Watlow CLS200 User Manual

CLS200 Series

User’s Guide

Watlow

1241 Bundy Boulevard

Winona, MN 55987

Customer Service:

Phone........[phone]

Fax.............1-800-445-8992

Technical Support:

Phone........[phone]

Fax ............+1 [phone]

Email [e-mail]

Part No. 0600-3050-2000 Rev. A
November 2008

Copyright © 1998-2003, Watlow Anafaze

Information in this manual is subject to change without notice. No part of this publi­cation may be reproduced, stored in a retrieval system, or transmitted in any form
without written permission from Watlow Anafaze.

Warranty

Watlow Anafaze, Incorporated warrants that the products furnished under this Agree­ment will be free from defects in material and workmanship for a period of three years
from the date of shipment. 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.

Table of Contents

List of Figures xi

List of Tables xv

1 System Overview 1

Manual Contents 1
Getting Started 2

Safety Symbols 2
Initial Inspection 2

Product Features 3
CLS200 Parts List 5
Technical Description 7

CLS200 7
TB50 8
CLS200 Cabling 9

Safety 9

External Safety Devices 9
Power-Fail Protection 10

2 Installation 11

Typical Installation 12
Mounting Controller Components 12

Recommended Tools 13
Mounting the Controller 13
Mounting the TB50 16
Mounting the Power Supply 18
Mounting the Dual DAC or Serial DAC Module 19

System Wiring 21

Wiring Recommendations 21
Noise Suppression 22
Ground Loops 24

Power Connections 25

Wiring the Power Supply 25
Connecting TB50 to CLS200 27

Testing Your System 28

TB50 or TB18 Test 28
Digital Output Test 28
Digital Input Test 29

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Table of Contents CLS200 Series User’s Guide

Sensor Wiring 29

Input Wiring Recommendations 30
Thermocouple Connections 31
RTD Input Connections 32
Reference Voltage Terminals 32
Voltage Input Connections 32
Current Input Connections 33
Pulse Input Connections 34

Wiring Control and Digital I/O 35

Output Wiring Recommendations 35
Cable Tie Wraps 35
Digital Outputs 35
Digital Inputs 38
TB18 Connections (CLS204 and CLS208 Only) 40
TB50 Connections 41

Analog Outputs 43

Wiring the Dual DAC 43
Wiring the Serial DAC 44

Serial Communications 45

EIA/TIA-232 Interface 45
EIA/TIA-485 Interface 47
EIA/TIA-485 Converters and Laptop Computers 49

3 Using the CLS200 51

Front Panel 52

Front Panel Keys 53

Displays 55

Bar Graph Display 55
Single Loop Display 57
Alarm Displays 58
System Alarms 60

Job Display 60
Changing the Setpoint 61
Selecting the Control Status 61

Manual and Automatic Control 61
Autotuning a Loop 62

Using Alarms 64

Alarm Delay 64
Failed Sensor Alarms 65
Process Alarms 66
Global Alarm 68

Ramp/Soak 69

4 Setup 71

How to Access the Setup Menus 71

How to Change a Parameter 72

Setup Global Parameters Menu

Load Setup From Job 75
Save Setup to Job 75
Job Select Digital Inputs 76

74

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CLS200 Series User’s Guide Table of Contents

Job Select Digital Inputs Active 77
Output Override Digital Input 77
Override Digital Input Active 77
Startup Alarm Delay 78
Keyboard Lock Status 78
Power Up Output Status 78
Process Power Digital Input 79
Controller Address 79
Communications Baud Rate 80
Communications Protocol 80
Communications Error Checking 80
AC Line Frequency 81
Digital Output Polarity on Alarm 81
EPROM Information 81

Setup Loop Input Menu 82

Input Type 83
Loop Name 84
Input Units 84
Input Reading Offset 84
Reversed T/C Detection 85
Input Pulse Sample Time 85
Linear Scaling Parameters 86
Input Filter 89

Setup Loop Control Parameters Menu 90

Heat or Cool Control PB 91
Heat or Cool Control TI 91
Heat or Cool Control TD 91
Heat or Cool Output Filter 91
Spread 92
Restore PID Digital Input 92

Setup Loop Outputs Menu 93

Enable or Disable Heat or Cool Outputs 94
Heat or Cool Output Type 94
Heat or Cool Cycle Time 95
SDAC Mode 95
SDAC Low Value 95
SDAC High Value 95
Heat or Cool Output Action 96
Heat or Cool Output Limit 96
Heat or Cool Output Limit Time 96
Sensor Fail Heat or Cool Output 97
Heat or Cool Thermocouple Break Output Average 97
Heat or Cool Linearity 98

Setup Loop Alarms Menu 99

High Process Alarm Setpoint 100
High Process Alarm Type 100
High Process Alarm Output Number 100
Deviation Alarm Value 100
High Deviation Alarm Type 101
High Deviation Alarm Output Number 101
Low Deviation Alarm Type 101
Low Deviation Alarm Output Number 101
Low Process Alarm Setpoint 102

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Table of Contents CLS200 Series User’s Guide

Low Process Alarm Type 102
Low Process Alarm Output Number 102
Alarm Deadband 102
Alarm Delay 103

Manual I/O Test 103

Digital Inputs 103
Test Digital Output 104
Digital Output Number 104
Keypad Test 105
Display Test 105

5 Extruder Control 107

Setup Loop Outputs Menu 107

Cool Output Nonlinear Output Curve 107

Defaults 108
Extruder Control Algorithm 110

6 Enhanced Features 111

Process Variable Retransmit 113

Setup Loop Process Variable Retransmit Menu 113
Process Variable Retransmit Example: Data Logging 115

Cascade Control 118

Setup Loop Cascade Menu 119
Cascade Control Example: Water Tank 121

Ratio Control 124

Setup Loop Ratio Control Menu 125
Ratio Control Example: Diluting KOH 126

Remote Analog Setpoint 129

Remote Analog Setpoint Example: Setting a Setpoint with a PLC 129

Differential Control 131

Differential Control Example: Thermoforming 131

7 Ramp/Soak 133

Features 134
Ramp/Soak Menus 136
Setup Global Parameters Menu 137

Ramp/Soak Time Base 137

Setup Ramp/Soak Profile Menu 137

Edit Ramp/Soak Profile 137
Copy Setup From Profile 138
Tolerance Alarm Time 138
Ready Segment Setpoint 138
Ready Segment Edit Events 139
External Reset Input Number 139
Edit Segment Number 140
Segment Time 140
Segment Setpoint 140
Edit Segment Events 141
Edit Segment Triggers 142
Segment Tolerance 143

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CLS200 Series User’s Guide Table of Contents

Last Segment 144
Repeat Cycles 144
Setpoints and Tolerances for Various Input Types 144

Using Ramp/Soak 145

Ramp/Soak Displays 146
Assigning a Profile to a Loop 148
Running a Profile 148
Holding a Profile or Continuing from Hold 150
Responding to a Tolerance Alarm 151
Resetting a Profile 151
In Case of a Power Failure 152

8 Tuning and Control 153

Control Algorithms 153

On/Off Control 154
Proportional Control 154
Proportional and Integral Control 155
Proportional, Integral and Derivative Control 155
Heat and Cool Outputs 156

Control Outputs 157

Output Control Signals 157
Output Filter 158
Reverse and Direct Action 159

Setting Up and Tuning PID Loops 159

Proportional Band (PB) Settings 159
Integral Settings 160
Derivative Settings 160

General PID Constants by Application 161

Proportional Band Only (P) 161
Proportional with Integral (PI) 161
PI with Derivative (PID) 161

9 Troubleshooting and Reconfiguring 163

When There is a Problem 163

Returning Your Unit 164

Troubleshooting Controllers 164

Process and Deviation Alarms 164
Failed Sensor Alarms 166
System Alarms 166
Other Behaviors 167

Corrective and Diagnostic Procedures 168

Low Power 168
Battery Dead 168
Ambient Warning 168
H/W Ambient Failure 169
H/W Gain or Offset Failure 170
Keys Do Not Respond 170
Checking Analog Inputs 171
Earth Grounding 172
Checking Control Outputs 172
Testing Control Output Devices 173

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Table of Contents CLS200 Series User’s Guide

Testing the TB18 and TB50 173
Testing Control and Digital Outputs 173
Testing Digital Inputs 173

Additional Troubleshooting for Computer Supervised Systems 174

Computer Problems 174
Communications 175
Ground Loops 175
Software Problems 176

NO-Key Reset 176
Replacing the EPROM 176
Changing Communications 179
Installing Scaling Resistors 180

CLS204 and CLS208 Input Circuit 180
CLS204 and CLS208 Current Inputs 181
CLS204 and CLS208 Voltage Inputs 182
CLS204 and CLS208 RTDs and Thermistors 183
CLS216 Input Circuit 184
CLS216 Current Inputs 184
CLS216 Voltage Inputs 185
Scaling and Calibration 186

Configuring Dual DAC Outputs 186
Configuring Serial DAC Outputs 188

10 Linear Scaling Examples 189

Example 1: A 4-to-20 mA Sensor 189

Î

Example 2: A 0-to-5V

(dc) Sensor 191

Example 3: A Pulse Encoder 192

11 Specifications 193

CLS200 System Specifications 193

CLS200 Processor Physical Specifications 194
TB50 Physical Specifications 196
Inputs 200
Outputs 202

CLS200 Power Supply 205
Dual DAC Specifications 207

Dual DAC Inputs 208
Dual DAC Analog Outputs 208

Serial DAC Specifications 209

Serial DAC Inputs 210
Serial DAC Analog Outputs 211

Glossary 213

Index 221

Menu Structure 233

Declaration of Conformity 234

viii Watlow Anafaze Doc.# 0600-3050-2000

1 System Overview

Figure 1.1—CLS200 Part Numbering 5
Figure 1.2—CLS200 Special Inputs Parts List 6
Figure 1.3—CLS200 Rear Views 7
Figure 1.4—CLS200 Front Panel 8
Figure 1.5—TB50 8

List of Figures

2 Installation

Figure 2.1—CLS200 System Components 12
Figure 2.2—Clearance with Straight SCSI Cable 14
Figure 2.3—Clearance with Right-Angle SCSI Cable 14
Figure 2.4—Wiring Clearances 15
Figure 2.5—Mounting Bracket 16
Figure 2.6—Mounting the TB50 16
Figure 2.7—TB50 Mounted on a DIN Rail (Front) 17
Figure 2.8—TB50 Mounted on DIN Rail (Side) 17
Figure 2.9—Mounting a TB50 with Standoffs 18
Figure 2.10—CLS200 Power Supply Mounting Bracket 19
Figure 2.11—Dual DAC and Serial DAC Dimensions 20
Figure 2.12—CLS200 Series Controller with TB18 25
Figure 2.13—CLS200 Series Controller with TB50 25
Figure 2.14—Power Connections with the CLS200 Power Supply 27
Figure 2.15—CLS200 Connector Locations 30
Figure 2.16—Thermocouple Connections 31
Figure 2.17—RTD Connections to CLS204 or CLS208 32
Figure 2.18—Linear Voltage Signal Connections 33
Figure 2.19—Linear Current Signal Connections 33
Figure 2.20—Encoder with 5V Î (dc) TTL Signal 34
Figure 2.21—Encoder Input with Voltage Divider 34
Figure 2.22—Digital Output Wiring 36
Figure 2.23—Sample Heat, Cool and Alarm Output Connections 37
Figure 2.24—Output Connections Using External Power Supply 38
Figure 2.25—TB50 Watchdog Timer Output 38
Figure 2.26—TB18 Watchdog Timer Output 38
Figure 2.27—Wiring Digital Inputs 39
Figure 2.28—Dual DAC with Current Output 43
Figure 2.29—Dual DAC with Voltage Output 44

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List of Figures CLS200 Series User’s Guide

Figure 2.30—Single/Multiple Serial DACs 45
Figure 2.31—Connecting One CLS200 to a Computer Using EIA/TIA-232 46
Figure 2.32—EIA/TIA-485 Wiring 47
Figure 2.33—Recommended System Connections 48

3 Using the CLS200

Figure 3.1—Operator Displays 51
Figure 3.2—CLS200 Front Panel 52
Figure 3.3—Bar Graph Display 55
Figure 3.4—Single Loop Display 57
Figure 3.5—Single Loop Display, Heat and Cool Outputs Enabled 57
Figure 3.6—Single Loop Display with a Process Alarm 58
Figure 3.7—Failed Sensor Alarm in the Single Loop Display 58
Figure 3.8—Alarm Symbols in the Bar Graph Display 58
Figure 3.9—Activation and Deactivation of Process Alarms 68

4 Setup

Figure 4.1—CLS200 Menu Tree 73
Figure 4.2—Two Points Determine Process Variable Conversion 86
Figure 4.3—Process Variable Limited by Input Reading Range 87
Figure 4.4—Linear and Nonlinear Outputs 98
Figure 4.5—Digital Inputs Screen 104

5 Extruder Control

Figure 5.1—Cool Output Nonlinear Output Curve 108

6 Enhanced Features

Figure 6.1—Enhanced Features Option Menus 112
Figure 6.2—Linear Scaling of Process Variable for Retransmit 115
Figure 6.3—Application Using Process Variable Retransmit 116
Figure 6.4—Relationship Between the Primary Loop’s Output and the Secondary

Loop’s Setpoint 119
Figure 6.5—Application Using Cascade Control 121
Figure 6.6—Secondary Loop Setpoint Related to Primary Loop Output 123
Figure 6.7—Relationship Between the Master Loop’s Process Variable and the Ratio

Loop’s Setpoint 124
Figure 6.8—Application Using Ratio Control 127

7 Ramp/Soak

Figure 7.1—Sample Ramp/Soak Profile 133
Figure 7.2—Setup Ramp/Soak Profiles Menu 136
Figure 7.3—Positive and Negative Tolerances 143
Figure 7.4—Ramp/Soak Screens 145

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CLS200 Series User’s Guide List of Figures

8 Tuning and Control

Figure 8.1—On/Off Control 154
Figure 8.2—Proportional Control 155
Figure 8.3—Proportional and Integral Control 155
Figure 8.4—Proportional, Integral and Derivative Control 156
Figure 8.5—Time Proportioning and Distributed Zero Crossing Waveforms 157

9 Troubleshooting and Reconfiguring

Figure 9.1—Removal of Electronics Assembly from Case 177
Figure 9.2—Screws Locations on PC Board 178
Figure 9.3—EPROM Location 178
Figure 9.4—Remove EPROM 178
Figure 9.5—Jumper Configurations 179
Figure 9.6—CLS204 and CLS208 Input Circuit 181
Figure 9.7—CLS216 Input Circuit 184
Figure 9.8—Dual DAC 187
Figure 9.9—Serial DAC Voltage/Current Jumper Positions 188

11 Specifications

Figure 11.1—CLS200 Processor Module Dimensions 194
Figure 11.2—CLS200 Clearances with Straight SCSI Cable 195
Figure 11.3—CLS200 Clearances with Right-Angle SCSI Cable 195
Figure 11.4—TB50 Dimensions 197
Figure 11.5—TB50 Dimensions with Straight SCSI Cable 198
Figure 11.6—TB50 Dimensions with Right-Angle SCSI Cable 199
Figure 11.7—Power Supply Dimensions (Bottom View) 206
Figure 11.8—Dual DAC Dimensions 207
Figure 11.9—Serial DAC Dimensions 209

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List of Figures CLS200 Series User’s Guide

xii Watlow Anafaze Doc.# 0600-3050-2000

2 Installation

Table 2.1—Cable Recommendations 22
Table 2.2—Power Connections 26
Table 2.3—Digital Output States and Values Stored in the Controller 36
Table 2.4—Digital Inputs States and Values Stored in the Controller 39
Table 2.5—TB18 Connections 40
Table 2.6—TB50 Connections for CLS204 and CLS208 41
Table 2.7—TB50 Connections for CLS216 42
Table 2.8—EIA/TIA-232 Connections 46
Table 2.9—RTS/CTS Pins in DB-9 and DB-25 Connectors 46

List of Tables

3 Using the CLS200

Table 3.1—Bar Graph Display Symbols 55
Table 3.2—Control Status Symbols on the Bar Graph and Single Loop Displays 56
Table 3.3—Alarm Type and Symbols 59

4 Setup

Table 4.1—Global Parameters 74
Table 4.2—Job Select Inputs 76
Table 4.3—Job Selected for Various Input States 76
Table 4.4—Firmware Option Codes 81
Table 4.5—Setup Loop Input 82
Table 4.6—CLS200 Input Types and Ranges 83
Table 4.7—Input Character Sets 84
Table 4.8—Input Reading Offset 85
Table 4.9—Display Formats 87
Table 4.10—Setup Loop Control Parameters 90
Table 4.11—Setup Loop Outputs 93
Table 4.12—Heat / Cool Output Types 94
Table 4.13—Setup Loop Alarms 99
Table 4.14—Manual I/O Test 103

5 Extruder Control

Table 5.1—Default Control Parameters for Fan Cool Output 109
Table 5.2—Default Control Parameters for Oil Cool Output 109
Table 5.3—Default Control Parameters for H2O Cool Output 109

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List of Tables CLS200 Series User’s Guide

6 Enhanced Features

Table 6.1—Application Example: Setting Up Process Variable Retransmit 117
Table 6.2—Application Example: Setting Up Cascade Control 122
Table 6.3—Application Example: Setting Up Ratio Control 128
Table 6.4—Application Example: Setting Up Remote Setpoint 130
Table 6.5—Application Example: Setting Up Differential Control 132

7 Ramp/Soak

Table 7.1—Ramp/Soak Specifications 135
Table 7.2—Trigger Latch Logic 143
Table 7.3—Display Formats 145
Table 7.4—Ramp/Soak Single Loop Display 146
Table 7.5—Ramp/Soak Control Status Symbols 147
Table 7.6—Ramp/Soak Profile Modes 150

8 Tuning and Control

Table 8.1—Proportional Band Settings 159
Table 8.2—Integral Term and Reset Settings 160
Table 8.3—Derivative Term Versus Rate 160
Table 8.4—General PID Constants 162

9 Troubleshooting and Reconfiguring

Table 9.1—Controller Alarm Codes for Process and Deviation Alarms 164
Table 9.2—Operator Response to Alarms 165
Table 9.3—Failed Sensor Alarm Codes 166
Table 9.4—Hardware Error Messages 166
Table 9.5—Other Symptoms 167
Table 9.6—Resistor Values for CLS204 and CLS208 Current Inputs 181
Table 9.7—Resistor Locations for CLS204 and CLS208 Current Inputs 181
Table 9.8—Resistor Values for CLS204 and CLS208 Voltage Inputs 182
Table 9.9—Resistor Locations for CLS204 and CLS208 Voltage Inputs 182
Table 9.10—Resistor Values for CLS204/208 RTD and Thermistor Inputs 183
Table 9.11—Resistor Locations for CLS204/208 RTD and Thermistor Inputs 183
Table 9.12—Resistor Values for CLS216 Current Inputs 184
Table 9.13—Resistor Locations for CLS216 Current Inputs 185
Table 9.14—Resistor Values for CLS216 Voltage Inputs 185
Table 9.15—Resistor Locations for CLS216 Voltage Inputs 186
Table 9.16—Dual DAC Jumper Settings 187

10 Linear Scaling Examples

Table 10.1—Input Readings 190
Table 10.2—Scaling Values 190
Table 10.3—Input Readings and Calculations 191
Table 10.4—Scaling Values 191
Table 10.5—Scaling Values 192

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CLS200 Series User’s Guide List of Tables

11 Specifications

Table 11.1—Agency Approvals / Compliance 193
Table 11.2—Environmental Specifications 194
Table 11.3—Physical Dimensions 194
Table 11.4—Processor with Straight SCSI 195
Table 11.5—Processor with Right Angle SCSI 195
Table 11.6—Processor Connections 196
Table 11.7—TB50 Physical Dimensions 196
Table 11.8—TB50 Connections 197
Table 11.9—TB50 with Straight SCSI 198
Table 11.10—TB50 with Right Angle SCSI 199
Table 11.11—Analog Inputs 200
Table 11.12—Pulse Inputs 201
Table 11.13—Thermocouple Range and Resolution 201
Table 11.14—RTD Range and Resolution 201
Table 11.15—Input Resistance for Voltage Inputs 202
Table 11.16—Digital Inputs 202
Table 11.17—Digital Outputs Control / Alarm 203
Table 11.18—CPU Watchdog Output 203
Table 11.19—5V Î (dc) Output (Power to Operate Solid-State Relays) 204
Table 11.20—Reference Voltage Output (Power to Operate Bridge Circuit

Sensors) 204
Table 11.21—Processor Serial Interface 204
Table 11.22—Processor Power Requirements 204
Table 11.23—Power Supply Environmental Specifications 205
Table 11.24—Power Supply Agency Approvals / Compliance 205
Table 11.25—Power Supply Physical Specifications 205
Table 11.26—Power Supply with Mounting Bracket 205
Table 11.27—Power Supply Inputs 206
Table 11.28—Power Supply Outputs 206
Table 11.29—Dual DAC Environmental Specifications 207
Table 11.30—Dual DAC Physical Specifications 207
Table 11.31—Dual DAC Power Requirements 208
Table 11.32—Dual DAC Specifications by Output Range 208
Table 11.33—Serial DAC Environmental Specifications 209
Table 11.34—Serial DAC Physical Specifications 209
Table 11.35—Serial DAC Agency Approvals / Compliance 210
Table 11.36—Serial DAC Inputs 210
Table 11.37—Serial DAC Power Requirements 210
Table 11.38—Serial DAC Analog Output Specifications 211

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List of Tables CLS200 Series User’s Guide

xvi Watlow Anafaze Doc.# 0600-3050-2000

1

System Overview

Manual Contents

This manual describes how to install, set up, and operate a
CLS204, CLS208 or CLS216 controller. Each chapter cov­ers a different aspect of your control system and may apply
to different users:

• Chapter 1: System Overview provides a component
list and summary of features for the CLS200 series
controllers.

• Chapter 2: Installation provides detailed instruc­tions on installing the CLS200 series controller and its
peripherals.

• Chapter 3: Using the CLS200 provides an overview
of operator displays used for system monitoring and
job selection.

• Chapter 4: Setup provides detailed descriptions of
all menus and parameters for controller setup.

• Chapter 5: Extruder Control explains the addition­al features of a CLS200 controller equipped with Ex­truder Control Firmware.

• Chapter 6: Enhanced Features describes process
variable retransmit, ratio, differential and cascade
control features available with the enhanced features
option.

• Chapter 7: Ramp/Soak explains how to set up and
use the features of the ramp/soak option.

• Chapter 8: Tuning and Control describes available
control algorithms and provides suggestions for appli­cations.

• Chapter 9: Troubleshooting and Reconfiguring
includes troubleshooting, upgrading and reconfigur­ing procedures for technical personnel.

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Chapter 1: System Overview CLS200 Series User’s Guide

Chapter 10: Linear Scaling Examples provides an

example configuring a pressure sensor, a flow sensor,
and an encoder using linear scaling.

• Chapter 11: Specifications
tions of the controller and optional components.

lists detailed specifica-

Getting Started

The following sections provide information regarding prod­uct features, technical descriptions, safety requirements,
and preparation for operation.

Safety Symbols

These symbols are used throughout this manual:

•

Initial Inspection

WARNING!

CAUTION!

NOTE!

Indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury.

Indicates a potentially hazardous situation
which, if not avoided, could result in minor or
moderate injury or property damage.

Indicates pertinent information or an item
that may be useful to document or label for
later reference.

Accessories may or may not be shipped in the same con­tainer as the CLS200, depending upon their size. Check the
shipping invoice carefully against the contents received in
all boxes.

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CLS200 Series User’s Guide Chapter 1: System Overview

Product Features

The CLS200 series controllers provide 4, 8 or 16 fully inde­pendent control loops. When used as a stand-alone control­ler, you may operate the CLS200 via the two-line 16­character display and touch keypad. You can also use it as
the key element in a computer-supervised data acquisition
and control system; the CLS200 can be locally or remotely
controlled via an EIA/TIA-232 or EIA/TIA-485 serial com­munications interface.

The CLS200 features include:

•

Direct Connection of Mixed Thermocouple Sen­sors:

Connect most thermocouples to the controller
with no hardware modifications. Thermocouple inputs
feature reference junction compensation, lineariza­tion, process variable offset calibration to correct for
sensor inaccuracies, detection of broken, shorted or re­versed thermocouples, and a choice of Fahrenheit or
Celsius display.

•

Accepts Resistive Temperature Detectors
(RTDs):

sensors with two choices for range and precision of
measurements. (To use this input, order a CLS204 or
CLS208 controller with scaling resistors.)

•

Automatic Scaling for Linear Analog Inputs:

CLS200 series automatically scales linear inputs used
with industrial process sensors. Enter two points, and
all input values are automatically scaled in your units.
Scaling resistors must be installed.

•

Dual Outputs:

and cool control outputs for each loop. Independent
control parameters are provided for each output.

•

Independently Selectable Control and Output
Modes:

proportioning, Serial DAC (digital-to-analog convert­er), or distributed zero crossing mode. Set up to two
outputs per loop for on/off, P, PI or PID control with re­verse or direct action.

•

Control Outputs:

low process limits to operate digital outputs as on/off
control functions or alarms.

• 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.

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

Use 3-wire, 100 Ω, platinum, 0.00385-curve

The

The CLS200 series includes both heat

You can set each control output to on/off, time

Set high/low deviation and high/

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Chapter 1: System Overview CLS200 Series User’s Guide

• CPU Watchdog: The CLS200 series CPU watchdog
timer output notifies you of system failure. Use it to
hold a relay closed while the controller is running, so
you are notified if the microprocessor shuts down.

• Front Panel or Computer Operation: Set up and
run the controller from the front panel or from a local
or remote computer. Watlow Anafaze offers WatView,
a Windows® compatible Human Machine Interface
(HMI) software package that includes data logging
and graphing features in addition to process monitor­ing and parameter setup screens.

• Modbus RTU Protocol, EIA/TIA-232 and 485
Communications: Connect to PLCs, operator inter­face terminals and third-party software packages us­ing the widely supported Modbus RTU protocol.

• Multiple Job Storage: Store up to eight jobs in 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.

• Nonlinear Output Curves: Select either of two non­linear output curves for each control output.

• Autotuning: Use the autotune feature to set up your
system quickly and easily. The CLS200 internal ex­pert system table finds the correct PID parameters for
your process.

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

• Low Power Shutdown: The controller shuts down
and turns off all outputs when it detects the input volt­age drop below the minimum safe operating level.

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CLS200 Series User’s Guide Chapter 1: System Overview

CLS200 Parts List

You may have received one or more of the following compo­nents. See Figure 2.1 on page 12 for CLS200 configuration
information.

• CLS200 series controller

• Controller mounting kit

• TB50 with 50-pin SCSI cable

• EIA/TIA-232 or EIA/TIA-485 communications cable

• Power supply with mounting bracket and screws

• Serial DAC (digital-to-analog converter)

• Special input resistors (installed in CLS200)

• User’s guide

2_ _–_ _ _ _ _ _

Number of Loops

04 = 4 loops
08 = 8 loops
16 = 16 loops

Controller Type

1 = Standard EPROM
2 = Extruder applications
3 = Ramp/soak option
4 = Enhanced features option (includes cascade, PV retransmit, ratio, remote setpoint)

Terminal Board

0 = No terminal board accessory
1 = 18-terminal block mounted on unit, no SCSI cable required
2 = 50-pin terminal board, includes 3 ft. SCSI cable

Power Supply

0 = No power supply
2 = 120/240V

(5V

SCSI Cables (for use with 50-pin terminal board)

0 = No special SCSI cable (3 ft. cable is included with 50-pin terminal board)
1 = 6 ft. SCSI cable
2 = 3 ft. right angle SCSI cable
3 = 6 ft. right angle SCSI cable )

Communications Cables (For EIA/TIA-232 communications with computer)

0 = No communications cable
1 = 10 ft. (3.0 m) communications cable, DB-9 female/bare wire
2 = 25 ft. (7.6 m) communications cable, DB-9 female/bare wire
3 = 50 ft. (15.2 m) communications cable, DB-9 female/bare wire

Serial Communications Jumper Settings

0 = EIA/TIA-232
1 = EIA/TIA-485
2 = EIA/TIA-485 terminated

Special Inputs (one or two digits)

(Standard unit is conf gured for thermocouples and -10 to 60mV linear inputs.
For other sensors, special inputs are required.
00 = Thermocouples and -10 to 60mV inputs only
XX = Number of current and voltage inputs. RTDs are not available on the CLS216. Include

leading zero as needed.

Å (ac), 50/60Hz panel mount power supply adapter

Î [dc] @ 4A, 15VÎ [dc] @ 1.2A) CE approved

___

Figure 1.1 CLS200 Part Numbering

Doc.# 0600-3050-2000 Watlow Anafaze 5

Chapter 1: System Overview CLS200 Series User’s Guide

CLSSI _ _–_ _–_ _

If special inputs are ordered in the
controller part number, the following
is specified in the pa t description.

Special Input Type

20 = RTD1: 0.1°, -100.0 to 275.0° C (-148.0 to 572.0° F) (Not available on CLS216)
21 = RTD2: 1°, -120.0 to 840.0° C (-184.0 to 1544.0° F) (Not available on CLS216)
43 = 0 to 10 mA
44 = 0 to 20mA
50 = 0 to 100mV
52 = 0 to 500mV
53 = 0 to 1V
55 = 0 to 5V
56 = 0 to 10V
57 = 0 to 12V

Start Channel

XX = Channel number XX

End Channel

XX = Channel number XX

Note:

Make sure the number of special inputs specif ed is equal to
the number of special inputs in the controller part number.

Uninstalled kits are available.

Î (dc)
Î (dc)

Î (dc)
Î (dc)

(Not required for thermocouple sensor inputs)

Î (dc)

Î (dc)/4 to 20mAÎ (dc)

Î (dc)
Î (dc)

Figure 1.2 CLS200 Special Inputs Parts List

6 Watlow Anafaze Doc.# 0600-3050-2000

CLS200 Series User’s Guide Chapter 1: System Overview

Technical Description

This section contains a technical description of each compo­nent of your CLS200 series controller.

CLS200

The CLS200 is housed in an 1/8-DIN panel mount package.
It contains the CPU, RAM with a built-in battery, EPROM,
serial communications, digital I/O, analog inputs, the
screen and touch keypad.

CLS200 Series
with SCSI Connector

CLS204 or CLS208
with TB18 Connector

Figure 1.3 CLS200 Rear Views

The CLS200 has the following features:

• Keypad and 2-line 16-character display.

• Screw terminals for the power and analog inputs and
communications.

• Input power is 12 to 24V

• A 50-pin SCSI cable connects the digital inputs and
outputs to the 50-terminal block (TB50). The CLS204
and CLS208 are available with an 18-terminal block
(TB18) in place of the SCSI connector, as shown in Fig-
ure 1.3.

The firmware resides in an EPROM. See Replacing the
EPROM on page 176 for information on removing and re­placing the EPROM.

The operating parameters are stored in battery-backed
RAM. If there is a power loss the operating parameters are
unchanged. The battery has a ten-year shelf life, and it is
not used when the unit is on.

The microprocessor performs all calculations for input sig­nal linearization, PID control, alarms and communica­tions.

Î (dc) at 1 Amp.

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Chapter 1: System Overview CLS200 Series User’s Guide

Front Panel Description

The display and touch keypad provide an intelligent way to
operate the controller. The display has 16 alphanumeric or
graphic characters per line. The 8-key keypad allows you to
change the operating parameters, controller functions, and
displays.

The information-packed displays show process variables,
setpoints, and output levels for each loop. A bar graph dis­play, single loop display, scanning display and an alarm
display offer a real-time view of process conditions. Two ac­cess levels allow operator changes and supervisor changes.

WATLOW ANAFAZE CLS200

TB50

Figure 1.4 CLS200 Front Panel

The TB50 is a screw-terminal interface for control wiring
which allows you to connect relays, encoders and discrete I/
O devices to the CLS200. The screw terminal blocks accept

2

wires as large as 18 AWG (0.75 mm
connects the TB50 to the CLS200.

). A 50-pin SCSI cable

Figure 1.5 TB50

8 Watlow Anafaze Doc.# 0600-3050-2000

CLS200 Series User’s Guide Chapter 1: System Overview

CLS200 Cabling

Watlow Anafaze provides cables required to install your
CLS200. A 50-pin SCSI cable connects the TB50 to the
CLS200.

The optional cable used to connect the CLS200 to a comput­er using EIA/TIA-232 communications has a DB9 or DB25
connector for the computer and bare wires for connecting to
the CLS200.

Safety

Watlow Anafaze has made every effort to ensure the reli­ability and safety of this product. In addition, we have pro­vided recommendations that will allow you to safely install
and maintain this controller.

External Safety Devices

The CLS200 controller may fail full-on (100% output pow­er) or full-off (0% output power), or may remain full-on if an
undetected sensor failure occurs. For more information
about failed sensor alarms, see Failed Sensor Alarms on

page 65.

Design your system to be safe even if the controller sends a
0% or 100% output power signal at any time. Install inde­pendent, external safety devices that will shut down the
system if a failure occurs.

Typically, a shutdown device consists of an FM-approved
high/low process limit controller that operates a shutdown
device such as an mechanical contactor. The limit control­ler monitors for a hazardous condition such as an under­temperature or over-temperature fault. If a hazardous con­dition is detected, the limit controller sends a signal to open
the contactor.

The safety shutdown device (limit controller and contactor)
must be independent from the process control equipment.

WARNING!

The controller may fail in a 0% or 100% power
output state. To prevent death, personal inju­ry, equipment damage or property damage,
install external safety shutdown devices. If

must

death or injury may occur, you

install
FM-approved safety shutdown devices that
operate independently from the process con­trol equipment.

With proper approval and installation, thermal fuses may
be used in some processes.

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Chapter 1: System Overview CLS200 Series User’s Guide

Power-Fail Protection

In the occurrence of a sudden loss of power, this controller
can be programmed to reset the control outputs to off (this
is the default). Typically, when power is re-started, the con­troller restarts to data stored in memory. If you have pro­grammed the controller to restart with control outputs on,
the memory-based restart might create an unsafe process
condition for some installations. Therefore, you should only
set the restart with outputs on if you are certain your sys­tem will safely restart. (See the Process Power Digital In-
put on page 79).

When using a computer or host device, you can program the
software to automatically reload desired operating con­stants or process values on power-up. Keep in mind that
these convenience features do not eliminate the need for in­dependent safety devices.

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

10 Watlow Anafaze Doc.# 0600-3050-2000

2

Installation

This chapter describes how to install the CLS200 series
controller and its peripherals. Installation of the controller
involves the following procedures:

• Determining the best location for the controller

• Mounting the controller and TB50

• Power connection

• Input wiring

• Communications wiring (EIA/TIA-232 or EIA/TIA-

485)

• Output wiring

WARNING!

WARNING!

Doc.# 0600-3050-2000 Watlow Anafaze 11

Risk of electric shock. Shut off power to your
entire process before you begin installation
of the controller.

The controller may fail in a 0% or 100% power
output state. To prevent death, personal inju­ry, equipment damage or property damage,
install external safety shutdown devices. If
failure may cause death or injury, you must
install FM-approved safety shutdown devic­es that operate independently from the pro­cess control equipment.

Chapter 2: Installation CLS200 Series User’s Guide

Typical Installation

Figure 2.1 shows typical installations of the controller with
the TB50 and the TB18 terminal blocks. The type of termi­nal block you use greatly impacts the layout and wiring of
your installation site.

We recommend that you read this entire chapter first be­fore beginning the installation procedure. This will help
you to carefully plan and assess the installation.

(See Figures 2.2 to 2.11.)

CLS200 with TB50

Signal Inputs

CLS200 with TB18

Signal Inputs

11 Digital Outputs (Control/Alarm)
2 Digital Inputs, 1 Digital/Pulse Input

SCSI Cable

CLS200
Power supply

CLS200
Power supply

Figure 2.1 CLS200 System Components

8 Digital Inputs,
35 Digital Outputs
(Control/Alarm)
Pulse Input

Mounting Controller Components

Install the controller in a location free from excessive heat
(more than 50º C [122° F]), dust, and unauthorized han­dling. Electromagnetic and radio frequency interference
can induce noise on sensor wiring. Select locations for the
CLS200 and TB50 such that wiring can be routed clear of
sources of interference such as high voltage wires, power
switching devices and motors.

NOTE!

12 Watlow Anafaze Doc.# 0600-3050-2000

For indoor use only.

CLS200 Series User’s Guide Chapter 2: Installation

WARNING!

Recommended Tools

Mounting the Controller

To reduce the risk of fire or electric shock, in­stall the CLS200 in a controlled environment,
relatively free of contaminants.

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 heavy-

weight panel doors.

• Greenlee 1/8-DIN rectangular punch (Greenlee part

number 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

• 1/8 in. (3 mm) flathead screwdriver for wiring

• Multimeter

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.

Ensure there is enough clearance for mounting brackets,
terminal blocks, and cable and wire connections; the con­troller extends up to 7.0 inches (178 mm) behind the panel
face and the screw brackets extend 0.5 inch (13 mm) above
and below it. If using a straight SCSI cable, allow for an ad­ditional 1.6 inches (41 mm) beyond the terminal block. If
using a right-angle SCSI cable, allow an additional 0.6 inch
(15 mm). (See Figure 2.2 and Figure 2.3.)

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Chapter 2: Installation CLS200 Series User’s Guide

1.0 inch 7.0 inches 1.6 inch
(25 mm) (178 mm) (41 mm)

Figure 2.2 Clearance with Straight SCSI Cable

1.0 inch 7.0 inches 0.6 inch
(25 mm) (178 mm) (41 mm)

Figure 2.3 Clearance with Right-Angle SCSI

Cable

14 Watlow Anafaze Doc.# 0600-3050-2000