Watlow CLS User Manual
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
Copyright © 1996
Watlow Anafaze
Information in this manual is subject to change without notice. No part of this publication may be
reproduced, stored in a retrieval system, or transmitted in any form without written permission
from Watlow Anafaze.
Warranty
Watlow Anafaze, Incorporated warrants that the products furnished under this Agreement will be
free from defects in material and workmanship for a period of three years from the date of shipment. The Customer shall provide notice of any defect to Watlow Anafaze, 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
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
i
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
ii
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
iv
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
v
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
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
F
°
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
C
°
* True for 10% to 100% of span.
RTD Ranges and Resolution (4 and 8 CLS only)
Range in
C
°
Resolution
Measure-
ment
Temp. In
°
-100.0 to
275.0
-120 to 840
0.023
0.062
°
C
275 ±1 ±1.8 ±1.5 ±2.7
°
C
840 ±1.1 ±1.98 ±4.3 ±7.74
* Accuracy:
C
25
°
Ambient
°
C
±
0.5
±
0.6
±
1.3
±
2.5
±
2.5
±
6.6
±
±
±
±
±
±
°
F
0.9
1.2
2.4
4.5
4.5
12.0
* Accuracy:
C Full
0-50
°
Temp. Range
±
±
±
±
±
±
°
C
1.1
1.35
2.9
5.6
5.6
14.9
±
±
±
±
±
±
°
10.1
10.1
27.0
2.0
2.7
5.4
:
Accuracy:
C
25
°
Ambient
C
25 ±0.35 ±0.63 ±0.5 ±0.9
25 ±0.9 ±1.62 ±2.8 ±5.04
C °F
°
Accuracy:
C
0-50
°
Ambient
C °F
°
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
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.
34
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
°
C
°
C
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
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
1
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.)
A
B
3938B
4443424140
504948474645
A
36
B
B
A
B
Holes labeled "A"are m ounting holes.
Holes labeled "B"aretiewrap holes.
35
3738A
34
3233
29
3031
262728
25242322212019181716151413B
12345678910111213A
A
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
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
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