Copyright (c) 1987-1988. All RIGHTS RESERVED: No part of this publication
may be reproduced, stored in a retrieval system or transmitted in any form by any
means; electronic, mechanical, photo copying, recording, or otherwise, without
the prior written permission of Watlow Anafaze
Printed in U.S.A.
STATEMENT OF WARRANTY
ANAFAZE, Incorporated warrants that the Products furnished under this Agreement will
be free from material defects in material and workmanship for a period of 90 days from
the date of shipment. The customer shall provide notice to ANAFAZE, Incorporated of
any such defect within one week after the Customer's discovery of such defect. The sole
obligation and liability of ANAFAZE, Incorporated under this warranty shall be to
repair or replace, at its option, without cost to the Customer, the product or part which is
so defective and as to which such notice is given.
Upon request by ANAFAZE, Incorporated, the product or part claimed to be defective
shall immediately be returned at the Customer's expense to ANAFAZE, Inc. Replaced or
repaired products or parts will be shipped to the Customer at the expense of ANAFAZE,
Incorporated
There shall be no warranty or liability for any products or parts which have been subject
to misuse, accident, negligence, failure of electric power or modification by the
Customer without ANAFAZE, Incorporated's approval. Final determination of warranty
eligibility shall be made by ANAFAZE, Incorporated. If a warranty claim is considered
invalid for any reason, the Customer will be charged for services performed and
expenses incurred by ANAFAZE, Incorporated in handling and shipping the returned
unit.
As to replacement parts supplied or repairs made during the original warranty period, the
warranty period of the replacement or repaired part shall terminate with the termination
of the warranty period with respect to the original product or part.
THE FOREGOING WARRANTY CONSTITUTES THE SOLE LIABILITY OF
ANAFAZE INCORPORATED AND THE CUSTOMER'S SOLE REMEDY WITH
RESPECT TO THE PRODUCTS AND IS IN LIEU OF ALL OTHER
WARRANTIES, LIABILITIES AND REMEDIES. EXCEPT AS THUS
PROVIDED, ANAFAZE, INC. DISCLAIMS ALL WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE.
PLEASE NOTE EXTERNAL SAFETY DEVICES MUST BE USED WITH THIS
EQUIPMENT SEE WARNING ON NEXT PAGE.
WARNING
ANAFAZE HAS MADE EFFORTS TO ENSURE THE RELIABILITY AND
SAFETY OF THE ANAFAZE 8 PID CONTROLLER AND PROVIDE
RECOMMENDATIONS FOR ITS SAFE USE IN SYSTEMS APPLICATIONS.
PLEASE NOTE THAT IN ANY APPLICATION, FAILURES CAN OCCUR
THAT WILL RESULT IN FULL CONTROL OUTPUTS OR OTHER OUTPUTS
THAT MAY CAUSE DAMAGE OR UNSAFE CONDITIONS IN THE
EQUIPMENT OR PROCESS CONNECTED TO THE ANAFAZE 8 PID.
GOOD ENGINEERING PRACTICES, ELECTRICAL CODES, AND
INSURANCE REGULATIONS REQUIRE INDEPENDENT, EXTERNAL,
SAFETY DEVICES BE USED TO PREVENT POTENTIALLY DANGEROUS OR
UNSAFE CONDITIONS ASSUMING THAT THE ANAFAZE 8 PID CAN FAIL
WITH OUTPUTS FULL ON, OR OUTPUTS FULL OFF, OR OTHER
CONDITIONS THAT WOULD BE UNEXPECTED.
THE ANAFAZE 8 PID INCLUDES A RESET CIRCUIT THAT WILL SET THE
CONTROL OUTPUTS TO ZERO IF THE MICROPROCESSOR RESETS -NORMALLY THE RESULT OF A POWER FAILURE AND POWER RETURN.
THE COMPUTER OR OTHER HOST DEVICE SHOULD BE PROGRAMMED
TO AUTOMATICALLY RELOAD THE CURRENT ANAFAZE 8 PID
OPERATING CONSTANTS, OR SAFE VALUES FOR THE PROCESS, UPON
RETURN OF SYSTEM POWER. THE COMPUTER CAN ALSO BE
PROGRAMMED TO CHECK PROCESS DATA AND CAUSE ALARMS
INCLUDING CONTACT OUTPUTS FOR AUTOMATIC SHUT DOWN TO
ASSIST IN PREVENTING DANGEROUS OR UNSAFE CONDITIONS.
ANAFAZE WILL BE PLEASED TO PROVIDE APPLICATION ASSISTANCE
AND PROGRAMMING IF DESIRED. IN ANY EVENT, THESE SAFETY
FEATURES DO NOT ELIMINATE THE NEED TO PROVIDE EXTERNAL,
INDEPENDENT SAFETY DEVICES IN POTENTIALLY DANGEROUS OR
UNSAFE CONDITIONS.
ANAFAZE ALSO OFFERS AN OPTIONAL EEROM MEMORY THAT WILL
STORE COMPUTER ENTERED OPERATING CONDITIONS THAT WILL BE
USED BY THE ANAFAZE 8 PID AS INITIAL CONDITIONS AT START-UP.
THIS FEATURE STILL DOES NOT ELIMINATE THE NEED FOR
APPROPRIATE EXTERNAL, INDEPENDENT SAFETY DEVICES.
7.2 ANALOG INPUT TYPE AND CONTROL SETPOINT _________________25
7.3 CONTROL CONSTANTS__________________________________________26
7.4 ANALOG (CONTROL) OUTPUT ___________________________________29
7.5 DIGITAL INPUT AND OUTPUTS __________________________________31
7.6 ANALOG INPUTS ________________________________________________31
1.0 INTRODUCTION
The ANAFAZE 8 PID is a full-featured, industrial-quality, eight- loop, three-mode
controller offering unique shared processing technology in local or distributed systems.
Through shared processing, the operational functions are divided: the ANAFAZE 8 PID
microprocessor intelligence controls the eight loops while a computer or programmable
controller enters control settings and performs other operations as needed.
Up to eight loops can be controlled by each ANAFAZE 8 PID, with separate selection of
setpoints, alarm points and control constants. A group of optically isolated measurement
circuits accept direct connection of sensors -- including thermocouples, RTD's, infrared
non-contact, milliamp, and voltage -- reducing the need for costly isolators or
transmitters. Sensor and control cable costs are reduced by installing the controller near
the process and using serial communication to the host computer. Plug-in RS-232, RS422, or 20ma current loop interfaces are available at selectable baud rates. Control output
for each loop is a separate plug-in board with a choice of time proportioning voltage,
on/off output, or analog voltage or current. With the alarm expander option two alarms
can be set for each loop with digital outputs on alarm for annunciation or emergency
shutdown. Indicator LEDs show the status of each loop, the communication interface,
and the AC power.
For simple applications any computer with a serial interface may be used to set the input
types, control constants, control setpoints, and alarm levels for each loop. Once set, the
ANAFAZE 8 PID functions as a stand-alone controller, with alarm checking on each
loop, and the computer need only periodically poll the controller to generate operator
displays and to verify correct operation.
ANAFAZE offers ANASOFT which is a menu driven software applications package for
IBM PC and compatible computers. Please contact ANAFAZE for additional
information.
Up to 32 local or remote ANAFAZE 8 PID controllers can be connected on a single
communication line, totaling 256 loops, and multiple lines can be used for very large
systems. Since the ANAFAZE 8 PID fully controls each loop, supervision requirements
are simplified, thus allowing the use of inexpensive programmable controllers or
personal computers.
1
2.0 SPECIFICATIONS
2.1 ANALOG INPUTS
Number of channels:eight
Multiplexing:three wire reed relay, guarded inputs
A/D converter:integrating voltage to frequency
Loop update:each loop 2 times per second
Input isolation:optical coupling
Input resolution:0.02% full scale
Temp. coefficient:.025% per degree
Measurement accuracy:+0.2% full scale
Thermocouple break:up scale standard
Standard input types:All are present in every system: select by command
from host, any order, any mix:
(a)Thermocouple ranges: *
J T/C: -50F to 1400F
K T/C: -110F to 2500F
T T/C: -120F to 750F
(b)Voltage and current scaling:
0 to 100% (0 to 50ma, 0 to 10v etc.)
(c)Voltage input ranges, set for each channel:
0 to 60mv min, 0 to 100v max: normal
(d)Current input ranges: select resistor to match
above voltage ranges
Optional input types:E, S, R, or B T/C
RTD
Non-contact infrared
Temperature Ranges below 0 degrees
* Assumes PID temp is 0 to 50 degrees C
If otherwise, contact factory.
2.2 OPERATING PARAMETERS
Independently set for each loop from computer or programmable controller.
Input typeany standard type (see above), any mix
Gain (proportional)0 to 499
Reset (integral)0 (off) to 1020 seconds
Rate (derivative)0 (off) to 255 seconds
Digital Filter0 to 15 levels [0-7.5 sec.time const.]
Setpoint0 to span
High alarm0 to span [requires alarm expander]
Low alarm0 to span [requires alarm expander]
Control output levelautomatic, 0-100% or when using manual control 0 to
100% (0.1% resolution). As set from keyboard.
2
2.3 REPORTING PARAMETERS
The computer can request any of the following for any loop:
Operating parameters:all of the above
Analog inputs:sensor input
2.4 COMMUNICATIONS
TypesRS-232, RS-422, or 20ma current loop
Baud ratejumper selectable, 300 to 9600
Error checkfull echo of all settings
Isolationoptical for 20ma, optional for RS-232
Data formatstandard ASCII
DisplayLED indicates communication active
2.5 CONTROL AND ALARM OUTPUTS
Select up to eight:
Time proportioning:voltage output: pulsed 6VDC at 6ma (or
On/Off)maximum -- for solid state or other relays
Analog:voltage or current: selectable (4 to 20ma, 2 to 10v
etc.)
Display:LED indicates control output is active
2.6 DIGITAL INPUT OR OUTPUT
2 DigitalOutputs:opencollector;
true= < 0.5v @ 4ma
false = 5v @ 400ohms
1 Digital Input:true = < 0.5v; false = > 3.5v
2.7 GENERAL
Power input:120VAC, 60Hz
Operating ambient:0 to 50 C
Humidity:10% to 90%, non-condensing
Enclosures:NEMA 4, 12, 13 and others optional
Physical:11.2" wide, 13.25" high, 4" deep
Mounting:4 bolts; 10.25" wide, 12.25" high
Weight:approximately 5 pounds
3
2.8 SUBASSEMBLY IDENTIFICATION
The ANAFAZE 8 PID controller consists of a measurement/processing unit with integral
mounting frame, plug-in terminals for field wiring, LED indicators, power supply, and 9
card slots.
ANAFAZE 8 PID MEASUREMENT PROCESSOR UNIT
A8PID-MPUStandard measurement/processing unit
A8PID-MPU-IR4Standard MPU wired for 4 IR inputs
A8PID-MPU-IR8Standard MPU wired for 8 IR inputs
A8PID-SIXXXCustom input scaling per input
COMMUNICATION INTERFACES (must select one per MPU)
ALARM OUTPUT AND MEMORY CARD (optional one per MPU)
A8PID-AEXAlarm expansion card
CABLES
CA-232M25' RS-232 cable male computer connector
CA-232F25' RS-232 cable female computer connector
CA-AEX2'50 pin ribbon cable: AEX to PCB-24
INPUT/OUTPUT ACCESSORIES -- USE WITH AEX
PCB-2424-position input/output module board
PCB-IAC15120VAC input module
PCB-IAC5A240VAC input module
PCB-IDC5N3.3-60VDC input module
PCB-OAC5120VAC output module 5A SSR
PCB-OAC5A240VAC output module 5A SSR
G280D10280VAC 10A solid state relay SSR
G280D45280VAC 45A solid state relay SSR
SOFTWARE
ANASOFT-PIDSoftware operating program for ANAFAZE 8 PID
4
3.0 INSTALLATION
There are some precautions that must be observed when installing the ANAFAZE 8 PID:
WARNING-ELECTRICAL SHOCK DANGER
It is very important that all signal lines including the power input be
disconnected before servicing the ANAFAZE 8 PID. HIGH
VOLTAGE MAY BE PRESENT EVEN WHEN POWER IS
TURNED OFF.
Since the ANAFAZE 8 PID can make measurements of input signals that are not
referenced to ground, the ANAFAZE 8 PID ground and other signal lines can have
power line or other high voltage present even if the input power is turned off. This could
happen, for example, if a thermocouple was inadvertently shorted to the AC power line.
WARNING - USE CORRECT INSULATION TRIM LENGTH
AND WIRE GAGE
The correct insulation trim length is 1/4" or 5mm. Care must be
taken to prevent contact between any wires and the case which is
grounded. The terminal manufacturer has UL approval for #14 to
#30 AWG (American Wire Gage). ANAFAZE recommends using #18
or #20 AWG.
To effectively use the plug-in terminals, the wire insulation should be trimmed so that
the wire fits inside the terminal with no bare wire exposed. Stranded wire should be
tinned.
WARNING - SUPPORT CABLES
Power, input, and output cables should be supported to reduce strain
on the connectors and to prevent them from being pulled out of the
terminal strips.
3.1 PHYSICAL CONSIDERATIONS
The ANAFAZE 8 PID consists of a single PC board with an aluminum housing. Nine
rear slots are provided for plug-in option boards, one for communication and eight for
control outputs.
3.1.1 MOUNTING [SEE PHYSICAL LAYOUT ON NEXT PAGE]
WARNING ELECTRICAL SHOCK DANGER
Always mount the ANAFAZE 8 PID so that access is controlled to
prevent any contact with the terminals. HIGH VOLTAGE MAY BE
PRESENT EVEN WHEN POWER IS TURNED OFF.
5
6
For optimum performance when directly connecting thermocouple inputs, the terminal
strips should be kept horizontal. In addition the unit should be protected from thermal
shocks whenever possible. This will minimize any temperature gradients across the
terminal strips and result in the highest accuracy.
3.1.2 ENCLOSURES
Different enclosures can be used depending on the environmental protection required.
3.1.3 DETACHABLE TERMINAL BLOCKS
WARNING - ALWAYS CHECK TERMINAL LOCATION AND
ORIENTATION
All connections except, for the AC power supply, are made on
removable terminal strips. Terminal strip removal is achieved by
pulling them directly away from the circuit board. The terminal
strips must be carefully installed in the correct position on the circuit
with all 10 pins correctly aligned.
3.2 COMMUNICATIONS SET-UP AND CONNECTIONS
The ANAFAZE 8 PID is designed for three types of serial communications: RS232, RS-422, and 20ma current loop. Up to 32 units can be connected on one
communication line.
3.2.1 COMMUNICATIONS PROTOCOL
The unit uses standard ASCII codes for characters. Parity is not used since the
ANAFAZE 8 PID responds to every command verifying to the host computer that the
command has been correctly received. The ASCII format is the most commonly used. It
contains one start bit, 8 data bits and one stop bit. The computer manual contains
information on how to set- up the parameters for communication. For example using an
IBM PC in BASIC the command is:
OPEN "COM1:2400,N,8,1,RS,CS,DS as #1
This statement does the following:
opens communication port 1
at 2400 baud
with no parity
1 start bit, 8 data bits, 1 stop bit
suppresses RTS (Ready To Send)
ignores CTS (Clear To Send)
ignores DSR (Data Set Ready)
as file #1.
Please see your computer manual for additional details.
7
Please note that the ANAFAZE 8 PID does not require an automatic LF line feed at the
end of each communication. Do not use this feature available in the IBM PC BASIC or
any other software package.
3.2.2 COMMUNICATIONS PLUG IN OPTIONS
Communication interfaces plug into slot 1 at the back of the ANAFAZE 8 PID frame.
The standard selection includes: RS- 232, RS-422, and 20ma current loop. An optically
isolated RS-232 interface is available.
3.2.3 RS-232 Option [Non-Isolated]
The ANAFAZE 8 PID is designed to communicate with the host computer using three
wires, thus minimizing the interconnection cost. SEE DIAGRAM:
The ANAFAZE 8 PID transmits data on TXD and receives data on RXD. The host
computer TXD output should be connected to the ANAFAZE 8 PID RXD input. The
ANAFAZE 8 PID TXD output should be connected to the host computer RXD input.
Host computer communication ground should be connected to the ANAFAZE 8 PID
communication ground.
Multiple ANAFAZE 8 PID units are connected on the RS-232 line in parallel. The
ANAFAZE 8 PID nearest to the computer is connected as described above. Then each
Anafaze 8 PID controller is daisy chained wire for wire to the next unit. The next units'
TXD is connected to the first units' TXD, RXD to RXD, and ground to ground etc.
Some host computers or other RS-232 devices use additional communication lines that
are not required by ANAFAZE 8 PID. These include:
RTS - Ready To SendDSR - Data Set Ready
CTS - Clear To SendDTR - Data Terminal Ready
8
If the host computer uses RTS and CTS or DSR and DTR, these lines should be
connected together in pairs [or as shown in the computer manual]. Normally this is done
in the RS-232 connector hood at the host computer. Alternately the effect of these lines
can be eliminated in software. The ANAFAZE 8 PID is ready to receive data; therefore
these lines are not required.
3.2.4 RS-232 NOISE PICK-UP
The RS-232 interface is designed so that all ANAFAZE 8 PID controllers on the same
RS-232 interface will be listening on initial power up. None of the units will have control
of the TXD line. A command sent through the host computer initializing the desired unit
starts proper communication between that ANAFAZE 8 PID and the host computer.
Since the TXD line is not controlled, a high impedance may result, causing some 60Hz
or 50Hz noise to be picked-up on the line. The noise may be interpreted as characters by
the host computer. This may continue until the first unit is selected. After unit selection,
the host computer should clear its input buffer. To prevent this, lower the impedance of
the TXD line by connecting a 15K ohm resistor between the host computer RXD line
and the -5 or -15 volt communication supply at the host. The reduction in the impedance
should be enough to prevent this character pick-up.
3.2.5 RS-422 OPTION
The RS-422 is similar to RS-232 with the exception that the RS-422 requires two
balanced lines for transmit and two lines for receive. The lines operate exactly out of
phase referenced to +5 and 0 volts, permitting longer interconnect lengths. ANAFAZE 8
PID connections are as follows:
Current loop is recommended for longer cable runs and noisy environments. The
ANAFAZE 8 PID current loop is optically isolated. It uses an external power supply for
the current loop which is normally included in the device communicating with the
controller. Consult ANAFAZE for recommendations.
9
The connections are shown for a single controller:
Multiple ANAFAZE 8 PIDs' are connected in series. R+ is connected to the first unit
TXD and TXD* from the first unit is connected to TXD of the next unit. These serial
connections are continued until the last unit is reached. The last unit TXD* is connected
to the computer R-. T+ is connected to the first unit RXD and the RXD* is connected to
the next unit. The last unit RXD* is connected to the computer T- as shown:
3.2.7 OPTICALLY ISOLATED RS-232 INTERFACE
The optically isolated interface allows connection to computers using RS-232 with
additional noise protection. Many computer RS-232 interfaces connect the RS-232 signal
ground directly to the computer third wire ground. Thus any power line noise is directly
connected to the ANAFAZE 8 PID through the serial interface. In addition if there is
common mode voltage between the ANAFAZE 8 PID and the computer this noise will
also be coupled into the communication lines. To prevent this problem for RS-232 users,
the optically isolated RS-232 interface is recommended. The connections are different
from the normal serial interface since the ground is isolated. The connections are as
diagrammed:
10
Multiple ANAFAZE 8 PID's are connected in parallel. The RXD of the first unit is
connected to the RXD of the next unit, the RXD* to the RXD*, and the TXD* to the
TXD*.
3.3 CONFIGURATION
3.3.1 CONFIGURATION SWITCH
WARNING - TURN OFF POWER BEFORE CHANGING
SWITCH
The unit configuration switch is located near the center of the main
circuit board. It is a six position DIP switch which is used to set the
unit number. The switch functions are:
Position one:
Position two:
Position three through six:
units are selected by commands in the format Bab, where "B" is the unit command
code,"a" is the unit group select either 1 or 2, and "b" is 0 through F. Unit group 1 or 2
are selected by SW1. Selection of 0 through F is made on the configuration switch
according to the following table:
Unit group select 1 or 2
Spare
Selects the unit number using the standard binary code. The
Unit numbersw3sw4sw5sw6
0FFFF
1FFFO
2FFOF
3FFOO
4FOFF
5FOFO
6F OOF
7F OOO
8OFFF
9OFFO
AOFOF
BOFOO
COOF F
DOOF O
EOOOF
FOOOO
Where O = on and F = off
11
3.3.2 BAUD RATE SELECTION
WARNING - TURN OFF POWER BEFORE CHANGING BAUD
RATE
Baud rate is selected by positioning a selector jumper on J1 on the main circuit board.
The position farthest from the card cage is 600 baud and the positions are then as
follows:
600
300
2400
4800
1200
9600
Units are normally shipped from the factory with the baud rate set at 2400 baud. This
rate is recommended for most applications.
3.4 AC POWER INPUT
WARNING - POWER MUST BE 110VAC, 60HZ
The ANAFAZE 8 PID requires 110VAC at 60Hz for power input. A power on LED will
indicate when power is applied.
WARNING - HIGH VOLTAGE MAY BE PRESENT WHEN
POWER IS DISCONNECTED
3.4.2 POWER CONNECTIONS
The power must be connected according to the terminal labels. The abbreviations are:
GND Third wire ground -- normally Green wire
NEU 110VAC Neutral -- normally white wire
HOT 110VAC Hot -- normally black wire
3.4.3 POWER FUSE
A 1/4 amp fuse is located beneath the circuit board near the power terminals. Power to
the ANAFAZE 8 PID must be removed before changing the fuse.
12
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