Page 1
CAS200
User’s Guide
WATLOW
1241 Bundy Boulevard
Winona, MN 55987
Phone: +1 (507) 454-5300. Fax: +1 (507) 452-4507
Document No. 0600-3050-2400. Revision A
November 2008
Page 2
Copyright © 2001
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. The customer shall provide notice of any defect to Watlow
Anafaze within one week after the Customer's discovery of such defect. The sole obligation and liability of Watlow Anafaze under this warranty shall be to repair or
replace, at its option and without cost to the Customer, the defective product or part.
Upon request by Watlow Anafaze, Incorporated, the product or part claimed to be
defective shall immediately be returned at the Customer's expense to Watlow Anafaze.
Replaced or repaired products or parts will be shipped to the Customer at the expense
of Watlow Anafaze.
There shall be no warranty or liability for any products or parts that have been subject
to misuse, accident, negligence, failure of electric power or modification by the Customer without the written approval of Watlow Anafaze. Final determination of warranty eligibility shall be made by Watlow Anafaze. If a warranty claim is considered
invalid for any reason, the Customer will be charged for services performed and
expenses incurred by Watlow Anafaze in handling and shipping the returned unit.
If replacement parts are supplied or repairs made during the original warranty
period, the warranty period for the replacement or repaired part shall terminate with
the termination of the warranty period of the original product or part.
The foregoing warranty constitutes the sole liability of Watlow Anafaze and the customer's sole remedy with respect to the products. It is in lieu of all other warranties,
liabilities, and remedies. Except as thus provided, Watlow Anafaze 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.
Page 3
Contents
List of Figures ix
List of Tables xiii
System Overview 1
Manual Contents 1
Getting Started 2
Safety symbols 2
Contacting Watlow Anafaze 2
Product Features 3
System Diagram 4
Parts List 4
Mounting Scanner Components 5
Safety 5
Installation 7
Typical Installation 8
Safety 9
External Safety Devices 9
Mounting 10
Location 10
Recommended Tools 10
Mounting the Scanner 11
Mounting the TB50 13
System Wiring 14
Wiring Recommendations 15
Noise Suppression 16
Ground Loops 18
Power Connections 19
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Contents CAS200 User’s Guide
Wiring the Power Supply 19
Testing Power to the Scanner 21
Connecting the TB50 to the CAS200 22
Input Wiring 22
Sensor Connection 22
Thermocouple Connections 23
Voltage Input Connections 24
Current Input Connections 24
Serial Communications 25
EIA/TIA-232 Interface 25
EIA/TIA-485 Interface 26
EIA/TIA-485 Converters and Laptop Computers 29
Wiring Digital I/O 29
Noise Suppression 29
Digital Outputs 30
Alarm Output Connections 31
CPU Watchdog 32
Digital Inputs 32
Using the CAS200 35
Introduction 35
Front Panel 36
Front Panel Keys 36
Single Channel Display 38
Job Display 38
Change Setpoint 39
Alarms 40
Setup 41
CAS200 Menus 41
How to Enter the Setup Menus 41
How to Edit a Menu 42
Setup Global Parameters Menu 44
Load a Job 44
Save Setup to Job 45
Job Select Inputs 45
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CAS200 User’s Guide Contents
Job Select Input Polarity 46
Startup Alarm Delay 46
Keyboard Lock Status 47
Scanner Address 47
Communications Baud Rate 47
Communications Protocol 48
Communications Error Checking 48
AC Line Frequency 49
Digital Output Polarity 49
External Alarm Acknowledge Input Active 49
EPROM Information 50
Setup Channel Inputs 50
Input Type 50
Display Resolution 51
Pulse Sample Time 52
Channel Name 52
Input Units 52
Input Reading Offset 53
Linear Scaling Menus 54
Display Format 55
High Process Value 56
Input Scaling High Reading 56
Input Scaling Low Process Value 56
Input Scaling Low Reading 57
Input Filter 57
Setup Channel Alarms 58
Failed Sensor Alarms 58
Global Alarms 58
Process Alarms 58
Alarm Delay 60
High Process Alarm Setpoint 60
High Process Alarm Type 60
High Process Alarm Output Number 61
Deviation Alarm Value 61
High Deviation Alarm Type 61
High Deviation Alarm Output Number 62
Low Deviation Alarm Type 62
Low Deviation Alarm Output Number 62
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Contents CAS200 User’s Guide
Low Process Alarm Setpoint 63
Low Process Alarm Type 63
Low Process Alarm Output Number 63
Alarm Deadband 64
Alarm Delay 64
Manual I/O Test 65
Digital Input Testing 65
Digital Output Selection 65
Digital Output Test 66
Keypad Test 66
Troubleshooting and Reconfiguring 67
When There is a Problem 67
Returning Your Unit 68
Troubleshooting Scanners 68
Process and Deviation Alarms 68
Thermocouple Break Alarm 69
System Alarms 69
Other Behaviors 70
Corrective and Diagnostic Procedures 71
Additional Troubleshooting for Computer Supervised Systems 76
Computer Problems 76
Communications 77
Ground Channels 78
Software Problems 78
NO-Key Reset 78
Replacing the EPROM 79
Changing Communications 81
Installing Scaling Resistors 82
CAS200 Input Circuit 82
CAS200 Current Inputs 83
CAS200 Voltage Inputs 84
Scaling and Calibration 85
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CAS200 User’s Guide Contents
Linear Scaling Examples 87
Example 1: 4-20mA Sensor 88
Situation 88
Setup 88
Example 2: 0-5Vdc Sensor 89
Situation 89
Setup 89
Example 3: Pulse Encoder 90
Situation 90
Setup 90
Specifications 91
CAS200 System Specifications 91
CAS200 Processor Physical Specifications 92
TB50 Physical Specifications 95
Inputs 98
Outputs 101
CAS200 Power Supply 103
Glossary 105
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Contents CAS200 User’s Guide
vi Watlow Anafaze
Page 9
1 System Overview 1
Figure 1.1— System Components 4
2 Installation 7
Figure 2.1— System Components 8
Figure 2.2— Clearance Recommendations 10
Figure 2.3— Mounting with the Mini-Bracket 11
Figure 2.4— Mounting with the Collar Bracket 12
Figure 2.5— Mounting 13
Figure 2.6— Mounting Dimensions 14
Figure 2.7— CAS200 Series Scanner 19
Figure 2.8— Power Connections with the CAS200 Power Supply 20
Figure 2.9— Sensor Connections 22
Figure 2.10— Wiring Thermocouple Inputs 23
Figure 2.11— Wiring Voltage Input Connections 24
Figure 2.12— Wiring Current Input Connections 24
Figure 2.13— Connecting One CAS200 to a Computer Using EIA/TIA-232 26
Figure 2.14— EIA/TIA-485 Wiring 27
Figure 2.15— Recommended System Connections 28
Figure 2.16— Wiring Digital Outputs 31
Figure 2.17— Wiring Alarm Output Connections 31
Figure 2.18— Wiring Watchdog Timer Output 32
Figure 2.19— Wiring Digital Inputs 33
List of Figures
3 Using the CAS200 35
Figure 3.1— Navigating with a Single Channel Display 35
Figure 3.2— Front Panel Display 36
5 Troubleshooting and Reconfiguring 67
Figure 5.1— Removal of Electronics Assembly from Case 80
Figure 5.2— Screws Locations on PC Board 80
Figure 5.3— EPROM Location 81
Figure 5.4— Remove EPROM 81
Figure 5.5— Jumper Configurations 81
Figure 5.6— CAS200 Input Circuit 83
Watlow Anafaze vii
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List of Figures CAS200 User’s Guide
7 Specifications 91
Figure 7.1— CAS200 Processor Module Dimensions 92
Figure 7.2— CAS200 Clearances with Straight SCSI Cable 93
Figure 7.3— CAS200 Clearances with Right-Angle SCSI Cable 93
Figure 7.4— TB50 Dimensions 95
Figure 7.5— TB50 Dimensions with Straight SCSI Cable 96
Figure 7.6— TB50 Dimensions with Right-Angle SCSI Cable 97
Figure 7.7— Power Supply Dimensions (Bottom View) 104
viii Watlow Anafaze
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2 Installation
Table 2.1— Cable Recommendations 16
Table 2.2— Power Connections 20
Table 2.3— EIA/TIA-232 Connections 25
Table 2.4— RTS/CTS and DSR/DTR Pins in DB-9 and DB-25 Connectors 26
Table 2.5— TB50 Connections for CAS200 33
Table 2.6— TB18 Connections 34
List of Tables
5 Troubleshooting and Reconfiguring
Table 5.1— Hardware Error Messages 69
Table 5.2— Other Symptoms 70
Table 5.3— Resistor Values for CAS200 Current Inputs 83
Table 5.4— Resistor Locations for CAS200 Current Inputs 84
Table 5.5— Resistor Values for CAS200 Voltage Inputs 84
Table 5.6— Resistor Locations for CAS200 Voltage Inputs 85
6 Linear Scaling Examples
Table 6.1— Input Readings 88
Table 6.2— Scaling Values 88
Table 6.3— Input Readings and Calculations 89
Table 6.4— Scaling Values 89
Table 6.5— Scaling Values 90
7 Specifications
Table 7.1— Agency Approvals / Compliance 91
Table 7.2— Environmental Specifications 92
Table 7.3— Physical Dimensions 92
Table 7.4— Processor with Straight SCSI 93
Table 7.5— Processor with Right Angle SCSI 93
Table 7.6— Processor Connections 94
Table 7.7— TB50 Physical Dimensions 95
Table 7.8— TB50 Connections 95
Table 7.9— TB50 with Straight SCSI 96
Table 7.10— TB50 with Right Angle SCSI 97
Table 7.11— Analog Inputs 98
Table 7.12— Pulse Inputs 99
Table 7.13— Thermocouple Range and Resolution 99
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List of Tables CAS200 User’s Guide
Table 7.14— Input Resistance for Voltage Inputs 100
Table 7.15— Digital Inputs 100
Table 7.16— Digital Outputs Control / Alarm 101
Table 7.17— CPU Watchdog Output 101
Table 7.18— 5Vdc Output (Power to Operate Solid State Relays) 102
Table 7.19— Reference Voltage Output (Power to Operate Bridge Circuit Sensors) 102
Table 7.20— Processor Serial Interface 102
Table 7.21— Processor Power Requirements 102
Table 7.22— Power Supply Environmental Specifications 103
Table 7.23— Power Supply Agency Approvals / Compliance 103
Table 7.24— Power Supply Physical Specifications 103
Table 7.25— Power Supply with Mounting Bracket 103
Table 7.26— Power Supply Inputs 104
Table 7.27— Power Supply Outputs 104
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1
System Overview
Manual Contents
This manual describes how to install, setup, and operate a
CAS200. Included are six chapters and a glossary of terms.
Each chapter covers a different aspect of the alarm scanner
and may apply to different users. The following describes
the chapters and their purpose.
• Chapter 1: System Overview provides a component
• Chapter 2: Installation provides detailed
• Chapter 3: Using the CAS200 provides an overview
• Chapter 4: Setup provides detailed descriptions of all
• Chapter 5: Troubleshooting and
• Chapter 6: Linear Scaling Examples provides
• Chapter 7: Specifications lists detailed
list and summary of features for the CAS200 series
alarm scanners.
instructions on installing the CAS200 and its
peripherals.
of operator displays used for system monitoring and
job selection.
menus and parameters for scanner setup.
Reconfiguration provides some basic guidelines for
solving operational problems and provides procedures
for changing some of the hardware options (e.g.
installing special input resistors and changing EIA/
TIA-232 to EIA/TIA-485).
three examples where linear scaling is used.
specifications of the scanner and optional components.
Watlow Anafaze 1
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Chapter 1: System Overview CAS200 User’s Guide
Getting Started
The following sections provide information regarding
product features, technical descriptions, safety
requirements, and preparation for operation.
Safety symbols
These symbols are used throughout this manual:
∫
WARNING!
Indicates a potentially hazardous situation which,
if not avoided, could result in death or serious
injury.
ç
CAUTION!
NOTE!
Contacting Watlow Anafaze
Indicates a potentially hazardous situation which,
if not avoided, could result in minor or moderate
injury or property damage.
Indicates pertinent information or an item that
may be useful to document or label for later reference.
To contact Watlow Anafaze, send correspondence to:
Watlow Anafaze, Inc.
314 Westridge Drive
Watsonville, CA 95076
Our technical support and customer service departments
may be reached Monday-Friday, 8 a.m. to 5 p.m. Pacific
time:
Telephone: +1 (831) 724-3800
Email: anafazetechsupport@watlow.com
Be sure to specify CAS200 when asking for technical
support.
2 Watlow Anafaze
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CAS200 User’s Guide Chapter 1: System Overview
Product Features
The CAS200 is a modular monitoring system with 16
analog inputs. It can function as a stand-alone system; the
CAS200 1/8 DIN front panel has a Vacuum Fluorescent
Display (VFD) and touch keypad for local display and local
parameter entry. You can also use it as the key element in
a computer supervised data acquisition system; the
CAS200 can be locally or remotely controlled via an EIA/
TIA-232 or EIA/TIA-485 serial communications interface.
Features include:
Direct Connection of Mixed Thermocouple Sensors:
Connect most thermocouples to the scanner with no
hardware modifications. Thermocouple inputs feature
reference junction compensation, linearization, process
variable offset calibration to correct for sensor
inaccuracies, detection of broken, shorted or reversed
thermocouples, and a choice of Fahrenheit or Celsius
display.
Automatic Scaling for Linear Analog Inputs: The
CAS200 series automatically scales linear inputs used with
industrial process sensors. Enter two points and all input
values are automatically scaled in your units. Scaling
resistors must be installed.
Flexible Alarm Outputs: Independently set high/low
process alarms and a high/low deviation band alarm for
each channel. Alarms can activate a digital output by
themselves, or they can be grouped with other alarms to
activate an output.
Alarm Outputs: You can set high/low deviation and high/
low process alarm setpoints to operate digital outputs as
latched or unlatched functions.
Global Alarm Output: When any alarm is triggered, the
global alarm output is also triggered, and it stays on until
you acknowledge it.
CPU Watchdog: The CAS200 series CPU watchdog timer
output notifies you of system failure. Use it to hold a relay
closed while the system is running, so you are notified if the
microprocessor shuts down.
Front Panel or Computer Operation: Set up and run
the scanner from the front panel or from a local or remote
computer. Watlow Anafaze offers WatView, a Windows®
compatible Human Machine Interface (HMI) software
package that includes data logging and graphing features
in addition to process monitoring and parameter setup
screens.
Multiple Job Storage: Store up to eight jobs in protected
memory, and access them locally by entering a single job
number or remotely via digital inputs. Each job is a set of
alarm conditions.
Watlow Anafaze 3
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Chapter 1: System Overview CAS200 User’s Guide
Pulse Counter Input: Use the pulse counter input for
precise monitoring of motor or belt speed.
System Diagram
The illustration below shows how the parts of the CAS200
are connected. When unpacking your system, use the
diagram and parts list below to ensure all parts have been
shipped. Please don't hesitate to call Watlow Anafaze if you
have problems with your shipment, or if any CAS200
components are missing or damaged.
Figure 1.1 System Components
SCSI Cable
TB50
Digital inputs
and outputs
and pulse input
Parts List
CAS200
Signal Inputs
Power Supply
• CAS200 Scanner
• Mounting Kit
• TB50 Terminal Board
• 50-Pin SCSI Cable
• DC Power Supply
4 Watlow Anafaze
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CAS200 User’s Guide Chapter 1: System Overview
Mounting Scanner Components
Install the scanner in a location free from excessive heat
(>50°C), dust, and unauthorized handling.
Electromagnetic and radio frequency interference can
induce noise on sensor wiring. Select locations for the CAS
200 and TB50 such that wiring can be routed clear of
sources of interference such as high voltage wires, power
switching devices and motors.
∫
Safety
WARNING!
To reduce the risk of fire or electric shock, install
CAS200 in a controlled environment, relatively
free of contaminants.
Watlow Anafaze has made efforts to ensure the reliability
and safety of the CAS200 and to recommend safe uses in
systems applications. Note that in any application failures
can occur.
Good engineering practices, electrical codes, and insurance
regulations require that you use independent external
safety devices to prevent potentially dangerous or unsafe
conditions. Assume that the CAS200 can fail or that other
unexpected conditions can occur.
Install high or low temperature protection in systems
where an overtemperature or undertemperature fault
condition could present a fire hazard or other hazard.
Failure to install temperature control protection where a
potential hazard exists could result in damage to
equipment and property, and injury to personnel.
For additional process safety, program a computer or other
host device to automatically reload your desired operating
parameters after a power failure. However, this safety
feature does not eliminate the need for other external,
independent safety devices in dangerous conditions.
∫
WARNING!
Watlow Anafaze 5
The CAS200 should never be used as a safety
shutdown device. It should only be used with
other approved independent safety shutdown
devices.
Contact Watlow Anafaze immediately if you have any
questions about system safety or system operation.
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Chapter 1: System Overview CAS200 User’s Guide
6 Watlow Anafaze
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2
Installation
This chapter describes how to install the CAS200 series
scanner and its peripherals. Installation of the scanner
involves the following procedures:
• Determining the best location for the scanner
• Mounting the scanner and TB50
• Power Connection
• Input Wiring
• Communications Wiring (EIA/TIA-232 or EIA/TIA-
485)
• Output Wiring
Watlow Anafaze 7
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Chapter 2: Installation CAS200 User’s Guide
Typical Installation
The illustrations below show typical installations of the
scanner with the TB50 terminal block. Observe the
illustration below to determine potential space
requirements.
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.
Figure 2.1 System Components
SCSI Cable
CAS200
Signal Inputs
TB50
Digital inputs
and outputs
and pulse input
Power Supply
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CAS200 User’s Guide Chapter 2: Installation
Safety
∫
WARNING!
Ensure that power has been shut off to your entire
process before you begin installation of the
scanner
Watlow Anafaze has made every effort to ensure the
reliability and safety of this product. In addition, we have
provided recommendations that will allow you to safely
install and maintain this scanner.
∫
WARNING!
External Safety Devices
In any application, failures can occur. These
failures can result in full control output (100%
power), or the occurrence of other output failures
which can cause damage to the scanner, or to the
equipment or process connected to the scanner.
Therefore, always follow good engineering
practices, electrical codes, and insurance
regulations when installing and operating this
equipment.
∫
WARNING!
External safety devices should be used to prevent
potentially dangerous and unsafe conditions upon
equipment failure. Always assume that this device can fail
with outputs full-On, or full-Off, by the occurrence of an
unexpected external condition.
Always install high or low temperature protection
in installations where an overtemperature or
undertemperature fault will present a potential
hazard. Failure to install external protection
devices where hazards exist can result in damage
to equipment, property, or human life.
Watlow Anafaze 9
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Chapter 2: Installation CAS200 User’s Guide
Mounting
We recommend you mount the scanner in a panel not more
than 0.2 inches thick.
∫
Location
WARNING!
1.00 in.
(25 mm)
To reduce the risk of fire or electric shock, install
the CAS200 in a controlled environment,
relatively free of contaminants.
Install the scanner in a location free from excessive (>50°C)
heat, dust, and unauthorized handling.
Ensure there is enough clearance for mounting brackets,
terminal blocks, and cable and wire connections; the
scanner extends 7.0 in. behind the panel face and the screw
brackets extend 0.5 in. above and below it. Allow an
additional 1 to 3 inches for the SCSI cable.
Figure 2.2 Clearance Recommendations
0.50 in.
(13 mm)
7.00 in.
(178 mm)
Terminals
2.00 in.*
(51 mm)
Bezel
0.50 in.
(13 mm)
Steel Case
Recommended Tools
Use these tools to install the CAS200 series scanner and
TB50:
Panel Hole Cutters:
Use any of the following tools to cut a hole of the
appropriate size in the panel.
• Jigsaw and metal file, for stainless steel and
heavyweight panel doors.
• Greenlee 1/8 DIN rectangular punch (Greenlee part
#600-68), for most panel materials and thicknesses.
• Nibbler and metal file, for aluminum and lightweight
panel doors.
10 Watlow Anafaze
SCSI Cable
*1.00 in. with right-angle SCI cable.
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CAS200 User’s Guide Chapter 2: Installation
Other Tools:
You will also need these tools:
• Phillips head screwdriver
• Flathead screwdriver for wiring
• Multimeter
Mounting the Scanner
Mount the scanner before you mount the TB50 or do any
wiring. The scanner's placement affects placement and
wiring considerations for the other components of your
system.
You receive one of two types of mounting brackets with
your scanner, the mini-bracket or the collar bracket. Refer
to the corresponding sections below for instructions.
Steps Using the Mini-Bracket
1. Cut a hole in the panel to the dimensions shown in the
illustration below. To do this, use a punch, nibbler, or
jigsaw, and file the edges of the hole.
2. Insert the scanner into the hole through the front of
the panel.
3. Screw the top and bottom clips in place: insert the
clip’s lip into the cutout in the scanner’s metal housing
just behind the front panel. Tighten the screws.
4. If you expect much panel vibration, use a rear support
for the scanner and its interconnecting cables.
Figure 2.3 Mounting with the Mini-Bracket
Maximum Panel
Thickness
1.80 in. ±0.02 in.
(45.7mm ±0.5mm)
3.63 in. ±0.02 in.
(92.2mm ±0.5mm)
Watlow Anafaze 11
0.2 in. (5mm)
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Chapter 2: Installation CAS200 User’s Guide
Steps Using the Collar Bracket
Installing and mounting requires access to the back of the
panel.
NOTE! Removing the scanner chassis from its case
makes mounting easier.
1. Make a panel cutout. Refer to Figure 2.3 on page 11 for
dimensions of the cutout.
2. Slide the scanner into the panel cutout.
3. Slide the mounting collar over the back of the scanner,
making sure the mounting screw indentations face
toward the back of the scanner.
4. 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 scanner). Push each
bracket backward then to the side to secure it to the
scanner case.
5. Make sure the case is seated properly. Tighten the
installation screws firmly against the mounting collar
to secure the unit. Ensure that the end of the mounting screws fit into the indentations on the mounting
collar.
Figure 2.4 Mounting with the Collar Bracket
Panel
Bezel
Adjustable
Mounting
Brackets
(top and bottom
of scanner)
Mounting Collar
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
+
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CAS200 User’s Guide Chapter 2: Installation
Mounting the TB50
There are two ways you can mount the TB50, by using the
pre-installed DIN rail mounting brackets provided or by
using the plastic standoffs. Follow the procedures for each
to mount the board.
Figure 2.5 Mounting
TB50
Mounted to
DIN Rail
TB50 Mounted
with Standoffs
NOTE! If you choose to use the standoffs, you will need
to remove the DIN rail brackets before you can
mount the board.
DIN Rail Mounting
1. Attach the SCSI connector to the TB50.
2. Snap the TB50 to the DIN rail.
3. To remove the TB50 from the rail, use a screw driver
Mounting with Standoffs
1. Remove the DIN rail mounting brackets from the
2. Select a location with enough clearance to safely
3. Place the TB50 where you will mount it and use a pen-
4. Drill and tap #6-32 holes in the locations you marked.
5. Place the TB50 where you will mount it. Insert the #6
6. There are also four smaller holes on the terminal
to unsnap the bracket from the rail with a flat-head
screw driver.
TB50.
remove the TB50, its SCSI cable and the scanner itself.
cil to trace around the standoffs.
screws in the standoffs and tighten them.
board for mounting with tie wraps. Use these holes to
secure wiring to the terminal block.
Watlow Anafaze 13
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Chapter 2: Installation CAS200 User’s Guide
Figure 2.6 Mounting Dimensions
3.60 in.
2.60 in.
0.50 in.
3.40 in.
Standoffs, 4 places
for use with #6-32 screws
System Wiring
∫
WARNING! To reduce the risk of electrical shock, fire, and
Successful installation and operation of the alarm scanner
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 system. This
section includes wiring recommendations, instructions for
proper grounding and noise suppression, and
considerations for avoiding ground loops.
equipment damage, follow all local and national
electrical codes. Correct wire sizes, fuses and
thermal breakers are essential for safe operation
of this equipment.
14 Watlow Anafaze
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CAS200 User’s Guide Chapter 2: Installation
ç
CAUTION! Do not wire bundles of low-voltage signal and
control circuits next to bundles of high-voltage ac
wiring. High voltage may be inductively coupled
onto the low-voltage circuits, which may damage
the scanner or induce noise and cause poor
control.
Physically separate high-voltage circuits from
low-voltage circuits and from CAS200 hardware.
If possible, install high-voltage ac power circuits
in a separate panel.
Wiring Recommendations
Follow these guidelines for selecting wires and cables:
• Use stranded wire. (Solid wire can be used for fixed
service; it makes intermittent connections when you
move it for maintenance.)
2
• Use 20 AWG (0.5 mm
Larger or smaller sizes may be difficult to install, may
break easily, or may cause intermittent connections.
• Use shielded wire. The electrical shield protects the
signals and the CAS200 from electrical noise. Connect
one end of the input and output wiring shield to earth
ground.
• Use copper wire for all connections other than
thermocouple sensor inputs.
) thermocouple extension wire.
Watlow Anafaze 15
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Chapter 2: Installation CAS200 User’s Guide
Table 2.1 Cable Recommendations
Function Mfr. P/N
Analog Inputs
RTD Inputs
Thermocouple Inputs T/C Ext. Wire 2 20 0.5
Control Outputs and Digital I/O
Analog Outputs
Computer Communication: EIA/TIA-232, 422 or
485, or 20 mA
Belden 9154
Belden 8451
Belden 8772
Belden 9770
Belden 9539
Belden 9542
Ribbon Cable
Belden 9154
Belden 8451
Belden 9729
Belden 9730
Belden 9842
Belden 9843
Belden 9184
No. of
Wires
2
2
3
3
9
20
50
2
2
4
6
4
6
4
AWG
20
22
20
22
24
24
22-14
20
22
24
24
24
24
22
mm
0.5-2.5
Noise Suppression
0.5
0.5
0.5
0.5
0.2
0.2
0.5
0.5
0.2
0.2
0.2
0.2
0.5
2
4000 ft. (1219 m)
4000 ft. (1219 m)
6000 ft. (1829 m)
Maximum
Length
Symptoms of RFI/EMI
The CAS200’s outputs are typically used to drive solid state
relays. These relays may in turn operate more inductive
types of loads such as electromechanical relays, alarm
horns and motor starters. Such devices may generate
electromagnetic interference (EMI or noise). If the scanner
is placed close to sources of EMI, it may not function
correctly. Below are some tips on how to recognize and
avoid problems with EMI.
For earth ground wire, use a large gauge and keep the
length as short as possible. Additional shielding may be
achieved by connecting a chassis ground strap from the
panel to CAS200 case.
If your scanner displays the following symptoms, suspect
EMI:
• The scanner’s display blanks out and then reenergizes
as if power had been turned off for a moment.
• The process variable does not display correctly.
EMI may also damage the digital output circuit—so digital
outputs will not turn on. If the digital output circuit is
damaged, return the scanner to Watlow Anafaze for repair.
16 Watlow Anafaze
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CAS200 User’s Guide Chapter 2: Installation
Avoiding RFI/EMI
To avoid or eliminate most RFI/EMI noise problems:
• Connect the CAS200 case to earth ground. The
CAS200 system includes noise suppression circuitry.
This circuitry requires proper grounding.
• Separate the 120 or 240 Vac power leads from the lowlevel input and output leads connected to the CAS200
series scanner. Do not run the digital I/O or alarm
output leads in bundles with ac wires.
• Where possible, use solid state relays (SSRs) instead of
electromechanical (EM) relays. If you must use EM
relays, try to avoid mounting them in the same panel
as the CAS200 series equipment.
• If you must use EM relays and you must place them in
a panel with CAS200 series equipment, use a 0.01
microfarad capacitor rated at 1000 Vac (or higher) in
series with a 47Ω, 0.5 watt resistor across the N.O.
contacts of the relay load. This is known as a snubber
network and can reduce the amount of electrical noise.
• You can use other voltage suppression devices, but
they are not usually required. For instance, you can
place a metal oxide varistor (MOV) rated at 130 Vac
for 120 Vac control circuits across the load, which
limits the peak ac voltage to about 180 Vac (Watlow
Anafaze part number 26-130210-00). You can also
place a transorb (back-to-back zener diodes) across the
digital output, which limits the digital output voltage.
Additional Recommendations for a Noise Immune System
It is strongly recommended that you:
• Isolate outputs through solid state relays, where
possible.
• Isolate RTDs or “bridge” type inputs from ground.
• Isolate digital inputs from ground through solid state
relays. If this is not possible, then make sure the
digital input is the only connection to earth ground
other than the chassis ground.
• If you are using EIA/TIA-232 from a non-isolated host,
either (1) do not connect any other power common
point to earth ground, or (2) use an optical isolator in
the communications line.
Watlow Anafaze 17
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Chapter 2: Installation CAS200 User’s Guide
Ground Loops
Ground loops occur when current passes from the process
through the scanner 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. Do not connect any of
the following terminals to each other or to earth ground:
• Power supply dc common
• TB1, terminals 5, 6, 11, 12 (analog common)
• TB1, terminal 17 (reference voltage common)
• TB1, terminals 23, 24 (communications common)
• TB2, terminal 2 (dc power common)
The CAS200 has single-ended inputs. All the negative
sensor leads are tied to the analog common. That means
there is no sensor-to-sensor isolation. Proper grounding is
critical for this unit. Take these precautions:
• Use all ungrounded or all well-grounded
thermocouples, not a mix.
• If using a mixture of thermocouples or low-voltage
inputs (<500 mV) and current inputs, connect the
negative leads of the current transmitters to terminal
17 (Ref Com) on TB1.
• If using voltage transmitters, use only sourcing
models or configuration. Sinking configurations will
not work.
• Isolate the scanner’s communication port (if used) by
using an optically isolated 232-to-485 converter.
Personal Computers and Ground Loops
Many PC communications ports connect the
communications common to chassis ground. When such a
PC is connected to the scanner, this can provide a path to
ground for current from the process that can enter the
scanner through a sensor (such as a thermocouple). This
creates a ground loop that can affect communications and
other scanner functions. To eliminate a ground loop, either
use an optically isolated communications adapter or take
measures to ensure that sensors and all other connections
to the scanner are isolated and not conducting current into
the unit.
18 Watlow Anafaze
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CAS200 User’s Guide Chapter 2: Installation
Power Connections
Figure 2.7 CAS200 Series Scanner
TB2
(to power
supply)
Wiring the Power Supply
ç
CAUTION! Use a power supply with a Class 2 rating only. UL
approval requires a Class 2 power supply.
Connect power to the scanner before any other connections.
This allows you to ensure that the scanner is working
before any time is taken installing inputs and outputs.
TB1
(to signal
inputs
SCSI Port
(to TB50)
Watlow Anafaze 19
Page 32
Chapter 2: Installation CAS200 User’s Guide
Figure 2.8 Power Connections with the
CAS200 Power Supply
Power Supply
+5V
5V COM
+15V
15V COM
-15V
Ground
AC Line
AC Neutral
white
120/240
Vac
Supply
** Connect terminals to ac panel ground.
N
black
H
green
G
**
* If using 5Vdc for outputs, jumper 5V common to 15V common.
Add jumper *
SSR
SSR
G
C
N
OMV
D
+
CAS200
**
SSR
SSR
Table 2.2 Power Connections
Function Power Supply CAS200 TB2
DC Power +12 to 24Vdc +
DC Common
Earth Ground Ground
1. Plug in and test the +/- voltage of your power supply to
determine polarity.
2. Locate the + and - connectors at the left on the back of
the scanner.
3. Attach the positive wire to the + connector on TB2 and
tighten.
4. Attach the negative wire to the COM connector on TB2
and tighten.
20 Watlow Anafaze
12 to 24Vdc
Common
-
Page 33
CAS200 User’s Guide Chapter 2: Installation
5. A third Ground connector on TB2 is available for chassis ground. This terminal is connected to the CAS200
chassis and must be connected to earth ground.
NOTE! Connect the dc common of the power supply
used for loads to the dc common of the supply
powering the scanner. If the supplies are not referenced to one another, the scanner’s outputs
will not be able to switch the loads.
NOTE! When making screw terminal connections, tight-
en to 4.5 – 5.4 inch-pound (0.5 – 0.6 Nm).
ç
CAUTION! Without proper grounding, the CAS200 may not
operate properly or may be damaged.
ç
CAUTION! To prevent damage from incorrect connections,
do not turn on the ac power before testing the
connections as explained in Testing Power to the
Scanner on page 21.
NOTE! Do not connect the scanner’s dc common (COM)
to earth ground . Doing so will defeat the noise
protection circuitry, making measurements less
stable.
Testing Power to the Scanner
1. Perform a no-key reset by holding the "NO" key while
applying power to the CAS200. The no-key reset sets
all parameters to their defaults.
2. When powered up, the following screen should be
displayed on the scanner. If it is not, try repeating the
no-key reset.
CHANNEL PROCESS UNITS
RESET WITH
DEFAULTS ?
CHANNEL NAME ALARM STATUS
Watlow Anafaze 21
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Chapter 2: Installation CAS200 User’s Guide
3. Press "Y" for Yes to reset all the parameters. When all
parameters are reset the scanner will display the
following.
CHANNEL PROCESS UNITS
01 70°F
CHAN 01
CHANNEL NAME ALARM STATUS
Connecting the TB50 to the CAS200
For a CAS200 scanner with the TB50 option:
1. Connect the SCSI cable to the scanner.
2. Connect the SCSI cable to the TB50.
Input Wiring
Sensor Connection
∫
WARNING! Never run input leads in bundles with high power
This section describes how to properly install inputs to your
scanner. Inputs refer to thermocouples, current and
voltage Inputs. The scanner can accept any mix of available
input types. Some input types require that special scaling
resistors be installed (generally done by Watlow Anafaze
before the scanner is delivered). All inputs are installed at
the channel input connectors (TB1) at the back of the
scanner. The illustrations below show the connector
locations for the CAS216 scanner.
leads.
Figure 2.9 Sensor Connections
1 3 5 7 9 11 13 15 17 19 21 23 25
TB2
+
+V C
-
m
TB1
o
C
CH
CH
CH
o
1
2
m
IN+
IN+
IN+
2 4 6 8 10 12 14 16 18 20 22 24 26
C
CH
IN+
CH
o
9
10
m
IN+
Gnd
C
CH
o
3
4
m
IN+
CH
CH
11
12
IN+
IN+
CH
IN+
C
m
Ref
CH
CH
Com
5
6
CH
14
IN+
IN+
+5V
Ref
7
IN+
CH
o
13
IN+
IN+
CH
15
IN+
CH
8
RXB
IN+
Gnd
CH
16
CLS216
RX
CAS200
/
/
RXA
TX
TXA
MADE
IN THE
/
USA
Gnd
TXB
/
Follow the instructions pertaining to the type(s) of input(s)
you are installing.
22 Watlow Anafaze
Page 35
CAS200 User’s Guide Chapter 2: Installation
The scanner accepts the following inputs without any
special scaling resistors:
• J, K, T, S, R, and B thermocouples.
• Linear inputs with ranges between -10 and 60 mV.
Any unused inputs should be set to “SKIP” or jumpered to
avoid thermocouple break alarms.
Connect signal inputs to TB1 as shown below. Note that
some inputs require scaling resistors that are generally
factory installed.
Thermocouple Connections
Use 18 or 20 AWG thermocouple (T/C) extension wire for
all the thermocouple inputs. Most thermocouple wire is
solid unshielded wire. Use shielded wire if required at your
installation; ground one end only.
Figure 2.10 Wiring Thermocouple Inputs
Ch # IN +
Com
White
Red
Shield (if present)
Type J T/C
Earth Ground
at Process End
Since the CAS200 has single ended inputs, it has little
protection from common mode voltage sources. Therefore,
Watlow Anafaze highly recommends that you use
ungrounded thermocouples with the external
thermocouple sheath electrically connected to earth
ground.
You can use 400 to 500 feet of thermocouple extension wire,
depending on wire type and size, and keep to accuracy and
source impedance specifications. Always install
thermocouple wiring in separate conduit away from AC
power (the 120Vac control supply) and high power (240Vac
or higher) wiring.
Watlow Anafaze 23
Page 36
Chapter 2: Installation CAS200 User’s Guide
∫
WARNING! The scanner uses a floating ground system.
Therefore, isolate input devices or host
computers connected through communications
cables (like EIA/TIA-232) from earth ground. Use
ungrounded thermocouples with the
thermocouple sheath electrically connected to
earth ground. Use optically isolated EIA/TIA-232
devices to isolate earth grounded host computers
from the scanners.
When you use grounded thermocouples, tie the
thermocouple sheaths to a common earth ground
in one place. Otherwise any common mode
voltages that exceed 5 volts may cause incorrect
readings or damage to the scanner.
Voltage Input Connections
This input type requires scaling resistors. Special input
resistors installed at Watlow Anafaze divide analog input
voltages such that the scanner sees a -20 to 60mV signal on
the channel.
Figure 2.11 Wiring Voltage Input Connections
Ch# IN+
Current Input Connections
This input type requires special input resistors. Resistors
installed at Watlow Anafaze for analog current signals are
such that the scanner sees a -10 to 60mV signal across its
inputs for the channel.
Figure 2.12 Wiring Current Input Connections
Com/Ref Com
Com
Ch# IN+
Device with
Voltage
Output
Device with
Current
Output
Do not use the scanner’s power supply to power sensors,
transmitters or output devices.
24 Watlow Anafaze
Page 37
CAS200 User’s Guide Chapter 2: Installation
NOTE! When mixing current inputs with low voltage in-
puts (thermocouples or voltage inputs less than
one volt), connect the current signal to the IN+
and Ref Com terminals. When no low voltage sensors are used, the current inputs can be wired to
the IN+ and Com terminals on the TB1.
Serial Communications
The CAS200 series scanners are factory-configured for
EIA/TIA-232 communications unless otherwise specified
when purchased. However, the communications are
jumper-selectable, so you can switch between EIA/TIA-232
and EIA/TIA-485. See Changing Communications on page
81.
EIA/TIA-232 Interface
EIA/TIA-232 provides communication to the serial port of
an IBM PC or compatible computer. It is used for singlescanner installations where the cable length does not
exceed 50 feet (15 m).
The EIA/TIA-232 interface is a standard three-wire
interface. Table 2.3 shows EIA/TIA-232 connections for 25pin and 9-pin connectors or cables that are supplied by the
factory.
If you are using EIA/TIA-232 communications with
grounded thermocouples, use an optical isolator between
the scanner and the computer to prevent ground loops.
EIA/TIA-232 may be used to connect a computer through a
232-to-485 converter to an EIA/TIA-485 communications
network with up to 32 CAS200 scanners.
Table 2.3 EIA/TIA-232 Connections
Wire
Color
White TX Pin 26 RX Pin 2 RX Pin 3
Red RX Pin 25 TX Pin 3 TX Pin 2
Black GND Pin 23 GND Pin 5 GND Pin 7
Green GND Pin 24 N/U Pin 9 N/U Pin 22
Shield N/C GND Pin 5 GND Pin 7
CAS200
TB1
DB 9
Connector
DB 25
Connector
Jumpers in EIA/TIA-232 Connectors
Some software programs and some operator interface
terminals require a clear to send (CTS) signal in response
Watlow Anafaze 25
Page 38
Chapter 2: Installation CAS200 User’s Guide
to their request to send (RTS) signal, or a data set ready
(DSR) in response to their data terminal ready (DTR). The
CAS200 is not configured to receive or transmit these
signals. To use such software with the CAS200, jumper the
RTS to the CTS and the DTR to the DSR in the DB
connector. Table 2.4 lists the standard pin assignments for
DB-9 and DB-25 connectors.
Table 2.4 RTS/CTS and DSR/DTR Pins in
DB-9 and DB-25 Connectors
DB-9 DB-25
RTS 74
CTS 85
DTR 420
DSR 66
Cables manufactured by Watlow Anafaze for EIA/TIA-232
communications include these jumpers. WATVIEW does
not require these jumpers.
EIA/TIA-485 Interface
Figure 2.13 Connecting One CAS200 to a
Computer Using EIA/TIA-232
EIA/TIA-232
cable
P
M
A
K
R
RAMP
A
O
S
SOAK
M
R
A
L
A
ALARM
K
C
A
ACK
UNITSUNITS
ENTER ENTER
OUT%OUT%
PROCESSPROCESS
K
C
A
B
BACK
LOOPLOOP
STATUSSTATUS
WATLOW ANAFAZE CLS200WATLOW ANAFAZE CLS200
NO NO
SETPOINTSETPOINT
S
E
Y
YES
ALARMALARM
G
N
H
C
CHNG
P
S
SP
N
A
M
O
MAN
T
U
A
AUTO
To communicate with more than one CAS200 series
scanner on a scanner network, or to use communication
cable lengths greater than 50 feet (15 m) from PC to
scanner, you must use EIA/TIA-485 communications.
When using EIA/TIA-485 communications, you must
attach an optically isolated 232-to-485 converter to the
computer.
Figure 2.13 and Figure 2.15 show the recommended system
wiring. To avoid ground loops, use an optically isolated 232to-485 converter between the computer and the EIA/TIA485 network.
26 Watlow Anafaze
Page 39
CAS200 User’s Guide Chapter 2: Installation
Figure 2.14 EIA/TIA-485 Wiring
232-to-485 Converter
TXA/TDA/TX-
TXB/TDB/TX+
Personal
Computer
RXA/RDA/RX-
RXB/RDB/RX+
Cable Recommendations
Watlow Anafaze recommends Belden 9843 cable or its
equivalent. This cable includes three 24 AWG (0.2 mm
shielded twisted pairs. It should carry signals of up to
19200 baud with acceptable losses for up to 4000 feet (1220
m).
First CAS200 Last CAS200
JU1
RXA 25
RXB 23
TXA 26
TXB 24
JU1
A
B
Do not
connect
shield to
CAS200
RXA 25
RXB 23
TXA 26
TXB 24
A
B
2
),
EIA/TIA-485 Network Connections
Watlow Anafaze recommends that you use a single daisy
chain configuration rather than spurs. Run a twisted-pair
cable from the host or converter to the first CAS200, and
from that point run a second cable to the next CAS200, and
so on. See Figure 2.15.
If necessary for servicing, instead of connecting each
scanner directly to the next, install a terminal strip or
connector as close as possible to each CAS200, run a
communications cable from one terminal strip to the next
and connect the scanners to the bus with short lengths of
cable.
To avoid unacceptable interference, use less than 10 feet (3
m) of cable from the terminal or connector to the CAS200
serial port.
Some systems may experience problems with sensor signal
readings if the commons of multiple scanners are
connected. See Signal Common on page 28 for more
information.
Refer to Termination on page 28 for more on terminating
resistors.
Connect the shield drain to earth ground only at the
computer or host end.
Watlow Anafaze 27
Page 40
Chapter 2: Installation CAS200 User’s Guide
Figure 2.15 Recommended System
Connections
232 Communications 485 Communications
Serial Port
Optically
Isolating
232-to-485
Converter
Shielded Twisted Pair Cable
Signal Common
Termination
P
RAM
RAMP
AK
SO
SOAK
M
R
A
L
A
ALARM
K
C
A
ACK
S
IT
UN
UNITS
R
SS
E
T
N
UT%
CE
E
ENTER
O
OUT%
RO
P
PROCESS
S
P
U
O
BACK BACK
LO
LOOP
TAT
STATUS
S
WATLOW ANAFAZE CLS200WATLOW ANAFAZE CLS200
NO NO
T
IN
O
P
SETPOINT
SET
S
M
E
R
Y
YES
ALA
ALARM
G
CHN
CHNG
SP
SP
AN
M
MAN
UTO
A
AUTO
First CAS200 Second CAS200
S
ES
C
RO
P
PROCESS
P
O
LO
LOOP
WATLOW ANAFAZE CLS200WATLOW ANAFAZE CLS200
T
IN
PO
ET
SETPOINT
S
S
M
E
Y
YES
LAR
A
ALARM
G
CHN
CHNG
SP
SP
MAN
MAN
AUTO
AUTO
P
M
RA
RAMP
AK
SO
SOAK
M
R
A
L
A
ALARM
K
C
A
ACK
UNITSUNITS
R
E
T%
T
N
U
E
ENTER
O
OUT%
S
U
BACK BACK
TAT
STATUS
S
NO NO
ESS
C
O
R
P
PROCESS
P
O
LO
LOOP
WATLOW ANAFAZE CLS200WATLOW ANAFAZE CLS200
T
N
I
O
P
T
SE
SETPOINT
S
E
RM
Y
A
YES
L
A
ALARM
G
CHN
CHNG
SP
SP
AN
M
MAN
AUTO
AUTO
MP
RA
RAMP
AK
SO
SOAK
M
R
A
L
A
ALARM
K
C
A
ACK
S
NIT
U
UNITS
R
E
T
N
UT%
E
ENTER
O
OUT%
S
U
BACK BACK
TAT
STATUS
S
NO NO
Last CAS200
For usual installations, do not connect the dc commons of
the scanners together or to the converter or host device.
Use an optically isolating 232-to-485 converter to prevent
problems with sensor readings.
For EIA/TIA-485 signals to be transmitted properly, each
pair must be properly terminated. The value of the
termination resistor should be equal to the impedance of
the communications cable used. Values are typically 150 to
200Ω.
The receive lines at the converter or host device should be
terminated in the converter, the connector to the host
device or the device itself. Typically the converter
documentation provides instructions for termination.
Use a terminating resistor on the receive lines on the last
scanner on the 485 line. Set jumper JU1 in position B to
connect a 200Ω resistor across the receive lines. See
Changing Communications on page 81.
28 Watlow Anafaze
Page 41
CAS200 User’s Guide Chapter 2: Installation
EIA/TIA-485 Converters and Laptop Computers
For a 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. These computer/
converter combinations can usually be used by connecting
an external power supply to the 232 side of the converter.
Not all converters have power inputs for the 232 side,
however.
Wiring Digital I/O
This section describes how to wire and configure the alarm
outputs for the CAS200 series scanner.
All digital outputs are sink outputs referenced to the
CAS200 common. These outputs are Low (pulled to
common) when they are On.
All digital inputs are Transistor-Transistor Logic (TTL)
level inputs referenced to control common.
The digital I/O are located on the (EIA/TIA-232 remote
TB50.
Noise Suppression
Symptoms of RFI/EMI
The CAS200 outputs are typically used to drive solid state
relays. These relays may in turn operate more inductive
loads such as electromechanical relays and alarm horns.
These devices may generate electromagnetic interference
(EMI or noise). If the scanner is placed near sources of EMI,
it may not function correctly. Below are some tips on how
to recognize and avoid problems with EMI.
If your scanner displays the following symptoms, suspect
EMI.
• The scanner's display blanks out and then reenergizes
as if power had been turned Off for a moment.
• The process variable does not display correctly.
EMI may also damage the digital output circuit—so digital
outputs will not energize. If the digital output circuit is
damaged, return the scanner to Watlow Anafaze for repair.
Watlow Anafaze 29
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Chapter 2: Installation CAS200 User’s Guide
Avoiding Noise Problems
To avoid noise problems be sure ground wire terminal (on
TB2) is connected to earth ground.
Where possible, use solid state relays (SSRs) instead of
electromechanical (EM) relays. If you must use EM relays,
try to avoid mounting them in the same panel as the
CAS200 series equipment.
Separate the 120/240Vac power leads from the low level
input and output leads connected to the CAS200 series
scanner. Don't run the digital output or control output
leads in bundles with 120/240Vac wires. (Never run input
leads in bundles with high power leads).
If you must use EM relays and you must place them in a
panel with CAS200 series equipment, use a 0.01
microfarad capacitor rated at 1000Vac (or higher) in series
with a 47Ω, ∫ watt resistor across the NO contacts of the
relay load. This network is known as an arc suppressor or
snubber network.
You can use other voltage suppression devices, but they are
not usually required. For instance, you can place a metal
oxide varistor (MOV) rated at 130Vac for 120Vac control
circuits across the load, which limits the peak AC voltage
to about 180Vac (Watlow Anafaze P/N 26-130210-00). You
can also place a transorb (back to back zener diodes) across
the digital output, which limits the digital output voltage.
The above steps will eliminate most noise problems. If you
have further problems or questions, please contact Watlow
Anafaze.
Digital Outputs
The CAS200 scanner provides 35 digital outputs. The
digital outputs sink current from a load connected to the
scanner's internal power supply or from an external power
supply referenced to the scanner analog common.
• If you use an external power supply, do not exceed +24
volts.
• If you tie the external load to ground, or if you cannot
connect it as shown on the following page, then use a
solid state relay.
• If you connect an external supply to earth or
equipment ground, use solid state relays to avoid
ground loop currents. (Ground loop currents may
degrade analog measurements in the scanner.)
The outputs conduct current when they are LOW or ON.
The maximum current sink capability is 60mA at 24Vdc.
They cannot “source” current to a load.
30 Watlow Anafaze
Page 43
CAS200 User’s Guide Chapter 2: Installation
Figure 2.16 Wiring Digital Outputs
TB50
External
+5Vdc
Digital Output 1
Digital Output 2
Load
Power Supply
+
-
Do not connect to earth
ground or equipment ground
Using Internal Power Supply
Alarm Output Connections
Typical alarm outputs use external optically isolated solidstate relays (SSRs). The SSRs use a 3 to 32Vdc input for
control, and you can size them to switch up to 100A at
480Vac. For larger currents, you can use SCR power
controls or optically isolated SSRs to drive contactors.
NOTE! Alarm outputs are SINK outputs. They are Low
when the output is On. Connect them to the negative side of Solid State Relays.
Control Common
Digital Output 1
Digital Output 2
Using External Power Supply
The figure below shows sample alarm output connections.
Figure 2.17 Wiring Alarm Output Connections
TB50
Alarm Output 1
Alarm Output 2
Alarm Output 3
+5Vdc
Watlow Anafaze 31
SSR SSR SSR
+-
+-
+-
Page 44
Chapter 2: Installation CAS200 User’s Guide
CPU Watchdog
The CPU watchdog monitors the microprocessor. Its sink
output is located on
5Vdc, 10mAdc rating for the watchdog timer.) The output
is Low (On) when the microprocessor is operating; when it
stops operating, the output goes High (Off), which deenergizes the SSR.
The figure below shows the recommended circuit for the
watchdog timer output.
Figure 2.18 Wiring Watchdog Timer Output
TB50
TB50 terminal #6. (Do not exceed the
Digital Inputs
+ 5Vdc
(pin 1)
CPU Watchdog
(pin 6)
All digital inputs are transistor-transistor logic (TTL) level
inputs referenced to control common and the internal +5V
power supply of the CAS200.
The eight digital inputs are pulled up to 5Vdc with respect
to the scanner common by internal 10kW resistors when
not pulled low by an external device. In this high state, the
input is considered off. When an input is connected to the
scanner common, the input is pulled low and considered on.
Features that use the digital inputs can be user-configured
to activate when an input is either high or low.
To insure the inputs are reliably switched, use a switching
device with the appropriate impedances in the on and off
states and do not connect the inputs to external power
sources. When off, the switching device must provide an
impedance of at least 11kW in order to ensure the voltage
will rise to greater than 3.7Vdc. When on, the switch must
provide not more than 1kW impedance in order to insure
the voltage drops below 1.3Vdc.
To install a switch as a digital input, connect one lead to the
common terminal on the TB50 (terminals 3 and 4). Connect
the other lead to the desired digital input terminal on the
TB50 (terminals 43-50).
Digital inputs are used to activate various functions. See
Chapter 4, Setup on page 41.
+
SSR
-
32 Watlow Anafaze
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CAS200 User’s Guide Chapter 2: Installation
Figure 2.19 Wiring Digital Inputs
TB50
Input
Control Com
Digital
Input
Device
Table 2.5 TB50 Connections for CAS200
Terminal Function Terminal Function
1 +5Vdc 2 +5Vdc
3 CTRL COM 4 CTRL COM
5 Not Used 6 Watchdog Timer
7 Pulse Input 8 Global Alarm
9 DIG output 1 10 DIG output 34
11 DIG output 2 12 DIG output 33
13 DIG output 3 14 DIG output 32
15 DIG output 4 16 DIG output 31
17 DIG output 5 18 DIG output 30
19 DIG output 6 20 DIG output 29
21 DIG output 7 22 DIG output 28
23 DIG output 8 24 DIG output 27
25 DIG output 9 26 DIG output 26
27 DIG output 10 28 DIG output 25
29 DIG output 11 30 DIG output 24
31 DIG output 12 32 DIG output 23
33 DIG output 13 34 DIG output 22
35 DIG output 14 36 DIG output 21
37 DIG output 15 38 DIG output 20
39 DIG output 16 40 DIG output 19
41 DIG output 17 42 DIG output 18
43 DIG input 1 44 DIG input 2
45 DIG input 3 46 DIG input 4
47 DIG input 5 48 DIG input 6
49 DIG input 7 50
Watlow Anafaze 33
DIG input 8 External Alarm
Acknowledge
Page 46
Chapter 2: Installation CAS200 User’s Guide
Table 2.6 TB18 Connections
Terminal Function
1 +5 Vdc
2 CTRL COM
3 Watchdog timer
4 Global alarm
5 Output 1
6 Output 2
7 Output 3
8 Output 4
9 Output 5
10 Output 6
11 Output 7
12 Output 8
13 Output 9
14 Output 10
15 Output 34
16 Input 1
17 Input 2
18 Input 3/Pulse input
34 Watlow Anafaze
Page 47
Introduction
This chapter will show you how to use the CAS200 from the
front panel. The next diagram shows how to reach the
operator menus from Single Channel display. (To change
global parameters, channel inputs, and alarms from the
setup menus, you must enter a special sequence of keys. To
learn how, see Chapter 4, Setup on page 41.
Figure 3.1 Navigating with a Single Channel
3
Using the CAS200
Display
BACK
BACK
BACK
CHNG
Job
Display
SP
Change
Setpoint
Power ON
ENTER
Watlow Anafaze 35
Single
channel
display
ENTER
Any Key
Single
channel
scanning
display
Page 48
Chapter 3: Using the CAS200 CAS200 User’s Guide
Front Panel
The front panel provides a convenient interface with the
CAS200 system. You can program and operate the CAS200
with the front panel keys shown below, or you can use
WatView or ANASCAN software.
Figure 3.2 Front Panel Display
FUNC
FUNC
-No function in the
CAS200.
Change Setpoint
-Used for changing setpoints.
Front Panel Keys
YES
CHANNEL PROCESS UNITS
CHANNEL NAME ALARM STATUS
CHNG
SP
Yes
-Selects a menu
-Answers Yes to Yes/No prompts
-Increases a number or choice
YES
NO
No
-Skips a menu
-Answers No to Yes/No prompts
-Decreases a number or choice
you are editing
BACK
Back
-Aborts editing and
returns to a previous menu
ALARM
RESET
ALARM
ACK
ENTER
Yes
Press Yes to:
• Select a menu.
• Answer Yes to Yes/No questions.
• Increase a number or choice you're editing.
Alarm Reset
-Resets alarms when
the process is safe
Alarm Ack
-Turns off global alarm,
digital alarm stays active
Enter
-Stores data or menu choices
& advances to the next menu
- Starts scanning mode
(if pressed twice)
NO
No
Press No to:
• Skip a menu you don't want to edit when the prompt is
blinking.
• Answer No to Yes/No prompts.
• Decrease a number or choice when editing.
• Perform a
36 Watlow Anafaze
NO-key reset to clear the memory.
Page 49
CAS200 User’s Guide Chapter 3: Using the CAS200
∫
WARNING! The NO-key reset clears the system's memory
and reinitializes the CAS200 factory defaults. To
do a Manual System Reset, power down the
CAS200, press and hold the No key during powerup. This is required during installation, after
changing the EPROM, or when troubleshooting.
BACK
ENTER
ALARM
ACK
Back
The Back key works like an "escape" key. Press it to:
• Abort editing.
• Return to a previous menu.
• Switch between single channel and job control
displays.
Enter
• Press the Enter key to:
• Store data or menu choices after editing and go to the
next menu.
• Start scanning mode (if pressed twice).
Alarm Ack
• Press Alarm Ack to:
• Acknowledge an alarm condition and reset the global
alarm.
• Stop the scanning display.
ALARM
RESET
Alarm Reset
• Press Alarm Reset to:
• Clear an alarm when the process is in a non-alarming
state.
• Acknowledge an alarm if the process is in an alarming
state.
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Chapter 3: Using the CAS200 CAS200 User’s Guide
CHNG
SP
Change SP
Press Change SP to change the setpoints.
FUNC
Func
The FUNC key is not used in normal operation. It is
reserved for future enhancement.
Single Channel Display
Single Channel display (below) shows detailed information
for one channel.
Process Variable
Channel Number
Default Channel
Name
Engineering Units
CHANNEL PROCESS UNITS
02 347 ˚F
CHAN 01
CHANNEL NAME ALARM STATUS
Job Display
From Single Channel Display,
• Press Yes to go to the next channel.
• Press No to go to the previous channel.
• Press the Back key once to go to Job display (if it is
enabled).
• Press Enter twice to start Single Channel Scanning
display. (The Single Channel Scanning Display shows
information for each channel for one second.)
• Press any key to stop scanning mode.
Job display appears only if:
• You have turned on the Remote Job Select function.
(This function is explained in Chapter 4: Setup.)
• You have selected a job from the job load menu.
38 Watlow Anafaze
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CAS200 User’s Guide Chapter 3: Using the CAS200
When you load a job, Job display shows you this screen:
CHANNEL PROCESS UNITS
JOB 3 RUNNING
CHANNEL NAME ALARM STATUS
If you remotely loaded the job, Job display looks like this:
CHANNEL PROCESS UNITS
JOB 3 RUNNING
REMOTELY LOADED
CHANNEL NAME ALARM STATUS
If you modify a job's parameters while the job is running,
you'll see this message:
CHANNEL PROCESS UNITS
JOB 3 RUNNING
DATA MODIFIED
CHANNEL NAME ALARM STATUS
Change Setpoint
If an alarm occurs, the scanner switches to Single Channel
Display.
To change the set point, go to the Single Channel Display
of the channel you want to change, and press the Change
Setpoint key (the set point is the desired temperature, pH,
et cetera, for the process). You should see a display like
this:
CHANNEL PROCESS UNITS
03 SETPOINT ?
500 ˚ F
CHANNEL NAME ALARM STATUS
• Press Yes to change the set point.
• Then press Yes or No to change the set point value.
• When you are satisfied with the set point value you
have chosen, press Enter to save your changes and
return to Single Channel Display; or
• To return to Single Channel Display without saving
your changes, press No or Back.
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Chapter 3: Using the CAS200 CAS200 User’s Guide
Alarms
If an alarm occurs, an eight character alarm code is
displayed in the lower-right section of the display.
Channel Number
Channel Name
These alarm codes and messages are shown in the table
below.
TC BREAK Thermocouple Break
HIGH PRC High process alarm
HIGH DEV High deviation alarm
LOW DEV Low deviation alarm
LOW PRC Low process alarm
Acknowledging an Alarm
Press the Alarm Acknowledge key to acknowledge an
alarm. If there are other channels with alarm conditions,
the Alarm display switches to the next channel in alarm.
Acknowledge all alarms to clear the global alarm.
The Alarm Acknowledge key operates differently in latched
and unlatched modes. In latched mode, an alarm can only
be cleared when the process is in a non-alarming state, and
the Alarm Reset key is pressed. In un-latched mode, the
alarm clears automatically when the Alarm Acknowledge
key is pressed and the system is in a non-alarming state.
Process Variable
CHANNEL PROCESS UNITS
Engineering Units
01 90 ˚F
HTR1 HIGH PRC
CHANNEL NAME ALARM STATUS
Alarm Message
Alarm Message Alarm Type
Resetting an Alarm
Pressing the Alarm Reset key clears an alarm only if the
system in a non-alarming state. Otherwise, the key will
operate the same as the Alarm Acknowledge key.
40 Watlow Anafaze
Page 53
CAS200 Menus
The Setup menus let you change detailed configuration
information.
How to Enter the Setup Menus
1. In Single Channel Display, select the channel you wish
to edit.
2. While still in Single Channel Display, enter the pass
sequence below: Press Enter, Alarm Ack, Change
Setpoint.
4
Setup
ENTER
3. The first setup menu appears.
SETUP GLOBAL
PARAMETERS?
ALARM
ACK
CHANNEL PROCESS UNITS
CHANNEL NAME ALARM STATUS
CHNG
SP
NOTE! If you are in the Setup menus and you don't make
any changes for three minutes, the CAS200 reverts to Single Channel Display for your protection.
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Chapter 4: Setup CAS200 User’s Guide
How to Edit a Menu
• Press Yes to select the menu or No to advance to the
next menu.
• Press Yes or No to toggle between the option in your
menu.
• Press Enter to store the value you have selected.
• If you decide not to edit the menu, press Back to stop
editing and return to the main menu.
Each display contains the default value for that specific
menu, and below each display, you will see the range of
choices for that menu.
The following sections tell more about the submenus for
each of the four main menus. The next page shows the
setup menus accessible from Single Channel Display.
42 Watlow Anafaze
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CAS200 User’s Guide Chapter 4: Setup
Single Channel Display
CHNG
ALARM
Passkey Sequence
ENTER
SP
ACK
Setup Global
Parameters
Job Select Inputs
Job Select Input
Startup Alarm Del.
Controller Address
NO
Digital Output Pol
EPROM Informa-
YES
Load Job (1- 8)
Save Job (1- 8)
(None - 3)
Pol.
(0-60 min)
Keyboard Lock
Stat.
(1-32)
Com Baud Rate
(9600/2400)
Com Protocol
(Ana, AB, Mod)
Comm ERR
Chckng
AC Line Freq.
(60/50Hz)
(Low/High)
Ext. Alarm Ack
Inp.
tion
If
Mod
NO
Setup Chan.
999 or 999.0
(T T/C only)
Channel Name
Input Units(ßF/ ßC)
Pulse Sample Time.
Input Reading
Disp. Formt -Linear
NO
& Plse (-999-3000)
High PV-Linear &
Pulse- (10000Hz)
High RDG -Linear &
Pulse -(10000Hz)
Low PV -Linear &
Low RDG -Linear &
Input Filter
YES
Input type
DISP RES?
(0-20 sec)
Offset
Pulse -(0Hz)
Pulse -(0Hz)
(3 Scans)
NO
Setup Chan.
Hi Proc alarm Set
Hi Proc Alarm Type
(OFF/UNL/LCH)
Hi Proc Alarm
Dev Alarm Value
Hi Dev Alarm type
(UNL/LCH/OFF)
Hi Dev Alarm Out#
NO
Lo Dev Alarm Type
(UNL/LCH/OFF)
Lo Dev Alarm Out#
Lo Proc Alarm
Lo Proc Alarm Type
(OFF/UNL/LCH)
Lo Proc Alarm
Outp# (None)
Alarm Deadband
Alarm Delay
YES
(1000˚)
Outp#
(25°)
(None)
(None)
Setp
(2)
(0-255)
NO
NO
Manual I/O Test
YES
Test Digital
Inputs
Test Digital
Outputs
Digital Output #
Test Keypad
Default settings are shown in BOLD typeface.
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Chapter 4: Setup CAS200 User’s Guide
Setup Global Parameters Menu
The setup global parameters menu looks like this.
CHANNEL PROCESS UNITS
SETUP GLOBAL
PARAMETERS?
CHANNEL NAME ALARM STATUS
Load a Job
CHANNEL PROCESS UNITS
LOAD SETUP
FROM JOB ? 1
CHANNEL NAME ALARM STATUS
Selectable values: 1 to 8
The following parameters are loaded as part of a job:
• Set points and spread values
• Alarm functions (Off and Alarm), set points, high/low
process set points, high\low deviation set points and
deadband settings, and channel alarm delay.
ç
CAUTION! All current job settings will be overwritten if you
select a job from memory. Save your current
programming to a job number if you want to keep
it.
CHANNEL PROCESS UNITS
CANNOT LOAD JOB
REMOTE SELECT ON
CHANNEL NAME ALARM STATUS
44 Watlow Anafaze
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CAS200 User’s Guide Chapter 4: Setup
Save Setup to Job
Use this menu to save job information for every channel, to
one of eight jobs in the CAS200 battery-backed RAM.
CHANNEL PROCESS UNITS
SAVE SETUP
TO JOB ? 1
CHANNEL NAME ALARM STATUS
If you have not enabled the remote job control function, you
will not be able to save a job. If you try it, you will get this
message.
CHANNEL PROCESS UNITS
CANNOT SAVE JOB
REMOTE SELECT ON
CHANNEL NAME ALARM STATUS
Job Select Inputs
Use this menu to run up to eight jobs remotely. It lets you
set the number of job select inputs. The CAS200 uses these
inputs as a binary code that specifies the job number to run.
The number of inputs you choose in this menu controls the
number of jobs you can select remotely.
CHANNEL PROCESS UNITS
JOB SELECT
DIG INPUTS ? NONE
CHANNEL NAME ALARM STATUS
Below is the truth table that tells you which input states
select which jobs.
Digital
Input 3
Digital
Input 2
Digital
Input 1
Job #
FFF1
FFT2
FTF3
FTT4
TFF5
TFT6
TTF7
TTT8
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Chapter 4: Setup CAS200 User’s Guide
Selectable values: 1, 2, or 3 inputs, or None. These
choices have the following effect:
Setting Enables
1 input Jobs 1-2
2 inputs Jobs 1-4
3 inputs Jobs 1-8
None (no inputs) Remote Select disabled
Job Select Input Polarity
This menu lets you set the polarity of the digital inputs
used for job selection. You can set the Active state to closed
(low) or open (high).
CHANNEL PROCESS UNITS
JOB SEL DIG INS
ACTIVE ? LO
CHANNEL NAME ALARM STATUS
Startup Alarm Delay
Selectable values: High or Low.
Use this menu to set a startup delay for process and
deviation alarms for all channels. The scanner does not
report these alarm conditions for the specified number of
minutes after the scanner powers up. (The scanner will
always report failed sensor alarms, no matter what startup
delay you set.)
CHANNEL PROCESS UNITS
STARTUP ALARM
DELAY ? 0 MINS
CHANNEL NAME ALARM STATUS
Selectable values: 0 - 60 minutes.
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CAS200 User’s Guide Chapter 4: Setup
Keyboard Lock Status
This selection lets you lock the front panel operator
function key, Change SP, so that pressing this key has no
effect. If you want to use this function, turn off the
Keyboard Lock.
CHANNEL PROCESS UNITS
KEYBOARD LOCK
STATUS ? OFF
CHANNEL NAME ALARM STATUS
Selectable values: On or Off
Scanner Address
This menu allows you to set the CAS200 scanner address.
The scanner address is used for multiple scanner
communications on a single EIA/TIA-485 cable, so each
CAS200 must have a different address. Begin with address
1 for the first scanner and assign each subsequent scanner
the next higher address.
CHANNEL PROCESS UNITS
CONTROLLER
ADDRESS ? 1
CHANNEL NAME ALARM STATUS
Selectable values: 1 - 32
Communications Baud Rate
This menu allows you to set the Communications Baud
Rate. If using Anascan, ensure that the program has the
same baud rate set through the ‘scaninst’ program.
CHANNEL PROCESS UNITS
COMMUNICATIONS
BAUD RATE ? 9600
CHANNEL NAME ALARM STATUS
Selectable values: 19200, 2400 or 9600
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Chapter 4: Setup CAS200 User’s Guide
Communications Protocol
This menu is located under the Setup Global Parameters
main menu. It allows you to select the Communications
Protocol.
CHANNEL PROCESS UNITS
COMMUNICATIONS
PROTOCOL ? ANA
CHANNEL NAME ALARM STATUS
Selectable values: Anafaze (ANA), Allen Bradley (AB),
ModBus RTU (MOD)
Communications Error Checking
This selection allows you to set the data check algorithm
used in the Anafaze communications protocol to Block
Check Character (BCC) or to Cyclic Redundancy Check
(CRC). CRC is a more secure error checking algorithm than
BCC, but it requires more calculation time and slows the
CAS200 communications. BCC ensures a high degree of
communications integrity, so we recommend that you use
BCC unless your application specifically requires CRC.
Also, if using Anascan, ensure that the same error checking
algorithm has been set through the ’scaninst’ program.
CHANNEL PROCESS UNITS
COMMUNICATIONS
ERR CHECK ? BCC
CHANNEL NAME ALARM STATUS
Selectable values: BCC or CRC
48 Watlow Anafaze
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CAS200 User’s Guide Chapter 4: Setup
AC Line Frequency
This menu lets you configure the scanner to match an AC
line frequency of 50 or 60Hz. (This function is provided for
international users who require 50Hz lines.) Since the
scanner reduces the effect of power line noise on the analog
measurement by integrating the signal over the period of
the AC line frequency, the scanner's noise rejection will
suffer if the line frequency is not set correctly. Cycle power
to enable this change.
CHANNEL PROCESS UNITS
AC LINE FREQ. ?
60 HERTZ
CHANNEL NAME ALARM STATUS
Selectable values: 50 or 60Hz.
Digital Output Polarity
This menu lets you set the state of the digital outputs used
for alarms. When set to CLOSED, the output closes the
circuit when an alarm occurs. This setting does not affect
the function of the Global Alarm.
CHANNEL PROCESS UNITS
DIG OUT POLARITY
ON ALARM ? CLOSED
CHANNEL NAME ALARM STATUS
Selectable values: Closed or Open
External Alarm Acknowledge Input Active
An external alarm reset or acknowledge button can be
wired to the CAS200 at input 8. When activated, it
performs the same function as if the "ALARM ACK" key
was pressed.
CHANNEL PROCESS UNITS
EXTRN ALARM ACK
INPT ACTIVE ? LOW
CHANNEL NAME ALARM STATUS
Selectable values: High or Low
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Chapter 4: Setup CAS200 User’s Guide
EPROM Information
This view-only display shows the scanner's EPROM
version and checksum.
CHANNEL PROCESS UNITS
CAS200
V 1.00 CS=2233
CHANNEL NAME ALARM STATUS
Setup Channel Inputs
The Setup Channel Input main menu lets you access
menus which change parameters related to the channel
input:
• Input type
• Input units
• Input scaling and calibration
The next section explains how to use the Input menus to
configure your scanner.
Input Type
CHANNEL PROCESS UNITS
SETUP CHANNEL 02
INPUT ?
CHANNEL NAME ALARM STATUS
This is the first menu of the Setup Channel Inputs menu.
It lets you configure the input sensor for each channel as
one of these input types:
• Thermocouple types (J, K, T, S, R,B, PL-II, and N).
• Linear inputs.
• Skip (an input type available for unused channels.)
The scanning display doesn't show channels you've set
to Skip.
CHANNEL PROCESS UNITS
01 INPUT
TYPE ? J T/C
CHANNEL NAME ALARM STATUS
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CAS200 User’s Guide Chapter 4: Setup
NOTE! If you set the input type to Skip, you won't see any
of the other submenus in the Setup Channel Input
menu. Channel #17 toggles between pulse and
skip. If you set the input type to any thermocouple, you will see the Offset menu. If you set the input type to Linear, or you are editing the Pulse
channel (#17), you will see the Input Scaling submenus.
Selectable values: The table shows the input types and
ranges.
Display Resolution
Input Type
Fahrenheit
Range
Celsius Range
J -350 to 1400 -212 to 760
K -450 to 2500 -268 to 1371
T -450 to 750 -18 to 1766
S 0 to 3200 -18 to 1760
R 0 to 3210 -18 to 1765
B +150 to 3200 +66 to 1760
PL-II +50 to 2012 +10 to 1100
N -450 to 2370 -268 to 1299
Pulse 0-2KHz (Channel #17 only)
Skip
Linear
Channel is not scanned or
displayed
See the Linear Scaling section
(this chapter) and appendix.
When type T thermocouples are selected the display may be
in tenths of a degree or whole number.
CHANNEL PROCESS UNITS
01 DISP RES?
-999 to 999
CHANNEL NAME ALARM STATUS
Selectable values: -999 to 999 or -999.0 to 999.0
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Chapter 4: Setup CAS200 User’s Guide
Pulse Sample Time
You can connect a digital pulse signal of up to 2KHz to the
scanner's pulse input. In this menu, you specify the pulse
sample period. (This is the second menu of the Setup
Channel Inputs menu for the pulse input channel only.)
Every sample period, the number of pulses the scanner
receives is divided by the sample time. The scanner scales
this number and uses it as the pulse channel's process
variable.
CHANNEL PROCESS UNITS
05 INPUT PULSE
SAMPLE TIME ? 1s
CHANNEL NAME ALARM STATUS
Selectable values: 1 to 20 seconds
Channel Name
This menu lets you enter a channel name (up to seven
characters) from this menu. If no name is entered, the
CAS200 will default to the current channel number.
Input Units
CHANNEL PROCESS UNITS
01 CHANNEL
NAME ?
CHANNEL NAME ALARM STATUS
Selectable values: A-Z, 0-9, %, /, °, space
The Input Units menu lets you choose a three-character
description of the channel's engineering units.
• Thermocouples can only be °F or °C.
• If you have selected a linear or pulse input type, you
can choose any available character for each character
position. For example, you can use GPM or psi or % for
a linear input's units.
CHANNEL PROCESS UNITS
02 INPUT
UNITS ? °F
CHANNEL NAME ALARM STATUS
The table below shows the character set for input units.
Input Character Sets for Units
Thermocouple °F or °C
Linear & Pulse 0-9, A-Z, %, /,°, space
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CAS200 User’s Guide Chapter 4: Setup
Input Reading Offset
This menu lets you set an input reading offset function to
make up for the input signal's inaccuracy at any given
point. For example, at temperatures below 400
thermocouple may be inaccurate ("offset") by several
degrees F. Use an independent thermocouple or your own
calibration equipment to find the offset for your equipment.
To correct for offset errors, change the factory default
setting to a positive or negative value for the channel you
are editing. (A positive value increases the reading and a
negative value decreases it.)
CHANNEL PROCESS UNITS
01 INPUT READING
OFFSET ? 0˚ F
CHANNEL NAME ALARM STATUS
Selectable values: -300 to 300 for thermocouples with the
following exceptions when Input Units are set to
TC Offset Range
°F, a type J
°F
B -300 to 76
S -300 to 76
R -300 to 66
NOTE! If the input type is set to Linear, Pulse, or Skip,
you will not see this menu.
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Chapter 4: Setup CAS200 User’s Guide
Linear Scaling Menus
The linear scaling menus appear under the Setup Channel
Inputs main menu. Linear scaling is available for linear
and pulse inputs only. It lets you scale the "raw" input
readings (readings in millivolts or hertz) to the engineering
units of the process variable.
NOTE! The linear scaling menus will only be present if
you set the channel’s input type to Linear (or, for
channel 17, to Pulse).
For linear inputs, the input reading is in percent (-16.6 to
100%) representing the -10 to 60mV input range of the
CAS200. For pulse inputs, the input reading is in hertz
(cycles per second.) The scaling function is defined by two
points on a conversion line, the high PV and the low PV.
High PV is the high end of the input in engineering units,
and the low PV is the low end. The engineering units of the
process variable can be any arbitrary units.
The example below shows a high PV of 20 psi and a low PV
of 0 psi. The high reading is the high end of the input signal
(where 60mV = 100%).
20 PSI
Hi PV
Process
Variable
Lo PV
0 PSI
0%
0mV
Lo
Rdg
Input Reading
Hi
Rdg
100%
60mV
Before you enter the values that determine the two points
for the conversion line, you must choose an appropriate
display format. The CAS200 has six characters available
for process variable display; select the setting with the
desired number of decimal places before and after the
decimal point. Use a display format that matches the range
and resolution of the process variable. The display format
you choose is used for the setpoint, alarms, deadband, and
alarm deviation.
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CAS200 User’s Guide Chapter 4: Setup
The PV (Process Variable) range for the scaled input is
between the PV values that correspond to the 0% and 100%
input readings. For the pulse input, it is between the 0Hz
and 2000Hz readings. This PV range defines the limits for
the setpoint and alarms, as shown here.
Hi PV
Process
Variable
Range
Lo PV
NOTE! For example linear scaling calculations, see
Display Format
0 PSI
0%
0mV
0 Hz
Lo
Rdg
Input Reading
100%
} Linear input type
60mV
2000 Hz} Pulse input type
Chapter 6, Linear Scaling Examples on page 87.
This menu lets you select a display format for a linear or
pulse input. Choose a format appropriate for your input
range and accuracy. (You will only see the Display Format
menu if you are editing a linear or pulse input.)
CHANNEL PROCESS UNITS
01 DISP FORMAT ?
-999 TO 3000
CHANNEL NAME ALARM STATUS
The CAS200 has several available display formats; the
display format you choose determines the default values for
the rest of the linear scaling menus.
Display Format Default High PV Default Low PV
-9999 to +30000 10000 0
-999 to +3000 1000 0
-99.9 to +3000.0 1000.0 .0
-99.99 to +300.00 100.00 .00
-9.999 to +30.000 10.000 .000
-.9999 to +3.0000 1.0000 .0000
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Chapter 4: Setup CAS200 User’s Guide
High Process Value
From this menu, you can enter a high process value. The
high process value and the high reading value together
define one of the points on the linear scaling function's
conversion line.
CHANNEL PROCESS UNITS
01 INPUT SCALING
HI PV ? 1000
CHANNEL NAME ALARM STATUS
Selectable Values: The CAS200 displays the process
value based on the table above.
Input Scaling High Reading
Use this menu to enter the input level that corresponds to
the high process value you entered in the previous menu.
For linear inputs, the high reading is a percentage of the
full scale input range. For the pulse input, the high reading
is in Hertz.
The full scale range of the linear input type is -10 to 60mV
where 0mV corresponds to 0% and 60mV corresponds to
100%. The actual signal is scaled to be within this range
with scaling resistors. For pulse inputs, it is 0 to 2000Hz.
CHANNEL PROCESS UNITS
01 INPUT SCALING
HI RDG ? 100.0
CHANNEL NAME ALARM STATUS
Selectable values: Depends on the Input Type, -99.9 to
999.9 when Input Type is set to Linear; 1 to 2000 Hz when
Input Type is set to Pulse.
Input Scaling Low Process Value
Use this menu to set a low process value for input scaling
purposes. The low process value and the low reading value
together define one of the points on the linear scaling
function's conversion line.
CHANNEL PROCESS UNITS
01 INPUT SCALING
LO PV ? 0˚ F
CHANNEL NAME ALARM STATUS
The default low PV is determined by the display format you
selected (refer to Display Format table).
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Input Scaling Low Reading
Use this menu to enter the input level that corresponds to
the low process value you entered in the previous menu.
For linear inputs, the low reading is a percentage of the full
scale input range. For the pulse input, the low reading is in
Hertz.
The full scale range of the linear input type is -10 to 60mV
where 0mV corresponds to 0% and 60mV corresponds to
100%. The actual signal is scaled to be within this range
with scaling resistors. For pulse inputs, it is 0 to 2000Hz.
CHANNEL PROCESS UNITS
01 INPUT SCALING
LO RDG ? 0.0% FS
CHANNEL NAME ALARM STATUS
Selectable values: Depends on the Input Type, -99.9 to
999.9 when Input Type is set to Linear; 1 to 2000Hz when
Input Type is set to Pulse.
Input Filter
The CAS200 has two different types of input filter:
• A noise rejection filter that rejects high frequency
input signal noise. This filter keeps a "trend log" of
input readings. If a reading is outside the filter's
"acceptance band", and later readings are within the
acceptance band, the CAS200 ignores the anomalous
reading. (The acceptance band for thermocouples is 5
degrees above and 5 degrees below the input reading.
For linear inputs, it's 0.5% above and 0.5% below the
input reading.) If later readings are also outside the
acceptance band, the CAS200 accepts the anomalous
reading and calculates a new acceptance band. (You
cannot adjust this input filter.)
• A standard resistor-capacitor (RC) filter that lets you
dampen the input response if inputs change
unrealistically or change faster than the system can
respond. If the input filter is enabled, the process
variable responds to a step change by going to 2/3 of
the actual value within the number of scans you set.
CHANNEL PROCESS UNITS
01 INPUT FILTER ?
3 SCANS
CHANNEL NAME ALARM STATUS
Selectable values: 0 to 255 scans
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Setup Channel Alarms
The Setup Channel Alarms menu lets you access menus
which change alarm function parameters for the current
channel. The main alarms menu looks like this:
CHANNEL PROCESS UNITS
SETUP CHANNEL 01
ALARMS ?
CHANNEL NAME ALARM STATUS
The CAS200 has three different kinds of alarms: failed
sensor alarms, global alarms, and process alarms.
Failed Sensor Alarms
Failed sensor alarms alert you to thermocouple breaks.
Global Alarms
Global alarms occur when a channel alarm is active and
unacknowledged, or when there are any unacknowledged
failed sensor alarms. (If an alarm occurs, the CAS200 front
panel displays an appropriate alarm code, see Chapter 3,
Using the CAS200 on page 35). Even if the alarm condition
goes away, the global alarm stays on until you use the front
panel Alarm Ack key to acknowledge it.
Process Alarms
Process alarms include high and low deviation and high
and low process alarms. You can set each of these alarms to
Off, Latched or Unlatched, as shown here.
Function Description
Off No alarm
Alarm is only cleared if it is in a Non-
Alarming state and the ALARM RESET
Latched
Unlatched
• High process and high deviation alarms activate when
the process variable goes above a value you set. They
remain active until the process variable goes below
that value minus the deadband. (See the diagram
below.)
key is pressed. If ALARM ACKNOWLEDGE has not been previously pressed,
the ALARM RESET will acknowledge
the global alarm as well.
Digital output activates on alarm, and
deactivates when channel is in a Non-
Alarming state. The ALARM ACK key
must be pressed to shut off the global
alarm.
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• Any digital output can be assigned to one or more
process variable alarms. The output is active if any of
its alarms are active. All alarm outputs are active Low
or active High, depending on the Digital Output
Polarity On Alarm parameter setting.
• Low process and low deviation alarms activate when
the process variable goes below a value you set. They
remain active until the process variable goes above
that value plus the deadband. (The diagram below
shows these alarms.)
When the scanner powers up or the setpoint changes,
deviation alarms do not activate until the process goes
inside the deviation alarm band, preventing deviation
alarms during a cold start. (High and low process alarms
are always enabled.)
High process alarm on
High process alarm off
High Alarm Limit
SP + Deviation
Set Point
SP - Deviation
Low Alarm Limit
}Deadband
High deviation alarm on
}Deadband
High deviation alarm off
Low deviation alarm off
}Deadband
Low deviation alarm on
}Deadband
Low process alarm on
Low process alarm off
Use menus to set the following process alarm parameters
for each channel:
• High and low process alarm type, setpoint, and digital
output
• High and low deviation alarm type, deviation alarm
value, and digital output
• Alarm deadband
• Alarm delay
The set points, deviation alarm values, and deadband all
use the same decimal format as the channel's process
variable.
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Alarm Delay
You can set the CAS200 to delay normal alarm detection
and alarm reporting. There are two kinds of alarm delay:
• Startup alarm delay delays detection of process
alarms (but not failed sensor alarms) for all channels
for a time period you set in the Setup Global
Parameters main menu.
• Channel alarm delay delays failed sensor alarms and
process alarms for one channel until the alarm
condition is continuously present for longer than the
channel alarm delay time you set.
NOTE! Failed sensor alarms are detected at startup. They
are affected by the channel alarm delay, not the
startup alarm delay time.
High Process Alarm Setpoint
This menu lets you select the setpoint (temperature or
other value within the scaled sensor range) at which the
high process alarm activates. The high process alarm
activates when the process variable (PV) goes above the
high process setpoint. It deactivates when the PV goes
below the high process setpoint minus the deadband value,
if you have set a deadband value.
CHANNEL PROCESS UNITS
01 HI PROC ALARM
SETPT ? 1000
CHANNEL NAME ALARM STATUS
Selectable values: Any point within the scaled sensor
range
High Process Alarm Type
This menu lets you turn off the high process alarm or set it
to one of the alarm functions. (See the previous description
for an explanation of these choices).
CHANNEL PROCESS UNITS
01 HI PROC ALARM
TYPE ? OFF
CHANNEL NAME ALARM STATUS
Selectable values: Off, Latched, Unlatched
° F
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High Process Alarm Output Number
This menu lets you choose the digital output that activates
when the channel is in high process alarm. You can use this
output to activate a second alarm horn or buzzer.
CHANNEL PROCESS UNITS
01 HI PROC ALARM
OUTPUT ? NONE
CHANNEL NAME ALARM STATUS
Selectable values: 1 to 34, None
NOTE! All digital outputs are combined. Therefore you
can assign more than one alarm to the same output number, and that output will be On if any of
those alarms is On.
Deviation Alarm Value
This menu lets you set the deviation bandwidth, a positive
and negative alarm point relative to the setpoint. If the
setpoint changes, the alarm points also change. You can
assign a separate digital output to the high and low
deviation alarm set points.
CHANNEL PROCESS UNITS
01 DEV ALARM
VALUE ? 25
CHANNEL NAME ALARM STATUS
Selectable values: 0 to 255, 25.5, 2.55, .255 or .0255,
depending on the way you set up the Input menus.
High Deviation Alarm Type
This menu lets you disable the high deviation alarm
function or set it to the alarm functions. (The high
deviation alarm activates if the process value (PV) rises
above the deviation band value, and remains active until
the PV goes below the deviation band value minus the
deadband value.)
CHANNEL PROCESS UNITS
01 HI DEV ALARM
TYPE ? LATCHED
CHANNEL NAME ALARM STATUS
Selectable values: Latched, Unlatched, or Off.
° F
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High Deviation Alarm Output Number
This menu assigns a digital output which activates when
the channel is in high deviation alarm. The digital output
only activates if you have set the high deviation alarm to
On.
CHANNEL PROCESS UNITS
01 HI DEV ALARM
OUTPUT ? NONE
CHANNEL NAME ALARM STATUS
Selectable values: 1 to 34, None
NOTE! All digital outputs are combined. Therefore, you
can assign more than one alarm to the same output number, and that output will be On if any of
those alarms are On.
Low Deviation Alarm Type
This menu turns off the low deviation alarm or set it to the
alarm function.
CHANNEL PROCESS UNITS
01 LO DEV ALARM
TYPE ? LATCHED
CHANNEL NAME ALARM STATUS
Selectable values: Off, Latched, or Unlatched
Low Deviation Alarm Output Number
This menu is used to assign a digital output that activates
when the channel is in low deviation alarm.
CHANNEL PROCESS UNITS
01 LO DEV ALARM
OUTPUT ? NONE
CHANNEL NAME ALARM STATUS
Selectable values: 1 to 34, None
NOTE! All digital outputs are OR'd together (combined).
Therefore you can assign more than one alarm to
the same output number, and that output will be
On if any of those alarms is On.
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Low Process Alarm Setpoint
This menu is used to set a low process alarm setpoint. (The
low process alarm activates when the process variable goes
below the low process alarm setpoint. It deactivates when
the process variable goes above the low process alarm
setpoint plus the deadband.)
CHANNEL PROCESS UNITS
01 LO PROC ALARM
SETPT ? 0
CHANNEL NAME ALARM STATUS
Selectable values: Any value within the input sensor's
range
Low Process Alarm Type
This menu lets you turn off the low process alarm or set it
to the alarm function.
CHANNEL PROCESS UNITS
01 LO PROC ALARM
TYPE ? OFF
CHANNEL NAME ALARM STATUS
Selectable values: Off, Latched, Unlatched
Low Process Alarm Output Number
This menu lets you assign the digital output that activates
when the channel is in low process alarm.
CHANNEL PROCESS UNITS
01 LO PROC ALARM
OUTPUT ? NONE
CHANNEL NAME ALARM STATUS
Selectable values: NONE, 1 to 34
NOTE! All digital outputs are combined. Therefore you
can assign more than one alarm to the same output number, and that output will be On if any of
those alarms is On.
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Alarm Deadband
This menu lets you set an alarm deadband. This deadband
value applies to the high process, low process, high
deviation, and low deviation alarms for the channel you are
editing.
The alarm deadband sets the hysteresis of the alarm action
which is used to avoid intermittent alarms as the PV
returns to a normal state.
CHANNEL PROCESS UNITS
01 ALARM DEAD
BAND ? 2˚ C
CHANNEL NAME ALARM STATUS
Selectable values: 0 to 255, 25.5, 2.55, .255, or .0255,
depending on your input menu setup.
Alarm Delay
This menu sets a channel alarm delay. There are two types
of alarm delay: the startup alarm delay and channel alarm
delay. Startup alarm delay (which you can set in the Setup
Global Parameters main menu) delays process alarms
(but not failed sensor alarms) for all channels for a specified
time after the CAS200 powers up.
The channel alarm delay, in contrast, is set separately for
each channel. It delays failed sensor and process alarms
until the alarm condition has been continuously present for
longer than the alarm delay time. (Failed sensor alarms are
not subject to the startup alarm delay, but they are affected
by the channel's alarm delay during the startup alarm
delay period.)
CHANNEL PROCESS UNITS
01 ALARM DELAY ?
0 SECONDS
CHANNEL NAME ALARM STATUS
Selectable values: 0 to 255 seconds
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Manual I/O Test
Press Yes at this prompt to see menus which can help you
test the digital inputs, digital outputs and the CAS200
keypad.
CHANNEL PROCESS UNITS
MANUAL I/O
TEST ?
CHANNEL NAME ALARM STATUS
Digital Input Testing
This is a read-only menu that shows the logic state of the 8
digital inputs as H (High- the input is at 5 volts or is not
connected) or L (Low- the input is at zero volts). Inputs 1 to
8 are displayed from left to right. Since inputs are pulled
High when they are not connected, test an input by
shorting it to scanner common and making sure this menu
shows the correct state for that input.
CHANNEL PROCESS UNITS
DIGITAL INPUTS
HHLLHHHH
CHANNEL NAME ALARM STATUS
Digital Output Selection
This menu lets you select one of the digital alarm outputs
to test in the next menu.
CHANNEL PROCESS UNITS
TEST DIGITAL
OUTPUT ? 34
CHANNEL NAME ALARM STATUS
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Digital Output Test
This menu lets you manually toggle a digital output On or
Off to test it. (Select the output to test in the previous
menu.) On may be Low or High depending on the digital
output polarity you set. (All outputs are set to Off when you
exit this menu.)
CHANNEL PROCESS UNITS
DIGITAL OUTPUT
NUMBER 34: OFF
CHANNEL NAME ALARM STATUS
Press Yes or No to toggle the output state between On and
Off.
Keypad Test
This menu lets you test the keypad. Press any key on the
keypad to test the response. The CAS200 will display the
name of the key you have pressed.
CHANNEL PROCESS UNITS
KEYPAD TEST
QUIT = "NO" + "NO"
CHANNEL NAME ALARM STATUS
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Troubleshooting and Reconfiguring
The first sections of this chapter describe general
troubleshooting for the CAS200. Later sections describe
specific procedures such as checking an input, changing the
EPROM, and testing the scanner
When There is a Problem
Even in stand-alone systems, the CAS200 is only part of
your control system. Often, what appears to be a problem
with the CAS200 is really a problem with other equipment,
so check these things first:
• Scanner is installed correctly. (See Chapter 2 ,
Installation on page 7, for help.)
• Inputs, like thermocouples, are installed correctly and
working.
5
NOTE! If you suspect your scanner has been damaged,
do not attempt to repair it yourself, or you may
void the warranty.
If the troubleshooting procedures in this chapter do not
solve your system’s problems, call the Technical Services
department for additional troubleshooting help. If you need
to return the unit to Watlow Anafaze for testing and repair,
Customer Services will issue you an RMA number. See
Returning Your Unit on page 68.
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ç
CAUTION! Before trying to troubleshoot a problem by replac-
ing your scanner with another one, first check the
installation. If you have shorted sensor inputs to
high voltage lines or a transformer is shorted out,
and you replace the scanner, you will risk damage
to the new scanner.
If you are certain the installation is correct, you can try
replacing the scanner. If the second unit works correctly,
then the problem is specific to the scanner you replaced.
Returning Your Unit
Before returning a scanner, contact your supplier or call
Watlow Anafaze at +1 (831) 724-3800 for technical support.
Scanners purchased as part of a piece of equipment must be
serviced or returned through the equipment manufacturer.
Equipment manufacturers and authorized distributors
should call customer service at Watlow Anafaze to obtain a
return materials authorization (RMA) number. Shipments
without an RMA will not be accepted. Other users should
contact their suppliers for instructions on returning
products for repair.
Troubleshooting Scanners
A problem may be indicated by one or more of several types
of symptoms:
• A process or deviation alarm
• A failed sensor alarm
• A system alarm
• Unexpected or undesired behavior
The following sections list symptoms in each of these
categories and suggest possible causes and corrective
actions.
Process and Deviation Alarms
When a process or deviation alarm occurs, the scanner
switches to the single channel display for the channel with
the alarm and displays the alarm code on the screen.
Software such as ANASCAN or WatView displays a
message on the alarm screen and logs the alarm in the
event log.
See Alarms on page 40 for a description of alarm behavior
and how to respond to alarms.
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Thermocouple Break Alarm
When a thermocouple break alarm occurs, the scanner
switches to the single channel display for the channel with
the alarm and displays an alarm code on the screen.
ANASCAN or WatView displays a message on the alarm
screen and logs the alarm in the event log.
A failed sensor alarm clears once it has been acknowledged
and the sensor is repaired.
System Alarms
If the scanner detects a hardware problem, it displays a
message. The message persists until the condition is
corrected.
Table 5.1 Hardware Error Messages
Message Possible Cause Recommended Action
LOW POWER
BATTERY DEAD
HW FAILURE AMBIENT
HW FAILURE GAIN
HW FAILURE OFFSET
Power supply failed. See Low Power on page 71.
RAM battery is dead. See Battery Dead on page 71.
Cold junction is too hot
Hardware failed due to excessive voltage on inputs.
Hardware failed due to excessive voltage on inputs.
Hardware failed due to excessive voltage on inputs.
See HW Gain or Offset Failure
on page 72.
See HW Gain or Offset Failure
on page 72.
See HW Gain or Offset Failure
on page 72.
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Other Behaviors
The following table indicates potential problems with the
system or scanner and recommends corrective actions.
Table 5.2 Other Symptoms
Symptom Possible Causes Recommended Action
Scanner not communicating
Indicated temperature not as expected
Sensor wiring incorrect
Noise
See Checking Analog Inputs on page 73.
CAS200 display is
not lit
CAS200 display is
lit, but keys do not
work
Alarm limits or other
settings change
Acknowledged
alarms reoccur or
alarms fail to be indicated
Power connection incorrect
No EPROM or bad EPROM
CAS200 damaged or failed
Keypad is locked See Keys Do Not Respond on page 73.
CAS200 damaged or failed
Digital job select feature is
enabled and has changed
jobs
Power is intermittent
Analog reference voltage is
overloaded
Check wiring and service. See Wiring the
Power Supply on page 19.
Replace the EPROM. See Replacing the
EPROM on page 79.
Return the CAS200 for repair. See Returning Your Unit on page 68.
Return the CAS200 for repair. See Returning Your Unit on page 68.
Set JOB SELECT DIG INPUTS TO NONE.
This parameter is only accessible using the
scanner’s keypad and display. See Job
Select Inputs on page 45.
Check wiring and service. See Wiring the
Power Supply on page 19.
Use a separate dc supply for the scanner.
Provide backup power (UPS).
Disconnect any wiring from the +5V Ref
connection on TB1.
Hardware failure
Scanner does not
behave as expected
70 Watlow Anafaze
Corrupt or incorrect values in
RAM
Check the scanner front panel for a hardware alarm. See System Alarms on page
69.
Perform a
Reset on page 78.
NO-key reset. See NO-Key
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Corrective and Diagnostic Procedures
The following sections detail procedures you may use to
diagnose and correct problems with the scanner.
Low Power
If the scanner displays LOW POWER or the display is not
lit:
1. Turn the power to the scanner off, then on again.
2. If the error message returns, check that the power
supplied to the scanner is at least 12.0Vdc @ 1 A. See
Wiring the Power Supply on page 19.
3. If the error message returns again, make a record of
the settings if possible (using software). Then, perform
NO-key reset (see NO-Key Reset on page 78).
a
4. If the error is not cleared, contact your supplier for further troubleshooting guidance. See Returning Your
Unit on page 68.
Battery Dead
NOTE! The scanner will retain its settings when powered.
The dead battery alarm indicates that the CAS200 battery
is not functioning correctly or has low power or no power.
Parameter settings may return to the default settings.
The battery is required to keep the settings in
memory only when the scanner is powered down.
If the scanner displays BATTERY DEAD:
1. Verify that the parameters are set as desired.
2. Make a record of all scanner settings before continuing. When you power off the scanner in the next step,
parameter settings may return to their default settings if the battery is dead.
3. Turn the power to the scanner off, then on again.
4. If the error message returns when power is restored,
perform a
5. If the error is not cleared, contact your supplier for further troubleshooting guidelines. See Returning Your
Unit on page 68.
NO-key reset. See NO-Key Reset on page 78.
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HW Ambient Failure
The hardware failure ambient alarm indicates that the
ambient sensor in the CAS200 is reporting that the
temperature around the scanner is outside of the
acceptable range of 0-50˚ C. This error can also occur when
there is a hardware failure.
If the scanner displays HW AMBIENT FAILURE:
1. Check the ambient air temperature near the scanner.
Adjust ventilation, cooling or heating to ensure that
the temperature around the scanner is 0-50˚ C. If the
unit is functioning correctly, the error will clear
automatically when the ambient temperature is
within range.
2. If the ambient temperature is within range and the error persists:
a) Turn n the power to the scanner off.
b) Remove the boards from the CAS200 housing.
3. If the error persists, make a record of the settings,
4. If the error is not cleared, contact your supplier for fur-
NOTE! If the scanner has failed, it is likely that it was
damaged by excessive voltage or noise. Before
replacing the scanner, troubleshoot for noise and
ground channels.
HW Gain or Offset Failure
If the scanner displays HW FAILURE GAIN or HW FAILURE
OFFSET:
1. Turn the power to the scanner off, the on again.
2. If the error persists, make a record of the settings (us-
c) Reseat the boards and turn power on.
then perform a
page 78.
ther troubleshooting guidelines. See Returning Your
Unit on page 68.
ing software), then perform a
Key Reset on page 78.
NO-key reset. See NO-Key Reset on
NO-key reset. See NO-
3. If the error is not cleared, contact your supplier for further troubleshooting guidelines. See Returning Your
Unit on page 68.
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NOTE! If the scanner has failed, it is likely that it was
damaged by excessive voltage or noise. Before
replacing the scanner, troubleshoot for noise and
ground channels.
Keys Do Not Respond
If the CAS200 seems to function but the CHNG SP key does
not respond when you press it, the keypad is probably
locked. Unlock the keypad according to the instructions in
Keyboard Lock Status on page 47.
Checking Analog Inputs
If the process variable displayed in the software and on the
scanner do not agree:
1. Verify that the scanner is communicating.
2. If the process variable indicated on the scanner display is incorrect:
a) Verify that you have selected the correct input type
for the affected channels.
b) Verify that sensors are properly connected.
3. If the sensors are correctly connected, with power on to
the heaters check for high common mode voltage:
a) Set a voltmeter to measure volts ac.
b) Connect the negative lead to a good earth ground.
c) One by one, check each input for ac voltage by con-
necting the positive lead on the voltmeter to the
positive and negative sensor input connections.
The process variable should indicate ambient temperature. If it does not, contact your supplier to return the unit for repair. See Returning Your Unit
on page 68.
NOTE! Noise in excess of 1Vac should be eliminated by
correctly grounding the CAS200. See Wiring the
Power Supply on page 19.
4. Verify the sensors:
• For thermocouples, remove the thermocouple
leads and use a digital voltmeter to measure the
resistance between the positive and negative
thermocouple leads. A value of 2 to 20Ω is normal.
Readings in excess of 200Ω indicate a problem
with the sensor.
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5. To verify that the scanner hardware is working
correctly, check any input (except the pulse input) as
follows:
a) Disconnect the sensor wiring.
b) Set the INPUT TYPE to J thermocouple in the SETUP
LOOP INPUT menu.
c) Place a short across the input. The scanner should
indicate the ambient temperature on the channel
you are testing.
Earth Grounding
If you suspect a problem with the ac ground or a ground
channel:
• Measure for ac voltage between ac neutral and panel
chassis ground. If ac voltage above 2Vac 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. Any
ac voltage above 2Vac may indicate problems with the
ac ground circuit.
• Check for ac voltage on thermocouples with the heater
power on. A control output providing power to the
heaters will increase the ac voltage if there is heater
leakage and an improper grounding circuit. Measure
from either positive or negative thermocouple lead to
ac ground. AC voltage above 2Vac may indicate the
ground lead is not connected to the CAS200 TB2
ground terminal.
If the above tests indicate proper ac grounding but the
scanner is indicating incorrect temperatures or process
readings:
• Verify which type of sensor is installed and that the
INPUT TYPE parameter is set accordingly.
• For a linear voltage or current input, check that the
correct input scaling resistors are installed (page 82)
and check the input scaling parameter settings (page
54).
• If readings are erratic, look for sources of electrical
noise. SeeNoise Suppression on page 29.
• Eliminate possible ground channels. SeeConnecting
the TB50 to the CAS200 on page 22.
• Contact your supplier for further troubleshooting
guidance. SeeReturning Your Unit on page 68.
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Testing Output Devices
Connect the solid state relay (SSR) control terminals to the
CAS200 control output and connect a light bulb (or other
load that can easily be verified) to the output terminals on
the SSR. Put the channel 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. Without a load connected, the SSR’s output
terminals do not turn off. This makes it difficult to
determine whether the SSR is actually working. Measure
the voltage across a load or use a load that can be visually
verified, such as a light bulb.
Testing the TB18 and TB50
1. Turn on power to the scanner.
2. Measure the +5Vdc supply at the TB18 or TB50. The
voltage should be +4.75 to +5.25 Vdc:
a) Connect the voltmeter’s common lead to the TB18
screw terminal 2 or TB50 screw terminal 3.
Testing Digital Outputs
1. Turn off power to the scanner.
2. Disconnect any output wiring on the output to be test-
3. Connect a 500Ω to 100kΩ resistor between the
4. Connect the voltmeter’s common lead to the output
5. Restore power to the scanner.
6. If you are testing a digital output, use the MANUAL IO
b) Connect the voltmeter’s positive lead to the TB18
or TB50 screw terminal 1.
ed.
+5V terminal (TB18 or TB50 screw terminal 1) and the
output terminal you want to test.
terminal, and connect the voltmeter’s positive lead to
the +5V terminal.
TEST menu to turn the output on and off. See Manual
I/O Test on page 65. When the output is off, the output
voltage should be less than 1V. When the output is on,
the output voltage should be between +3.75 and
+5.25V.
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Testing Digital Inputs
1. Turn off power to the scanner.
2. Disconnect any system wiring from the input to be
tested.
3. Restore power to the scanner.
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). When you connect the
other end of the wire to scanner common (TB50 terminal 3), the DIGITAL INPUTS parameter should show
that the input is L (low).
Additional Troubleshooting for Computer
Supervised Systems
Computer Problems
These four elements must work properly in a computersupervised system:
• The scanner
• The computer and its EIA/TIA-232 or EIA/TIA-485
serial interface
• The EIA/TIA-232 or EIA/TIA-485 communication
lines
• The computer software
For troubleshooting, disconnect the communications line
from the computer and follow the troubleshooting steps in
the first section of this chapter. The next few sections
explain troubleshooting for the other elements of computer
supervised systems.
If you are having computer or serial interface problems,
check the following:
• Check your software manual and make sure your
computer meets the software and system
requirements.
• Check the communications interface, cables, and
connections. Make sure the serial interface is set
according to the manufacturer’s instructions.
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• To test an EIA/TIA-232 interface, purchase an EIA/
TIA-232 tester with LED indicators. Attach the tester
between the scanner and the computer. When the
computer sends data to the scanner, the tester’s TX
LED should blink. When the computer receives data
from the scanner, the RX LED should blink.
• You can also connect an oscilloscope to the transmit or
receive line to see whether data is being sent or
received. If the serial port does not appear to be
working, the software setup may need to be modified
or the hardware may need to be repaired or replaced.
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 scanner is
connected.
• Software protocol: Set the scanner to MOD (Modbus)
for WatView, ANA (Anafaze) for ANASCAN.
• Scanner address: Configure software to look for the
scanner at the correct address. In a multiple-scanner
installation, each scanner must have a unique
address.
• Baud rate: Software and scanner must be set the
same.
• Error checking (ANA protocol only): Software and
scanner must be set the same (CRC or BCC).
• Hardware protocol: PC and scanner must use the
same protocol, or a converter must be used. The
scanner is typically configured for EIA/TIA-232 when
it is shipped. See Changing Communications on page
81 to change between EIA/TIA-232 and EIA/TIA-485.
To communicate with more than one scanner, or when
more than 50 feet of cable is required, use EIA/TIA-
485. Even for a single scanner, you may use EIA/TIA485 and an optically isolating converter to eliminate
ground channels.
• Converter: Make sure that the EIA/TIA-232-to-485
converter is powered, configured and wired correctly.
• Cables: Check continuity by placing a resistor across
each pair of wires and measuring the resistance with
an ohmmeter at the other end.
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Ground Channels
Many PC communications ports have their common wires
connected to chassis ground. Once connected to the
scanner, this can provide a path to ground for current from
the process that can enter the scanner through a sensor
(such as a thermocouple). This creates a ground channel
that can affect communications and other scanner
functions. To eliminate a ground channel, either use an
optically isolated communications adapter or take
measures to ensure that sensors and all other connections
to the scanner are isolated and not conducting current into
the unit.
Software Problems
If the scanner 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, ANASCAN
Consult the ANASCAN User’s Guide for help with the user
interface. WatView comes with a context-sensitive help
explaining operation of the software. Context-sensitive
means that you can press the F1 key to get help related to
the part of the program you are using.
User-Written Software
NO-Key Reset
You can request a communications specification from
Watlow Anafaze if you want to write your own software.
Watlow Anafaze will answer technical questions that arise
during your software development process. For userwritten Windows interfaces use WatConnect, the ModbusRTU dynamic link library software from Watlow
Performing a NO-key reset returns all scanner settings to
their defaults. All recipes are also cleared.
To perform a NO-key reset:
1. Make a record of the scanner’s settings.
2. Turn off power to the unit.
3. Press and hold the NO key on the keypad.
4. Turn on power to the scanner still holding the
5. When prompted RESET WITH DEFAULTS?, release the
NO key.
NO key and press the YES key.
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6. If you do not see the RESET WITH DEFAULTS? prompt
or do not get a chance to press
dure.
7. Restore the scanner settings.
If you have a stand-alone system, there is no way to recover
your original parameters. If you have a computersupervised system with WatView or ANASCAN, a copy of
your parameters can be saved to a job file.
YES, repeat the proce-
Replacing the EPROM
Replacing the EPROM involves minor mechanical
disassembly and reassembly of the scanner. You will need
a Phillips screwdriver and a small flathead screwdriver.
ç
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 re-
sults 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 scanner.
3. Remove the four screws from the sides of the scanner
front panel.
4. Remove the electronics assembly from the case, as
shown in .
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Chapter 5: Troubleshooting and Reconfiguring CAS200 User’s Guide
Figure 5.1 Removal of Electronics Assembly
from Case
WATLOW ANAFAZE CAS200
WATLOW ANAFAZE CAS200
5. Unscrew the four screws at the corners of the top
board and carefully unplug this board to access the
bottom board (processor board). Figure 5.2 shows the
screws to remove:
Figure 5.2 Screws Locations on PC Board
WATLOW ANAFAZE CAS200
6. Locate the EPROM on the circuit board. The EPROM
is a 32-pin socketed chip that is labeled with the model, version and checksum.
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Figure 5.3 EPROM Location
EPROM Detail
U2
EPROM
MP
Notch
Pin 1
7. Remove the existing EPROM from its socket with an
IC extraction tool or a jeweler’s flathead screwdriver.
SRAM
Figure 5.4 Remove EPROM
8. Carefully insert the new EPROM into the EPROM
socket. Make sure that the chip is oriented so that its
notch fits in the corresponding corner of the socket.
9. Reverse steps 2 through 4 to reassemble the unit.
10. Power up the scanner.
11. Re-enter parameters.
Changing Communications
To switch between EIA/TIA-232 and EIA/TIA-485, change
the jumpers as shown in Figure 5.5.
Figure 5.5 Jumper Configurations
JU1
JU2
JU3
JU4
JU5
A
A
B
Configured for
EIA/TIA-232
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Configured for
EIA/TIA-485
B
A
B
Last scanner in
system configured
for EIA/TIA-485
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Chapter 5: Troubleshooting and Reconfiguring CAS200 User’s Guide
You will need tweezers and a Phillips head screwdriver to
switch between EIA/TIA-232 and EIA/TIA-485. Follow
these steps:
1. Power down the unit.
2. Remove the scanner’s metal casing. See Replacing the
EPROM on page 79 for step-by-step instructions.
3. Find jumpers JU2, JU3, JU4, and JU5 on the board.
4. Use tweezers to carefully grasp the jumpers and gently slide them off the pins.
5. Use tweezers to gently slide jumpers JU2, JU3, JU4
and JU5 onto the correct pins (see Figure 5.5).
6. If you are configuring the scanner as the last device on
an EIA/TIA-485 network, move JU1 to the B position.
7. Reassemble the scanner.
Installing Scaling Resistors
ç
CAUTION! Scaling resistors are soldered to the circuit
CAS200 Input Circuit
Resistors are installed for all inputs on the CAS200. Inputs
with signal ranges between -10 and +60mV use 0Ω
resistors in the RC position only. All other input signals
require special input scaling resistors.
board. Only qualified technicians should attempt
to install or remove these components. Improper
techniques, tools or materials can result in damage to the scanner that is not covered by the warranty.
The CAS200 can accept single-ended thermocouple, mVdc,
Vdc and mA dc inputs. Unless ordered with special inputs,
the scanner accepts only signals within the standard range
-10 to 60 mVdc.
To accommodate other signals, the input circuit must be
modified. When configured for thermocouple inputs, 0 Ω
resistors are installed in all RC locations. To accommodate
milliamp current signals or voltage signals outside the
standard range, resistors are added or replaced to scale the
signals to the standard range. These resistor can be
installed by Watlow Anafaze or by a qualified electronics
technician using scaling resistors supplied by Watlow
Anafaze.
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Figure 5.6 shows the schematic for one single-ended sensor
input to the CAS200. See CAS200 Current Inputs on page
83 and CAS200 Voltage Inputs on page 84 for specific
instructions and resistor values for voltage and current
inputs.
Figure 5.6 CAS200 Input Circuit
Analog
Input
Terminals
CAS200 Current Inputs
For each current input on a CAS200 scanner, you must
install one resistor. The value of the resistor must be
correct for the expected input range. Install the resistor in
the listed resistor location.
Table 5.3 Resistor Values for CAS200
IN +
Com
(Voltage only)
RC
(Voltage and Current)
RD
To CAS200
Measurement
Circuitry
Current Inputs
Input Range Resistor Value RD
0 - 10mA 6.0Ω
0 - 20mA 3.0Ω
Resistor tolerance: ±0.1%
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Table 5.4 Resistor Locations for CAS200
Current Inputs
CAS200 Voltage Inputs
For each voltage input on a CAS200 scanner, you must
install two resistors. The resistance must be correct for the
expected input range. Install the resistors in the listed
locations.
Resistor
Channel
Location
Channel
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
Resistor
Location
RD
Table 5.5 Resistor Values for CAS200
Input Range
0 - 100mVdc 499Ω 750Ω
0 - 500mVdc 5.49kΩ 750Ω
0 - Vdc 6.91kΩ 422.0Ω
0 - 5Vdc 39.2kΩ 475.0Ω
0 - 10Vdc 49.9kΩ 301.0Ω
0 - 12Vdc 84.5kΩ 422.0Ω
Resistor tolerance: ±0.1%
84 Watlow Anafaze
Voltage Inputs
Resistor Values
RC RD
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CAS200 User’s Guide Chapter 5: Troubleshooting and Reconfiguring
Table 5.6 Resistor Locations for CAS200
Voltage Inputs
Resistor Locations
Channel
RC RD RC RD
1 R58 R42 9 R57 R41
2 R56 R40 10 R55 R39
3 R54 R38 11 R53 R37
4 R52 R36 12 R51 R35
5 R50 R34 13 R49 R33
6 R48 R32 14 R47 R31
7 R46 R30 15 R45 R29
8 R44 R28 16 R43 R27
Scaling and Calibration
The scanner provides offset calibration for thermocouples
and offset and span (gain) calibration for linear and pulse
inputs. In order to scale linear input signals, you must:
1. Install appropriate scaling resistors. (Contact Watlow
Resistor Locations
Channel
Anafaze’s Customer Service Department for more
information about installing scaling resistors.)
2. Select the display format. The smallest possible range
is -.9999 to +3.0000; the largest possible range is -9999
to 30000.
3. Enter the appropriate scaling values for your process.
See Chapter 6, Linear Scaling Examples on page 87.
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6
Linear Scaling Examples
This chapter provides three linear scaling examples. The
examples describe:
• A pressure sensor generating a 4 to 20mA signal.
• A flow sensor generating a 0 to 5V signal.
• A pulse encoder generating 900 pulses per inch of
movement.
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Chapter 6: Linear Scaling Examples CAS200 User’s Guide
Example 1: 4-20mA Sensor
Situation
A pressure sensor that generates a 4-20 milliamp signal is
connected to the scanner. The specifications of the sensor
state that it generates 4mA at 0.0 pounds per square inch
(psi) and 20mA at 50.0 psi.
Setup
The sensor is connected to a loop input set up with a
resistor scaling network to produce 60 millivolts at 20mA.
The INPUT TYPE for the loop is let to LINEAR. The sensor
measures psi in tenths, so the DISP FORMAT is set to
-999.9 TO +3000.0.
Table 6.1 Input Readings
Process
Variable
Displayed
50.0 psi 20mA 100%FS
0.0 psi 4mA 100% x (4mA/20mA) = 20%FS
The scaling values set up in the SETUP LOOP INPUT menu
are shown in Table 9.2.
Sensor
Input
Reading, Percent of
Full Scale (%FS)
Table 6.2 Scaling Values
Parameter Prompt Value
High Process Variable HIGH PV 50.0 psi
High Sensor Reading HIGH RDG 100.0%FS
Low Process Variable LO PV 0.0 psi
Low Sensor Reading LO RDG 20.0%FS
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