Watlow CLS Manual de usuario

CLSUser’s Guide Part No. 21952-00. Revision 3.2October 1996Watlow Controls1241 Bundy Blvd.Winona, MN 55987Customer ServicePhone: (800) 414-4299Fax: (8

2 CLS User’s GuideOverview System DiagramThe illustration below shows how the parts of the CLS are connected.When unpacking your system, use t

92 CLS User’s GuideSetup Low Deviation Alarm TypeUse this menu to turn Off the low deviation alarm or set it to Alarm orControl mode.Selectabl

SetupCLS User’s Guide 93Low Process Alarm TypeThis menu lets you turn off the low process alarm or set it to the Alarmor Control function.Selectable v

94 CLS User’s GuideSetup Alarm DelayUse this menu to set a loop alarm delay. There are two types of alarmdelay: the start-up alarm delay and l

SetupCLS User’s Guide 95Manual I/O TestPress Yes at this prompt to see menus which can help you test the digitalinputs, digital outputs and the contro

96 CLS User’s GuideSetup Test Digital OutputUse this menu to select one of the digital alarm outputs to test in thenext menu. Toggle Digital O

PID Tuning and ControlCLS User’s Guide 97PID Tuning and ControlIntroductionThis chapter explains PID control and supplies some starting PID valuesand

98 CLS User’s GuidePID Tuning and Control Control ModesThe next sections explain the different modes you can use to control aloop.On/Off Contr

PID Tuning and ControlCLS User’s Guide 99However, a process which uses only Proportional control may settle at apoint above or below the setpoint; it

100 CLS User’s GuidePID Tuning and Control Proportional, Integral and Derivative ControlFor an improved level of control, use Derivative contr

PID Tuning and ControlCLS User’s Guide 101Time Proportioning (TP)Time Proportioning attempts to digitally simulate an analog outputpercentage by turni

OverviewCLS User’s Guide 3SafetyWatlow Anafaze has made efforts to ensure the reliability and safety ofthe CLS Controller and to recommend safe usage

102 CLS User’s GuidePID Tuning and Control The output filter can also enhance PID control. Some processes are verysensitive and require a high

PID Tuning and ControlCLS User’s Guide 103Setting Up and Tuning PID LoopsAfter you have installed your control system, tune each control loop andthen

104 CLS User’s GuidePID Tuning and Control Integral Term (TI) SettingsThis table shows TI settings vs. Reset settings.As a general rule, use 6

PID Tuning and ControlCLS User’s Guide 105General PID Constants by ApplicationThis section gives PID values for many applications. They are useful asc

106 CLS User’s GuidePID Tuning and Control

TroubleshootingCLS User’s Guide 107TroubleshootingThe next few sections describe general troubleshooting for the CLS.Later sections describe specific

108 CLS User’s GuideTroubleshooting NOTEA No key reset clears the CLS memory and resets itsparameters to their default values. If you have a s

TroubleshootingCLS User’s Guide 109Checking Digital I/OThe following steps will help you test digital inputs and outputs.TB-18 and TB-50 Test1. Plug i

110 CLS User’s GuideTroubleshooting Checking Computer Supervised SystemsFour elements must work properly in a computer supervised system thatu

TroubleshootingCLS User’s Guide 111From the setup menus, make sure that the communications parameters(address, error checking and baud rate) are set c

4 CLS User’s GuideOverview

112 CLS User’s GuideTroubleshooting 2. Remove the two screws from the sides of the controller front panel.3. Remove the electronics assembly f

TroubleshootingCLS User’s Guide 1136. Remove the existing EPROM from its socket by prying it out with a small flathead screwdriver, as shown below.7.

114 CLS User’s GuideTroubleshooting

Linear Scaling ExamplesCLS User’s Guide 115Linear Scaling ExamplesExample 1SituationA pressure sensor that generates a 4-20 milliamp signal is connect

116 CLS User’s GuideLinear Scaling Example 2SituationA flow sensor connected to the CLS measures the flow in a pipe. Thesensor generates a 0-5V signal

Linear Scaling ExamplesCLS User’s Guide 117Example 3SituationA pulse encoder which measures the movement of a conveyor isconnected to the CLS. The enc

118 CLS User’s GuideLinear Scaling

Appendix A: Ramp SoakCLS User’s Guide 119Appendix A: Ramp Soak IntroductionThis Appendix will teach you how to set up and use Ramp/Soak profilesin CLS

120 CLS User’s GuideAppendix A: Ramp Soak SpecificationsConfiguring Ramp/SoakThis section will teach you how to set up R/S profiles. The foll

Appendix A: Ramp SoakCLS User’s Guide 121Setting the R/S Time BaseThe R/S time base menu is in the Setup Globals main menu.Use this menu to set the ti

IntroductionCLS User’s Guide 5IntroductionThe CLS is a modular control system with up to 16 fully independentloops of PID control (16 CLS). It functi

122 CLS User’s GuideAppendix A: Ramp Soak Copying the Setup from Another ProfileUse this menu to setup similar profiles quickly, by copying a

Appendix A: Ramp SoakCLS User’s Guide 123Editing the Ready SetpointWhen you assign a profile to a loop, the profile doesn’t startimmediately; instead,

124 CLS User’s GuideAppendix A: Ramp Soak Choosing an External Reset InputUse this menu to select an external reset input. Toggle the input t

Appendix A: Ramp SoakCLS User’s Guide 125Setting a Segment SetpointUse this menu to set a setpoint for the segment you are editing. Theprocess will go

126 CLS User’s GuideAppendix A: Ramp Soak Editing Event OutputsThis menu appears only if you answered YES to the previous menu. Useit to assi

Appendix A: Ramp SoakCLS User’s Guide 127Assigning an Input to a TriggerThis menu appears only if you answered YES to the Edit SegmentTriggers menu. U

128 CLS User’s GuideAppendix A: Ramp Soak Setting Segment ToleranceUse this menu to set a positive or negative tolerance value for eachsegmen

Appendix A: Ramp SoakCLS User’s Guide 129Using Ramp/SoakThis section explains how to assign a profile to a loop, how to put aprofile in Run, Continue,

130 CLS User’s GuideAppendix A: Ramp Soak 1. In Single Loop display, switch to the loop you want to edit.2. Press the RAMP/SOAK key. The assi

Appendix A: Ramp SoakCLS User’s Guide 131Running a ProfileWhen you assign a profile, it does not start running immediately;instead, the loop enters th

6 CLS User’s GuideIntroduction Watchdog Timer: The CLS watchdog timer output notifies you ofsystem failure. You can use it to hold a relay clo

132 CLS User’s GuideAppendix A: Ramp Soak This is the Single Loop display when a profile is running.Bar graph displayLoops that are running R

Appendix A: Ramp SoakCLS User’s Guide 133All the menus you can reach from the RAMP/SOAK key have the sameinformation on the top line.How long has the

134 CLS User’s GuideAppendix A: Ramp Soak Holding a Profile or Continuing from HoldUse the profile mode menu to hold a profile or continue fr

Appendix A: Ramp SoakCLS User’s Guide 135Resetting a profileUse this menu to reset a profile. When you reset a profile, the followinghappens:• The pro

136 CLS User’s GuideAppendix A: Ramp Soak

Appendix B: Enhanced Process Control137Appendix B: Enhanced Process ControlThis Appendix explains five new features added to the CLS and MLScontroller

138Appendix B: Enhanced Process ControlEnhanced Process Control MenusSetup GlobalParametersSetupLoopInputsSetupLoop Control ParametersSetupLoopOutputs

Appendix B: Enhanced Process Control139Process Variable RetransmitThe PV Retransmit feature allows you to select the PV of any loop inthe controller t

140Appendix B: Enhanced Process ControlBy adjusting the Maximum and Minimum inputs, you can scale theoutput appropriately:PV Retransmit MenusThe Setup

Appendix B: Enhanced Process Control141Minimum InputSelectable Values: From the input loop PV minimum reading to themaximum reading.Minimum OutputNOTE

IntroductionCLS User’s Guide 7SpecificationsThe following section contains specifications for inputs, outputs, theserial interface, system power requi

142Appendix B: Enhanced Process ControlMaximum OutputOutput will never go above the this Maximum Output percentage,regardless of how high the PV goes

Appendix B: Enhanced Process Control143Cascade ControlThe Cascade control feature allows the output percentage of one controlloop to influence the set

144Appendix B: Enhanced Process Control7) By adjusting the SP parameters, the user can adjust the influence the primary loop has on the SP of the seco

Appendix B: Enhanced Process Control145Base SetpointSelectable Values: From the secondary loop PV minimum reading tothe maximum reading.Minimum Setpoi

146Appendix B: Enhanced Process ControlCool Cascade SpanSelectable Values: -9999 to 9999.NOTECascade control cannot be used on the same control loop a

Appendix B: Enhanced Process Control147Ratio controlRatio control allows you to specify a process variable of one loop,(Master loop), multiplied by a

148Appendix B: Enhanced Process ControlRatio Control MenusThe Ratio control parameters appear under a new menu option, whichfollows the Cascade menu:A

Appendix B: Enhanced Process Control149Setpoint DifferentialSelectable Values: From the ratio loop PV minimum reading to themaximum reading.NOTERatio

150Appendix B: Enhanced Process ControlTypical ApplicationsThis section provides usage examples of the Enhanced features for theCLS and MLS manuals.Pr

Appendix B: Enhanced Process Control1511) First, set up the standard control loop parameters according to the fur-nace application, in this case on lo

8 CLS User’s GuideIntroduction Thermocouple Ranges and Resolution:RTD Ranges and Resolution (4 and 8 CLS only):T/C Break Detection: Pulse type

152Appendix B: Enhanced Process ControlNow press the "Back" key several times until the normal loop displayappears. The Process Variable Ret

Appendix B: Enhanced Process Control153Cascade ControlCascade Control is used to control thermal systems with long lag times,which cannot be as accura

154Appendix B: Enhanced Process ControlFirst, switch the controller to display loop 2, which will be thesecondary loop, and then enter the 3-key seque

Appendix B: Enhanced Process Control155Now press the "Back" key several times until the normal loop displayappears. The output percentage of

156Appendix B: Enhanced Process ControlRatio ControlA chemical process requires a formula of two parts Water (H2O) to onepart Potassium Hydroxide (KOH

Appendix B: Enhanced Process Control157Now press Back several times until the normal loop display appears. The setpoint of loop 2 will now be equal to

158Appendix B: Enhanced Process ControlRemote SetpointRemote Setpoint can be used to allow external equipment, such as aPLC or other control system, t

Appendix B: Enhanced Process Control159Now press the "Back" key several times until the normal loop displayappears. The setpoint of loop 2 w

160Appendix B: Enhanced Process ControlThe loops using the IR sensor as an input is assigned to the Master Loopin the Ratio Control Option Menu. The s

Appendix B: Enhanced Process Control161Now press the "Back" key several times until the normal loop displayappears. The setpoint of loop 2 w

IntroductionCLS User’s Guide 9Digital Inputs Number: 8Configuration: 8 selectable for output override, remote job selection.Input Voltage Protection:

162Appendix B: Enhanced Process Control

163GlossaryAACSee Alternating Current.AC Line FrequencyThe frequency of the AC power line measured inHertz (Hz), usually

Glossary 164Block Check Character (BCC)A serial communications error checking method.An acceptable method for most applications,BCC is the default me

Glossary 165Default ParametersThe programmed instructions that are perma-nently stored in the microprocessor software.Deri

Glossary 166temperature detector (RTD) open or short fail-ures.FilterFilters are used to handle various electrical noiseproblems. Digital Filter (DF)

Glossary 167Input TypeThe signal type that is connected to an input, suchas thermocouple, RTD, linear or process.Integral

Glossary 168Non LinearThrough Watlow-Anafaze software, the Non Lin-ear field sets the system to linear control, or toone of two non linear control op

Glossary 169RRampA programmed increase in the temperature of asetpoint system. RangeThe area between two limits in which a

Glossary 170SignalAny electrical transmittance that conveys infor-mation.Solid State Relay (SSR)See Relay, Solid State.SpanThe difference between the

Glossary 171ZZero CrossAction that provides output switching only at ornear the zero-voltage crossing points of the acsine

10 CLS User’s GuideIntroduction Analog OutputsThe Watlow Anafaze Digital to Analog Converter (DAC) is an optionalmodule for the CLS. It lets y

Glossary 172

IntroductionCLS User’s Guide 11Miscellaneous SpecificationsSerial InterfaceType: RS-232 3 wire or RS-485 4 wire.Isolation: RS-232 None RS-

Copyright © 1996Watlow AnafazeInformation in this manual is subject to change without notice. No part of this publication may bereproduced, stored in

12 CLS User’s GuideIntroduction

InstallationCLS User’s Guide 13InstallationThese installation instructions are written for non-technical users; if youare an electrician or you are te

14 CLS User’s GuideInstallation Precautions and WarningsDANGERShut off power to your process before you install the CLS.High voltage may be pr

InstallationCLS User’s Guide 15Recommended ToolsUse these tools to install the CLS:Panel Hole CuttersUse any of the following tools to cut a hole of t

16 CLS User’s GuideInstallation CLS Mounting ProcedureNOTEMount the controller before you mount the terminal blockor do any wiring. The contro

InstallationCLS User’s Guide 17TB-18 Mounting InstructionsThese steps describe how to mount the TB-18 on the rear of the CLS.(Please follow these step

18 CLS User’s GuideInstallation TB-50 Mounting InstructionsThese steps tell you how to mount the TB-50. (Please follow these stepsexactly, so

InstallationCLS User’s Guide 194. 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

20 CLS User’s GuideInstallation General Wiring RecommendationsUse the cables below or their equivalent. For best results, useappropriate mater

InstallationCLS User’s Guide 21GroundingConnect the CLS chassis to an external ground at only one point, toavoid ground loops that can cause instrumen

CLS User’s Guide Contents iContentsOverview 1System Diagram...2Parts List ...

22 CLS User’s GuideInstallation Thermocouple WiringUse 18 or 20 AWG thermocouple (T/C) extension wire for all the T/Cinputs.NOTEMost thermocou

InstallationCLS User’s Guide 23Output Wiring Use multicolored stranded shielded cable for analog outputs (if youhave installed an SDAC) and PID digita

24 CLS User’s GuideInstallation Wiring: Noise SuppressionIf the CLS's outputs control dry contact electromechanical relays withinductive

InstallationCLS User’s Guide 25General WiringThe following sections explain how to test your installation before youconnect power to it and how to con

26 CLS User’s GuideInstallation Connections TestAgain, follow these instructions if you have purchased your own powersupply, or if you are usi

InstallationCLS User’s Guide 27OutputsNOTEYour CLS is shipped with heat outputs enabled and cooloutputs disabled. You can disable any PID output and u

28 CLS User’s GuideInstallation

InstallationCLS User’s Guide 29Using the Cable Tie WrapsWhen you have wired outputs to the TB-50, use the cable tie wrapsshipped with it. This diagram

30 CLS User’s GuideInstallation PID Control and Alarm Output ConnectionsTypical digital control outputs use external optically isolated solid-

InstallationCLS User’s Guide 31TB-18 ConnectionsThis table shows TB-18 connections to the 4CLS and the 8CLS.*If you install a Watlow Anafaze Serial DA

ii Contents CLS User’s Guide Inputs ...34Input Scaling ...

32 CLS User’s GuideInstallation TB-50 Connections4 and 8 CLS TB-50 Connections.If you install a Watlow Anafaze Serial Digital to Analog Conver

InstallationCLS User’s Guide 3316 CLS TB-50 Connections.If you install a Watlow Anafaze Serial digital to Analog Converter(SDAC), the CLS uses digital

34 CLS User’s GuideInstallation InputsThis section covers input scaling and input installation for all inputtypes, including thermocouples, RT

InstallationCLS User’s Guide 354 and 8 CLS Scaling Values• For RTD1 inputs, RA and RB are a matched pair (RP). Their match-ing tolerance is 0.02% (2 p

36 CLS User’s GuideInstallation The next table shows scaling resistor values.The following tables show the location of RA, RB, RC and RD on th

InstallationCLS User’s Guide 374CLS: Voltage/Current Inputs8CLS: Voltage/Current Inputs4CLS: RTD/Thermister Inputs8CLS: RTD/Thermister InputsPlace res

38 CLS User’s GuideInstallation 16 CLS Scaling ValuesFor linear mVdc, Vdc, and mAdc ranges, use 0.1% tolerance resistors.Higher tolerances may

InstallationCLS User’s Guide 39Scaling and CalibrationThe CLS provides offset calibration for thermocouple, RTD, and otherfixed ranges, and offset and

40 CLS User’s GuideInstallation You can connect J, K, T, S, R, B, and E thermocouples directly to theCLS. Watlow Anafaze provides standard lin

InstallationCLS User’s Guide 41Below is a typical RTD.Current InputsTo connect current (milliamp) inputs, install resistors that convert themilliamp i

CLS User’s Guide Contents iiiCommunications Protocol ...68Communications Error Checking ...

42 CLS User’s GuideInstallation Unused InputsSet the input type for unused inputs to “SKIP” to avoid the default T/Cbreak alarms. (See Input T

InstallationCLS User’s Guide 43Serial CommunicationsThe CLS is factory-configured for RS-232 communications. However,the communications are jumper-sel

44 CLS User’s GuideInstallation The diagram on the next page shows the recommended system hookup.To avoid ground loops, it uses an optically i

InstallationCLS User’s Guide 45Use a 200 ohm terminating resistor on the RX line of the last controllerin the system. (If you have only one controller

46 CLS User’s GuideInstallation Configuring CommunicationsYour controller is shipped configured for RS-232. To switch betweenRS-232 and RS-485

InstallationCLS User’s Guide 47Recommended Wire GaugesWatlow Anafaze recommends the following maximum distances andwire gauges:You may wish to use a s

48 CLS User’s GuideInstallation

Using the CLSCLS User’s Guide 49Using the CLSIntroduction This chapter will show you how to use the CLS from the front panel. (Ifyou are using ANASOFT

50 CLS User’s GuideUsing the CLS Front PanelThe front panel provides a convenient interface with the controller. Youcan program and operate th

Using the CLSCLS User’s Guide 51WARNINGPressing the No key on power up will clear the RAM mem-ory and reinitialize the CLS' factory default value

iv Contents CLS User’s Guide High Deviation Alarm Output Number ...91Low Deviation Alarm Type ...

52 CLS User’s GuideUsing the CLS Ramp/Soak If Ramp/Soak is installed on your controller, press the Ramp/Soak keyto:• Assign a ramp/soak profil

Using the CLSCLS User’s Guide 53DisplaysThe next section discusses the CLS' main displays--Bar Graph, SingleLoop, and Job displays. Bar Graph Dis

54 CLS User’s GuideUsing the CLS The next table explains the symbols you see on the bottom line of BarGraph display. These symbols appear when

Using the CLSCLS User’s Guide 55If only one output is enabled (heat or cool, but not both), Single Loopdisplay looks like this:From Single Loop Displa

56 CLS User’s GuideUsing the CLS AlarmsIf an alarm occurs, a two-character alarm code appears in the lower leftcorner of the display (below).

Using the CLSCLS User’s Guide 57Job DisplayJob display appears only if:• You have turned on the Remote Job Select function. (This function is explaine

58 CLS User’s GuideUsing the CLS Operator Menus You can reach the following Operator Menus from Single Loop Display.(If your CLS is already in

Using the CLSCLS User’s Guide 59Press any key to exit this display. If at least one control output (heat orcool) is enabled, you'll see this disp

60 CLS User’s GuideUsing the CLS AutotuneIf you set the current loop's control status to TUNE and press Enter, thecontroller automaticall

CLS User’s Guide 61SetupThe Setup menus let you change the CLS detailed configurationinformation.If you have not set up a CLS before, or if you don&ap

CLS User’s Guide Contents vLinear Scaling Examples 115Example 1 ...115E

62 CLS User’s GuideSetup Setup GlobalParameters?Setup Loop Inputs?Setup LoopControl Params? Setup LoopOutputs?Setup LoopAlarms?Manual I/OTest?

SetupCLS User’s Guide 63Set up Global Parameters MenuThe Set up Global Parameters menu looks like this:Below is the setup global parameters menu tree.

64 CLS User’s GuideSetup Load a JobUse this menu to load any one of 8 saved jobs from the controller's frontpanel. The following paramete

SetupCLS User’s Guide 65Job Select InputsUse this menu to set the number of job select inputs. The controller usesthese inputs as a binary code that s

66 CLS User’s GuideSetup Output Override Digital InputUse this menu to set a digital input that sets all loops in manual output atoutput level

SetupCLS User’s Guide 67Keyboard Lock StatusUse this menu to lock the front panel operator function keys ChangeSP, Man/Auto, and Ramp/Soak so that pre

68 CLS User’s GuideSetup Communications Baud RateUse this menu to set the Communications Baud Rate. Selectable values: 2400 or 9600.Communica

SetupCLS User’s Guide 69AC Line FrequencyUse this menu to configure the controller to match an AC line frequencyof 50 or 60 Hz. (This function is prov

70 CLS User’s GuideSetup Set up Loop InputThe Set up Loop Input main menu lets you access menus which changeparameters related to the loop inp

SetupCLS User’s Guide 71Input Type Use this menu to configure the input sensor for each loop as one of theseinput types:• Thermocouple types (J, K, T,

vContents CLS User’s Guide Process Variable Retransmit ...139Setting Up a PV Retransmit ...

72 CLS User’s GuideSetup RTD Ranges (4 and 8CLS)Pulse Sample TimeYou can connect a digital pulse signal of up to 2 KHz to the controller'

SetupCLS User’s Guide 73Selectable values: The table below shows the character set for inputunits.Input Reading OffsetThis menu does not appear if the

74 CLS User’s GuideSetup The scaling function is defined by two points on a conversion line. Itrelates the high PV to the high reading and the

SetupCLS User’s Guide 75Display Format This menu appears under the Set up Loop Inputs main menu. It lets youselect a display format for a linear input

76 CLS User’s GuideSetup High ReadingUse this menu to enter the input level that corresponds to the highprocess value you entered in the previ

SetupCLS User’s Guide 77Input FilterThe CLS has two different types of input filter: • A noise rejection filter that rejects high frequency input sign

78 CLS User’s GuideSetup Set up Loop Control ParametersUse these menus to change control parameters for heat and cool outputsof the selected l

SetupCLS User’s Guide 79Heat or Cool Control PB This menu allows you to set the Proportional Band (also known asGain).NOTEThe CLS internally represent

80 CLS User’s GuideSetup Heat or Cool Output FilterUse this menu to dampen the heat or cool output's response. The outputresponds to a st

SetupCLS User’s Guide 81Set up Loop OutputsPress Ye s at this prompt to access menus to change loop outputparameters for the current loop, including:•

OverviewCLS User’s Guide 1OverviewThis manual describes how to install, setup, and operate a 4CLS, an8CLS, or a 16CLS. Included are seven chapters, t

82 CLS User’s GuideSetup Enable/Disable Heat or Cool Outputs From this menu you can enable or disable the heat or cool output for thecurrent l

SetupCLS User’s Guide 83Heat or Cool Cycle Time From this menu you can set the Cycle Time for Time Proportioningoutputs.NOTEThe Cycle Time menu will o

84 CLS User’s GuideSetup SDAC High ValueUse this menu to set a high value for the SDAC output. Set the high andlow value to match the range of

SetupCLS User’s Guide 85Heat or Cool Output LimitUse this menu to limit the maximum PID control output for a loop's heatand cool outputs. This li

86 CLS User’s GuideSetup Heat or Cool Nonlinear Output CurveUse this menu to select one of two nonlinear output curves for nonlinearprocesses.

SetupCLS User’s Guide 87Set up Loop AlarmsPress Yes at the Set up Loop Alarms prompt to access menus whichchange alarm function parameters for the cur

88 CLS User’s GuideSetup Global AlarmsGlobal alarms occur when a loop alarm set to Alarm (not Control) isunacknowledged, or when there are any

SetupCLS User’s Guide 89When the controller powers up or the setpoint changes, deviation alarmsdo not activate until the process goes inside the devia

90 CLS User’s GuideSetup High Process Alarm SetpointUse this menu to select the setpoint (temperature or other value withinthe scaled sensor r

SetupCLS User’s Guide 91Deviation Band ValueUse this menu to set the deviation bandwidth, a positive and negativealarm or control point relative to th