 User’s Guide Possible Causes Check the display or HMI software for a failed sensor message. Failed sensor Control mode of one or more loops changes from automatic to manual Recommended Action Check whether the new job was supposed to be loaded. If not, check the BCD job load setup: BCD job selection feature loaded a different job Check the settings of the BCD job load parameters in the Global setup menu.
Series D8 User’s Guide Chapter 7: Troubleshooting and Reconfiguring Table 7.4 Indicator Light Network Status Indicator Light Description The device is not online. Off The device has not completed the duplicate MAC ID test yet. The device may not be powered. Look at Table 2.10, Module Status Indicator Light. The device is online and has connections in the established state. Green For a Group 2 Only device it means that the device is allocated to a Master. Failed communication device.
Chapter 7: Troubleshooting and Reconfiguring Series D8 User’s Guide If the Battery Dead alarm occurs, the controller displays an alarm message and the global alarm output turns on. Acknowledging the alarm restores all settings to factory defaults and turns off the global alarm output. CAUTION! Acknowledging this alarm restores all setting to factory defaults. NOTE! The controller retains its settings when powered.
Series D8 User’s Guide Chapter 7: Troubleshooting and Reconfiguring NOTE! If the controller has failed, it is likely that it was damaged by excessive voltage or noise. Before replacing the controller, troubleshoot for noise and ground loops. H/W Error: Ambient The H/W error: Ambient alarm indicates that the ambient sensor in the D8 is reporting that the temperature around the controller is outside of the acceptable range of 0 to 50° C. This alarm can also occur if there is a hardware failure.
Chapter 7: Troubleshooting and Reconfiguring NOTE! Series D8 User’s Guide 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 Work If the D8 seems to function but one or more keys do not work, check the following: • • If the . key does not work, but other keys work, then the keypad is probably locked. Unlock the keypad according to the instructions in Keypad Lock on page 129.
Series D8 User’s Guide Chapter 7: Troubleshooting and Reconfiguring • • 5. 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.
Chapter 7: Troubleshooting and Reconfiguring • • Series D8 User’s Guide Eliminate possible ground loops. See Ground Loops on page 22. Contact your supplier for further troubleshooting guidance. Testing Control Output Devices Connect the solid-state relay (SSR) control terminals to the D8 control output and connect a light bulb (or other load that can easily be verified) to be switched by the SSR's outputs. Put the loop in manual mode and set the output to 100 percent. The ac load should turn on.
Series D8 User’s Guide Chapter 7: Troubleshooting and Reconfiguring put is on (100 percent), the output voltage should be between +4.75 and +5.25V. 7. If you are testing a digital output not used for control, use the I/O tests menu to turn the output on and off. See Test Digital Output 1 to 20 on page 153. 1. Switch off power to the controller. 2. Disconnect any system wiring from the input to be tested. 3. Restore power to the controller. 4.
Chapter 7: Troubleshooting and Reconfiguring Series D8 User’s Guide Replacing the Flash Memory Chip This procedure requires a 32-pin PLCC IC extraction tool. CAUTION! The flash memory chip and other components are sensitive to damage from electrostatic discharge (ESD). To prevent ESD damage, use an ESD wrist strap or other antistatic device. NOTE! Replacing the flash memory chip results in full erasure of RAM. Make a record of all parameters before changing the flash memory chip. 1.
Series D8 User’s Guide Chapter 7: Troubleshooting and Reconfiguring 6. Unscrew the four screws at the corners of the top board and carefully unplug this board to access the bottom board. Figure 7.2 shows the screws to remove: D8 Figure 7.2 7. Screw Locations on PC Board Locate the flash memory chip on the circuit board. The flash memory chip is a 32-pin socketed chip that is labeled with the model, version and checksum. Figure 7.3 Location of Flash Memory Chip 8.
Chapter 7: Troubleshooting and Reconfiguring Series D8 User’s Guide Installing Scaling Resistors Resistors are installed for all inputs on the D8. Inputs with signal ranges between -10 and +60 mV use 0 Ω resistors in the RC position only. All other input signals require special input scaling resistors. CAUTION! Scaling resistors are soldered to the circuit board. Only qualified technicians should attempt to install or remove these components.
Series D8 User’s Guide Chapter 7: Troubleshooting and Reconfiguring RC (Voltage) + IN+ RP Internal +5 Vdc Reference Analog Input Terminal RD RC (RTD) IN- RP To D8 Circuitry - Com Figure 7.4 Input Circuit Current Inputs For each current input, you must install a resistor. The value of the resistor must be correct for the expected input range. Install the resistor in the listed resistor pack (RP) location. Note the resistor pack locations have three through-holes.
Chapter 7: Troubleshooting and Reconfiguring Series D8 User’s Guide Voltage Inputs For each voltage input, you must install two resistors. The resistances must be correct for the expected input range. Note the resistor pack (RP) locations have three through-holes. Install the RD resistor as indicated in the illustration below. Table 7.7 Resistor Values for Voltage Inputs Resistor Values Input Range RC RD 0 to 100 mVdc 499 Ω 750 Ω 0 to 500 mVdc 5.49 kΩ 750 Ω 0 to 1 Vdc 6.91 kΩ 442.
Series D8 User’s Guide Chapter 7: Troubleshooting and Reconfiguring RTD Inputs For each RTD input, you must install three resistors: RA, RB, and RC. The resistance must be correct for the expected input range. RA and RB are a matched pair of resistors. Install them in the resistor pack (RP) locations as shown in the illustration below. Resistor values: • • RA/RB: 25 kΩ RC: 18.2 Ω Resistor tolerances: • RA/RB: Matched to 0.02% (±5 ppm/°C) with absolute tolerance of 0.
Chapter 7: Troubleshooting and Reconfiguring Series D8 User’s Guide Scaling and Calibration The controller provides offset calibration for thermocouple, RTD, and other fixed ranges, and offset and span (gain) calibration for process inputs. In order to scale the input signal, you must: 1. Install appropriate scaling resistors. 2. Enter the input range at the Disp format parameter in the Input menu. The smallest possible range is -.9999 to 3.0000; the largest possible range is -9999 to 30000. 3.
Series D8 User’s Guide Chapter 7: Troubleshooting and Reconfiguring Configuring Dual DAC Outputs Dual DAC modules ship with both of the outputs configured for the signal type and span that were ordered. The module contains two independent circuits (DAC1 and DAC 2). These circuits can be configured for different output types. Remove the board from the housing and set the jumpers. The odd-numbered jumpers determine the signal from DAC 1; the evennumbered jumpers determine the output from DAC 2.
Chapter 7: Troubleshooting and Reconfiguring Series D8 User’s Guide 1. Power down the system (if the Dual DAC is already installed and wired). 2. Ensure the DAC 1 and DAC 2 terminal blocks or associated wires are labeled such that you will know which terminal block connects to which side of the board if the module is already installed and wired. 3. Unplug the two terminal blocks. 4. Depending on the installation, you may need to unmount the Dual DAC module before proceeding.
8 Specifications This chapter contains specifications for the D8 series controllers, TB50 terminal board, Dual DAC module, Serial DAC module and the D8 power supply. System Specifications This section contains D8 series controller specifications for environmental specifications and physical dimensions, inputs, outputs, the serial interface and system power requirements. The controller consists of a processor module with a 50-terminal block (TB50) or a processor module with an 18-terminal block (TB18).
Chapter 8: Specifications Series D8 User’s Guide 96 m m (3 .78 in ) 50 mm (1.96 in) 45 mm (1.76 in) 213 mm (8.4 in) 188 mm (7.4 in) 90 mm (3.55 in) Figure 8.1 D8 Module Dimensions Table 8.3 D8 with Straight SCSI Length* 10.0 to 10.5 in. 254 to 267 mm Width 3.78 inches 96 mm Height 1.96 inches 50 mm *Exact requirement depends on usage and choice of cables. 180 Watlow Anafaze Doc.
Series D8 User’s Guide Chapter 8: Specifications 188 mm (7.4 in) 25 mm (1.0 in) 41 mm to 54 mm (1.6 in to 2.1 in) for cables and clearance Figure 8.2 Module Dimensions and Clearance Table 8.4 D8 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) Thermocouple: 20 AWG (0.
Chapter 8: Specifications Series D8 User’s Guide 4.1 in. (104 mm) 4.0 in. (102 mm) Figure 8.3 TB50 Dimensions Table 8.6 TB50 Connections Screw Terminal Torque 4.4 to 5.3 in.-lb. (0.5 to 0.6 Nm) SCSI Connector on Board SCSI-2 female Output Terminals Captive screw cage clamp Output Wire Gauge Output Terminal Torque Table 8.7 182 1.5 in. (37 mm) 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.
Series D8 User’s Guide Chapter 8: Specifications 6.4 in. (163 mm) 4.0 in. (102 mm) Doc. 0600-3120-2000 1.5 in. (37 mm) Figure 8.4 TB50 Dimensions with Straight SCSI Cable Table 8.8 TB50 with Right Angle SCSI Length 5.4 inches 137 mm Width 4.0 inches 102 mm Height 1.
Chapter 8: Specifications Series D8 User’s Guide 5.4 in. (137 mm) 4.0 in. (102 mm) Figure 8.5 184 1.5 in. (37 mm) TB50 Dimensions with Right-Angle SCSI Cable Watlow Anafaze Doc.
Series D8 User’s Guide Chapter 8: Specifications Inputs The controller accepts analog sensor inputs which are measured and may be used as feedback for control loops. It also accepts digital (TTL) inputs which may be used to trigger certain firmware features. Table 8.
Chapter 8: Specifications Series D8 User’s Guide Table 8.10 Thermocouple Type Range in ˚F Range in ˚C Thermocouple Range and Resolution Accuracy* at 25˚C Ambient Accuracy* at 0 to 50˚C Ambient ˚F ˚C ˚F ˚C J -350 to 1400 -212 to 760 ±2.2 ±1.2 ±3.3 ±1.8 K -450 to 2500 -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 3200 -18 to 1760 ±5.0 ±2.8 ±8.8 ±4.9 R 0 to 3210 -18 to 1766 ±5.0 ±2.8 ±8.8 ±4.9 B 150 to 3200 66 to 1760 ±7.
Series D8 User’s Guide Chapter 8: Specifications Table 8.13 Digital Inputs With TB50: 8 Number With TB18: 3 Function Selectable for output override or remote job selection Input Voltage Protection Diodes to supply and common. Source must limit current to 10 mA for override conditions Voltage Levels <1.3 V = Low >3.7 V = High (TTL) 5 V maximum, 0 V minimum Maximum Switch Resistance to Pull Input Low 1.7 kΩ Minimum Switch Off Resistance 1.
Chapter 8: Specifications Series D8 User’s Guide Digital Outputs Table 8.14 Digital Outputs Control / Alarm Number 20 with TB50 option or 13 with TB18 option Operation Open collector output; ON state sinks to logic common Function 1 Global alarm output 1 CPU watchdog output Balance selectable as closed-loop control or alarms Number of Control Outputs per PID Loop 2 (maximum) Control Output Types Time proportioning, distributed zero crossing, Serial DAC or on/off.
Series D8 User’s Guide Chapter 8: Specifications Power Supply Specifications for the D8 power supply are available at www.watlow.com. See the links on the D8 page. Doc.
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Series D8 User’s Guide Chapter 8: Specifications Dual DAC Specifications The Watlow Anafaze Dual DAC (digital-to-analog converter) is an optional module for the D8 series controller. The Dual DAC converts a distributed zero crossing (DZC) output signal to an analog process control signal. Watlow Anafaze provides the following version of the Dual DAC: • • • 4 to 20 mAdc 0 to 5 Vdc 0 to 10 Vdc Table 8.
Chapter 8: Specifications Series D8 User’s Guide Dual DAC Inputs The Dual DAC accepts an open-collector signal from the D8 controller and the power from an external power supply. See Table 8.25 . Table 8.25 Dual DAC Power Requirements Parameter Description Voltage 12 to 24 Vdc Current 100 mA @ 15 Vdc Dual DAC Analog Outputs Table 8.26 Version Dual DAC Specifications by Output Range 4 to 20 mA 0 to 5 V 0 to 10 V Units ±6 ±6 ±6 percent ± 0.75 ± 0.75 ± 0.
Series D8 User’s Guide Chapter 8: Specifications Serial DAC Specifications Watlow Anafaze offers a Serial DAC for precision open-loop analog outputs. The Serial DAC is jumper-selectable for a 0 to 10 Vdc or 4 to 20 mA output. Multiple Serial DAC modules can be used with one D8. The Serial DAC carries a CE mark. Table 8.27 Serial DAC Environmental Specifications Storage Temperature -20 to 60° C Operating Temperature 0 to 50° C Humidity 10 to 95% non-condensing Table 8.
Chapter 8: Specifications Series D8 User’s Guide Table 8.29 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 D8 via the TB50. Any control output can be configured to provide the data signal. The Serial DAC also requires a 5 Vdc power input. Table 8.
Series D8 User’s Guide Chapter 8: Specifications Serial DAC Analog Outputs Table 8.32 Serial DAC Analog Output Specifications Absolute Maximum Common Mode Voltage Measured between output terminals and controller common: 1000 V Resolution 15 bits (plus polarity bit for voltage outputs) (0.305 mV for 10 V output range) (0.00061 mA for 20 mA output range) Accuracy (Calibrated for Voltage Output) For voltage output: ± 0.005 V (0.
Chapter 8: Specifications Series D8 User’s Guide Declaration of Conformity Erklärt, daß das folgende Produkt: Deutsch Beschreibung: Serie D8 Modellnummer(n): D8(4 oder 8)(jede Zahl oder Buchstabe)-(4 beliebige Buchstaben oder Ziffern)- (4 beliebige Buchstaben oder Ziffern) Klassifikation: Installationskategorie II, Emissionsgrad II Nennspannung: 12 bis 24 Vdc Nominaler Stromverbrauch: max.
Series D8 User’s Guide Glossary Glossary Ampere (Amp, A) A unit that defines the rate of f w of electricity (cur rent) in the circuit. Units are one coulomb (6.25 x 1018 electrons) per second. A AC See Alternating Current. AC Line Frequency The frequency of the ac line power measured in Hertz (Hz), usually 50 or 60 Hz. Accuracy Closeness between the value indicated by a measuring instrument and a physical constant or kno wn standards.
Glossary Series D8 User’s Guide Celsius A temperature scale in which w ater freezes at 0° C and boils at 100° C at standard atmospheric pressure. The formula for con version to the F ahrenheit scale is °F = (1.8 x °C) + 32. Formerly known as Centigrade. Central Processing Unit (CPU) The unit of a computing system that includes the cir cuits controlling the interpretation of instructions and their execution. Circuit Any closed path for electrical current.
Series D8 User’s Guide Glossary Direct Action An output control action in which an increase in the process variable causes an increase in the output. Usually used with cooling applications. Emissivity The ratio of radiation emitted from a surf ace compared to radiation emitted from a blackbody at the same temperature. Direct Current (DC) An electric current that fl ws in one direction.
Glossary Series D8 User’s Guide Global Alarm Warns that one or more alarm conditions exist by activating a digital output. Input Scaling The con verting of input signals to the engineering units of the process variable. Ground An electrical line with the same electrical potential as the surrounding earth. Electrical systems are usually grounded to protect people and equipment from shocks due to malfunctions. Also referred to as “safety ground.
Series D8 User’s Guide Glossary The item or substance that is to be heated or cooled. Low Deviation Alarm Warns that the process has dropped more than a cer tain amount belo w set point. It can be used as either an alarm or control function. Low Alarm A signal that is associated with a set minimum v alue that can be used as either an alarm or boost control function.
Glossary Series D8 User’s Guide Proportional Band (PB) A range in which the proportioning function of the control is acti ve. Expressed in units, de grees or per cent of span. See also PID. semiconductor material. The wire R TD is a positi ve temperature coef ficient sensor onl , while the ther mistor can have either a negative or positive temperature coefficient Proportional Control A control using only the P (proportional) value of PID control.
Series D8 User’s Guide Glossary Thermocouple (T/C) A temperature sensing de vice made by joining tw o dissimilar metals. This junction produces an electrical voltage in proportion to the dif ference in temperature between the hot junction (sensing junction) and the lead wire connection to the instrument (cold junction). Thermocouple Extension Wire A grade of wire used between the measuring junction and the reference junction of a thermocouple.
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Series D8 User’s Guide Index Index setting 85 autotuning 85, 91–93, 122 AW 160 B A AC Line Frequency 76, 129 Address 61 see also Node Address agency compliance controller 179 power supply 189 Serial DAC 194 AH alarm code 82 AL alarm code 82 Alarm Acknowledge 72, 153 Alarm Delay 72, 147 Alarm Enable 72, 153 Alarm Function 72, 154 Alarm High Function 144 Alarm High Output 72, 144 Alarm High Set Point 71, 96, 143 Alarm Hysteresis 72, 147 Alarm Low Function 146 Alarm Low Output 72, 146 Alarm Low Set Point 7
Index on/off 118, 139 reverse action 120, 141 SCRs 33 Serial DAC, see Serial DAC solid-state relays 33 status on powerup 128 time proportioning 118, 139 troubleshooting 168 type 139 wiring 33 Control Ratio 74, 151 controller agency compliance 179 clearance 181 connecting to TB50 25 environment 179 input specification 185–187 mounting 13–15 output specification 187–188 specification 179–181 troubleshooting, see troubleshooting Cool Action 69, 141 Cool Cycle Time 69, 140 Cool Derivative 70, 137 Cool Filter 7
Series D8 User’s Guide Index ESD, see electrostatic discharge Exception Status Byte 45, 53 explicit messages 53, 55–58, 66, 68 external bridge circuit 30 external safety devices 8 F Fahrenheit 132 failed sensor alarms behavior of 160 codes 81–82 messages 81–82 output power if sensor alarm occurs 142 restoring automatic control after sensor repair 95, 138 RTD alarm 94 setting up 93–95 thermocouple open 94, 142 thermocouple reversed 94, 133 thermocouple short 94 filte output 120, 137 sensor input 135 firm
Index tools 13 torque for screw terminals 24 typical 12 wire recommendations 20, 31 wire sizes controller 21 TB50 output 182 wiring 20–25, 27–39 instance 57, 61, 67, 68, 70, 71, 72, 73, 74, 75 instance attributes 61 integral description 113 guidelines for setting 116–117 setting a value 137 settings from other controllers 116 term versus reset settings 115 J job display 83 jobs remote selection 126 saving to memory 125 jumpers Dual DAC 177 power supply common 25 Serial DAC 176 when using 2-wire RTD 30 K
Series D8 User’s Guide filte 137 process variable retransmit, see process variable retransmit reference voltage, see reference voltage solid-state relays 33 specification 187–188 wiring, see installation over-temperature shutdown devices 8 P panel, see installation parameters alarm 143–147 cascade control 149–150 control 136–138 editing through keypad 86 via DeviceNet 58–59 global 125–131 I/O tests 151–153 input 131–135 map of 124, 213 navigating 86 output 139–143 process variable retransmit 148 ratio con
Index S safety external safety devices 8 output status on power up 9 symbols and signal words in this manual 2 Save Setup As Job 76, 125 scaling resistors for current inputs 30, 173 for RTD inputs 30, 175 for thermistor inputs 175 for voltage inputs 30, 174 installing 172–176 scan 50, 51, 60 scanner 49, 50, 51, 52, 53, 54, 55, 57 SCSI cable 7, 8 clearance 14, 181 installing 25 Sensor Fail Cool Output 69, 142 and failed sensor alarm 93 mode override 127 reversed thermocouple detection 133 thermocouple short
Series D8 User’s Guide Index TR alarm code 82 troubleshooting 157–176 alarms 159–161 all loops are set to manual 0% 162 Battery Dead alarm 163 check these things firs 157 control mode switches unexpectedly 162 control outputs 168 digital inputs 27, 152, 169 digital outputs 26, 153, 168 display does not work 161 grounding problems 167 H/W failure: Ambient alarm 165 H/W failure: Gain alarm 164 H/W failure: Offset alarm 164 keypad 152, 161, 166 low power alarm 163 process variable incorrect on display 161, 1
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Menu Structure Global setup (page 125) Load setup from job Save setup as job BCD job load BCD job load logic Mode override Mode override D/I active Power up alarm delay Power up loop mode Keypad lock TC short alarm AC line freq D/O alarm polarity MAC ID Baud rate Module LED Network LED Bus off count WATLOW D8x Vx.
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