CLS User’s Guide Watlow Controls 1241 Bundy Blvd. Winona, MN 55987 Customer Service Phone: (800) 414-4299 Fax: (800) 445-8992 Technical Support Phone: (507) 494-5656 Fax: (507) 452-4507 Email: wintechsupport@watlow.com Part No. 21952-00. Revision 3.
Copyright © 1996 Watlow Anafaze Information in this manual is subject to change without notice. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form without written permission from Watlow Anafaze. Warranty Watlow Anafaze, Incorporated warrants that the products furnished under this Agreement will be free from defects in material and workmanship for a period of three years from the date of shipment.
CLS User’s Guide Contents Contents Overview 1 System Diagram.....................................................................2 Parts List ...............................................................................2 Safety .....................................................................................3 Introduction 5 Specifications ........................................................................7 Analog Inputs ..................................................................
Contents CLS User’s Guide Inputs ....................................................................................34 Input Scaling ...................................................................34 4 and 8 CLS Scaling Values ...........................................35 16 CLS Scaling Values ...................................................38 Scaling and Calibration ...................................................39 T/C Inputs ....................................................................
CLS User’s Guide Contents Communications Protocol ...............................................68 Communications Error Checking ...................................68 AC Line Frequency .........................................................69 Digital Output Polarity ....................................................69 EPROM Information .......................................................69 Set up Loop Input .................................................................70 Input Type ............
Contents CLS User’s Guide High Deviation Alarm Output Number ..........................91 Low Deviation Alarm Type ............................................92 Low Deviation Alarm Output Number ...........................92 Low Process Alarm Setpoint ..........................................92 Low Process Alarm Type ...............................................93 Low Process Alarm Output Number ..............................93 Alarm Deadband ...........................................................
CLS User’s Guide Contents Linear Scaling Examples 115 Example 1 .............................................................................115 Example 2 .............................................................................116 Example 3 .............................................................................117 Appendix A: Ramp Soak 119 Introduction ...........................................................................119 R/S Features ...............................................
CLS User’s Guide vContents Process Variable Retransmit .................................................139 Setting Up a PV Retransmit ............................................139 PV Retransmit Menus .....................................................140 Cascade Control ....................................................................143 Setting Up Cascade Control ............................................143 Cascade Control Menus ..................................................
Overview Overview This manual describes how to install, setup, and operate a 4CLS, an 8CLS, or a 16CLS. Included are seven chapters, two Appendices, and a glossary of terms. Each chapter covers a different aspect of your control system and may apply to different users. The following describes the chapters and their purpose. • Introduction: Gives a general description of the CLS and its related specifications. • Installation: Describes how to install the CLS and its peripheral devices.
Overview System Diagram The illustration below shows how the parts of the CLS are connected. When unpacking your system, use the diagrams and parts list below to ensure all parts have been shipped. Please don't hesitate to call Watlow Anafaze's Technical Service Department if you have problems with your shipment, or if the CLS components are missing or damaged. .
Overview Safety Watlow Anafaze has made efforts to ensure the reliability and safety of the CLS Controller and to recommend safe usage practices in systems applications. Please note that, in any application, failures can occur. These failures may result in full control outputs or other outputs which may cause damage to or unsafe conditions in the equipment or process connected to the CLS Controller.
Overview 4 CLS User’s Guide
Introduction Introduction The CLS is a modular control system with up to 16 fully independent loops of PID control (16 CLS). It functions as a stand-alone controller; the CLS 1/8 DIN front panel has a Liquid Crystal Display (LCD) and touch keypad for local display and local parameter entry. You can also use it as the key element in a computer-supervised data acquisition and control system; the CLS can be locally or remotely controlled via an RS-232 or RS-485 serial communications interface.
Introduction Watchdog Timer: The CLS watchdog timer output notifies you of system failure. You can use it to hold a relay closed while the controller is running, so you are notified if the microprocessor shuts down. Front Panel or Computer Operation: Set up and run the CLS from the front panel or from a local or remote computer. Watlow Anafaze offers ANASOFT, our IBM AT or IBM-PC compatible software you can use to operate the CLS.
Introduction Specifications The following section contains specifications for inputs, outputs, the serial interface, system power requirements, environmental specifications, and the CLS physical dimensions. Analog Inputs Number of Control Loops: 4 (4CLS), 8 (8CLS), 16 (16CLS), plus one pulse loop. Number of Analog Inputs: 4 (4CLS), 8 (8CLS), 16 (16CLS). Input Switching: differential solid state MUX switching. Input Sampling Rate: 4CLS: 6x/sec (167 ms) at 60 Hz; 5x/sec (200 ms) at 50 Hz.
Introduction Thermocouple Ranges and Resolution: T/C Type Range in °F * Accuracy: 25°C Ambient Range in °C °C J T/C -350 to 1400 -212 to 760 K T/C -450 to 2500 -268 to 1371 T T/C -450 to 750 -268 to 399 S T/C 0 to 3200 -18 to 1760 R T/C 0 to 3210 -18 to 1766 B T/C 150 to 3200 66 to 1760 E T/C -328 to 1448 -200 to 787 * Accuracy: 0-50°C Full Temp. Range °C °F °C °F ±0.5 ±0.6 ±1.3 ±2.5 ±2.5 ±6.6 ±0.9 ±1.2 ±2.4 ±4.5 ±4.5 ±12.0 ±1.1 ±1.35 ±2.9 ±5.6 ±5.6 ±14.9 ±2.0 ±2.7 ±5.
Introduction Digital Inputs Number: 8 Configuration: 8 selectable for output override, remote job selection. Input Voltage Protection: Diodes to supply and common. Source must limit to 10 mA for override conditions. Voltage Levels: <1.3V=Low; >3.7V=High (TTL). Maximum Switch Resistance to Pull Input Low: 1 Kohms. Minimum Switch Off Resistance: 11 Kohms. User-Selectable Digital Outputs Number: 34 Operation: Open collector output; On state sinks to logic common. Current ≤ 20 mA for 35 loads.
Introduction Analog Outputs The Watlow Anafaze Digital to Analog Converter (DAC) is an optional module for the CLS. It lets you convert a Distributed Zero Crossing control output signal to an analog process control signal. You can purchase a 4-20 mAdc, 0-5 Vdc, and 0-10 Vdc versions of the DAC. Watlow Anafaze also offers the Serial DAC for precision open-loop control. 0-5 Vdc/4-20 mAdc jumper selectable. Contact Watlow Anafaze for more information about the DAC and Serial DAC.
Introduction Miscellaneous Specifications Serial Interface Type: RS-232 3 wire or RS-485 4 wire. Isolation: RS-232 None RS-485 To EIA RS-485 Specification. Baud Rate: 2400 or 9600, user selectable. Error Check: BCC or CRC, user selectable. Number of Controllers: 1 with RS-232 communications; 32 with RS-485 communications. Protocol: Form of ANSI X3.28-1976 (D1, F1), compatible with Allen Bradley PLC, full duplex.
Introduction 12 CLS User’s Guide
Installation Installation These installation instructions are written for non-technical users; if you are an electrician or you are technically proficient, they may seem simple to you. Please at least skim all of the instructions, to make sure you don't miss anything vital. This section explains installation for the CLS only. If you are installing another Watlow Anafaze product (such as an SDAC), see the manual shipped with it to learn how to install it.
Installation Precautions and Warnings DANGER Shut off power to your process before you install the CLS. High voltage may be present even when power is turned off! Reduce the danger of electric shock after installation by mounting the CLS in an enclosure that prevents personal contact with electrical components.
Installation Recommended Tools Use these tools to install the CLS: Panel Hole Cutters 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 # 600-68), for most panel materials and thicknesses. • Nibbler and metal file--for aluminum and lightweight panel doors. Other Tools You will also need these tools: • Phillips head screwdriver.
Installation CLS Mounting Procedure NOTE Mount the controller before you mount the terminal block or do any wiring. The controller's placement affects placement and wiring considerations for the other components of your system. Mounting Environment Install the CLS in a location free from excessive (>50ºC) heat, dust, and unauthorized handling. The controller can mount in any panel material up to 0.2" thick.
Installation TB-18 Mounting Instructions These steps describe how to mount the TB-18 on the rear of the CLS. (Please follow these steps exactly, so you do not damage either the terminal block or the controller.) 1. Install the cable support on the underside of the CLS. The TB-18 was shipped to you in a plastic bag. The bag also contained a cable tie (the long plastic strip) and a cable tie mount (the square plastic piece with one sticky side). a. Stick the cable tie mount to the underside of the CLS.
Installation TB-50 Mounting Instructions These steps tell you how to mount the TB-50. (Please follow these steps exactly, so you don’t damage the terminal block, the ribbon cable, or the controller.) 1. Choose a mounting location. Be sure there is enough clearance to install and remove the TB-50; it measures 3.4" long X 3.2" wide X 1.27" tall. 2. Watlow Anafaze shipped the TB-50 to you in an antistatic bag. Make sure these parts are also in the bag: •Five plastic standoffs. •Five 6-32 screws.
Installation 4. Place the TB-50 where you will mount it and use a pencil to trace around the standoffs. 5. Drill and tap #6-32 holes in the locations you marked. 6. Place the TB-50 where you will mount it. Insert the #6 screws in the standoffs and tighten them. NOTE Save the cable tie wraps, ribbon cable, and ribbon cable clamps. You’ll use them when you wire outputs to the TB50 and when you connect the ribbon cable. WARNING Do not connect power to the CLS now.
Installation General Wiring Recommendations Use the cables below or their equivalent. For best results, use appropriate materials, proper installation techniques and the correct equipment. For example, choose wire type by function, installation requirements, and the likelihood of mechanical or electrical problems at your installation. Function No.
Installation Grounding Connect the CLS chassis to an external ground at only one point, to avoid ground loops that can cause instrument errors or malfunctions.
Installation Thermocouple Wiring Use 18 or 20 AWG thermocouple (T/C) extension wire for all the T/C inputs. NOTE Most thermocouple wire is solid unshielded wire. Use shielded wire if required at your installation; ground one end only. WARNING The CLS uses a floating ground system. Therefore: Isolate input devices or host computers connected through communications cables (like RS-232) from earth ground. Use ungrounded thermocouples with the thermocouple sheath electrically connected to earth ground.
Installation Output Wiring Use multicolored stranded shielded cable for analog outputs (if you have installed an SDAC) and PID digital outputs connected to panel mount SSRs. Analog outputs generally use a twisted pair, while digital outputs have 9-20 conductors, depending on wiring technique. For instructions on using the cable tie wraps included in the TB-50’s packaging, see the Wiring Outputs section. Communications Wiring Large systems can pull in an extra pair to the computer communications wiring.
Installation Wiring: Noise Suppression If the CLS's outputs control dry contact electromechanical relays with inductive loads--like alarm horns and motor starters--you may get Electro-magnetic Interference (EMI, or “noise”) The following section explains how to avoid noise problems; read it before you wire the CLS. Symptoms of RFI/EMI If your controller displays the following symptoms, suspect EMI. • The CLS's display blanks out and then reenergizes as if power had been turned off for a moment.
Installation General Wiring The following sections explain how to test your installation before you connect power to it and how to connect inputs and outputs to it. Power Wiring and Controller Test When you have installed each component of the controller and the TB50 (if used), use this checklist to connect them. These instructions are written so that non-electricians can understand them. If you are an experienced electrician, they may seem elementary to you. If so, feel free to skim them.
Installation Connections Test Again, follow these instructions if you have purchased your own power supply, or if you are using a Watlow Anafaze power supply, you don’t need to perform this test. 1. Unscrew the two screws on the sides of the CLS front panel. 2. Gently slide the electronics assembly out of the case. You have now removed the parts of the CLS which will be damaged by excess voltage, so plug in the transformer power supply and use a voltmeter to check voltages: 3.
Installation Outputs NOTE Your CLS is shipped with heat outputs enabled and cool outputs disabled. You can disable any PID output and use it for other digital output functions. All digital outputs and PID outputs are sink outputs referenced to the 5Vdc supply. These outputs are Low (pulled to common) when they are On. All digital inputs are Transistor-Transistor Logic (TTL) level inputs referenced to control common.
Installation 28 CLS User’s Guide
Installation Using the Cable Tie Wraps When you have wired outputs to the TB-50, use the cable tie wraps shipped with it. This diagram shows the cable tie wrap holes. A B 38B 39 40 41 42 43 44 45 46 47 48 49 50 38A 37 36 35 34 33 32 31 30 29 28 27 26 13B 14 15 16 17 18 19 20 21 22 23 24 25 13A 12 11 10 9 8 7 6 5 4 3 2 1 A B 1 B A B H oles labeled "A"are m ounting holes. H oles labeled "B"are tie w rap holes.
Installation PID Control and Alarm Output Connections Typical digital control outputs use external optically isolated solid-state relays (SSRs). The SSRs use a 3 to 32 Vdc input for control, and you can size them to switch up to 100 amps at 480 Vac. For larger currents, you can use these optically isolated relays to drive contactors. You can also use Silicon Control Rectifiers (SCRs) and an SDAC for phaseangle fired control. NOTE Control outputs are SINK outputs. They are Low when the output is On.
Installation TB-18 Connections This table shows TB-18 connections to the 4CLS and the 8CLS.
Installation TB-50 Connections 4 and 8 CLS TB-50 Connections.
Installation 16 CLS TB-50 Connections.
Installation Inputs This section covers input scaling and input installation for all input types, including thermocouples, RTDs, current inputs, and voltage inputs. Input Scaling The CLS analog input circuitry accepts any mix of thermocouples, 2 or 3 wire RTD inputs, current inputs, and voltage inputs. You can directly connect the following inputs: • J, K, T, S, R, B, and E thermocouples. • Linear inputs with ranges between -10 and 60 mV. Other inputs require custom scaling resistors.
Installation 4 and 8 CLS Scaling Values • For RTD1 inputs, RA and RB are a matched pair (RP). Their matching tolerance is 0.02% (2 ppm/ºC) and their absolute tolerance is 0.1% (10 ppm/ºC). RC has 0.05% tolerance. • For RTD2 inputs, use 0.05% tolerance resistors. • For linear mVdc, Vdc, and mAdc ranges, use 0.1% tolerance resistors. Higher tolerances may cause significant errors. Correct any errors due to resistor tolerance with the CLS's built-in linear scaling.
Installation The next table shows scaling resistor values. Input Range RA RB All T/C, 0-60 mV DC RTD 1: -100.0 to 275.0ºC RTD 2: -120 to 840ºC RC RD Jumper 10.0 Kohms 25.0 Kohms 10.0 Kohms 25.0 Kohms 80 ohms 100 ohms 0-10 mA DC 0-20 mA DC Jumper Jumper 6.0 ohms 3.0 ohms 0-100 mV 0-500 mV 499 ohms 5.49 Kohms 750 ohms 750 ohms 0-1 VDC 0-5 VDC 0-10 VDC 0-12 VDC 6.91 Kohms 39.2 Kohms 49.9 Kohms 84.5 Kohms 422.0 ohms 475.0 ohms 301.0 ohms 422.
Installation 4CLS: Voltage/Current Inputs Loop # RC RD 1 58 RP1 2 56 RP2 3 54 RP3 4 52 RP4 8CLS: Voltage/Current Inputs Loop RC RD Loop RC RD 1 58 RP1 5 50 RP5 2 56 RP2 6 48 RP6 3 54 RP3 7 46 RP7 4 52 RP4 8 44 RP8 4CLS: RTD/Thermister Inputs Loop # RA/RB RC 1 RP1 57 2 RP2 55 3 RP3 53 4 RP4 51 8CLS: RTD/Thermister Inputs Loop RA/RB RC Loop RA/RB RC 1 RP1 57 5 RP5 49 2 RP2 55 6 RP6 47 3 RP3 53 7 RP7 45 4 RP4 51 8 RP8 43
Installation 16 CLS Scaling Values For linear mVdc, Vdc, and mAdc ranges, use 0.1% tolerance resistors. Higher tolerances may cause significant errors. Correct any errors due to resistor tolerance with the CLS’ built-in linear scaling. You can also install other components (like capacitors) for signal conditioning; please consult Watlow Anafaze for more information. Analog Input Terminals IN + IN + RC RD Analog Common CLS Measurement Circuitry The next table shows scaling resistor values.
Installation Scaling and Calibration The CLS provides offset calibration for thermocouple, RTD, and other fixed ranges, and offset and span (gain) calibration for linear and pulse inputs. (Offset and span calibration convert linear analog inputs into engineering units using the Mx+B function.) In order to scale linear input signals, you must: 1. Install appropriate scaling resistors. (Contact Watlow Anafaze's Customer Service Department for more information about installing scaling resistors.) 2.
Installation You can connect J, K, T, S, R, B, and E thermocouples directly to the CLS. Watlow Anafaze provides standard linearization and cold junction compensation for these thermocouple types. (Other thermocouple types require custom linearization; please contact Watlow Anafaze for more information about them.) Connecting Thermocouples Connect the positive T/C lead to the In+ terminal. Connect the negative T/C lead to the TB1 In- (4 or 8CLS) or analog common 16CLS)( terminal.
Installation Below is a typical RTD. Back Terminal Block Connections In+ I nAnalog Common Current Inputs To connect current (milliamp) inputs, install resistors that convert the milliamp input to a voltage. Watlow Anafaze offers resistors for 0-20 mA and 0-10 mA current inputs. Voltage Inputs • Connect the + side of the voltage input to the In+ terminal. • Connect the - side of the input to the In- terminal for the 4 and 8CLS, or analog common for the 16CLS. The 0voltage input range is -10 to 60 mV.
Installation Unused Inputs Set the input type for unused inputs to “SKIP” to avoid the default T/C break alarms. (See Input Type in Chapter 4: Setup for information on setting the input type.) Back Terminal Block Connections Wire inputs to the back terminal block as shown below.
Installation Serial Communications The CLS is factory-configured for RS-232 communications. However, the communications are jumper-selectable, so you can switch between RS-232 and RS-485. (See Configuring Communications below.) You can also order a communications cable from Watlow Anafaze or make your own cable. RS-232 Interface With RS-232 communications, you can connect the CLS directly to the serial communications connector on an IBM-PC or compatible computer.
Installation The diagram on the next page shows the recommended system hookup. To avoid ground loops, it uses an optically isolated RS-232 to RS-485 converter at the host computer. The system is powered from the CLS's power source or from a secure, isolated supply. Power Supply Host Computer + Optically Isolated Converter + CLS Power Supply Power Supply Fifth Wire - - + CLS Optional Capacitor Wire equipment in a single “daisy chain” using twisted shielded pairs for the RS-485 cables.
Installation Use a 200 ohm terminating resistor on the RX line of the last controller in the system. (If you have only one controller, it is the last controller in the system.) Use jumper JU1 to select the terminating resistor; place it in B position for termination and A position for non-termination. NOTE Connect the shields to earth ground only at the computer or other 485 interface. Do not connect the shield to the controller.
Installation Configuring Communications Your controller is shipped configured for RS-232. To switch between RS-232 and RS-485, change the jumpers as shown here. You'll need tweezers and a Phillips head screwdriver to switch between RS-232 and RS-485. Follow these steps: 46 CLS User’s Guide 1. Power down the unit. 2. Remove the controller's metal casing.
Installation Recommended Wire Gauges Watlow Anafaze recommends the following maximum distances and wire gauges: Distance Wire Gauge Recommended Cable 4000 ft. 24 AWG Belden #9729 Belden #9842 6000 ft. 22 AWG Belden #9184 You may wish to use a shield, depending on your noise environment and grounding problems. The above cables are shielded. NOTE These recommendations are conservative, to ensure that your controller will operate reliably.
Installation 48 CLS User’s Guide
Using the CLS Using the CLS Introduction This chapter will show you how to use the CLS from the front panel. (If you are using ANASOFT or AnaWin, please see the related User's Guide.) The next diagram shows how to reach the operator menus from Single Loop display. (To change global parameters, loop inputs, control parameters, outputs, and alarms from the setup menus, you must enter a special sequence of keys. To learn how, see the next chapter: setup.
Using the CLS Front Panel The front panel provides a convenient interface with the controller. You can program and operate the CLS with the front panel keys shown below, or you can use ANASOFT, a program designed specifically for Watlow Anafaze controllers. Front Panel Keys Yes/Up Press Yes to • Select a menu. • Answer Yes to Yes/No questions. • Increase a number or choice you're editing. No/Down Press No to • Skip a menu you don't want to edit, when the prompt is blinking.
Using the CLS WARNING Pressing the No key on power up will clear the RAM memory and reinitialize the CLS' factory default values. To do a No Key Reset, power down the controller, press and hold the No key, and power up the controller while holding the No key. A No Key Reset is appropriate: • After you change the EPROM. (See Chapter 6: Troubleshooting.) • In some cases when troubleshooting (see Chapter 6: Troubleshooting). • When you install the controller. Back The Back key works like an “escape key”.
Using the CLS Ramp/Soak If Ramp/Soak is installed on your controller, press the Ramp/Soak key to: • Assign a ramp/soak profile to the current loop. • Perform operations on an assigned profile. • See the status of a running profile. NOTE Your CLS may not have the Ramp/Soak feature. If it does not, then the Ramp/Soak key will not operate.
Using the CLS Displays The next section discusses the CLS' main displays--Bar Graph, Single Loop, and Job displays. Bar Graph Display On power up, the CLS displays general symbolic information for all four primary loops. This display is called Bar Graph mode. The diagram below shows the symbols used in Bar Graph mode.
Using the CLS The next table explains the symbols you see on the bottom line of Bar Graph display. These symbols appear when the controller is in both dual output mode and single output mode. If an alarm occurs, the controller automatically switches to Single Loop display and shows an alarm code. Symbol Symbol’s Meaning M One or both outputs enabled. Loop is in manual control. A Only one output (heat or cool, but not both) is enabled. Loop is in automatic control. T Loop is in Autotune mode.
Using the CLS If only one output is enabled (heat or cool, but not both), Single Loop display looks like this: Engineering Units Process Variable Loop Number Output Percentage LOOP PROCESS UNITS or Name Cool 02 160 ºF 0 180 AUTO 100 Output Percentage Setpoint ALARM SETPOINT STATUS OUT% Heat Control Status From Single Loop Display, • Press Yes to go to the next loop. • Press No to go to the previous loop. • Press the Back key once to go to Job display (if enabled) or Bar Graph display.
Using the CLS Alarms If an alarm occurs, a two-character alarm code appears in the lower left corner of the display (below). If a Failed Sensor alarm occurs, the controller also displays a short alarm message. Process Variable LOOP Loop number or Name 02 LP Engineering Units PROCESS ºF 180 180 AUTO 0 ALARM SETPOINT Alarm Symbols UNITS STATUS Output Percentage OUT% Setpoint These alarm codes and messages are shown in the table below.
Using the CLS Job Display Job display appears only if: • You have turned on the Remote Job Select function. (This function is explained in Setup.) • You have selected a job from the job load menu.
Using the CLS Operator Menus You can reach the following Operator Menus from Single Loop Display. (If your CLS is already installed, try each procedure as you read about it.) Change Setpoint To change the setpoint, go to Single Loop display of the loop you wish to change, and then press the Change Setpoint key. (The setpoint is the desired temperature, pH, et cetera, for the process.
Using the CLS Press any key to exit this display. If at least one control output (heat or cool) is enabled, you'll see this display: LOOP PROCESS UNITS 01 CONTROL STATUS ? AUTO ALARM SETPOINT STATUS OUT% • Press Yes to change the mode. • Press Yes or No to switch between Manual, Automatic, and Tune. • To exit this menu and return to the Single Loop Display without saving your changes, press Back. • Press Enter to save your changes.
Using the CLS Autotune If you set the current loop's control status to TUNE and press Enter, the controller automatically sets the loop to Manual control, 100% output. (If you selected a continuous output limit, the controller sets the loop to the output limit.) The autotune function then calculates the appropriate PID constants for the loop and puts the loop in automatic control with the calculated PID values. The Autotune function will abort if: • Process variable goes over 75% of the setpoint.
Setup The Setup menus let you change the CLS detailed configuration information. If you have not set up a CLS before, or if you don't know what values to enter, please read first the Tuning and Control section, which contains PID tuning constants and useful starting values. How to Enter the Setup Menus? 1. In Single Loop Display, select the loop you wish to edit. 2. While still in Single Loop Display, enter the pass sequence below: Press Enter, Alarm Ack, Change Setpoint. 3.
Setup Setup Global Parameters? Setup Loop Inputs? Setup Loop Control Params? Setup Loop Outputs? Load setup from job? Input type? Heat control PB? Heat control output? Pulse sample time? Heat control TI? Save setup to job? Loop name? Job select dig inputs? Heat control TD? Heat control filter? Input units? Job sel dig ins active? Output override dig input? Override dig in active? Startup alarm delay? * Ramp/Soak time base? (only if R/S installed Keyboard lock status? Power up output status
Setup Set up Global Parameters Menu The Set up Global Parameters menu looks like this: LOOP PROCESS UNITS SETUP GLOBAL PARAMETERS ? ALARM SETPOINT STATUS OUT% Below is the setup global parameters menu tree. Notice the default values inside the boxes.
Setup Load a Job Use this menu to load any one of 8 saved jobs from the controller's front panel. LOOP PROCESS UNITS LOAD SETUP FROM JOB ? 1 ALARM SETPOINT STATUS OUT% The following parameters are loaded as part of a job: • PID constants, filter settings, setpoints and spread values • Loop control status (Automatic or Manual) and output values (if the loop is in Manual control).
Setup Job Select Inputs Use this menu to set the number of job select inputs. The controller uses these inputs as a binary code that specifies the job number to run. The number of inputs you choose in this menu controls the number of jobs you can select remotely. LOOP PROCESS UNITS JOB SELECT DIG INPUTS ? NONE ALARM SETPOINT STATUS OUT% Below is the truth table that tells you which input states select which jobs.
Setup Output Override Digital Input Use this menu to set a digital input that sets all loops in manual output at output levels you select in the Outputs menu. This menu, and the next one, let you configure a “panic button” or “kill switch” that sets all outputs to the output override percentage you set in the Set up Loop Outputs main menu. LOOP PROCESS UNITS OUTPUT OVERRIDE DIG INPUT ? NONE ALARM SETPOINT STATUS OUT% Selectable values: NONE or input number 1-8.
Setup Keyboard Lock Status Use this menu to lock the front panel operator function keys Change SP, Man/Auto, and Ramp/Soak so that pressing these keys has no effect. If you want to use these functions, turn off the Keyboard Lock. LOOP PROCESS UNITS KEYBOARD LOCK STATUS ? OFF ALARM SETPOINT STATUS OUT% Selectable values: On or Off. Power-Up Output Status Use this menu to set the initial power-up state of the control outputs to Off or Memory.
Setup Communications Baud Rate Use this menu to set the Communications Baud Rate. LOOP PROCESS UNITS COMMUNICATIONS BAUD RATE ? 9600 ALARM SETPOINT STATUS OUT% Selectable values: 2400 or 9600. Communications Protocol Use this menu to set the communications protocol type. LOOP PROCESS UNITS COMMUNICATIONS PROTOCOL?ANA ALARM SETPOINT STATUS OUT% Selectable values: ANA (Watlow Anafaze’s protocol), AB (Allen Bradley’s), MOD (Modbus).
Setup AC Line Frequency Use this menu to configure the controller to match an AC line frequency of 50 or 60 Hz. (This function is provided for international users who require 50 Hz lines.) Since the controller reduces the effect of power line noise on the analog measurement by integrating the signal over the period of the AC line frequency, the controller's noise rejection will suffer if the line frequency is not set correctly.
Setup Set up Loop Input The Set up Loop Input main menu lets you access menus which change parameters related to the loop input: • Input type • Input units • Input scaling and calibration • Input filtering The next section explains how to use the Input menus to configure your controller. LOOP PROCESS UNITS SETUP LOOP 02 INPUT ? ALARM SETPOINT STATUS OUT% Below is the setup inputs menu tree. Notice the default values inside the boxes. Setup Loop Inputs? Input Scaling Hi RDG? 100.
Setup Input Type Use this menu to configure the input sensor for each loop as one of these input types: • Thermocouple types (J, K, T, S, R, B and E). • RTD (4 and 8CLS). Two ranges: RTD1 (Platinum Class A) and RTD2 (Platinum Class B). • Linear inputs. • Skip (an input type available for unused channels.) The scanning display doesn't show loops you've set to Skip. LOOP PROCESS UNITS 01 INPUT TYPE ? ALARM SETPOINT J T/C STATUS OUT% The following tables show the input types and ranges.
Setup RTD Ranges (4 and 8CLS) Accuracy: 25ºC Ambient ºC ºF Accuracy: 050ºC Ambient ºC ºF Name Range in ºF Range in ºC Resolution Probe Temp. In ºC RTD1 -148.0 to 527.0 -100.0 to 275.0 0.023 ºC 25 ±0.35 ±0.63 ±0.5 ±0.9 275 ±1 ±1.8 ±1.5 ±2.7 -184 to 1544 -120 to 840 0.062 ºC 25 ±0.9 ±1.62 ±2.8 ±5.04 840 ±1.1 ±1.98 ±4.3 ±7.74 RTD2 Pulse Sample Time You can connect a digital pulse signal of up to 2 KHz to the controller's pulse input.
Setup Selectable values: The table below shows the character set for input units. Input Character Sets for Units Thermocouple, and RTD ºF or ºC Linear & Pulse 0 to 9, A to Z,%, /, degrees, space Input Reading Offset This menu does not appear if the input type is linear, pulse, or skip. Use it to make up for the input signal's inaccuracy at any given point. For example, at temperatures below 400 ºF, a type J thermocouple may be inaccurate (“offset”) by several degrees F.
Setup The scaling function is defined by two points on a conversion line. It relates the high PV to the high reading and the low PV to the low reading to define the line. The engineering units of the process variable can be any arbitrary units. The graph below shows PSI as an example. Before you enter the values that determine the two points for the conversion line, you must choose an appropriate display format.
Setup Display Format This menu appears under the Set up Loop Inputs main menu. It lets you select a display format for a linear input. Choose a format appropriate for your input range and accuracy. (You will only see the Display Format menu if you are editing a linear input.) LOOP PROCESS UNITS 04 DISP FORMAT ? -999 to 3000 ALARM SETPOINT STATUS OUT% Selectable values: The CLS has several available display formats, as shown below. This table also shows the high and low PV values.
Setup High Reading Use this menu to enter the input level that corresponds to the high process value you entered in the previous menu. For linear inputs, the high reading is a percentage of the full scale input range. For pulse inputs, the high reading is expressed in Hz. The 100% full scale input value is 60 mV for the linear input type. LOOP PROCESS UNITS 04 INPUT SCALING HI RDG ? 100.0%FS ALARM SETPOINT STATUS OUT% Selectable range: Any value between -99.9 and 999.9.
Setup Input Filter The CLS has two different types of input filter: • A noise rejection filter that rejects high frequency input signal noise. This filter keeps a “trend log” of input readings. If a reading is outside the filter's “acceptance band”, and later readings are within the acceptance band, the CLS ignores the anomalous reading. (The acceptance band for thermocouples is 5 degrees above and 5 degrees below the input reading. For linear inputs, it's 0.5% above and 0.5% below the input reading.
Setup Set up Loop Control Parameters Use these menus to change control parameters for heat and cool outputs of the selected loop, including: • Proportional Band (PB or Gain), Integral (TI or Reset), and Derivative (TD or Rate) settings. • Output Filter. • Spread between heat and cool outputs. LOOP PROCESS UNITS SETUP LOOP 01 CONTROL PARAMS ? ALARM SETPOINT STATUS OUT% Below is the setup control parameters menu tree.
Setup Heat or Cool Control PB This menu allows you to set the Proportional Band (also known as Gain). LOOP PROCESS UNITS 02 HEAT CONTROL PB? 50 ºF ALARM SETPOINT STATUS OUT% NOTE The CLS internally represents the proportional band (PB) as a gain value. When you edit the PB, you'll see the values change in predefined steps--small steps for narrow PB values and large steps for wide PB values.
Setup Heat or Cool Output Filter Use this menu to dampen the heat or cool output's response. The output responds to a step change by going to approximately 2/3 of its final value within the number of scans you set here. LOOP PROCESS UNITS 04 HEAT CONTROL FILTER ? 2 SCANS ALARM SETPOINT STATUS OUT% Selectable range: 0-255. Setting the output filter to 0 turns it off. Heat and Cool Spread Use this menu to set the spread between the heat and cool output and the spread of the On/Off control action.
Setup Set up Loop Outputs Press Yes at this prompt to access menus to change loop output parameters for the current loop, including: • Enable or disable outputs • Output type • Cycle time (for TP outputs) • SDAC parameters (for SDAC outputs) • Control action • Output level limit and limit time • Output override • Nonlinear output curve . LOOP PROCESS UNITS SETUP LOOP 03 OUTPUTS ? ALARM SETPOINT STATUS OUT% Below is the setup outputs menu tree.
Setup Enable/Disable Heat or Cool Outputs From this menu you can enable or disable the heat or cool output for the current loop. If you want the loop to have PID control, you must enable one output. You can also disable a heat or cool control output and use the output pin for something else, like an alarm. LOOP PROCESS UNITS 01 HEAT CONTROL OUTPUT ? ENABLED ALARM SETPOINT STATUS OUT% Selectable values: Enabled or Disabled. Heat or Cool Output Type This menu lets you set the output type.
Setup Heat or Cool Cycle Time From this menu you can set the Cycle Time for Time Proportioning outputs. LOOP PROCESS UNITS 02 HEAT OUTPUT CYCLE TIME ? 10 s ALARM SETPOINT STATUS OUT% NOTE The Cycle Time menu will only be present if the output type for the current loop is Time Proportioning. Selectable range: 1-255 seconds. SDAC Menus If you attach the optional SDAC to an output, you must configure that output for the SDAC using the following series of menus.
Setup SDAC High Value Use this menu to set a high value for the SDAC output. Set the high and low value to match the range of the output device. For instance, if the output device has a 4-20 mA range, set the SDAC high value to 20.00 mA and the SDAC low value to 4.00 mA. The controller converts 0% output to a 4.00 mA signal and 100% output to a 20.00 mA signal. LOOP PROCESS UNITS 03 SDAC HI VALUE ? 10.
Setup Heat or Cool Output Limit Use this menu to limit the maximum PID control output for a loop's heat and cool outputs. This limit may be continuous, or it may be in effect for a specified number of seconds (see Output Limit Time below). If you choose a timed limit, the output limit restarts when the controller powers up and when the output goes from Manual to Automatic control (via the front panel, when the controller changes jobs, or from ANASOFT).
Setup Heat or Cool Nonlinear Output Curve Use this menu to select one of two nonlinear output curves for nonlinear processes. LOOP PROCESS UNITS 03 HEAT OUTPUT ? LINEAR ALARM SETPOINT STATUS OUT% Selectable values: Curve 1, Curve 2, or Linear. These curves are shown in the figure below.
Setup Set up Loop Alarms Press Yes at the Set up Loop Alarms prompt to access menus which change alarm function parameters for the current loop. The main alarms menu looks like this: LOOP PROCESS UNITS SETUP LOOP 04 ALARMS ? ALARM SETPOINT STATUS OUT% Below is the setup alarms menu tree.
Setup Global Alarms Global alarms occur when a loop alarm set to Alarm (not Control) is unacknowledged, or when there are any unacknowledged failed sensor alarms. (If an alarm occurs, the CLS front panel displays an appropriate alarm code--see Using the CLS section.) Even if the alarm condition goes away, the global alarm stays on until you use the front panel Alarm Ack key (or ANASOFT) to acknowledge it. Process Alarms Process alarms include high and low deviation and high and low process alarms.
Setup When the controller powers up or the setpoint changes, deviation alarms do not activate until the process goes inside the deviation alarm band, preventing deviation alarms during a cold start. (High and low process alarms are always enabled.
Setup High Process Alarm Setpoint Use this menu to select the setpoint (temperature or other value within the scaled sensor range) at which the high process alarm activates. The high process alarm activates when the process variable (PV) goes above the high process setpoint. It deactivates when the PV goes below the high process setpoint minus the deadband value, if you have set a deadband value.
Setup Deviation Band Value Use this menu to set the deviation bandwidth, a positive and negative alarm or control point relative to the setpoint. If the setpoint changes, the alarm or control points also change. You can assign a separate digital output to the high and low deviation alarm/control setpoints--so that, for example, a high deviation alarm turns on a fan and a low deviation alarm turns on a heater.
Setup Low Deviation Alarm Type Use this menu to turn Off the low deviation alarm or set it to Alarm or Control mode. LOOP PROCESS UNITS 01 LO DEV ALARM TYPE ? OFF ALARM SETPOINT STATUS OUT% Selectable values: Off, Alarm, or Control. Low Deviation Alarm Output Number Use this menu to assign a digital output that activates when the loop is in low deviation alarm. LOOP PROCESS UNITS 04 LO DEV ALARM OUTPUT ? NONE ALARM SETPOINT STATUS OUT% NOTE All digital outputs are OR'd together (combined).
Setup Low Process Alarm Type This menu lets you turn off the low process alarm or set it to the Alarm or Control function. LOOP PROCESS UNITS 02 LO PROC ALARM TYPE ? OFF ALARM SETPOINT STATUS OUT% Selectable values: Off, Alarm or Control. Low Process Alarm Output Number Use this menu to assign the digital output that activates when the loop is in low process alarm.
Setup Alarm Delay Use this menu to set a loop alarm delay. There are two types of alarm delay: the start-up alarm delay and loop alarm delay. Start-up alarm delay (which you can set in the Set up Global Parameters main menu) delays process alarms (but not failed sensor alarms) for all loops for a specified time after the controller powers up. The loop alarm delay, in contrast, is set separately for each loop.
Setup Manual I/O Test Press Yes at this prompt to see menus which can help you test the digital inputs, digital outputs and the controller’s keypad. LOOP PROCESS UNITS MANUAL I/O TEST ? ALARM SETPOINT STATUS OUT% Below is the manual I/O menu tree.
Setup Test Digital Output Use this menu to select one of the digital alarm outputs to test in the next menu. LOOP PROCESS UNITS TEST DIGITAL OUTPUT ? 34 ALARM SETPOINT STATUS OUT% Toggle Digital Output Use this menu to manually toggle a digital output On or Off to test it. (You select the output to test in the previous menu.) On may be Low or High depending on the digital output polarity you set in the Output Polarity menu. (All outputs are set to Off when you exit Manual I/O Test menu.
PID Tuning and Control PID Tuning and Control Introduction This chapter explains PID control and supplies some starting PID values and tuning instructions, so that you can use control parameters appropriate for your system. If you would like more information on PID control, consult the Watlow Anafaze Practical Guide to PID. The control mode dictates how the controller responds to an input signal. The control mode is different from the type of control output signal (like analog or pulsed DC voltage).
PID Tuning and Control Control Modes The next sections explain the different modes you can use to control a loop. On/Off Control On/Off control is the simplest way to control a process; a controller using On/Off control turns an output on or off when the process variable reaches a certain limit above or below the desired setpoint. You can adjust this limit, since Watlow Anafaze controllers use an adjustable spread.
PID Tuning and Control However, a process which uses only Proportional control may settle at a point above or below the setpoint; it may never reach the setpoint at all. This behavior is known as “offset” or “droop”. (This diagram shows a process under proportional control only.) Proportional and Integral Control For Proportional and Integral control, use the Integral term, or Reset, with Proportional control.
PID Tuning and Control Proportional, Integral and Derivative Control For an improved level of control, use Derivative control with Proportional or Proportional and Integral control. Derivative control corrects for overshoot by anticipating the behavior of the process variable and adjusting the output appropriately. For example, if the process variable is rapidly approaching the setpoint, Derivative control reduces the output, anticipating that the process variable will reach setpoint.
PID Tuning and Control Time Proportioning (TP) Time Proportioning attempts to digitally simulate an analog output percentage by turning the output on or off for each time step so that the cumulative average of the output is the desired setting. You must enter a cycle time for TP outputs. The cycle time is the time over which the output is proportioned, and it can be any value from 1 to 255 seconds.
PID Tuning and Control The output filter can also enhance PID control. Some processes are very sensitive and require a high PB, so normal control methods are ineffective. You can use a smaller PB- and get better control- if you use the digital filter to reduce the high and low process output swings. You can also use the filter to reduce output noise when a large derivative is necessary, or to make badly tuned PID loops and poorly designed processes behave properly.
PID Tuning and Control Setting Up and Tuning PID Loops After you have installed your control system, tune each control loop and then set the loop to automatic control. (When you tune a loop, you choose PID parameters that will best control the process.) If you don't mind minor process fluctuations, you can tune the loop in automatic control mode. This section gives PID values for a variety of heating and cooling applications.
PID Tuning and Control Integral Term (TI) Settings This table shows TI settings vs. Reset settings. TI (secs./repeat) Reset (repeats/min) TI (secs./repeat0 Reset (repeats/min) 30 2.0 210 0.28 45 1.3 240 .25 60 1.0 270 .22 90 .66 300 .20 120 .50 400 .15 150 .40 500 .12 180 .33 600 .10 As a general rule, use 60, 120, 180, or 240 as a starting value for the TI. Derivative Term (TD) Settings This table shows Derivative term (TD) versus Rate Minutes (RM); Rate=TD/60. TD (secs.
PID 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) PB: Set the PB to 7% of the setpoint (SP) (Example: Setpoint = 450, so Proportional Band = 31). Proportional with Integral (PI) PB: Set the PB to 10% of SP (Example: Setpoint = 450, so PB = 45). Set TI to 60. Set TD to Off. Set the Output Filter to 2.
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Troubleshooting Troubleshooting The next few sections describe general troubleshooting for the CLS. Later sections describe specific procedures, like checking an input, changing the EPROM, and testing the controller. First, Check your Installation Please bear in mind that, even in stand-alone systems, the controller is only part of your control system.
Troubleshooting NOTE A No key reset clears the CLS memory and resets its parameters to their default values. If you have a standalone system, there is no way to recover your original parameters. If you have a computer-supervised system with ANASOFT, ANASOFT can store a copy of your parameters to a job file. WARNING Do not attempt to repair the controller yourself.
Troubleshooting Checking Digital I/O The following steps will help you test digital inputs and outputs. TB-18 and TB-50 Test 1. Plug in the CLS power supply, if you have not already done so. 2. Measure the +5Vdc supply at your TB-18 or TB-50: A. Connect the voltmeter's Common lead to your TB-18 screw terminal #2 or TB-50 screw terminal #3. B. Connect the voltmeter's Power lead to your TB-18 or TB-50 screw terminal #1. The voltage should be 4.75 to 5.25 Vdc. Control and Digital Output Testing 1.
Troubleshooting Checking Computer Supervised Systems Four elements must work properly in a computer supervised system that uses an IBM-compatible computer and ANASOFT: • The CLS. • The computer and its RS-232 or RS-485 serial interface. • The RS-232 or RS-485 communications line. • The computer's software. For CLS troubleshooting, disconnect the communications line from the computer before you follow the troubleshooting steps explained in the previous sections.
Troubleshooting From the setup menus, make sure that the communications parameters (address, error checking and baud rate) are set correctly for each CLS in your system. Every controller must have a separate address, starting with 1 and increasing by 1 for each controller. The error checking method and baud rate must be set the same way in the controller's setup menus and in ANASOFT. Ground Loops On some computers, the RS-232 common wire is tied to earth ground.
Troubleshooting 2. Remove the two screws from the sides of the controller front panel. 3. Remove the electronics assembly from the case, as shown below. 4. Unscrew the four screws at the corners of the top board and carefully unplug this board to access the bottom board (processor board), as shown below. 5. Find the installed EPROM. This is a 28 pin socketed chip which should have an Watlow Anafaze label on top of it.
Troubleshooting 6. Remove the existing EPROM from its socket by prying it out with a small flathead screwdriver, as shown below. 7. The EPROM is shipped with its legs bent at an angle that best fits its packaging. Bend the legs slightly so that the legs line up with the holes in the EPROM socket. Don't try to bend the legs one at a time; instead, gently press the legs against a flat surface until they're at a 90-degree angle to the EPROM body, as shown below. 8.
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Linear Scaling Examples Linear Scaling Examples Example 1 Situation A pressure sensor that generates a 4-20 milliamp signal is connected to the CLS. The specifications of the sensor state that it generates 4 milliamps at 0.0 PSI and 20 mA at 50.0 PSI. Setup The sensor is connected to a loop input set up with a resistor scaling network to produce 60 millivolts at 20 mA. (See the Inputs section of Installation for more information on scaling networks.
Linear Scaling Example 2 Situation A flow sensor connected to the CLS measures the flow in a pipe. The sensor generates a 0-5V signal. The sensor's output depends on its installation. Independent calibration measurements of the flow in the pipe indicate that the sensor generates 0.5 volts at three gallons per minute (GPM) and 4.75 volts at 65 GPM. The calibration instruments are precise to ñ1 gallon per minute.
Linear Scaling Examples Example 3 Situation A pulse encoder which measures the movement of a conveyor is connected to the CLS. The encoder generates 900 pulses for every inch the conveyor moves. You want to measure conveyor speed in feet per minute (f/m). Setup The encoder input is connected to the CLS' pulse input. An one second sample time gives adequate resolution of the conveyor's speed. The resolution is: 1 pulse 60 seconds X 1 second 1 minute X 1 inch 1 foot = 0.
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Appendix A: Ramp Soak Appendix A: Ramp Soak Introduction This Appendix will teach you how to set up and use Ramp/Soak profiles in CLS controllers. The Ramp/Soak feature turns your controller into a powerful and flexible batch controller. Ramp/Soak lets you program the controller to change a process setpoint in a preset pattern over time. This preset pattern, or temperature profile, consists of several segments.
Appendix A: Ramp Soak Specifications Number of possible profiles 17 Number of times to repeat a profile 1-99 or continuous Number of segments per profile 1-20 Number of triggers per segment Up to 2 Type of triggers Latched/ Unlatched Number of possible inputs for triggers 8 Number of events per segment 4 Number of possible outputs for events (At least one of these outputs must be used for control) 34 Configuring Ramp/Soak This section will teach you how to set up R/S profiles.
Appendix A: Ramp Soak Setting the R/S Time Base The R/S time base menu is in the Setup Globals main menu. Use this menu to set the time base in all your R/S profiles. LOOP PROCESS UNITS RAMP/SOAK TIME BASE? HOURS/MINS ALARM SETPOINT STATUS OUT% Selectable Values: Hours/Mins or Mins/Secs. Editing R/S Parameters You can reach the rest of the menus in this section from the Setup Ramp/Soak profile main menu. This menu is located between the Setup Loop Alarms main menu and the Manual I/O Test main menu.
Appendix A: Ramp Soak Copying the Setup from Another Profile Use this menu to setup similar profiles quickly, by copying a profile to another one. LOOP PROCESS UNITS COPY SETUP FROM PROFILE? A ALARM SETPOINT STATUS OUT% Selectable Values: A to Q. Editing the tolerance Alarm Time Use this menu to set a tolerance time that applies to the entire profile.
Appendix A: Ramp Soak Editing the Ready Setpoint When you assign a profile to a loop, the profile doesn’t start immediately; instead, it goes to the ready segment (segment 0) and stays there until you put the profile in Start mode. You can set a setpoint, assign events, and set event states for the ready segment. Use this menu to set the ready segment setpoint. LOOP PROCESS UNITS A READY SEGMENT SETPOINT ? OFF ALARM SETPOINT STATUS OUT% Selectable Values: -999 to 9999, or Off.
Appendix A: Ramp Soak Choosing an External Reset Input Use this menu to select an external reset input. Toggle the input to reset a profile to Ready state when it is in Run, Hold, or Wait mode. You can make any of the eight digital inputs the external reset input. LOOP PROCESS UNITS C EXTERNAL RESET INPUT NUMBER ? N ALARM SETPOINT STATUS OUT% Selectable Values: 1-8, or N (for no external reset). Editing a Segment Each profile is made up of several segments (up to 20).
Appendix A: Ramp Soak Setting a Segment Setpoint Use this menu to set a setpoint for the segment you are editing. The process will go to this setpoint by the end of the segment time. LOOP PROCESS UNITS C SEGMENT 5 SEG SETPT ? OFF ALARM SETPOINT STATUS OUT% Selectable Values: -999 to 9999, or Off (no segment setpoint). Configuring Segment Events You can assign up to four digital outputs—Events—to each segment. When the segment ends, the events you select go to the output state you specify.
Appendix A: Ramp Soak Editing Event Outputs This menu appears only if you answered YES to the previous menu. Use it to assign a digital output to each event. Assign digital outputs that are not being used for PID control or for SDAC clock. LOOP PROCESS UNITS A SEG 20 EVENT 3 OUTPUT #? 30 ALARM SETPOINT STATUS OUT% Selectable Values: Any digital output from 1 to 34, except those IN USE, or None (no event).
Appendix A: Ramp Soak Assigning an Input to a Trigger This menu appears only if you answered YES to the Edit Segment Triggers menu. Use it to assign one of the controller’s eight digital inputs to a segment trigger. You can assign any digital input to any trigger. You can also assign the same digital input to multiple triggers. LOOP PROCESS UNITS C SEG18 TRIG1 INPUT NR ?NONE ALARM SETPOINT STATUS OUT% Selectable Values: Any digital input from 1-8, or None (no input assigned).
Appendix A: Ramp Soak Setting Segment Tolerance Use this menu to set a positive or negative tolerance value for each segment. this value is displayed in the engineering units of the process and is a deviation from the setpoint.
Appendix A: Ramp Soak Using Ramp/Soak This section explains how to assign a profile to a loop, how to put a profile in Run, Continue, or Hold mode, how to reset a profile, and how to display profile statistics. The next figure shows the Ramp/Soak key menus.
Appendix A: Ramp Soak 1. In Single Loop display, switch to the loop you want to edit. 2. Press the RAMP/SOAK key. The assigning menu appears. (See menu in previous page) 3. Choose one of the available profiles and press ENTER. 4. Press BACK if you wish to return to Single Loop display without saving any changes. Assigning a different profile To assign a new profile to a loop that already has one assigned, follow these steps: 1. Press the RAMP/SOAK key three times. 2. Press the NO key.
Appendix A: Ramp Soak Running a Profile When you assign a profile, it does not start running immediately; instead, the loop enters the Ready segment (segment 0). Use this menu to start a profile (put it in Start mode). LOOP PROCESS UNITS 01 A SEG01/05 R SET MODE? START ALARM SETPOINT STATUS OUT% Starting a profile You can start a profile only when it’s in the Ready segment. 1. Press the RAMP/SOAK key repeatedly until you see the Ramp/ Soak mode menu. 2.
Appendix A: Ramp Soak Code Mode STRT The profile is in the Ready segment. RUN The profile is running. HOLD The user has put the profile in Hold mode. TOHO The profile is in tolerance hold. WAIT The profile is in trigger wait state. This is the Single Loop display when a profile is running.
Appendix A: Ramp Soak All the menus you can reach from the RAMP/SOAK key have the same information on the top line. Profile letter Number of segments in profile Current segment Loop number LOOP PROCESS UNITS 01 A SEG01/05 R SET MODE? START ALARM SETPOINT STATUS Mode (Run/Hold/Continue) OUT% How long has the profile run? From Single Loop display, press the RAMP/SOAK key once. The next menu appears only if you have already assigned a profile to the loop.
Appendix A: Ramp Soak Holding a Profile or Continuing from Hold Use the profile mode menu to hold a profile or continue from Hold. The next table shows the available modes. Current Mode Available Mode Description Start Run Begin running the assigned profile. Hold Cont Continue from user-selected hold. Profile runs from the point when you put the profile in Hold mode. (You cannot continue from a tolerance hold or a trigger wait.) After you choose this mode, the controller switches back to Run mode.
Appendix A: Ramp Soak Resetting a profile Use this menu to reset a profile. When you reset a profile, the following happens: • The profile returns to the ready segment. The PV goes to the ready setpoint, and the ready segment events go to the state you specified in the Edit Ready Event State menu. • The controller shows you the Assign Profile menu in case you would like to assign a different profile to the loop. To reset a profile, follow these steps: 1.
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Appendix B: Enhanced Process Control Appendix B: Enhanced Process Control This Appendix explains five new features added to the CLS and MLS controllers: • Process Variable Retransmit • Cascade Control • Ratio Control • Remote Analog Setpoint • Differential Control 137
Appendix B: Enhanced Process Control Enhanced Process Control Menus Setup Global Parameters Setup Loop Inputs Setup Loop Control Parameters Setup Loop Outputs Yes Heat Output Retrans PV? Setup Loop PV Retransmit Setup Loop Cascade Yes Setup Loop Ratio Control Setup Loop Alarms Yes Cascade Prim.
Appendix B: Enhanced Process Control Process Variable Retransmit The PV Retransmit feature allows you to select the PV of any loop in the controller to be directed to any heat or cool output, including the loop which is providing the PV to be retransmitted. Once an output is defined as a “PV Retransmit”, it cannot be used for PID control.
Appendix B: Enhanced Process Control By adjusting the Maximum and Minimum inputs, you can scale the output appropriately: Linear Scaling of PV for Retransmit Output(OV%) 100% Max. Output Min. Output 0% Min. Input Min. Input(PV) Input PV Retransmit Menus The Setup menus for the PV Retransmit feature appear under the Setup Loop PV Retransmit menu. In order to view the PV retransmit menus, you need to select "Yes" at the following prompt.
Appendix B: Enhanced Process Control Minimum Input LOOP PROCESS UNITS 02 HEAT RETRANS MIN INP? 1000 ALARM SETPOINT STATUS OUT% Selectable Values: From the input loop PV minimum reading to the maximum reading. Minimum Output LOOP PROCESS UNITS 02 HEAT RETRANS MIN OUT%? 0% ALARM SETPOINT STATUS OUT% NOTE If you select a Min. Out other than 0%, one output will never drop below Min. Out, even if the PV drops below the Min. Input you specify.
Appendix B: Enhanced Process Control Maximum Output LOOP PROCESS UNITS 02 HEAT RETRANS MAX OUT%? 100% ALARM SETPOINT STATUS OUT% Output will never go above the this Maximum Output percentage, regardless of how high the PV goes. Selectable Values: 0-100%. NOTE Any available output (heat or cool) may be used as a retransmit output. Any PV (including the same loop number input) may be retransmitted.
Appendix B: Enhanced Process Control Cascade Control The Cascade control feature allows the output percentage of one control loop to influence the setpoint of a second control loop. A loop designated as a Cascade output loop (primary loop) can still be used for direct PID control of an output. A single loop can be either set up as Cascade or Ratio control, but not both.
Appendix B: Enhanced Process Control 7) By adjusting the SP parameters, the user can adjust the influence the primary loop has on the SP of the secondary loop. Primary loop output Calculation of new secondary loop setpoint: SP=(base sp) + (primary heat output) * (heat span) +(primary cool output) * (cool span) Min setpoint Secondary Loop Max setpoint Cascade Control Menus The Setup menus for the Cascade control feature appear under the Setup Loop Cascade main menu (See Setup section in this manual).
Appendix B: Enhanced Process Control Base Setpoint LOOP PROCESS UNITS 02 CASCADE BASE SP? 25 ALARM SETPOINT STATUS OUT% Selectable Values: From the secondary loop PV minimum reading to the maximum reading. Minimum Setpoint LOOP PROCESS UNITS 02 CASCADE MIN SP? 25 ALARM SETPOINT STATUS OUT% Selectable Values: From the secondary loop PV minimum reading to the maximum reading.
Appendix B: Enhanced Process Control Cool Cascade Span LOOP PROCESS UNITS 02 CASCADE CL SPAN? +9999 ALARM SETPOINT STATUS OUT% Selectable Values: -9999 to 9999. NOTE Cascade control cannot be used on the same control loop as Ratio control; however, both features may be used in the same multi-loop controller.
Appendix B: Enhanced Process Control Ratio control Ratio control allows you to specify a process variable of one loop, (Master loop), multiplied by a Ratio, to be the SP of another loop (Ratio loop). A single loop can be either set up as Cascade or Ratio control, but not both. You can assign any Process Variable to determine the SP of a Ratio loop. Setting Up Ratio Control In order to set up Ratio control, you must configure the following variables: 1) Ratio Process Variable assignment.
Appendix B: Enhanced Process Control Ratio Control Menus The Ratio control parameters appear under a new menu option, which follows the Cascade menu: LOOP PROCESS UNITS SETUP LOOP 02 RATIO CONTROL? ALARM SETPOINT STATUS OUT% Answering YES to this prompt will allow you to set up the Ratio control parameters with loop number 02 as the Ratio loop, which performs the actual control of the final control element.
Appendix B: Enhanced Process Control Setpoint Differential LOOP PROCESS UNITS 02 RATIO CONTROL SP DIFF.? 0 ALARM SETPOINT STATUS OUT% Selectable Values: From the ratio loop PV minimum reading to the maximum reading. NOTE Ratio control cannot be used on the same control loop as Cascade control; however, both features may be used in the same multi-loop controller. Remote Analog setpoint The Remote Analog Setpoint (Remote SP) is set up identically to the Ratio control.
Appendix B: Enhanced Process Control Typical Applications This section provides usage examples of the Enhanced features for the CLS and MLS manuals. Process Variable Retransmit The Process Variable Retransmit [PVR] feature provides retransmission of the process signal of one channel [primary] via the control output of another channel [secondary]. This signal is a linear output signal which is proportional to the engineering units of the primary channel input.
Appendix B: Enhanced Process Control 1) First, set up the standard control loop parameters according to the furnace application, in this case on loop 1. 2) Select another unused PID output for retransmitting the thermocouple value (for example, loop 2 heat output).
Appendix B: Enhanced Process Control Display LOOP PROCESS User Input UNITS 02 HEAT RETRANS MAX OUT%? 100 ALARM SETPOINT LOOP PROCESS STATUS OUT% UNITS 02 COOL OUTPUT RETRANS PV? NONE ALARM SETPOINT STATUS OUT% Enter the maximum output percentage, from 0 to 100%. For this example we will assume a full span with a maximum of 100%. Press Enter. The PV retransmit section of the CLS programming is now completed. You are not using the cool output of loop 2 for retransmitting a PV, so choose None.
Appendix B: Enhanced Process Control Cascade Control Cascade Control is used to control thermal systems with long lag times, which cannot be as accurately controlled with a single control loop. The output of the first (primary) loop is used to adjust the setpoint of the second (secondary) loop. The secondary loop normally executes the actual PID control.
Appendix B: Enhanced Process Control First, switch the controller to display loop 2, which will be the secondary loop, and then enter the 3-key sequence to display the following: Display LOOP PROCESS User Input Press Yes to setup the Cascade parameters with loop 2 as the secondary loop. UNITS SETUP LOOP 02 CASCADE? ALARM SETPOINT LOOP PROCESS STATUS OUT% Enter 01 to make loop 1 the primary loop. Press Enter. UNITS 02 CASCADE PRIM.
Appendix B: Enhanced Process Control Display LOOP PROCESS User Input UNITS 02 CASCADE HT SPAN? 40 ALARM SETPOINT LOOP PROCESS STATUS OUT% UNITS 02 CASCADE CL SPAN? 0 ALARM SETPOINT STATUS OUT% Enter the heat span of the secondary loop. This is the span over which the primary output from 0-100% is used to change the setpoint. For this example we will assume a linear rise in SP, so the heat span is 40°F. Press Enter. Enter the cool span of the secondary loop.
Appendix B: Enhanced Process Control Ratio Control A chemical process requires a formula of two parts Water (H2O) to one part Potassium Hydroxide (KOH) to produce diluted Potassium Hydroxide. The desired flow of H2O is 10 gallons per second (gps), and the KOH should be 5 gps. Each chemical has a pipe feeding a common pipe. The flow rate of each feeder pipe is measured and supplied to a 4CLS, with H2O flow as PV1 and KOH flow as PV2. The outputs of loops 1 and 2 adjust motorized valves.
Appendix B: Enhanced Process Control Display LOOP PROCESS User Input UNITS 02 RATIO CONTROL MIN SP? 0.0 ALARM SETPOINT LOOP PROCESS STATUS OUT% UNITS 02 RATIO CONTROL MAX SP? 7.0 ALARM SETPOINT LOOP PROCESS STATUS OUT% UNITS 02 RATIO CONTROL CTRL: RATIO? 0.5 ALARM SETPOINT STATUS OUT% Enter the minimum Ratio loop SP. For this example, we will use 0 gallons per minute as a minimum Press Enter. Enter the maximum Ratio loop SP. For this example, we will use 7.
Appendix B: Enhanced Process Control Remote Setpoint Remote Setpoint can be used to allow external equipment, such as a PLC or other control system, to provide an analog output (4-20 mA, 0-5 Vdc, etc.) used to change the setpoint of a loop. The method of configuring the Remote Setpoint is the same as Ratio Control. In the previous example, loop 1 would be the remote analog value and loop 2 would be the PID control loop.
Appendix B: Enhanced Process Control Display LOOP PROCESS User Input UNITS 02 RATIO CONTROL MAX SP? 300 ALARM SETPOINT LOOP PROCESS STATUS OUT% UNITS 02 RATIO CONTROL CTRL: RATIO? 1.0 ALARM SETPOINT LOOP PROCESS STATUS OUT% UNITS 02 RATIO CONTROL SP DIFF.? 0 ALARM SETPOINT STATUS OUT% Enter the maximum Ratio loop SP. For this example, we will use 300 ºF as a maximum Press Enter. Enter the control ratio, which is the multiple applied to the master Process Variable.
Appendix B: Enhanced Process Control The loops using the IR sensor as an input is assigned to the Master Loop in the Ratio Control Option Menu. The secondary loop is the Differential control loop. By setting the setpoint differential "SP DIFF." to the desired offset, this will produce the desired offset between the secondary and master loop setpoints for differential control.
Appendix B: Enhanced Process Control Display LOOP PROCESS User Input UNITS 02 RATIO CONTROL CTRL: RATIO? 1.0 ALARM SETPOINT LOOP PROCESS STATUS OUT% UNITS 02 RATIO CONTROL SP DIFF.? 50 ALARM SETPOINT STATUS OUT% Enter the control ratio, which is the multiple applied to the master Process Variable. In this example the ration is 1.0. Press Enter. Enter the setpoint differential (or offset). For this example we have an offset of +50. Press Enter.
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Glossary A AC See Alternating Current. AC Line Frequency The frequency of the AC power line measured in Hertz (Hz), usually 50 or 60 Hz. Accuracy Closeness between the value indicated by a measuring instrument and a physical constant or known standards. Action The response of an output when the process variable is changed. See also Direct action, Reverse action. Address A numerical identifier for a controller when used in computer communications.
Glossary Block Check Character (BCC) A serial communications error checking method. An acceptable method for most applications, BCC is the default method. See CRC. Bumpless Transfer A smooth transition from Auto (closed loop) to Manual (open loop) operation. The control output does not change during the transfer. C Calibration The comparison of a measuring device (an unknown) against an equal or better standard. Celsius (Centigrade) Formerly known as Centigrade.
Glossary Default Parameters The programmed instructions that are permanently stored in the microprocessor software. Derivative Control (D) The last term in the PID algorithm. Action that anticipated the rate of change of the process, and compensates to minimize overshoot and undershoot. Derivative control is an instantaneous change of the control output in the same direction as the proportional error.
Glossary temperature detector (RTD) open or short failures. Filter Filters are used to handle various electrical noise problems. Digital Filter (DF) — A filter that allows the response of a system when inputs change unrealistically or too fast. Equivalent to a standard resistor-capacitor (RC) filter Digital Adaptive Filter — A filter that rejects high frequency input signal noise (noise spikes). Heat/Cool Output Filter — A filter that slows the change in the response of the heat or cool output.
Glossary Input Type The signal type that is connected to an input, such as thermocouple, RTD, linear or process. Integral Control (I) Control action that automatically eliminates offset, or droop, between setpoint and actual process temperature. See Auto-reset. J Job A set of operating conditions for a process that can be stored and recalled in a controller’s memory. also called a Recipe.
Glossary Non Linear Through Watlow-Anafaze software, the Non Linear field sets the system to linear control, or to one of two non linear control options. Input 0 for Linear, 1 or 2 for non linear. P Panel Lock A feature that prevents operation of the front panel by unauthorized people. PID O Offset The difference in temperature between the setpoint and the actual process temperature. Offset is the error in the process variable that is typical of proportional-only control.
Glossary R Ramp A programmed increase in the temperature of a setpoint system. Range The area between two limits in which a quantity or value is measured. It is usually described in terms of lower and upper limits. Recipe See Job. Reflection Compensation Mode A control feature that automatically corrects the reading from a sensor. Relay A switching device.
Glossary Signal Any electrical transmittance that conveys information. Solid State Relay (SSR) See Relay, Solid State. Span The difference between the lower and upper limits of a range expressed in the same units as the range. Spread In heat/cool applications, the +/- difference between heat and cool. Also known as process deadband. See deadband. Stability The ability of a device to maintain a constant output with the application of a constant input.
Glossary Z Zero Cross Action that provides output switching only at or near the zero-voltage crossing points of the ac sine wave.
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