Watlow CLS User Manual

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CLS

User’s Guide

Watlow Controls

1241 Bundy Blvd. Winona, MN 55987

Customer Service

Phone: (800) 414-4299 Fax: (800) 445-8992

Technical Support

Phone: (507) 494-5656 Fax: (507) 452-4507 Email: wintechsupport@watlow.com

Part No. 21952-00. Revision 3.2 October 1996

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, Incorporated within one week after the Customer's discovery of such defect. The sole obligation and liability of Watlow Anafaze, Incorporated 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, Incorporated. Replaced or repaired products or parts will be shipped to the Customer at the expense of Watlow Anafaze, Incorporated.

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, Incorporated. Final determination of warranty eligibility shall be made by Watlow Anafaze, Incorporated. If a warranty claim is considered invalid for any reason, the Customer will be charged for services performed and expenses incurred by Watlow Anafaze, Incorporated 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, Incorporated 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, Inc. disclaims all warranties, express or implied, including any warranty of merchantability or fitness for a particular purpose.

Please Note: External safety devices must be used with this equipment.

CLS User’s Guide Contents

Overview 1

System Diagram.....................................................................2

Parts List ...............................................................................2

Safety .....................................................................................3

Introduction 5

Specifications ........................................................................7

Analog Inputs ..................................................................7

Digital Inputs ..................................................................9

User-Selectable Digital Outputs .....................................9

System Digital Outputs....................................................9

Analog Outputs................................................................10

Miscellaneous Specifications ................................................11

Physical Dimensions .......................................................11

Installation 13

Precautions and Warnings ....................................................14

Recommended Tools ............................................................15

Panel Hole Cutters ..........................................................15

Other Tools .....................................................................15

CLS Mounting Procedure .....................................................16

Mounting Environment ...................................................16

Steps: ...............................................................................16

TB-18 Mounting Instructions ...............................................17

TB-50 Mounting Instructions ...............................................18

General Wiring Recommendations .......................................20

Grounding .......................................................................21

Thermocouple Wiring .....................................................22

Input Wiring ....................................................................22

Output Wiring .................................................................23

Communications Wiring .................................................23

Wiring: Noise Suppression ...................................................24

General Wiring .....................................................................25

Power Wiring and Controller Test ..................................25

Outputs ..................................................................................27

PID Control and Alarm Output Connections 2................30

Watchdog Timer .............................................................30

TB-18 Connections .........................................................31

TB-50 Connections .........................................................32

Contents CLS User’s Guide

Inputs ....................................................................................34

Input Scaling ...................................................................34

4 and 8 CLS Scaling Values ...........................................35

16 CLS Scaling Values ...................................................38

Scaling and Calibration ...................................................39

T/C Inputs .......................................................................39

RTD Inputs (4 and 8 CLS only) ......................................40

Current Inputs .................................................................41

Voltage Inputs .................................................................41

Unused Inputs .................................................................41

Back Terminal Block Connections .................................42

Serial Communications .........................................................42

RS-232 Interface .............................................................43

RS-485 Interface .............................................................43

Using the CLS 49

Introduction ...........................................................................49

Front Panel ............................................................................50

Front Panel Keys .............................................................50

Displays ................................................................................53

Bar Graph Display ..........................................................53

Single Loop Display .......................................................54

Alarms .............................................................................56

Job Display ...........................................................................57

Operator Menus ....................................................................58

Change Setpoint ..............................................................58

Manual/Automatic Control .............................................58

Ramp/Soak ......................................................................60

Setup 61

How to Enter the Setup Menus? .....................................61

How to edit a menu? .......................................................61

Set up Global Parameters Menu ...........................................63

Load a Job .......................................................................64

Save Setup to Job ............................................................64

Job Select Inputs .............................................................65

Job Select Input Polarity .................................................65

Output Override Digital Input .........................................66

Output Override Input Polarity .......................................66

Start-up Alarm Delay ......................................................66

Keyboard Lock Status .....................................................67

Power-Up Output Status .................................................67

Controller Address ..........................................................67

Communications Baud Rate ............................................68

CLS User’s Guide Contents

Communications Protocol ...............................................68

Communications Error Checking ...................................68

AC Line Frequency .........................................................69

Digital Output Polarity ....................................................69

EPROM Information .......................................................69

Set up Loop Input .................................................................70

Input Type .......................................................................71

Pulse Sample Time .........................................................72

Loop Name .....................................................................72

Input Units ......................................................................72

Input Reading Offset .......................................................73

Linear Scaling Menus .....................................................73

Display Format ...............................................................75

High Process Value .........................................................75

High Reading ..................................................................76

Low Process Value .........................................................76

Low Reading ...................................................................76

Input Filter ......................................................................77

Set up Loop Control Parameters ...........................................78

Heat or Cool Control PB .................................................79

Heat or Cool Control TI ..................................................79

Heat or Cool Control TD ................................................79

Heat or Cool Output Filter ..............................................80

Heat and Cool Spread .....................................................80

Set up Loop Outputs .............................................................81

Enable/Disable Heat or Cool Outputs .............................82

Heat or Cool Output Type ..............................................82

Heat or Cool Cycle Time ................................................83

SDAC Menus ........................................................................83

SDAC Mode ...................................................................83

SDAC High Value ..........................................................84

SDAC Low Value ...........................................................84

Heat or Cool Output Action ............................................84

Heat or Cool Output Limit ..............................................85

Heat or Cool Output Limit Time ....................................85

Heat or Cool Output Override ........................................85

Heat or Cool Nonlinear Output Curve ............................86

Set up Loop Alarms ..............................................................87

Alarm Types ...................................................................87

High Process Alarm Setpoint ..........................................90

High Process Alarm Type ...............................................90

High Process Alarm Output Number ..............................90

Deviation Band Value .....................................................91

High Deviation Alarm Type ...........................................91

iii

Contents CLS User’s Guide

High Deviation Alarm Output Number ..........................91

Low Deviation Alarm Type ............................................92

Low Deviation Alarm Output Number ...........................92

Low Process Alarm Setpoint ..........................................92

Low Process Alarm Type ...............................................93

Low Process Alarm Output Number ..............................93

Alarm Deadband .............................................................93

Alarm Delay.....................................................................94

Manual I/O Test ....................................................................95

Digital Input Testing .......................................................95

Test Digital Output .........................................................96

Toggle Digital Output .....................................................96

Keypad Test ....................................................................96

PID Tuning and Control 97

Introduction ...........................................................................97

Control Modes ......................................................................98

On/Off Control ................................................................98

Proportional Control .......................................................98

Proportional and Integral Control ...................................99

Proportional, Integral and Derivative Control ................100

Control Outputs ...............................................................100

Digital Output Control Forms .........................................100

Setting Up and Tuning PID Loops .......................................103

Proportional Band (PB) Settings .....................................103

Integral Term (TI) Settings .............................................104

Derivative Term (TD) Settings .......................................104

General PID Constants by Application .................................105

Proportional Band Only (P) ............................................105

Proportional with Integral (PI) ........................................105

PI with Derivative (PID) .................................................105

Troubleshooting 107

No Key Reset ..................................................................107

Returning your Unit ........................................................108

Troubleshooting Stand-Alone Systems ................................108

Checking an Analog Input ..............................................108

Checking Digital I/O .......................................................109

Checking Computer Supervised Systems .............................110

Computer Problems ........................................................110

Software Problems ..........................................................111

Changing the EPROM ....................................................111

CLS User’s Guide Contents

Linear Scaling Examples 115

Example 1 .............................................................................115

Example 2 .............................................................................116

Example 3 .............................................................................117

Appendix A: Ramp Soak 119

Introduction ...........................................................................119

R/S Features ....................................................................119

Specifications ..................................................................120

Configuring Ramp/Soak .......................................................120

Setting the R/S Time Base ..............................................121

Editing R/S Parameters ...................................................121

Choosing a Profile to Edit ...............................................121

Copying the Setup from Another Profile ........................122

Editing the tolerance Alarm Time ..................................122

Editing the Ready Setpoint .............................................123

Editing the Ready Event States .......................................123

Choosing an External Reset Input ..................................124

Editing a Segment ...........................................................124

Setting Segment Time .....................................................124

Setting a Segment Setpoint .............................................125

Configuring Segment Events ..........................................125

Editing Event Outputs .....................................................126

Changing Event States ....................................................126

Editing Segment Triggers ...............................................126

Assigning an Input to a Trigger ......................................127

Changing a Trigger’s True State .....................................127

Latching or Unlatching a Trigger ...................................127

Setting Segment Tolerance .............................................128

Ending a Profile ..............................................................128

Repeating a Profile ..........................................................128

Using Ramp/Soak .................................................................129

Assigning a profile to a loop ...........................................129

Assigning a Profile to a Linear Input Loop ....................130

Running a Profile ............................................................131

Ramp/Soak Displays .......................................................131

Holding a Profile or Continuing from Hold ....................134

Resetting a profile ...........................................................135

Appendix B: Enhanced Process Control 137

Enhanced Process Control Menus ........................................138

vContents CLS User’s Guide

Process Variable Retransmit .................................................139

Setting Up a PV Retransmit ............................................139

PV Retransmit Menus .....................................................140

Cascade Control ....................................................................143

Setting Up Cascade Control ............................................143

Cascade Control Menus ..................................................144

Ratio control .........................................................................147

Setting Up Ratio Control ................................................147

Ratio Control Menus .......................................................148

Remote Analog setpoint ........................................................149

Differential Control ...............................................................149

Typical Applications .............................................................150

Process Variable Retransmit ...........................................150

Cascade Control ..............................................................153

Ratio Control ...................................................................156

Remote Setpoint ..............................................................158

Differential Control .........................................................159

Glossary 163

Overview

This manual describes how to install, setup, and operate a 4CLS, an 8CLS, or a 16CLS. Included are seven chapters, two Appendices, and a glossary of terms. Each chapter covers a different aspect of your control system and may apply to different users. The following describes the chapters and their purpose.

•

Introduction: Gives a general description of the CLS and its related

specifications.

•

Installation: Describes how to install the CLS and its peripheral

devices.

•

Using the CLS: Provides an overview of operator displays used for

system monitoring.

•

Setup: Describes all the setup displays for the controller, and how to

access them.

•

Tuning and Control: Explains PID control and provides tips for

tuning your system.

•

Troubleshooting: Gives some basic guidelines for solving control

problems.

•

Linear Scaling Examples: Provides an example configuring a pres-

sure sensor, and one configuring a flow sensor.

•

Appendix A: Ramp and Soak. This section explains how to setup

and use Ramp/Soak profiles in your application.

•

Appendix B: Enhanced Process Control. This appendix describes

optional process variable retransmit and cascade control features.

CLS User’s Guide 1

Overview

System Diagram

The illustration below shows how the parts of the CLS are connected. When unpacking your system, use the diagrams and parts list below to ensure all parts have been shipped. Please don't hesitate to call Watlow Anafaze's Technical Service Department if you have problems with your shipment, or if the CLS components are missing or damaged.

Parts List

•

CLS controller

•

Controller mount kit

•

AC adapter (110V or 220V)

•

Terminal Block (TB-50 or TB-18)

•

TB-50 or TB-18 mounting kit

•

50 pin flat ribbon cable (50 pin ribbon cable)

•

DAC or SDAC (optional)

•

User Manual

2 CLS User’s Guide

Safety

Overview

Watlow Anafaze has made efforts to ensure the reliability and safety of the CLS Controller and to recommend safe usage practices in systems applications. Please note that, in any application, failures can occur. These failures may result in full control outputs or other outputs which may cause damage to or unsafe conditions in the equipment or process connected to the CLS Controller.

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 Watlow Anafaze CLS Controller can fail with outputs full on, outputs full off, 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.

The CLS includes a reset circuit that sets the control outputs off or to the data stored in memory if the microprocessor resets--normally the result of a power failure and power return. If a memory-based restart will be unsafe for your process, program the CLS Controller to restart with outputs off. For additional safety, program the computer or other host device to automatically reload the desired operating constants or process values on return of operating power. However, these safety features do not eliminate the need for external, independent safety devices in potentially dangerous or unsafe conditions.

Watlow Anafaze also offers ANASOFT

program for IBM-AT event of a reset, ANASOFT will reload the CLS Controller with the current values in computer memory. The user must ensure that this reset will be safe for the process. Again, use of ANASOFT does not eliminate the need for appropriate external, independent safety devices.

Contact Watlow Anafaze immediately if you have any questions about system safety or system operation.

or IBM-PC® compatible computers. In the

, an optional software

CLS User’s Guide 3

Overview

4 CLS User’s Guide

Introduction

The CLS is a modular control system with up to 16 fully independent loops of PID control (16 CLS). It functions as a stand-alone controller; the CLS 1/8 DIN front panel has a Liquid Crystal Display (LCD) and touch keypad for local display and local parameter entry. You can also use it as the key element in a computer-supervised data acquisition and control system; the CLS can be locally or remotely controlled via an RS-232 or RS-485 serial communications interface.

The CLS features include:

Direct Connection of Mixed Thermocouple Sensors: Directly connect most thermocouples with the CLS versatile hardware. Thermocouple inputs feature reference junction compensation, linearization, PV offset calibration to correct for sensor inaccuracies, T/ C upscale break detection, and a choice of Fahrenheit or Celsius display.

Introduction

Resistive Temperature Detector Sensors are Standard Inputs: Two types of standard three wire 100 ohm platinum DIN curve sensor are standard inputs for the CLS. (To use this input, order the CLS with scaling resistors.)

Automatic Scaling for Linear Analog Inputs: The CLS automatically scales linear inputs used with other industrial process sensors. Simply enter two measurement points. For example, to scale a PSI sensor enter the endpoints: Low PV is 10 PSI, while High PV is 100 PSI. All other values for that loop will automatically be in PSI.

Dual Outputs Standard: The CLS includes dual control outputs for each loop, with independent control constants for each output.

Independently Selectable PID Output Modes: You can set each control output to ON/OFF, Time Proportioning, Serial DAC, or Distributed Zero Crossing mode. You can set each output control mode for ON/OFF, P, PI, or PID control with reverse or direct action.

Flexible Alarm Outputs: Independently set high/low process alarms and a high/low deviation band alarm for each loop. Alarms can activate a digital output by themselves, or they can be grouped with other alarms to activate an output.

Alarm or Control Outputs: You can set high/low deviation and high/ low process setpoints to operate digital outputs as on/off control functions instead of alarms. (The control function has no alarm notification or global alarm output.)

Global Alarm Output: When any alarm is triggered, the Global Alarm Output is also triggered, and it stays on until you acknowledge it.

CLS User’s Guide 5

Introduction

Watchdog Timer: The CLS watchdog timer output notifies you of system failure. You can use it to hold a relay closed while the controller is running, so you are notified if the microprocessor shuts down.

Front Panel or Computer Operation: Set up and run the CLS from the front panel or from a local or remote computer. Watlow Anafaze offers ANASOFT, our IBM AT or IBM-PC compatible software you can use to operate the CLS. ANASOFT has these features:

•

Process Overviews

•

Parameter Setup

•

Graphic Trend Plotting

•

Data Logging

Multiple Job Storage: Store up to 8 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 operating conditions, including setpoints and alarms.

Non-Linear Output Curves Standard: Select either of two non-linear output curves for each control output.

Autotuning Makes Setup Simple: Use the Autotune feature to set up your system quickly and easily. The CLS internal expert system table finds the correct PID parameters for your process.

Pulse Counter Input Standard: Use the pulse counter input for precise control of motor or belt speed.

6 CLS User’s Guide

Specifications

Analog Inputs

Introduction

The following section contains specifications for inputs, outputs, the serial interface, system power requirements, environmental specifications, and the CLS physical dimensions.

Number of Control Loops:

pulse loop.

Number of Analog Inputs:

Input Switching:

Input Sampling Rate:

4CLS: 6x/sec (167 ms) at 60 Hz; 5x/sec (200 ms) at 50 Hz. 8CLS: 3x/sec (333 ms) at 60 Hz; 2.5x/sec (400 ms) at 50 Hz. 16CLS:1.5x/sec (667 ms) at 60 Hz; 1.25x/sec (300 ms) at 50 Hz.

Analog Over Voltage Protection:

Common Mode Rejection (CMR):

>60 dB DC to 1 kHz, and 120 dB at selected line frequency.

A/D Converter:

Input Range:

resistors.

Resolution:

measurement resolution, not the display resolution.)

differential solid state MUX switching.

Integrates voltage to frequency.

-10 to +60 mV. Other ranges are available with scaling

0.006%, greater than 14 bits. (This is the internal

4 (4CLS), 8 (8CLS), 16 (16CLS), plus one

4 (4CLS), 8 (8CLS), 16 (16CLS).

20 V referenced to digital ground.

For inputs that don't exceed +

5 V,

Calibration:

Automatic zero and full scale.

CLS User’s Guide 7

Introduction

Thermocouple Ranges and Resolution:

Name

RTD1 -148.0 to

RTD2 -184 to

Range in

527.0

1544

T/C

Type

J T/C -350 to 1400 -212 to 760

K T/C -450 to 2500 -268 to 1371

T T/C -450 to 750 -268 to 399

S T/C 0 to 3200 -18 to 1760

R T/C 0 to 3210 -18 to 1766

B T/C 150 to 3200 66 to 1760

E T/C -328 to 1448 -200 to 787

Range in °F Range in °C

* True for 10% to 100% of span.

RTD Ranges and Resolution (4 and 8 CLS only)

Range in

Resolution

Measure-

ment

Temp. In

-100.0 to

275.0

-120 to 840

0.023

0.062

275 ±1 ±1.8 ±1.5 ±2.7

840 ±1.1 ±1.98 ±4.3 ±7.74

* Accuracy:

Ambient

0.5

0.6

1.3

2.5

6.6

0.9

1.2

2.4

4.5

12.0

* Accuracy:

C Full

0-50

Temp. Range

1.1

1.35

2.9

5.6

14.9

10.1

27.0

2.0

2.7

5.4

Accuracy:

Ambient

25 ±0.35 ±0.63 ±0.5 ±0.9

25 ±0.9 ±1.62 ±2.8 ±5.04

C °F

Accuracy:

0-50

Ambient

C °F

8 CLS User’s Guide

T/C Break Detection: Pulse type for upscale break detection.

Milliamp inputs: 0-20 mA (3 ohms resistance) or 0-10 mA (6 ohms

resistance), with scaling resistors.

Voltage inputs: 0-12V, 0-10V, 0-5V, 0-1V, 0-500mV, 0-100 mV with scaling resistors.

Range

0-12 V 85 Kohms 0-10 V 50 Kohms 0-5 V 40 Kohms 0-1 V 7.4 Kohms 0-500 mV 6.2 Kohms 0-100 mV 1.2 Kohms

Source Impedance: For 60 mV T/C, measurements are within specification with up to 500 ohms source resistance.

Input

Resistance

Digital Inputs

Introduction

Number:

Configuration:

Input Voltage Protection:

limit to 10 mA for override conditions.

Voltage Levels:

Maximum Switch Resistance to Pull Input Low:

Minimum Switch Off Resistance:

User-Selectable Digital Outputs

Number:

Operation:

Current

Function:

Number of PID Control Outputs per PID Loop:

PID Control Output Types:

Crossing, SDAC, or On/Off output. Heat and cool control outputs can be individually disabled for use as alarm outputs.

8 selectable for output override, remote job selection.

Diodes to supply and common. Source must

<1.3V=Low; >3.7V=High (TTL).

1 Kohms.

11 Kohms.

Open collector output; On state sinks to logic common.

≤

20 mA for 35 loads. Single load ≤ 40 mA. I total ≤ 700 mA.

Selectable as PID control or alarm/control.

2 (max)

Time Proportioning, Distributed Zero

—

all independently selectable for each

System Digital Outputs

Time Proportioning Cycle Time:

each output.

PID Control Action:

selectable for each output.

Off State Leakage Current:

System Digital Outputs:

Operation:

Current

Open collector output; On state sinks to logic common.

≤

20 mA for 35 loads. Single load ≤ 40 mA. I total ≤ 700 mA.

Reverse (heat) or direct (cool), independently

<.01 mA to DC common.

1 Global Alarm, 1 CPU watchdog.

1-255 seconds, programmable for

CLS User’s Guide 9

Introduction

Analog Outputs

The Watlow Anafaze Digital to Analog Converter (DAC) is an optional module for the CLS. It lets you convert a Distributed Zero Crossing control output signal to an analog process control signal. You can purchase a 4-20 mAdc, 0-5 Vdc, and 0-10 Vdc versions of the DAC.

Watlow Anafaze also offers the Serial DAC for precision open-loop control. 0-5 Vdc/4-20 mAdc jumper selectable.

Contact Watlow Anafaze for more information about the DAC and Serial DAC.

10 CLS User’s Guide

Miscellaneous Specifications

Serial Interface

Type :

Introduction

RS-232 3 wire or RS-485 4 wire.

Isolation:

RS-232 None

RS-485 To EIA RS-485 Specification.

Baud Rate:

Error Check:

Number of Controllers:

32 with RS-485 communications.

Protocol:

Bradley PLC, full duplex.

2400 or 9600, user selectable.

BCC or CRC, user selectable.

1 with RS-232 communications;

Form of ANSI X3.28-1976 (D1, F1), compatible with Allen

System Power Requirements

Vo lt age:

Input Current (no load):

Maximum Current Requirement:

externally loaded, add 1 mA supply current for every 1 mA of load up to a maximum load of 100 mA. If using the +5V logic supply to power digital outputs, add 0.6 mA supply current for every 1 mA of load up to a maximum load of 350 mA. Therefore, the maximum current requirement is 300 +100 + (0.6 x 350) = 610 mA.)

12-24 Vdc

300 mA max

610 mA. (If the reference voltage is

Physical Dimensions

Environmental Specifications

0 to 50

Storage Temperature:

Operating Temperature:

Humidity:

CLS:

mm.)

TB-18:

TB-50:

10 to 95% non-condensing.

1.75 lbs., 1.98

" x

1.025

3.2

x 3.4" (8.03 cm x 8.53 cm)

-20 to 60

x 3.78" x 7.10" (.8 kg, 50 mm x 96 mm x 180

3.700" (2.57 cm x 9.29 cm)

CLS User’s Guide 11

Introduction

12 CLS User’s Guide

Installation

These installation instructions are written for non-technical users; if you are an electrician or you are technically proficient, they may seem simple to you. Please at least skim all of the instructions, to make sure you don't miss anything vital.

This section explains installation for the CLS only. If you are installing another Watlow Anafaze product (such as an SDAC), see the manual shipped with it to learn how to install it.

These symbols are used throughout the rest of this manual:

DANGER

This symbol warns you about hazards to human life.

WARNING

This symbol warns you of possible damage to property or equipment.

NOTE

This symbol denotes information you must know in order to proceed.

CLS User’s Guide 13

Installation

Precautions and Warnings

DANGER

Shut off power to your process before you install the CLS. High voltage may be present even when power is turned off! Reduce the danger of electric shock after installation by mounting the CLS in an enclosure that prevents personal contact with electrical components.

The CLS measures input signals that are not normally referenced to ground, so the CLS inputs and other signal lines can have high voltage present even when power is turned off--for example, if you inadvertently short a thermocouple to the AC power line.

WARNING

During installation and wiring, place temporary covers over the housing slots and the rear of the CLS so dirt, pieces of wire, et cetera don't fall through the slots. Remove these covers after installation.

Install the CLS so the slots in the housing receive unrestricted airflow after installation. Make sure that other equipment does not block airflow to the housing slots.

Use #20 or #22 AWG wires and trim wire insulation to 1/4” (5 mm). Wire should fit inside the terminal with no bare wire exposed, to prevent contact between wires and the grounded case. Tin any stranded wire.

Support power, input and output cables to reduce strain on the terminals and to prevent wire removal.

14 CLS User’s Guide

NOTE

Be sure to select a panel location that leaves enough clearance to install and remove the CLS and its components.

Recommended Tools

Panel Hole Cutters

Other Tools

Installation

Use these tools to install the CLS:

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.

You will also need these tools:

•

Phillips head screwdriver.

•

Flathead screwdriver for wiring.

•

Multimeter.

CLS User’s Guide 15

Installation

CLS Mounting Procedure

Mounting Environment

NOTE

Mount the controller before you mount the terminal block or do any wiring. The controller's placement affects placement and wiring considerations for the other components of your system.

Install the CLS in a location free from excessive (>50ºC) heat, dust, and unauthorized handling. The controller can mount in any panel material up to 0.2" thick. (Make sure there is enough clearance for mounting brackets and terminal blocks; the controller extends 6.2" behind the panel face and the screw brackets extend 0.5" above and below it.)

Steps:

1. Cut a hole 3.630+0.020" long by 1.800+0.020" tall in the panel. This figure shows the mounting hole. (The figure is not a template.) Cut carefully; the 0.020" (0.5 mm) tolerances don't allow much room for error. Use a punch, nibbler, or jigsaw, and file the edges of the hole.

16 CLS User’s Guide

2. Insert the controller into the hole through the front of the panel.

3. Screw the top and bottom clips in place: insert the screw's lip into the cutout in the metal housing just behind the front panel. Tighten the screw.

4. If you expect much panel vibration, use a rear support for the CLS and its interconnecting cables.

TB-18 Mounting Instructions

These steps describe how to mount the TB-18 on the rear of the CLS. (Please follow these steps exactly, so you do not damage either the terminal block or the controller.)

1. Install the cable support on the underside of the CLS. The TB-18 was shipped to you in a plastic bag. The bag also contained a cable tie (the long plastic strip) and a cable tie mount (the square plastic piece with one sticky side).

a. Stick the cable tie mount to the underside of the CLS. Install it

b. Thread the cable tie through the hole in the cable tie mount.

Installation

in a spot that won't block the vents.

When you're finished wiring the outputs, it should look like this illustration.

2. Next, wire outputs to the terminal block. (For help, see Wiring Outputs later in this chapter.) Route wires through the cable support, leaving about 9" of wire between the TB-18 and the support.

3. Gently slide the female part of the terminal block into the 50-pin header on the rear of the controller, as shown here.

WARNING

Do not connect power to the CLS now. Test the unit first, as explained in the Power Wiring and Controller Test section.

CLS User’s Guide 17

Installation

TB-50 Mounting Instructions

These steps tell you how to mount the TB-50. (Please follow these steps exactly, so you don’t damage the terminal block, the ribbon cable, or the controller.)

1. Choose a mounting location. Be sure there is enough clearance to install and remove the TB-50; it measures 3.4" long X 3.2" wide X

1.27" tall.

2. Watlow Anafaze shipped the TB-50 to you in an antistatic bag. Make sure these parts are also in the bag:

•

Five plastic standoffs.

•

Five 6-32 screws.

•

Five cable tie wraps.

•

One 50-pin ribbon cable.

•

Five ribbon cable clamps.

3. Snap four of the plastic standoffs into the four mounting holes on the TB-50.

There are also four smaller holes on the terminal board, as shown here. These holes are for the cable tie wraps--the plastic standoffs won’t fit them. You’ll use these holes to secure wiring to the terminal block. (See

Wiring Outputs

in this chapter for help installing

cable tie wraps.)

3938B

4443424140

504948474645

Holes labeled "A"are m ounting holes. Holes labeled "B"aretiewrap holes.

3738A

3233

3031

262728

25242322212019181716151413B

12345678910111213A

18 CLS User’s Guide

Installation

4. Place the TB-50 where you will mount it and use a pencil to trace around the standoffs.

5. Drill and tap #6-32 holes in the locations you marked.

6. Place the TB-50 where you will mount it. Insert the #6 screws in the standoffs and tighten them.

NOTE

Save the cable tie wraps, ribbon cable, and ribbon cable clamps. You’ll use them when you wire outputs to the TB50 and when you connect the ribbon cable.

WARNING

Do not connect power to the CLS now. Test the unit first, as explained in the Power Wiring and Controller Test section.

CLS User’s Guide 19

Installation

General Wiring Recommendations

Use the cables below or their equivalent. For best results, use appropriate materials, proper installation techniques and the correct equipment. For example, choose wire type by function, installation requirements, and the likelihood of mechanical or electrical problems at your installation.

Function MFR P/N

Analog inputs Belden #9154

Belden #8451

RTD Inputs (4 & 8 CLS) Belden #8772

Belden #9770 T/C Inputs T/C Ext. Wire 2 20 Digital PID outputs and Dig-

ital I/O

Computer Communication: RS232 or RS485

Belden #9539

Belden #9542

Ribbon Cable

Belden #9729

Belden #9730

Belden #9842

Belden #9843

No. of Wires

2 2

3 3

9 20 50

4 6 4 6

20 22

24 24

24 24 24 24

WARNING

Never wire bundles of low power controller circuits next to bundles of high power AC wiring. Instead, physically separate high power circuits from the controller. If possible, install high voltage AC power circuits in a separate panel.

AWG

20 CLS User’s Guide

•

Use stranded wire. Solid wire is used for fixed service; it makes

intermittent connections when you move it for maintenance.

•

Use #20 or #22 AWG wire. Larger or smaller sizes may be difficult

to install, may break easily, or may cause intermittent connections.

•

Use shielded wire. (The electrical shield helps protect the CLS from

electrical noise.) Connect one end of the input wiring shield to the CLS panel's 120 Vac panel ground, and connect one end of the output wiring shield to the CLS panel's 120 Vac panel ground. (Some installations may require a different shield configuration. Contact Watlow Anafaze for more information if these instructions do not apply to your system.)

For more noise suppression measures, see

Noise Suppression

Grounding

Installation

Connect the CLS chassis to an external ground at only one point, to avoid ground loops that can cause instrument errors or malfunctions. Since the CLS uses a non-isolated measurement system, it has the following connections to power supply common:

•

Analog common TB1 pins 5, 6, 11, & 12

•

Reference common, TB1 pin 17

•

Communications ground (TB1 pins 23 & 24) if using RS-232

•

Power supply ground, TB2 pin 2

•

Control common (TB-18 pin 2; TB-50 pin 3 and 4)

Watlow Anafaze strongly recommends that you:

•

Do not connect any one of these pins to earth ground. Do not tie

them together externally.

•

Isolate outputs through solid state relays, where possible.

•

Isolate RTDs or “bridge” type inputs from ground, if used.

•

Isolate digital inputs from ground through solid state relays. If you

can't do that, then make sure the digital input is the only place that one of the above pins connects to ground.

•

If you are using RS-232 from an un-isolated host, don't connect any

other power common point to earth ground.

CLS User’s Guide 21

Installation

Thermocouple Wiring

Use 18 or 20 AWG thermocouple (T/C) extension wire for all the T/C inputs.

NOTE

Most thermocouple wire is solid unshielded wire. Use shielded wire if required at your installation; ground one end only.

WARNING

The CLS uses a floating ground system. Therefore:

Isolate input devices or host computers connected through communications cables (like RS-232) from earth ground.

Use ungrounded thermocouples with the thermocouple sheath electrically connected to earth ground.

Use optically isolated RS-232 devices to isolate earth grounded host computers from CLSs.

When you use grounded T/Cs, tie the thermocouple shields 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 controller.

Input Wiring

WARNING

The 16CLS has single ended inputs, offering 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' of thermocouple extension wire, depending on wire type and wire size, and keep to accuracy and source impedance specifications. Be sure to install thermocouple wiring in a separate conduit away from AC power (the 120 Vac control supply) and high power (240 Vac or higher) wiring.

Use multicolored stranded shielded cable for analog inputs. Watlow Anafaze recommends that you use #20 AWG wire. (If the sensor manufacturer requires it, you can also use #22 or #24 AWG wiring.) Most inputs use a shielded twisted pair; some require a 3 wire input.

22 CLS User’s Guide

Output Wiring

Communications Wiring

Installation

Use multicolored stranded shielded cable for analog outputs (if you have installed an SDAC) and PID digital outputs connected to panel mount SSRs. Analog outputs generally use a twisted pair, while digital outputs have 9-20 conductors, depending on wiring technique.

For instructions on using the cable tie wraps included in the TB-50’s packaging, see the

Large systems can pull in an extra pair to the computer communications wiring. The extra pair services a sound power phone system for communications between the Watlow Anafaze controller and a computer.

If you choose this option for maintenance, calibration checking, et cetera, Watlow Anafaze recommends a David Clark #H5030 system.

Wiring Outputs

section.

CLS User’s Guide 23

Installation

Wiring: Noise Suppression

If the CLS's outputs control dry contact electromechanical relays with inductive loads--like alarm horns and motor starters Electro-magnetic Interference (EMI, or “noise”) The following section

explains how to avoid noise problems; read it before you wire the CLS.

you may get

Symptoms of RFI/EMI

If your controller displays the following symptoms, suspect EMI.

•

The CLS's display blanks out and then reenergizes as if power had

been turned off for a moment.

•

The process value 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 controller to Watlow Anafaze for repair.

Avoiding Noise Problems

To avoid noise problems:

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 CLS equipment.

Separate the 120 Vac power leads from the low level input and output leads connected to the CLS. Don't run the digital output or PID control output leads in bundles with 120 Vac wires. (Never run input leads in bundles with high power leads. See the General Wiring section.)

If you must use EM relays and you must place them in a panel with CLS equipment, use a .01 microfarad capacitor rated at 1000 Vac (or higher)

in series with a 47 ohm, 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 130 Vac for 120 Vac control circuits across the load, which limits the peak AC voltage to about 180 Vac (Watlow Anafaze P/N 26130210-00). You can also place a transorb (back to back zener diodes) across the digital output, which limits the digital output loop to 5 Vdc. (All the parts mentioned here are available from Watlow Anafaze).

watt resistor across the NO contacts of the

24 CLS User’s Guide

The above steps will eliminate most noise problems. If you have further problems or questions, please contact Watlow Anafaze.

General Wiring

The following sections explain how to test your installation before you connect power to it and how to connect inputs and outputs to it.

Power Wiring and Controller Test

When you have installed each component of the controller and the TB50 (if used), use this checklist to connect them. These instructions are written so that non-electricians can understand them. If you are an experienced electrician, they may seem elementary to you. If so, feel free to skim them.

Connecting Power and TB-50 to CLS

1. Remove the temporary covers on the CLS housing.

2. The plug-in power supply, included with your controller, has two bare wires. The + side connects to TB2-1, and the - side to TB2-2. As a precaution, you should check the polarity of the wires with a multimeter (color coding of the wires is not always reliable with older power supplies).

3. Connect the ribbon cable to the controller, as shown here. Plug it in so the red stripe is on the left side as you face the back of the controller.

Installation

Do not turn on the AC power yet

4. Connect the ribbon cable to the TB-50. The cable is keyed, so you cannot insert it backwards.

WARNING

Do not turn on the AC power yet. Test the connections first, as explained in the Connections Test section below.

Excessive voltage to the CLS will damage it, and you will need to return it to Watlow Anafaze for repair. If you use your own power supply, read the next section completely and follow its instructions before you apply power to the CLS.

CLS User’s Guide 25

Installation

Connections Test

Again, follow these instructions if you have purchased your own power supply, or if you are using a Watlow Anafaze power supply, you don’t need to perform this test.

1. Unscrew the two screws on the sides of the CLS front panel.

2. Gently slide the electronics assembly out of the case. You have now removed the parts of the CLS which will be damaged by excess voltage, so plug in the transformer power supply and use a voltmeter to check voltages:

3. Touch the meter Common lead to the back Terminal Block 2 (TB2) terminal 2 on the CLS. The voltage on TB2 terminal 1 should then be +12 to 24 Vdc.

4. If the voltages are within the limits described above, a. Turn off power. b. Slide the electronics assembly back into the processor mod-

ule’s casing.

c. Reinsert screws into the screw holes on the casing and lighten

them.

d. Turn the power back on. The CLS display should light up, and

after about a second the Bar Graph display should appear.

If you have not connected analog inputs yet, the CLS may display a “T/C Break” alarm message for each channel. This is normal; to clear the alarm messages, press ALARM ACK once for each alarm message.

26 CLS User’s Guide

Outputs

Installation

NOTE

Your CLS is shipped with heat outputs enabled and cool outputs disabled. You can disable any PID output and use it for other digital output functions.

All digital outputs and PID outputs are sink outputs referenced to the 5Vdc supply. These outputs are Low (pulled to common) when they are On.

All digital inputs are Transistor-Transistor Logic (TTL) level inputs referenced to control common.

The control outputs are located on the 50 pin header which connects to the TB-18 or TB-50 pin flat ribbon cable. This section explains how to wire and configure them.

Wiring Outputs

The CLS provides dual PID control outputs for each loop. The digital outputs sink current from a load connected to the CLS's internal power supply or from an external power supply referenced to CLS ground.

•

If you use an external power supply, do not exceed +12 volts.

•

If you tie the external load to ground, or if you cannot connect it as

shown below, then use a solid state relay.

•

If you connect an external supply to earth or equipment ground, use

solid state relays to avoid ground currents. (Ground currents may degrade analog measurements in the CLS).

The outputs conduct current when they are “True”. The maximum current sink capability is 20 mA (when all outputs are used). They cannot “source” current to a ground load

CLS User’s Guide 27

Installation

28 CLS User’s Guide

Installation

Using the Cable Tie Wraps

When you have wired outputs to the TB-50, use the cable tie wraps shipped with it. This diagram shows the cable tie wrap holes.

50494847464544434241403938B

3738A

Holes labeled "A"are m ounting holes. Holes labeled "B"aretiewrap holes.

303132

262728

25242322212019181716151413B

12345678910111213A

Each row of terminals has a cable tie wrap hole at one end. Thread the cable tie wrap through the cable tie wrap hole. Then wrap the cable tie wrap around the wires attached to that terminal block.

Configuring Outputs

•

You can enable or disable the control outputs. The default setting is

heat outputs enabled, cool outputs disabled.

•

You can program each control output individually for On/Off, TP,

SDAC, or DZC control.

•

You can individually program each control output for direct or

reverse action.

CLS User’s Guide 29

Installation

PID Control and Alarm Output Connections

Typical digital control outputs use external optically isolated solid-state relays (SSRs). The SSRs use a 3 to 32 Vdc input for control, and you can size them to switch up to 100 amps at 480 Vac. For larger currents, you can use these optically isolated relays to drive contactors. You can also use Silicon Control Rectifiers (SCRs) and an SDAC for phaseangle fired control.

NOTE

Control outputs are SINK outputs. They are Low when the output is On. Connect them to the negative side of Solid State Relays.

The figure below shows sample heat/cool and alarm output connections.

Watchdog Timer

The CLS watchdog timer constantly monitors the CLS microprocessor. It is a sink output located on TB-18 terminal #3, or on TB-50 terminal #6. (Do not exceed the 10 mAdc rating for the watchdog timer.) Its output is Low (on) when the microprocessor is operating; when it stops operating, the output goes High (off), which de-energizes the SSR.

This figure shows the recommended circuit for the watchdog timer output.

30 CLS User’s Guide

TB-18 Connections

Installation

This table shows TB-18 connections to the 4CLS and the 8CLS.

PIN Function

1+5 Vdc 2 Digital ground 3 Watchdog timer 4Global alarm 5 Digital output 1 Loop 1 heat Loop 1 heat 6 Digital output 2 Loop 2 heat Loop 2 heat 7 Digital output 3 Loop 3 heat Loop 3 heat 8 Digital output 4 Loop 4 heat Loop 4 heat 9 Digital output 5 Pulse loop heat Loop 5 heat 10 Digital output 6 Loop 1 cool Loop 6 heat 11 Digital output 7 Loop 2 cool Loop 7 heat 12 Digital output 8 Loop 3 cool Loop 8 heat 13 Digital output 9 Loop 4 cool Pulse loop heat 14 Digital output 10 Pulse loop cool Loop 1 cool 15 Digital output 34* SDAC clock SDAC clock 16 Digital input 1 17 Digital input 2 18 Digital input 3

/Pulse input

PID Output

4CLS 8CLS

*If you install a Watlow Anafaze Serial DAC (SDAC), the CLS uses digital output #34 for a clock line. You cannot use output #34 for anything else when you have an SDAC installed.

CLS User’s Guide 31

Installation

TB-50 Connections

4 and 8 CLS TB-50 Connections.

Pin Function

1 +5 Vdc 2 +5 Vdc 3 CTRL COM 4 CTRL COM 5 Not Used 6 Watchdog Timer 7 Pulse Input 8 Global Alarm 9 DIG output 1 Loop 1 heat Loop 1 heat 10 DIG output 34* 11 DIG output 2 Loop 2 heat Loop 2 heat 12 DIG output 33 13 DIG output 3 Loop 3 heat Loop 3 heat 14 DIG output 32 15 DIG output 4 Loop 4 heat Loop 4 heat 16 DIG output 31 17 DIG output 5 Loop 5 heat Pulse loop

19 DIG output 6 Loop 6 heat Loop 1 cool 20 DIG output 29 21 DIG output 7 Loop 7 heat Loop 2 cool 22 DIG output 28 23 DIG output 8 Loop 8 heat Loop 3 cool 24 DIG output 27 25 DIG output 9 Pulse loop

heat

27 DIG output 10 Loop 1 cool Pulse loop

29 DIG output 11 Loop 2 cool 30 DIG output 24 31 DIG output 12 Loop 3 cool 32 DIG output 23 33 DIG output 13 Loop 4 cool 34 DIG output 22 35 DIG output 14 Loop 5 cool 36 DIG output 21 37 DIG output 15 Loop 6 cool 38 DIG output 20 39 DIG output 16 Loop 7 cool 40 DIG output 19 41 DIG output 17 Loop 8 cool 42 DIG output 18 Pulse loop

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 DIG input 8

PID Output*

8CLS 4CLS

heat

Loop 4 cool 26 DIG output 26

cool

Pin Function

18 DIG output 30

28 DIG output 25

PID Output*

8CLS 4CLS

cool

32 CLS User’s Guide

If you install a Watlow Anafaze Serial Digital to Analog Converter (SDAC), the CLS uses digital output #34 for a clock line. You cannot use output #34 for anything else when you have an SDAC installed.

* The indicated outputs are dedicated to PID (or control) when enabled in the loop setup. If one or both of a loop’s outputs are disabled, the corresponding digital outputs become available for alarms or ramp/soak events.

Installation

16 CLS TB-50 Connections.

Pin Function PID Output* Pin Function PID Output*

1 +5 Vdc 2 +5 Vdc 3 Digital Ground 4 Digital Ground 5 Not Used 6 Watchdog Timer 7 Pulse Input 8 Global Alarm 9 DIG output 1 Loop 1 heat 10 DIG output 34* Pulse loop cool 11 DIG output 2 Loop 2 heat 12 DIG output 33 Loop 16 cool 13 DIG output 3 Loop 3 heat 14 DIG output 32 Loop 15 cool 15 DIG output 4 Loop 4 heat 16 DIG output 31 Loop 14 cool 17 DIG output 5 Loop 5 heat 18 DIG output 30 Loop 13 cool 19 DIG output 6 Loop 6 heat 20 DIG output 29 Loop 12 cool 21 DIG output 7 Loop 7 heat 22 DIG output 28 Loop 11 cool 23 DIG output 8 Loop 8 heat 24 DIG output 27 Loop 10 cool 25 DIG output 9 Loop 9 heat 26 DIG output 26 Loop 9 cool 27 DIG output 10 Loop 10 heat 28 DIG output 25 Loop 8 cool 29 DIG output 11 Loop 11 heat 30 DIG output 24 Loop 7 cool 31 DIG output 12 Loop 12 heat 32 DIG output 23 Loop 6 cool 33 DIG output 13 Loop 13 heat 34 DIG output 22 Loop 5 cool 35 DIG output 14 Loop 14 heat 36 DIG output 21 Loop 4 cool 37 DIG output 15 Loop 15 heat 38 DIG output 20 Loop 3 cool 39 DIG output 16 Loop 16 heat 40 DIG output 19 Loop 2 cool 41 DIG output 17 Pulse loop heat 42 DIG output 18 Loop 1 cool 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 DIG input 8

If you install a Watlow Anafaze Serial digital to Analog Converter (SDAC), the CLS uses digital output #34 for a clock line. You cannot use output #34 for anything else when you have an SDAC installed.

CLS User’s Guide 33

Installation

Inputs

Input Scaling

This section covers input scaling and input installation for all input types, including thermocouples, RTDs, current inputs, and voltage inputs.

The CLS analog input circuitry accepts any mix of thermocouples, 2 or 3 wire RTD inputs, current inputs, and voltage inputs. You can directly connect the following inputs:

•

J, K, T, S, R, B, and E thermocouples.

•

Linear inputs with ranges between -10 and 60 mV.

Other inputs require custom scaling resistors. If you didn't order your unit with the appropriate resistors, you have the following options:

•

Watlow Anafaze can install scaling resistors on your unit for a nomi-

nal fee.

•

Watlow Anafaze can supply a scaling resistor kit that a qualified

technician can use to install scaling resistors.

WARNING

A qualified technician can install scaling resistors in the CLS. However, damage to the CLS due to improper resistor installation is not covered under warranty, and repairs can be expensive. If you have any doubts about your ability to install scaling resistors, send your CLS to Watlow Anafaze for resistor installation.

34 CLS User’s Guide

4 and 8 CLS Scaling Values

Installation

•

For RTD1 inputs, RA and RB are a matched pair (RP). Their match-

ing tolerance is 0.02% (2 ppm/

0.1% (10 ppm/

•

For RTD2 inputs, use 0.05% tolerance resistors.

•

For linear mVdc, Vdc, and mAdc ranges, use 0.1% tolerance resis-

C). RC has 0.05% tolerance.

C) and their absolute tolerance is

tors. Higher tolerances may cause significant errors. Correct any errors due to resistor tolerance with the CLS's built-in linear scaling. You can also install other components (like capacitors) for signal conditioning; please consult Watlow Anafaze for more information.

To CLS

Circuitry

C .47 uF

A +

( Voltage/Current)

Internal +5 Vdc Reference

(RTD/Thermister)

A -

A COM

Analog Input Ter min al

C .47 uF

NOTE

When adding your own scaling resisters to the 4 and 8 CLS, the shorting pads of the RC must be cut before installing to the bottom of the PC board.

IN +

IN -

CLS User’s Guide 35

Installation

The next table shows scaling resistor values.

Input Range RA RB RC RD

All T/C, 0-60 mV DC Jumper RTD 1: -100.0 to

275.0 RTD 2: -120 to 840

0-10 mA DC 0-20 mA DC

0-100 mV 0-500 mV

0-1 VDC 0-5 VDC 0-10 VDC 0-12 VDC

10.0 Kohms

25.0 Kohms

10.0 Kohms

25.0 Kohms

80 ohms 100 ohms

Jumper Jumper

499 ohms

5.49 Kohms

6.91 Kohms

39.2 Kohms

49.9 Kohms

84.5 Kohms

6.0 ohms

3.0 ohms 750 ohms

750 ohms

422.0 ohms

475.0 ohms

301.0 ohms

422.0 ohms

The following tables show the location of RA, RB, RC and RD on the analog input boards of the 4CLS and the 8CLS. (The analog input board is the upper board of the two-board set.)

36 CLS User’s Guide

Installation

4CLS: Voltage/Current Inputs

Loop # RC RD

158 RP1 256 RP2 354 RP3 452 RP4

8CLS: Voltage/Current Inputs

Loop RC RD Loop RC RD

158RP1 550RP5 256RP2 648RP6 354RP3 746RP7 452RP4 844RP8

4CLS: RTD/Thermister Inputs

Loop # RA/RB RC

1RP157 2RP255 3RP353 4RP451

8CLS: RTD/Thermister Inputs

Loop RA/RB RC Loop RA/RB RC

1RP157 5RP549 2RP255 6RP647 3RP353 7RP745 4RP451 8RP843

Place resistors RA, RB and RD in the resistor pair locations this way:

A wire trace on the printed circuit board jumpers the RC position. When you place a resistor in the RC position, cut the wire trace that connects the two resistor terminals.

CLS User’s Guide 37

Installation

16 CLS Scaling Values

For linear mVdc, Vdc, and mAdc ranges, use 0.1% tolerance resistors. Higher tolerances may cause significant errors. Correct any errors due to resistor tolerance with the CLS’ built-in linear scaling. You can also install other components (like capacitors) for signal conditioning; please consult Watlow Anafaze for more information.

Analog Input Term in als

IN +

Analog Common

CLS Measurement Circuitry

IN +

The next table shows scaling resistor values.

Input Range RC RD

All T/C, 0-60 mV DC Jumper 0-10 mA DC

0-20 mA DC 0-100 mV

0-500 mV 0-1 VDC

0-5 VDC 0-10 VDC 0-12 VDC

Jumper Jumper

499 ohms

5.49 Kohms

6.91 Kohms

39.2 Kohms

49.9 Kohms

84.5 Kohms

6.0 ohms

3.0 ohms 750 ohms

750 ohms

422.0 ohms

475.0 ohms

301.0 ohms

422.0 ohms

The next table shows the location of RC and RD on the analog input board. (The analog input board is the upper board of the two-board set.)

Loop # RC RD Loop # 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

38 CLS User’s Guide

A wire trace on the printed circuit board jumpers the RC position. When you place a resistor in the RC position, cut the wire trace that connects the two resistor terminals.

Scaling and Calibration

Installation

The CLS provides offset calibration for thermocouple, RTD, and other fixed ranges, and offset and span (gain) calibration for linear and pulse inputs. (Offset and span calibration convert linear analog inputs into engineering units using the Mx+B function.)

In order to scale linear input signals, you must:

1. Install appropriate scaling resistors. (Contact Watlow Anafaze's Customer Service Department for more information about installing scaling resistors.)

2. 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.

For more information about input scaling and input offset, see

Loop Inputs

Chapter 4: Setup

Setup

T/C Inputs

WARNING

The CLS uses a floating ground system. Therefore:

Isolate input devices or host computers connected through communications cables (like RS-232) from earth ground.

Use ungrounded thermocouples with the thermocouple sheath electrically connected to earth ground.

Use optically isolated RS-232 devices to isolate earth grounded host computers from the CLS.

WARNING

The 16CLS has single ended inputs, offering little protection from common mode voltage sources. Therefore Watlow Anafaze highly recommend that you use ungrounded thermocouples with the external thermocouple sheath electrically connected to earth ground.

CLS User’s Guide 39

Installation

You can connect J, K, T, S, R, B, and E thermocouples directly to the CLS. Watlow Anafaze provides standard linearization and cold junction compensation for these thermocouple types. (Other thermocouple types require custom linearization; please contact Watlow Anafaze for more information about them.)

Connecting Thermocouples

Connect the positive T/C lead to the In+ terminal. Connect the negative T/C lead to the TB1 In- (4 or 8CLS) or analog common 16CLS)( terminal. A typical thermocouple connection is shown in the figure below.

•

Use 20 gauge thermocouple extension wire for all thermocouple

inputs.

•

If you use shielded wire, tie it to panel ground or to ground at the

measurement end.

RTD Inputs (4 and 8 CLS only)

Name Temp. Range

in ºF

RTD1 -148.0 to

527.0 ºF

RTD2 -184 to 1544 ºF-120 to 840

Temp. Range in

-100.0 to

275.0

IN +

–

The standard industrial RTD is an 100-ohm, 3-wire platinum assembly as shown in the figure below. Watlow Anafaze highly recommends that you use the 3-wire RTD to prevent reading errors due to cable resistance.

•

If you order an RTD1 or RTD2 configuration, Watlow Anafaze will

configure your CLS for the standard 3-wire RTD.

•

If you must use a 4-wire RTD, leave the fourth wire unconnected.

Watlow Anafaze offers 2 standard DIN 385 curve RTD input ranges, as shown here:

RTD Ranges in Degrees

Resolution Measurement

0.023

0.062

White

Red

Case

Frame Ground

Temperature

C 25 ºC

275

C 25 ºC

840

Shield (if present)

Type J T/C

Error @ 25

C Ambient

±0.35 ºC ±0.5 ºC

1 ºC

±0.9 ºC ±2.8 ºC

±1.1 ºC ±4.3 ºC

Error @ 0-50

C Ambient

±1.5 ºC

40 CLS User’s Guide

Current Inputs

Voltage Inputs

Installation

Below is a typical RTD.

Back Terminal Block Connections

In+

In-

Analog Common

To connect current (milliamp) inputs, install resistors that convert the milliamp input to a voltage. Watlow Anafaze offers resistors for 0-20 mA and 0-10 mA current inputs.

•

Connect the + side of the voltage input to the In+ terminal.

•

Connect the - side of the input to the In- terminal for the 4 and 8CLS,

or analog common for the 16CLS. The 0voltage input range is -10 to 60 mV.

•

Scale signals larger than 60 mV with scaling resistors that make full

scale input 60 mV. (For more information, see the Input Scaling section.)

The figures below show typical voltage input.

16CLS

Back Terminal Block Connections

4 and 8 CLS

Back Terminal Block Connections

In+

Analog Common

In+

In-

CLS User’s Guide 41

Installation

Unused Inputs

Back Terminal Block Connections

Set the input type for unused inputs to “SKIP” to avoid the default T/C break alarms. (See Input Type in Chapter 4: Setup for information on setting the input type.)

Wire inputs to the back terminal block as shown below.

4CLS

8CLS

16 CLS

42 CLS User’s Guide

Serial Communications

RS-232 Interface

Installation

The CLS is factory-configured for RS-232 communications. However, the communications are jumper-selectable, so you can switch between RS-232 and RS-485. (See Configuring Communications below.) You can also order a communications cable from Watlow Anafaze or make your own cable.

With RS-232 communications, you can connect the CLS directly to the serial communications connector on an IBM-PC or compatible computer. (PC-compatible computers typically use RS-232 communications.) The RS-232 interface is a standard three-wire interface. See the table below for connection information. (Some computers reverse transmit (TX) and receive (RX), so check your computer manual to verify your connections.)

RX Pin 3 RX Pin 2 TX Pin 26 White TX Pin 2 TX Pin 3 RX Pin 25 Red GND Pin 7 GND Pin 5 GND Pin 23 Black

RS-485 Interface

DB 25

Connector

You can use either RS-232 or RS-485 communications in these situations:

•

When you are using local communications (up to 50 feet).

•

When you are using a single CLS.

If you are using RS-232 communications with grounded thermocouples, use an optical isolator between the controller and the computer.

This table shows RS-232 connections for 25-pin and 9-pin connectors.

DB 9

Connector

•

If you use more than one CLS, you must use RS-485 communica-

tions.

•

If you have connected the CLS to a computer more than 50 feet

away, Watlow Anafaze recommends that you use RS-485 communications.

If you use RS-485 communications, attach an optically isolated RS-232 to RS-485 converter to the computer. You can use an internal converter card or an external plug-in converter.

CLS Back TB

Watlow Anafaze

Cable

CLS User’s Guide 43

Installation

The diagram on the next page shows the recommended system hookup. To avoid ground loops, it uses an optically isolated RS-232 to RS-485 converter at the host computer. The system is powered from the CLS's power source or from a secure, isolated supply.

Power Suppl

Host

Computer

Fifth Wire

Opticall Isolated Converter

Power Suppl

Optional Capacitor

CLS

Power Suppl

CLS

Wire equipment in a single “daisy chain” using twisted shielded pairs for the RS-485 cables. Don't use “octopus connections” or “spurs”.

44 CLS User’s Guide

Installation

Use a 200 ohm terminating resistor on the RX line of the last controller in the system. (If you have only one controller, it is the last controller in the system.) Use jumper JU1 to select the terminating resistor; place it in B position for termination and A position for non-termination.

NOTE

Connect the shields to earth ground only at the computer or other 485 interface. Do not connect the shield to the controller.

If you connect RS-485 communications and they do not function properly, or if you have measurement problems when communications lines are connected, request additional technical information from the Watlow Anafaze Customer Service Department.

CLS User’s Guide 45

Installation

Configuring Communications

Your controller is shipped configured for RS-232. To switch between RS-232 and RS-485, change the jumpers as shown here.

You'll need tweezers and a Phillips head screwdriver to switch between RS-232 and RS-485. Follow these steps:

1. Power down the unit.

2. Remove the controller's metal casing. If you haven't removed the casing before, please don't try to figure it out yourself; see Changing the PROM in the Troubleshooting section for step-by-step instructions.

3. Find jumpers JU2, JU3, JU4, and JU5 (above).

4. (This part of the explanation assumes that you're changing the communications from RS-232 to RS-485. If you're not, follow the next two steps but move the jumpers from the B position to the A position.) Use tweezers to carefully grasp the jumpers and gently slide them off the pins.

5. Use tweezers to gently slide the jumpers onto the B pins. Move jumpers JU2, JU3, JU4, and JU5 to the B position, as shown above.

6. If you have changed the controller to 485 communications, put the 200 ohm terminating resistor on the RX line of the last controller in the system. (If you're only using one controller, it's the last controller in the system.) Place jumper JU1 in the B position . All other controllers in the system should have JU1 in the A position.

7. Put the casing back on. If you haven't removed or reinstalled the CLS's casing before, see Chapter 7: Troubleshooting for instruc- tions.

46 CLS User’s Guide

Installation

Recommended Wire Gauges

Watlow Anafaze recommends the following maximum distances and wire gauges:

Distance Wire Gauge

4000 ft. 24 AWG Belden #9729

6000 ft. 22 AWG Belden #9184

You may wish to use a shield, depending on your noise environment and grounding problems. The above cables are shielded.

Recommended

Cable

Belden #9842

NOTE

These recommendations are conservative, to ensure that your controller will operate reliably. Expect satisfactory performance even if you must deviate slightly from a design specification.

CLS User’s Guide 47

Installation

48 CLS User’s Guide

Using the CLS

Introduction

This chapter will show you how to use the CLS from the front panel. (If you are using ANASOFT or AnaWin, please see the related User's Guide.) The next diagram shows how to reach the operator menus from Single Loop display. (To change global parameters, loop inputs, control parameters, outputs, and alarms from the setup menus, you must enter a special sequence of keys. To learn how, see the next chapter:

Using the CLS

setup

CLS User’s Guide 49

Using the CLS

Front Panel

The front panel provides a convenient interface with the controller. You can program and operate the CLS with the front panel keys shown below, or you can use ANASOFT, a program designed specifically for Watlow Anafaze controllers.

Front Panel Keys

Yes /U p

Ye s

Press

•

Select a menu.

Ye s

Answer Increase a number or choice you're editing.

Ye s /N o

questions.

No/Down

Press No to

•

Skip a menu you don't want to edit, when the prompt is blinking.

•

Answer No to

•

Decrease a number or choice when editing.

•

Perform a No Key Reset.

Ye s/ No

prompts.

50 CLS User’s Guide

Using the CLS

WARNING

Pressing the No key on power up will clear the RAM memory and reinitialize the CLS' factory default values.

To do a No Key Reset, power down the controller, press and hold the No key, and power up the controller while holding the No key. A No Key Reset is appropriate:

•

After you change the EPROM. (See Chapter 6: Troubleshooting.)

•

In some cases when troubleshooting (see Chapter 6: Troubleshoot-

ing).

•

When you install the controller.

Back

The

key works like an “escape key”. Press it to:

•

Abort editing.

•

Return to a previous menu.

•

Switch between Bar Graph, Single Loop, and Job Control displays.

Enter

Press

•

Store data or menu choices after editing and go on to the next menu.

•

Start scanning mode (if pressed twice).

to:

Change SP

•

Press this key to change the loop setpoint.

Man/Auto

Press the

•

Man/Auto

Toggle a loop between manual and automatic control. Adjust the output power level of loops in Manual control. Automatically tune a loop.

key to:

CLS User’s Guide 51

Using the CLS

Ramp/Soak

If Ramp/Soak is installed on your controller, press the Ramp/Soak key to:

•

Assign a ramp/soak profile to the current loop.

•

Perform operations on an assigned profile.

•

See the status of a running profile.

NOTE

Your CLS may not have the Ramp/Soak feature. If it does not, then the Ramp/Soak key will not operate. If you press the Ramp/Soak key, you'll see the following message:

LOOP PROCESS UNITS

OPTION UNAVAILABLE

ALARM SETPOINT STATUS OUT%

Alarm Ack

Press Alarm Ack to acknowledge an alarm condition and reset the global alarm digital output.

52 CLS User’s Guide

Displays

Bar Graph Display

Using the CLS

The next section discusses the CLS' main displays--Bar Graph, Single Loop, and Job displays.

On power up, the CLS displays general symbolic information for all four primary loops. This display is called Bar Graph mode. The diagram below shows the symbols used in Bar Graph mode.

Alarm Symbol Loop Number

or Name

LOOP PROCESS UNITS

01 08 AAAA MAMA

ALARM SETPOINT STATUS OUT%

Loop Status

The next table explains the symbols you see on the top line of the Bar Graph display. These symbols appear when the controller is in dual output mode (heat and cool outputs enabled) and single output mode (heat or cool outputs enabled, but not both).

Symbol Symbol’s Meaning

< Loop is in low process or low deviation alarm. > Loop is in high process or high deviation alarm.

Loop is above setpoint. If you enable the high or low deviation alarm, this symbol is scaled to it. If you don’t enable these alarms, these symbols are scaled to the setpoint + the sensor’s range.

Loop is at setpoint. If you enable the high or low deviation alarm, this symbol is scaled to it. If you don’t enable these alarms, these symbols are scaled to the setpoint + sensor’s range.

Loop is below setpoint. If you enable the high or low deviation alarm, this symbol is scaled to it. If you don’t enable these alarms, these symbols are scaled to the setpoint +5% of the sensor’s range.

Blank

(

) Loop is set to SKIP.

F Sensor has failed.

5% of

5% of the

CLS User’s Guide 53

Using the CLS

The next table explains the symbols you see on the bottom line of Bar Graph display. These symbols appear when the controller is in both dual output mode and single output mode. If an alarm occurs, the controller automatically switches to Single Loop display and shows an alarm code.

Symbol Symbol’s Meaning

M One or both outputs enabled. Loop is in manual control. A Only one output (heat or cool, but not both) is enabled. Loop is

in automatic control. T Loop is in Autotune mode. H

T C

Both heat and cool outputs are enabled. Loop is in Automatic

control and heating.

Both heat and cool outputs are enabled. Loop is in Automatic

control and cooling.

Navigating in Bar Graph Display

•

Press Ye s (up) or No (down) to see Bar Graph Display for the Pulse

Input loop.

•

Press Enter twice to start Bar Graph scanning mode. In scanning

mode, the controller alternately displays the first four loops and then the pulse input loop for three seconds each.

•

Press any key to stop scanning mode.

•

From Bar Graph Display, press Back once to go to Single Loop dis-

play.

Single Loop Display

Single Loop display (below) shows detailed information for only one loop. If the heat and cool outputs are enabled, Single Loop display looks like this:

Process Variable

Loop Number or Name

Setpoint

The control status indicator shows HEAT or COOL if the loop is in automatic control, and MAN or TUNE if the loop is in manual control.

LOOP PROCESS UNITS

02 160 180 AUTO 100

ALARM SETPOINT STATUS OUT%

Control Status

Engineering Units Output percentage

54 CLS User’s Guide

Using the CLS

If only one output is enabled (heat or cool, but not both), Single Loop display looks like this:

Engineering Units

F 0

Output Percentage Cool

Output Percentage Heat

Loop Number or Name

Setpoint

Process Variable

LOOP PROCESS UNITS

02 160 180 AUTO 100

ALARM SETPOINT STATUS OUT%

Control Status

From Single Loop Display,

•

Press Ye s to go to the next loop.

•

Press No to go to the previous loop.

•

Press the Back key once to go to Job display (if enabled) or Bar

Graph display.

•

Press Enter twice to start Single Loop Scanning display. (The Single

Loop Scanning Display shows information for each loop in sequence. Data for each loop displays for one second.)

•

Press any key to stop scanning mode.

CLS User’s Guide 55

Using the CLS

Alarms

If an alarm occurs, a two-character alarm code appears in the lower left corner of the display (below). If a Failed Sensor alarm occurs, the controller also displays a short alarm message.

Loop number or Name

Alarm Symbols

Process Variable

LOOP PROCESS UNITS

02 180 LP 180 AUTO 0

ALARM SETPOINT STATUS OUT%

Setpoint

Engineering Units

Output Percentage

These alarm codes and messages are shown in the table below.

Symbol Alarm Message Alarm Type

FS TC Break Thermocouple break FS (RO) RTD Open RTD break FS (RS) RTD Short RTD Short HP No message High process alarm HD No message High deviation alarm LD No message Low deviation alarm LP No message Low process alarm

Acknowledging an Alarm

Press Alarm Ack to acknowledge the alarm. If there are other loops with alarm conditions, the Alarm display switches to the next loop in alarm. Acknowledge all alarms to clear the global alarm digital output. (You must acknowledge each alarm before displays and keyboard operation will resume.)

56 CLS User’s Guide

NOTE

In the 4 and 8 CLS, the controller cannot detect all RTD open and RTD short failures. Detection of open or shorted RTDs depends on which wires are open or shorted.

Job Display

Using the CLS

Job display appears only if:

•

You have turned on the Remote Job Select function. (This function is

explained in

•

You have selected a job from the job load menu.

Setup

When you load a job, Job display shows you the following screen:

LOOP PROCESS UNITS

JOB 3 RUNNING

ALARM SETPOINT STATUS OUT%

If you remotely loaded the job, Job display looks like this:

LOOP PROCESS UNITS

JOB 3 RUNNING REMOTELY LOADED

ALARM SETPOINT STATUS OUT%

If you modify a job's parameters while the job is running, you'll see this job message:

LOOP PROCESS UNITS

JOB 3 RUNNING DATA MODIFIED

ALARM SETPOINT STATUS OUT%

If an alarm occurs, the controller switches to Single Loop Display.

CLS User’s Guide 57

Using the CLS

Operator Menus

Change Setpoint

You can reach the following Operator Menus from Single Loop Display. (If your CLS is already installed, try each procedure as you read about it.)

To change the setpoint, go to Single Loop display of the loop you wish to change, and then press the Change Setpoint key. (The setpoint is the desired temperature, pH, et cetera, for the process.) You should see a display like this:

LOOP PROCESS UNITS

03 SETPOINT ? 500

ALARM SETPOINT STATUS OUT%

Manual/Automatic Control

•

Yes

Press Then press

to change the setpoint.

Ye s

or No to change the setpoint value.

When you are satisfied with the setpoint value you have chosen,

Enter

press

to save your changes and return to Single Loop Display;

•

To return to Single Loop display without saving your changes, press

Back

Press the

Man/Auto

key to set a loop's control mode, set manual output levels, or automatically tune a loop. The control mode determines whether the CLS automatically controls the process according to the configuration information you give it (Automatic control), or you set the output to a constant level (Manual control).

If both outputs are disabled when you press the Man/Auto key, you'll see a display like this one:

LOOP PROCESS UNITS

MAN/AUTO CONTROL OUTPUTS DISABLED

ALARM SETPOINT STATUS OUT%

58 CLS User’s Guide

Using the CLS

Press any key to exit this display. If at least one control output (heat or cool) is enabled, you'll see this display:

LOOP PROCESS UNITS

01 CONTROL STATUS ? AUTO

ALARM SETPOINT STATUS OUT%

•

Press Ye s to change the mode.

•

Press Ye s or No to switch between Manual, Automatic, and Tune.

•

To exit this menu and return to the Single Loop Display without sav-

ing your changes, press Back.

•

Press Enter to save your changes. If you have set the mode to Man-

ual, you can now set the manual heat and cool output levels.

Manual Output Levels

The Manual Output Levels menu will only appear if you have set the current loop to Manual control. This menu lets you set the manual output levels for the enabled outputs. The cool output menu is just like the heat output menu, except that the word COOL replaces the word HEAT in the display. You should see a display like the one below:

LOOP PROCESS UNITS

01 SET HEAT OUTPUT ? 90%

ALARM SETPOINT STATUS OUT%

•

Press Ye s to change the output power.

•

Then press Ye s or No to select a new output power level.

•

When you are satisfied with the power level you have chosen, press

Enter to store your changes.

•

To discard your changes and return to Single Loop display, press

Back.

CLS User’s Guide 59

Using the CLS

Autotune

If you set the current loop's control status to TUNE and press Enter, the controller automatically sets the loop to Manual control, 100% output. (If you selected a continuous output limit, the controller sets the loop to the output limit.) The autotune function then calculates the appropriate PID constants for the loop and puts the loop in automatic control with the calculated PID values.

The Autotune function will abort if:

•

Process variable goes over 75% of the setpoint. Remember, the con-

troller is at 100% output or at the output limit you set.

•

It has not calculated PID constants after 10 minutes (due to heater

failure, sensor failure, et cetera.)

If the autotune function aborts, it puts the loop into its previous control state (Automatic control or Manual control at the previous output percentages.)

To automatically tune a loop, follow these steps:

Ramp/Soak

1. Make sure the process is cold (or stable and well below setpoint).

2. Initiate Autotune:

a. Use the front panel keypad to go to Single Loop Display b. Press the Man/Auto key c. Choose Tune d. Press Enter.

The Tune indicator will begin flashing and the controller will go back to Single Loop Display. The Tune indicator will keep flashing as long as the loop is tuning.

If you have a CLS without the Ramp/Soak option, pressing the Ramp/ Soak key has no effect. If you have a CLS with Ramp/Soak installed, please refer to the Ramp/Soak Appendix at the end of this manual.

60 CLS User’s Guide

Setup

How to Enter the Setup Menus?

The Setup menus let you change the CLS detailed configuration information.

If you have not set up a CLS before, or if you don't know what values to enter, please read first the PID tuning constants and useful starting values.

1. In Single Loop Display, select the loop you wish to edit.

2. While still in Single Loop Display, enter the pass sequence below:

Press Enter, Alarm Ack, Change Setpoint.

3. The first setup menu appears.

Tuning and Control

section, which contains

NOTE

For your protection, CLS reverts to Single Loop Display If you don't make any changes for three minutes.

How to edit a menu?

•

Press Ye s to select this menu or No to advance to the next menu.

•

press Ye s or No to toggle between the options 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 six main menus. If you have a CLS with the Ramp/Soak option, there will also be a Ramp/Soak menu. (Please refer to the Ramp/Soak documentation included with your CLS for use instructions.)

The next page shows the setup menus accessible from Single Loop Display.

CLS User’s Guide 61

Setup

Setup Global Parameters?

Load setup from job?

Save setup to job?

Job select dig inputs?

Job sel dig ins active?

Output override dig input?

Override dig in active?

Startup alarm delay?

Ramp/Soak

time base? (only if R/S installed

Keyboard lock status?

Power up output status?

Controller address?

Communications baud rate?

Communication

protocol?

Communications

ERR check?

AC line freq?

Dig out polarity

on alarm?

EPROM information

Setup Loop Inputs?

Input type?

Pulse sample time?

Loop name?

Heat control filter?

Input units?

Input reading offset ? (T/C)

Disp format? (Linear)

Input scaling Hi PV? (Linear & Pulse)

Input scaling Hi RDG? (Linear & Pulse)

Input scaling Lo PV? (Linear & Pulse)

Input scaling Lo RDG? (Linear & Pulse)

Input Filter?

If Ramp/Soak is installed

Heat/Cool spread?

in your controller, see

Ramp/Soak Appendix

the end of this Guide.

Setup Loop

Control Params?

Heat control PB?

Heat control TI?

Heat control TD?

Cool control PB?

Cool control TI?

Cool control TD?

Cool control filter?

Setup Loop Outputs?

Heat control output?

Heat output type?

Heat output cycle time? (TP)

SDAC menus (SDAC only)

Heat output action?

Heat output limit?

Heat output limit time?

Heat override output?

Heat output?

Cool control output?

Cool output type?

Cool output cycle time? (TP)

SDAC menus (SDAC only)

Cool output action?

Cool output limit?

Cool output limit time?

Cool override output?

Cool output?

Setup Loop Alarms?

Hi proc alarm setpt?

Hi proc alarm type?

Hi proc alarm output?

Dev alarm

value?

Hi dev alarm type?

Hi dev alarm output?

Lo dev alarm type?

Lo dev alarm output?

Lo proc alarm setpt?

Lo proc alarm type?

Lo proc alarm output?

Alarm deadband?

Alarm delay?

Manual I/O Test?

Digital inputs

Test digital

output?

Keypad test

62 CLS User’s Guide

Set up Global Parameters Menu

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

The Set up Global Parameters menu looks like this:

SETUP GLOBAL PARAMETERS ?

Below is the setup global parameters menu tree. Notice the default values inside the boxes.:

Setup Global Parameters?

Setup

Load setup from job? 1

Save setup to job? 1

Job select dig inputs?

NONE

Job sel dig ins active?

LOW

Output override di input? NONE

Override dig in active? LOW

Startup alarm delay? 0 MINS

Keyboard lock status? OFF

Power up output status? OFF

Controller address? 1

Communications baud rate? 9600

Communications protocol? ANA

Communications err check? BCC

AC line freq.? 60 HERTZ

out polarity on alarm?

LOW

EPROM information

CLS User’s Guide 63

Setup

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

Load a Job

Use this menu to load any one of 8 saved jobs from the controller's front panel.

LOAD SETUP FROM JOB ? 1

The following parameters are loaded as part of a job:

•

PID constants, filter settings, setpoints and spread values

•

Loop control status (Automatic or Manual) and output values (if the

loop is in Manual control).

•

Alarm functions (Off, Alarm, Control), setpoints, high\low process

setpoints, high\low deviation setpoints and deadband settings, and loop alarm delay.

Save Setup to Job

WARNING

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.

If you have enabled the remote job control function, this menu will be disabled; you will not be able to load a job from the front panel. If you try it, you'll see the message below.

CANNOT LOAD JOB REMOTE SELECT

Use this menu to save the job information for every loop to one of 8 jobs in the CLS' battery-backed RAM.

SAVE SETUP TO JOB ? 1

64 CLS User’s Guide

If you have enabled the remote job control function, you will not be able to save a job. If you try it, you'll see this message:

CANNOT SAVE JOB REMOTE SELECT

Job Select Inputs

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

Setup

Use this menu to set the number of job select inputs. The controller uses these inputs as a binary code that specifies the job number to run. The number of inputs you choose in this menu controls the number of jobs you can select remotely.

JOB SELECT DIG INPUTS ? NONE

Below is the truth table that tells you which input states select which jobs.

Digital Input 3 Digital Input 2 Digital Input 1 Job #

FF F1 FF T2 FT F3

FT T4 TF F5 TF T6 TT F7 TT T8

Job Select Input Polarity

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

Use this menu to set the polarity of the digital outputs used for job selection.

JOB SEL DIG INS ACTIVE ? LOW

Selectable values:

High or Low.

When nothing is connected, the inputs are all False and Job 1 is selected (as shown in the truth table above).

CLS User’s Guide 65

Setup

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

Output Override Digital Input

Use this menu to set a digital input that sets all loops in manual output at output levels you select in the

Outputs

menu. This menu, and the next one, let you configure a “panic button” or “kill switch” that sets all outputs to the output override percentage you set in the

Outputs

main menu.

Set up Loop

OUTPUT OVERRIDE DIG INPUT ? NONE

Selectable values:

WARNING

Watlow Anafaze recommends that you install additional external safety devices or over-temperature devices for emergency shutdowns. Do not rely solely on the output override feature to shut down your process.

Output Override Input Polarity

Use this menu to toggle the polarity of the Output Override digital input. You can set the input to be active when Low or active when High.

OVERRIDE DIG IN ACTIVE ? LOW

Selectable values:

Start-up Alarm Delay

NONE or input number 1-8.

High or Low.

66 CLS User’s Guide

Use this menu to set a start-up delay for process and deviation alarms for all loops. The controller does not report these alarm conditions for the specified number of minutes after the controller powers up. (The controller will always report failed sensor alarms, no matter what startup delay you set.)

STARTUP ALARM DELAY ? 0 mins

Selectable values:

0-60 minutes.

Keyboard Lock Status

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

Setup

Power-Up Output Status

Use this menu to lock the front panel operator function keys

SP, Man/Auto

, and

Ramp/Soak

so that pressing these keys has no

Change

effect. If you want to use these functions, turn off the Keyboard Lock.

KEYBOARD LOCK STATUS ? OFF

Selectable values:

On or Off.

Use this menu to set the initial power-up state of the control outputs to Off or Memory. If you choose Off, all control outputs are initially set to Manual mode at 0% output level. If you choose Memory, the outputs are restored to the last output state stored in memory.

POWER UP OUTPUT STATUS ? OFF

Controller Address

WARNING

Do not set the CLS to start from memory if a memorybased restart is unsafe for your process.

Selectable values:

Use this menu to set the CLS address. The controller address is used for multiple controller communications on a single 485 cable, so each CLS must have a different address. Begin with address 1 for the first controller and assign each subsequent controller the next higher address.

CONTROLLER ADDRESS ? 1

Selectable values:

Off or Memory.

1-32.

CLS User’s Guide 67

Setup

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

Communications Baud Rate

Use this menu to set the Communications Baud Rate.

COMMUNICATIONS BAUD RATE ? 9600

Selectable values:

Communications Protocol

Use this menu to set the communications protocol type.

LOOP PROCESS UNITS

COMMUNICATIONS PROTOCOL?ANA

ALARM SETPOINT STATUS OUT%

Selectable values:

Bradley’s), MOD (Modbus).

Communications Error Checking

This menu appears only when you choose ANA or AB as your communications protocol. Use it to set the data check algorithm used in the CLS communications protocol to Block Check Character (BCC) or to Cyclic Redundancy Check (CRC).

COMMUNICATIONS ERR CHECK ? BCC

2400 or 9600.

ANA (Watlow Anafaze’s protocol), AB (Allen

68 CLS User’s Guide

Selectable values:

BCC or CRC.

CRC is a more secure error checking algorithm than BCC, but it requires more calculation time and slows the CLS communications. BCC ensures a high degree of communications integrity, so Watlow Anafaze recommends that you use BCC unless your application specifically requires CRC

NOTE

If you are using ANASOFT, be sure to configure ANAINSTL for the same Error Checking method and the same Baud Rate that you set in this menu and in the next one.

AC Line Frequency

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

Setup

Use this menu to configure the controller to match an AC line frequency of 50 or 60 Hz. (This function is provided for international users who require 50 Hz lines.) Since the controller reduces the effect of power line noise on the analog measurement by integrating the signal over the period of the AC line frequency, the controller's noise rejection will suffer if the line frequency is not set correctly.

AC LINE FREQ ? 60 HERTZ

Digital Output Polarity

EPROM Information

Selectable values:

50 Hz or 60 Hz.

NOTE

You must switch power to the CLS on and off for a change in AC line frequency to take effect.

Use this menu to set the polarity of the digital outputs used for alarms.

DIG OUT POLARITY ON ALARM ? LOW

Selectable values:

This is a view-only display. It shows the controller's EPROM version and checksum.

High or Low.

CLS164 V03.02 CS=2233

Press any key to return to the Set up Global Parameters menu.

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Setup

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Set up Loop Input

The Set up Loop Input main menu lets you access menus which change parameters related to the loop input:

•

Input type

•

Input units

•

Input scaling and calibration

•

Input filtering

The next section explains how to use the Input menus to configure your controller.

SETUP LOOP 02 INPUT ?

Below is the setup inputs menu tree. Notice the default values inside the boxes.

Setup Loop Inputs?

Input Type? J T/C

Pulse Sample Time? 1s (only for pulse input)

Loop Name?

Input Units?

Input Readin

F (only for T/C inputs)

Disp Format?-999 to 3000

Input Scalin 1000 (linear & pulse)

Offset?

(only for linear)

Hi PV?

Input Scalin

100.0%FS

Input Scalin

(linear & pulse)

Input Scalin

.0%FS (linear & pulse)

Input Filter? 3 Scans

Hi RDG?

(linear&pulse)

Lo PV? 0

Lo RDG?

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Input Type

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Setup

Use this menu to configure the input sensor for each loop as one of these input types:

•

Thermocouple types (J, K, T, S, R, B and E).

•

RTD (4 and 8CLS). Two ranges: RTD1 (Platinum Class A) and

RTD2 (Platinum Class B).

•

Linear inputs.

•

Skip (an input type available for unused channels.) The scanning dis-

play doesn't show loops you've set to Skip.

01 INPUT TYPE ? J T/C

The following tables show the input types and ranges.

* Accuracy:

Input Type

J T/C -350 to 1400 -212 to 760

K T/C -450 to 2500 -268 to 1371

T T/C -450 to 750 -268 to 399

S T/C 0 to 3200 -18 to 1760

R T/C 0 to 3210 -18 to 1766

B T/C 150 to 3200 66 to 1760

E T/C -328 to 1448 -200 to 787

Pulse 0-2 KHz

Skip Loop is not scanned or displayed

Linear See the Linear Scaling section

Range in ºF Range in ºC

* True for 10% to 100% of span.

Ambient

0.5

0.6

1.3

2.5

6.6

* Accuracy:

0.9

1.2

2.4

4.5

12.0

C Full

0-50

Temp . Ra nge

1.35

14.9

1.1

2.9

5.6

2.0

2.7

5.4

10.1

27.0

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RTD Ranges (4 and 8CLS)

Name Range in ºF Range in ºC Resolution

RTD1 -148.0 to

527.0

RTD2 -184 to

-100.0 to

275.0

-120 to 840

0.023

0.062

1544

Pulse Sample Time

You can connect a digital pulse signal of up to 2 KHz to the controller's pulse input. In this menu, you specify the pulse sample period. (This is the second menu of the Set up Loop Inputs menu for the pulse input loop only.) Every sample period, the number of pulses the controller receives is divided by the sample time. The controller scales this number and uses it as the pulse loop's process variable.

05 INPUT PULSE SAMPLE TIME ? 1s

Selectable Range:

Probe

Tem p. In ºC

Accuracy: 25ºC

Ambient

C ºF

Accuracy: 0-

50ºC Ambient

C ºF

25 ±0.35 ±0.63 ±0.5 ±0.9

275 ±1 ±1.8 ±1.5 ±2.7

25 ±0.9 ±1.62 ±2.8 ±5.04

840 ±1.1 ±1.98 ±4.3 ±7.74

1-20 seconds.

Loop Name

Input Units

Use this menu to name your loop using two-characters. After specifying a new name, it is placed on the single loop display instead of the loop’s number.

A5 LOOP NAME ? A5

Use this menu to choose a three-character description of the loop’s engineering units

02 INPUT UNITS ?

72 CLS User’s Guide

Selectable values: The table below shows the character set for input

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units.

Input Character Sets for Units

Thermocouple, and RTD

Linear & Pulse 0 to 9, A to Z,%, /, degrees, space

F or ºC

Input Reading Offset

This menu does not appear if the input type is linear, pulse, or skip.

Use it to make up for the input signal's inaccuracy at any given point. For example, at temperatures below 400 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 loop you are editing. (A positive value increases the reading and a negative value decreases it.)

F, a type J thermocouple may

Setup

Linear Scaling Menus

02 INPUT READING OFFSET ? 0

Selectable range: For thermocouples, infrared inputs and RTD2s, the offset correction ranges from -300 to +300.

For RTD1s and IR inputs set to Average mode, the offset range is 300.0 to +300.0.

The linear scaling menus appear under the Set up Loop 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

Linear scaling menus appear only if the loop's input type is set to Linear (or, for some menus, to Pulse).

For linear inputs, the input reading is in percent (0 to 100%) representing the 0-60 mV input range of the CLS. For pulse inputs, the input reading is in Hertz (cycles per second.)

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Setup

Process Variable

InputR eading

0PSI

0% 0mV 0Hz

100% 60 m V 2000 Hz

HiPV

Lo PV

Lo RDG

Hi RDG

}

Linearin

}Pulse in

Range

The scaling function is defined by two points on a conversion line. It relates the high PV to the high reading and the low PV to the low reading to define the line. The engineering units of the process variable can be any arbitrary units. The graph below shows PSI as an example.

Before you enter the values that determine the two points for the conversion line, you must choose an appropriate display format. The CLS 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, spread, and proportional band.

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 0 Hz and 2000 Hz readings. This PV range defines the limits for the setpoint and alarms, as shown here.

NOTE

For example linear scaling calculations, see Linear Scaling section.

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Display Format

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Setup

This menu appears under the Set up Loop Inputs main menu. It lets you select a display format for a linear input. Choose a format appropriate for your input range and accuracy. (You will only see the Display Format menu if you are editing a linear input.)

04 DISP FORMAT ?

-999 to 3000

High Process Value

Selectable values:

The CLS has several available display formats, as

shown below. This table also shows the high and low PV values.

Display Format Default High PV Default Low PV

-9999 to +30000 10000 0

-999 to +3000 1000 0

-999.9 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

This menu appears under the Set up Loop Inputs main menu. Use it to 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.

01 INPUT SCALING HI PV ? 1000

Selectable values:

See table on the previous page.

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High Reading

Use this menu to enter the input level that corresponds to the high process value you entered in the previous menu. For linear inputs, the high reading is a percentage of the full scale input range. For pulse inputs, the high reading is expressed in Hz.

The 100% full scale input value is 60 mV for the linear input type.

04 INPUT SCALING HI RDG ? 100.0%FS

Low Process Value

Low Reading

Selectable range:

Any value between -99.9 and 999.9. However, you cannot set the high reading to a value less than or equal to the low reading.

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.

01 INPUT SCALING

LO PV ? 0

Selectable values:

See table under

Display Format

Use this menu to enter the input level that corresponds to the low process value you selected in the previous menu. For linear inputs, the low reading is a percentage of the full scale input range; for pulse inputs, the low reading is expressed in Hz.

76 CLS User’s Guide

01 INPUT SCALING LO RDG ? 0.0%FS

The full scale input value for the linear input type is 60 mV. For pulse inputs, it is 2000 Hz.

Selectable range:

99.9-999.9. You cannot set the low reading to a value

greater than or equal to the high reading.

Input Filter

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Setup

The CLS has two different types of input filter:

•

A noise rejection filter that rejects high frequency input signal noise.

This filter keeps a “trend log” of input readings. If a reading is outside the filter's “acceptance band”, and later readings are within the acceptance band, the CLS ignores the anomalous reading. (The acceptance band for thermocouples is 5 degrees above and 5 degrees below the input reading. For linear inputs, it's 0.5% above and 0.5% below the input reading.) If later readings are also outside the acceptance band, the CLS 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.

If all input loops are enabled (none of them are set to SKIP) the CLS scans each input loop 6 times per second. The input filter applies to all input types except those set to SKIP.

01 INPUT FILTER ? 3 SCANS

Selectable range:

0-255 scans. 0 disables the filter.

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Setup

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Set up Loop Control Parameters

Use these menus to change control parameters for heat and cool outputs of the selected loop, including:

•

Proportional Band (PB or Gain), Integral (TI or Reset), and Deriva-

tive (TD or Rate) settings.

•

Output Filter.

•

Spread between heat and cool outputs.

SETUP LOOP 01 CONTROL PARAMS ?

Below is the setup control parameters menu tree.

NOTE

Both heat and cool outputs have the same menus, so only one of each menu is shown here. The controller will show both heat and cool menus even if the heat or cool output is disabled. (See Set up Loop Outputs for help enabling or disabling the heat or cool output.)

Refer to Tuning and Control for help in selecting control parameter values.

Setup Loop Control Params?

Heat/Cool Control PB?

Heat/cool Control TI?

Heat/Cool Control TD?

Heat/Cool Control Filter?

78 CLS User’s Guide

Heat/Cool Spread?

Heat or Cool Control PB

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Setup

This menu allows you to set the Proportional Band (also known as Gain).

02 HEAT CONTROL PB? 50

NOTE

The CLS internally represents the proportional band (PB) as a gain value. When you edit the PB, you'll see the values change in predefined steps--small steps for narrow PB values and large steps for wide PB values.

Heat or Cool Control TI

Heat or Cool Control TD

The controller calculates the default PB for each input type according to the following equation:

(High Range - Low Range)

Default PB =

Gain

This menu lets you set the Integral term, or Reset.

02 HEAT CONTROL TI ? 180 Sec/R

Selectable range:

This menu lets you set the derivative constant.

03 HEAT CONTROL TD ? 0 sec

0 (off) - 6000 seconds.

Selectable range:

0-255 seconds.

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Heat or Cool Output Filter

Use this menu to dampen the heat or cool output's response. The output responds to a step change by going to approximately 2/3 of its final value within the number of scans you set here.

04 HEAT CONTROL FILTER ? 2 SCANS

Heat and Cool Spread

Selectable range:

0-255. Setting the output filter to 0 turns it off.

Use this menu to set the spread between the heat and cool output and the spread of the On/Off control action.

01 SPREAD ? 5

Selectable ranges:

0 - 255, 25.5, 2.55, .255 or .0255, depending on the

way you set up the Input menus.

80 CLS User’s Guide

Set up Loop Outputs

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Ye s

Press parameters for the current loop, including:

•

at this prompt to access menus to change loop output

Enable or disable outputs Output type Cycle time (for TP outputs) SDAC parameters (for SDAC outputs) Control action Output level limit and limit time Output override Nonlinear output curve

Setup

SDAC Mode?

SDAC Hi

SDAC Low Value?

h Value?

SETUP LOOP 03 OUTPUTS ?

Below is the setup outputs menu tree. Both heat and cool outputs have the same menus, so only one of each menu is shown here.

Setup Loop Outputs?

Heat/Cool Control Output?

Heat/Cool Output Type?

Heat/Cool Output Cycle Time? (TP only )

SDAC Menus (SDAC only )

Heat/Cool Output Action?

Heat/Cool Output Limit?

Heat/Cool Output Limit Time?

Heat/Cool Override Output?

Heat/Cool Output?

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Setup

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Enable/Disable Heat or Cool Outputs

From this menu you can enable or disable the heat or cool output for the current loop. If you want the loop to have PID control, you must enable one output. You can also disable a heat or cool control output and use the output pin for something else, like an alarm.

01 HEAT CONTROL OUTPUT ? ENABLED

Heat or Cool Output Type

Selectable values:

Enabled or Disabled.

This menu lets you set the output type.

03 HEAT OUTPUT TYPE ? TP

This table shows the available output types.

Display

Code

TP Time

Output

Type

proportioning

Definition

Percent output converted to a percent duty cycle over the programmed cycle time.

DZC Distributed

Zero Crossing

Output on/off state calculated for every AC line cycle.

SDAC Serial DAC Output type for optional Serial

Digital to Analog Converter.

ON/OFF On / Off Output either full ON or full OFF.

82 CLS User’s Guide

For an expanded description of these output types, see

Control.

Tuning and

Heat or Cool Cycle Time

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Setup

From this menu you can set the Cycle Time for Time Proportioning outputs.

02 HEAT OUTPUT CYCLE TIME ? 10 s

NOTE

The Cycle Time menu will only be present if the output type for the current loop is Time Proportioning.

SDAC Menus

SDAC Mode

Selectable range:

1-255 seconds.

If you attach the optional SDAC to an output, you must configure that output for the SDAC using the following series of menus. The CLS will also assign digital output #34 as a clock line for the SDAC. You won't be able to assign another function to output #34 while any loop's output is set to SDAC.

From this menu you can toggle the SDAC between current and voltage output. The SDAC menus only appear if the output type for the loop is set to SDAC.

01 SDAC MODE ? VOLTAGE

Selectable values:

Current or voltage.

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SDAC High Value

Use this menu to set a high value for the SDAC output. Set the high and low value to match the range of the output device. For instance, if the output device has a 4-20 mA range, set the SDAC high value to 20.00 mA and the SDAC low value to 4.00 mA. The controller converts 0% output to a 4.00 mA signal and 100% output to a 20.00 mA signal.

03 SDAC HI VALUE ? 10.00 VDC

SDAC Low Value

Heat or Cool Output Action

Selectable values:

If the output is set to Voltage, the default high value

is 10.00 volts. If the output is set to Current, the default high value is

20.00 mA. You cannot set the high value to be less than or equal to the low value.

Use this menu to set a low value for the SDAC output. Set the high and low value to match the range of the output device. For instance, if the output device has a 0.00-10.00 V range, set the SDAC high value to

10.00 V and the SDAC low value to 0.00 V. The controller converts 0% output to a 0.00 V signal and 100% output to a 10.00 V signal.

04 SDAC LO VALUE ? 0.00 VDC

Selectable values:

If the output is set to Voltage, the default low value is 0.00 volts. If the output is set to Current, the default low value is 4.00 mA. You cannot set the low value to be greater than or equal to the high value.

84 CLS User’s Guide

Use this menu to select the control action for the current output. Normally, heat outputs are set to reverse action and cool outputs are set to direct action.

01 HEAT OUTPUT ACTION ? REVERSE

Selectable values:

Reverse or direct. For heat outputs, set to reverse; for

cool outputs, set to direct.

Heat or Cool Output Limit

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Setup

Use this menu to limit the maximum PID control output for a loop's heat and cool outputs. This limit may be continuous, or it may be in effect for a specified number of seconds (see Output Limit Time below). If you choose a timed limit, the output limit restarts when the controller powers up and when the output goes from Manual to Automatic control (via the front panel, when the controller changes jobs, or from ANASOFT). The output limit only affects loops under automatic control. It does not affect loops under manual control.

01 HEAT OUTPUT LIMIT ? 100%

Selectable range:

Heat or Cool Output Limit Time

Use this menu to set a time limit for the output limit.

03 HEAT OUTPUT LIMIT TIME ? CONT

Selectable values:

CONT (continuous).

Heat or Cool Output Override

Use this menu to set an output override percentage. (You can configure a digital input for the output override in the main menu.) If the current loop is in Automatic mode and a sensor failure occurs, the loop switches to the output override percentage. If you change the polarity of the override output to the active state--for instance, by flipping a “kill switch” you have set up--every loop switches to the output override percentage you set here.

0-100%.

1-999 seconds (1 second to over 16 minutes), or to

Set up Global Parameters

03 HEAT OVERRIDE OUTPUT ? 0%

Selectable range:

0-100%.

CLS User’s Guide 85

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100

Linear

Output

Calculated by PID

20 40 60 80 100

Heat or Cool Nonlinear Output Curve

Use this menu to select one of two nonlinear output curves for nonlinear processes.

03 HEAT OUTPUT ? LINEAR

Selectable values:

Curve 1, Curve 2, or Linear.

These curves are shown in the figure below.

86 CLS User’s Guide

Set up Loop Alarms

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Setup

Press Yes at the Set up Loop Alarms prompt to access menus which change alarm function parameters for the current loop. The main alarms menu looks like this:

SETUP LOOP 04 ALARMS ?

Below is the setup alarms menu tree.

Alarm Types

Setup Loop Alarms?

h Process Alarm

Hi Setpoint?

h Process Alarm

Hi Type?

h Process Alarm

Hi Output?

Deviation Alarm Valu e?

h Deviation Alarm

Hi Type?

h Deviation Alarm

Hi Output?

The CLS has three different kinds of alarms: failed sensor alarms, global alarms, and process alarms.

Low Deviation Alarm Type?

Low Deviation Alarm Output?

Low Process Alarm Setpoint?

Low Process Alarm Type?

Low Process Alarm Output?

Alarm Deadband?

Alarm Delay?

Failed Sensor Alarms

Failed sensor alarms alert you to T/C breaks and these RTD open or short failures:

•

Open + input.

•

Open - input.

•

Short between + and - input.

Failed sensor alarms alert you to T/C breaks. When the loop is in Automatic or Tune mode and a failed sensor alarm occurs, the CLS sets the loop to Manual control at the output override percentage you set in the Set up Loop Outputs menus.

CLS User’s Guide 87

Setup

Global Alarms

Global alarms occur when a loop alarm set to Alarm (not Control) is unacknowledged, or when there are any unacknowledged failed sensor alarms. (If an alarm occurs, the CLS front panel displays an appropriate alarm code--see Using the CLS section.) Even if the alarm condition goes away, the global alarm stays on until you use the front panel Alarm Ack key (or ANASOFT) to acknowledge it.

Process Alarms

Process alarms include high and low deviation and high and low process alarms. You can set each of these alarms to Off, Alarm, or Control, as shown here.

Function Description

Off No alarm or control function Alarm Standard alarm function Control Digital output activities on alarm, deactivates

when loop is not in alarm. Global alarm output does not activate.

•

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 next diagram)

•

Any digital output not used as a control 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 global alarm output polarity 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 next diagram shows these alarms.)

88 CLS User’s Guide

High Alarm Limit

Setup

When the controller powers up or the setpoint changes, deviation alarms do not activate until the process goes inside the deviation alarm band, preventing deviation alarms during a cold start. (High and low process alarms are always enabled.)

h process alarm on

High process alarm off

Deadband

}

SP + Deviation

Setpoint

SP - Deviation

Low Alarm Limit

High deviation alarm on

Deadband

}

h 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 loop:

•

High and low process alarm type, setpoint, and digital output

•

High and low deviation alarm type, deviation alarm value, and digi-

tal output

•

Alarm deadband

•

Alarm delay

The setpoints, deviation alarm values, and deadband all use the same decimal format as the loop's process variable.

Alarm Delay

You can set the CLS to delay normal alarm detection and alarm reporting. There are two kinds of alarm delay:

•

Start-up alarm delay delays process alarms (but not failed sensor

alarms) for all loops for a time period you set in the Set up Global Parameters main menu.

•

Loop alarm delay delays failed sensor alarms and process alarms for

one loop until the alarm condition is continuously present for longer than the loop alarm delay time you set.

NOTE

Failed sensor alarms are affected by the loop alarm delay even during the start-up alarm delay time period.

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High Process Alarm Setpoint

Use this menu to select the setpoint (temperature or other value within the scaled sensor range) at which the high process alarm activates. The high process alarm activates when the process variable (PV) goes above the high process setpoint. It deactivates when the PV goes below the high process setpoint minus the deadband value, if you have set a deadband value.

04 HI PROC ALARM

SETPT ? 1000

Selectable range:

High Process Alarm Type

Use this menu to turn off the high process alarm or set it to the alarm or control function. (See the previous description for an explanation of these choices).

02 HI PROC ALARM TYPE ? OFF

Selectable values:

High Process Alarm Output Number

Use this menu to choose the digital output that activates when the loop is in high process alarm. You can use this output to activate a second alarm horn or buzzer. You can also use it to control your process. For example, you can set the output you have chosen to activate heating or cooling mechanisms, or to turn off the system.

01 HI PROC ALARM OUTPUT ? NONE

any point within the scaled sensor range.

Off, Alarm, or Control.

90 CLS User’s Guide

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.

Selectable values:

not already used for control or the SDAC clock, or you may select None.

any output number between 1 and 34, as long as it's

Deviation Band Value

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Setup

Use this menu to set the deviation bandwidth, a positive and negative alarm or control point relative to the setpoint. If the setpoint changes, the alarm or control points also change. You can assign a separate digital output to the high and low deviation alarm/control setpoints--so that, for example, a high deviation alarm turns on a fan and a low deviation alarm turns on a heater.

02 DEV ALARM

VALUE ? 5

Selectable values:

way you set up the Input menus.

High Deviation Alarm Type

Use this menu to disable the high deviation alarm function or set it to the alarm or control function. (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.)

03 HI DEV ALARM TYPE ? OFF

Selectable values:

High Deviation Alarm Output Number

Use this menu to assign a digital output which activates when the loop is in high deviation alarm. The digital output only activates if you have set the high deviation alarm type to Alarm or Control.

01 HI DEV ALARM OUTPUT ? NONE

0-255, 25.5, 2.55, .255 or .0255, depending on the

Alarm, Control, Off

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.

Selectable values:

output is not already used for control or the SDAC clock, or you may select None.

Any output number between 1 and 34, as long as that

CLS User’s Guide 91

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Low Deviation Alarm Type

Use this menu to turn Off the low deviation alarm or set it to Alarm or Control mode.

01 LO DEV ALARM TYPE ? OFF

Selectable values:

Low Deviation Alarm Output Number

Use this menu to assign a digital output that activates when the loop is in low deviation alarm.

04 LO DEV ALARM OUTPUT ? 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.

Selectable values:

for control or the SDAC clock, or you may select None.

Low Process Alarm Setpoint

Off, Alarm, or Control.

1 and 34, as long as that output is not already used

92 CLS User’s Guide

Use this menu 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.

01 LO PROC ALARM

SETPT ? 0

Selectable range:

Any value within the input sensor's range.

Watlow CLS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Overview

System Diagram

Parts List

Safety

Introduction

Specifications

Analog Inputs

Digital Inputs

User-Selectable Digital Outputs

System Digital Outputs

Analog Outputs

Miscellaneous Specifications

Physical Dimensions

Installation

Precautions and Warnings

Recommended Tools

Panel Hole Cutters

Other Tools

CLS Mounting Procedure

Mounting Environment

TB-18 Mounting Instructions

TB-50 Mounting Instructions

General Wiring Recommendations

Grounding

Thermocouple Wiring

Input Wiring

Output Wiring

Communications Wiring

Wiring: Noise Suppression

General Wiring

Power Wiring and Controller Test

Outputs

PID Control and Alarm Output Connections

Watchdog Timer

Inputs

Input Scaling

4 and 8 CLS Scaling Values

16 CLS Scaling Values

Scaling and Calibration

T/C Inputs

RTD Inputs (4 and 8 CLS only)

Current Inputs

Voltage Inputs

Unused Inputs

Back Terminal Block Connections

Serial Communications

RS-232 Interface

RS-485 Interface

Using the CLS

Introduction

Front Panel

Front Panel Keys

Displays

Bar Graph Display

Single Loop Display

Alarms

Job Display

Operator Menus

Change Setpoint

Manual/Automatic Control

Ramp/Soak

Setup

How to Enter the Setup Menus?

How to edit a menu?

Set up Global Parameters Menu

Load a Job

Save Setup to Job

Job Select Inputs

Job Select Input Polarity

Output Override Digital Input

Output Override Input Polarity

Start-up Alarm Delay

Keyboard Lock Status

Power-Up Output Status

Controller Address