CLS200 Series User’s Guide Watlow 1241 Bundy Boulevard Winona, MN 55987 Customer Service: Phone........1-800-414-4299 Fax.............1-800-445-8992 Technical Support: Phone........+1 (507) 494-5656 Fax ............+1 (507) 452-4507 Email .........wintechsupport@watlow.com Part No. 0600-3050-2000 Rev.
Copyright © 1998-2003, Watlow Anafaze Information in this manual is subject to change without notice. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form without written permission from Watlow Anafaze. Warranty Watlow Anafaze, Incorporated warrants that the products furnished under this Agreement will be free from defects in material and workmanship for a period of three years from the date of shipment.
Table of Contents List of Figures xi List of Tables xv 1 System Overview 1 Manual Contents 1 Getting Started 2 Safety Symbols 2 Initial Inspection 2 Product Features 3 CLS200 Parts List 5 Technical Description 7 CLS200 7 TB50 8 CLS200 Cabling 9 Safety 9 External Safety Devices 9 Power-Fail Protection 10 2 Installation 11 Typical Installation 12 Mounting Controller Components 12 Recommended Tools 13 Mounting the Controller 13 Mounting the TB50 16 Mounting the Power Supply 18 Mounting the Dual DAC or Ser
Table of Contents CLS200 Series User’s Guide Sensor Wiring 29 Input Wiring Recommendations 30 Thermocouple Connections 31 RTD Input Connections 32 Reference Voltage Terminals 32 Voltage Input Connections 32 Current Input Connections 33 Pulse Input Connections 34 Wiring Control and Digital I/O 35 Output Wiring Recommendations 35 Cable Tie Wraps 35 Digital Outputs 35 Digital Inputs 38 TB18 Connections (CLS204 and CLS208 Only) 40 TB50 Connections 41 Analog Outputs 43 Wiring the Dual DAC 43 Wiring the Se
CLS200 Series User’s Guide Table of Contents Job Select Digital Inputs Active 77 Output Override Digital Input 77 Override Digital Input Active 77 Startup Alarm Delay 78 Keyboard Lock Status 78 Power Up Output Status 78 Process Power Digital Input 79 Controller Address 79 Communications Baud Rate 80 Communications Protocol 80 Communications Error Checking 80 AC Line Frequency 81 Digital Output Polarity on Alarm 81 EPROM Information 81 Setup Loop Input Menu 82 Input Type 83 Loop Name 84 Input Units 84 In
Table of Contents CLS200 Series User’s Guide Low Process Alarm Type 102 Low Process Alarm Output Number 102 Alarm Deadband 102 Alarm Delay 103 Manual I/O Test 103 Digital Inputs 103 Test Digital Output 104 Digital Output Number 104 Keypad Test 105 Display Test 105 5 Extruder Control 107 Setup Loop Outputs Menu 107 Cool Output Nonlinear Output Curve 107 Defaults 108 Extruder Control Algorithm 110 6 Enhanced Features 111 Process Variable Retransmit 113 Setup Loop Process Variable Retransmit Menu 113
CLS200 Series User’s Guide Table of Contents Last Segment 144 Repeat Cycles 144 Setpoints and Tolerances for Various Input Types 144 Using Ramp/Soak 145 Ramp/Soak Displays 146 Assigning a Profile to a Loop 148 Running a Profile 148 Holding a Profile or Continuing from Hold 150 Responding to a Tolerance Alarm 151 Resetting a Profile 151 In Case of a Power Failure 152 8 Tuning and Control 153 Control Algorithms 153 On/Off Control 154 Proportional Control 154 Proportional and Integral Control 155 Proport
Table of Contents CLS200 Series User’s Guide Testing the TB18 and TB50 173 Testing Control and Digital Outputs 173 Testing Digital Inputs 173 Additional Troubleshooting for Computer Supervised Systems 174 Computer Problems 174 Communications 175 Ground Loops 175 Software Problems 176 NO-Key Reset 176 Replacing the EPROM 176 Changing Communications 179 Installing Scaling Resistors 180 CLS204 and CLS208 Input Circuit 180 CLS204 and CLS208 Current Inputs 181 CLS204 and CLS208 Voltage Inputs 182 CLS204 and
List of Figures 1 System Overview Figure 1.1—CLS200 Part Numbering 5 Figure 1.2—CLS200 Special Inputs Parts List Figure 1.3—CLS200 Rear Views 7 Figure 1.4—CLS200 Front Panel 8 Figure 1.5—TB50 8 6 2 Installation Figure 2.1—CLS200 System Components 12 Figure 2.2—Clearance with Straight SCSI Cable 14 Figure 2.3—Clearance with Right-Angle SCSI Cable 14 Figure 2.4—Wiring Clearances 15 Figure 2.5—Mounting Bracket 16 Figure 2.6—Mounting the TB50 16 Figure 2.7—TB50 Mounted on a DIN Rail (Front) 17 Figure 2.
List of Figures CLS200 Series User’s Guide Figure 2.30—Single/Multiple Serial DACs 45 Figure 2.31—Connecting One CLS200 to a Computer Using EIA/TIA-232 Figure 2.32—EIA/TIA-485 Wiring 47 Figure 2.33—Recommended System Connections 48 46 3 Using the CLS200 Figure 3.1—Operator Displays 51 Figure 3.2—CLS200 Front Panel 52 Figure 3.3—Bar Graph Display 55 Figure 3.4—Single Loop Display 57 Figure 3.5—Single Loop Display, Heat and Cool Outputs Enabled Figure 3.
CLS200 Series User’s Guide List of Figures 8 Tuning and Control Figure 8.1—On/Off Control 154 Figure 8.2—Proportional Control 155 Figure 8.3—Proportional and Integral Control 155 Figure 8.4—Proportional, Integral and Derivative Control 156 Figure 8.5—Time Proportioning and Distributed Zero Crossing Waveforms 157 9 Troubleshooting and Reconfiguring Figure 9.1—Removal of Electronics Assembly from Case 177 Figure 9.2—Screws Locations on PC Board 178 Figure 9.3—EPROM Location 178 Figure 9.
List of Figures xii CLS200 Series User’s Guide Watlow Anafaze Doc.
List of Tables 2 Installation Table 2.1—Cable Recommendations 22 Table 2.2—Power Connections 26 Table 2.3—Digital Output States and Values Stored in the Controller 36 Table 2.4—Digital Inputs States and Values Stored in the Controller 39 Table 2.5—TB18 Connections 40 Table 2.6—TB50 Connections for CLS204 and CLS208 41 Table 2.7—TB50 Connections for CLS216 42 Table 2.8—EIA/TIA-232 Connections 46 Table 2.9—RTS/CTS Pins in DB-9 and DB-25 Connectors 46 3 Using the CLS200 Table 3.
List of Tables CLS200 Series User’s Guide 6 Enhanced Features Table 6.1—Application Example: Setting Up Process Variable Retransmit Table 6.2—Application Example: Setting Up Cascade Control 122 Table 6.3—Application Example: Setting Up Ratio Control 128 Table 6.4—Application Example: Setting Up Remote Setpoint 130 Table 6.5—Application Example: Setting Up Differential Control 132 117 7 Ramp/Soak Table 7.1—Ramp/Soak Specifications 135 Table 7.2—Trigger Latch Logic 143 Table 7.
CLS200 Series User’s Guide List of Tables 11 Specifications Table 11.1—Agency Approvals / Compliance 193 Table 11.2—Environmental Specifications 194 Table 11.3—Physical Dimensions 194 Table 11.4—Processor with Straight SCSI 195 Table 11.5—Processor with Right Angle SCSI 195 Table 11.6—Processor Connections 196 Table 11.7—TB50 Physical Dimensions 196 Table 11.8—TB50 Connections 197 Table 11.9—TB50 with Straight SCSI 198 Table 11.10—TB50 with Right Angle SCSI 199 Table 11.11—Analog Inputs 200 Table 11.
List of Tables xvi CLS200 Series User’s Guide Watlow Anafaze Doc.
1 System Overview Manual Contents This manual describes how to install, set up, and operate a CLS204, CLS208 or CLS216 controller. Each chapter covers a different aspect of your control system and may apply to different users: • • • • • • • • • Doc.# 0600-3050-2000 Chapter 1: System Overview provides a component list and summary of features for the CLS200 series controllers. Chapter 2: Installation provides detailed instructions on installing the CLS200 series controller and its peripherals.
Chapter 1: System Overview CLS200 Series User’s Guide • • Chapter 10: Linear Scaling Examples provides an example configuring a pressure sensor, a flow sensor, and an encoder using linear scaling. Chapter 11: Specifications lists detailed specifications of the controller and optional components. Getting Started The following sections provide information regarding product features, technical descriptions, safety requirements, and preparation for operation.
CLS200 Series User’s Guide Chapter 1: System Overview Product Features The CLS200 series controllers provide 4, 8 or 16 fully independent control loops. When used as a stand-alone controller, you may operate the CLS200 via the two-line 16character display and touch keypad. You can also use it as the key element in a computer-supervised data acquisition and control system; the CLS200 can be locally or remotely controlled via an EIA/TIA-232 or EIA/TIA-485 serial communications interface.
Chapter 1: System Overview CLS200 Series User’s Guide • • • • • • • • 4 CPU Watchdog: The CLS200 series CPU watchdog timer output notifies you of system failure. Use it to hold a relay closed while the controller is running, so you are notified if the microprocessor shuts down. Front Panel or Computer Operation: Set up and run the controller from the front panel or from a local or remote computer.
CLS200 Series User’s Guide Chapter 1: System Overview CLS200 Parts List You may have received one or more of the following components. See Figure 2.1 on page 12 for CLS200 configuration information.
Chapter 1: System Overview CLS200 Series User’s Guide CLSSI _ _–_ _–_ _ If special inputs are ordered in the controller part number, the following is specified in the pa t description. Special Input Type (Not required for thermocouple sensor inputs) 20 = RTD1: 0.1°, -100.0 to 275.0° C (-148.0 to 572.0° F) (Not available on CLS216) 21 = RTD2: 1°, -120.0 to 840.0° C (-184.0 to 1544.
CLS200 Series User’s Guide Chapter 1: System Overview Technical Description This section contains a technical description of each component of your CLS200 series controller. CLS200 The CLS200 is housed in an 1/8-DIN panel mount package. It contains the CPU, RAM with a built-in battery, EPROM, serial communications, digital I/O, analog inputs, the screen and touch keypad. CLS200 Series with SCSI Connector CLS204 or CLS208 with TB18 Connector Figure 1.
Chapter 1: System Overview CLS200 Series User’s Guide Front Panel Description The display and touch keypad provide an intelligent way to operate the controller. The display has 16 alphanumeric or graphic characters per line. The 8-key keypad allows you to change the operating parameters, controller functions, and displays. The information-packed displays show process variables, setpoints, and output levels for each loop.
CLS200 Series User’s Guide Chapter 1: System Overview CLS200 Cabling Watlow Anafaze provides cables required to install your CLS200. A 50-pin SCSI cable connects the TB50 to the CLS200. The optional cable used to connect the CLS200 to a computer using EIA/TIA-232 communications has a DB9 or DB25 connector for the computer and bare wires for connecting to the CLS200. Safety Watlow Anafaze has made every effort to ensure the reliability and safety of this product.
Chapter 1: System Overview CLS200 Series User’s Guide Power-Fail Protection In the occurrence of a sudden loss of power, this controller can be programmed to reset the control outputs to off (this is the default). Typically, when power is re-started, the controller restarts to data stored in memory. If you have programmed the controller to restart with control outputs on, the memory-based restart might create an unsafe process condition for some installations.
2 Installation This chapter describes how to install the CLS200 series controller and its peripherals. Installation of the controller involves the following procedures: • • • • • • Determining the best location for the controller Mounting the controller and TB50 Power connection Input wiring Communications wiring (EIA/TIA-232 or EIA/TIA485) Output wiring WARNING! Risk of electric shock. Shut off power to your entire process before you begin installation of the controller.
Chapter 2: Installation CLS200 Series User’s Guide Typical Installation Figure 2.1 shows typical installations of the controller with the TB50 and the TB18 terminal blocks. The type of terminal block you use greatly impacts the layout and wiring of your installation site. (See Figures 2.2 to 2.11.) We recommend that you read this entire chapter first before beginning the installation procedure. This will help you to carefully plan and assess the installation.
CLS200 Series User’s Guide Chapter 2: Installation WARNING! To reduce the risk of fire or electric shock, install the CLS200 in a controlled environment, relatively free of contaminants. Recommended Tools Use any of the following tools to cut a hole of the appropriate size in the panel. • • • Jigsaw and metal file, for stainless steel and heavyweight panel doors. Greenlee 1/8-DIN rectangular punch (Greenlee part number 600-68), for most panel materials and thicknesses.
Chapter 2: Installation 1.0 inch (25 mm) CLS200 Series User’s Guide 7.0 inches (178 mm) Figure 2.2 1.0 inch (25 mm) 14 Clearance with Straight SCSI Cable 7.0 inches (178 mm) Figure 2.3 1.6 inch (41 mm) 0.6 inch (41 mm) Clearance with Right-Angle SCSI Cable Watlow Anafaze Doc.
CLS200 Series User’s Guide Chapter 2: Installation Maximum Panel Thickness 0.2 inch (5 mm) 1.80 ± 0.020 inch (45.7 ± 0.5 mm) 3.63 ± 0.020 inches (92.2 ± 0.5 mm) Figure 2.4 Wiring Clearances We recommend you mount the controller in a panel not more than 0.2 in. (5 mm) thick. Doc.# 0600-3050-2000 1. Choose a panel location free from excessive heat (more than 50° C [122° F]), dust, and unauthorized handling. (Make sure there is adequate clearance for the mounting hardware, terminal blocks, and cables.
CLS200 Series User’s Guide Bracket (top and bottom) 24 22 20 18 16 14 12 10 8 6 4 2 Panel 26 Chapter 2: Installation 25 23 21 19 17 15 13 11 9 7 5 3 1 + Bezel Figure 2.5 Mounting Collar Mounting Bracket 7. Loosen the mounting bracket screws enough to allow for the mounting collar and panel thickness. Place each mounting bracket into the mounting slots (head of the screw facing the back of the processor module).
CLS200 Series User’s Guide Chapter 2: Installation DIN Rail Mounting Snap the TB50 on to the DIN rail by placing the hook side on the rail first, then pushing the snap latch side in place. (See Figure 2.7.) Figure 2.7 TB50 Mounted on a DIN Rail (Front) To remove the TB50 from the rail, use a flathead screwdriver to unsnap the bracket from the rail. (See Figure 2.8.) Removal catch for screwdriver DIN Rail snap latch Hook side Figure 2.8 Doc.
Chapter 2: Installation CLS200 Series User’s Guide Mounting with Standoffs 1. Remove the DIN rail mounting brackets from the TB50. 2. Select a location with enough clearance to remove the TB50, its SCSI cable and the controller itself. 3. Mark the four mounting holes. 4. Drill and tap four mounting holes for #6 (3.5 mm) screws or bolts. 5. Mount the TB50 with four screws. There are four smaller holes on the terminal board. Use these holes to secure wiring to the terminal block with tie wraps. 0.
CLS200 Series User’s Guide Chapter 2: Installation Mounting Environment Leave enough clearance around the power supply so that it can be removed. Two holes for #10 (5.0 mm) screws or bolts 0.3 inch (8 mm) 1.4 inch (36 mm) 7.5 inches (191 mm) 8.1 inches (206 mm) 0.7 inch (18 mm) Figure 2.10 CLS200 Power Supply Mounting Bracket Mounting Steps CAUTION! Use 6-32, 1/4-inch screws only. Longer screws may extend too far into the power supply and short to components, damaging the power supply. 1.
Chapter 2: Installation CLS200 Series User’s Guide Installation Installation of the Dual DAC and Serial DAC is essentially the same. The main differences are in the dimensions and the wiring. Follow this procedure to correctly install these devices. Jumpers The output signal range of the Dual DAC and Serial DAC modules is configured with jumpers. See Configuring Dual DAC Outputs on page 186 and Configuring Serial DAC Outputs on page 188 for information on setting these jumpers. Mounting 1.
CLS200 Series User’s Guide Chapter 2: Installation System Wiring Successful installation and operation of the control system can depend on placement of the components and on selection of the proper cables, sensors, and peripheral components. Routing and shielding of sensor wires and proper grounding of components can insure a robust control system. This section includes wiring recommendations, instructions for proper grounding and noise suppression, and considerations for avoiding ground loops.
Chapter 2: Installation CLS200 Series User’s Guide Table 2.1 Function Mfr. P/N Cable Recommendations No. of Wires AWG mm2 Analog Inputs Belden 9154 Belden 8451 2 2 20 22 0.5 0.5 RTD Inputs Belden 8772 Belden 9770 3 3 20 22 0.5 0.5 Thermocouple Inputs T/C Ext. Wire 2 20 0.5 Control Outputs and Digital I/O Belden 9539 Belden 9542 Ribbon Cable 9 20 50 24 24 22 to 14 0.2 0.2 0.5 to 2.5 Analog Outputs Belden 9154 Belden 8451 2 2 20 22 0.5 0.
CLS200 Series User’s Guide Chapter 2: Installation Avoiding RFI/EMI • • To avoid or eliminate most RFI/EMI noise problems: Connect the CLS200 case to earth ground. The CLS200 system includes noise suppression circuitry. This circuitry requires proper grounding. • Separate the 120 or 240VÅ (ac) power leads from the low-level input and output leads connected to the CLS200 series controller. Do not run the digital I/O or control output leads in bundles with ac wires.
Chapter 2: Installation CLS200 Series User’s Guide Ground Loops Ground loops occur when current passes from the process through the controller to ground. This can cause instrument errors or malfunctions. A ground loop may follow one of these paths, among others: • • • From one sensor to another. From a sensor to the communications port. From a sensor to the dc power supply. The best way to avoid ground loops is to minimize unnecessary connections to ground.
CLS200 Series User’s Guide Chapter 2: Installation Power Connections This section covers making the power connections to the CLS200 and connecting the TB50. TB1 (to signal inputs TB2 (to power supply) TB18 (to digital outputs) Figure 2.12 CLS200 Series Controller with TB18 TB1 (to signal inputs TB2 (to power supply) SCSI-2 (to TB50) Figure 2.13 CLS200 Series Controller with TB50 Wiring the Power Supply WARNING! Use a power supply with a Class 2 rating only.
Chapter 2: Installation CLS200 Series User’s Guide Table 2.2 Power Connections Function 26 Power Supply CLS200 TB2 DC Power (Controller) +12 to 24VÎ (dc) + DC Common 12 to 24VÎ (dc) Common - Earth Ground Ground 1. Connect the dc common terminal on the power supply to the dc common (-) terminal on CLS200 TB2. 2. Connect the positive terminal on the power supply to the dc positive (+) terminal on CLS200 TB2. 3.
CLS200 Series User’s Guide Chapter 2: Installation CAUTION! NOTE! To prevent damage from incorrect connections, do not turn on the ac power before testing the connections as explained in Testing Your System on page 28. Do not connect the controller’s dc common (COM) to earth ground . Doing so will defeat the noise protection circuitry, making measurements less stable.
Chapter 2: Installation CLS200 Series User’s Guide Testing Your System This section explains how to test the controller after installation and prior to making field wiring connections. TB50 or TB18 Test Use this procedure to verify that the TB50 or TB18 is properly connected and supplied with power: 1. Turn on power to the CLS200. The display should read CALCULATING CHECKSUM then show the bar graph display. (See Figure 3.3.
CLS200 Series User’s Guide Chapter 2: Installation Digital Input Test Use the following procedure to test digital inputs before connecting to field devices: 1. Disconnect any system wiring from the input to be tested. 2. Go to the DIGITAL INPUTS test in the MANUAL I/O TEST menu. (See Digital Inputs on page 103.) This test shows whether the digital inputs are H (high, or open) or L (low, or closed). 3. Attach a wire to the terminal of the digital input you want to test. See tables 2.5 to 2.
Chapter 2: Installation CLS200 Series User’s Guide Figure 2.15 CLS200 Connector Locations Input Wiring Recommendations Use multicolored stranded shielded cable for analog inputs. Watlow Anafaze recommends that you use 20 AWG wire (0.5 mm2). If the sensor manufacturer requires it, you can also use 24 or 22 AWG wiring (0.2 mm2). Most inputs use a shielded twisted pair; some require a 3-wire input. Follow the instructions pertaining to the type(s) of input(s) you are installing.
CLS200 Series User’s Guide Chapter 2: Installation Thermocouple Connections Connect the positive lead of any of the supported thermocouple types to the IN+ terminal for one of the loops and the negative lead to the corresponding IN- terminal. Use 18 or 20 AWG (0.5 or 0.75 mm2) for all the thermocouple inputs. Most thermocouple wire is solid, unshielded wire. When using shielded wire, ground one end only.
Chapter 2: Installation CLS200 Series User’s Guide and each should be connected to ground at the process end. • Connect the earth ground terminal on TB2 to a good earth ground, but do not connect the analog common to earth ground. The CLS200 uses a floating analog common for sensor measurements. The noise protection circuits on the sensor inputs function correctly only when the controller is correctly installed. See Ground Loops on page 24.
CLS200 Series User’s Guide Chapter 2: Installation CLS204 and CLS208 CH IN+ CH IN- Device with Voltage Output CLS216 CH IN+ Com Device with Voltage Output Figure 2.18 Linear Voltage Signal Connections Current Input Connections This input type requires scaling resistors. Special input resistors installed at Watlow Anafaze for analog current signals are such that the controller sees a -10 to 60 mV signal across its inputs for the loop.
Chapter 2: Installation CLS200 Series User’s Guide Pulse Input Connections The CLS200 can accept a pulse input of up to 2000 Hz from a device such as an encoder. The frequency of this input is scaled with user-set parameters. See Setup Loop Input Menu on page 82 and Chapter 9, Linear Scaling Examples. This scaled value is the process variable for loop 5 on a CLS204, loop 9 on a CLS208, or loop 17 on a CLS216.
CLS200 Series User’s Guide Chapter 2: Installation Wiring Control and Digital I/O This section describes how to wire and configure the control outputs for the CLS200 series controller. NOTE! Control outputs are connected to the CLS200’s common when the control output is on (low). Be careful when you connect external devices that may have a low side at a voltage other than controller ground, since you may create ground loops.
Chapter 2: Installation CLS200 Series User’s Guide Table 2.3 Digital Output States and Values Stored in the Controller State Value Description Off High Open circuit On Low Sinking current to common The digital outputs sink current from the load to the controller common. The load may powered by the 5VÎ (dc) supplied by the controller at the TB50. Alternately, an external power supply may be used to drive loads.
CLS200 Series User’s Guide Chapter 2: Installation Configuring Outputs Keep in mind the following points as you choose outputs for control and alarms: • • • • • • You can enable or disable the control outputs. The default setting is heat outputs enabled, cool outputs disabled. You can program each control output individually for on/off, time proportioning, distributed zero crossing, or Serial DAC control. You can individually program each control output for direct or reverse action.
Chapter 2: Installation CLS200 Series User’s Guide Heat Output Cool Output Alarm Output Common SSR SSR TB50 or TB18 - - + + SSR - + - PS + Figure 2.24 Output Connections Using External Power Supply CPU Watchdog Timer The CPU watchdog timer constantly monitors the microprocessor. It is a sink output located on TB50 terminal 6 or TB18 terminal 3. The output can be connected to an external circuit or device in order to determine if the controller is powered and operational.
CLS200 Series User’s Guide Chapter 2: Installation off. Most features that use the digital inputs can be userconfigured to activate when an input is either on or off. In the off state, internal 10 k resistors pull the digital inputs high to 5VÎ (dc) with respect to the controller common. Table 2.
Chapter 2: Installation CLS200 Series User’s Guide TB18 Connections (CLS204 and CLS208 Only) Table 2.
CLS200 Series User’s Guide Chapter 2: Installation TB50 Connections Table 2.
Chapter 2: Installation CLS200 Series User’s Guide Table 2.
CLS200 Series User’s Guide Chapter 2: Installation Analog Outputs Analog outputs can be provided by using a Dual DAC or Serial DAC module to convert the open collector outputs from the controller. Use multicolored stranded shielded cable for analog outputs. Analog outputs generally use a twisted pair wiring. The following sections describe how to connect the Dual DAC and Serial DAC modules to power the controller outputs and the load. Wiring the Dual DAC A Dual DAC module includes two identical circuits.
Chapter 2: Installation CLS200 Series User’s Guide Dual DAC TB50 or TB18 +5VÎ (dc) 1 1 +5VÎ (dc) CTRL PID Loop Output 2 DZC CTRL PID Output 3 4 +12/24VÎ (dc) External Power Supply +VÎ (dc) Load Conn. 5 -mAÎ (dc) Load Conn. 6 -External Power Supply/ VÎ (dc) Load Conn. VÎ (dc) Load + - + 12 to 24VÎ (dc) Power Supply Figure 2.29 Dual DAC with Voltage Output Wiring the Serial DAC The Serial DAC provides a robust analog output signal.
CLS200 Series User’s Guide Chapter 2: Installation Controller Power Supply Daisy chain up to 16 Serial DACs Serial DAC 1 +5V In 5V Common 2 COM In 15V Common 3 CLK In 4 Data In 5 + Out 6 - Out +5V TB50 or TB18 Serial DAC Clock Control Output Load + Figure 2.30 Single/Multiple Serial DACs Serial Communications The CLS200 series controllers are factory-configured for EIA/TIA-232 communications unless otherwise specified when purchased.
Chapter 2: Installation CLS200 Series User’s Guide Table 2.
CLS200 Series User’s Guide Chapter 2: Installation EIA/TIA-485 Interface To communicate with more than one CLS200 series controller on a controller network, or to use communication cable lengths greater than 50 feet (15.2 m) from PC to controller, you must use EIA/TIA-485 communications. When using EIA/TIA-485 communications, you must attach an optically isolated EIA/TIA-232 to EIA/TIA-485 converter to the computer. Figure 2.32 and Figure 2.33 show the recommended system wiring.
Chapter 2: Installation CLS200 Series User’s Guide To avoid unacceptable interference, use less than 10 feet (3 m) of cable from the terminal or connector to the CLS200 serial port. Some systems may experience problems with sensor signal reading if the commons of multiple controllers are connected. See Signal Common on page 48. Refer to Termination on page 48 for more on terminating resistors. Connect the shield drain to earth ground only at computer or host end. .
CLS200 Series User’s Guide Chapter 2: Installation EIA/TIA-485 Converters and Laptop Computers In order for an EIA/TIA-232-to-485 converter to optically isolate the computer from the 485 network, the 232 and 485 sides must be powered independently. Many 232-to-485 converters can be powered by the computer’s communications port. Some computers, laptops in particular, do not automatically provide the appropriate voltages.
Chapter 2: Installation 50 CLS200 Series User’s Guide Watlow Anafaze Doc.
3 Using the CLS200 This chapter explains how to use the keypad and display to operate the controller. Figure 3.1 shows the operator menus and displays accessible from the front panel. To change global parameters, loop inputs, control parameters, outputs, and alarms using the setup menus, see Chapter 4, Setup.
Chapter 3: Using the CLS200 CLS200 Series User’s Guide Front Panel The CLS200 front panel provides a convenient interface with the controller. You can use the front panel keys to program and operate the CLS200.
CLS200 Series User’s Guide Chapter 3: Using the CLS200 Front Panel Keys YES (up) Press YES to: • • • • Select a menu or parameter Answer YES to the flashing ? prompts Increase a value or choice when editing Stop scanning mode NO (down) Press NO to: NOTE! • Skip a menu or parameter when the prompt is blinking • • • • Answer NO to the flashing ? prompts Decrease a value or choice when editing Stop scanning mode Perform a NO-key reset Pressing the NO key on power up performs a NO-key reset.
Chapter 3: Using the CLS200 CLS200 Series User’s Guide CHNG SP Press CHNG SP to change the loop setpoint MAN AUTO Press MAN/AUTO to: • • • Toggle a loop between manual and automatic control Adjust the output power level of manual loops Automatically tune the loop RAMP SOAK If your controller has the ramp/soak option, press RAMP/ SOAK to: • • • Assign a ramp/soak profile to the current loop Select the ramp/soak mode See the status of a running profile Your controller may not have the ramp/soak option.
CLS200 Series User’s Guide Chapter 3: Using the CLS200 Displays This section discusses the controller’s main displays: bar graph, single loop and job. Bar Graph Display On power up, the controller displays general symbolic information for up to eight loops. This screen is called the bar graph display. The diagram below shows the symbols used in the bar graph display. Symbol Loop Number or Name Control Status Figure 3.3 01> > AAAA < < 08 MAMA ALARM Bar Graph Display Table 3.
Chapter 3: Using the CLS200 CLS200 Series User’s Guide Table 3.2 explains the control status symbols on the bottom line of bar graph display. Additional symbols may appear with the ramp/soak option. See Bar Graph Display on page 146. Table 3.2 Control Status Symbols on the Bar Graph and Single Loop Displays Bar Graph Display Symbol Single Loop Display Symbol M MAN One or both outputs are enabled. Loop is in manual control. A AUTO Only one output (heat or cool) is enabled.
CLS200 Series User’s Guide Chapter 3: Using the CLS200 Single Loop Display The single loop display shows detailed information for one loop at a time. Process Variable Loop Number or Name 02 160˚F 180AUTO100 ALARM Setpoint Figure 3.4 Control Status Engineering Units Output Percentage Single Loop Display The control status indicator shows MAN, AUTO or TUNE modes.
Chapter 3: Using the CLS200 CLS200 Series User’s Guide Alarm Displays If a process, deviation, failed or system sensor alarm occurs, the controller switches from any Single Loop display or Bar Graph display to the Single Loop display for the loop with the alarm. The global alarm output turns on and a two-character alarm code appears in the lower left corner of the Single Loop display. If the alarm is for a failed sensor, a short message appears in place of the process variable and units.
CLS200 Series User’s Guide Chapter 3: Using the CLS200 Table 3.3 shows the symbols used in each form of the alarm display. Table 3.3 Alarm Type and Symbols Alarm Code Bar Graph Symbol Alarm Message Alarm Description FS F T/C BREAK Failed Sensor: Break detected in thermocouple circuit. RO F RTD OPEN RTD Open: Break detected in RTD circuit. RS F RTD SHORTED RTD Short: Short detected in RTD circuit. REVERSED TC Reversed Thermocouple: Reversed polarity detected in thermocouple circuit.
Chapter 3: Using the CLS200 CLS200 Series User’s Guide System Alarms When a system alarm occurs, the global alarm output turns on and an alarm message appears on the display. The message continues to be displayed until the error condition is removed and the alarm is acknowledged. The CLS200 can display the following system alarms: • • • • • • BATTERY DEAD See Battery Dead on page 168. LOW POWER See Low Power on page 168. AW See Ambient Warning on page 168.
CLS200 Series User’s Guide Chapter 3: Using the CLS200 Changing the Setpoint Select the single loop display for the loop you want to change. Press CHNG SP. This display appears: 01 SETPOINT ? 25 ° F ALARM Press YES to change the setpoint. • Press the up or down keys (YES or NO) to increase or decrease the setpoint value. Press ENTER to save your changes and return to single loop display. – or – Press NO or BACK (without pressing ENTER) to return to single loop display without saving the new setpoint.
Chapter 3: Using the CLS200 CLS200 Series User’s Guide Go to the next subsection, Manual Output Levels. – or – press NO if in AUTO to cancel and remain in AUTO mode. 4. Select a mode by pressing the up or down key (YES or NO) to scroll through the modes. 5. Press ENTER to make the mode change – or – press BACK to return to the single loop display without saving the new mode setting. 6. If you set the loop to manual, you are prompted for the output power. Go to Manual Output Levels below.
CLS200 Series User’s Guide Chapter 3: Using the CLS200 It must be safe to operate the thermal system, and the approximate desired operating temperature (setpoint) must be known. The technician or engineer performing the autotune should know how to use the controller front panel or MMI software interface (e.g., AnaWin or Anasoft) to do the following: 1. Select a loop to operate and monitor. 2. Set a loop’s setpoint. 3. Change a loop’s control status (MAN, TUNE, AUTO). 4.
Chapter 3: Using the CLS200 CLS200 Series User’s Guide 2. Ensure the loop’s process variable is stable and the loop is in MAN control status. 3. Set the setpoint to a value as near the normal operating temperature as is safe for the system. WARNING! During autotuning, the controller will set the output to 100% until the process variable rises near the setpoint. Set the setpoint within the safe operating limits of your system. 4.
CLS200 Series User’s Guide Chapter 3: Using the CLS200 Failed Sensor Alarms Failed sensor alarms alert you if one of the following conditions occurs: • • • • • Thermocouple open Thermocouple shorted (must be enabled) Thermocouple reversed (must be enabled) RTD open positive input or open negative input RTD short between the positive and negative inputs What Happens if a Failed Sensor Alarm Occurs? If a failed sensor alarm occurs: • • • The controller switches to manual mode at the output power indicat
Chapter 3: Using the CLS200 CLS200 Series User’s Guide Thermocouple Short Alarm The thermocouple short alarm occurs if the process power is on and the temperature does not rise or fall as expected. To enable the thermocouple short alarm, you must do the following: • • Choose a digital input for the PROCESS POWER DIGIN parameter in the SETUP GLOBAL PARAMETERS menu. Connect the digital input to a device that connects the input to controller common when the process power is on.
CLS200 Series User’s Guide Chapter 3: Using the CLS200 What Happens If a Process Alarm Occurs? If a process alarm occurs, the controller does the following: • • • Shows an alarm code on the display. (See Alarm Displays on page 58.) . Activates the global alarm output. (See Global Alarm on page 68.) Activates the digital output that is assigned to the process alarm (if applicable). The digital output remains active until the process variable returns within the corresponding limit and deadband.
Chapter 3: Using the CLS200 CLS200 Series User’s Guide High process alarm on High process alarm off High process alarm set point Setpoint + Deviation alarm value } Deadband High deviation alarm on High deviation alarm off Setpoint } Deadband Low deviation alarm off Setpoint - Deviation alarm value Low deviation alarm on Low process alarm setpoint Low process alarm on Figure 3.
CLS200 Series User’s Guide Chapter 3: Using the CLS200 • A process alarm occurs and is unacknowledged. The global alarm occurs only if the alarm type is set to ALARM in the SETUP LOOP ALARMS menu. (The global alarm does not occur if the alarm function is set to CONTROL.) The global alarm output stays active until all alarms have been acknowledged. When the global alarm output is active, it conducts current to the controller’s dc common.
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4 Setup The setup menus let you change detailed configuration information. This section describes how to set up the controller from menus in the controller firmware.
Chapter 4: Setup CLS200 Series User’s Guide How to Change a Parameter To change a parameter, first select the appropriate menu, then the parameter. When you enter the setup menus, the first menu is SETUP GLOBAL PARAMETERS. Refer to Figure 4.1 for a listing of all top level menus and their related parameters. 1. Select the single loop display for the loop to set up. 2. Enter the three-key sequence. (See How to Access the Setup Menus on page 71.) The first menu is displayed: SETUP GLOBAL PARAMETERS. 3.
CLS200 Series User’s Guide Chapter 4: Setup SETUP GLOBAL PARAMETERS? SETUP LOOP INPUT? SETUP LOOP CONTROL PARAMS? SETUP LOOP OUTPUTS? SETUP LOOP ALARMS? MANUAL I/O TEST LOAD SETUP FROM JOB? INPUT TYPE? HEAT CONTROL PB? HEAT CONTROL OUTPUT? HI PROC ALARM SETPT? DIGITAL INPUTS SAVE SETUP TO JOB? LOOP NAME? HEAT CONTROL TI? HEAT OUTPUT TYPE? HI PROC ALARM TYPE? TEST DIGITAL OUTPUT? JOB SELECT DIG INPUTS? INPUT UNITS? HEAT CONTROL TD? HEAT OUTPUT CYCLE TIME? (TP) HI PROC ALARM OUTPUT? D
Chapter 4: Setup CLS200 Series User’s Guide Setup Global Parameters Menu SETUP GLOBAL PARAMETERS ALARM Table 4.1 shows the parameters available in this menu. Table 4.
CLS200 Series User’s Guide Chapter 4: Setup Load Setup From Job NOTE! Current settings are overwritten when you select a job from memory. Save your current settings to another job number if you want to keep them. Load any one of eight jobs saved in battery-backed RAM. LOAD SETUP FROM JOB? 1 ALARM Selectable values: 1 to 8 The following parameters are loaded for each loop as part of a job: • • • PID constants, filter settings, setpoints and spread values.
Chapter 4: Setup CLS200 Series User’s Guide Job Select Digital Inputs Set the number of job select inputs. The controller uses these inputs as a binary code that specifies the job number to run. The number of inputs you choose in this parameter controls the number of jobs you can select remotely. If you select NONE, digital inputs do not affect job selection. Jobs may be loaded and saved using the LOAD SETUP FROM JOB and SAVE SETUP TO JOB parameters.
CLS200 Series User’s Guide Chapter 4: Setup Job Select Digital Inputs Active Specify which state is considered “true” for the digital inputs used for job selection. Default is LOW, meaning that an input must be pulled low to be considered true. If HIGH is selected, an input will be considered true unless it is pulled low. JOB SEL DIG INS ACTIVE ? LOW ALARM Selectable values: HIGH or LOW. Changing this setting has the effect of reversing the order of the jobs in Table 4.3.
Chapter 4: Setup CLS200 Series User’s Guide You can set the input to be active when low or active when high. When the input selected for OUTPUT OVERRIDE DIG INPUT changes to the specified state, all the loop’s outputs are set to their sensor fail levels. Startup Alarm Delay Set a startup delay for process and deviation alarms for all loops. The controller does not report these alarm conditions for the specified number of minutes after the controller powers up.
CLS200 Series User’s Guide Chapter 4: Setup POWER UP OUTPUT STATUS ? OFF ALARM Selectable values: OFF or MEMORY. Process Power Digital Input To enable the thermocouple short detection feature, select a digital input (1 to 8). Connect the specified input to a device that pulls the input low when the process power is on. A short is indicated when the process power is on and the temperature does not rise as expected.
Chapter 4: Setup CLS200 Series User’s Guide Communications Baud Rate Set the communications baud rate. COMMUNICATIONS BAUD RATE ? 9600 ALARM Selectable values: 9600, 2400 or 19200. NOTE! Set the baud rate to the same speed in both the controller and the HMI software or panel. Communications Protocol Set the communications protocol. Choose the correct protocol for the software or device with which the controller will communicate.
CLS200 Series User’s Guide Chapter 4: Setup AC Line Frequency Specify the ac line frequency. Since the controller reduces the effect of power line noise on the analog measurement by integrating the signal over the period of the ac line frequency, the controller must know the frequency of power in use. You must switch power to the controller off, then back on, to make a change to this parameter take effect. AC LINE FREQ 60 HERTZ ? ALARM Selectable values: 50 or 60 Hz.
Chapter 4: Setup CLS200 Series User’s Guide NOTE! If the EPROM information does not match this description, the EPROM probably contains a custom program. Custom programs may not work as described in this manual. If that is the case, contact your dealer for more information about the firmware. Setup Loop Input Menu SETUP LOOP 01 INPUT ? ALARM The SETUP LOOP INPUT menu includes parameters related to the loop input: • • • • Input type Input units Input scaling and calibration Input filtering Table 4.
CLS200 Series User’s Guide Chapter 4: Setup Input Type Specify the type of input sensor used on this loop: • • • • • Thermocouple type J, K, T, S, R, B or E. RTD 1 or RTD 2. Linear input. Skip (an input type available for unused loops). Alarms are not detected, and the scanning display does not show loops that are set to SKIP. Pulse input (available only for loop 5 on CLS204, loop 9 on CLS208 or loop 17 on CLS216). 01 INPUT TYPE ? J T/C ALARM Selectable values: See Table 4.6. Table 4.
Chapter 4: Setup CLS200 Series User’s Guide Loop Name Assign a two-character name to the loop. This name is shown on the single loop display in place of the loop number. 01 LOOP NAME ? 01 ALARM Selectable values: 0 to 9, A to Z, %, /, ° (degree symbol). Input Units For loops with temperature sensor input types, choose a temperature scale: Fahrenheit or Celsius. For a linear or pulse loop, choose a three-character description of the loop’s engineering units.
CLS200 Series User’s Guide Chapter 4: Setup Table 4.8 Input Reading Offset Offset Range Type of Sensor °F °C RTD2 J K T -300 to +300 -300 to +300 RTD1 -300.0 to +300.0 -300.0 to +300.0 B S -300 to +76 -300 to +300 R -300 to +66 -300 to +300 Reversed T/C Detection Set this parameter to ON to enable polarity checking for thermocouples.
Chapter 4: Setup CLS200 Series User’s Guide Linear Scaling Parameters The following parameters are only available if the input type is LINEAR or PULSE. These parameters let you scale the raw input readings (in millivolts or Hertz) to the engineering units of the process variable. For linear inputs, the input reading is in percent (0 to 100%) representing the 0 to 60mV input range of the controller. For pulse inputs, the input reading is in Hertz (cycles per second.
CLS200 Series User’s Guide Chapter 4: Setup High Process Variabale Process Variable Low Process Variabale Low Reading Figure 4.3 Input Reading High Reading Process Variable Limited by Input Reading Range Display Format Select a display format for a linear or pulse input. Choose a format appropriate for the input range and sensor accuracy. 01 DISP FORMAT ? -999 TO 3000 ALARM Selectable values: The controller has several available display formats, as shown in Table 4.9.
Chapter 4: Setup CLS200 Series User’s Guide High Process Variable Set a high process variable for input scaling purposes. The high process variable and the high reading (HI RDG) together define one of the points on the linear scaling function’s conversion line. Set HI PV to the value you want displayed when the signal is at the level set for the high reading (HI RDG).
CLS200 Series User’s Guide Chapter 4: Setup Low Reading Enter the input signal level that corresponds to the low process variable (LO PV) you entered in the previous parameter. 01 INPUT SCALING LO RDG? 0.0%FS ALARM Selectable values: For linear inputs, any value between -99.9% and 999.9% percent of full scale, where 100% corresponds to 60mV and 0% corresponds to 0mV. For pulse inputs, any value between 0 and 2000 HZ. The low reading must be less than the high reading (HI RDG).
Chapter 4: Setup CLS200 Series User’s Guide Setup Loop Control Parameters Menu Use the SETUP LOOP CONTROL PARAMS menu to adjust heat and cool control parameters, including: • • • Proportional band (PB, or gain), integral (TI or reset), and derivative (TD, or rate) settings Output filter Spread between heat and cool outputs The controller has separate PID and filter settings for heat and cool outputs. The screens used to set these parameters are nearly identical.
CLS200 Series User’s Guide Chapter 4: Setup Heat or Cool Control PB Set the proportional band (also known as gain). A larger value yields less proportional action for a given deviation from setpoint. 01 HEAT CONTROL PB ? 50 ALARM Selectable values: Dependent upon sensor type. The controller internally represents the proportional band (PB) as a gain value.
Chapter 4: Setup CLS200 Series User’s Guide larger value results in a slower, or more dampened, response to changes in the process variable. 01 HEAT CONTROL FILTER ? 3 ALARM Selectable values: 0 to 255. 0 disables the output filter. Spread For a loop using on/off control, the spread is the control hysteresis. This determines the difference between the point at which a heat output turns off as the temperature rises, and the point at which it turns back on as the temperature falls.
CLS200 Series User’s Guide Chapter 4: Setup Setup Loop Outputs Menu Use the SETUP LOOP OUTPUTS menu to: • • • • • • • • Enable or disable outputs Set output type Set cycle time for time proportioning outputs Enter Serial DAC parameters (for Serial DAC outputs) Select control action Set output level limit and limit time Select sensor fail output (output override) Select a nonlinear output curve SETUP LOOP 01 OUTPUTS ? ALARM Table 4.11 shows the parameters available in the SETUP LOOP OUTPUTS menu.
Chapter 4: Setup CLS200 Series User’s Guide Enable or Disable Heat or Cool Outputs Enable or disable the heat or cool output for the loop. If you want the loop to have a control output, you must enable at least one output. You can also disable a heat or cool control output and use the output for something else, such as an alarm. 01 HEAT CONTROL OUTPUT ? ENABLED ALARM Selectable values: ENABLED or DISABLED. Heat or Cool Output Type Select the output type.
CLS200 Series User’s Guide Chapter 4: Setup Heat or Cool Cycle Time Set the cycle time for time proportioning outputs. 01 HEAT OUTPUT CYCLE TIME? 10S ALARM This parameter appears only if the heat or cool output type for the loop is set to time proportioning (TP). Selectable values: 1 to 255 seconds. SDAC Mode Select the Serial DAC output signal. 01 SDAC MODE? VOLTAGE ALARM Selectable values: CURRENT or VOLTAGE. SDAC Low Value Set the low output signal level for the Serial DAC.
Chapter 4: Setup CLS200 Series User’s Guide mA range, set the SDAC HI VALUE to 20.00 MA and the SDAC LO VALUE to 4.00 MA. 01 SDAC HI VALUE? 10.00 VDC ALARM Selectable values: 0.10 to 10.00 VDC or 0.10 to 20.00 mA. This value must be greater than the SDAC LO VALUE. Heat or Cool Output Action Select the control action for the output. Normally, heat outputs are set to reverse action and cool outputs are set to direct action.
CLS200 Series User’s Guide Chapter 4: Setup Sensor Fail Heat or Cool Output When a sensor fail alarm occurs or when the OUTPUT OVERRIDE DIG INPUT (page 77) becomes active on a loop that is in automatic control, that loop goes to manual control at the percent power output set here. 01 SENSOR FAIL HT OUTPUT ? 0% ALARM Selectable values: 0 to 100%. NOTE! When a sensor fails or the override input is detected, both the heat and cool outputs are set to their fail settings.
Chapter 4: Setup CLS200 Series User’s Guide Heat or Cool Linearity Select an output curve. For a nonlinear process, select CURVE 1 or CURVE 2. 01 HEAT OUTPUT? LINEAR ALARM Selectable values: CURVE 1, CURVE 2, or LINEAR. Refer to Figure 4.4. 100 90 80 80 79 Actual Output 70 62 60 60 Linear 40 40 50 48 Curve 1 36 30 20 20 10 3 19 8 2 4 44 Curve 2 29 27 13 66 19 12 7 0 PID Calculation Figure 4.
CLS200 Series User’s Guide Chapter 4: Setup Setup Loop Alarms Menu Use the SETUP LOOP ALARMS menu to set: • • • • • High and low process and deviation alarm limits Alarm outputs Alarm/control behavior Alarm deadband Alarm delay SETUP LOOP 01 ALARMS ? ALARM Table 4.13 shows the parameters available in the SETUP LOOP ALARMS menu. Table 4.
Chapter 4: Setup CLS200 Series User’s Guide High Process Alarm Setpoint Set the value at which the high process alarm activates. 01 HI PROC ALARM SETPT ? 1000 ALARM Selectable values: Any point within the scaled sensor range. High Process Alarm Type Select an alarm type for the high process alarm. 01 HI PROC ALARM TYPE ? OFF ALARM Selectable values: OFF, ALARM, or CONTROL. High Process Alarm Output Number Choose a digital output to activate when the high process alarm occurs, if desired.
CLS200 Series User’s Guide Chapter 4: Setup High Deviation Alarm Type Select an alarm type for the high deviation alarm. 01 HI DEV ALARM TYPE ? OFF ALARM Selectable values: ALARM, CONTROL or OFF High Deviation Alarm Output Number Choose a digital output to activate when the high deviation alarm occurs, if desired. 01 HI DEV ALARM OUTPUT ? NONE ALARM Selectable values: NONE, or any output from 1 to 34 not enabled for closed-loop control or for the Serial DAC clock.
Chapter 4: Setup CLS200 Series User’s Guide Low Process Alarm Setpoint Set a low process alarm setpoint. See Process Alarms on page 66. 01 LO PROC ALARM SETPT? 0 ALARM Selectable values: Any value within the input sensor’s range. Low Process Alarm Type Select an alarm type for the low process alarm. 01 LO PROC ALARM TYPE ? OFF ALARM Selectable values: ALARM, CONTROL or OFF. Low Process Alarm Output Number Choose a digital output to activate when the low process alarm occurs, if desired.
CLS200 Series User’s Guide Chapter 4: Setup Alarm Delay Set a loop alarm delay. This parameter delays failed sensor and process alarms until the alarm condition has been continuously present for longer than the alarm delay time. 01 ALARM DELAY ? 0 SECONDS ALARM Selectable range: 0 to 255 seconds. Manual I/O Test This menu facilitates testing of: • • • Digital inputs Digital outputs The keypad buttons MANUAL I/O TEST ? ALARM Table 4.14 shows the screens available in the MANUAL I/O TEST menu. Table 4.
Chapter 4: Setup CLS200 Series User’s Guide This screen shows the state of inputs 1 to 8 from left to right. See Figure 4.5. Since inputs are pulled high when they are not connected, test an input by shorting it to controller common and making sure this screen shows the correct state for that input. Input 8 DIGITAL INPUTS HHHHHHHH Input 1 ALARM Figure 4.
CLS200 Series User’s Guide Chapter 4: Setup Keypad Test Test the keypad. The test begins automatically when the screen appears. KEYPAD TEST QUIT = "NO"+"NO" ALARM • • Press any key to test the keypad. The controller will display the name of the key you have pressed. Press NO twice to end the test and return to the top of the MANUAL I/O TEST menu. Display Test Use this function to test the display. DISPLAY TEST? ALARM Press YES to enter the test and display the instruction screen.
Chapter 4: Setup 106 CLS200 Series User’s Guide Watlow Anafaze Doc.
5 Extruder Control This chapter explains the additional features for the CLS200 series controller equipped with Extruder Control Firmware. Except for setup, default and control algorithm differences described below, the Extruder Control Firmware operates the same as the standard control firmware. Setup Loop Outputs Menu The SETUP LOOP OUTPUTS menu contains a parameter with descriptors for the selections that are different than those in the standard control firmware.
Chapter 5: Extruder Control CLS200 Series User’s Guide 100 100 90 80 80 Fan 70 66 62 60 Output 60 50 40 Oil 79 48 44 40 36 30 20 20 10 0 0 3 Figure 5.1 19 19 13 8 4 2 29 27 12 7 H2O Calculated by PID Cool Output Nonlinear Output Curve The COOL OUTPUT parameter is located in the SETUP LOOP OUTPUTS menu. Select one of three nonlinear or linear output curves for cooling.
CLS200 Series User’s Guide Chapter 5: Extruder Table 5.1 Default Control Parameters for Fan Cool Output Parameter Default Value HEAT CONTROL PB? 50 (for J-type thermocouple) depends on Input Type setting HEAT CONTROL TI? 500 sec/repeat HEAT CONTROL TD? 125 sec HEAT CONTROL FILTER 6 COOL CONTROL PB? 10 (for J-type thermocouple) depends on Input Type setting COOL CONTROL TI? 0 sec/repeat COOL CONTROL TD? 0 sec COOL CONTROL FILTER? 4 Table 5.
Chapter 5: Extruder Control CLS200 Series User’s Guide Extruder Control Algorithm The Extruder Control Firmware uses a control algorithm that has been optimized for controlling temperature loops in plastic extruder equipment. Typically, overshoot is undesirable and ambient cooling is not sufficient to dampen the effects of self heating that are inherent in the extrusion process. This control method uses both heat and cool outputs.
6 Enhanced Features This chapter explains five additional features for the CLS200 controller when enabled with enhanced features option firmware: • • • • • Doc.
Chapter 6: Enhanced Features SETUP GLOBAL PARAMETERS SETUP LOOP INPUTS CLS200 Series User’s Guide SETUP LOOP CONTROL PARAMETERS SETUP LOOP OUTPUTS SETUP LOOP PV RETRANSMIT SETUP LOOP CASCADE YES YES HEAT OUTPUT RETRANS PV? SETUP LOOP RATIO CONTROL SETUP LOOP ALARMS MANUAL I/O TEST YES CASCADE PRIM.
CLS200 Series User’s Guide Chapter 6: Enhanced Features Process Variable Retransmit The process variable retransmit feature retransmits the process signal of one loop (primary) via the control output of another loop (secondary). This signal is linear and proportional to the engineering units of the primary loop input. Typical uses include data logging to analog recording systems and long distance transmission of the primary signal to avoid degradation of the primary signal.
Chapter 6: Enhanced Features CLS200 Series User’s Guide Retransmit Process Variable Enter the number of the loop that provides the process variable for the retransmit calculation. 02 HEAT OUTPUT RETRANS PV? 02 ALARM If you set this parameter NONE and press NO, the controller skips to the COOL OUTPUT RETRANS PV screen. The COOL parameter is set up the same way as the HEAT parameter. Selectable values: Any loop or NONE. Minimum Input Enter the lowest value of the process variable to be retransmitted.
CLS200 Series User’s Guide Chapter 6: Enhanced Features By adjusting the maximum and minimum inputs, you can scale the output appropriately. See Figure 6.2. Output Power (%) 100% Maximum Output Minimum Output 0% Minimum Input Maximum Input Input Process Variable Figure 6.2 Linear Scaling of Process Variable for Retransmit Maximum Output Enter the output value (0 to 100%) which corresponds to the maximum input.
Chapter 6: Enhanced Features CLS200 Series User’s Guide Loop 1 Input Process Variable Loop 1 PID Output Loop 2 PID Output Furnace CLS200 Heater Serial DAC Power Controller Figure 6.3 To Data Logger Application Using Process Variable Retransmit To set up this application, you would do the following: 116 1. First, set up the standard control loop parameters according to the furnace application, in this case on loop 1. 2.
CLS200 Series User’s Guide Chapter 6: Enhanced Features Table 6.1 Application Example: Setting Up Process Variable Retransmit Display SETUP LOOP 02 PV RETRANSMIT User Input Press YES. ALARM 02 HEAT OUTPUT RETRANS PV? 01 Enter 01 for loop 1 process variable. Press ENTER. ALARM 02 HEAT RETRANS MIN INP? 0 Enter the minimum input value, which corresponds to the minimum output percentage. For a range of 0 to 1000° F, set the minimum input value to 0° F. Press ENTER.
Chapter 6: Enhanced Features CLS200 Series User’s Guide Notes about this application: • • • This is not a thermocouple curve type of signal and requires a linear input range in the recorder. To complete this configuration, the loop 2 output must be enabled and tailored to meet the requirements of the data-application. In this example, the data logger requires an analog input of 4 to 20 mA. The CLS200 Series controllers must be used with a Watlow Anafaze Serial DAC.
Chapter 6: Enhanced Features Secondary Loop’s Setpoint CLS200 Series User’s Guide Maximum SP Base SP an Sp l oo n * C t Spa | r e a ow He t P r| * u utp owe l O ut P o Co tp + | t Ou P a e S |He as Minimum SP + B 100% Cool 0% Heat 100% Primary Loop’s Output (%) Calculation of new secondary loop setpoint: SP2 = Base SP + |Cool Output Power| * Cool Span + |Heat Output Power| * Heat Span Figure 6.
Chapter 6: Enhanced Features CLS200 Series User’s Guide Base Setpoint Enter the setpoint that corresponds to 0% (heat and cool) output from the primary loop (PRIM. LOOP). This value is expressed in the same engineering units as the secondary loop’s process variable. 02 CASCADE BASE SP? 25 ALARM Selectable values: Any value from the secondary loop’s minimum process variable to its maximum process variable. Minimum Setpoint Enter the lowest value of the secondary loop setpoint.
CLS200 Series User’s Guide Chapter 6: Enhanced Features Heat Span Enter the multiplier to apply to the primary loop heat output percentage. 02 CASCADE HT SPAN? +9999 ALARM Selectable values: -9999 to +9999. Cool Span Enter the multiplier to apply to the primary loop cool output percentage. 02 CASCADE CL SPAN? +9999 ALARM Selectable values: -9999 to +9999. Cascade Control Example: Water Tank A tank of water has an inner and outer thermocouple.
Chapter 6: Enhanced Features CLS200 Series User’s Guide To set up this application, you would do the following: 1. Change the display to loop 2, which will be the secondary loop, and then enter the three-key sequence (ENTER, then ALARM ACK, then CHNG SP) and go to the first screen in Table 6.2. 2. Follow the steps in Table 6.2 to configure cascade control. Table 6.
CLS200 Series User’s Guide Chapter 6: Enhanced Features 3. Press BACK several times until the normal loop display appears. The output percentage of loop 1 will now control the setpoint of loop 2. To verify that cascade is working as expected, you would follow these steps: 1. Set loop 1 to MANUAL and the OUTPUT to 0%. Loop 2 setpoint should equal 150 (BASE SP). 2. Adjust loop 1 MANUAL OUTPUT to 50%. Loop 2 setpoint should equal 170 (BASE SP + 50% of HT SPAN) 3. Adjust loop 1 MANUAL OUTPUT to 100%.
Chapter 6: Enhanced Features CLS200 Series User’s Guide even though the temperature near the element may have been at setpoint (150˚ F). With proportional control, when loop 1 is at setpoint, its output is 0%, and the setpoint of loop 2 is equal to the base setpoint (150˚ F). If the temperature of loop 1 drops to 149˚ F, the deviation results in a proportional output of 10%. This times the span of 40˚ F results in an increase in setpoint for loop 2 of 4˚ F. The loop 2 setpoint increases to 154˚ F.
CLS200 Series User’s Guide Chapter 6: Enhanced Features NOTE! Ratio control cannot be used on the same control loop as cascade control. However, both features may be used in the same multiloop controller. Setup Loop Ratio Control Menu The ratio control parameters appear in the SETUP LOOP RATIO CONTROL menu. SETUP LOOP 02 RATIO CONTROL? ALARM Press YES to set up the ratio control parameters with loop number 2 as the ratio loop.
Chapter 6: Enhanced Features CLS200 Series User’s Guide for a higher setpoint. This value is expressed in the same engineering units as the ratio loop’s process variable. 02 RATIO CONTROL MAX SP? 25 ALARM Selectable values: Any value from the minimum value of the ratio loop’s process variable to its maximum value. Control Ratio Enter the multiplier to apply to the master loop’s process variable. 02 RATIO CONTROL CTRL RATIO? 1.0 ALARM Selectable values: 0.1 to 999.9.
CLS200 Series User’s Guide Chapter 6: Enhanced Features KOH Input Water Input Loop 1: Water Flow Control Loop Loop 2: KOH Flow Control Loop Loop 1 Input Process Variable Flow Transducer Loop 1 PID Output Loop 2 Input CLS200 Loop 2 PID Output Process Variable Motorized Control Valve 2 Motorized Control Valve 1 Serial DAC Serial DAC Mixture Output Figure 6.8 Application Using Ratio Control To set up this application, you would do the following: Doc.# 0600-3050-2000 1.
Chapter 6: Enhanced Features CLS200 Series User’s Guide Table 6.3 Application Example: Setting Up Ratio Control Display SETUP LOOP 02 RATIO CONTROL? User Input Press YES to set up the ratio control parameters for loop 02. ALARM 02 RATIO CONTROL MSTR LOOP? 01 Assign loop 01 as the master loop. Press ENTER. ALARM 02 RATIO CONTROL MIN SP? 0.0 Enter the minimum ratio loop setpoint. For this example, we will use 0.0 gallons per second as a minimum. Press ENTER. ALARM 02 RATIO CONTROL MAX SP? 7.
CLS200 Series User’s Guide Chapter 6: Enhanced Features Remote Analog Setpoint The remote analog setpoint is set up identically to ratio control. To provide a setpoint remotely, typically a voltage or current source is connected to an analog input on the controller. This input is configured as a linear input type and the master loop for ratio control. All other input types are also usable as remote analog setpoint inputs.
Chapter 6: Enhanced Features CLS200 Series User’s Guide Table 6.4 Application Example: Setting Up Remote Setpoint Display SETUP LOOP 02 RATIO CONTROL? User Input Press YES to set up the ratio control parameters for loop 2. ALARM 02 RATIO CONTROL MSTR LOOP? 01 Assign loop 01 to be the master loop. Press ENTER. ALARM 02 RATIO CONTROL MIN SP? 0 Enter the minimum ratio loop setpoint. For this example, we will use 0° F. Press ENTER. ALARM 02 RATIO CONTROL MAX SP? 300.
CLS200 Series User’s Guide Chapter 6: Enhanced Features Differential Control Differential control is a simple application of the ratio control option, used to control one process (ratio loop) at a differential, or offset, to another (master loop). To use differential control, set the ratio value to 1.0 to provide the desired offset. Differential Control Example: Thermoforming A thermal forming application requires that the outside heaters operate at a higher temperature than the center heaters.
Chapter 6: Enhanced Features CLS200 Series User’s Guide Table 6.5 Application Example: Setting Up Differential Control Display SETUP LOOP 02 RATIO CONTROL? User Input Press YES to setup the ratio control parameters for loop 2. ALARM 02 RATIO CONTROL MSTR LOOP? 01 Assign loop 01 to be the master loop. Press ENTER. ALARM 02 RATIO CONTROL MIN SP? 300.0 Enter the minimum ratio loop setpoint. For this example, we will use 300.0° F. Press ENTER. ALARM 02 RATIO CONTROL MAX SP? 400.
7 Ramp/Soak This chapter covers setup and operation of ramp/soak profiles in CLS200 series controllers. These features are available in controllers that have the optional ramp/soak firmware installed. The ramp/soak feature turns your controller into a powerful and flexible batch controller. Ramp/soak lets you program the controller to change a process setpoint in a preset pattern over time. This preset pattern, or temperature profile, consists of several segments.
Chapter 7: Ramp/Soak CLS200 Series User’s Guide Features Ramp/soak in the CLS200 includes the following features: • • • • • • • • • • • Ready segment sets loop up for profile: Ready segment can control at setpoint until profile needs to run. Ready segment events set all available event outputs to desired states before profile starts. Up to 20 segments per profile: The controller can store up to 17 profiles, each with up to 20 segments.
CLS200 Series User’s Guide Chapter 7: Ramp/Soak Table 7.1 Ramp/Soak Specifications Number of possible profile Number of times to repeat a profil 1 to 99 or Continuous Number of segments per profil 1 to 20 Number of triggers per segment Up to 2 Type of triggers Number of possible inputs for triggers Number of events per segment Number of possible outputs for events (At least one of these outputs must be used for control) Doc.
Chapter 7: Ramp/Soak CLS200 Series User’s Guide Ramp/Soak Menus The SETUP R/S PROFILES menu appears between the SETUP LOOP ALARMS and MANUAL I/O TEST menus. Figure 7.2 shows the ramp/soak setup menu tree. SETUP GLOBAL PARAMETERS SETUP LOOP INPUTS SETUP LOOP CONTROL PARAMETERS YES SETUP SETUP LOOP PV LOOP RETRANSMIT* OUTPUTS SETUP LOOP ALARMS MANUAL I/O TEST SETUP RAMP/SOAK PROFILE YES RAMP/SOAK TIME BASE EDIT RAMP & SOAK PROFILE? * See Process Variable Retransmit on page 113.
CLS200 Series User’s Guide Chapter 7: Ramp/Soak Setup Global Parameters Menu With the Ramp and Soak option an additional menu appears on the Setup Global Parameters Menu Ramp/Soak Time Base The RAMP/SOAK TIME BASE parameter is in the SETUP GLOBAL PARAMETERS menu. Use this parameter to set the time base in all your ramp/ soak profiles. When set to HOURS/MINS, the setpoint is updated once every minute. When set to MINS/SECS, the setpoint is updated once every second.
Chapter 7: Ramp/Soak CLS200 Series User’s Guide Copy Setup From Profile Set up similar profiles quickly by copying the setup of an existing profile. COPY SETUP FROM PROFILE ? Q ALARM Selectable values: A to Q. Tolerance Alarm Time Set a limit on how long the process variable can be outside the tolerance set for the segment before the tolerance alarm occurs.
CLS200 Series User’s Guide Chapter 7: Ramp/Soak Ready Segment Edit Events Press YES to set or edit the ready state for all outputs that are not used for control or for the Serial DAC clock. When you assign a profile, the controller starts the ready segment: it goes to the setpoint and puts all the outputs in the state you set here. The outputs stay in the states they are set to until their states are changed at the end of subsequent segments.
Chapter 7: Ramp/Soak CLS200 Series User’s Guide Edit Segment Number Each profile is made up of several segments (up to 20). Choose the segment to edit. A EDIT SEGMENT NUMBER? 15 ALARM Selectable values: 1 to 20. The first time you use this parameter, it defaults to segment 1. When you finish editing a segment, the controller goes to the next segment. This loop continues until you make a segment the last segment of a profile. Segment Time Enter the duration of the segment.
CLS200 Series User’s Guide Chapter 7: Ramp/Soak Edit Segment Events You can assign up to four digital outputs, or events, to each segment. When the segment ends, the outputs you select are set to the state you specify. Press YES to select outputs and specify their states. A SEGMENT 5 EDIT SEG EVENTS? ALARM Press NO to advance to the EDIT SEG TRGGRS parameter. NOTE! Events are set at the end of segments. If you want a segment to start with an event, program the event in the previous segment.
Chapter 7: Ramp/Soak CLS200 Series User’s Guide Edit Segment Triggers Each segment may have up to two triggers (digital inputs). Both triggers must be true in order for the segment to run. If a trigger is not true, the profile goes into the trigger wait state. A SEGMENT 15 EDIT SEG TRGGRS? ALARM Press YES to edit triggers for the current segment, or NO to advance to the SEGMENT TOLERANCE parameter. Trigger Input Number Assign a digital input to a segment trigger.
CLS200 Series User’s Guide Chapter 7: Ramp/Soak Trigger Latch Status Choose whether the trigger is latched or unlatched. • A latched trigger is checked once, at the beginning of a segment. An unlatched trigger is checked constantly while a segment is running. If an unlatched trigger becomes false, the segment timer stops and the loop goes into trigger wait state. • When using two triggers with a segment, the following logic applies: Table 7.
Chapter 7: Ramp/Soak CLS200 Series User’s Guide If you enter a negative tolerance, the process goes out of tolerance when the process variable goes below the setpoint minus the tolerance. A SEGMENT 01 SEG TOLERNCE? OFF ALARM Selectable values: -99 to 99, or OFF (no tolerance limit). See Setpoints and Tolerances for Various Input Types on page 144. Last Segment Specify whether the current segment is the last one in the profile. A SEGMENT 01 LAST SEGMENT? NO ALARM Selectable values: NO or YES.
CLS200 Series User’s Guide Chapter 7: Ramp/Soak Table 7.3 Input Type Display Format Thermocouples and RTDs N/A Linear Display Formats Effect on Parameter No decimal shift -999 to 3000 No decimal shift -9999 to 30000 Setting multiplied by 10 -999.9 to 3000.0 No decimal shift; additional tenth in display -99.99 to 300.00 Settings divided by 10 -9.999 to 30.000 Settings divided by 100 -0.9999 to 3.
Chapter 7: Ramp/Soak CLS200 Series User’s Guide Ramp/Soak Displays The single loop and bar graph displays show additional codes when ramp/soak firmware is installed. Single Loop Display When the controller is running a profile, the single loop display shows the ramp/soak mode where it would usually show MAN or AUTO. Table 7.4 describes the modes. Table 7.4 Ramp/Soak Single Loop Display Ramp/Soak Mode Description STRT The profile is in the ready segment RUN The profile is unning.
CLS200 Series User’s Guide Chapter 7: Ramp/Soak Table 7.5 Ramp/Soak Control Status Symbols Ramp/Soak Symbol Description R A profile is unning. H A profile is holding S A profile is in ready stat . O A profile is in tole ance hold. W A profile is in t igger wait. Time Remaining Display From the single loop display, press the RAMP/SOAK key once. This screen shows how much time remains to complete the profile.
Chapter 7: Ramp/Soak CLS200 Series User’s Guide See Running a Profile on page 148 and Holding a Profile or Continuing from Hold on page 150 for instructions on changing the ramp/soak mode. Assigning a Profile to a Loop Use this parameter to assign a profile to a loop. 01 ASSIGN R/S PROFILE? A ALARM Selectable Values: A to Q or NONE Assigning a Profile the First Time To assign a profile to a loop that does not have a profile currently assigned: 1.
CLS200 Series User’s Guide Chapter 7: Ramp/Soak READY segment (segment 0). Use the SET MODE parameter to start a profile (put it in RUN mode). 01 A SEG01/05 R SET MODE? RUN ALARM Starting a Profile You can start a profile only when it is in the READY segment. 1. In the single loop display, switch to the loop you want to start. 2. Press the RAMP/SOAK key three times. The SET MODE parameter appears. 3. Press YES and ENTER to start the profile.
Chapter 7: Ramp/Soak CLS200 Series User’s Guide Holding a Profile or Continuing from Hold Use the SET MODE parameter to select the ramp/soak profile mode. Table 7.6 shows the available modes. Table 7.6 Current Mode Available Mode START RUN HOLD CONT Ramp/Soak Profile Modes Description Begin running the assigned profil . Continue from user-selected hold. The profile uns from the point when you put the profile in HOLD mode. (You cannot continue from a tolerance hold or a trigger wait.
CLS200 Series User’s Guide Chapter 7: Ramp/Soak Responding to a Tolerance Alarm A tolerance can be set for each segment.
Chapter 7: Ramp/Soak CLS200 Series User’s Guide • The controller shows you the ASSIGN R/S PROFILE screen in case you would like to assign a different profile to the loop or select NONE to unassign the profile. In Case of a Power Failure If the power fails or the controller is otherwise powered down while running a ramp/soak profile, by default the profile is set to the START mode when power is restored.
8 Tuning and Control This chapter describes the different methods of control available with the CLS200. This chapter covers control algorithms, control methods, PID control, starting PID values and tuning instructions to help appropriately set control parameters in the CLS200 system. For more information on PID control, consult the Watlow Anafaze Practical Guide to PID. Control Algorithms This section explains the algorithms available for controlling a loop.
Chapter 8: Tuning and Control CLS200 Series User’s Guide On/Off Control On/off control is the simplest way to control a process. The controller turns an output on or off when the process variable reaches limits around the desired setpoint. This limit is adjustable; Watlow Anafaze controllers use an adjustable spread. For example, if the setpoint is 1,000˚ F and the spread is 20˚ F, the heat output switches on when the process variable drops below 980˚ F and off when the process rises above 1,000˚ F.
CLS200 Series User’s Guide Chapter 8: Tuning and Control Setpoint Offset Proportional Band Process Variable Figure 8.2 Proportional Control Proportional and Integral Control With proportional and integral control, the integral term corrects for offset by repeating the proportional band’s error correction until there is no error.
Chapter 8: Tuning and Control CLS200 Series User’s Guide rapidly approaching the setpoint from below, derivative control reduces the output, anticipating that the process variable will reach setpoint. Use it to reduce overshoot and oscillation of the process variable common to PI control. Figure 8.4 shows a process under full PID control. Setpoint Proportional Band Process Variable Figure 8.4 Proportional, Integral and Derivative Control Heat and Cool Outputs Each loop may have one or two outputs.
CLS200 Series User’s Guide Chapter 8: Tuning and Control Control Outputs The controller provides open collector outputs for control. These outputs normally control the process using solid state relays. Open collector outputs can be configured to drive a serial digital-to-analog converter (Serial DAC) which, in turn, can provide 0 to 5 VÎ (dc), 0 to 10 VÎ (dc) or 4 to 20 mA control signals to operate field output devices.
Chapter 8: Tuning and Control CLS200 Series User’s Guide Distributed Zero Crossing (DZC) With DZC outputs, the PID algorithm calculates an output between 0 and 100%, but the output is distributed on a variable time base. For each ac line cycle, the controller decides whether the power should be on or off. There is no fixed cycle time since the decision is made for each line cycle.
CLS200 Series User’s Guide Chapter 8: Tuning and Control Reverse and Direct Action With reverse action an increase in the process variable causes a decrease in the output. Conversely, with direct action an increase in the process variable causes an increase in the output. Heating applications normally use reverse action and cooling applications usually use direct action.
Chapter 8: Tuning and Control CLS200 Series User’s Guide Integral Settings The controller’s integral parameter (TI) is set in seconds per repeat. Some other products use an integral term called reset, in units of repeats per minute. Table 8.2 shows integral settings versus reset settings. Table 8.2 Integral Term and Reset Settings Integral (Seconds/Repeat) Reset (Repeats/Minute) Integral (Seconds/Repeat) Reset (Repeats/Minute) 30 45 60 90 120 150 180 2.0 1.3 1.0 0.66 0.50 0.40 0.
CLS200 Series User’s Guide Chapter 8: Tuning and Control NOTE! While the basic PID algorithm is well defined and widely recognized, various controllers implement it differently. Parameters may not be taken from one controller and applied to another with optimum results even if the above unit conversions are performed. General PID Constants by Application This section gives PID values for many applications. They are useful as control values or as starting points for PID tuning.
Chapter 8: Tuning and Control CLS200 Series User’s Guide Table 8.
9 Troubleshooting and Reconfiguring When There is a Problem The controller is only one part of your control system. Often, what appears to be a problem with the controller is really a problem with other equipment, so check these things first: • • NOTE! Controller is installed correctly. (See Chapter 2, Installation for help.) Sensors, such as thermocouples and RTDs, are installed correctly and working.
Chapter 9: Troubleshooting and Reconfiguring CLS200 Series User’s Guide If you are certain the installation is correct, you can try replacing the controller. If the second unit works correctly, then the problem is specific to the controller you replaced. Returning Your Unit Before returning a controller, contact your supplier or call Watlow for technical support. Controllers purchased as part of a piece of equipment must be serviced or returned through the equipment manufacturer.
CLS200 Series User’s Guide Chapter 9:Troubleshooting and Reconfiguring Responding to Process and Deviation Alarms In a heating application, a low process or low deviation alarm may indicate one of the following: • • • • • • • NOTE! The heater has not had time to raise the temperature. The load has increased and the temperature has fallen. The control status is set to manual instead of automatic. The heaters are not working due to a hardware failure.
Chapter 9: Troubleshooting and Reconfiguring CLS200 Series User’s Guide Failed Sensor Alarms When a failed sensor alarm occurs, the controller switches to the single loop display for the loop with the alarm and displays an alarm code on the screen. AnaWin or WatView displays a message on the alarm screen and logs the alarm in the event log. Table 9.3 Failed Sensor Alarm Codes Alarm Code Description FS Failed Sensor Open thermocouple.
CLS200 Series User’s Guide Chapter 9:Troubleshooting and Reconfiguring Other Behaviors The following table indicates potential problems with the system or controller and recommends corrective actions. Table 9.
Chapter 9: Troubleshooting and Reconfiguring CLS200 Series User’s Guide Corrective and Diagnostic Procedures The following sections detail procedures you may use to diagnose and correct problems with the controller. Low Power If the controller displays LOW POWER or the display is not lit: 1. Acknowledge the alarm. 2. If the error message remains, turn the power to the controller off, then on again. 3. If the error message returns, check that the power supplied to the controller is at least 12.
CLS200 Series User’s Guide Chapter 9:Troubleshooting and Reconfiguring range of 23 to 32° F or 122 to 131° F (-5 to 0° C or 50 to 55° C). The operating limits are 32 to 122° F (0 to 50° C). If the controller displays AW in the lower left corner of the display: 1. Acknowledge the alarm. 2. If the error message remains, check the ambient air temperature near the controller. Adjust ventilation, cooling or heating to ensure that the temperature around the controller is 32 to 122° F (0 to 50° C).
Chapter 9: Troubleshooting and Reconfiguring NOTE! CLS200 Series User’s Guide a) Turn the power to the controller off. b) Remove the boards from the CLS200 housing. c) Reseat the boards and turn power on. 5. If the error persists, make a record of the settings, then perform a NO-key reset. See NO-Key Reset on page 176. 6. If the error is not cleared, contact your supplier for further troubleshooting guidelines. See Returning Your Unit on page 164.
CLS200 Series User’s Guide Chapter 9:Troubleshooting and Reconfiguring Checking Analog Inputs If the process variable displayed in the software and on the controller do not agree: 1. Verify that the controller is communicating. 2. If the process variable indicated on the controller display is incorrect: 3. NOTE! a) Verify that you have selected the correct input type for the affected loops. b) Verify that sensors are properly connected.
Chapter 9: Troubleshooting and Reconfiguring CLS200 Series User’s Guide Earth Grounding If you suspect a problem with the ac ground or a ground loop: • • • Measure for ac voltage between ac neutral and panel chassis ground. If ac voltage above 2VÅ (ac) is observed, then there may be a problem with the ac power wiring. This should be corrected per local electrical codes. With ac power on, measure for ac voltage that may be present between control panels’ chassis grounds.
CLS200 Series User’s Guide Chapter 9:Troubleshooting and Reconfiguring Testing Control Output Devices Connect the solid state relay (SSR) control terminals to the CLS200 control output and connect a light bulb (or other load that can easily be verified) to the output terminals on the SSR. Put the loop in manual mode and set the output to 100%. The ac load should turn on. Do not attempt to measure ac voltage at the SSR’s output terminals.
Chapter 9: Troubleshooting and Reconfiguring CLS200 Series User’s Guide 3. Restore power to the controller. 4. Go to the DIGITAL INPUTS parameter in the MANUAL I/O TEST menu. This parameter shows whether the digital inputs are H (high, or open) or L (low, or closed). 5. Attach a wire to the terminal of the digital input to test. When the wire is connected only to the digital input terminal, the DIGITAL INPUTS parameter should show that the input is H (high).
CLS200 Series User’s Guide Chapter 9:Troubleshooting and Reconfiguring Communications Most communications problems are due to incorrect wiring or incorrectly set communications parameters. Therefore, when there is a problem, check the wiring and communications settings first. Verify the following: • • • • • • • • Communications port: Software must be configured to use the communications port to which the controller is connected.
Chapter 9: Troubleshooting and Reconfiguring CLS200 Series User’s Guide Software Problems If the controller and serial communications connections seem to be working correctly, but you are still not getting the result you expect, consult the resources you have available for the software program you are using. WatView, AnaWin or Anasoft Consult the AnaWin or Anasoft User’s Guide for help with the user interface. WatView comes with a context-sensitive help explaining operation of the software.
CLS200 Series User’s Guide Chapter 9:Troubleshooting and Reconfiguring CAUTION! The EPROM and other components are sensitive to damage from electrostatic discharge (ESD). To prevent ESD damage, use an ESD wrist strap or other antistatic device. NOTE! Replacing the EPROM with another version results in full erasure of RAM. Make a record of all parameters before changing the EPROM. 1. Make a record of system parameters. 2. Power down the controller. 3.
Chapter 9: Troubleshooting and Reconfiguring CLS200 Series User’s Guide WA TL OW AN AF AZ EC LS Figure 9.2 6. 20 0 Screws Locations on PC Board Locate the EPROM on the circuit board. The EPROM is a 32-pin socketed chip that is labeled with the model, version and checksum. EPROM Detail EPROM U2 Pin 1 MP SRAM Notch Figure 9.3 7. EPROM Location Remove the existing EPROM from its socket with an IC extraction tool or a jeweler’s flathead screwdriver. Figure 9.4 Remove EPROM 8.
CLS200 Series User’s Guide Chapter 9:Troubleshooting and Reconfiguring Changing Communications To switch between EIA/TIA-232 and EIA/TIA-485, change the jumpers as shown in Figure 9.5. JU1 JU2 JU3 JU4 JU5 A A B Configured for EIA/TIA-232 Figure 9.5 A B Configured for EIA/TIA-485 B Last controller in system configured for EIA/TIA-485 Jumper Configurations You will need tweezers and a Phillips head screwdriver to switch between EIA/TIA-232 and EIA/TIA-485. Follow these steps: Doc.
Chapter 9: Troubleshooting and Reconfiguring CLS200 Series User’s Guide Installing Scaling Resistors Resistors are installed for all inputs on the CLS200. Inputs with signal ranges between -10 and +60 mV use 0 Ω resistors in the RC position only. All other input signals require special input scaling resistors. CAUTION! Scaling resistors are soldered to the circuit board. Only qualified technicians should attempt to install or remove these components.
CLS200 Series User’s Guide Chapter 9:Troubleshooting and Reconfiguring RC (Voltage) + IN+ RP Internal +5VÎ (dc) Reference Analog Input Terminal RD RC (RTD) IN- RP To CLS200 Circuitry - Com Figure 9.6 CLS204 and CLS208 Input Circuit CLS204 and CLS208 Current Inputs For each current input on a CLS204 or CLS208 controller you must install a resistor. The value of the resistor must be correct for the expected input range. Install the resistor in the listed resistor pack (RP) location.
Chapter 9: Troubleshooting and Reconfiguring CLS200 Series User’s Guide CLS204 and CLS208 Voltage Inputs For each voltage input on a CLS204 and CLS208 controller you must install two resistors. The resistances must be correct for the expected input range. Note the resistor pack (RP) locations have three through holes. Install the RD resistor as indicated in the illustration below. Table 9.
CLS200 Series User’s Guide Chapter 9:Troubleshooting and Reconfiguring CLS204 and CLS208 RTDs and Thermistors For each RTD or thermistor input on a CLS204 or CLS208 controller, you must install three resistors: RA, RB, and RC. The resistance must be correct for the expected input range. RA and RB are a matched pair of resistors. Install them in the resistor pack (RP) locations as shown in the illustration below. Table 9.
Chapter 9: Troubleshooting and Reconfiguring CLS200 Series User’s Guide CLS216 Input Circuit The CLS216 can accept single-ended thermocouple, mVÎ (dc), VÎ (dc) and mAÎ (dc) inputs. Unless ordered with special inputs, the controller accepts only signals within the standard range of -10 to 60mVÎ (dc). To accommodate other signals, the input circuit must be modified. When configured for thermocouple inputs, 0 Ω resistors are installed in all RC locations.
CLS200 Series User’s Guide Chapter 9:Troubleshooting and Reconfiguring Table 9.13 Resistor Locations for CLS216 Current Inputs Loop Resistor Location RD Loop Resistor Location RD 1 R42 9 R41 2 R40 10 R39 3 R38 11 R37 4 R36 12 R35 5 R34 13 R33 6 R32 14 R31 7 R30 15 R29 8 R28 16 R27 CLS216 Voltage Inputs For each voltage input on a CLS216 controller, you must install two resistors. The resistance must be correct for the expected input range.
Chapter 9: Troubleshooting and Reconfiguring CLS200 Series User’s Guide Table 9.
CLS200 Series User’s Guide Chapter 9:Troubleshooting and Reconfiguring A N A FA D L +5V IN DZC IN +10-24V IN V OUT I SINK OUT COM 1 C A D ZE A U C A D 1 C A D 2 3 4 +5V IN DZC IN +10-24V IN V OUT I SINK OUT COM 6 2 5 1 2 3 4 5 6 Figure 9.8 Dual DAC Table 9.
Chapter 9: Troubleshooting and Reconfiguring CLS200 Series User’s Guide 5. If necessary, remove the two mounting screws holding the loosened end plate in place. 6. Slide the board out of the housing. 7. Set the jumpers for the two outputs as desired. See Table 9.16. 8. Replace the board such that the connectors extend through the opposite end plate. The board fits in the third slot from the bottom. 9. Reconnect the two terminal blocks to the DAC1 and DAC2 connectors. 10.
10 Linear Scaling Examples This chapter provides three linear scaling examples. The examples describe: • • • A pressure sensor generating a 4 to 20 mA signal A flow sensor generating a 0 to 5V signal A pulse encoder generating 900 pulses per inch of movement Example 1: A 4-to-20 mA Sensor Situation A pressure sensor that generates a 4 to 20 mA signal is connected to the controller. The specifications of the sensor state it generates 4 mA at 0.0 pounds per square inch (PSI) and 20 mA at 50.0 PSI.
Chapter 10: Linear Scaling Examples CLS200 Series User’s Guide Table 10.1 Input Readings Process Variable Displayed Sensor Input Reading, Percent of Full Scale (%FS) 50.0 PSI 20 mA 100%FS 0.0 PSI 4 mA 100% x (4 mA/20 mA) = 20%FS The scaling values setup in the SETUP LOOP INPUT menu are shown in Table 10.2 . Table 10.2 Scaling Values Parameter 190 Prompt Value High Process Variable HIGH PV 50.0 PSI High Sensor Reading HIGH RDG 100.
CLS200 Series User’s Guide Chapter 10: Linear Scaling Examples Example 2: A 0-to-5VÎ (dc) Sensor Situation A flow sensor connected to the controller measures the flow in a pipe. The sensor generates a 0 to 5V signal. The sensor’s output depends on its installation. Independent calibration measurements of the flow in the pipe indicate that the sensor generates 0.5V at three gallons per minute (GPM) and 4.75V at 65 GPM. The calibration instruments are accurate to within 1 gallon per minute.
Chapter 10: Linear Scaling Examples CLS200 Series User’s Guide Example 3: A Pulse Encoder Situation A pulse encoder which measures the movement of a conveyor is connected to the controller. The encoder generates 900 pulses for every inch the conveyor moves. You want to measure conveyor speed in feet per minute (FPM). Setup The encoder input is connected to the controller’s pulse input. The INPUT TYPE for the loop is set to PULSE. A onesecond sample time gives adequate resolution of the conveyor’s speed.
11 Specifications This chapter contains specifications for the CLS200 series controllers, TB50 terminal board, Dual DAC module, Serial DAC module and the CLS200 power supply. CLS200 System Specifications This section contains CLS200 series controller specifications for environmental specifications and physical dimensions, inputs, outputs, the serial interface and system power requirements. The controller described consists of a processor module and a 50-terminal block (TB50). Table 11.1 Doc.
Chapter 11: Specifications CLS200 Series User’s Guide CLS200 Processor Physical Specifications Table 11.2 Environmental Specifications Storage Temperature -20 to 60° C Operating Temperature 0 to 50° C Humidity 10 to 95% non-condensing Environment The controller is for indoor use only Table 11.3 Physical Dimensions Weight 1.98 lbs 0.9 kg Length* 8.0 inches 203 mm Width 3.78 inches 96 mm Height 1.96 inches 50 mm * Without SCSI connector or with TB18 option. 3.78 in. (96 mm) 1.
CLS200 Series User’s Guide Chapter 11: Specifications Table 11.4 Processor with Straight SCSI Length 9.6 inches 244 mm Width 3.78 inches 96 mm Height 1.96 inches 50 mm 1.0 in. 7.0 in. (178 mm) (25 mm) 1.6 in. (41 mm) 1.96 in. (50 mm) Figure 11.2 CLS200 Clearances with Straight SCSI Cable Table 11.5 1.0 in. (25 mm) Processor with Right Angle SCSI Length 8.6 inches 218 mm Width 3.78 inches 96 mm Height 1.96 inches 50 mm 7.0 in. (178 mm) 0.60 in. (15 mm) 1.96 in.
Chapter 11: Specifications CLS200 Series User’s Guide Table 11.6 Processor Connections Power Terminals (TB2) Captive screw cage clamp Power Wire Gauge (TB2) 22 to 18 AWG (0.5 to 0.75 mm2) Power Terminal Torque (TB2) 4.4 to 5.3 in-lb. (0.5 to 0.6 Nm) Sensor Terminals (TB1) Captive screw cage clamp Sensor Wire Gauge (TB1) Thermocouples: 20 AWG (0.5 mm2) Linear: 22 to 20 AWG (0.5 mm2) Communications: 24 AWG (0.2 mm2) Sensor Terminal Torque (TB1) 4.4 to 5.3 in-lb. (0.5 to 0.
CLS200 Series User’s Guide Chapter 11: Specifications 4.1 in. (104 mm) 4.0 in. (102 mm) 1.5 in. (37 mm) Figure 11.4 TB50 Dimensions Table 11.8 TB50 Connections Screw Terminal Torque 4.4 to 5.3 in-lb. (0.5 to 0.6 Nm) SCSI Connector on Board SCSI-2 female Output Terminals Captive screw cage clamp Output Wire Gauge Output Terminal Torque Doc.# 0600-3050-2000 Watlow Anafaze Multiconductor cables: 24 AWG (0.2 mm2) Single-wire: 22 to 18 AWG (0.5 to 0.75 mm2) 4.4 to 5.3 in-lb. (0.5 to 0.
Chapter 11: Specifications CLS200 Series User’s Guide Table 11.9 TB50 with Straight SCSI Length 6.4 inches 163 mm Width 4.0 inches 102 mm Height 1.5 inches 37 mm 6.4 in. (163 mm) 4.0 in. (102 mm) 1.5 in. (37 mm) Figure 11.5 TB50 Dimensions with Straight SCSI Cable 198 Watlow Anafaze Doc.
CLS200 Series User’s Guide Chapter 11: Specifications Table 11.10 TB50 with Right Angle SCSI Length 5.4 inches 137 mm Width 4.0 inches 102 mm Height 1.5 inches 37 mm 5.4 in. (137 mm) 4.0 in. (102 mm) 1.5 in. (37 mm) Figure 11.6 TB50 Dimensions with Right-Angle SCSI Cable Doc.
Chapter 11: Specifications CLS200 Series User’s Guide Inputs The controller accepts analog sensor inputs which are measured and may be used as feedback for control loops. It also accepts digital (TTL) inputs which may be used to trigger certain firmware features. Table 11.
CLS200 Series User’s Guide Chapter 11: Specifications Table 11.12 Pulse Inputs Parameter Description Number 1 Frequency Range 0 to 2,000 Hz Input Voltage Protection Diodes to supply and common Voltage Levels <1.3V: Low >3.7V: High (TTL) Maximum Switch Resistance to Pull Input Low 2 kΩ Minimum Switch Off Resistance 30 kΩ Table 11.
Chapter 11: Specifications CLS200 Series User’s Guide Table 11.15 Input Resistance for Voltage Inputs Range Input Resistance 0 to 12V 85 kΩ 0 to 10V 50 kΩ 0 to 5V 40 kΩ 0 to 1V 7.4 kΩ 0 to 500mV 6.2 kΩ 0 to 100mV 1.2 kΩ Table 11.16 Digital Inputs Parameter Description Number 8 Configu ation 8 selectable for output override, remote job selection Input Voltage Protection Diodes to supply and common. Source must limit current to 10 mA for override conditions Voltage Levels <1.
CLS200 Series User’s Guide Chapter 11: Specifications Analog Outputs No direct analog outputs are provided. The digital outputs may be used in conjunction with Dual DAC or Serial DAC modules to provide analog signals. See Dual DAC Specifications on page 207 and Serial DAC Specifications on page 209. Digital Outputs Table 11.
Chapter 11: Specifications CLS200 Series User’s Guide Table 11.19 5VÎ (dc) Output (Power to Operate Solid-State Relays) Parameter Description Voltage 5VÎ (dc) Maximum Current 350 mA Table 11.20 Reference Voltage Output (Power to Operate Bridge Circuit Sensors) Parameter Description Voltage 5VÎ (dc) Maximum Current 100 mA Table 11.
CLS200 Series User’s Guide Chapter 11: Specifications CLS200 Power Supply Complete specifications for the CLS200 power supply are available at www.watlow.com. See the links on the CLS200 page. Doc.
Chapter 11: Specifications CLS200 Series User’s Guide 0.7 inch (18 mm) 8.1 inches with mounting bracket (206 mm) 7.5 inches (191 mm) 3.9 inches (99 mm) 0.3 inch (8 mm) 1.4 in (36 mm) 6.9 inches (175 mm) 0.19 (3/16) inch diameter (5 mm) Figure 11.7 Power Supply Dimensions (Bottom View) Table 11.27 Power Supply Inputs Voltage 120/240Vı (ac) at 0.75 A, 50/60 Hz Table 11.28 Power Supply Outputs 206 Voltage V1 5VÎ (dc) @ 4 A Voltage V2 15 VÎ (dc) @ 1.2 A Watlow Anafaze Doc.
CLS200 Series User’s Guide Chapter 11: Specifications Dual DAC Specifications The Watlow Anafaze Dual DAC (digital-to-analog converter) is an optional module for the CLS200 series controller. The Dual DAC converts a distributed zero crossing (DZC) output signal to an analog process control signal. Watlow Anafaze provides the following version of the Dual DAC: • 4 to 20 mA dc • 0 to 5VÎ (dc) • 0 to 10VÎ (dc) Table 11.
Chapter 11: Specifications CLS200 Series User’s Guide Dual DAC Inputs The Dual DAC accepts an open-collector signal from the CLS200 controller and the power from an external power supply. See Table 11.31. Table 11.31 Dual DAC Power Requirements Parameter Description Voltage 12 to 24VÎ (dc) Current 100 mA @ 15VÎ (dc) Dual DAC Analog Outputs Table 11.32 Dual DAC Specifications by Output Range Version 4-20 mA 0-5 V ±6 ±6 ± 0.75 ± 0.75 ± 0.75 % of full scale range 1.6 1.6 1.
CLS200 Series User’s Guide Chapter 11: Specifications Serial DAC Specifications Watlow Anafaze offers a Serial DAC for precision open-loop analog outputs. The Serial DAC is jumper-selectable for a 0 to 10VÎ (dc) or 4 to 20 mA output. Multiple Serial DAC modules can be used with one CLS200. The Serial DAC carries a CE mark. Table 11.33 Serial DAC Environmental Specifications Storage Temperature -20 to 60° C Operating Temperature 0 to 70° C Humidity 10 to 95% non-condensing Table 11.
Chapter 11: Specifications CLS200 Series User’s Guide Table 11.35 Serial DAC Agency Approvals / Compliance CE Directive Electromagnetic Compatibility (EMC) directive 89/336/EEC UL and C-UL UL 916 Standard for Energy Management Equipment File E177240 Serial DAC Inputs The Serial DAC requires a proprietary serial data signal and the clock signal from the CLS200 via the TB50. Any control output can be configured to provide the data signal. The Serial DAC also requires a 5VÎ (dc) power input. Table 11.
CLS200 Series User’s Guide Chapter 11: Specifications Serial DAC Analog Outputs Table 11.38 Serial DAC Analog Output Specifications Parameter Description Absolute Maximum Common Mode Voltage Measured between output terminals and controller common: 1,000V Resolution 15 bits (plus polarity bit for voltage outputs) (0.305mV for 10V output range) (0.00061 mA for 20 mA output range) Accuracy (Calibrated for Voltage Output) For voltage output: ± 0.005V (0.
Chapter 11: Specifications 212 CLS200 Series User’s Guide Watlow Anafaze Doc.
CLS200 Series User’s Guide Glossary Glossary system. American Wire Gauge (AWG) A standard of the dimensional characteristics of wire used to conduct electrical current or signals. AWG is identical to the Brown and Sharpe (B&S) wire gauge. A AC See Alternating Current. AC Line Frequency The frequency of the AC power line measured in Hertz (Hz), usually 50 or 60 Hz. Accuracy Closeness between the value indicated by a measuring instrument and a physical constant or known standards.
Glossary CLS200 Series User’s Guide C Calibration The comparison of a measuring device (an unknown) against an equal or better standard. Celsius (Centigrade) Formerly known as Centigrade. A temperature scale in which water freezes at 0˚C and boils at 100˚C at standard atmospheric pressure. The formula for conversion to the Fahrenheit scale: ˚F = (1.8 x ˚C) + 32.
CLS200 Series User’s Guide Glossary A set of technical, scientific and dimensional standards developed in Germany. Many DIN standards have worldwide recognition. Deviation Alarm Warns that a process has exceeded or fallen below a certain range around the setpoint. Digital-to-Analog Converter (DAC) A device that converts a numerical input signal to a signal that is proportional to the input in some way. body at the same temperature.
Glossary CLS200 Series User’s Guide time, usually measured in cycles per second. Also referred to as Hertz (Hz). The reciprocal is called the period. G Gain The amount of amplification used in an electrical circuit. Gain can also refer to the Proportional (P) mode of PID. Global Alarm Alarm associated with a global digital output that is cleared directly from a controller or through a user interface.
CLS200 Series User’s Guide Glossary Linearity The deviation in response from an expected or theoretical straight line value for instruments and transducers. also called linearity error. Liquid Crystal Display (LCD) A type of digital display made of a material that changes reflectance or transmittance when an electrical field is applied to it. Load The electrical demand of a process, expressed in power (watts), current (amps) or resistance (ohms). The item or substance that is to be heated or cooled.
Glossary CLS200 Series User’s Guide proportioning, distributed zero crossing, Serial DAC or analog. Also the description of the electrical hardware that makes up the output. Overshoot The amount by which a process variable exceeds the setpoint before it stabilizes. R Ramp A programmed increase in the temperature of a setpoint system. P Range The area between two limits in which a quantity or value is measured. It is usually described in terms of lower and upper limits.
CLS200 Series User’s Guide Glossary limits of a range expressed in the same units as the range. temperature coefficient. Reverse Action An output control action in which an increase in the process variable causes a decrease in the output. Heating applications usually use reverse action. Stability The ability of a device to maintain a constant output with the application of a constant input. RTD See Resistance Temperature Detector.
Glossary CLS200 Series User’s Guide U Upscale Break Protection A form of break detection for burned-out thermocouples. Signals the operator that the thermocouple has burned out. Undershoot The amount by which a process variable falls below the setpoint before it stabilizes. V Volt (V) The unit of measure for electrical potential, voltage or electromotive force (EMF). See also Voltage. Voltage (V) The difference in electrical potential between two points in a circuit.
CLS200 Series User’s Guide Index A A control status symbol 56 AC LINE FREQ default value 74 description 81 location 73, 233 agency compliance controller 193 power supply 205 Serial DAC 210 ALARM ACK key acknowledging alarms 59–60 description 54 does not work 170 ALARM DEADBAND default value 99 description 102 location 73, 233 ALARM DELAY default value 99 description 103 location 73, 233 location of 64 Alarm High SP parameter 67 Alarm Low SP parameter 67 alarms acknowledging 59–60 alarm high, see process al
Index CLS200 Series User’s Guide CASCADE MIN SP description 120 location 112, 233 CASCADE PRIM.
CLS200 Series User’s Guide COOL OUTPUT LIMIT description 96 location 73, 233 COOL OUTPUT LIMIT TIME description 96 location 73, 233 COOL OUTPUT RETRANS PV description 114 location 112, 233 COOL OUTPUT TYPE description 94 location 73, 233 cool output, see control outputs COOL RETRANS MAX INP description 114 location 112, 233 COOL RETRANS MAX OUT% description 115 location 112, 233 COOL RETRANS MIN INP description 114 location 112, 233 COOL RETRANS MIN OUT% description 114 location 112, 233 COOL T/C BRK OUT A
Index CLS200 Series User’s Guide E earth, see ground EDIT RAMP & SOAK PROFILE description 137 location 136, 233 EDIT SEGMENT NUMBER description 140 location 136, 233 EIA/TIA-232 45–46 connections 46 jumper configurations 179 jumpers in connectors 46 specifications 204 troubleshooting 174–175 see also communications EIA/TIA-485 47–49 EIA/TIA-232-to-485 converter 47, 49 jumper configurations 179 network connections 47–48 signal common 48 specifications 204 termination 48 troubleshooting 175 see also communi
CLS200 Series User’s Guide HEAT OUTPUT LIMIT default value 93 description 96 location 73, 233 HEAT OUTPUT LIMIT TIME default value 93 description 96 location 73, 233 HEAT OUTPUT RETRANS PV description 114 location 112, 233 HEAT OUTPUT TYPE default value 93 description 94 location 73, 233 heat output, see control outputs HEAT RETRANS MAX INP description 114 location 112, 233 HEAT RETRANS MAX OUT% description 115 location 112, 233 HEAT RETRANS MIN INP description 114 location 112, 233 HEAT RETRANS MIN OUT% d
Index control output wiring 37 controller 13–16 CPU watchdog timer 38 digital output wiring 35–36 Dual DAC 19–20 environment 12 ground loops, see ground loops location 12 noise suppression, see noise overview 11 panel hole dimensions 15 panel thickness 15 power supply 18–19, 25–27 reference voltage terminals 32 sensor input wiring 29–34 Serial DAC 19–20 TB50 16–18, 27 testing 28–29 tie-wrapping cables 35 tools 13 torque for screw terminals 26 typical 12 wire recommendations 21, 30, 35, 47 wire sizes 22 wir
CLS200 Series User’s Guide Index number available 200 ramp/soak profiles, see ramp/soak 148 single loop display, see single loop display tuning 159–161 low deviation alarm, see process alarms LOW POWER 166, 168 LP alarm code 164 M M control status symbol 56 MAN 56, 61 MAN/AUTO CONTROL OUTPUTS DISABLED 61 MAN/AUTO key 54 does not work 170 locking and unlocking 78 switching control statuses 61 manual control selecting 61 setting the output level 62 MANUAL I/O TEST 103 location 73, 233 parameters in menu 10
Index CLS200 Series User’s Guide power supply dimensions 205–206 dimensions of mounting bracket 19 for Dual DAC 43 inputs 206 mounting 18–19 outputs 206 powering loads with 36 requirements 18 specifications 205–206 wiring 25–27 POWER UP OUTPUT STATUS default value 74 description 78 effect on ramp/soak profiles 152 location 73, 233 process alarms alarm high 67 alarm low 67 boost output 67 function 67 high deviation 68 low deviation 68 outputs 67 setting up 66 PROCESS POWER DIGIN default value 74 descriptio
CLS200 Series User’s Guide Index location 136, 233 Ref terminals, see reference voltage reference voltage 32, 204 remote analog setpoint, see ratio control repair, returning controller for 164 REPEAT CYCLES description 144 location 136, 233 reset external 139 integral, see integral NO-key reset 176 RESET PROFILE 148 RESET WITH DEFAULTS 176 RESTORE PID DIGIN default value 90 description 92 location 73, 233 RestoreAuto parameter 66 retransmit, see process variable retransmit returning the controller 164 rev
Index Sensor Fail Heat Output parameter and failed sensor alarm 65 SENSOR FAIL HT OUTPUT and output override feature 77 and reversed thermocouple detection 85 and thermocouple short detection 79 default value 93 description 97 location 73, 233 values 97 sensor inputs engineering units 84 failed sensor alarms 166 filter 89 offset 84 ranges 83 specifications 200 troubleshooting 171 type, setting 83 wiring 29–34 Serial DAC agency compliance 210 clock input 210 configuring outputs 188 configuring the controlle
CLS200 Series User’s Guide Index TD, see derivative temperature incorrect on display 167, 171 operating 194, 205, 207, 209 storage 194, 205, 207, 209 terminal specifications controller 196 TB50 197 TEST DIGITAL OUTPUT default value 103 description 104 location 73, 233 testing TB18 after installation 28 TB50 after installation 28 see also troubleshooting thermistor inputs, scaling resistors for 183 Thermocouple Short Alarm parameter 66 thermocouples accuracy 201 ground loops 31 manual mode if break occurs
Index 232 CLS200 Series User’s Guide Watlow Anafaze Doc.
Menu Structure SETUP GLOBAL PARAMETERS (p. 74) SETUP LOOP INPUT (p. 82) SETUP LOOP CONTROL PARAMS (p. 90) SETUP LOOP OUTPUTS (p. 93) SETUP LOOP ALARMS (p. 99) MANUAL I/O TEST (p.
Declaration of Conformity Declaration of Conformity CLS200 Series WATLOW ANAFAZE 314 Westridge Drive Watsonville, California 95076 USA Declares that the following product: English Designation: CLS200 Series Model Number(s): 2 (04, 08 or 16) - (1,2,3 or 4) (0,1 or 2) (0 or 2) (0,1,2 or 3) (0,1,2 or 3) (0,1, or 2) (1 or 2 letters or numbers) Classification: Installation Category II, Pollution Degree II Rated Voltage: 15 to 24 VDC Rated Current: 610mA maximum Meets the essential requirements of the following
