Watlow CLS200 Operating Manual

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CLS200 User’s Guide

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CLS200 Series User’s Guide

Safety Warnings, Cautions, and Notes

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 death or injury may occur, you must install approved safety shutdown devices that operate independently from the process control equipment.

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

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

WARNING! To reduce the risk of electrical shock, ﬁre, and equipment damage, follow all local and national electrical codes. Correct wire sizes, fuses and thermal breakers are essential for safe operation of this equipment.

WARNING! Use a power supply with a Class 2 rating only. UL® approval requires a Class 2 power supply.

WARNING! During autotuning, the controller will set the output to 100% until the process variable rises near the setpoint. Set the setpoint within the safe operating limits of your system.

WARNING! Do not rely solely on the output override feature to shut down your process. Install external safety devices or overtemperature devices for emergency shutdowns.

WARNING! Do not rely solely on the sensor fail alarm to adjust the output in the event of a sensor failure. If the loop is in manual control when a failed sensor alarm occurs, the output is not adjusted. Install independent external safety devices that will shut down the system if a failure occurs.

CAUTION! Never run input leads in bundles with high power wires or near other sources of EMI. This could inductively couple voltage onto the input leads and damage the controller or could induce noise and cause poor measurement and control.

Physically separate high-voltage circuits from low-voltage circuits and from CLS200 hardware. If possible, install high-voltage ac power circuits in a separate panel.

CAUTION! Without proper grounding, the CLS200 may not operate properly or may be damaged.

CAUTION! To prevent damage from incorrect connections, do not turn on the ac power before testing the connections.

CAUTION! The EPROM and other components are sensitive to damage from electrostatic discharge (ESD). To prevent ESD damage, use an ESD wrist strap or another antistatic device.

NOTE! For indoor use only.

Avertissements, Attentions et Remarques

AVERTISSEMENT! Le régulateur peut s’avérer défaillant avec

un régime de puissance de sortie à 0 % ou à 100 %. Pour éviter tout risque de décès, blessure personnelle, endommagements de l’équipement ou dégâts matériels, veuillez installer des équipements d’arrêt d’urgence externes. Si un décès ou un accident venait à se produire, vous devez installer des équipements d’arrêt d’urgence approuvés qui fonctionnent indépendamment du matériel de contrôle du processus.

AVERTISSEMENT! Risques de choc électrique. Coupez le courant de votre processus tout entier avant de commencer à installer le régulateur.

AVERTISSEMENT! Aﬁn de minimiser les risques d’incendie ou de choc électrique, installez le CLS200 dans un environnement sous contrôle et relativement épargné par les contaminants.

AVERTISSEMENT! Aﬁn de minimiser les risques de choc électrique, d’incendie, et de dégâts matériels, suivez tous les codes de l’électricité locaux et nationaux. Des diamètres de ﬁls, des fusibles et des disjoncteurs magnéto-thermiques adaptés sont indispensables pour un fonctionnement sécurisé de cet équipement.

AVERTISSEMENT! Utilisez uniquement une alimentation électrique avec une note de rang 2. Une approbation UL® impose une alimentation électrique de rang 2.

AVERTISSEMENT! Pendant le réglage automatique, le régulateur déﬁnira la sortie sur 100 % jusqu’à ce que la variable du processus s’élève près de la valeur seuil. Déﬁnissez la valeur seuil dans les limites de fonctionnement sécurisées de votre système.

AVERTISSEMENT! Ne comptez pas uniquement sur la fonction de priorité de sortie pour arrêter le processus. Installez les dispositifs de sécurité externes ou de protection contre l’excès de température pour les arrêts d’urgence.

AVERTISSEMENT! Ne comptez pas uniquement sur l’alarme d’échec du capteur pour ajuster la sortie dans l’éventualité d’une défaillance du capteur. Si la boucle est en contrôle manuel lorsqu’une alarme d’échec du capteur se déclenche, la sortie n’est pas ajustée. Installez des dispositifs externes indépendants qui éteindront le système si une défaillance se produit.

ATTENTION! Ne faites jamais fonctionner des conducteurs d’entrée en faisceau avec des câbles à haute puissance ou près d’autres sources d’EMI. Cela pourrait lier par couplage inductif la tension sur les conducteurs d’entrée et endommager le régulateur, ou créer un bruit et être à l’origine de mauvaises mesures et de régulations erronées.

Séparez physiquement les circuits haute-tension des circuits basse-tension et du matériel CLS200. Si possible, installez des circuits électriques ca haute-tension dans un panneau séparé.

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CLS200 Series User’s Guide

ATTENTION! Sans mise à la terre appropriée, il se peut que le CLS200 ne fonctionne pas correctement ou soit endommagé.

ATTENTION! Pour éviter tout dommage causé par des connexions incorrectes, n’allumez pas l’alimentation électrique en ca avant d’avoir testé les connexions.

ATTENTION! L’EPROM et les autres composants sont sensibles aux dégâts provoqués par les décharges électrostatiques (ESD). Pour éviter de tels dommages, utilisez un bracelet antistatique ou tout autre dispositif antistatique.

REMARQUE : Destiné à un usage intérieur uniquement.

Technical Assistance

If you encounter a problem with your Watlow® controller, review your conﬁguration information to verify that your selections are consistent with your application: inputs, outputs, alarms, limits, etc. If the problem persists, you can get technical assistance from your local Watlow representative (see back cover), by e-mailing your questions to wintechsupport@watlow.com or by dialing +1 (507) 494-5656 between 7 a.m. and 5 p.m. Central Time USA & Canada. Ask for for an Applications Engineer. Please have the complete model number available when calling.

Return Material Authorization (RMA)

1. Call Watlow Customer Service, (507) 454-5300, for a Return Material Authorization (RMA) number before returning any failed product to Watlow. If you do not know why the product failed, contact an Application Engineer. All RMA’s require:

• Ship-to address

• Bill-to address

• Contact name

• Phone number

• Method of return shipment

• Your P.O. number

• Detailed description of the problem

• Any special instructions

• Name and phone number of person returning the product

2. Prior approval and an RMA number from the customer service department is required when returning any product. Make sure the RMA number is on the outside of the carton and on all paperwork returned. Ship on a freight prepaid basis.

3. After we receive your return, we will examine it to verify the reason for the product failure. Unless otherwise agreed to in writing, Watlow’s standard warranty provisions, which can be located at www.watlow.com/terms, will apply to any failed product.

4. In the event that the product is not subject to an applicable warranty, we will quote repair costs to you and request a purchase order from you prior to proceeding with the repair work.

5. Watlow reserves the right to charge for no trouble found (NTF) returns.

Contact Watlow

1241 Bundy Boulevard Winona, Minnesota 55987 USA Phone: +1 (507) 454-5300 Fax: +1 (507) 452-4507

http://www.watlow.com

Warranty

This product is warranted by Watlow for a period of 36 months in accordance with the terms and conditions set forth on Watlow’s website, which may be accessed at www.watlow.com/terms.

Document

Document Number: 10-30466 Revision – August 2019

©2019 Watlow Electric Manufacturing Company, all rights reserved. Watlow® is a registered trademark of Watlow Electric and Manufacturing Company. Modbus® is a registered trademark of Schneider Automation Incorporated. UL® is a registered trademark of Underwriter’s Laboratories, Inc. Windows® is a registered trademark of Microsoft Corporation.

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Chapter 1: System Overview—12

Manual Contents 12 Getting Started 13

Safety Symbols 13 Initial Inspection 13

Product Features 13 CLS200 Parts List 15

CLS200 16 TB50 17 CLS200 Cabling 18 External Safety Devices 18 Power-Fail Protection 18

Chapter 2: Installation—19

Typical Installation 19 Mounting Controller Components 20

Recommended Tools 20 Mounting the Controller 21 Mounting the TB50 23 Mounting the Power Supply 25

System Wiring 25

Wiring Recommendations 26 Noise Suppression 26 Ground Loops 28

Power Connections 29

Wiring the Power Supply 29 Connecting TB50 to CLS200 31

Testing Your System 31

TB50 or TB18 Test 31 Digital Output Test 31 Digital Input Test 31

Sensor Wiring 32

Input Wiring Recommendations 33 Thermocouple Connections 33 RTD Input Connections 34 Reference Voltage Terminals 34 Voltage Input Connections 34 Current Input Connections 35 Pulse Input Connections 35

Wiring Control and Digital I/O 36

Output Wiring Recommendations 36 Cable Tie Wraps 37 Digital Outputs 37 Digital Inputs 40

TB18 Connections 41 TB50 Connections 42

Analog Outputs 44

Wiring the Dual DAC 44 Wiring the Serial DAC 44

Serial Communications 44

EIA/TIA-232 Interface 44 EIA/TIA-485 Interface 46 EIA/TIA-485 Converters and Laptop Computers 47

Chapter 3: Using CLS200—48

Front Panel 49

Front Panel Keys 49

Displays 51

Bar Graph Display 51 Single Loop Display 52 Alarm Displays 53 System Alarms 55

Job Display 55 Changing the Setpoint 56 Selecting the Control Status 56

Manual and Automatic Control 57 Autotuning a Loop 57

Using Alarms 59

Alarm Delay 59 Failed Sensor Alarms 59 Process Alarms 61 Global Alarm 63

Ramp/Soak 63

Chapter 4: Setup—64

How to Access the Setup Menus 64

How to Change a Parameter 64

Standard Menus 66 Setup Global Parameters Menu 67

Load Setup From Job 67 Save Setup to Job 68 Job Select Digital Inputs 68 Job Select Digital Inputs Active 69 Output Override Digital Input 70 Override Digital Input Active 70 Startup Alarm Delay 70 Keyboard Lock Status 71

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CLS200 Series User’s Guide

Power Up Output Status 71 Process Power Digital Input 71 Controller Address 72 Communications Baud Rate 72 Communications Protocol 72 Communications Error Checking 72 AC Line Frequency 73 Digital Output Polarity on Alarm 73 EPROM Information 73

Setup Loop Input Menu 74

Input Type 75 Loop Name 76 Input Units 76 Input Reading Offset 76 Reversed T/C Detection 77 Input Pulse Sample Time 77 Linear Scaling Parameters 77 Input Filter 80

Setup Loop Control Parameters Menu 81

Heat or Cool Control PB 82 Heat or Cool Control TI 82 Heat or Cool Control TD 82 Heat or Cool Output Filter 83 Spread 83 Restore PID Digital Input 83

Setup Loop Outputs Menu 84

Enable or Disable Heat or Cool Outputs 85 Heat or Cool Output Type 85 Heat or Cool Cycle Time 86 SDAC Mode 86 SDAC Low Value 86 SDAC High Value 86 Heat or Cool Output Action 87 Heat or Cool Output Limit 87 Heat or Cool Output Limit Time 87 Sensor Fail Heat or Cool Output 88 Heat or Cool Thermocouple Break Output Average 88 Heat or Cool Linearity 88

Setup Loop Alarms Menu 89

High Process Alarm Setpoint 90 High Process Alarm Type 90 High Process Alarm Output Number 90 Deviation Alarm Value 91 High Deviation Alarm Type 91 High Deviation Alarm Output Number 91 Low Deviation Alarm Type 91 Low Deviation Alarm Output Number 92 Low Process Alarm Setpoint 92 Low Process Alarm Type 92 Low Process Alarm Output Number 92 Alarm Deadband 92 Alarm Delay 93

Manual I/O Test 93

Digital Inputs 94 Test Digital Output 94

Digital Output Number 94 Keypad Test 95 Display Test 95

Chapter 5: Enhanced Features—96

Enhanced Features Menus 97 Process Variable Retransmit 98

Process Variable Retransmit Menu 98 Process Variable Retransmit Example: Data Logging 100

Cascade Control 102

Setup Loop Cascade Menu 103 Cascade Control Example: Water Tank 105

Ratio Control 108

Setup Loop Ratio Control Menu 108 Ratio Control Example: Diluting KOH 110

Remote Analog Setpoint 112

Remote Analog Setpoint Example: Setting a Setpoint with a PLC 112

Differential Control 113

Differential Control Example: Thermoforming 113

Chapter 6: Ramp/Soak—115

Features 116 Ramp/Soak Menus 117 Setup Global Parameters Menu 118

Ramp/Soak Time Base 118

Setup Ramp/Soak Proﬁle Menu 118

Edit Ramp/Soak Proﬁle 118 Copy Setup From Proﬁle 118 Tolerance Alarm Time 119 Ready Segment Setpoint 119 Ready Segment Edit Events 119 External Reset Input Number 120 Edit Segment Number 120 Segment Time 120 Segment Setpoint 121 Edit Segment Events 121 Edit Segment Triggers 122 Segment Tolerance 123 Last Segment 124 Repeat Cycles 124 Setpoints and Tolerances for Various Input Types 124

Using Ramp/Soak 125

Ramp/Soak Displays 125 Assigning a Proﬁle to a Loop 127 Running a Proﬁle 128 Holding a Proﬁle or Continuing from Hold 128 Responding to a Tolerance Alarm 129 Resetting a Proﬁle 130 In Case of a Power Failure 130

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CLS200 Series User’s Guide

Chapter 7: Turning and Control—131

Control Algorithms 131

On/Off Control 131 Proportional Control 132 Proportional and Integral Control 133 Proportional, Integral and Derivative Control 133 Heat and Cool Outputs 134

Control Outputs 134

Output Control Signals 134 Output Filter 135 Reverse and Direct Action 135

Setting Up and Tuning PID Loops 136

Proportional Band (PB) Settings 136 Integral Settings 136 Derivative Settings 137

General PID Constants by Application 138

Proportional Band Only (P) 138 Proportional with Integral (PI) 138 PI with Derivative (PID) 138

Chapter 8: Troubleshooting and Reconﬁguring—139

When There is a Problem 139 Troubleshooting Controllers 140

Process and Deviation Alarms 140 Failed Sensor Alarms 141 System Alarms 142 Other Behaviors 142

Corrective and Diagnostic Procedures 143

Low Power 143 Battery Dead 143 Ambient Warning 144 H/W Ambient Failure 144 H/W Gain or Offset Failure 145 Keys Do Not Respond 145 Checking Analog Inputs 145 Earth Grounding 146 Checking Control Outputs 147 Testing Control Output Devices 147 Testing the TB18 and TB50 147 Testing Control and Digital Outputs 147 Testing Digital Inputs 148

Additional Troubleshooting for Computer Supervised Systems 148

Computer Problems 148 Communications 149 Ground Loops 149 Software Problems 149

NO-Key Reset 150 Replacing the EPROM 150 Removing or Replacing the Battery 152 Changing Communications 153 Scaling Resistors 154

Four-Loop and Eight-Loop Input Circuit 154 Current Inputs to Four-Loop and Eight-Loop

Controllers 155 Voltage Inputs to Four-Loop and Eight-Loop Controllers 155 RTDs and Thermistor Inputs to Four-Loop and Eight-Loop Controllers 156 Sixteen-Loop Input Circuit 157 Current Inputs to Sixteen-Loop Controllers 157 Voltage Inputs to Sixteen-Loop Controllers 158 Scaling and Calibration 158

Chapter 9: Linear Scaling Examples—159

Example 1: A 4-to-20mA Sensor 159

Situation 159 Setup 159

Example 2: A 0-to-5VDC Sensor 160

Situation 160 Setup 160

Example 3: A Pulse Encoder 161

Situation 161 Setup 161

Chapter 10: Speciﬁcations—162

CLS200 System Speciﬁcations 162

CLS200 Processor Physical Speciﬁcations 162 TB50 Physical Speciﬁcations 164 Inputs 166 Outputs 168

Glossary—171

Index—180

Menu Structure—192

Declaration of Conformity—193

How to Reach Us—194

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List of Figures

Chapter 1: System Overview—12

Figure 1.1 — CLS200 Rear Views 16 Figure 1.2 — CLS200 Front Panel 17 Figure 1.3 — TB50 17

Chapter 2: Installation—19

Figure 2.1 — CLS200 System Components 20 Figure 2.2 —Clearance with TB18 Option 21 Figure 2.3 —Clearance with Standard SCSI Cable 21 Figure 2.3a — Clearance with Right-Angle SCSI Cable 22 Figure 2.4 —Mounting Bracket Clearance 22 Figure 2.5 —Panel Thickness and Cutout Size 22 Figure 2.6 — Mounting the TB50 23 Figure 2.7 — TB50 Mounted on a DIN Rail (Front) 24 Figure 2.8 — TB50 Mounted on DIN Rail (Side) 24 Figure 2.9 — Mounting a TB50 with Standoffs 25 Figure 2.10 — CLS200 Series Controller with TB18 29 Figure 2.11 — CLS200 Series Controller with TB50 29 Figure 2.12 — Power Connections 30 Figure 2.13 — Thermocouple Connections 33 Figure 2.14 — RTD Connections 34 Figure 2.15 — Linear Voltage Signal Connections 35 Figure 2.16 — Linear Current Signal Connections 35 Figure 2.17 — Encoder with 5VDC TTL Signa 36 Figure 2.18 — Encoder Input with Voltage Divider 36 Figure 2.19 — Digital Output Wiring 38 Figure 2.20 — S ample Heat, Cool and Alarm Output Connections 39 Figure 2.21 — Output Connections Using External Power Supply 39 Figure 2.22 — TB50 Watchdog Timer Output 39 Figure 2.23 — TB18 Watchdog Timer Output 40 Figure 2.24 — Wiring Digital Inputs 41 Figure 2.25 — Connecting One CLS200 to a Computer Using EIA/TIA-232 45 Figure 2.26 — EIA/TIA-485 Wiring 46 Figure 2.27 — Recommended System Connections 47

Chapter 3: Using CLS200—48

Figure 3.1 — Operator Displays 48 Figure 3.2 — CLS200 Front Panel 49 Figure 3.3 — Bar Graph Display 51 Figure 3.4 — Single Loop Display 52 Figure 3.5 — Single Loop Display, Heat and Cool Outputs Enabled 53 Figure 3.6 — Single Loop Display with a Process Alarm 53

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CLS200 Series User’s Guide

Figure 3.7 — Failed Sensor Alarm in the Single Loop Display 54 Figure 3.8 — Alarm Symbols in the Bar Graph Display 54 Figure 3.9 — Activation and Deactivation of Process Alarms 62

Chapter 4: Setup—64

Figure 4.1 — CLS200 Menu Tree 66 Figure 4.2 — Two Points Determine Process Variable Conversion 78 Figure 4.3 — Process Variable Limited by Input Reading Range 78 Figure 4.4 — Linear and Nonlinear Outputs 89 Figure 4.5 — Digital Inputs Screen 94

Chapter 5: Enhanced Features—96

Figure 5.1 — Enhanced Features Option Menus 97 Figure 5.2 — Linear Scaling of Process Variable for Retransmit 100 Figure 5.3 — Application Using Process Variable Retransmit 101 Figure 5.4 — Relationship Between the Primary Loop’s Output and the Secondary Loop’s Setpoint 103 Figure 5.5 — Application Using Cascade Control 105 Figure 5.6 — Secondary Loop Setpoint Related to Primary Loop Output 107 Figure 5.7 — Relationship Between the Master Loop’s Process Variable and the Ratio Loop’s Setpoint 108 Figure 5.8 — Application Using Ratio Control 110

Chapter 6: Ramp/Soak—115

Figure 6.1 — Sample Ramp/Soak Proﬁle 115 Figure 6.2 — Setup Ramp/Soak Proﬁles Menu 117 Figure 6.3 — Positive and Negative Tolerances 123 Figure 6.4 — Ramp/Soak Screens 125

Chapter 7: Turning and Control—131

Figure 7.1 — On/Off Control 132 Figure 7.2 — Proportional Control 132 Figure 7.3 — Proportional and Integral Control 133 Figure 7.4 — Proportional, Integral and Derivative Control 133 Figure 7.5 — Time Proportioning and Distributed Zero Crossing Waveforms 134

Chapter 8: Troubleshooting and Reconﬁguring—139

Figure 8.1 — Remove Board Assembly from Case 151 Figure 8.2 — Disconnect Keypad Ribbon Cable from Processor Board 151 Figure 8.3 — Unlatch Boards from Carrier 151 Figure 8.4 — Remove the Standoffs 151 Figure 8.5 — EPROM Location 152 Figure 8.6 — Remove EPROM 152 Figure 8.7 — Battery-Backed RAM Module on the Processor Board 153 Figure 8.8 — Jumper Conﬁgurations 153 Figure 8.9 — Differential Input Circuit in Four-Loop and Eight-Loop Controllers 154 Figure 8.10 — Single-Ended Input Circuit in Sixteen-Loop Controllers 157

Chapter 10: Speciﬁcations—162

Figure 10.1 — CLS200 Processor Module Dimensions 163 Figure 10.2 — CLS200 Clearances with Straight SCSI Cable 163 Figure 10.3 — CLS200 Clearances with Right-Angle SCSI Cable 164 Figure 10.4 — TB50 Dimensions 165 Figure 10.5 — TB50 Dimensions with Standard SCSI Cable 165 Figure 10.6 — TB50 Dimensions with Right-Angle SCSI Cable 166

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List of Tables

Chapter 1: System Overview—12

Table 1.1 — Ordering Options 15

Chapter 2: Installation—19

Table 2.1 — Cable Recommendations 26 Table 2.2 — Power Connections 29 Table 2.3 — Analog Input Connections on TB1 for Four-Loop and Eight-Loop Models 32 Table 2.4 — Analog Input Connections on TB1 for Sixteen-Loop Models 32 Table 2.5 — Digital Output States and Values Stored in the Controller 37 Table 2.6 — Digital Inputs States and Values Stored in the Controller 40 Table 2.7 — TB18 Connections 41 Table 2.8 — TB50 Connections for Four-Loop and Eight-Loop Controllers 42 Table 2.9 — TB50 Connections for Sixteen-Loop Controllers 43 Table 2.10 — EIA/TIA-232 Connections 45 Table 2.11 — RTS/CTS Pins in DB-9 and DB-25 Connectors 45

Chapter 3: Using CLS200—48

Table 3.1 — Bar Graph Display Symbols 51 Table 3.2 — Control Status Symbols on the Bar Graph and Single Loop Displays 52 Table 3.3 — Alarm Type and Symbols 54

Chapter 4: Setup—64

Table 4.1 — Global Parameters 67 Table 4.2 — Job Select Inputs 69 Table 4.3 — Job Selected for Various Input States 69 Table 4.4 — Firmware Option Codes 74 Table 4.5 — Setup Loop Input 74 Table 4.6 — CLS200 Input Types and Ranges 75 Table 4.7 — Input Character Sets 76 Table 4.8 — Input Reading Offset 77 Table 4.9 — Display Formats 79 Table 4.10 — Setup Loop Control Parameters 81 Table 4.11 — Setup Loop Outputs 84 Table 4.12 — Heat / Cool Output Types 85 Table 4.13 — Setup Loop Alarms 90 Table 4.14 — Manual I/O Test 93

Chapter 5: Enhanced Features—96

Table 5.1 — Application Example: Setting Up Process Variable Retransmit 101 Table 5.2 — Application Example: Setting Up Cascade Control 106 Table 5.3 — Application Example: Setting Up Ratio Control 111

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CLS200 Series User’s Guide

Table 5.4 — Application Example: Setting Up Remote Setpoint 112 Table 5.5 — Application Example: Setting Up Differential Control 114

Chapter 6: Ramp/Soak—115

Table 6.1 — Ramp/Soak Speciﬁcations 116 Table 6.2 — Trigger Latch Logic 123 Table 6.3 — Display Formats 124 Table 6.4 — Ramp/Soak Single Loop Display 125 Table 6.5 — Ramp/Soak Control Status Symbols 126 Table 6.6 — Ramp/Soak Proﬁle Modes 129

Chapter 7: Turning and Control—131

Table 7.1 — Proportional Band Settings 136 Table 7.2 — Integral Term and Reset Settings 137 Table 7.3 — Derivative Term Versus Rate 137 Table 7.4 — General PID Constants 138

Chapter 8: Troubleshooting and Reconﬁguring—139

Table 8.1 — Controller Alarm Codes for Process and Deviation Alarms 140 Table 8.2 — Operator Response to Alarms 141 Table 8.3 — Failed Sensor Alarm Codes 141 Table 8.4 — Hardware Error Messages 142 Table 8.5 — Other Symptoms 142 Table 8.6 — Resistor Values for Current Inputs to Four-Loop and Eight-Loop Controllers 155 Table 8.7 — Resistor Locations for Current Inputs to Four-Loop and Eight-Loop Controllers 155 Table 8.8 — Resistor Values for Voltage Inputs to Four-Loop and Eight-Loop Controllers 155 Table 8.9 — Resistor Locations for Voltage Inputs to Four-Loop and Eight-Loop Controllers 156 Table 8.10 — Resistor Values for RTD and Thermistor Inputs to Four-Loop and Eight-Loop Controllers 156 Table 8.11 — Resistor Locations for RTD and Thermistor Inputs to Four-Loop and Eight-Loop Controllers 156 Table 8.12 — Resistor Values for Current Inputs to Sixteen-Loop Controllers 157 Table 8.13 — Resistor Locations for Current Inputs to Sixteen-Loop Controllers 157 Table 8.14 — Resistor Values for Voltage Inputs to Sixteen-Loop Controllers 158 Table 8.15 — Resistor Locations for Voltage Inputs to Sixteen-Loop Controllers 158

Chapter 9: Linear Scaling Examples—159

Table 9.1 — Input Readings 159 Table 9.2 — Scaling Values 159 Table 9.3 — Input Readings and Calculations 160 Table 9.4 — Scaling Values 160 Table 9.5 — Scaling Values 161

Chapter 10: Speciﬁcations—162

Table 10.1 — Agency Approvals / Compliance 162 Table 10.2 — Environmental Speciﬁcations 162 Table 10.3 — Physical Dimensions 162 Table 10.4 — Processor with Standard SCSI Cable 163 Table 10.5 — Processor with Right Angle SCSI Cable 163 Table 10.6 — Processor Connections 164 Table 10.7 — TB50 Physical Dimensions 164 Table 10.8 — TB50 Connections 165 Table 10.9 — TB50 with Straight SCSI Cable 165 Table 10.10 — TB50 with Right Angle SCSI Cable 166 Table 10.11 — Analog Inputs 166

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CLS200 Series User’s Guide

Table 10.12 — Pulse Inputs 167 Table 10.13 — Thermocouple Range and Resolution 167 Table 10.14 — RTD Range and Resolution 168 Table 10.15 — Input Resistance for Voltage Inputs 168 Table 10.16 — Digital Inputs 168 Table 10.17 — Digital Outputs Control / Alarm 169 Table 10.18 — CPU Watchdog Output 169 Table 10.19 — 5VDC Output (Power to Operate Solid-State Relays) 169 Table 10.20 — Reference Voltage Output (Power to Operate Bridge Circuit Sensors) 170 Table 10.21 —Serial Communication 170 Table 10.22 — Power Requirements 170

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Chapter 1: System Overview

Manual Contents

This manual describes how to install, set up, and operate CLS200 controllers. 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 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: Enhanced Features describes process variable retransmit, ratio, differential and cascade control features available with the enhanced features option.

• Chapter 6: Ramp/Soak explains how to set up and use the features of the ramp/soak option.

• Chapter 7: Turning and Control describes available control algorithms and provides suggestions for applications.

• Chapter 8: Troubleshooting and Reconﬁguring includes troubleshooting, upgrading and reconﬁguring procedures for technical personnel.

• Chapter 9: Linear Scaling Examples provides an example conﬁguring a pressure sensor, a ﬂow sensor, and an encoder using linear scaling.

• Chapter 10: Speciﬁcations lists detailed speciﬁcations of the controller and optional components.

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CLS200 Series User’s Guide

Chapter 1: System Overview

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:

NOTE! Marks a short message to alert you to an important detail.

CAUTION! Information that is important for protecting your equipment and

performance. Be especially careful to read and follow all cautions that apply to your application.

WARNING! Safety alert appears with information that is important for protecting you, others and equipment from damage. Pay very close attention to all warnings that apply to your application.

Initial Inspection

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.

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 16-character 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): Use 3-wire, 100Ω, platinum,

0.00385-curve sensors with two choices for range and precision of measurements. (To use this input, order a four-loop or eight-loop controller with scaling resistors.)

• Automatic Scaling for Linear Analog Inputs: The 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: The CLS200 series includes both heat and cool control outputs for each loop. Independent control parameters are provided for each output.

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CLS200 Series User’s Guide

Chapter 1: System Overview

• Independently Selectable Control and Output Modes: You can set each control output to on/off, time 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: Set high/low deviation and high/ 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.

• 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® offers SpecView, a Windows® compatible Human Machine Interface (HMI) software package that includes data logging and graphing features in addition to process monitoring.

• 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 non-linear output curves for each control output.

• Autotuning: Use the autotune feature to set up your system quickly and easily.

• 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 Table 1.1 – Ordering Options for conﬁguration information.

• CLS200 series controller

• Controller mounting kit

• TB50 with 50-pin SCSI cable

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

• Special input resistors (installed in CLS200)

Table 1.1 — Ordering Options

CHARACTERISTIC OPTIONS DESCRIPTION

4 Loops

Number of Loops

Firmware

Digital I/O Termination

Digital I/O Termination Board Accessory

Digital I/O Termination Cable Accessory

Serial Communication Jumper Settings

Serial Communication Cable

Mounting Hardware

Customer Speciﬁc None Not applicable to standard product

8 Loops

16 Loops

Standard

Ramp and Soak

Enhanced Features

Screw Terminals (TB18) TB18 Terminal Block

Mass Termination (SCSI) SCSI Connector

None No external terminal board included

TB50 Terminal Board TB50-SCSI (50 Pin terminal board)

None

3-foot SCSI cable

6-foot SCSI cable

3-foot SCSI cable with right angle connector

EIA/TIA-232

EIA/TIA-485, not terminated

EIA/TIA-485, terminated

None No communication cable

10 foot communication cable (DB-9 female/bare wires)

Plastic collar and screw clips Standard mounting hardware

Low proﬁle metal L-brackets and screws

The number of analog inputs and control loops that can be controlled based on the feedback from the analog inputs. There is an additional control loop that uses feedback from the pulse input.

Includes closed-loop, PID control, autotune, alarms, job memory and failed sensor detection

Provides the features of the standard version plus the additional Ramp and Soak features

Provides the features of the standard version plus the additional Enhanced Features

Accessory cable to connect digital I/O signals between the SCSI connector on the controller and the TB50 board

Application uses 232 communication or no communication

Application uses 485 communication, this controller is not last in the network

Application uses 485 communication, this controller is last in the network

Cable for 232 communication

Mounting hardware for legacy applications with tight ﬁt

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Chapter 1: System Overview

CHARACTERISTIC OPTIONS DESCRIPTION

Analog Input 1 Options for all units:

Analog Input 2

Analog Input 3

Analog Input 4

Analog Input 5

Analog Input 6

Analog Input 7

Analog Input 8

Analog Input 9

Analog Input 10

Analog Input 11

Analog Input 12

Analog Input 13

Analog Input 14

Analog Input 15

Analog Input 16

• Standard (Thermocouples and

-10 to 60mV)

• Linear Current: 0-20mA DC / 4-20mA DC

• Linear Voltage: 0-5VDC

• Linear Voltage: 0-10VDC

Additional options for 4-loop and 8-loop units:

• 100 Ohm RTD Tenths Degree

• 100 Ohm RTD Whole Degree

Standard units accept thermocouples on all inputs. Controllers can be equipped with resistors to scale signals for various types of sensors. These resistors must be factory installed.

Sixteen loop controllers cannot accept RTD sensors.

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.

SCSI Digital I/O Option TB18 Digital I/O Option

Figure 1.1 — 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 24VDC at 1 Amp.

• A 50-pin SCSI cable connects the digital inputs and outputs to the 50-terminal block (TB50). Four-loop and eight-loop models are available with an 18-terminal block (TB18) in place of the SCSI connector, as shown in Figure 1.2.

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The ﬁrmware resides in an EPROM. See Replacing the EPROM on page 150 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.

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.

1.98 in.

(50 mm)

3.80 in. (96 mm)

Figure 1.2 — CLS200 Front Panel

TB50

The TB50 is an optional 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 wires as large as 18 AWG (0.75 mm2). A 50-pin SCSI cable connects the TB50 to the CLS200.

Figure 1.3 — TB50

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CLS200 Cabling

Watlow offers optional cables to support installing 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 connector for the computer and bare wires for connecting to the CLS200.

Safety

Watlow 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 59.

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 agency approved high/low process limit controller that operates a shutdown device such as a 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 death or injury may occur, you must install 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.

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 Process Power Digital Input on page 71.)

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 if you have any questions about system safety or system operation.

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

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 failure may cause death or injury, you must install approved safety shutdown devices that operate independently from the process control equipment.

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. (See Figures 2.2 to 2.11.)

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.

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CLS200 with SCSI Digital I/O

Sensor Inputs

SCSI Connector

CLS200 with TB18 Digital I/O

Sensor Inputs

TB18 allows connection to... 11 Outputs for Control & Alarms 2 Digital Inputs 1 Pulse Input

Figure 2.1 — CLS200 System Components

TB50 Accessory Board

SCSI Cable

TB50 allows connection to... 35 Outputs for Control & Alarms 8 Digital Inputs 1 Pulse Input

Mounting Controller Components

Install the controller in a location free from excessive heat (below 50ºC [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! For indoor use only.

WARNING! To reduce the risk of ﬁre or electric shock, install the CLS200 in a controlled

environment, relatively free of contaminants.

Recommended Tools

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.

• 1/8-DIN rectangular punch for most panel materials and thicknesses.

• Nibbler and metal ﬁle, for aluminum and lightweight panel doors.

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2.44 in.

Chapter 2: Installation

You will also need these tools:

• Phillips head screwdriver

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

• Multimeter

Mounting the Controller

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.

(62 mm)

1.98 in. (50 mm)

1.00 in. (25 mm)

Figure 2.2 —Clearance with TB18 Option

1.98 in. (50 mm)

1.00 in.

(25 mm)

Figure 2.3 —Clearance with Standard SCSI Cable

8.00 in.

(203 mm)

2.44 in. (62 mm)

10.00 in. (254 mm)

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2.44 in.

(62 mm)

1.98 in. (50 mm)

1.00 in. (25 mm)

Figure 2.3a — Clearance with Right-Angle SCSI Cable

9.00 in.

(229 mm)

4.02 in.

(102 mm)

Figure 2.4 —Mounting Bracket Clearance

1.80 ± 0.020 in. (45.7 ± 0.5 mm)

Figure 2.5 —Panel Thickness and Cutout Size

3.63 ± 0.020 in. (92.2 ± 0.5 mm)

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We recommend you mount the controller in a panel not more than 0.2 in. (5 mm) thick.

1. Choose a panel location free from excessive heat (below 50°C [122°F]), dust, and unauthorized handling. (Make sure there is adequate clearance for the mounting hardware, terminal blocks, and cables. The controller extends 7.00 in. (178 mm) behind the panel. Allow adequate room for wiring and cables beyond the connectors.)

2. Temporarily cover slots in the metal housing so that dirt, metal ﬁlings, and pieces of wire do not enter the housing and lodge in the electronics.

3. Cut a hole in the panel 1.80 in. (46 mm) by 3.63 in. (92 mm) as shown above. (Use caution; the dimensions given here have 0.02 in. (0.5 mm) tolerances.

4. Remove the brackets and collar from the controller, if they are already in place.

5. Slide the controller into the panel cutout.

6. Slide the mounting collar over the back of the controller, making sure the mounting screw indentations face toward the back of the controller.

7. Loosen the mounting bracket screws enough to allow for the mounting collar and panel thickness. Place each mounting bracket into the mounting slots (head of the screw facing the back of the controller). Push each bracket backward then to the side to secure it to the controller’s case.

8. Make sure the controller is seated properly. Tighten the installation screws ﬁrmly against the collar to secure the unit. Ensure that the end of the mounting screws ﬁt into the indentations on the mounting collar.

Mounting the TB50

There are two ways you can mount the TB50: use the pre-installed DIN rail mounting brackets or use the plastic standoffs. Follow the corresponding procedure to mount the board.

DIN Rail Mount

Standoffs

Figure 2.6 — Mounting the TB50

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DIN Rail Mounting

Snap the TB50 on to the DIN rail by placing the hook side on the rail ﬁrst, then pushing the snap latch side in place. (See Figure 2.7.)

Figure 2.7 — TB50 Mounted on a DIN Rail (Front)

To remove the TB50 from the rail, use a ﬂathead screwdriver to unsnap the bracket from the rail. (See Figure 2.8.)

Figure 2.8 — TB50 Mounted on DIN Rail (Side)

Mounting with Standoffs

1. Remove the DIN rail mounting brackets from the TB50.

2. Select a location with enough clearance to remove the TB50, its SCSI cable and the controller itself.

3. Mark the four mounting holes.

4. Drill and tap four mounting holes for #6 (3.5 mm) screws or bolts.

5. Mount the TB50 with four screws.

There are four smaller holes on the terminal board. Use these holes to secure wiring to the terminal block with tie wraps.

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0.2 in. (5 mm)

3.6 in.

(91 mm)

3.6 in.

(91 mm)

0.7 in.

(18 mm)

Figure 2.9 — Mounting a TB50 with Standoffs

2.6 in.

(66 mm)

0.2 in. (5 mm)

Mounting the Power Supply

Refer to the power supply manufacturer’s instructions for mounting information. Choose a Class 2 power supply that supplies an isolated regulated 12 to 24VDC at 1A.

Mounting Environment

Leave enough clearance around the power supply so that it can be removed.

System Wiring

Successful installation and operation of the control system can depend on placement of the components and on selection of the proper cables, sensors, and peripheral components.

Routing and shielding of sensor wires and proper grounding of components can insure a robust control system. This section includes wiring recommendations, instructions for proper grounding and noise suppression, and considerations for avoiding ground loops.

CAUTION! Do not wire bundles of low-voltage signal and control circuits next to bundles of high voltage ac wiring. High voltage may be inductively coupled onto the low-voltage circuits, which may damage the controller or induce noise and cause poor control.

Physically separate high-voltage circuits from low-voltage circuits and from CLS200 hardware. If possible, install high-voltage ac power circuits in a separate panel.

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Wiring Recommendations

Follow these guidelines for selecting wires and cables:

• Use stranded wire. (Solid wire can be used for ﬁxed service; it makes intermittent connections when you move it for maintenance.)

• Use 20 AWG (0.5 mm2) thermocouple extension wire. Larger or smaller sizes may be difﬁcult to install, may break easily, or may cause intermittent connections.

• Use shielded wire. The electrical shield protects the signals and the CLS200 from electrical noise. Connect one end of the input and output wiring shield to earth ground.

• Use copper wire for all connections other than thermocouple sensor inputs.

Table 2.1 — Cable Recommendations

FUNCTION MFR. P/N NO. OF WIRES AWG MM

Analog Inputs

RTD Inputs

Thermocouple Inputs

Control Outputs and Digital I/O

Analog Outputs

Computer Communication: EIA/TIA-232, 422 or 485, or 20mA

Belden 9154

Belden 8451

Belden 8772

Belden 9770

T/C Ext. Wire 2 20 0.5

Belden 9539

Belden 9542

Ribbon Cable

Belden 9154

Belden 8451

Belden 9729

Belden 9730

Belden 9842

Belden 9843

Belden 9184

22 to 14

0.5

0.2

0.5 to 2.5

0.5

0.2

0.5

MAXIMUM LENGTH

4,000 ft. (1,219 m)

6,000 ft. (1,829 m)

Noise Suppression

The CLS200’s outputs are typically used to drive solid state relays. These relays may in turn operate more inductive types of loads such as electromechanical relays, alarm horns and motor starters. Such devices may generate electromagnetic interference (EMI or noise). If the controller is placed close to sources of EMI, it may not function correctly. Below are some tips on how to recognize and avoid problems with EMI.

For earth ground wire, use a large gauge and keep the length as short as possible. Additional shielding may be achieved by connecting a chassis ground strap from the panel to CLS200 case.

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Symptoms of RFI/EMI

If your controller displays the following symptoms, suspect EMI:

• The controller’s display blanks out and then reenergizes as if power had been turned off for a moment.

• The process variable does not display correctly.

Noise may also damage the digital output circuit—so digital outputs will not turn on. If the digital output circuit is damaged, return the controller to Watlow for repair.

Avoiding RFI/EMI

To avoid or eliminate most RFI/EMI noise problems:

• Connect the CLS200 case to earth ground. The CLS200 system includes noise suppression circuitry. This circuitry requires proper grounding.

• Separate the 120 or 240VAC power leads from the low-level input and output leads connected to the CLS200 series controller. Do not run the digital I/O or control output leads in bundles with ac wires.

• Where possible, use solid-state relays (SSRs) instead of electromechanical relays. If you must use electromechanical relays, try to avoid mounting them in the same panel as the CLS200 series equipment.

• If you must use electromechanical relays and you must place them in a panel with CLS200 series equipment, use a 0.01 microfarad capacitor rated at 1000VAC (or higher) in series with a 47Ω, 0.5 watt resistor across the normally-open contacts of the relay load. This is known as a snubber network and can reduce the amount of electrical noise.

• You can use other voltage suppression devices, but they are not usually required. For instance, you can place a metal oxide varistor (MOV) rated at 130VAC for 120VAC control circuits across the load, which limits the peak ac voltage to about 180VAC. You can also place a transorb (back-to-back zener diodes) across the digital output, which limits the digital output voltage.

Additional Recommendations for a Noise Immune System

It is strongly recommended that you:

• Isolate outputs through solid-state relays, where possible.

• Isolate RTDs or “bridge” type inputs from ground.

• Isolate digital inputs from ground through solid state relays. If this is not possible, then make sure the digital input is the only connection to earth ground other than the chassis ground.

• If you are using EIA/TIA-232 from a non-isolated host, either (1) do not connect any other power common point to earth ground, or (2) use an optical isolator in the communications line.

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Ground Loops

Ground loops occur when current passes from the process through the controller to ground. This can cause instrument errors or malfunctions.

A ground loop may follow one of these paths, among others:

• From one sensor to another.

• From a sensor to the communications port.

• From a sensor to the dc power supply.

The best way to avoid ground loops is to minimize unnecessary connections to ground. Do not connect any of the following terminals to each other or to earth ground:

• Power supply dc common

• TB1, terminals 5, 6, 11, 12 (analog common)

• TB1, terminal 17 (reference voltage common)

• TB1, terminals 23, 24 (communications common)

• TB2, terminal 2 (dc power common)

Special Precautions for the Sixteen-Loop Models

Sixteen-loop models have single-ended inputs. All the negative sensor leads are tied to the analog common. That means there is no sensor-to-sensor isolation. Proper grounding is critical for this unit. Take these additional precautions with a sixteen-loop controller:

• Use all ungrounded or all well-grounded thermocouples, not a mix.

• If using a mixture of thermocouples or low-voltage inputs (<500mV) and current inputs, connect the negative leads of the current transmitters to terminal 17 (Ref Com) on TB1.

• If using voltage transmitters, use only sourcing models or conﬁguration. Sinking conﬁgurations will not work.

• Isolate the controller’s communication port (if used) by using an optically isolated 232-to-485 converter.

Personal Computers and Ground Loops

Many PC communications ports connect the communications common to chassis ground. When such a PC is connected to the controller, this can provide a path to ground for current from the process that can enter the controller through a sensor (such as a thermocouple). This creates a ground loop that can affect communications and other controller functions. To eliminate a ground loop, either use an optically isolated communications adapter or take measures to ensure that sensors and all other connections to the controller are isolated and not conducting current into the unit.

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Power Connections

This section covers making the power connections to the CLS200 and connecting the TB50.

TB1

Sensor Inputs

TB2

Power Input

Figure 2.10 — CLS200 Series Controller with TB18

TB2

Power Input

Serial Communication

TB18

Digital Inputs Digital Outputs Pulse Input

TB1

Sensor Inputs Serial Communication

SCSI to TB50

Digital Inputs Digital Outputs Pulse Input

Figure 2.11 — CLS200 Series Controller with TB50

Wiring the Power Supply

WARNING! Use a power supply with a Class 2 rating only. UL® approval requires a Class 2 power supply.

Connect power to the controller before any other connections, This allows you to ensure that the controller is working before any time is taken installing inputs and outputs.

Table 2.2 — Power Connections

FUNCTION POWER SUPPLY CLS200 TB2

DC Power (Controller) +12 to 24VDC +

DC Common 12 to 24VDC Common –

Earth Ground Ground

1. Connect the dc common terminal on the power supply to the dc common (-) terminal on CLS200 TB2.

2. Connect the positive terminal on the power supply to the dc positive (+) terminal on CLS200 TB2.

3. If using an isolated dc output or another power supply to power the loads, connect the dc common of the supply powering the loads to the dc common of the supply powering the controller.

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4. Use the ground connector on TB2 for chassis ground. This terminal is connected to the CLS200 chassis and must be connected to earth ground.

5. Connect 120/240VAC power to the power supply.

NOTE! Connect the dc common of the power supply used for loads to the dc common of the supply powering the controller. If the supplies are not referenced to one another, the controller’s outputs will not be able to switch the loads.

NOTE! When making screw terminal connections, tighten to 4.5 to 5.4 inch-pound (0.5 to 0.6 Nm).

CAUTION! Without proper grounding, the CLS200 may not operate properly or may be damaged.

CAUTION! To prevent damage from incorrect connections, do not turn on the ac power before testing the connections as explained in Testing Your System on page 31.

NOTE! Do not connect the controller’s dc common (COM) to earth ground. Doing so will defeat the noise protection circuitry, making measurements less stable.

Power Supply

+V1 (5V)

0 (5V COM)

+V2 (+15V)

COM (15V COM)

-V2 (-15V)

(Ground)

ACL (AC Line)

ACN (AC Neutral)

white

120/240 VAC Supply

black

green

* If using 5VDC for outputs, jumper 5V common to 15V common.

** Connect terminals to ac panel ground.

Add jumper *

1 2 3 4 +

O M

SSR

Serial DAC

OMV

CLS200

SSR

Figure 2.12 — Power Connections

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Connecting TB50 to CLS200

1. Connect the SCSI cable to the controller.

2. Connect the SCSI cable to the TB50.

Testing Your System

This section explains how to test the controller after installation and prior to making ﬁeld wiring connections.

TB50 or TB18 Test

Use this procedure to verify that the TB50 or TB18 is properly connected and supplied with power:

1. Turn on power to the CLS200. The display should read CALCULATING CHECKSUM then show the bar graph display. (See Figure 3.3.) If you do not see these displays, disconnect power and check wiring and power supply output.

2. Measure the +5VDC supply at the TB50 or TB18:

a. Connect the voltmeter’s common lead to TB50 or TB18 terminal 3 or TB18 terminal 2.

b. Connect the voltmeter’s positive lead to TB50 or TB18 screw terminal 1. The voltage

should be +4.75 to +5.25VDC.

Digital Output Test

Use this procedure to test the controller’s outputs before loads are connected. If using it at another time for troubleshooting, disconnect loads from outputs before testing.

1. Connect a 500Ω to 100kΩ resistor between TB50 or TB18 screw terminal 1 and a digital output terminal. (See Table 2.7 TB18 Connections; Table 2.8 TB50 Connections for CLS204 and CLS208; or Table 2.9 TB50 Connections for CLS216.)

2. Connect the voltmeter’s positive lead to screw terminal 1.

3. Connect the common lead to the digital output terminal.

4. Use the digital output test in the MANUAL I/O TEST menu to turn the digital output on and off. (See Test Digital Output on page 94 and Digital Output Number on page 94.) When the output is ON, the output voltage should be less than 1V. When the output is OFF, the output voltage should be between 4.75 and 5.25V.

NOTE! By default, heat outputs are enabled. Only disabled outputs may be turned on using the manual I/O test. To test heat outputs, set the corresponding loop to manual mode 100% output. See Selecting the Control Status on page 56.

Digital Input Test

Use the following procedure to test digital inputs before connecting to ﬁeld devices:

1. Disconnect any system wiring from the input to be tested.

2. Go to the DIGITAL INPUTS test in the MANUAL I/O TEST menu. (See Digital Inputs on page 94.) This test shows whether the digital inputs are H (high, or open) or L (low, or closed).

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3. Attach a wire to the terminal of the digital input you want to test. See Table 2.7 to Table 2.9 for connections.

a. When the wire is connected only to the digital input terminal, the digital input test should

show that the input is H (high, or open).

b. When you connect the other end of the wire to the controller common (TB50 terminal 3 or

TB18 terminal 2), the digital input test should show that the input is L (low, or closed).

Sensor Wiring

This section describes how to properly connect thermocouples, RTDs, current and voltage inputs to your controller. The controller can accept any mix of available input types. Some input types require that special scaling resistors be installed (done by Watlow before the controller is delivered).

All inputs are connected to the terminals on TB1 on the back of the controller. The tables below list the connector locations.

CAUTION! Never run input leads in bundles with high power wires or near other sources of EMI. This could inductively couple voltage onto the input leads and damage the controller, or could induce noise and cause poor measurement and control.

Table 2.3 — Analog Input Connections on TB1 for Four-Loop and Eight-Loop Models

INPUT + TERMINAL – TERMINAL

Input 1 1 2

Input 2 3 4

Input 3 7 8

Input 4 9 10

Input 5 13 14

Input 6 15 16

Input 7 19 20

Input 8 21 22

Table 2.4 — Analog Input Connections on TB1 for Sixteen-Loop Models

INPUT + TERMINAL COMMON REFERENCE COMMON*

Input 1 1 5 17

Input 2 3 5 17

Input 3 7 5 17

Input 4 9 5 17

Input 5 13 11 17

Input 6 15 11 17

Input 7 19 11 17

Input 8 21 11 17

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INPUT + TERMINAL COMMON REFERENCE COMMON*

Input 9 2 6 17

Input 10 4 6 17

Input 11 8 6 17

Input 12 10 6 17

Input 13 14 12 17

Input 14 16 12 17

Input 15 20 12 17

Input 16 22 12 17

For sixteen-loop controllers when mixing current inputs and low-voltage inputs (thermocouples or voltage inputs less than 1V), connect the current signal to the positive input and reference common (terminal TB1-17). If no low-voltage sensors are used, connect current inputs to the positive input and common terminals listed in the table above.

Input Wiring Recommendations

Use multicolored stranded shielded cable for analog inputs. Watlow recommends that you use 20 AWG wire (0.5 mm2). If the sensor manufacturer requires it, you can also use 24 or 22 AWG wiring (0.2 mm2). Most inputs use a shielded twisted pair; some require a 3-wire input.

Follow the instructions pertaining to the type(s) of input(s) you are installing.

The controller accepts the following inputs without any special scaling resistors:

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

• Linear inputs with ranges between -10 and 60mV.

Any unused inputs should be set to SKIP or jumpered to avoid thermocouple break alarms.

Thermocouple Connections

Connect the positive lead of any of the supported thermocouple types to the IN+ terminal for one of the loops and the negative lead to the corresponding IN- terminal.

Use 18 or 20 AWG (0.5 or 0.75 mm2) for all the thermocouple inputs. Most thermocouple wire is solid, unshielded wire. When using shielded wire, ground one end only.

CH IN+

*CH IN-

White

Red

Shield (if present)

Type J thermocouple

Earth Ground at Process End

*For sixteen-channel models connect negative to Com on TB1

Figure 2.13 — Thermocouple Connections

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Com

Chapter 2: Installation

NOTE! When mixing current inputs with low-voltage inputs (thermocouples or voltage inputs less than 1V) to a sixteen-loop controller, connect the current inputs to the IN+ and Ref Com terminals. If no low-voltage sensors are used, connect current inputs to the IN+ and Com terminals on TB1. For all inputs to a four or eight-loop controller, connect the sensors to the IN+ and IN- terminals.

CAUTION! Ground loops and common mode noise can damage the controller or disrupt measurements. To minimize ground loops and common mode noise:

• With a sixteen-loop controller, use only ungrounded thermocouples with each thermocouple sheath electrically connected to earth ground. The negative sensor terminals on sixteen-loop controllers are tied to analog common.

• With a four-loop or eight-loop controller, do not mix grounded and ungrounded thermocouples. If any thermocouple connected to the controller is of grounded construction, all thermocouples should be of grounded construction and each should be connected to ground at the process end.

• Connect the earth ground terminal on TB2 to a good earth ground, but do not connect the analog common to earth ground. The CLS200 uses a ﬂoating analog common for sensor measurements. The noise protection circuits on the sensor inputs function correctly only when the controller is correctly installed. See Ground Loops on page 28.

RTD Input Connections

This input type requires scaling resistors. Watlow recommends that you use a 100 W, 3-wire platinum RTD to prevent reading errors due to cable resistance. If you use a 2-wire RTD, jumper the negative input to common. If you must use a 4-wire RTD, leave the fourth wire unconnected.

CH IN +

100Ω RTD

CH IN –

Figure 2.14 — RTD Connections

Reference Voltage Terminals

The +5V Ref and Ref Com terminals are provided in order to power external bridge circuits for special sensors. Do not connect any other types of devices to these terminals.

Voltage Input Connections

This input type requires scaling resistors. Special input resistors installed at Watlow divide analog input voltages such that the controller sees a -10 to 60mV signal on the loop.

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CLS200 Series User’s Guide

Four-Loop or Eight-Loop Controller

Chapter 2: Installation

CH IN+

CH IN-

Sixteen-Loop Controller

CH IN+

Com

Figure 2.15 — Linear Voltage Signal Connections

Device with Voltage Output

Current Input Connections

This input type requires scaling resistors. Special input resistors installed at Watlow for analog current signals are such that the controller sees a -10 to 60mV signal across its inputs for the loop.

Four-Loop or Eight-Loop Controller

CH IN+

CH IN-

Sixteen-Loop Controller

Device with Current Output

CH IN+

Com/Ref Com

Figure 2.16 — Linear Current Signal Connections

Device with Current Output

Pulse Input Connections

The CLS200 can accept a pulse input of up to 2000Hz from a device such as an encoder. The frequency of this input is scaled with user-set parameters. See Setup Loop Input Menu on page 74 and Example 3: A Pulse Encoder on page 161. This scaled value is the process variable for loop 5 on a four-loop model, loop 9 on an eight-loop model or loop 17 on a sixteen-loop model.

The CLS200 can accommodate encoder signals up to 24VDC using a voltage divider or can power encoders with the 5VDC from the TB50 or TB18. The following ﬁgures illustrate connecting encoders. A pull-up resistor in the CLS200 allows open collector inputs to be used.

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Chapter 2: Installation

CLS200 and TB50 or TB18

+5VDC

10kΩ

Pulse Input

Encoder

Com

Figure 2.17 — Encoder with 5VDC TTL Signa

+5VDC

10kΩ

Figure 2.18 — Encoder Input with Voltage Divider

Pulse Input

Com

Encoder

For encoders with signals greater than 5VDC, use a voltage divider to drop the voltage to 5 volts at the input. Use appropriate values for R1 and R2 depending on the encoder excitation voltage. Be sure not to exceed the speciﬁc current load on the encoder.

Wiring Control and Digital I/O

This section describes how to wire and conﬁgure the control outputs for the CLS200 series controller.

NOTE! Control outputs are connected to the CLS200’s common when the control output is on (low). Be careful when you connect external devices that may have a low side at a voltage other than controller ground, since you may create ground loops.

If you expect grounding problems, use isolated solid state relays and isolate the control device inputs.

The CLS200 provides dual PID control outputs for each loop. These outputs can be enabled or disabled, and are connected via TB50 or TB18.

Output Wiring Recommendations

When wiring output devices, use multicolored, stranded, shielded cable for analog outputs and digital outputs connected to panel-mounted solid state relays.

• Analog outputs usually use a twisted pair.

• Digital outputs usually have 9 to 20 conductors, depending on wiring technique.

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Chapter 2: Installation

Cable Tie Wraps

Once you have wired outputs to the TB50, install the cable tie wraps to reduce strain on the connectors.

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.

Digital Outputs

The CLS200 series provides dual control outputs for up to 16 loops. The controller’s default conﬁguration has all heat outputs enabled and all cool outputs disabled. Disabling a heat output makes that output available to be used as a control or an alarm output. See Enable or Disable Heat or Cool Outputs on page 85. The CPU watchdog timer output can be used to monitor the state of the controller with an external circuit or device. See CPU Watchdog Timer on page 39.

Table 2.5 — Digital Output States and Values Stored in the Controller

STATE VALUE DESCRIPTION

Off High Open circuit

On Low Sinking current to common

The digital outputs sink current from the load to the controller common. The load may powered by the 5VDC supplied by the controller at the TB50. Alternately, an external power supply may be used to drive loads.

Keep in mind the following points when using an external power supply:

• The CLS200 power supply available from Watlow includes a 5VDC supply. When using it to supply output loads, connect the 5VDC common to the 15VDC common at the power supply.

• Do not exceed +24 volts.

• If you tie the external load to earth ground, or if you cannot connect it as shown in (See Figure 2.21), then use a solid-state relay.

All digital outputs are sink outputs referenced to the CLS200 series controller common supply. These outputs are low (pulled to common) when they are on.

The outputs conduct current when they are low or on. The maximum current sink capability is 60mA at 24VDC. They cannot “source” current to a load.

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Chapter 2: Installation

TB50 or TB18

+5VDC

Loads

External Power Supply

Digital Output 1

Digital Output 2

Do not connect

to earth ground or

equipment ground

TB50 or TB18

Using Internal Power Supply

Control Common

Loads

Digital Output 1

Digital Output 2

Using External Power Supply

Figure 2.19 — Digital Output Wiring

Conﬁguring Outputs

Keep in mind the following points as you choose outputs for control and alarms:

• 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, time proportioning, distributed zero crossing, or Serial DAC control.

• You can individually program each control output for direct or reverse action.

• Alarm outputs other than the global alarm are nonlatching.

• Alarms can be suppressed during process start up and for preprogrammed durations. See Alarm Delay on page 93.

• Alarm outputs can be conﬁgured as a group as normally on (low) or normally off (high). See Digital Output Polarity on Alarm on page 73.

Control and Alarm Output Connections

Typically control and alarm outputs use external optically isolated solid state relays (SSRs). SSRs accept a 3 to 32VDC input for control, and some can switch up to 100 Amps at 480VAC. For larger currents, use silicon control rectiﬁer (SCR) power controllers up to 1000 Amps at 120 to 600VAC. You can also use SCRs and a Serial DAC for phase-angle ﬁred control.

The 34 control and alarm outputs are open collector outputs referenced to the CLS200’s common. Each output sinks up to 60mA DC to the controller common when on.

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NOTE! Control outputs are SINK outputs. They are Low when the output is ON. Connect them to the negative side of solid state relays.

Figure 2.20 shows sample heat, cool and alarm output connections.

TB50 or TB18

Heat Output

Cool Output

Alarm Output

+5VDC

Figure 2.20 — S ample Heat, Cool and Alarm Output Connections

TB50 or TB18

Heat Output Cool Output

Alarm Output

Common

Figure 2.21 — Output Connections Using External Power Supply

SSR SSR SSR

SSR

- PS +

SSR

CPU Watchdog Timer

The CPU watchdog timer constantly monitors the microprocessor. It is a sink output located on TB50 terminal 6 or TB18 terminal 3. The output can be connected to an external circuit or device in order to determine if the controller is powered and operational. Do not exceed 5VDC, 10mA DC) rating for the watchdog output. The output is low (on) when the microprocessor is operating; when it stops operating, the output goes high (off).

Figure 2.22 and Figure 2.23 show the recommended circuit for the watchdog timer output for the TB50 and the TB18.

TB50

+ 5VDC

(Terminal 1)

Watchdog Timer

(Terminal 6)

Figure 2.22 — TB50 Watchdog Timer Output

SSR

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TB18

+ 5VDC

(Terminal 1)

Watchdog Timer

SSR

(Terminal 3)

Figure 2.23 — TB18 Watchdog Timer Output

Digital Inputs

All digital inputs are transistor-transistor logic (TTL) level inputs referenced to control common and the internal +5V power supply of the CLS200.

When an input is connected to the controller common, the input is considered on. Otherwise, the input is considered off. Most features that use the digital inputs can be user-conﬁgured to activate when an input is either on or off.

In the off state, internal 10k resistors pull the digital inputs high to 5VDC with respect to the controller common.

Table 2.6 — Digital Inputs States and Values Stored in the Controller

STATE VALUE DESCRIPTION

Off High Open circuit

On Low DIgital input connected to controller common

External Switching Devices

To ensure that the inputs are reliably switched, use a switching device with the appropriate impedances in the on and off states and do not connect the inputs to external power sources.

When off, the swiching device must provide an impedance of at least 11kΩ to ensure that the voltage will rise to greater than 3.7VDC. When on, the switch must provide not more than 1kΩ impedance to ensure the voltage drops below 1.3VDC.

To install a switch as a digital input, connect one lead to the common terminal on the TB50 (terminals 3 and 4) or TB18 (terminal 2). Connect the other lead to the desired digital input terminal on the TB50 (terminals 43 to 50) or TB18 (terminals 16 to 18).

Functions Activated by Digital Inputs

Use digital inputs to activate the following functions:

• Load a job that is stored in controller memory. See Job Select Digital Inputs on page 68.

• Change all loops to manual mode at speciﬁed output levels. See Output Override Digital Input on page 70.

• Enable thermocouple short detection. See Process Power Digital Input on page 71.

• Restore control automatically after a failed sensor has been repaired. See Restore PID Digital Input on page 83.

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Chapter 2: Installation

TB50

Input

Control Com

Figure 2.24 — Wiring Digital Inputs

TB18 Connections

Table 2.7 — TB18 Connections

TERMINAL FUNCTION

1 +5VDC

2 CTRL COM

3 Watchdog timer

4 Global alarm

5 Output 1 Loop 1 heat Loop 1 heat

6 Output 2 Loop 2 heat Loop 2 heat

External Switching Device

FOUR-LOOP

CONTROLLER

CONTROL OUTPUT

CONTROLLER

EIGHT-LOOP

7 Output 3 Loop 3 heat Loop 3 heat

8 Output 4 Loop 4 heat Loop 4 heat

9 Output 5 Pulse loop heat Loop 5 heat

10 Output 6 Loop 1 cool Loop 6 heat

11 Output 7 Loop 2 cool Loop 7 heat

12 Output 8 Loop 3 cool Loop 8 heat

13 Output 9 Loop 4 cool Pulse loop heat

14 Output 10 Pulse loop cool Loop 1 cool

15 Output 34

Serial DAC clock Serial DAC clock

16 Input 1

17 Input 2

18 Input 3/Pulse input

The indicated outputs are dedicated for 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.

For Watlow Serial DAC, the CLS200 series controller uses digital output 34 for a clock line. You cannot use output 34 for

anything else when you have a control output conﬁgured for the SDAC.

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TB50 Connections

Table 2.8 — TB50 Connections for Four-Loop and Eight-Loop Controllers

TERMINAL FUNCTION

CONTROL OUTPUT

8-LOOP 4-LOOP 8-LOOP 4-LOOP

1 +5VDC 2 +5VDC

CTRL

COM

5 Not Used 6

Pulse

Input

9 Output 1 Loop 1 heat Loop 1 heat 10 Output 34

11 Output 2 Loop 2 heat Loop 2 heat 12 Output 33

13 Output 3 Loop 3 heat Loop 3 heat 14 Output 32

15 Output 4 Loop 4 heat Loop 4 heat 16 Output 31

17 Output 5 Loop 5 heat

19 Output 6 Loop 6 heat Loop 1 cool 20 Output 29

21 Output 7 Loop 7 heat Loop 2 cool 22 Output 28

23 Output 8 Loop 8 heat Loop 3 cool 24 Output 27

25 Output 9

Pulse loop

heat

27 Output 10 Loop 1 cool

29 Output 11 Loop 2 cool 30 Output 24

31 Output 12 Loop 3 cool 32 Output 23

33 Output 13 Loop 4 cool 34 Output 22

35 Output 14 Loop 5 cool 36 Output 21

37 Output 15 Loop 6 cool 38 Output 20

39 Output 16 Loop 7 cool 40 Output 19

41 Output 17 Loop 8 cool 42 Output 18

43 Input 1 44 Input 2

45 Input 3 46 Input 4

47 Input 5 48 Input 6

49 Input 7 50 Input 8

The indicated outputs are dedicated for 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.

For Watlow Serial DAC, the controller uses digital output 34 (terminal 10) for a clock line. You cannot use output 34 for

anything else when you have a control output conﬁgured for the SDAC.

TERMINAL FUNCTION

4 CTRL COM

Watchdog

Timer

Global

Alarm

Pulse loop

heat

18 Output 30

Loop 4 cool 26 Output 26

Pulse loop

cool

28 Output 25

CONTROL OUTPUT

Pulse

loop cool

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Chapter 2: Installation

Table 2.9 — TB50 Connections for Sixteen-Loop Controllers

TERMINAL FUNCTION

CONTROL

OUTPUT

TERMINAL FUNCTION

CONTROL

OUTPUT

1 +5VDC 2 +5VDC

3 CTRL COM 4 CTRL COM

5 Not Used 6

Watchdog

Timer

7 Pulse Input 8 Global Alarm

9 Output 1 Loop 1 heat 10 Output 34

Pulse loop cool

11 Output 2 Loop 2 heat 12 Output 33 Loop 16 cool

13 Output 3 Loop 3 heat 14 Output 32 Loop 15 cool

15 Output 4 Loop 4 heat 16 Output 31 Loop 14 cool

17 Output 5 Loop 5 heat 18 Output 30 Loop 13 cool

19 Output 6 Loop 6 heat 20 Output 29 Loop 12 cool

21 Output 7 Loop 7 heat 22 Output 28 Loop 11 cool

23 Output 8 Loop 8 heat 24 Output 27 Loop 10 cool

25 Output 9 Loop 9 heat 26 Output 26 Loop 9 cool

27 Output 10 Loop 10 heat 28 Output 25 Loop 8 cool

29 Output 11 Loop 11 heat 30 Output 24 Loop 7 cool

31 Output 12 Loop 12 heat 32 Output 23 Loop 6 cool

33 Output 13 loop 13 heat 34 Output 22 Loop 5 cool

35 Output 14 Loop 14 heat 36 Output 21 Loop 4 cool

37 Output 15 Loop 15 heat 38 Output 20 Loop 3 cool

39 Output 16 Loop 16 heat 40 Output 19 Loop 2 cool

41 Output 17 Pulse loop heat 42 Output 18 Loop 1 cool

43 Input 1 44 Input 2

45 Input 3 46 Input 4

47 Input 5 48 Input 6

49 Input 7 50 Input 8

The indicated outputs are dedicated for 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.

For Watlow Serial DAC, the controller uses digital output 34 (terminal 10) for a clock line. You cannot use output 34 for

anything else when you have a control output conﬁgured or the SDAC.

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Chapter 2: Installation

Analog Outputs

Analog outputs can be provided by using a Dual DAC or Serial DAC module to convert the open collector outputs from the controller. Use multicolored stranded shielded cable for analog outputs. Analog outputs generally use a twisted pair wiring. The following sections describe the Dual DAC and Serial DAC modules.

Wiring the Dual DAC

A Dual DAC module includes two identical circuits. Each can convert a distributed zero-cross (DZC) signal from the controller to a voltage or current signal. Watlow strongly recommends using a power supply separate from the controller supply to power the Dual DAC. Using a separate power supply isolates the controller’s digital logic circuits and analog measurement circuits from the frequently noisy devices that take the analog signal from the Dual DAC.

Several Dual DAC modules may be powered by one power supply. Consult the Dual DAC’s manual for power requirements. Also note that the Dual DAC does not carry the same industry approvals as the Serial DAC.

Wiring the Serial DAC

The Serial DAC provides a robust analog output signal. The module converts the proprietary Serial DAC signal from the controller’s open collector output in conjunction with the clock signal to an analog current or voltage. The Serial DAC is user-conﬁgurable for voltage or current output.

The Serial DAC optically isolates the controller’s control output from the load. When a single Serial DAC is used, it may be powered by the 5VDC found on the TB50, or by an external supply referenced to the controller’s power supply. When using multiple Serial DACs, the controller cannot provide sufﬁcient current; use the 5VDC output from the CLS200 power supply.

Serial Communications

The CLS200 series controllers are factory-conﬁgured for EIA/TIA-232 communications unless otherwise speciﬁed when purchased. However, the communications are jumper-selectable, so you can switch between EIA/TIA-232 and EIA/TIA-485. See Changing Communications on page 153.

EIA/TIA-232 Interface

EIA/TIA-232 provides communication to the serial port of a compatible computer. It is used for single controller installations where the cable length does not exceed 50 feet (15.2 m).

The EIA/TIA-232 interface is a standard three-wire interface. See the table below for connection information.

If you are using EIA/TIA-232 communications with grounded thermocouples, use an optical isolator between the controller and the computer to prevent ground loops.

Table 2.10 shows EIA/TIA-232 connections for 25-pin and 9-pin connectors.

EIA/TIA-232 may be used to connect a computer through a 232/485 converter, to an EIA/TIA-485 communications network with up to 32 CLS200 controllers.

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Chapter 2: Installation

Table 2.10 — EIA/TIA-232 Connections

WIRE COLOR CLS200 TB1 DB 9 CONNECTOR DB 25 CONNECTOR

White TX Pin 26 RX Pin 2 RX Pin 3

Red RX Pin 25 TX Pin 3 TX Pin 2

Black GND Pin 23 GND Pin 5 GND Pin 7

Green GND Pin 24 N/U Pin 9 N/U Pin 22

Shield N/C GND Pin 5 GND Pin 7

Jumpers in EIA/TIA-232 Connectors

Some software programs and some operator interface terminals require a Clear to Send (CTS) signal in response to their Request to Send (RTS) signal, or a Data Set Ready (DSR) in response to their Data Terminal Ready (DTR). The CLS200 is not conﬁgured to receive or transmit these signals. To use such software with the CLS200, jumper the RTS to the CTS and the DTR to the DSR in the DB connector. Table 2.11 lists the standard pin assignments for DB-9 and DB-25 connectors.

Table 2.11 — RTS/CTS Pins in DB-9 and DB-25 Connectors

DB-9 DB-25

RTS 7 4

CTS 8 5

DTR 4 20

DSR 6 6

Cables manufactured by Watlow for EIA/TIA-232 communications include these jumpers.

EIA/TIA-232 cable

RAMP SOAK

M R A

L A

K C

UNITS

NTE E

OUT%

PROCESS

BACK

LOOP

STATUS

WATLOW ANAFAZE CLS200

SETPOINT

YES

ALARM

CHNG SP

MAN AUTO

Figure 2.25 — Connecting One CLS200 to a Computer Using EIA/TIA-232

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Chapter 2: Installation

EIA/TIA-485 Interface

To communicate with more than one CLS200 series controller on a controller network, or to use communication cable lengths greater than 50 feet (15.2 m) from PC to controller, you must use EIA/TIA-485 communications.

When using EIA/TIA-485 communications, you must attach an optically isolated EIA/TIA-232 to EIA/TIA-485 converter to the computer.

Figure 2.26 and Figure 2.27 show the recommended system wiring. To avoid ground loops, use an optically isolated EIA/TIA-232 to EIA/TIA-485 converter between the computer and the EIA/TIA-485 network.

Personal Computer

Figure 2.26 — EIA/TIA-485 Wiring

EIA/TIA-485 Converter

TXA/TDA/TX-

TXB/TDB/TX+

RXA/RDA/RX-

RXB/RDB/RX+

First CLS200 Last CLS200

JU1

RXA 25

RXB 23

TXA 26

TXB 24

JU1

A B

Do not connect shield to

CLS200

RXA 25

RXB 23

TXA 26

TXB 24

A B

Cable Recommendations

Watlow recommends Belden 9843 cable or its equivalent. This cable includes three 24 AWG (0.2 mm2) shielded, twisted pairs. It should carry signals of up to 19.2k baud with no more than acceptable losses for up to 4,000 feet (1,220 m).

EIA/TIA-485 Network Connections

Watlow recommends that you use a single daisy chain conﬁguration rather than spurs. Run a twisted-pair cable from the host or the converter to the ﬁrst CLS200, and from that point run a second cable to the next CLS200, and so on. (See Figure 2.27.)

If necessary for servicing, instead of connecting each controller directly into the next, install a terminal strip or connector as close as possible to each CLS200, run a communications cable from one terminal strip to the next and connect the controllers to the bus with short lengths of cable.

To avoid unacceptable interference, use less than 10 feet (3 m) of cable from the terminal or connector to the CLS200 serial port.

Some systems may experience problems with sensor signal reading if the commons of multiple controllers are connected. See Signal Common on page 47.

Refer to Termination on page 47 for more on terminating resistors.

Connect the shield drain to earth ground only at computer or host end.

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First CLS200 Second CLS200 Last CLS200

Chapter 2: Installation

232 Communications 485 Communications

Serial Port

Optically

Shielded Twisted Pair Cable

Isolating

232 to 485

Converter

RAMP SOAK

RM LA A

LOOP

WATLOW ANAFAZE CLS200

ALARM

CHNG SP

MAN AUTO

K C A

UNITS

R E T N E

OUT%

PROCESS

CK BA

STATUS

SETPOINT

S E Y

LOOP

WATLOW ANAFAZE CLS200

ALARM

H C S

N A M

O T U A

P M A K

A O

M R

A L A

CK A

UNITS

ENTER

OUT%

PROCESS

K AC B

STATUS

O N

SETPOINT

S E Y

G N P

PROCESS

LOOP

WATLOW ANAFAZE CLS200

SETPOINT

ALARM

N H C

P S

N A M

O T U A

P M

K R A O S

R A L A

K C A

UNITS

ENTER

OUT%

CK BA

STATUS

O N

S E Y

Figure 2.27 — Recommended System Connections

Signal Common

For usual installations, do not connect the dc commons of the controllers together or to the converter or host device. Use an optically isolating EIA/TIA-232-to-485 converter to prevent problems with sensor readings.

Termination

In order for EIA/TIA-485 signals to be transmitted properly, each pair must be properly terminated. The value of the termination resistor should be equal to the impedance of the communications cable used. Values are typically 150 to 200Ω.

The receive lines at the converter or host device should be terminated in the converter, the connector to the host device or the device itself. Typically the converter documentation provides instructions for termination.

Use a terminating resistor on the receive lines on the last controller on the 485 line. Set JU1 inside the CLS200 in position B to connect a 200Ω resistor across the receive lines. Refer to Changing Communications on page 153.

EIA/TIA-485 Converters and Laptop Computers

In order for an EIA/TIA-232-to-485 converter to optically isolate the computer from the 485 network, the 232 and 485 sides must be powered independently. Many 232-to-485 converters can be powered by the computer’s communications port. Some computers, laptops in particular, do not automatically provide the appropriate voltages. These computer/ converter combinations can usually be used by connecting an external power supply to the 232 side of the converter. Not all converters have power inputs for the 232 side, however.

Page 48

Chapter 3: Using CLS200

This chapter explains how to use the keypad and display to operate the controller. Figure 3.1 shows the operator menus and displays accessible from the front panel. To change global parameters, loop inputs, control parameters, outputs, and alarms using the setup menus, see Chapter 4: Setup.

BACK

Power on

Bar Graph Display

BACK

Single Loop Display

BACK

Job Display

ENTER ENTER

Scanning Bar Graph Display

Figure 3.1 — Operator Displays

Any Key

ENTER ENTER

Scanning Single Loop Display

Any Key

RAMP SOAK

Ramp/Soak

BACK

CHNG SP

Change Setpoint

BACK

MAN AUTO

Manual, Automatic or Autotune Mode

BACK

ENTER

(Manual)

BACK

Heat/Cool Output Percentage

(Manual mode only)

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Chapter 3: Using CLS200

Front Panel

The CLS200 front panel provides a convenient interface with the controller. You can use the front panel keys to program and operate the CLS200.

RAMP SOAK

• Assigns and

monitors proﬁles

ALARM ACK

MAN AUTO

• Changes loop output control from automatic to manual or tune

• Assigns output power level of manual loops

CHNG SP

• Changes process setpoint

YES

• Selects a menu or parameter

• Answers YES to YES/NO prompts

• Increases a value or choice

BACK

• Cancels editing and returns to a previous menu

• Skips a menu or parameter

• Answers NO to YES/NO prompts

• Decreases a value or choice

• Acknowledges alarms

ENTER

• Stores data or settings and advances to the next parameter

• Starts scanning mode (if pressed twice)

Figure 3.2 — CLS200 Front Panel

Front Panel Keys

YES (up) Press YES to:

NO (down) Press NO to:

• Select a menu or parameter

• Answer YES to the ﬂashing ? prompts

• Increase a value or choice when editing

• Stop scanning mode

• Skip a menu or parameter when the prompt is blinking

• Answer NO to the ﬂashing ? prompts

• Decrease a value or choice when editing

• Stop scanning mode

• Perform a NO-key reset

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NOTE! Pressing the NO key on power up performs a NO-key reset. This procedure clears the RAM and sets the controller’s parameters to their default values. See NO-Key Reset on page 150.

BACK Press BACK to:

• Cancel editing

• Return to a previous menu

• Switch between bar graph, single loop and job displays

• Stop scanning mode

ENTER Press ENTER to:

• Store data or a parameter choice after editing and go to the next parameter

• Start scanning mode (if pressed twice)

CHNG SP Press CHNG SP to change the loop setpoint

MAN AUTO Press MAN/AUTO to:

• Toggle a loop between manual and automatic control

• Adjust the output power level of manual loops

• Automatically tune the loop

RAMP SOAK If your controller has the ramp/soak option, press RAMP/SOAK to:

• Assign a ramp/soak proﬁle to the current loop

• Select the ramp/soak mode

• See the status of a running proﬁle

Your controller may not have the ramp/soak option. If it does not, pressing the RAMP/SOAK key displays the message OPTION UNAVAILABLE.

ALARM ACK Press ALARM ACK to:

• Acknowledge an alarm condition

• Reset the global alarm output

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Control Status

Chapter 3: Using CLS200

Displays

This section discusses the controller’s main displays: bar graph, single loop and job.

Bar Graph Display

On power up, the controller displays general symbolic information for up to eight loops. This screen is called the bar graph display. The diagram below shows the symbols used in the bar graph display.

Symbol

Loop Number or Name

Figure 3.3 — Bar Graph Display

01> > < < 08 AAAA MAMA

ALARM

Table 3.1 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).

Table 3.1 — Bar Graph Display Symbols

SYMBOL DESCRIPTION

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 do not enable these alarms, these symbols are scaled to the setpoint ±5% of 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 do not enable these alarms, these symbols are scaled to the setpoint ±5% of the sensor’s range.

(blank)

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

Loop’s input type is set to SKIP.

Open thermocouple (T/C), shorted T/C, reversed T/C, open RTD or shorted RTD.

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Chapter 3: Using CLS200

Table 3.2 explains the control status symbols on the bottom line of bar graph display. Additional symbols may appear with the ramp/soak option. (See Bar Graph Display on page 126.)

Table 3.2 — Control Status Symbols on the Bar Graph and Single Loop Displays

BAR GRAPH

DISPLAY SYMBOL

M MAN

A AUTO

T TUNE

H T

C L

(blank) (blank)

SINGLE LOOP

DISPLAY SYMBOL

HEAT

COOL

DESCRIPTION

One or both outputs are enabled. Loop is in manual control.

Only one output (heat or cool) is enabled. Loop is in automatic control.

The loop is in autotune mode.

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.

Both outputs disabled, or input type is set to SKIP.

Navigating in Bar Graph Display

When the bar graph display is visible:

• Press the YES (up) or NO (down) key to see a new group of loops.

• Press ENTER twice to scan all groups of loops. The groups will display sequentially for three

seconds each. This is called scanning mode.

• Press any key to stop scanning.

• Press BACK once to go to the job display, if enabled, or the single loop display.

Single Loop Display

The single loop display shows detailed information for one loop at a time.

Process Variable

Loop Number

or Name

02 160˚F

180AUTO100

ALARM

Setpoint

Figure 3.4 — Single Loop Display

Control Status

The control status indicator shows MAN, AUTO or TUNE modes.

If both control outputs for a loop are enabled and the loop is in automatic control, then the single loop display shows HEAT or COOL as the control status:

Engineering Units

Output Percentage

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Process Variable

Engineering Units

Loop Number or Name

02 160˚F 0

Cool Output Percentage

180HEAT100

ALARM

Setpoint

Figure 3.5 — Single Loop Display, Heat and Cool Outputs Enabled

Control Status

Heat Output Percentage

Navigating the Single Loop Display

In the single loop display:

• Press YES to go to the next loop.

• Press NO to go to the previous loop.

• Press BACK once to go to the job display (if enabled) or bar graph display.

• Press ENTER twice to start the 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.

Alarm Displays

If a process, deviation, failed or system sensor alarm occurs, the controller switches from any Single Loop display or Bar Graph display to the Single Loop display for the loop with the alarm. The global alarm output turns on and a two-character alarm code appears in the lower left corner of the Single Loop display.

If the alarm is for a failed sensor, a short message appears in place of the process variable and units. Control outputs associated with failed sensors are set to the value of the SENSOR FAIL HT/CL OUTPUT % parameter (default, 0%).

The alarm code blinks and displays cannot be changed until the alarm has been acknowledged. Once the alarm is acknowledged, the alarm code stops blinking. When the condition that caused the alarm is corrected, the alarm messages disappear.

Loop Number

Alarm Code

Figure 3.6 — Single Loop Display with a Process Alarm

ALARM

180 180AUTO

°F

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03 T/C BREAK FS 25MAN 0

ALARM

Failed Sensor

Description

Alarm Code

Figure 3.7 — Failed Sensor Alarm in the Single Loop Display

Alarms that still exist but have been acknowledged are displayed on the Bar Graph display. A letter or symbol indicates the alarm condition. See Table 3.3 for a full list of alarm codes, failed sensor messages and alarm symbols.

Thermocouple

Open

on Loop 1

01 F 08

Low Process or Low Deviation on Loop 5

AAAA MAMA

ALARM

Figure 3.8 — Alarm Symbols in the Bar Graph Display

Table 3.3 shows the symbols used in each form of the alarm display.

Table 3.3 — Alarm Type and Symbols

ALARM

CODE

FS F

BAR GRAPH

SYMBOL

ALARM

MESSAGE

T/C

BREAK

DESCRIPTION

Failed Sensor: Break detected in thermocouple circuit.

RO F RTD OPEN

RS F

RT F

ST F

HP >

HD >

LP <

LD <

AM *

RTD

SHORTED

REVERSED

T/C

SHORTED

message

RTD Open: Break detected in RTD circuit.

RTD Short: Short detected in RTD circuit.

Reversed Thermocouple: Reversed polarity detected in

thermocouple circuit. Shorted Thermocouple: Short detected in thermocouple

circuit. High Process Alarm: Process variable has risen above the

high alarm set point. High Deviation Alarm: Process variable has risen above the

setpoint plus the deviation alarm value. Low Process Alarm: Process variable has dropped below

the low alarm set point. Low Deviation Alarm: Process variable has dropped below

the setpoint minus the deviation alarm value. Ambient Warning: Controller’s ambient temperature has

exceeded operating limits by 5°C.

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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 (the keypad and display won’t work for anything else until you acknowledge each alarm). The alarm symbols are displayed as long as the alarm condition is valid.

System Alarms

When a system alarm occurs, the global alarm output turns on and an alarm message appears on the display. The message continues to be displayed until the error condition is removed and the alarm is acknowledged. The CLS200 can display the following system alarms:

• BATTERY DEAD

See Battery Dead on page 143.

• LOW POWER

See Low Power on page 143.

• AW

See Ambient Warning on page 144.

• H/W FAILURE: AMBIENT

See H/W Ambient Failure on page 144.

• H/W FAILURE: GAIN

See H/W Gain or Offset Failure on page 145.

• H/W FAILURE: OFFSET

See H/W Gain or Offset Failure on page 145.

Job Display

The job display appears only if:

• You have enabled JOB SELECT DIG INPUTS. (See Job Select Digital Inputs on page 68.) – or –

• You have selected a job from the job load menu.

After loading a job using the LOAD SETUP FROM JOB menu, the job display shows you the following screen:

JOB 3 RUNNING

ALARM

If parameters are modiﬁed while the job is running, this screen will display:

JOB 3 RUNNING DATA MODIFIED

ALARM

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If the job was loaded using digital inputs, the display shows:

JOB 3 RUNNING REMOTELY LOADED

ALARM

Changing the Setpoint

Select the single loop display for the loop you want to change. Press CHNG SP. This display appears:

01 SETPOINT ?

25°F

ALARM

• Press YES to change the setpoint.

• Press the up or down keys (YES or NO) to increase or decrease the setpoint value.

• Press ENTER to save your changes and return to single loop display. – or – Press NO or BACK (without pressing ENTER) to return to single loop display without saving the new setpoint.

Selecting the Control Status

If you set the control status to AUTO, the controller automatically controls the process according to the conﬁguration information you give it.

If you set the control status to MAN, you need to set the output level.

If you set the control status to TUNE, the controller performs an autotune and chooses PID parameters.

NOTE! If the loop outputs are disabled, you cannot toggle between manual and automatic control. If you try it, the screen shows an error message telling you that the outputs are disabled, as shown below. Use the SETUP LOOPS OUTPUT menu to enable the outputs. See Setup Loop Outputs Menu on page 84.

MAN/AUTO CONTROL OUTPUTS DISABLED

ALARM

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Manual and Automatic Control

1. Switch to the single loop display for the loop.

2. Press MAN/AUTO.

3. Press YES to change the mode

– or – if the mode is MAN, press NO to set the output power. Go to the next subsection, Manual Output Levels. – or – press NO if in AUTO to cancel and remain in AUTO mode.

4. Select a mode by pressing the up or down key (YES or NO) to scroll through the modes.

5. Press ENTER to make the mode change

– or – press BACK to return to the single loop display without saving the new mode setting.

6. If you set the loop to manual, you are prompted for the output power. Go to Manual Output Levels below.

Manual Output Levels

If the loop to is set to manual control, the controller prompts for output levels for the enabled control outputs. Use this menu to set the manual heat and cool output levels. You should see a display like this:

01 SET HEAT

OUTPUT? 90%

ALARM

1. Press YES to change the output power level. (If the heat output is enabled, you will be able to change the heat output power level. If only the cool output is enabled, you will be able to change only the cool output power level.) – or – Press NO to go to the cool output, if available, and then press YES to change the cool output.

2. Press up or down (YES or NO) to select a new output power level.

3. Press ENTER to store your changes – or – press BACK to discard your changes and return to single loop display.

4. Repeat from Step 1 for the cool output, if available.

5. Press BACK at any time to discard your changes and return to single loop display.

Autotuning a Loop

Autotuning is a process by which a controller determines the correct PID parameters for optimum control. This section explains how to autotune the CLS200.

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Prerequisites

Before autotuning the controller, it must be installed with control and sensor circuitry and the thermal load in place.

It must be safe to operate the thermal system, and the approximate desired operating temperature (setpoint) must be known.

The technician or engineer performing the autotune should know how to use the controller front panel or MMI software interface to do the following:

1. Select a loop to operate and monitor.

2. Set a loop’s setpoint.

3. Change a loop’s control status (MAN, TUNE, AUTO).

4. Read and change the controller’s global and loop setup parameters.

Background

Autotuning is performed at the maximum allowed output. If you have set an output limit, autotuning occurs at that value. Otherwise, the control output is set to 100% during the autotune. Only the heat output (output 1) of a loop may be autotuned.

The PID constants are calculated according to process’s response to the output. The loop need not reach or cross setpoint to successfully determine the PID parameters. While autotuning the controller looks at the delay between when power is applied and when the system responds in order to determine the integral term (TI). The controller then looks for the slope of the rising temperature to become constant in order to determine the proportional band (PB). The derivative term (TD) is derived mathematically from the TI.

When the controller has ﬁnished autotuning, the loop’s control status switches to AUTO. If the process reaches 75% of the setpoint or the autotuning time exceeds 30 minutes, the controller switches to AUTO and applies the PID constants it has calculated up to that point.

The autotune is started at ambient temperature or at a temperature above ambient. However, the temperature must be stable and there must be sufﬁcient time for the controller to determine the new PID parameters.

Performing an Autotune

NOTE! A loop must be stable at a temperature well below the setpoint in order to successfully autotune. The controller will not complete tuning if the temperature exceeds 75% of setpoint before the new parameters are found.

The following procedure explains how to autotune a loop:

1. Select the single loop display of the loop to be tuned.

2. Ensure the loop’s process variable is stable and the loop is in MAN control status.

3. Set the setpoint to a value as near the normal operating temperature as is safe for the system.

WARNING! During autotuning, the controller will set the output to 100% until the process variable rises near the setpoint. Set the setpoint within the safe operating limits of your system.

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4. Use the three-key sequence (ENTER, ALARM ACK, CHNG SP) to access the setup menus. In the SETUP LOOP INPUT menu, locate the INPUT FILTER parameter. Note the setting and then change it to 0 SCANS.

5. Press the BACK key until the single loop display appears.

6. Press the MAN/AUTO key.

7. Press the YES key to toggle to the TUNE mode.

8. Press the ENTER key to begin tuning the loop. TUNE ﬂashes throughout the tuning process. When tuning is completed the control status indicator changes to AUTO.

9. Adjust the setpoint to the desired temperature.

10. Restore the INPUT FILTER parameter to its original value.

Using Alarms

The CLS200 has three main types of alarms:

• Failed sensor alarms

• Process alarms

• System alarms

Alarm Delay

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

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

alarms) for all loops for a time period you set at the STARTUP ALARM DELAY parameter in the SETUP GLOBAL PARAMETERS menu.

• Loop alarm delay delays failed sensor alarms and process alarms (including deviation alarms) for one loop until the alarm condition is continuously present for longer than the loop alarm delay time you set.

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

Failed Sensor Alarms

Failed sensor alarms alert you if one of the following conditions occurs:

• Thermocouple open

• Thermocouple shorted (must be enabled)

• Thermocouple reversed (must be enabled)

• RTD open positive input or open negative input

• RTD short between the positive and negative inputs

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What Happens if a Failed Sensor Alarm Occurs?

If a failed sensor alarm occurs:

• The controller switches to manual mode at the output power set with the SENSOR FAIL HT OUTPUT and SENSOR FAIL CL OUTPUT parameters in the SETUP LOOP OUTPUTS menu. (The output power may be different for a thermocouple open alarm. See Thermocouple Open Alarm on page 60.)

• The controller displays an alarm code and alarm message on the display. See Alarm Displays on page 53.

• The global alarm output is activated.

Thermocouple Open Alarm

The thermocouple open alarm occurs if the controller detects a break in a thermocouple or its leads.

If a thermocouple open alarm occurs, the controller switches to manual mode. The output level is determined as follows:

• If the HEAT/COOL T/C BRK OUT parameter in the SETUP LOOP OUTPUTS menu is set to ON, then the controller sets the output power to an average of the recent output.

• If the HEAT/COOL T/C BRK OUT AVG parameter is set to OFF, then the controller sets the output to the level set with the SENSOR FAIL HT/CL OUTPUT parameter in the SETUP LOOP OUTPUTS menu.

Thermocouple Reversed Alarm

The thermocouple reversed alarm occurs if the temperature goes in the opposite direction and to the opposite side of ambient temperature than expected—for example, a loop is heating and the measured temperature drops below the ambient temperature.

The thermocouple reversed alarm is disabled by default. To enable this alarm, set the REVERSED T/C DETECT parameter in the SETUP LOOP INPUTS menu to ON. It may be disabled if false alarms occur in your application.

Thermocouple Short Alarm

The thermocouple short alarm occurs if the process power is on and the temperature does not rise or fall as expected. To enable the thermocouple short alarm, you must do the following:

• Choose a digital input for the PROCESS POWER DIGIN parameter in the SETUP GLOBAL PARAMETERS menu.

• Connect the digital input to a device that connects the input to controller common when the process power is on.

RTD Open or RTD Shorted Alarm

The RTD open alarm occurs if the controller detects that the positive or negative RTD lead is broken or disconnected.

The RTD shorted alarm occurs if the controller detects that the positive and negative RTD leads are shorted.

You do not have to set any parameters for the RTD alarms.

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Restore Automatic Control After a Sensor Failure

This feature returns a loop to automatic control after a failed thermocouple is repaired. To enable this feature:

• Choose a digital input for the RESTORE PID DIGIN parameter in the SETUP LOOP CONTROL PARAMS menu.

• Connect the digital input to the dc common terminal on the controller.

Process Alarms

The CLS200 has four process alarms, each of which you can conﬁgure separately for each loop:

• Low process alarm

• High process alarm

• Low deviation alarm

• High deviation alarm

Setting Up Alarms

To set up an alarm:

• Set the alarm setpoint

• Set the alarm type

• Choose an output, if desired

• Set the alarm deadband

• Set an alarm delay, if desired

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

What Happens If a Process Alarm Occurs?

If a process alarm occurs, the controller does the following:

• Shows an alarm code on the display. (See Alarm Displays on page 53.)

• Activates the global alarm output. (See Global Alarm on page 63.)

• Activates the digital output that is assigned to the process alarm (if applicable). The digital output remains active until the process variable returns within the corresponding limit and deadband; the alarm output deactivates when the process returns to normal.

Process Alarm Outputs

Any digital output that is not used as a control output can be assigned to one or more process alarms.

The controller activates the output if any alarm assigned to the output is active. Process alarm outputs are non-latching—that is, the output is deactivated when the process returns to normal, whether or not the alarm has been acknowledged.

Specify the active state of process alarm outputs at the DIG OUT POLARITY ON ALARM setting in the SETUP GLOBAL PARAMETERS.

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Alarm Type: Control or Alarm

You can conﬁgure each process alarm as either a control or alarm.

• Alarm conﬁguration provides traditional alarm functionality: The operator must acknowledge the alarm message on the controller display, a latching global alarm is activated, and the alarm can activate a user-speciﬁed, non-latching alarm output.

• Control conﬁguration provides on/off control output using the alarm setpoint. For example, you could conﬁgure a high deviation alarm to turn on a fan. The alarm activates a userspeciﬁed non-latching output. Alarm messages do not have to be acknowledged, and the global alarm is not activated.

High and Low Process Alarms

A high process alarm occurs if the process variable rises above a user-speciﬁed value. A low process alarm occurs if the process variable drops below a separate user-speciﬁed value. See Figure 3.9.

Enter the alarm high and low process setpoints at the HI PROC ALARM SETPT and LO PROC ALARM SETPT parameters in the SETUP LOOP ALARMS menu.

High process alarm on

High process alarm set point

High deviation

Setpoint + Deviation alarm value

Setpoint

Setpoint - Deviation alarm value

Low process alarm

Figure 3.9 — Activation and Deactivation of Process Alarms

setpoint

alarm on

High process alarm off

High deviation

alarm off

Low deviation alarm on

Low process alarm on

Low deviation

alarm off

Low process alarm off

}

Deadband

}

Deadband

}

Deadband

}

Deadband

Deviation Alarms

A deviation alarm occurs if the process deviates from setpoint by more than a user-speciﬁed amount. (See Figure 3.9.) Set the deviation with the DEV ALARM VALUE parameter in the SETUP LOOP ALARMS menu.

Upon power up or when the setpoint changes, the behavior of the deviation alarms depends upon the alarm function:

• If the alarm type parameter is set to ALARM, then deviation alarms do not activate until the after the process variable has ﬁrst come within the deviation alarm band. This prevents nuisance alarms.

• If the alarm type parameter is set to CONTROL, then the deviation output switches on whenever the setpoint and process variable differ by more than the deviation setting, regardless of whether the process variable has been within the deviation band. This allows you to use boost control upon power up and setpoint changes.

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Global Alarm

The CLS200 comes equipped with a global alarm output. The global output is activated if one or more of the following conditions occurs:

• A system alarm occurs, or

• A failed sensor alarm occurs and is unacknowledged, or

• A process alarm occurs and is unacknowledged. The global alarm occurs only if the alarm type is set to ALARM in the SETUP LOOP ALARMS menu. (The global alarm does not occur if the alarm type is set to CONTROL.)

The global alarm output stays active until all alarms have been acknowledged. When the global alarm output is active, it conducts current to the controller’s dc common. When the global alarm output is not active, it does not conduct current.

NOTE! You cannot conﬁgure any parameters for the global alarm. The active state of the global alarm output is NOT affected by the DIG OUT POLARITY ON ALARM polarity parameter in the SETUP GLOBAL PARAMETERS menu.

Ramp/Soak

If you have a controller without the Ramp/Soak option, pressing the RAMP/SOAK key has no effect.

If you have a controller with this option installed, see Chapter 6: Ramp/Soak on page 115.

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Chapter 4: Setup

The setup menus let you change detailed conﬁguration information. This section describes how to set up the controller using the built-in keypad and display. The following information is included in this chapter:

• Accessing the setup menus

• Changing parameter settings

• Description of controller parameters

If you have not set up a CLS200 series controller before, or if you do not know what values to enter, please read Chapter 7: Tuning and Control, which contains PID tuning constants and useful starting values.

How to Access the Setup Menus

Use the three-key sequence to enter the setup menus:

1. Select the single loop display for the loop you wish to edit.

2. Press ENTER then ALARM ACK then CHNG SP to access the setup menus. Do not press

these keys at the same time; press them one at a time.

3. The ﬁrst setup menu appears.

To prevent unauthorized personnel from accessing setup parameters, the controller reverts to the single loop display if you do not press any keys for three minutes.

How to Change a Parameter

To change a parameter, ﬁrst select the appropriate menu, then the parameter.

When you enter the setup menus, the ﬁrst menu is SETUP GLOBAL PARAMETERS. Refer to Figure 4.1 for a listing of all top level menus and their related parameters.

1. Select the single loop display for the loop to set up.

2. Enter the three-key sequence. The ﬁrst menu is displayed: SETUP GLOBAL PARAMETERS.

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3. To select the appropriate menu:

a. Press NO to move from one menu to the next. The menus wrap around; pressing NO

continuously advances through the top level menus.

b. Press YES to enter the displayed menu.

4. To select the parameter to be edited:

a. Press NO to advance from one parameter to the next. Parameters do not wrap around. b. Press YES to edit the displayed parameter.

5. To edit the parameter setting:

a. Press up or down (YES or NO) to scroll to the value or choice you want to select. b. Press ENTER to accept the change

- or press BACK to cancel the change without saving.

6. Select another parameter and repeat from step 4, or press BACK to return to the top level

menu.

7. Select another menu and repeat from step 3,

- or press BACK to exit the setup menus.

The following sections tell more about the parameters for each of the six top level menus. Each display illustration contains the default value for that speciﬁc parameter.

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Standard Menus

Figure 4.1 shows the top level menus accessible from the single loop display. If the enhanced features option or ramp/soak feature is installed, refer to Chapter 5: Enhanced Features on page 96 or Chapter 6: Ramp/Soak on page 115 for additional menus.

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?

(Ramp/soak)

KEYBOARD LOCK STATUS?

POWER UP OUTPUT STATUS?

PROCESS POWER DIGIN?

CONTROLLER ADDRESS?

COMMUNICATIONS BAUD RATE?

COMMUNICATIONS PROTOCOL?

COMMUNICATIONS

COMMUNICATIONS ERR CHECK?

AC LINE FREQ?

DIG OUT POLARITY ON ALARM?

CLS 200 [FIRMWARE INFO]

SETUP LOOP INPUT?

INPUT TYPE? HEAT CONTROL PB? HEAT CONTROL

LOOP NAME? HEAT CONTROL TI? HEAT OUTPUT TYPE? HI PROC ALARM

INPUT UNITS? HEAT CONTROL TD? HEAT OUTPUT

INPUT READING OFFSET?

REVERSED T/C DETECT?

INPUT PULSE

SAMPLE TIME?

(Pulse input)

DISP FORMAT?

(Linear and pulse)

INPUT SCALING HI PV?

(Linear and pulse)

INPUT SCALING HI RDG?

(Linear and pulse)

INPUT SCALING LO PV?

(Linear and pulse)

INPUT SCALING LO RDG?

(Linear and pulse)

INPUT FILTER?

SETUP LOOP CONTROL PARAMS?

HEAT CONTROL FILTER?

COOL CONTROL PB? HEAT OUTPUT

COOL CONTROL TI? HEAT OUTPUT

COOL CONTROL TD? HEAT OUTPUT

COOL CONTROL FILTER?

SPREAD? HEAT T/C BRK

RESTORE PID DIGIN?

SETUP LOOP OUTPUTS?

OUTPUT?

CYCLE TIME?

SDAC PARAMETERS

(SDAC)

ACTION?

LIMIT?

LIMIT TIME?

SENSOR FAIL HT OUTPUT?

OUT AVG?

HEAT OUTPUT? LO PROC ALARM

COOL CONTROL OUTPUT?

COOL OUTPUT TYPE? ALARM DEADBAND?

COOL OUTPUT CYCLE TIME?

(TP)

SDAC PARAMETERS

(SDAC)

COOL OUTPUT ACTION?

COOL OUTPUT LIMIT?

COOL OUTPUT LIMIT TIME?

SENSOR FAIL CL OUTPUT?

COOL T/C BRK OUT AVG?

COOL OUTPUT?

(TP)

SETUP LOOP ALARMS?

HI PROC ALARM SETPT?

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?

TYPE?

LO PROC ALARM OUTPUT?

ALARM DELAY?

MANUAL I/O TEST

DIGITAL INPUTS

TEST DIGITAL OUTPUT?

DIGITAL OUTPUT NUMBER XX

KEYPAD TEST

DISPLAY TEST

Figure 4.1 — CLS200 Menu Tree

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Setup Global Parameters Menu

SETUP GLOBAL PARAMETERS

ALARM

Table 4.1 shows the parameters available in this menu.

Table 4.1 — Global Parameters

PARAMETER DEFAULT VALUE

LOAD SETUP FROM JOB? 1

SAVE SETUP TO JOB? 1

JOB SELECT DIG INPUTS? NONE

JOB SEL DIG INS ACTIVE? LOW

OUTPUT OVERRIDE DIG INPUT? NONE

OVERRIDE DIG IN ACTIVE? LOW

STARTUP ALARM DELAY? 0 MINS

RAMP/SOAK TIME BASE?* HOURS/MIN

KEYBOARD LOCK STATUS? OFF

POWER UP OUTPUT STATUS? OFF

PROCESS POWER DIGIN? NONE

CONTROLLER ADDRESS? 1

COMMUNICATIONS BAUD RATE? 19200

COMMUNICATIONS PROTOCOL? MOD

COMMUNICATIONS ERR CHECK? BCC

AC LINE FREQ? 60 HERTZ

DIG OUT POLARITYON ALARM? LOW

CLS200

[model no., ﬁrmware rev.]

* The RAMP/SOAK TIME BASE parameter appears only if the ramp/soak feature is installed.

Load Setup From Job

NOTE! Current settings are overwritten when you select a job from memory. Save your current settings to another job number if you want to keep them.

Load any one of eight jobs saved in battery-backed RAM.

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LOAD SETUP FROM JOB? 1

ALARM

Selectable values: 1 to 8

The following parameters are loaded for each loop 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 function (off, alarm control) setpoints, high/low process setpoints, high/low deviation setpoints and deadband settings, and loop alarm delay.

If you have enabled the remote job select function (see Job Select Digital Inputs below), you will not be able to load a job. If you try, you will see this message:

CANNOT LOAD JOB REMOTE SELECT ON

ALARM

Save Setup to Job

Save the job information for every loop to one of eight jobs in the battery-backed RAM.

SAVE SETUP TO JOB? 1

ALARM

Selectable values: 1 to 8

If you have enabled the remote job select function (see Job Select Digital Inputs below), you will not be able to save a job. If you try, you will see this message:

CANNOT SAVE JOB REMOTE SELECT ON

ALARM

Job Select Digital Inputs

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 parameter controls the number of jobs you can select remotely.

If you select NONE, digital inputs do not affect job selection. Jobs may be loaded and saved using the LOAD SETUP FROM JOB and SAVE SETUP TO JOB parameters.

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JOB SELECT DIG INPUTS? NONE

ALARM

Selectable values: 1, 2 or 3 inputs, or NONE. These choices have the following effect:

Table 4.2 — Job Select Inputs

SETTING ENABLES

NONE

Disables remote selection

Jobs 1-2

Jobs 1-4

Jobs 1-8

Table 4.3 shows which input states select which jobs. When nothing is connected, the inputs are all false and job 1 is selected.

Table 4.3 — Job Selected for Various Input States

DIGITAL INPUT 3 DIGITAL INPUT 2 DIGITAL INPUT 2 JOB NO.

F F F 1

F F T 2

F T F 3

F T T 4

T F F 5

T F T 6

T T F 7

T T T 8

Job Select Digital Inputs Active

Specify which state is considered “true” for the digital inputs used for job selection. Default is LOW, meaning that an input must be pulled low to be considered true. If HIGH is selected, an input will be considered true unless it is pulled low.

JOB SEL DIG INS ACTIVE ? LOW

ALARM

Selectable values: HIGH or LOW.

Changing this setting has the effect of reversing the order of the jobs in Table 4.3.

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Output Override Digital Input

To enable the output override feature, select a digital input. When the speciﬁed input is activated, the controller sets all loops to manual mode at the output levels speciﬁed at the SENSOR FAIL HT OUTPUT and SENSOR FAIL CL OUTPUT parameters in the SETUP LOOP OUTPUTS menu.

OUTPUT OVERRIDE DIG INPUT? NONE

ALARM

Selectable values: NONE or input number 1 to 8.

Use the next parameter, OVERRIDE DIG IN ACTIVE, to set the signal state that activates the output override feature.

WARNING! Do not rely solely on the output override feature to shut down your process. Install external safety devices or over-temperature devices for emergency shutdowns.

Override Digital Input Active

Specify whether a low or high signal activates the output override feature (see OUTPUT OVERRIDE DIG INPUT above).

OVERRIDE DIG IN ACTIVE ? LOW

ALARM

Selectable values: HIGH or LOW.

You can set the input to be active when low or active when high. When the input selected for OUTPUT OVERRIDE DIG INPUT changes to the speciﬁed state, all the loop’s outputs are set to their sensor fail levels.

Startup Alarm Delay

Set a startup 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. This feature does not delay failed sensor alarms.

OUTPUT OVERRIDE DIG INPUT? NONE

ALARM

Selectable values: 0 to 60 minutes.

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Keyboard Lock Status

Set this parameter to ON to disable the CHNG SP, MAN/AUTO, and RAMP/SOAK keys on the keypad. If the keys are disabled, pressing them has no effect. If you want to use these functions, turn off the keyboard lock.

KEYBOARD LOCK STATUS ? OFF

ALARM

Selectable values: ON or OFF.

Power Up Output Status

WARNING! Do not set the controller to start from memory if it may be unsafe for your process to have outputs on upon power-up.

Set the initial power-up state of the control outputs. If you choose OFF, all loops are initially set to manual mode at 0% output. If you choose MEMORY, the loops are restored to the control status and output value prior to powering down.

See In Case of a Power Failure on page 130 for information about how this feature affects ramp/ soak proﬁles.

POWER UP OUTPUT STATUS ? OFF

ALARM

Selectable values: OFF or MEMORY.

Process Power Digital Input

To enable the thermocouple short detection feature, select a digital input (1 to 8). Connect the speciﬁed input to a device that pulls the input low when the process power is on. A short is indicated when the process power is on and the temperature does not rise as expected.

If the controller determines that there is a thermocouple short, it sets the loop to manual mode at the power level set for the SENSOR FAIL HT OUTPUT or SENSOR FAIL CL OUTPUT parameter in the SETUP LOOP OUTPUTS menu.

PROCESS POWER DIGIN ? NONE

ALARM

Selectable values: 1 to 8, or NONE.

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Controller Address

Set the communications address for the controller. On an EIA/TIA-485 communication network, each controller must have a unique address. Begin with address 1 for the ﬁrst controller and assign each subsequent controller the next higher address.

CONTROLLER ADDRESS ? 1

ALARM

Selectable values: 1 to 247.

Communications Baud Rate

Set the communications baud rate.

COMMUNICATIONS BAUD RATE ?19200

ALARM

Selectable values: 9600, 2400 or 19200.

NOTE! Set the baud rate to the same speed in both the controller and the HMI software or panel.

Communications Protocol

Set the communications protocol. Choose the correct protocol for the software or device with which the controller will communicate. You must switch power to the controller off, then back on, to make a change to this parameter take effect.

COMMUNICATIONS PROTOCOL ? MOD

ALARM

Selectable values: MOD (Modbus® RTU), ANA (Anafaze), AB (Allen Bradley).

Communications Error Checking

If you selected the ANA or AB communications protocol, set the data check algorithm for CLS200 communications.

CRC (Cyclic Redundancy Check) is a more secure error checking algorithm than BCC, but it requires more calculation time and slows communications. BCC (Block Check Character) ensures a high degree of communications integrity. We recommend BCC unless your application requires CRC.

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COMMUNICATIONS ERR CHECK ? BCC

ALARM

Selectable values: BCC or CRC.

AC Line Frequency

Specify the ac line frequency. 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 must know the frequency of power in use.

You must switch power to the controller off, then back on, to make a change to this parameter take effect.

AC LINE FREQ ? 60 HERTZ

ALARM

Selectable values: 50 HERTZ or 60 HERTZ.

Digital Output Polarity on Alarm

Set the polarity of all digital outputs used for alarms. If LOW is selected, if an alarm occurs the outputs sink to analog common. If HIGH is selected, the outputs sink to common when no alarm is active and go high when an alarm occurs.

DIG OUT POLARITY ON ALARM ? LOW

ALARM

Selectable values: HIGH or LOW.

This parameter does not affect the Global Alarm output or the Watchdog Alarm output.

EPROM Information

The display shows the controller type, ﬁrmware options, the ﬁrmware version and the EPROM checksum. Table 4.4 lists the available ﬁrmware options.

Controller Model

Firmware Version

CLS208-RS V03.13 CS=ED74

ALARM

Firmware Option

EPROM Checksum

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Table 4.4 — Firmware Option Codes

FIRMWARE OPTION DECRIPTION

(none) Standard Firmware

-EF Enhanced Features Option

-RS Ramp/Soak Option

NOTE! If the EPROM information does not match this description, the EPROM probably contains a custom program. Custom programs may not work as described in this manual. If that is the case, contact your dealer for more information about the ﬁrmware.

Setup Loop Input Menu

SETUP LOOP 01 INPUT ?

ALARM

The SETUP LOOP INPUT menu includes parameters related to the loop input:

• Input type

• Input units

• Input scaling and calibration

• Input ﬁltering

Table 4.5 — Setup Loop Input

PARAMETER DEFAULT VALUE

INPUT TYPE? J

LOOP NAME? 01

INPUT UNITS? ˚F

INPUT READING OFFSET? 0˚ F

REVERSED T/C DETECT?

INPUT PULSE SAMPLE TIME?

DISP FORMAT?

INPUT SCALING HI PV?

INPUT SCALING HI RDG?

INPUT SCALING LO PV?

INPUT SCALING LO RDG?

OFF

-999 to 3000

1000

100.0% FS

0.0% FS

INPUT FILTER? 3 SCANS

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This parameter is available only for the pulse loop (loop 5 on four-channel controller, loop 9 on an eight-channel controller

and loop 17 on a sixteen-channel controller).

These parameters are available only if LINEAR is selected for INPUT TYPE.

These parameter is available only if INPUT TYPE is set to one of the thermocouple or RTD options.

Input Type

Specify the type of input sensor used on this loop:

• Thermocouple type J, K, T, S, R, B or E.

• RTD 1 or RTD 2.

• Linear input.

• Skip (an input type available for unused loops). Alarms are not detected, and the scanning display does not show loops that are set to SKIP.

• Pulse input (available only for loop 5 on a four-channel controller, loop 9 on an eight-channel controller or loop 17 on a sixteen-channel controller).

01 INPUT TYPE ? J T/C

ALARM

Selectable values: See Table 4.6.

Table 4.6 — CLS200 Input Types and Ranges

INPUT TYPE INPUT RANGE

J T/C

K T/C

T T/C

S T/C

R T/C

B T/C

E T/C

RTD1

RTD2

PULSE

SKIP

-350 to 1,400˚ F (-212 to 760˚ C)

-450 to 2,500˚ F (-268 to 1,371˚ C)

-450 to 750˚ F (-268 to 399˚ C)

0 to 3,200˚ F (-18 to 1,760˚ C)

0 to 3,210˚ F (-18 to 1,766˚ C)

150 to 3,200˚ F (+66 to 1,760˚ C)

-148.0 to 572.0˚ F (-100.0 to 275.0˚ C)

-184 to 1,544˚ F (-120 to 840˚ C)

0 to 2kHz

Loop not used.

LINEAR

See Linear Scaling Parameters on page 77.

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Loop Name

Assign a two-character name to the loop. This name is shown on the single loop display in place of the loop number.

01 LOOP NAME ? 01

ALARM

Selectable values: 0 to 9, A to Z, %, /, ° (degree symbol).

Input Units

For loops with temperature sensor input types, choose a temperature scale: Fahrenheit or Celsius. For a linear or pulse loop, choose a three-character description of the loop’s engineering units.

01 INPUT UNITS ?

ALARM

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

Table 4.7 — Input Character Sets

INPUT CHARACTER SETS FOR UNITS

Thermocouple or RTD ˚ F or ˚ C

LINEAR or PULSE 0 to 9, A to Z,%, /, °, space

Input Reading Offset

If the input type is a thermocouple or RTD, specify the offset to correct for signal inaccuracy at a given point. For example, at temperatures below 400°F, a type J thermocouple may be inaccurate or “offset” by several degrees. Use an independent thermocouple or your own calibration equipment to ﬁnd the offset for your equipment.

A positive value increases the reading and a negative value decreases it.

01 INPUT READING OFFSET ? 0˚F

ALARM

Selectable values: See Table 4.8.

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Table 4.8 — Input Reading Offset

TYPE OF SENSOR

RTD2

RTD1 -300.0 to +300.0 -300.0 to +300.0

B S

R -300 to +66 -300 to +300

˚F ˚C

-300 to +300 -300 to +300

-300 to +76 -300 to +300

OFFSET RANGE

Reversed T/C Detection

Set this parameter to ON to enable polarity checking for thermocouples. If a reversed thermocouple is detected, the controller sets the loop to manual control at the SENSOR FAIL HT OUTPUT or SENSOR FAIL CL OUTPUT power level and displays the alarm.

01 REVERSED T/C DETECT ? OFF

ALARM

Selectable values: ON or OFF.

Input Pulse Sample Time

You can connect a digital pulse signal of up to 2kHz to the pulse input. Use this parameter to set the time over which pulses are counted. The controller counts pulses for the amount of time you set here before calculating the frequncy. The controller scales this frequency and uses the resulting value as the process variable for the pulse loop. Generally, the longer the pulse sample time, the more stable the process variable, but the slower the response of the pulse loop.

This parameter is available only for loop 5 on a four-loop model, loop 9 on an eight-loop model or loop 17 on a sixteen-loop model

17 INPUT PULSE SAMPLE TIME ? 1S

ALARM

Selectable values: 1 to 20 seconds.

Linear Scaling Parameters

The following parameters are only available if the input type is LINEAR or PULSE. These parameters let you scale the raw input readings (in millivolts or Hertz) to the engineering units of the process variable.

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

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The scaling function is deﬁned by two points on a conversion line. This line relates the process variable (PV) to the input signal. The engineering units of the process variable can be any units—the graph in Figure 4.2 shows PSI as an example.

High Process Variable

Low Process Variable

Low Reading

Figure 4.2 — Two Points Determine Process Variable Conversion

Input Reading

High Reading

Before you enter the values determining the two points for the conversion line, you must choose an appropriate display format. The controller has six characters available for process display; select the setting with the desired number of decimal places. Use a display format that matches the range of the process variable and resolution of the sensor. The display format you choose is used for the process variable setpoint, alarms limits, deadband, spread and proportional band.

The process variable range for the scaled input is between the process variable values that correspond to the 0% and 100% input readings. For the pulse input, it is between the 0Hz and 2000Hz readings. The process variable range deﬁnes the limits for the setpoint and alarms. See Figure 4.3.

High Process Variabale

Process Variable

Low Process Variabale

Low Reading

Figure 4.3 — Process Variable Limited by Input Reading Range

Input Reading

High Reading

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Display Format

Select a display format for a linear or pulse input. Choose a format appropriate for the input range and sensor accuracy.

01 DISP FORMAT ?

-999 TO 3000

ALARM

Selectable values: The controller has several available display formats, as shown in Table 4.9. The table also shows the maximum and minimum process variable for each display format.

Table 4.9 — Display Formats

DISPLAY FORMAT

-9999 TO +30000

-999 TO +3000

-999.9 TO +3000.0

-99.99 TO +300.00

-9.999 TO +30.000

-.9999 TO +3.0000

MAXIMUM PROCESS

VARIABLE

30,000 -9,999

3,000 -999

3,000.0 -999.9

300.00 -99.99

30.000 -9.999

3.0000 -0.9999

MINIMUM PROCESS VARIABLE

High Process Variable

Set a high process variable for input scaling purposes. The high process variable and the high reading (HI RDG) together deﬁne one of the points on the linear scaling function’s conversion line. Set HI PV to the value you want displayed when the signal is at the level set for the HI RDG.

01 INPUT SCALING HI PV ? 1000

ALARM

Selectable values: Any value between the low process variable (LO PV) and the maximum process variable for the selected display format. See Table 4.9.

High Reading

Enter the input signal level that corresponds to the high process variable (HI PV) you entered in the previous parameter.

01 INPUT SCALING HI RDG? 100.0%FS

ALARM

Selectable values: For linear inputs, any value between -99.9% and 999.9% of full scale, where 100% corresponds to 60mV and 0% corresponds to 0mV. For pulse inputs, any value between 0 and 2000HZ. The high reading must be greater than the low reading (LO RDG).

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Low Process Variable

Set a low process variable for input scaling purposes. The low process variable and the low reading (LO RDG) together deﬁne one of the points on the linear scaling function’s conversion line. Set LO PV to the value you want displayed when the signal is at the level set for the low reading (LO RDG).

01 INPUT SCALING LO PV ? 0

ALARM

Selectable values: Any value between the minimum process variable and the high process variable for the selected display format. See Table 4.9 on the previous page.

Low Reading

Enter the input signal level that corresponds to the low process variable (LO PV) you entered in the previous parameter.

01 INPUT SCALING LO RDG? 0.0%FS

ALARM

Selectable values: For linear inputs, any value between -99.9% and 999.9% percent of full scale, where 100% corresponds to 60mV and 0% corresponds to 0mV. For pulse inputs, any value between 0 and 2000 HZ. The low reading must be less than the high reading (HI RDG).

Input Filter

The controller has two types of input ﬁltering:

• The rejection ﬁlter ignores sensor readings outside the acceptance band when subsequent readings are within the band. For temperature sensors, the band is ±5° about the last accepted reading. For linear inputs the band is ±0.5% of the input range. This ﬁlter is not adjustable.

• A simulated resistor-capacitor (RC) ﬁlter damps 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.

01 INPUT FILTER? 3 SCANS

ALARM

Selectable values: 0 to 255 scans. 0 disables the ﬁlter.

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Setup Loop Control Parameters Menu

Use the SETUP LOOP CONTROL PARAMS menu to adjust heat and cool control parameters, including:

• Proportional band (PB, or gain), integral (TI or reset), and derivative (TD, or rate) settings

• Output ﬁlter

• Spread between heat and cool outputs

The controller has separate PID and ﬁlter settings for heat and cool outputs. The screens used to set these parameters are nearly identical. In this section, only the heat screens are shown and explained. The heat and cool parameters appear only if the corresponding output is enabled.

See Setup Loop Outputs Menu on page 84 for help enabling and disabling heat and cool outputs.

SETUP LOOP 01 CONTROL PARAMS?

ALARM

Table 4.10 shows the parameters available in the SETUP LOOP CONTROL PARAMS menu.

Table 4.10 — Setup Loop Control Parameters

PARAMETER DEFAULT VALUE

HEAT CONTROL PB? Depends upon the INPUT TYPE setting; 50 for J-type thermocouple.

HEAT CONTROL TI?

HEAT CONTROL TD?

HEAT CONTROL FILTER?

COOL CONTROL PB?

COOL CONTROL TI?

COOL CONTROL TD?

COOL CONTROL FILTER?

SPREAD?

RESTORE PID DIGIN?

Depends upon the INPUT TYPE setting; 180 SEC/R for J-type thermocouple.

Depends upon the INPUT TYPE setting; 60 SEC/R for J-type thermocouple.

Depends upon the INPUT TYPE setting; 0 SECONDS for J-type thermocouple.

NONE

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Heat or Cool Control PB

Set the proportional band (also known as gain). A larger value yields less proportional action for a given deviation from setpoint.

01 HEAT CONTROL PB ? 50

ALARM

Selectable values: Dependent upon sensor type.

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

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

Default PB =

(High Range - Low Range)

Gain

Heat or Cool Control TI

Set the integral term (also known as reset). A larger value yields less integral action.

01 HEAT CONTROL TI ? 180 SEC/R

ALARM

Selectable values: 0 (off) to 6000 seconds.

Heat or Cool Control TD

Set the derivative constant. A larger value yields greater derivative action.

01 HEAT CONTROL TD ? 0

ALARM

Selectable values: 0 to 255 seconds.

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Heat or Cool Output Filter

Dampen the response of the heat or cool output. 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. A larger value results in a slower, or more dampened, response to changes in the process variable.

01 HEAT CONTROL FILTER ? 3

ALARM

Selectable values: 0 to 255.0 disables the output ﬁlter.

Spread

For a loop using on/off control, the spread is the control hysteresis. This determines the difference between the point at which a heat output turns off as the temperature rises, and the point at which it turns back on as the temperature falls.

For a loop using PID control, the spread determines how far the process variable must be from the setpoint before the controller can switch from heating to cooling. A loop will not switch from heat to cool or vice versa unless the process variable deviates from setpoint by more than the spread.

When the loop is using PID control and the spread is set to 0, the PID calculation alone determines when the heat or cool output should be on.

01 SPREAD ? 5

ALARM

Selectable values: 0 to 255, 25.5, 2.55, .255, or .0255, depending upon the DISP FORMAT setting.

Restore PID Digital Input

To enable the sensor failure recovery feature, select a digital input at this parameter. If the speciﬁed input is held low when a thermocouple fails, the loop returns to automatic control after the thermocouple is repaired.

01 RESTORE PID DIGIN ? NONE

ALARM

Selectable range: NONE (disable the sensor failure recovery feature), 1 to 8.

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Setup Loop Outputs Menu

Use the SETUP LOOP OUTPUTS menu to:

• Enable or disable outputs

• Set output type

• Set cycle time for time proportioning outputs

• Enter Serial DAC parameters (for Serial DAC outputs)

• Select control action

• Set output level limit and limit time

• Select sensor fail output (output override)

• Select a nonlinear output curve

SETUP LOOP 01 OUTPUTS ?

ALARM

Table 4.11 shows the parameters available in the SETUP LOOP OUTPUTS menu. Both heat and cool outputs have the same parameters; only one of each parameter is shown.

Table 4.11 — Setup Loop Outputs

PARAMETER DEFAULT VALUE

HEAT CONTROL OUTPUT? ENABLED

HEAT OUTPUT TYPE? TP

HEAT OUTPUT CYCLE TIME? 10s

SDAC MODE?* VOLTAGE

SDAC LO VALUE?* 0.00 VDC

SDAC HI VALUE?* 10.00 VDC

HEAT OUTPUT ACTION? REVERSE

HEAT OUTPUT LIMIT? 100%

HEAT OUTPUT LIMIT TIME? CONT

SENSOR FAIL HT OUTPUT? O%

HEAT T/C BRK OUT AVG? OFF

HEAT OUTPUT? LINEAR

COOL CONTROL OUTPUT? DISABLED

The SDAC parameters are available only if you select SDAC as the output type.

Use these parameters to conﬁgure the Serial DAC signal output.

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Enable or Disable Heat or Cool Outputs

Enable or disable the heat or cool output for the loop. If you want the loop to have a control output, you must enable at least one output. You can also disable a heat or cool control output and use the output for something else, such as an alarm.

01 HEAT CONTROL OUTPUT ? ENABLED

ALARM

Selectable values: ENABLED or DISABLED.

Heat or Cool Output Type

Select the output type.

01 HEAT OUTPUT TYPE ? TP

ALARM

Selectable values: TP, DZC, SDAC, ON/OFF, 3P DZC. See Table 4.12 for a description of the output types.

NOTE! The controller assigns digital output 34 as a clock line for the Serial DAC. You will not be able to assign another function to output 34 if any loop’s output is set to SDAC.

Table 4.12 — Heat / Cool Output Types

OPTION OUTPUT TYPE DEFAULT VALUE

DZC

SDAC

ON/OFF

3P DZC

Time Proportioning

Distributed Zero Crossing

Serial DAC Use with Serial DAC.

On/Off Output either full on or full off.

3-Phase Distributed Zero Crossing

Percent output converted to a percent duty cycle over the user-selected, ﬁxed time base.

Output on/off state calculated for every ac line cycle. Use with solid state relay or Dual DAC.

Use with 3-phase heaters when wired in delta conﬁguration. (For grounded Y conﬁguration, use DZC instead.)

For an expanded description of these output types, see Chapter 8, Tuning and Control.

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Heat or Cool Cycle Time

Set the cycle time for time proportioning outputs.

This parameter appears only if the heat or cool output type for the loop is set to time proportioning (TP).

01 HEAT OUTPUT CYCLE TIME? 10s

ALARM

Selectable values: 1 to 255 seconds.

SDAC Mode

Select the Serial DAC output signal.

01 SDAC MODE? VOLTAGE

ALARM

Selectable values: CURRENT or VOLTAGE.

SDAC Low Value

Set the low output signal level for the Serial DAC. The Serial DAC converts 0% output from the controller to the value set here.

Set the high and low values to match the input range of the output device. For instance, if the output device has a 0.00 - 10.00 V range, set the SDAC LO VALUE to 0.00 VDC and set the SDAC HI VALUE to 10.00 VDC.

01 SDAC LO VALUE?

0.00 VDC

ALARM

Selectable values: 0.00 to 9.00 VDC or 0.0 to 19.90 MA. This value must be less than the SDAC HI VALUE.

SDAC High Value

Set the high output signal level for the Serial DAC. The Serial DAC converts 100% output from the controller to the value set here.

Set the high and low values to match the range of the output device. For instance, if the output device has a 4 to 20mA range, set the SDAC HI VALUE to 20.00 MA and the SDAC LO VALUE to 4.00 MA.

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01 SDAC HI VALUE?

10.00 VDC

ALARM

Selectable values: 0.10 to 10.00 VDC or 0.10 to 20.00 MA. This value must be greater than the SDAC LO VALUE.

Heat or Cool Output Action

Select the control action for the output. Normally, heat outputs are set to reverse action and cool outputs are set to direct action. When output action is set to REVERSE, the output goes up when the process variable goes down. When set to DIRECT, the output goes up when the process variable goes up.

01 HEAT OUTPUT ACTION? REVERSE

ALARM

Selectable values: REVERSE or DIRECT.

Heat or Cool Output Limit

This parameter limits the maximum PID control output for a loop’s heat or cool output. This limit may be continuous, or it or it may be in effect for a speciﬁed number of seconds (see the next parameter). If you choose a timed limit, the output limit time restarts when the controller powers up and whenever the loop goes from manual to automatic control. The output limit only affects loops under automatic control. It does not affect loops under manual control.

01 HEAT OUTPUT ACTION? REVERSE

ALARM

Selectable values: 0 to 100%.

Heat or Cool Output Limit Time

Set a time limit for the output limit set at the previous parameter.

01 HEAT OUTPUT LIMIT TIME? CONT

ALARM

Selectable values: 1 to 999 seconds, or to CONT (continuous).

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Sensor Fail Heat or Cool Output

When a sensor fail alarm occurs or when the OUTPUT OVERRIDE DIG INPUT becomes active on a loop that is in automatic control, that loop goes to manual control at the percent power output set here.

01 SENSOR FAIL HT OUTPUT ? 0%

ALARM

Selectable values: 0 to 100%.

NOTE! When a sensor fails or the override input is detected, both the heat and cool outputs are set to their fail settings. In most applications, SENSOR FAIL HT OUTPUT and SENSOR FAIL CL OUTPUT should be set to 0%.

Heat or Cool Thermocouple Break Output Average

If you set this parameter to ON and a thermocouple break occurs, a loop set to automatic control status will go to manual mode at a percentage equal to the average output prior to the break.

01 HEAT T/C BRK OUT AVG ? OFF

ALARM

Selectable range: ON or OFF.

Heat or Cool Linearity

Select an output curve. For a nonlinear process, select CURVE 1 or CURVE 2.

01 HEAT OUTPUT? LINEAR

ALARM

Selectable values: CURVE 1, CURVE 2, or LINEAR. Refer to Figure 4.4.

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100

Actual Output

Linear

Curve 1

19 19

PID Calculation

Curve 2

Figure 4.4 — Linear and Nonlinear Outputs

If curve 1 or 2 is selected, a PID calculation results in a lower actual output level than the linear output requires. One of the nonlinear curves may be used when the response of the system to the output device is nonlinear.

Setup Loop Alarms Menu

Use the SETUP LOOP ALARMS menu to set:

• High and low process and deviation alarms

• Alarm outputs

• Alarm/control behavior

• Alarm deadband

• Alarm delay

SETUP LOOP 01 ALARMS ?

ALARM

Table 4.13 shows the parameters available in the SETUP LOOP ALARMS menu.

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Table 4.13 — Setup Loop Alarms

PARAMETER DEFAULT VALUE

HI PROC ALARM SETPT? 1000

HI PROC ALARM TYPE? OFF

HI PROC ALARM OUTPUT? NONE

DEV ALARM VALUE? 5

HI DEV ALARM TYPE? OFF

HI DEV ALARM OUTPUT? NONE

LO DEV ALARM TYPE? OFF

LO DEV ALARM OUTPUT? NONE

LO PROC ALARM SETPT? O

LO PROC ALARM TYPE? OFF

LO PROC ALARM OUTPUT? NONE

ALARM DEADBAND? 2

ALARM DELAY? O SECONDS

High Process Alarm Setpoint

Set the value at which the high process alarm activates.

01 HI PROC ALARM SETPT ? 1000

ALARM

Selectable values: Any point within the scaled sensor range.

High Process Alarm Type

Select an alarm type for the high process alarm.

01 HI PROC ALARM TYPE ? OFF

ALARM

Selectable values: OFF, ALARM, or CONTROL.

High Process Alarm Output Number

Choose a digital output to activate when the high process alarm occurs, if desired.

01 HI PROC ALARM OUTPUT? NONE

ALARM

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Selectable values: NONE, or any output from 1 to 34 not enabled for closed-loop control or for the Serial DAC clock.

Deviation Alarm Value

Set the deviation from setpoint at which the high and low deviation alarms occur.

01 DEV ALARM VALUE ? 5

ALARM

Selectable values: 0 to 255, 25.5, 2.55, .255 or .0255, depending on the INPUT TYPE and DISP FORMAT settings.

High Deviation Alarm Type

Select an alarm type for the high deviation alarm.

01 HI DEV ALARM TYPE ? OFF

ALARM

Selectable values: ALARM, CONTROL or OFF.

High Deviation Alarm Output Number

Choose a digital output to activate when the high deviation alarm occurs, if desired.

01 HI DEV ALARM OUTPUT ? NONE

ALARM

Selectable values: NONE, or any output from 1 to 34 not enabled for closed-loop control or for the Serial DAC clock.

Low Deviation Alarm Type

Select an alarm type for the low deviation alarm.

01 HI DEV ALARM TYPE ? OFF

ALARM

Selectable values: ALARM, CONTROL or OFF.

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Low Deviation Alarm Output Number

Choose a digital output to activate when the low deviation alarm occurs, if desired.

01 LO DEV ALARM OUTPUT ? NONE

ALARM

Selectable values: NONE, or any output from 1 to 34 not enabled for closed-loop control or for the Serial DAC clock.

Low Process Alarm Setpoint

Set a low process alarm setpoint. See Process Alarms on page 61.

01 LO PROC ALARM SETPT? 0

ALARM

Selectable values: Any value within the input sensor’s range.

Low Process Alarm Type

Select an alarm type for the low process alarm.

01 LO PROC ALARM TYPE ? OFF

ALARM

Selectable values: ALARM, CONTROL or OFF.

Low Process Alarm Output Number

Choose a digital output to activate when the low process alarm occurs, if desired.

01 LO PROC ALARM OUTPUT ? NONE

ALARM

Selectable values: NONE, or any output from 1 to 34 not enabled for closed-loop control or for the Serial DAC clock.

Alarm Deadband

Set an alarm deadband. This deadband value applies to the high process, low process, high deviation and low deviation alarms for the loop. Use the alarm deadband to avoid repeated alarms as the process variable cycles around an alarm value.

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01 ALARM DEADBAND ? 2

ALARM

Selectable values: 0 to 255, 25.5, 2.55, .255 or .0255, depending on the INPUT TYPE and DISP FORMAT settings.

Alarm Delay

Set a loop alarm delay. This parameter delays failed sensor, process and deviation alarms until the alarm condition has been continuously present for longer than the alarm delay time.

01 ALARM DELAY ? 0 SECONDS

ALARM

Selectable range: 0 to 255 seconds.

Manual I/O Test

This menu facilitates testing of:

• Digital inputs

• Digital outputs

• The keypad buttons

MANUAL I/O TEST ?

ALARM

Table 4.14 shows the screens available in the MANUAL I/O TEST menu.

Table 4.14 — Manual I/O Test

PARAMETER DEFAULT VALUE

DIGITAL INPUTS HHHHHHHH

TEST DIGITAL OUTPUT? 1: IN USE

DIGITAL OUTPUT NUMBER XX? OFF

KEYPAD TEST N/A

DISPLAY TEST N/A

NOTE! The DIGITAL OUTPUT NUMBER screen appears only if an unassigned output has been selected in the TEST DIGITAL OUTPUT screen.

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Digital Inputs

View the logic state of the eight digital inputs as H (high) meaning the input is not pulled low, or L (low) meaning the input is connected to the controller common.

This screen shows the state of inputs 1 to 8 from left to right. See Figure 4.5. Since inputs are pulled high when they are not connected, test an input by shorting it to controller common and making sure this screen shows the correct state for that input.

Input 1

Figure 4.5 — Digital Inputs Screen

DIGITAL INPUTS HHHHHHHH

ALARM

Input 8

When you are done testing digital inputs, press YES or NO to advance to the next screen, or press BACK to return to the MANUAL I/O TEST menu.

Test Digital Output

Select one of the digital alarm outputs to test. You will test the output on the next screen.

You cannot force the state of an output enabled for control.

TEST DIGITAL OUTPUT? 1:IN USE

ALARM

Selectable values: Any output from 1 to 34 that is not enabled for closed-loop control or for the Serial DAC clock and GA, the global alarm output.

Digital Output Number

This screen appears only if you selected an output that is not in use for control at the TEST DIGITAL OUTPUT screen.

Use this parameter to manually toggle a digital output on or off to test it. Toggling an output ON sinks current from the output to the controller common. Toggling the output OFF stops current ﬂow. All tested outputs are set to OFF when you exit the MANUAL I/O TEST menu.

You cannot toggle outputs enabled for control. To test a control loop output, ﬁrst disable it using the SETUP LOOP OUTPUTS menu.

DIGITAL OUTPUT NUMBER XX ? OFF

ALARM

Selectable values: ON or OFF.

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Keypad Test

Test the keypad. The test begins automatically when the screen appears.

KEYPAD TEST QUIT = "NO"+"NO"

ALARM

• Press any key to test the keypad. The controller will display the name of the key you have pressed.

• Press NO twice to end the test and return to the top of the MANUAL I/O TEST menu.

Display Test

Use this function to test the display.

DISPLAY TEST?

ALARM

Press YES to enter the test and display the instruction screen.

TO TEST DISPLAY Y-TOGGLE N-QUIT

ALARM

Press YES to display the pixel test pattern.

• Press YES to toggle the pixel pattern.

• Press NO to end the test and return to the top of the MANUAL I/O TEST menu.

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Chapter 5: Enhanced Features

This chapter explains ﬁve additional features for the CLS200 controller when enabled with enhanced features option ﬁrmware:

• Process variable retransmit

• Cascade control

• Ratio control

• Remote analog setpoint

• Differential control

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Enhanced Features Menus

SETUP GLOBAL PARAMETERS

SETUP LOOP INPUTS

Enter

NONE

SETUP LOOP CONTROL PARAMETERS

Enter

NONE

SETUP LOOP OUTPUTS

HEAT OUTPUT RETRANS PV?

Enter 1-9

HEAT RETRANS MIN INP?

HEAT RETRANS MIN OUT%?

HEAT RETRANS MAX INP?

HEAT RETRANS MAX OUT%?

COOL OUTPUT RETRANS PV?

YES

SETUP LOOP PV RETRANSMIT

SETUP LOOP CASCADE

YES

CASCADE PRIM. LOOP?

CASCADE BASE SP?

CASCADE MIN SP?

CASCADE MAX SP?

CASCADE HT SPAN?

CASCADE CL SPAN?

SETUP LOOP RATIO CONTROL

SETUP LOOP ALARMS

YES

RATIO CONTROL MSTR LOOP?

RATIO CONTROL MIN SP?

RATIO CONTROL MAX SP?

RATIO CONTROL CTRL RATIO?

RATIO CONTROL SP DIFF?

MANUAL I/O TEST

Enter 1-9

COOL RETRANS MIN INP?

COOL RETRANS MIN OUT%?

COOL RETRANS MAX INP?

COOL RETRANS MAX OUT%?

Figure 5.1 — Enhanced Features Option Menus

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Process Variable Retransmit

The process variable retransmit feature retransmits the process signal of one loop (primary) via the control output of another loop (secondary). This signal is linear and proportional to the engineering units of the primary loop input.

Typical uses include data logging to analog recording systems and long distance transmission of the primary signal to avoid degradation of the primary signal. The signal can also be used as an input to other types of control systems such as a PLC.

Any available output (heat or cool) may be used as a retransmit output. Any process variable (including the same loop number input) may be retransmitted.

The controller output signal must be connected to a Dual DAC or Serial DAC converter to get a 4 to 20mA DC or 0 to 5VDC signal. The choice of converter depends on application requirements.

The process variable retransmit feature is included in both the ramp/soak and enhanced features options.

NOTE! If an output is deﬁned as a process variable retransmit, it cannot be used for PID control.

Process Variable Retransmit Menu

The setup parameters for the process variable retransmit feature appear in the SETUP LOOP PV RETRANSMIT menu.

SETUP LOOP 02 PV RETRANSMIT?

ALARM

Press YES to view the process variable retransmit parameters.

Retransmit Process Variable

Enter the number of the loop that provides the process variable for the retransmit calculation. If you set this parameter to NONE and press NO, the controller skips to the COOL OUTPUT

RETRANS PV screen. The COOL parameter is set up the same way as the HEAT parameter.

02 HEAT OUTPUT RETRANS PV? 02

ALARM

Selectable values: Any loop or NONE.

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Minimum Input

Enter the lowest value of the process variable to be retransmitted. This value is expressed in the same engineering units as the input loop.

If the process variable falls below the minimum, the output will stay at the minimum value.

02 HEAT RETRANS MIN INP? 1000

ALARM

Selectable values: Any value in the input loop’s range.

Minimum Output

Enter the output value (0 to 100%) that corresponds to the minimum input.

If you select a minimum output value other than 0%, the output will never drop below MIN OUT, even if the process variable drops below the MIN INP that you speciﬁed.

02 HEAT RETRANS MIN OUT%? 0%

ALARM

Selectable values: 0 to 100%.

Maximum Input

Enter the highest value of the process variable to be retransmitted. This value is expressed in the same engineering units as the input loop.

If the process variable goes above the maximum, the output will stay at the maximum value.

02 HEAT RETRANS MAX INP? 10000

ALARM

Selectable values: Any value in the input loop’s range.

By adjusting the maximum and minimum inputs, you can scale the output appropriately. See Figure 5.2.

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100%

Maximum

Output

Minimum

Output

Output Power (%)

Figure 5.2 — Linear Scaling of Process Variable for Retransmit

Minimum Input

Input Process Variable

Maximum Input

Maximum Output

Enter the output value (0 to 100%) which corresponds to the maximum input.

The output will never go above the this maximum output percentage, regardless of how high the process variable goes.

02 HEAT RETRANS MAX OUT%? 100%

ALARM

Selectable values: 0 to 100%.

Process Variable Retransmit Example: Data Logging

The CLS200 controls the temperature of a furnace. The thermocouple in one of the zones is connected to the controller and is used for closed-loop PID control. An analog recorder data logging system is also in place, and a recording of the process temperature is required. The recorder input is a linear 4 to 20mA DC signal representing a process variable range of 0 to 1000°F.

100

Watlow CLS200 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety Warnings, Cautions, and Notes

Technical Assistance

Return Material Authorization (RMA)

Contact Watlow

Warranty

Table of Contents

List of Figures

List of Tables

Chapter 1: System Overview

Manual Contents

Getting Started

Safety Symbols

Initial Inspection

Product Features

CLS200 Parts List

CLS200

TB50

CLS200 Cabling

External Safety Devices

Power-Fail Protection

Chapter 2: Installation

Typical Installation

Mounting Controller Components

Recommended Tools

Mounting the Controller

Mounting the TB50

Mounting the Power Supply

System Wiring

Wiring Recommendations

Noise Suppression

Ground Loops

Power Connections

Wiring the Power Supply

Connecting TB50 to CLS200

Testing Your System

TB50 or TB18 Test

Digital Output Test

Digital Input Test

Sensor Wiring

Input Wiring Recommendations

Thermocouple Connections

RTD Input Connections

Reference Voltage Terminals

Voltage Input Connections

Current Input Connections

Pulse Input Connections

Wiring Control and Digital I/O

Output Wiring Recommendations

Cable Tie Wraps

Digital Outputs

Digital Inputs

TB18 Connections

TB50 Connections

Analog Outputs

Wiring the Dual DAC

Wiring the Serial DAC

Serial Communications

EIA/TIA-232 Interface

EIA/TIA-485 Interface

EIA/TIA-485 Converters and Laptop Computers

Chapter 3: Using CLS200

Front Panel

Front Panel Keys

Displays

Bar Graph Display

Single Loop Display

Alarm Displays

System Alarms

Job Display

Changing the Setpoint

Selecting the Control Status

Manual and Automatic Control

Autotuning a Loop

Using Alarms

Alarm Delay

Failed Sensor Alarms