Watlow CLS200 Operating Manual

CLS200

User’s Guide

CLS200 Series User’s Guide

Safety Warnings, Cautions, and Notes

Avertissements, Attentions et Remarques

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.

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 [e-mail] or by dialing [phone] 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, [phone], 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: [phone] Fax: [phone] 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.

3

Table of Contents

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	Controllers  155
	Control Algorithms  131	Voltage Inputs to Four-Loop and Eight-Loop
	On/Off Control  131	Controllers  155
		RTDs and Thermistor Inputs to Four-Loop and
	Proportional Control  132
		Eight-Loop Controllers  156
	Proportional and Integral Control  133
		Sixteen-Loop Input Circuit  157
	Proportional, Integral and Derivative
		Current Inputs to Sixteen-Loop Controllers  157
	Control  133
		Voltage Inputs to Sixteen-Loop Controllers  158
	Heat and Cool Outputs  134
		Scaling and Calibration  158
	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 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 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

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

6

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

8

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

11

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.

12

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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•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 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	The number of analog inputs and control
			loops that can be controlled based on the
	Number of Loops	8 Loops	feedback from the analog inputs. There is an
			additional control loop that uses feedback
		16 Loops
			from the pulse input.
			Includes closed-loop, PID control, auto-
		Standard	tune, alarms, job memory and failed sensor
			detection
	Firmware	Ramp and Soak	Provides the features of the standard version
			plus the additional Ramp and Soak features
		Enhanced Features	Provides the features of the standard version
			plus the additional Enhanced Features
	Digital I/O Termination	Screw Terminals (TB18)	TB18 Terminal Block
		Mass Termination (SCSI)	SCSI Connector
	Digital I/O Termination	None	No external terminal board included
	Board Accessory	TB50 Terminal Board	TB50-SCSI (50 Pin terminal board)
		None
	Digital I/O Termination	3-foot SCSI cable	Accessory cable to connect digital I/O
		6-foot SCSI cable	signals between the SCSI connector on the
	Cable Accessory
			controller and the TB50 board
		3-foot SCSI cable with right angle
		connector
		EIA/TIA-232	Application uses 232 communication or no
			communication
	Serial Communication	EIA/TIA-485, not terminated	Application uses 485 communication, this
	Jumper Settings		controller is not last in the network
		EIA/TIA-485, terminated	Application uses 485 communication, this
			controller is last in the network
	Serial Communication	None	No communication cable
		10 foot communication cable
	Cable		Cable for 232 communication
		(DB-9 female/bare wires)
		Plastic collar and screw clips	Standard mounting hardware
	Mounting Hardware
		Low profile metal L-brackets and	Mounting hardware for legacy applications
		screws	with tight fit
	Customer Specific	None	Not applicable to standard product

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	CHARACTERISTIC		OPTIONS	DESCRIPTION
	Analog Input 1	Options for all units:		Standard units accept thermocouples on
				all inputs. Controllers can be equipped with
	Analog Input 2	• Standard (Thermocouples and
				resistors to scale signals for various types
			-10 to 60mV)
	Analog Input 3
				of sensors. These resistors must be factory
		• Linear Current: 0-20mA DC /
	Analog Input 4			installed.
			4-20mA DC
	Analog Input 5			Sixteen loop controllers cannot accept RTD
		•	Linear Voltage: 0-5VDC
	Analog Input 6			sensors.
		•	Linear Voltage: 0-10VDC
	Analog Input 7
		Additional options for 4-loop and
	Analog Input 8
		8-loop units:
	Analog Input 9
		• 100 Ohm RTD Tenths Degree
	Analog Input 10
		• 100 Ohm RTD Whole Degree
	Analog Input 11
	Analog Input 12
	Analog Input 13
	Analog Input 14
	Analog Input 15
	Analog Input 16

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	TB50 Accessory Board
	Sensor Inputs	SCSI Cable

SCSI Connector

TB50 allows connection to...

35 Outputs for Control & Alarms

CLS200 with TB18 Digital I/O 8 Digital Inputs 1 Pulse Input

Sensor Inputs

TB18 allows connection to...

11 Outputs for Control & Alarms

2 Digital Inputs

1 Pulse Input

Figure 2.1 — CLS200 System Components

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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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.

2.44 in.

(62 mm)

1.98 in.

(50 mm)

1.00 in.

(25 mm) 8.00 in.

(203 mm)

Figure 2.2 —Clearance with TB18 Option

2.44 in.

(62 mm)

1.98 in.

(50 mm)

1.00 in.

(25 mm) 10.00 in.

(254 mm)

Figure 2.3 —Clearance with Standard SCSI Cable

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2.44 in.

(62 mm)

1.98 in.

(50 mm)

1.00 in.

(25 mm) 9.00 in.

(229 mm)

Figure 2.3a — Clearance with Right-Angle SCSI Cable

4.02 in.

(102 mm)

Figure 2.4 —Mounting Bracket Clearance

1.80 ± 0.020 in.

(45.7 ± 0.5 mm)

3.63 ± 0.020 in.

(92.2 ± 0.5 mm)

Figure 2.5 —Panel Thickness and Cutout Size

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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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		3.6 in.
	0.2 in.	(91 mm)
	(5 mm)
			3.6 in.
			(91 mm)
	0.7 in.		0.2 in.
	(18 mm)	2.6 in.
			(5 mm)
		(66 mm)

Figure 2.9 — Mounting a TB50 with Standoffs

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.

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.

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	MM2	MAXIMUM LENGTH
	Analog Inputs	Belden 9154	2	20	0.5
		Belden 8451	2	22	0.5
	RTD Inputs	Belden 8772	3	20	0.5
		Belden 9770	3	22	0.5
	Thermocouple	T/C Ext. Wire	2	20	0.5
	Inputs
	Control Outputs	Belden 9539	9	24	0.2
		Belden 9542	20	24	0.2
	and Digital I/O
		Ribbon Cable	50	22 to 14	0.5 to 2.5
	Analog Outputs	Belden 9154	2	20	0.5
		Belden 8451	2	22	0.5
		Belden 9729	4	24	0.2	4,000 ft. (1,219 m)
	Computer	Belden 9730	6	24	0.2
	Communication:	Belden 9842	4	24	0.2	4,000 ft. (1,219 m)
	EIA/TIA-232, 422
		Belden 9843	6	24	0.2
	or 485, or 20mA
		Belden 9184	4	22	0.5	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	Serial Communication
Power Input

TB18

Digital Inputs

Digital Outputs

Pulse Input

Figure 2.10 — CLS200 Series Controller with TB18

TB2

Power Input

Figure 2.11 — CLS200 Series Controller with TB50

TB1

Sensor Inputs

Serial Communication

SCSI to TB50

Digital Inputs

Digital Outputs

Pulse Input

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)			C G
		Add jumper *		V O N
	0 (5V COM)			+ M D CLS200
	+V2 (+15V)			**
			SSR	SSR
	COM (15V COM)		SSR	SSR
	-V2 (-15V)
	(Ground)		2 3 4 Serial DAC
	ACL (AC Line)	1
		+	C
		5	O
	ACN (AC Neutral)		M

N white

120/240

VAC H black

Supply G green

**

* If using 5VDC for outputs, jumper 5V common to 15V common. ** Connect terminals to ac panel ground.

Figure 2.12 —Power Connections

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