Watlow CPC400 User Manual

CPC400 Series

User’s Guide

Watlow Controls

1241 Bundy Blvd.
Winona, MN 55987

Repairs and Returns:
334 Westridge Drive
Watsonville, CA 95076

Customer Service:

Phone.....[phone]

Fax.........[phone]

Technical Support:

Phone.....[phone]

Fax.........[phone]

Email [e-mail]

Part No. 0600-2900-2000 Rev. 2.2
August 2005

Copyright © 2005, Watlow Anafaze, Incorporated

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

Anafaze is a registered trademark, and LogicPro is a trademark, of Watlow Electric
Manufacturing Company. Modbus is a trademark of Schneider Automation Incorpo­rated. Windows is a registered trademark of Microsoft Corporation in the United
States and/or other countries. UL is a registered trademark of Underwriters Labora­tories, Inc. All other trademarks are the property of their respective owners.

Warranty

Watlow Anafaze, Incorporated warrants that the products furnished under this Agree­ment will be free from defects in material and workmanship for a period of three years
from the date of shipment. The Customer shall provide notice of any defect to Watlow
Anafaze, Incorporated within one week after the Customer's discovery of such defect.
The sole obligation and liability of Watlow Anafaze, Incorporated under this warranty
shall be to repair or replace, at its option and without cost to the Customer, the defec­tive product or part.

Upon request by Watlow Anafaze, Incorporated, the product or part claimed to be
defective shall immediately be returned at the Customer's expense to Watlow Anafaze,
Incorporated. Replaced or repaired products or parts will be shipped to the Customer
at the expense of Watlow Anafaze, Incorporated.

There shall be no warranty or liability for any products or parts that have been sub­ject to misuse, accident, negligence, failure of electric power or modification by the
Customer without the written approval of Watlow Anafaze, Incorporated. Final deter­mination of warranty eligibility shall be made by Watlow Anafaze, Incorporated. If a
warranty claim is considered invalid for any reason, the Customer will be charged for
services performed and expenses incurred by Watlow Anafaze, Incorporated in han­dling and shipping the returned unit.

If replacement parts are supplied or repairs made during the original warranty
period, the warranty period for the replacement or repaired part shall terminate with
the termination of the warranty period of the original product or part.

The foregoing warranty constitutes the sole liability of Watlow Anafaze, Incorporated
and the Customer's sole remedy with respect to the products. It is in lieu of all other
warranties, liabilities, and remedies. Except as thus provided, Watlow Anafaze, Inc.
disclaims all warranties, express or implied, including any warranty of merchantabil­ity or fitness for a particular purpose.

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

List of Figures v
List of Tables ix
1 System Overview 1

Manual Contents 1
Getting Started 2
Product Features 2
CPC400 Parts List 4
Technical Description 6
Safety 9

2 Installation 11

Typical Installation 12
Mounting Controller Components 13
System Wiring 20
Power Connections 23
Testing the System 26
Sensor Wiring 27
Wiring Control and Digital I/O 32
Analog Outputs 39
Serial Communications 41

Table of Contents

3 Operation and Setup 47

General Navigation Map 48
Keypad 49
Displays 50
Changing the Set Point 54
Changing the Control Mode and Output Power 55
Accessing and Navigating the Setup Menus 56
Setting Up Closed-Loop Control 57
Setting Up a Process or Pulse Input 58
Autotuning 62
Setting Up Alarms 63
Setting Up Process Variable Retransmit 67
Setting Up Cascade Control 69
Setting Up Ratio Control 73
Setting Up Differential Control 75

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Table of Contents CPC400 Series User’s Guide

Setting Up Remote Analog Set Point 76
Setting Parameters Through Serial Communications or a LogicPro Program 78

4 Tuning and Control 81

Control Algorithms 81
Manually Tuning PID Loops 85
Control Outputs 88

5 Menu and Parameter Reference 91

Operator Parameters 92
Overview of the Setup Menus 94
Global Setup Menu
Input Menu 104
Channel Menu 109
Control Menu 111
Output Menu 116
Alarms Menu 121
Process Variable Retransmit Menu 125
Cascade Menu 127
Ratio Menu 128
Soft Integers Menu 130
Soft Booleans Menu 131
I/O Tests Menu 131
Additional Parameters for Serial Communications and LogicPro Programs 132

96

6 Troubleshooting and Reconfiguring 139

When There is a Problem 139
Troubleshooting the Controller 140
Corrective and Diagnostic Procedures 145
Additional Troubleshooting for Computer Supervised Systems 152
Clearing the RAM 153
Replacing the Flash Memory Chip 154
Changing the Hardware Communications Protocol 157
Installing Scaling Resistors 157
Configuring Serial DAC Outputs 162
Configuring Dual DAC Outputs 163

7 Specifications 165

CPC400 System Specifications 165
CPC400 Power Supply 176
Dual DAC Specifications 178
Serial DAC Specifications 180

Appendix A: Modbus Protocol 183

Master-Slave Model 183
Modbus ASCII and RTU Modes 185
Message Framing 185
Error Checking Methods 188
Function Codes 190
Examples 193

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CPC400 Series User’s Guide Table of Contents

Glossary 195
Index 201
Parameter Address Reference 209
Declaration of Conformity 215
Menu Structure 216

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Table of Contents CPC400 Series User’s Guide

iv Watlow Anafaze Doc. 0600-2900-2000

List of Figures

1 System Overview 1

Figure 1.1—CPC400 Standard Parts List 5
Figure 1.2—CPC400 Special Inputs Parts List 6
Figure 1.3—CPC400 Rear Views 6
Figure 1.4—CPC400 Front Panel 7
Figure 1.5—TB50 8

2 Installation 11

Figure 2.1—CPC400 System Components 12
Figure 2.2—Clearance with Straight SCSI Cable (L) and Right-Angle SCSI Cable (R) 14
Figure 2.3—Wiring Clearances 14
Figure 2.4—Mounting Bracket 15
Figure 2.5—Mounting the TB50 16
Figure 2.6—TB50 Mounted on a DIN Rail (Front) 16
Figure 2.7—TB50 Mounted on DIN Rail (Side) 17
Figure 2.8—Mounting a TB50 with Standoffs 17
Figure 2.9—CPC400 Power Supply Mounting Bracket 18
Figure 2.10—Dual DAC and Serial DAC Dimensions 19
Figure 2.11—CPC400 Series Controller with TB18 23
Figure 2.12—CPC400 Series Controller with TB50 23
Figure 2.13—Power Connections with the CPC400 Power Supply 25
Figure 2.14—CPC400 Connector Locations 28
Figure 2.15—Thermocouple Connections 29
Figure 2.16—RTD Connections 29
Figure 2.17—Voltage Signal Connections 30
Figure 2.18—Current Signal Connections 30
Figure 2.19—Encoder with 5V
Figure 2.20—Encoder Input with Voltage Divider 31
Figure 2.21—Digital Output Wiring 33
Figure 2.22—Sample Heat, Cool and Alarm Output Connections 35
Figure 2.23—Output Connections Using External Power Supply 35
Figure 2.24—TB50 Watchdog Timer Output 35
Figure 2.25—TB18 Watchdog Timer Output 35
Figure 2.26—Wiring Digital Inputs 36
Figure 2.27—Dual DAC with Current Output 39
Figure 2.28—Dual DAC with Voltage Output 40
Figure 2.29—Single/Multiple Serial DACs 41

Î

(dc) TTL Signal 31

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List of Figures CPC400 Series User’s Guide

Figure 2.30—Connecting One CPC400 to a Computer Using EIA/TIA-232 42
Figure 2.31—Four-Wire EIA/TIA-485 Wiring 43
Figure 2.32—Two-Wire EIA/TIA-485 Wiring 43
Figure 2.33—Recommended System Connections 44

3 Operation and Setup 47

Figure 3.1—General Navigation Map 48
Figure 3.2—Keypad Navigation 49
Figure 3.3—Loop Display 50
Figure 3.4—Loop Display with Alarm Code 51
Figure 3.5—Display for Failed Sensor Alarm 51
Figure 3.6—Input Scaling 59
Figure 3.7—Activation and Deactivation of Process Alarms 66
Figure 3.8—Application Using Process Variable Retransmit 68
Figure 3.9—Secondary Set Point When Primary Loop Has Heat and Cool Outputs 70
Figure 3.10—Secondary Set Point When Primary Loop Has Heat Output Only 70
Figure 3.11—Example Application Using Cascade Control 72
Figure 3.12—Relationship of Secondary Loop Set Point to Primary Loop Process

Variable in Cascade Example 73

Figure 3.13—Relationship Between the Process Variable on the Master Loop and the

Set Point of the Ratio Loop 74

Figure 3.14—Application Using Ratio Control 75

4 Tuning and Control 81

Figure 4.1—On/Off Control 82
Figure 4.2—Proportional Control 83
Figure 4.3—Proportional and Integral Control 83
Figure 4.4—Proportional, Integral and Derivative Control 84
Figure 4.5—Time Proportioning and Distributed Zero Crossing Waveforms 88

5 Menu and Parameter Reference 91

Figure 5.1—Operator Parameter Navigation 92
Figure 5.2—Setup Menus and Parameters 95
Figure 5.3—The Effect of Tune Gain on Recovery from a Load Change 115
Figure 5.4—Linear and Nonlinear Outputs 121

6 Troubleshooting and Reconfiguring 139

Figure 6.1—Removal of Electronics Assembly from Case 155
Figure 6.2—Screw Locations on PC Board 155
Figure 6.3—Location of Flash Memory Chip 156
Figure 6.4—Removal of Flash Memory Chip 156
Figure 6.5—Jumper Configurations 157
Figure 6.6—Input Circuit 158
Figure 6.7—Serial DAC Voltage and Current Jumper Positions 162
Figure 6.8—Dual DAC 163

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CPC400 Series User’s Guide List of Figures

7 Specifications 165

Figure 7.1—CPC400 Module Dimensions 166
Figure 7.2—CPC400 Clearances with Straight SCSI Cable 167
Figure 7.3—CPC400 Clearances with Right-Angle SCSI Cable 167
Figure 7.4—TB50 Dimensions 169
Figure 7.5—TB50 Dimensions with Straight SCSI Cable 170
Figure 7.6—TB50 Dimensions with Right-Angle SCSI Cable 171
Figure 7.7—Power Supply Dimensions (Bottom View) 177
Figure 7.8—Dual DAC Dimensions 179
Figure 7.9—Serial DAC Dimensions 181

Appendix A: Modbus Protocol 183

Figure A.1—Query - Response Cycle 184
Figure A.2—Example Message Frame 186

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List of Figures CPC400 Series User’s Guide

viii Watlow Anafaze Doc. 0600-2900-2000

2 Installation 11

Table 2.1—Cable Recommendations 21
Table 2.2—Power Connections 24
Table 2.3—Digital Output States and Values Stored in the Controller 33
Table 2.4—Digital Input States and Values Stored in the Controller 36
Table 2.5—TB18 Connections 37
Table 2.6—TB50 Connections 38
Table 2.7—EIA/TIA-232 Connections 42
Table 2.8—RTS/CTS and DSR/DTR Pins in DB-9 and DB-25 Connectors 42

List of Tables

3 Operation and Setup 47

Table 3.1—Control Modes on the Loop Display 50
Table 3.2—Alarm Codes and Messages for Process and Failed Sensor Alarms 52
Table 3.3—System Alarm Messages 53
Table 3.4—Input Readings 60
Table 3.5—Scaling Values 60
Table 3.6—Input Readings and Calculations 61
Table 3.7—Scaling Values 61
Table 3.8—Scaling Values 62
Table 3.9—Parameters Settings for Process Variable Retransmit Example 69
Table 3.10—Parameter Settings for the Primary Loop in the Cascade Example 72
Table 3.11—Parameter Settings for the Secondary Loop in the Cascade Example 72
Table 3.12—Ratio Control Settings for the Ratio Loop (Loop 2) in the Example 75
Table 3.13—Parameter Settings for the Ratio Loop (Loop 2) for the Example 76
Table 3.14—Parameters Settings for the Master Loop (Loop 1) in the Example 77
Table 3.15—Parameter Settings for the Ratio Loop (Loop 2) in the Example 78
Table 3.16—Number of Decimal Places for Numeric Values via Modbus or Logic 80

4 Tuning and Control 81

Table 4.1—Proportional Band Settings 85
Table 4.2—Integral Term and Reset Settings 86
Table 4.3—Derivative Term Versus Rate 86
Table 4.4—General PID Constants 87

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List of Tables CPC400 Series User’s Guide

5 Menu and Parameter Reference 91

Table 5.1—Control Mode Menu Options 93
Table 5.2—CPC400 Setup Menus 94
Table 5.3—
Table 5.4—Digital Input States Required to Load Each Job 98
Table 5.5—Power Up Loop Modes 100
Table 5.6—Digital Output Alarm Polarity 103
Table 5.7—Input Types and Ranges 104
Table 5.8—Calibration Offset Ranges 106
Table 5.9—Display Formats 107
Table 5.10—Characters for the Loop Name and Input Units Parameters 110
Table 5.11—PV Source Options 110
Table 5.12—Proportional Band Values 111
Table 5.13—Values for the Control Hysteresis and Deviation Alarm Parameters 113
Table 5.14— Control Types 115
Table 5.15—Heat and Cool Output Types 116
Table 5.16—Alarm Functions 122
Table 5.17—Values for Alarm Hysteresis 125
Table 5.18—Bit Positions for Alarm Enable and Alarm Function 133
Table 5.19—Bit Positions for Alarm Status and Alarm Acknowledge 134
Table 5.20—System Status Bits 137

Values for BCD Job Load

97

6 Troubleshooting and Reconfiguring 139

Table 6.1—Operator Response to Process Alarms 142
Table 6.2—Other Symptoms 143
Table 6.3—Resistor Values for Current Inputs 159
Table 6.4—Resistor Locations for Current Inputs 159
Table 6.5—Resistor Values for Voltage Inputs 160
Table 6.6—Resistor Locations for Voltage Inputs 160
Table 6.7—Resistor Locations for RTD Inputs 161
Table 6.8—Dual DAC Jumper Settings 163

7 Specifications 165

Table 7.1—Agency Approvals / Compliance 165
Table 7.2—Environmental Specifications 165
Table 7.3—Physical Dimensions 166
Table 7.4—CPC400 with Straight SCSI 166
Table 7.5—CPC400 with Right Angle SCSI 167
Table 7.6—CPC400 Connections 168
Table 7.7—TB50 Physical Dimensions 168
Table 7.8—TB50 Connections 169
Table 7.9—TB50 with Straight SCSI 169
Table 7.10—TB50 with Right Angle SCSI 170
Table 7.11—Analog Inputs 172
Table 7.12—Pulse Inputs 172
Table 7.13—Programmable Logic 173
Table 7.14—Thermocouple Range and Resolution 173

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CPC400 Series User’s Guide List of Tables

Table 7.15—RTD Range and Resolution 173
Table 7.16—Input Resistance for Voltage Inputs 174
Table 7.17—Digital Inputs 174
Table 7.18—Digital Outputs Control / Alarm 175
Table 7.19—CPU Watchdog Output 175
Table 7.20—5V

Î

(dc) Output (Power to Operate Solid-State Relays) 175
Table 7.21—CPC400 Serial Interface 176
Table 7.22—CPC400 Power 176
Table 7.23—Power Supply Environmental Specifications 176
Table 7.24—Power Supply Agency Approvals / Compliance 176
Table 7.25—Power Supply Physical Specifications 177
Table 7.26—Power Supply with Mounting Bracket 177
Table 7.27—Power Supply Inputs and Outputs 178
Table 7.28—Dual DAC Physical Specifications 178
Table 7.29—Dual DAC Power Requirements 179
Table 7.30—Dual DAC Specifications by Output Range 180
Table 7.31—Serial DAC Environmental Specifications 180
Table 7.32—Serial DAC Physical Specifications 180
Table 7.33—Serial DAC Agency Approvals / Compliance 181
Table 7.34—Serial DAC Inputs 181
Table 7.35—Serial DAC Power Requirements 182
Table 7.36—Serial DAC Analog Output

Specifications 182

Appendix A: Modbus Protocol 183

Table A.1—Function Codes 190
Table A.2—Diagnostics Subfunctions 191
Table A.3—Sample Packet for Host Query 193
Table A.4—Sample Packet for Slave Response 193
Table A.5—Sample Packet for Host Query 194
Table A.6—Sample Packet for Slave Response 194
Table A.7—Sample Packet for Host Query 194
Table A.8—Sample Packet for Slave Response 194

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List of Tables CPC400 Series User’s Guide

xii Watlow Anafaze Doc. 0600-2900-2000

1

System Overview

Manual Contents

This manual describes how to install, set up, and operate a
CPC400 series controller. Each chapter covers a different as­pect of your control system and may apply to different users:

• Chapter 1: System Overview provides a component
list and summary of features for the CPC400 series
controllers.

• Chapter 2: Installation provides detailed instruc­tions on installing the CPC400 series controller and its
peripherals.

• Chapter 3: Operation and Setup provides instruc­tions about operating and setting up the CPC400.

• Chapter 4: Tuning and Control describes available
control algorithms and suggestions for applications.

• Chapter 5: Menu and Parameter Reference pro­vides detailed descriptions of all menus and parame­ters for controller setup and for accessing parameter
and I/O values with a LogicPro program or via the se­rial communications interface.

• Chapter 6: Troubleshooting and Reconfiguring
includes troubleshooting, upgrading and reconfigur­ing procedures for technical personnel.

• Chapter 7: Specifications lists detailed specifica­tions of the controller and optional components.

• Appendix: Modbus Reference describes the Mod­bus RTU communications protocol, which is used to
read and set parameter values through the serial com­munications interface. This information is intended
for programmers writing software to communicate
with the CPC400.

• Parameter Address Reference provides a way to
quickly locate parameter addresses.

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Chapter 1: System Overview CPC400 Series User’s Guide

Getting Started

Safety Symbols

These symbols are used throughout this manual:

Initial Inspection

WARNING!

CAUTION!

NOTE!

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

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

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

Accessories may or may not be shipped in the same con­tainer as the CPC400, depending upon their size. Check
the shipping invoice against the contents received in all
boxes.

Product Features

CPC400 series controllers offer high-performance closed­loop control and user-programmable logic to manipulate
process control algorithms and sequential logic.

The CPC400 provides four or eight independent control
loops with analog inputs—thermocouples, RTDs and pro­cess. An additional 2 kHz pulse loop is also provided.

When used as a stand-alone controller, you may operate
the CPC400 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 CPC400 can be locally or remotely controlled via an
EIA/TIA-232 or EIA/TIA-485 serial communications inter­face.

CPC400 features include:

2 Watlow Anafaze Doc. 0600-2900-2000

•

Ω

CPC400 Series User’s Guide Chapter 1: System Overview

TRU-TUNE+™Adaptive Control : Enable adaptive

control using the unique TRU-TUNE+™ adaptive al­gorithm and optimize even difficult-to-control or dy­namic processes. TRU-TUNE+™ monitors the process
variable and adjusts the control parameters automat­ically to keep your process at set point and optimize for
set point and load changes.

• User-Programmable Logic : Customize the control­ler to run custom closed-loop control algorithms or pro­cesses. All closed-loop control parameters and system
I/O are available for user programs. Program and
closed-loop control variables can be shared or indepen­dent. Use LogicPro software to write, monitor and de­bug logic programs.

• Direct Connection of Mixed Thermocouple Sen-

sors: Connect most thermocouples to the controller

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

• Accepts Resistive Temperature Detectors

(RTDs): Use three-wire, 100

, platinum, 0.00385-

curve sensors. Special inputs must be installed.

• Automatic Scaling for Process Analog Inputs:
The CPC400 series automatically scales process in­puts used with industrial process sensors. Enter two
points, and all input values are automatically scaled.
Special inputs must be installed.

• Dual Outputs: The CPC400 series includes both heat
and cool control outputs for each loop. Independent
control parameters are provided for each output.

• Independently Selectable Control and Output

Modes: Set each control output to on/off, time propor-

tioning, 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.

• Boost Output Function: Set digital outputs to func­tion as boost on/off control in association with any
alarm.

• Flexible Alarms: Independently set high and low
alarms and high and low deviation alarms 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: Any alarm event activates
the global alarm output.

• CPU Watchdog: The CPU watchdog timer output no­tifies you of system failure.

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•

Chapter 1: System Overview CPC400 Series User’s Guide

Keypad or Computer Operation: Set up and run

the controller from the keypad or from a local or re­mote computer. Use WATVIEW HMI software to set
up the controller, manage jobs (recipes), log data or
monitor system performance.

• Modbus RTU Protocol, EIA/TIA-232 and 485

Communications: Connect operator interface termi-

nals and third-party software packages using the
widely supported Modbus RTU protocol.

• Multiple Job Storage: Store up to eight jobs in the
controller’s battery-backed memory. Load a job
through the keypad, digital inputs or software. Each
job is a set of operating conditions, including set points
and alarm limits.

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

• Pulse Input: Use the pulse 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.

• Process Variable Retransmit: Scale a temperature
or process and convert it to an analog output for exter­nal devices such as chart recorders.

• Two-Zone Cascade Control: Control thermal sys­tems with long lag times, which cannot be accurately
controlled with a single loop.

• Ratio or Offset Control: Control one process as a ra­tio or offset of another process.

• Remote Analog Set Point: Scale an external voltage
or current source to provide a set point for a loop.

CPC400 Parts List

You may have received one or more of the following compo­nents. See Figure 2.1 on page 12 for CPC400 configuration
information.

• CPC400 series controller

• Controller mounting kit

• TB50 with 50-pin SCSI cable

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

• Power supply with mounting bracket and screws

• Serial DAC (digital-to-analog converter)

• Special input resistors (installed in CPC400)

• User’s guide

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CPC400 Series User’s Guide Chapter 1: System Overview

40 _ -1 _ _ _ _ _ _

Number of Loops

4 = 4 loops
8 = 8 loops

Controller T ype

1 = Standard firmware

Terminal Block

0 = No terminal block accessory
1 = 18-terminal block
2 = 50-terminal block, includes 3-foot (0.9 m) 50-pin SCSI cable (TB50-SCSI)

Power Supply

0 = No power supply
2 = 120/240V
(5V

Å (ac), 50/60 Hz power supply adapter

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

SCSI Cables (for use with TB50-SCSI)

0 = No special SCSI cable (3-foot [0.9 m] cable is included with 50-terminal block)
1 = 6-foot (1.8 m) SCSI cable (CA-SCSI-6)
2 = 3-foot (0.9 m) right-angle SCSI cable (CA-SCSI-RT-3)
3 = 6-foot (1.8 m) right-angle SCSI cable (CA-SCSI-RT-6)

Serial Cables (for communications with computer)

0 = No serial communications cable
1 = 10-foot (3.0 m) serial cable, DB-9 female/bare wire (CA-COMM-010)
2 = 25-foot (7.6 m) serial cable, DB-9 female/bare wire (CA-COMM-025)
3 = 50-foot (15.2 m) serial cable, DB-9 female/bare wire (CA-COMM-050)

Serial Communications Jumper Settings

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

Special Inputs

Standard unit is configured for thermocouples and -10 to +60mV process inputs.
For other sensors, special inputs are required.
0 = Thermocouples and -10 to +60mV inputs only
X = Number of current and voltage inputs.

Figure 1.1 CPC400 Standard Parts List

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Chapter 1: System Overview CPC400 Series User’s Guide

CPCSI _ _ - _ _ - _ _

Special/Process Input Type

(Not required for thermocouple sensor inputs)
23 = RTD
43 = 0 to 10 mA
44 = 0 to 20 mA
50 = 0 to 100 mV
52 = 0 to 500 mV
53 = 0 to 1 V
55 = 0 to 5 V
56 = 0 to 10 V
57 = 0 to 12 V

Start Loop

XX = Loop number XX

Î (dc)
Î (dc) or 4 to 20 mAÎ (dc)

Î (dc)
Î (dc)

Î (dc)
Î (dc)

Î (dc)
Î (dc)

End Loop

XX = Loop number XX

Technical Description

CPC400

Figure 1.2 CPC400 Special Inputs Parts List

This section contains a technical description of each compo­nent of the CPC400 series controller.

The CPC400 is housed in a 1/8-DIN panel mount package.
It contains the central processing unit (CPU), random ac­cess memory (RAM) with a built-in battery, flash memory,
serial communications, digital I/O, analog inputs, display
and touch keypad.

CPC400 Series
with SCSI Connector

CPC400 Series
with TB18 Connector

Figure 1.3 CPC400 Rear Views

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CPC400 Series User’s Guide Chapter 1: System Overview

The CPC400 has the following features:

• Keypad and two-line, 16-character display.

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

• Input power of 12 to 24 VÎ (dc) at 1 Amp.

• 50-pin SCSI cable to connect the digital inputs and
outputs to the 50-terminal block (TB50). The CPC400
is available with an 18-terminal block (TB18) in place
of the SCSI connector, as shown in Figure 1.3 on page

6.

• Nonvolatile flash memory for storage of firmware and
programmable logic.

• Battery-backed storage of operating parameters. If a
power loss occurs, the operating parameters are stored
in memory. The battery has a ten-year shelf life, and
it is not used when the controller is on.

• Microprocessor control of all calculations for input sig­nal linearization, PID control, alarms, and communi­cations.

Front Panel Description

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

The displays show process variables, set points and output
levels for each loop. A single-loop display, scanning display
and alarm display offer a real-time view of process condi­tions.

For useful tips, help and menu information, press i from
any screen.

Figure 1.4 CPC400 Front Panel

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Chapter 1: System Overview CPC400 Series User’s Guide

TB50

The TB50 is a screw-terminal interface for control wiring.
It allows you to connect relays, encoders and discrete I/O
devices to the CPC400. The screw terminal blocks accept

wires as large as 18 AWG (0.75 mm2). A 50-pin SCSI cable
connects the TB50 to the CPC400.

CPC400 Cabling

Figure 1.5 TB50

Watlow Anafaze provides cables required to install the
CPC400. A 50-pin SCSI cable connects the TB50 to the
CPC400.

The optional cable used to connect the CPC400 to a comput­er using EIA/TIA-232 communications has a DB-9 or DB­25 connector for the computer and bare wires for connect­ing to the CPC400.

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CPC400 Series User’s Guide Chapter 1: System Overview

Safety

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

External Safety Devices

The CPC400 controller may fail full-on (100 percent output
power) or full-off (0 percent output power), or may remain
full-on if an undetected sensor failure occurs.

Design your system to be safe even if the controller sends a
0 percent or 100 percent output power signal at any time.
Install independent, external safety devices such as the
Watlow Anafaze TLM-8 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 an mechanical contactor. The lim­it controller monitors for a hazardous condition such as an
under-temperature 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 percent or 100 per­cent output power state. To prevent death, per­sonal injury, equipment damage or property
damage, install external safety shutdown devices
that operate independently from the process con­trol equipment.

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

Doc. 0600-2900-2000 Watlow Anafaze 9

Chapter 1: System Overview CPC400 Series User’s Guide

Power-Fail Protection

In the occurrence of a sudden loss of power, the CPC400
controller can be programmed to reset the control outputs
to off (this is the default). The controller can also be config­ured to restart to data stored in memory.

A memory-based restart might create an unsafe process
condition for some installations. Use a memory-based re­start only if you are certain your system will safely restart.
See Power Up Loop Mode on page 100.

When using a computer or host device, you can program the
software to automatically reload desired operating con­stants or process values on powerup. These convenience
features do not eliminate the need for independent safety
devices.

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

10 Watlow Anafaze Doc. 0600-2900-2000

2

Installation

This chapter describes how to install the CPC400 series
controller and its peripherals. Installation of the controller
involves the following procedures:

• Determining the best location for the controller

• Mounting the controller and TB50

• Power connection

• Input wiring

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

485)

• Output wiring

WARNING!

WARNING!

Doc.0600-2900-2000 Watlow Anafaze 11

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

The controller may fail in a 0 percent or 100 per­cent power output state. To prevent death, per­sonal injury, equipment damage or property
damage, install external safety shutdown devices
that operate independently from the process con­trol equipment.

Chapter 2: Installation CPC400 Series User’s Guide

Typical Installation

Figure 2.1 shows typical installations of the controller with
the TB50 and the TB18 terminal blocks. The type of termi­nal block you use greatly impacts the layout and wiring of
your installation site. See Figure 2.2 to Figure 2.10 to de­termine potential space requirements.

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

CPC400 with TB50

Signal Inputs

CPC400 with TB18

Signal Inputs

3 Digital Inputs
Pulse Input
11 Digital Outputs (Control, Alarm, Logic)

SCSI Cable
8 Digital Inputs

Pulse Input

35 Digital Outputs

(Control, Alarm, Logic)

CPC400
Power Supply

CPC400
Power Supply

Figure 2.1 CPC400 System Components

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CPC400 Series User’s Guide Chapter 2: Installation

Mounting Controller Components

Install the controller in a location free from excessive heat
(>50º C), dust and unauthorized handling. Electromagnetic
and radio frequency interference can induce noise on sen­sor wiring. Choose locations for the CPC400 and TB50 such
that wiring can be routed clear of sources of interference
such as high voltage wires, power switching devices and
motors.

NOTE!

WARNING!

Recommended Tools

For indoor use only.

To reduce the risk of fire or electric shock, install
the CPC400 in a controlled environment, relative­ly free of contaminants.

Use any of the following tools to cut a hole of the appropri­ate size in the panel.

• Jigsaw and metal file, for stainless steel and heavy­weight panel doors.

• Greenlee 1/8-DIN rectangular punch (Greenlee part
number 600-68), for most panel materials and thick­nesses.

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

You will also need these tools:

• Phillips head screwdriver

• 1/8-inch (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 that there is enough clearance for mounting brack­ets, terminal blocks, and cable and wire connections. The
controller extends up to 7.0 inches (178 mm) behind the
panel face and the screw brackets extend 0.5 inch (13 mm)
above and below it. If using a straight SCSI cable, allow for
an additional 1.6 inches (41 mm) beyond the terminal
block. If using a right-angle SCSI cable, allow an additional

0.6 inch (15 mm). Refer to Figure 2.2.

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Chapter 2: Installation CPC400 Series User’s Guide

1.0 in.

(25 mm)

7.0 in.

(178 mm)

1.6 in.

(41 mm)

1.0 in.

(25 mm)

7.0 in.

(178 mm)

0.6 in.

(15 mm)

Figure 2.2 Clearance with Straight SCSI Cable (L) and Right-Angle SCSI Cable (R)

Maximum Panel Thickness

0.2 in. (5 mm)

1.80 ± 0.020 in.

(45.7 ± 0.5 mm)

3.63 ± 0.020 in.

(92.2 ± 0.5 mm)

Figure 2.3 Wiring Clearances

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 (more
than 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 7.0 in. (178 mm) behind the panel.

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CPC400 Series User’s Guide Chapter 2: Installation

Allow for an additional 0.60 to 1.60 in. (15 to 41 mm)
beyond the connectors.)

2. Temporarily cover any 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 below. Use caution; the dimensions giv­en here have 0.02 in. (0.5 mm) tolerances.

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

5. Slide the processor module into the panel cutout.

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

.

Bracket (top and bottom)

25

23

21

19

17

15

13

11

9

7

5

3

1

+

26

24

22

20

18

16

14

12

10

8

6

4

2

Bezel

Panel

Mounting Collar

Figure 2.4 Mounting Bracket

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 processor module).
Push each bracket backward then to the side to secure
it to the processor module case.

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

Doc. 0600-2900-2000 Watlow Anafaze 15

Chapter 2: Installation CPC400 Series User’s Guide

Mounting the TB50

There are two ways to mount the TB50: Use the pre-in­stalled DIN rail mounting brackets or use the plastic

standoffs.

TB50
Mounted
with Standoffs

TB50
Mounted to
DIN Rail

Figure 2.5 Mounting the TB50

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 2.6.

Figure 2.6 TB50 Mounted on a DIN Rail (Front)

16 Watlow Anafaze Doc. 0600-2900-2000