Watlow D8 User Manual [en, de, es]

Series D8

User’s Guide

Watlow Anafaze

1241 Bundy Blvd.
Winona, MN 55987

Customer Service:

Phone....... [phone]

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

Technical Support:

Phone....... [phone]

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

Email ........ [e-mail]

Part No. 0600-3120-2000 Rev. B

November 2008

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 retrie val system, or transmitted in an y form without written permission
from Watlow Anafaze.

Anafaze is a re gistered trademark of Watlow Electric Manuf acturing Compan y. De viceNet is a
trademark of the Open DeviceNet Vendor Association, Inc. UL is a registered trademark of Under­writers Laboratories, Inc. All other trademarks are the property of their respective owners.

RSNetWorx, RSLinx and RSLogix are trademarks of Rockwell Software Inc.

DeviceNet is a trademark of the Open DeviceNet Vendors Association.

Warranty

Watlow Anafaze, Incorporated w arrants that the products furnished under this Agreement will be
free from defects in material and w orkmanship 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 disco very of such defect. The sole obligation and liability of Watlow
Anafaze, Incorporated under this w arranty 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 defecti ve shall
immediately be returned at the Customer's e xpense to Watlow Anafaze, Incorporated. Replaced or
repaired products or parts will be shipped to the Customer at the e xpense of Watlow Anafaze,
Incorporated.

There shall be no w arranty or liability for an y products or parts that ha ve been subject to misuse,
accident, negligence, failure of electric power or modification by the Customer without the writte
approval of Watlow Anafaze, Incorporated. Final determination of w arranty eligibility shall be
made by Watlow Anafaze, Incorporated. If a w arranty claim is considered in valid for an y reason,
the Customer will be char ged for services performed and e xpenses incurred by Watlow Anafaze,
Incorporated in handling and shipping the returned unit.

If replacement parts are supplied or repairs made during the original w arranty period, the warranty
period for the replacement or repaired part shall terminate with the termination of the w arranty
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 w arranties, liabilities, and
remedies. Except as thus pro vided, Watlow Anafaze, Inc., disclaims all w arranties, e xpress or
implied, including any warranty of merchantability or fitness for a particular purpose

Please Note

: External safety devices must be used with this equipment.

Table of Contents

List of Figures ix

List of Tables xiii

1 System Overview 1

Manual Contents 1
Getting Started 2

Safety Symbols 2
Initial Inspection 2

Product Features 2
D8 Parts List 5
Technical Description 6

D8 6
TB50 8
D8 Cabling 8

Safety 8

External Safety Devices 8
Power-Fail Protection 9

2 Installation 11

Typical Installation 12
Mounting Controller Components 12

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

System Wiring 20

Wiring Recommendations 20
Noise Suppression 21
Ground Loops 22

Power Connections 23

Wiring the Power Supply 23
Connecting the TB50 to the D8 25

Testing the System 26

TB50 or TB18 Test 26
Digital Output Test 26
Digital Input Test 27

Sensor Wiring 27

Input Wiring Recommendations 28
Thermocouple Connections 29

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Table of Contents Series D8 User’s Guide

RTD Input Connections 30
Voltage Input Connections 30
Current Input Connections 30

Wiring Control and Digital I/O 31

Output Wiring Recommendations 31
Cable Tie Wraps 31
Digital Outputs 31
Digital Inputs 35
TB18 Connections 36
TB50 Connections 37

Analog Outputs 38

Wiring the Dual DAC 38
Wiring the Serial DAC 39

Connecting the D8 to a DeviceNet Network 40

Connector Type 40
Pinout 41
Network Length 42
Baud Rate (Data Rate) 42
Node Address (MAC ID) 42
Status Indicators 43

3 Communicating by DeviceNet 45

Accessing Data with a DeviceNet Master 45

Software 45
About The Electronic Data Sheet (EDS) 46
Configuring a D8 Using RSNetWorx 46
Registering the D8 without an EDS File 47
Registering the D8 with the Watlow EDS File 48

Mapping Polled I/O Data 50

Adding the D8 to the Master's Scanlist 50
Assigning PLC Addresses 51

Sample Ladder Logic 53

Accessing Polled I/O Data 53
Setting a Value with an Explicit Message 55
Reading a Value with an Explicit Message 57

Setting Parameters via DeviceNet 58

Non-Numeric Settings 58
Bit-Wise Values 59
Decimal Placement for Numeric Values 59
Decimal Placement for Percentage Values 60

D8 DeviceNet Overview 60

Master/Slave Connections 60
Addressing 61
Data Types 61

DeviceNet Objects 61

Identity Object 61
Message Router Object 62
DeviceNet Object 63
Assembly Object 63
Connection Object 66
Input Object 67
Output Object 68
Control Object 70
Alarm Object 71

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PV Retransmit Object 72
Ratio Object 73
Cascade Object 74
Global Object 75

4 Operation and Setup 77

General Navigation Map 77
Keypad 79
Displays 80

Loop Display 80
Alarm Displays 81
Job Display 83

Changing the Set Point 84

How to Manually Change the Set Point 84
Other Methods of Changing the Set Point 84

Changing the Control Mode and Output Power 85
Accessing and Navigating the Setup Menus 86

How to Access the Setup Menus 86
How to Edit a Setup Parameter 86

Setting Up Closed-Loop Control 87

Feedback 87
Control Algorithm 87
Control Output Signal Forms 87
Heat and Cool Outputs 87
How to Set Up Closed-Loop Control 88

Setting Up a Process Input 88

Input Scaling 88
Input Scaling Example: 4 to 20 mA Sensor 89
Input Scaling Example: 0 to 5 Vdc Sensor 90

Autotuning 91

How Does Autotuning Work? 91
Prerequisites 92
How to Autotune a Loop 92

Setting Up Alarms 93

Failed Sensor Alarms 93
Process Alarms 95
Global Alarm 97

Setting Up Process Variable Retransmit 97

How to Set Up Process Variable Retransmit 98
Process Variable Retransmit Example: Data Logging 98

Setting Up Cascade Control 100

How the Secondary Set Point is Determined 100
Proportional-Only Control on the Primary Loop 101
How To Set Up Cascade Control 102
Cascade Control Example: Water Tank 102

Setting Up Ratio Control 104

How to Set Up Ratio Control 105
Ratio Control Example: Diluting KOH 105

Setting Up Differential Control 106

How to Set Up Differential Control 107
Differential Control Example: Thermoforming 107

Setting Up Remote Analog Set Point 107

How to Set Up a Remote Analog Set Point 108
Remote Analog Set Point Example: Changing a Set Point with a PLC 108

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Table of Contents Series D8 User’s Guide

5 Tuning and Control 111

Control Algorithms 111

On/Off Control 112
Proportional Control (P) 112
Proportional and Integral Control (PI) 113
Proportional, Integral and Derivative Control (PID) 114
Heat and Cool Outputs 114

Setting Up and Tuning PID Loops 115

Proportional Band Settings 115
Integral Settings 115
Derivative Settings 116

General PID Constants by Application 117

Proportional Band Only (P) 117
Proportional with Integral (PI) 117
Proportional and Integral with Derivative (PID) 117

Control Outputs 118

Output Control Signals 118
Output Filter 120
Reverse and Direct Action 120

6 Menu and Parameter Reference 121

Operator Parameters 121

Set Point 122
Mode 122
Heat/Cool Output 122
Process Variable 123

Overview of the Setup Menus 123
Global Setup Menu 125

Load Setup From Job 125
Save Setup As Job 125
BCD Job Load 126
BCD Job Load Logic 126
Mode Override 127
Mode Override Digital Input Active 128
Power Up Alarm Delay 128
Power Up Loop Mode 128
Keypad Lock 129
Thermocouple Short Alarm 129
AC Line Frequency 129
Digital Output Alarm Polarity 129
MAC ID 130
Baud Rate 130
Module LED 130
Network LED 130
Bus Off Count 130
Model and Firmware Version 131

Input Menu 131

Input Type 131
Loop Name 132
Input Units 132
Calibration Offset 132
Reversed Thermocouple Detection 133
Display Format 133
Input Range High 134

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Input High Signal 134
Input Range Low 135
Input Low Signal 135
Input Filter 135

Control Menu 136

Heat/Cool Proportional Band 136
Heat/Cool Integral 137
Heat/Cool Derivative 137
Heat/Cool Manual Reset 137
Heat/Cool Filter 137
Hysteresis 138
Restore Automatic Mode 138

Output Menu 139

Heat/Cool Output Type 139
Heat/Cool Cycle Time 140
Heat/Cool SDAC Signal 140
Heat/Cool SDAC Low Signal 140
Heat/Cool SDAC High Signal 140
Heat/Cool Action 141
Heat/Cool Power Limit 141
Heat/Cool Power Limit Time 141
Sensor Fail Heat/Cool Output 142
Open Thermocouple Heat/Cool Output Average 142
Heat/Cool Output Curve 143

Alarms Menu 143

Alarm High Set Point 143
Alarm High Function 144
Alarm High Output 144
High Deviation Value 145
High Deviation Function 145
High Deviation Output 145
Low Deviation Value 145
Low Deviation Function 145
Low Deviation Output 146
Alarm Low Set Point 146
Alarm Low Function 146
Alarm Low Output 146
Alarm Hysteresis 147
Alarm Delay 147

Process Variable Retransmit Menu 148

Heat/Cool Output Retransmit 148
Heat/Cool Retransmit Low Process Variable 148
Heat/Cool Retransmit High Process Variable 148

Cascade Menu 149

Cascade Primary Loop 149
Cascade Low Set Point 149
Cascade High Set Point 149

Ratio Menu 150

Ratio Master Loop 150
Ratio Low Set Point 150
Ratio High Set Point 151
Control Ratio 151
Ratio Set Point Differential 151

I/O Tests Menu 151

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Table of Contents Series D8 User’s Guide

Digital Inputs 152
Keypad Test 152
Display Test 152
Test Digital Output 1 to 20 153

Parameters Only Available via Communications 153

Alarm Acknowledge 153
Alarm Enable 153
Alarm Function 154
Alarm Status 154
Ambient Sensor Reading 155
Heat/Cool Output Action for Watchdog Inactivity Fault 156

7 Troubleshooting and Reconfiguring 157

When There is a Problem 157

Returning a Unit 158

Troubleshooting the Controller 158

Process Alarms 159
Ambient Warning 160
Failed Sensor Alarms 160
System Alarms 160
Other Behaviors 161

Reading the DeviceNet Indicator Lights 162
Corrective and Diagnostic Procedures 163

Low Power 163
Battery Dead 163
H/W Error: Gain or Offset 164
H/W Error: Ambient 165
Keys Do Not Work 166
Checking Analog Inputs 166
Earth Grounding 167
Testing Control Output Devices 168
Testing the TB18 and TB50 168
Testing Control and Digital Outputs 168
Testing Digital Inputs 169

Clearing the RAM 169
Replacing the Flash Memory Chip 170
Installing Scaling Resistors 172

Input Circuit 172
Current Inputs 173
Voltage Inputs 174
RTD Inputs 175
Scaling and Calibration 176

Configuring Serial DAC Outputs 176
Configuring Dual DAC Outputs 177

8 Specifications 179

System Specifications 179

Physical Specifications 179
Inputs 185
Outputs 187

Power Supply 189
Dual DAC Specifications 191

Dual DAC Inputs 192
Dual DAC Analog Outputs 192

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Series D8 User’s Guide Table of Contents

Serial DAC Specifications 193

Serial DAC Inputs 194
Serial DAC Analog Outputs 195

Glossary 197

Index 205

Menu Structure 213

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viii Watlow Anafaze Doc. 0600-3120-2000

1 System Overview

Figure 1.1—D8 Standard Parts List 5
Figure 1.2—D8 Special Inputs Parts List 6
Figure 1.3—D8 Rear Views 6
Figure 1.4—D8 Front Panel 7
Figure 1.5—TB50 8

List of Figures

2 Installation

Figure 2.1—D8 System Components 12
Figure 2.2—Module Dimensions and Clearance 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—D8 Power Supply Mounting Bracket 18
Figure 2.10—Dual DAC and Serial DAC Dimensions 19
Figure 2.11—D8 Series Controller with TB50 23
Figure 2.12—Power Connections with the D8 Power Supply 25
Figure 2.13—Thermocouple Connections 29
Figure 2.14—RTD Connections 30
Figure 2.15—Voltage Signal Connections 30
Figure 2.16—Current Signal Connections 30
Figure 2.17—Digital Output Wiring 32
Figure 2.18—Sample Heat, Cool and Alarm Output Connections 33
Figure 2.19—Output Connections Using External Power Supply 34
Figure 2.20—TB50 Watchdog Timer Output 34
Figure 2.21—TB18 Watchdog Timer Output 34
Figure 2.22—Wiring Digital Inputs 35
Figure 2.23—Dual DAC with Current Output 38
Figure 2.24—Dual DAC with Voltage Output 39
Figure 2.25—Single/Multiple Serial DACs 40
Figure 2.26—DeviceNet Connector 40
Figure 2.27—DeviceNet Connector 41
Figure 2.28—Pinout 41
Figure 2.29—D8 Side with Rotary Switches 43

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List of Figures Series D8 User’s Guide

3 Communicating by DeviceNet

Figure 3.1—RSNetWorx On-line with Found Devices 47
Figure 3.2—The D8 Registered in RSNetWorx 48
Figure 3.3—D8 Properties in RSNetWorx 49
Figure 3.4—Parameters Tab 50
Figure 3.5—Adding the D8 to the Scanlist 51
Figure 3.6—Scanner Input Properties 52
Figure 3.7—Advanced Mapping Dialog Box 53
Figure 3.8—Using Scanned Data in Logic 54
Figure 3.9—Contents of the PLC Memory 55
Figure 3.10—Explicit Write in Ladder 56
Figure 3.11—Explicit Read in Ladder 58
Figure 3.12—D84 Produced Static Input 65
Figure 3.13— D84 Consumed Static Output 65
Figure 3.14—D88 Produced Static Input 65
Figure 3.15—D88 Consumed Static Output 66

4 Operation and Setup

Figure 4.1—General Navigation Map 78
Figure 4.2—Keypad Navigation 79
Figure 4.3—Loop Display 80
Figure 4.4—Loop Display with Alarm Code 81
Figure 4.5—Display for Failed Sensor Alarm 81
Figure 4.6—Input Scaling 89
Figure 4.7—Activation and Deactivation of Process Alarms 96
Figure 4.8—Application Using Process Variable Retransmit 99
Figure 4.9—Secondary Set Point When Primary Loop Has Heat and Cool Outputs

101
Figure 4.10—Secondary Set Point When Primary Loop Has Heat Output Only 101
Figure 4.11—Example Application Using Cascade Control 103
Figure 4.12—Relationship of Secondary Loop Set Point to Primary Loop Process

Variable in Cascade Example 104
Figure 4.13—Relationship Between the Process Variable on the Master Loop and the

Set Point of the Ratio Loop 105
Figure 4.14—Application Using Ratio Control 106

5 Tuning and Control

Figure 5.1—On/Off Control 112
Figure 5.2—Proportional Control 113
Figure 5.3—Proportional and Integral Control 113
Figure 5.4—Proportional, Integral and Derivative Control 114
Figure 5.5—Time Proportioning and Distributed Zero Crossing Waveforms 118

6 Menu and Parameter Reference

Figure 6.1—Operator Parameter Navigation 121
Figure 6.2—Setup Menus and Parameters 124
Figure 6.3—Linear and Nonlinear Outputs 143

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Series D8 User’s Guide List of Figures

7 Troubleshooting and Reconfiguring

Figure 7.1—Removal of Electronics Assembly from Case 170
Figure 7.2—Screw Locations on PC Board 171
Figure 7.3—Location of Flash Memory Chip 171
Figure 7.4—Input Circuit 173
Figure 7.5—Serial DAC Voltage and Current Jumper Positions 176
Figure 7.6—Dual DAC 177

8 Specifications

Figure 8.1—D8 Module Dimensions 180
Figure 8.2—Module Dimensions and Clearance 181
Figure 8.3—TB50 Dimensions 182
Figure 8.4—TB50 Dimensions with Straight SCSI Cable 183
Figure 8.5—TB50 Dimensions with Right-Angle SCSI Cable 184
Figure 8.6—Power Supply Dimensions (Bottom View) 190
Figure 8.7—Dual DAC Dimensions 191
Figure 8.8—Serial DAC Dimensions 193

Glossary

Index

Menu Structure

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List of Figures Series D8 User’s Guide

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2 Installation

Table 2.1—Cable Recommendations 21
Table 2.2—Power Connections 24
Table 2.3—TB1 Connections 28
Table 2.4—Digital Output States and Values Stored in the Controller 32
Table 2.5—Digital Input States and Values Stored in the Controller 35
Table 2.6—TB18 Connections 36
Table 2.7—TB50 Connections 37
Table 2.8—DeviceNet Connector 41
Table 2.9—Maximum Network Speed 42
Table 2.10—Module Status Indicator Light 44
Table 2.11—Network Status Indicator Light 44

List of Tables

3 Communicating by DeviceNet

Table 3.1—Number of Bytes 48
Table 3.2—Outbound Transaction Header 57
Table 3.3—Explicit Message Body 57
Table 3.4—Number of Decimal Places for Numeric Values via Logic 59
Table 3.5—Address Components 61
Table 3.6—Elementary Data Types 61
Table 3.7—Identity Class and Services 62
Table 3.8—Identity Instance Attributes 62
Table 3.9—Message Router Class and Services 62
Table 3.10—Message Router Instance Attributes 62
Table 3.11—DeviceNet Class and Services 63
Table 3.12—DeviceNet Class Attributes 63
Table 3.13—DeviceNet Instance Attributes 63
Table 3.14—Assembly Class and Services 64
Table 3.15—Assembly Instance Attributes 64
Table 3.16—Connection Class and Services 66
Table 3.17—Connection Instance Attributes 66
Table 3.18—Input Class and Services 67
Table 3.19—Input Class Attributes (Instance 0) 67
Table 3.20—Input Instance Attributes (Instances 1 to 4 or 8) 68
Table 3.21—Output Class and Services 68
Table 3.22—Output Class Attributes (Instance 0) 69
Table 3.23—Output Instance Attributes (Instances 1 to 4 or 8) 69

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List of Tables Series D8 User’s Guide

Table 3.24—Control Class and Services 70
Table 3.25—Control Class Attributes (Instance 0) 70
Table 3.26—Control Instance Attributes (Instances 1 to 4 or 8) 70
Table 3.27—Alarm Class and Services 71
Table 3.28—Alarm Class Attributes (Instance 0) 71
Table 3.29—Alarm Instance Attributes (Instances 1 to 4 or 8) 71
Table 3.30—PV Retransmit Class and Services 72
Table 3.31—PV Retransmit Class Attributes (Instance 0) 72
Table 3.32—PV Retransmit Instance Attributes (Instances 1 to 4 or 8) 73
Table 3.33—Ratio Class and Services 73
Table 3.34—Ratio Class Attributes (Instance 0) 73
Table 3.35—Ratio Instance Attributes (Instances 1 to 4 or 8) 74
Table 3.36—Cascade Class and Services 74
Table 3.37—Cascade Class Attributes (Instance 0) 74
Table 3.38—Cascade Instance Attributes (Instances 1 to 4 or 8) 75
Table 3.39—Global Class and Services 75
Table 3.40—Global Class Attributes (Instance 0) 75
Table 3.41—Global Instance Attributes (Instance 1) 76

4 Operation and Setup

Table 4.1—Control Modes 80
Table 4.2—Alarm Codes and Messages for Process and Failed Sensor Alarms 82
Table 4.3—System Alarm Messages 83
Table 4.4—Input Readings 90
Table 4.5—Scaling Values 90
Table 4.6—Input Readings and Calculations 91
Table 4.7—Scaling Values 91
Table 4.8—Parameters Settings for Process Variable Retransmit Example 99
Table 4.9—Parameter Settings for the Primary Loop in the Cascade Example 103
Table 4.10—Parameter Settings for the Secondary Loop in the Cascade Example

103
Table 4.11—Ratio Control Settings for the Ratio Loop (Loop 2) in the Example 106
Table 4.12—Parameter Settings for the Ratio Loop (Loop 2) for the Example 107
Table 4.13—Parameters Settings for the Master Loop (Loop 1) in the Example 108
Table 4.14—Parameter Settings for the Ratio Loop (Loop 2) in the Example 109

5 Tuning and Control

Table 5.1—Proportional Band Settings 115
Table 5.2—Integral Term and Reset Settings 116
Table 5.3—Derivative Term Versus Rate 116
Table 5.4—General PID Constants 117

6 Menu and Parameter Reference

Table 6.1—Control Modes 122
Table 6.2—D8 Setup Menus 123
Table 6.3—Values for BCD Job Load 126
Table 6.4—Digital Input States Required to Load Each Job 127

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Series D8 User’s Guide List of Tables

Table 6.5—Power Up Loop Modes 128
Table 6.6—Digital Output Alarm Polarity 130
Table 6.7—Input Types and Ranges 131
Table 6.8—Characters for the Loop Name and Input Units Parameters 132
Table 6.9—Calibration Offset Ranges 133
Table 6.10—Display Formats 134
Table 6.11—Proportional Band Values 136
Table 6.12—Values for the Control Hysteresis and Deviation Alarm Parameters 138
Table 6.13—Heat and Cool Output Types 139
Table 6.14—Alarm Functions 144
Table 6.15—Values for Alarm Hysteresis 147
Table 6.16—Bit Positions for Alarm Enable and Alarm Function 154
Table 6.17—Bit Positions for Alarm Status and Alarm Acknowledge 155
Table 6.18—System Status Bits 155
Table 6.19—DeviceNet Value for Watchdog Inactivity Fault 156

7 Troubleshooting and Reconfiguring

Table 7.1—Operator Response to Process Alarms 160
Table 7.2—Other Symptoms 161
Table 7.3—Module Status Indicator States and Descriptions 162
Table 7.4—Network Status Indicator Light 163
Table 7.5—Resistor Values for Current Inputs 173
Table 7.6—Resistor Locations for Current Inputs 173
Table 7.7—Resistor Values for Voltage Inputs 174
Table 7.8—Resistor Locations for Voltage Inputs 174
Table 7.9—Resistor Locations for RTD Inputs 175
Table 7.10—Dual DAC Jumper Settings 177

8 Specifications

Table 8.1— Agency Approvals / Compliance 179
Table 8.2—Environmental Specifications 179
Table 8.3—D8 with Straight SCSI 180
Table 8.4—D8 Connections 181
Table 8.5—TB50 Physical Dimensions 181
Table 8.6—TB50 Connections 182
Table 8.7—TB50 with Straight SCSI 182
Table 8.8—TB50 with Right Angle SCSI 183
Table 8.9—Analog Inputs 185
Table 8.10—Thermocouple Range and Resolution 186
Table 8.11—RTD Range and Resolution 186
Table 8.12—Input Resistance for Voltage Inputs 186
Table 8.13—Digital Inputs 187
Table 8.14—Digital Outputs Control / Alarm 188
Table 8.15—5 Vdc Output (Power to Operate Solid-State Relays) 188
Table 8.16—Communications 188
Table 8.17—D8 Power Requirements 188
Table 8.18—Power Supply Environmental Specifications 189
Table 8.19—Power Supply Agency Approvals / Compliance 189

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List of Tables Series D8 User’s Guide

Table 8.20—Power Supply Physical Specifications 189
Table 8.21—Power Supply with Mounting Bracket 189
Table 8.22—Power Supply Inputs and Outputs 190
Table 8.23—Dual DAC Environmental Specifications 191
Table 8.24—Dual DAC Physical Specifications 191
Table 8.25—Dual DAC Power Requirements 192
Table 8.26—Dual DAC Specifications by Output Range 192
Table 8.27—Serial DAC Environmental Specifications 193
Table 8.28—Serial DAC Physical Specifications 193
Table 8.29—Serial DAC Agency Approvals / Compliance 194
Table 8.30—Serial DAC Inputs 194
Table 8.31—Serial DAC Power Requirements 194
Table 8.32—Serial DAC Analog Output Specifications 195

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1

System Overview

Manual Contents

This manual describes how to install, set up, and operate a D8
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 D8 series controllers.

•

Chapter 2: Installation

on installing the D8 series controller and its peripherals.

•

Chapter 3: Communicating via DeviceNet

how to add the D8 controller to a network and how to ac­cess controller data via DeviceNet.

•

Chapter 4: Operation and Setup

about operating and setting up the D8.

•

Chapter 5: Tuning and Control

control algorithms and provides suggestions for applica­tions.

•

Chapter 6: Menu and Parameter Reference

detailed descriptions of all menus and parameters for
controller setup.

•

Chapter 7: Troubleshooting and Reconfiguring

cludes troubleshooting, upgrading and reconfiguring
procedures for technical personnel.

•

Chapter 8: Specifications

the controller and optional components.

provides detailed instructions

explains

provides instructions

describes available

provides

in-

lists detailed specifications of

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Chapter 1: System Overview Series D8 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 D8, depending upon their size. Check the shipping in­voice against the contents received in all boxes. If you are un­certain whether you have received all of the items you
ordered, contact your vendor or Watlow Anafaze.

Product Features

D8 series controllers offer high-performance closed-loop con­trol.

The D8 provides four or eight independent control loops with
analog inputs — thermocouples, RTDs and process — and
features DeviceNet communications.

When used as a stand-alone controller, you may operate the
D8 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 D8 can be lo­cally or remotely controlled via its DeviceNet communica­tions interface.

D8 features include:

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Series D8 User’s Guide Chapter 1: System Overview

•

Direct Connection of Mixed Thermocouple Sensors:

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):

, platinum, 0.00385-curve sensors.

Use three-wire, 100

Ω

Special inputs must be installed.

•

Automatic Scaling for Process Analog Inputs:

The D8
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 D8 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 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.

•

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 noti-

fies you of system failure.

•

Keypad or DeviceNet Operation:

Set up and run the
controller from the keypad or via the DeviceNet inter­face.

•

DeviceNet Communications:

Connect software, pro­grammable logic controllers and other master devices us­ing the widely supported DeviceNet protocol. The D8 is
compliant with both the ODVA DeviceNet specification
and the Interface Guidelines for DeviceNet on Semicon­ductor Manufacturing Tools.

•

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.

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Chapter 1: System Overview Series D8 User’s Guide

•

Nonlinear Output Curves:

Select either of two nonlin-

ear output curves for each control output.

•

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

• 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.

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D8 Parts List

You may have received one or more of the following compo­nents. See Figure 2.1 on page 12 for D8 configuration infor­mation.

• D8 series controller with mounting collar and brackets

• TB50 with 50-pin SCSI cable

• Power supply with mounting bracket and screws

• Serial DAC (digital-to-analog converter)

• Special input resistors (installed in D8)

• User’s guide

D8x0-0000-xx0x

Number of Loops
4 = 4-loop controller
8 = 8-loop controller

Digital I/O Termination
0 = TB18
1 = SCSI connector, no terminal board or cable
2 = SCSI connector, TB50 and 3-foot cable
3 = SCSI connector, TB50 and 6-foot cable
4 = SCSI connector, TB50 and 3-foot right angle cable
5 = SCSI connector, TB50 and 6-foot right angle cable

Power Supply
0 = No power supply
1 = CE Power Supply
2 = Wall mount power supply

Special Inputs
0 = Thermocouples and -10 to 60mV inputs only
X = Number of current, voltage and RTD inputs

Figure 1.1 D8 Standard Parts List

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Chapter 1: System Overview Series D8 User’s Guide

D8SI _ _ - _ _ - _ _

Special/Process Input Type
(Not required for thermocouple sensor inputs)
23 = RTD
43 = 0 to 10 mA dc
44 = 0 to 20 mA dc or 4 to 20 mA dc
50 = 0 to 100 mV dc
52 = 0 to 500 mV dc
53 = 0 to 1 Vdc
55 = 0 to 5 Vdc
56 = 0 to 10 Vdc
57 = 0 to 12 Vdc

Start Loop
XX = Loop number XX

End Loop
XX = Loop number XX

Figure 1.2 D8 Special Inputs Parts List

Technical Description

This section contains a technical description of each compo­nent of the D8 series controller.

D8

The D8 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, communi­cations, digital I/O, analog inputs, display and touch keypad.

Series D8 with SCSI Connector. Series D8 with TB18 Connector.

DeviceNet
Connector

Network LED
Indicator Light

Module LED
Indicator Light

Figure 1.3 D8 Rear Views

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Series D8 User’s Guide Chapter 1: System Overview

The D8 has the following features:

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

• Screw terminals for the power and analog inputs.

• Micro-style connector for DeviceNet.

• Input power of 12 to 24 Vdc at 1 Amp.

• 50-pin SCSI cable to connect the digital inputs and out­puts to the 50-terminal block (TB50). The D8 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 D8 Front Panel

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Chapter 1: System Overview Series D8 User’s Guide

TB50

The TB50 is a screw-terminal interface for control wiring. It
allows you to connect power controllers and other discrete I/O
devices to the D8. The screw terminal blocks accept wires as
large as 18 AWG (0.75 mm
the TB50 to the D8.

2

). A 50-pin SCSI cable connects

D8 Cabling

Safety

External Safety Devices

Figure 1.5 TB50

Watlow Anafaze provides cables required to install the D8. A
50-pin SCSI cable connects the TB50 to the D8.

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.

The D8 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
independent, external safety devices such as the Watlow
Anafaze TLM-8 that will shut down the system if a failure oc­curs.

. Install

Typically, a shutdown device consists of an agency-approved
high/low process limit controller that operates a shutdown de-

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Series D8 User’s Guide Chapter 1: System Overview

vice 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.

Power-Fail Protection

In the occurrence of a sudden loss of power, the D8 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 128.

When using the controller with a computer or other master 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.

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Chapter 1: System Overview Series D8 User’s Guide

10 Watlow Anafaze Doc. 0600-3120-2000

2

Installation

This chapter describes how to install the D8 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

• Output wiring

WARNING! Risk of electric shock. Shut off power to your

entire process before you begin installing
the controller.

WARNING! 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.

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Chapter 2: Installation Series D8 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.

D8 with TB50

Signal Inputs

D8 with TB18

Signal Inputs

3 Digital Inputs

11 Digital Outputs (Control, Alarm, Watchdog)

SCSI Cable

8 Digital Inputs

20 Digital Outputs

(Control Alarm,

Watchdog)

D8
Power Supply

D8
Power Supply

Figure 2.1 D8 System Components

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 D8 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.

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