Watlow MLS User Manual

Download

MLS

User’s Guide

Watlow Controls

1241 Bundy Blvd. Winona, MN 55987

Customer Service

Phone: (800) 414-4299 Fax: (800) 445-8992

Technical Support

Phone: (507) 494-5656 Fax: (507) 452-4507 Email: wintechsupport@watlow.com

Part No. 11570-00. Revision 3.7 November 1995

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 W atlo w-Anaf aze.

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 one year 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.

Addendum for MLS User’s Guide (3.6)

Addendum for MLS User’s

Guide (3.6)

The following are changes to revision 3.6 of the MLS User’s Guide. The changes pertain to a new power supply that is being used with the MLS. All changes are listed below by page number. Shaded portions refer to the actual changed text.

These changes will be incorporated in the next manual revision.

System Power Requirements (from page 10)

MLS-PM supply input 10-28 Vdc at <1 amp

MLS-AIM supply input 4.75 to 5.25 Vdc at <0.5 amp, supplied by MLS-

MLS-PS system power supply Input: 120/240 Vac at 0.75 amp

Output: 15 Vdc at 1.2 amp, 5 Vdc at 4 amp

Dimensions and Weight (from page 10)

MLS-PM 1.75 lbs., 1.89" x 3.78" x 6.75" (0.8 kg, 4.75 cm x 10 cm x 17

MLS-AIM-TB

& AIM cards

MLS-PS 1.2 lbs., 1.40" x 8.0" x 3.9" (0.6 kg, 3.56 cm x 20.32 cm x 9.91

RTB .5 lbs, 5.0’’ x 3.0’’ x 2.25’’ (.227 kg, 12.7 cm x 7.6 cm x 5.7 cm.)

1.50 lbs., 5.0" x 6.50" x 5.50" (0.7 kg, 12.5 cm x 16.25 cm x

cm.)

13.75 cm.)

cm.)

MLS User’s Guide (11570-00 rev. 3.6) I

Addendum for MLS User’s Guide (3.6)

Mounting the MLS-PS (from page 23)

Follow these instructions to mount the MLS-PS.

If you use your own power supply for the MLS, please refer to the power supply manufacturer's instructions for mounting information. Choose a power supply that supplies a regulated 10 to 28 Vdc at 1 watt, and isolated return line.

Mounting Environment

The MLS-PS measures 1.40" x 8" x 3.9". Leave enough clearance around the power supply that you can remove it later.

Mounting Steps

The MLS-PS has a mounting bracket. The bracket has two screw holes which will accept #6 or #10 screws. To mount the MLS-PS, attach the power supply to your panel with the two screws and the power supply mounting bracket.

II MLS User’s Guide (11570-00 r ev. 3.6)

Wiring Your System (from page 24)

This section explains how to wire the components of your system.

Below is the system connections diagram reprinted here for your

convenience. (See the next page for wiring instructions.)

Addendum for MLS User’s Guide (3.6)

MLS User’s Guide (11570-00 rev. 3.6) III

Addendum for MLS User’s Guide (3.6)

Wiring Recommendations (from page 25)

This section gives general wiring recommendations.

WARNING

Never wire bundles of low power Watlow-Anafaze circuits next to bundles of high power AC wiring. Instead, physically separate high power circuits from the controller. If possible, install high voltage

AC power circuits in a separate panel.

Use stranded wire. (Use solid wire for ﬁxed service; it makes inter-

•

mittent connections when you move it for maintenance.)

Use #18 or #20 AWG 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 MLS from

electrical noise.) Connect one end of the input wiring shield to the MLS panel's 120/240 Vac panel ground, and connect one end of the

output wiring shield to the MLS panel's

120/240 Vac panel ground. (If your system requires a different shield conﬁguration, contact Watlow-Anafaze for more information.)

For more information about noise suppression, see Noise Suppression .

Connecting Power and RTB to MLS-PM (from page 27)

1. Remove the temporary covers you placed on the MLS' housing.

2. Connect the power supply terminal labeled "DC COM" to the terminal labeled "GND" on the Processor Module. This terminal is DC common; it is not frame, chassis or earth ground.

3. Connect the power supply terminal labeled "+15V" to the terminal labeled "+V" on the Processor Module.

4. Connect the 50-pin ribbon cable to the Processor Module. Plug it in so that the red stripe is on the left side, under TB1.

5. Connect the ribbon cable to the RTB. Plug it in so that the red stripe is closest to screw terminal 1.

IV MLS User’s Guide (11570-00 rev. 3.6)

Overview .....................................................................1

System Diagram.................................................................. 2

Parts List .. .......................................................................... 2

Safety ....... .......................................................................... 3

Introduction................................................................5

Specifications......................................................................7

Analog Outputs.............................................................8

Digital Inputs ................................................................8

Digital Outputs.............................................................. 9

Miscellaneous Specifications............................................. 10

Serial Interface.............................................................. 10

System Power Requirements........................................ 10

Environmental Specifications.......................................10

Dimensions and Weight................................................10

Expanded Parts List............................................................11

MLS Processor Module Technical Description............ 11

MLS RTB Technical Description.................................13

MLS-AIM and AIM-TB Technical Description...........13

MLS Cabling Technical Description............................ 14

Installation..................................................................15

Read This Before Installation .............................................16

Recommended Tools ..........................................................17

Panel Hole Cutters........................................................ 17

Other Tools ...................................................................17

Additional Hardware..................................................... 17

Mounting the MLS-PM ...................................................... 18

Mounting Environment.................................................18

MLS-PM Mounting Steps............................................. 19

Mounting the MLS-AIM .................................................... 20

Mounting Environment.................................................20

Mounting Steps............................................................. 21

Mounting the RTB..............................................................22

Mounting the MLS-PS........................................................23

Mounting Environment.................................................23

Mounting Steps............................................................. 23

Wiring Your System........................................................... 24

Wiring Recommendations ............................................25

Cable Recommendations ..............................................26

Noise Suppression.........................................................26

Wiring and Testing Your System .......................................27

Contents MLS User’s Guide

Connecting Power and RTB to MLS-PM.....................27

Connecting Power and Common to AIM-TB...............28

Testing Connections ..................................................... 28

Testing Your System .......................................................... 30

MLS-AIM Test .............................................................30

RTB Test.......................................................................30

PID Output Test............................................................ 30

Outputs..... ..........................................................................31

PID Control and Alarm Output Connections................ 33

RTB Connections.......................................................... 34

AIM Communications Failure...................................... 35

Inputs ....... ..........................................................................36

Input Wiring Recommendations................................... 37

Input Scaling.................................................................37

T/C Inputs .....................................................................39

RTD Inputs ................................................................... 40

Current Inputs ...............................................................41

Voltage Inputs...............................................................41

Unused Inputs ...............................................................41

Communications................................................................. 42

Changing Communications...........................................42

Connecting RS-232 Communications .......................... 42

Connecting RS-485 Communications .......................... 43

Recommended Wire Gauges ........................................ 45

Using the MLS............................................................47

Front Panel.......................................................................... 48

Front Panel Keys........................................................... 49

Displays ... ..........................................................................51

Viewing Several Loops: Bar Graph Display ................ 51

Viewing One Loop: Single Loop Display ....................52

Interpreting Alarm Display........................................... 53

Displaying, Loading, and Saving Jobs................................55

Operator Menus .................................................................. 56

Changing the Setpoint................................................... 56

Selecting Manual, Automatic, or Tune Control............ 56

Setup ...........................................................................59

How to enter the Setup menus? ....................................59

How to edit a menu?..................................................... 59

Setup Global Parameters Menu ..........................................61

Save to Job....................................................................62

Load from Job............................................................... 62

Job Select Inputs........................................................... 63

MLS User’s Guide Contents

Job Digital Input Polarity.............................................. 64

Output Override Digital Input....................................... 64

Output Override Input Polarity.....................................64

Startup Alarm Delay..................................................... 65

Keyboard Lock Status................................................... 65

Power-Up Output Status............................................... 65

Controller Address........................................................ 66

Communications Error Checking .................................66

Communications Baud Rate .........................................67

Allen Bradley Protocol .................................................67

AC Line Frequency....................................................... 67

Digital Output Polarity..................................................68

AIM Communications Failure Output.......................... 68

EPROM Information.....................................................68

Setup Loop Input .......................................................... 69

Input Type.....................................................................70

Pulse Sample Time .......................................................71

Loop Name ................................................................... 71

Input Units ....................................................................71

Input Reading Offset..................................................... 72

Linear Scaling Menus................................................... 72

Display Format ............................................................. 74

High Process Value....................................................... 74

High Reading................................................................ 75

Low Process Value .......................................................75

Low Reading.................................................................75

Input Filter ....................................................................76

Setup Loop Control Parameters.......................................... 77

Heat/Cool Control PB................................................... 78

Heat/Cool Control TI....................................................78

Heat/Cool Control TD .................................................. 78

Heat/Cool Output Filter................................................ 79

Heat/Cool Spread.......................................................... 79

Setup Loop Outputs............................................................ 80

Enable/Disable Heat and Cool Outputs ........................82

Heat or Cool Output Type ............................................ 82

Heat/Cool Cycle Time..................................................83

SDAC Menus...................................................................... 83

SDAC Mode ................................................................. 83

SDAC High Value........................................................ 84

SDAC Low Value......................................................... 84

Heat/Cool Output Action..............................................84

Heat/Cool Output Limit................................................ 85

Heat/Cool Output Limit Time.......................................85

iii

Contents MLS User’s Guide

Heat/Cool Output Override........................................... 85

Heat/Cool Nonlinear Output Curve.............................. 86

Setup Loop Alarms............................................................. 87

Alarm Types ................................................................ 88

Alarm Delay..................................................................90

High Process Alarm Setpoint........................................ 91

High Process Alarm Type............................................. 91

High Process Alarm Output Number............................ 91

Deviation Band Value................................................... 92

High Deviation Alarm Type .........................................92

High Deviation Alarm Output Number ........................93

Low Deviation Alarm Type.......................................... 93

Low Deviation Alarm Output Number......................... 93

Low Process Alarm Setpoint ........................................94

Low Process Alarm Type ............................................. 94

Low Process Alarm Output Number ............................ 94

Alarm Deadband........................................................... 95

Loop Alarm Delay ........................................................95

Manual I/O Test..................................................................96

Digital Input Testing..................................................... 97

Keypad Test.................................................................. 97

Test Digital Output .......................................................97

Toggle Digital Output................................................... 98

Tuning and Control....................................................99

Introduction......................................................................... 99

Control Modes ....................................................................99

On/Off Control.............................................................. 99

Proportional Control..................................................... 100

Proportional and Integral Control.................................101

Proportional, Integral and Derivative Control.............. 101

Digital Output Control Forms....................................... 102

Setting Up and Tuning PID Loops ..................................... 104

Proportional Band (PB) Settings...................................104

Integral Term (TI) Settings........................................... 105

Derivative Term (TD) Settings..................................... 105

General PID Constants........................................................ 106

Proportional Band Only (P).......................................... 106

Proportional with Integral (PI)...................................... 106

PI with Derivative (PID)...............................................106

Troubleshooting..........................................................109

Manual Controller Reset............................................... 109

Returning your Unit to ANAFAZE..............................110

MLS User’s Guide Contents

Troubleshooting Stand-Alone Systems .............................. 110

MLS-PM Has No Power...............................................110

Keys Don't Respond......................................................111

Controller Message: AIM Comm Failure..................... 111

Checking Analog Inputs ...............................................111

Checking PID Control Outputs..................................... 112

Checking Digital I/O..................................................... 112

Checking Computer Supervised Systems...........................113

Computer Problems ......................................................113

Serial Interface Problems.............................................. 113

Communications Problems........................................... 114

Software Problems........................................................ 115

Changing the EPROM.................................................. 116

Linear Scaling Examples...........................................119

Example 1: Configuring a Pressure Sensor ........................119

Example 2: Configuring a Flow Sensor.............................. 120

Glossary ......................................................................121

Contents MLS User’s Guide

Overview

This manual describe s h ow t o in st all , s et up, and operate a 16 or 32 MLS

controller. Included are seven chapters and a glossary of terms. Each

chapter covers a different aspect of your control system and may apply

to different users. The following describes the chapters and their

purpose.

•

Introduction: Gives a general description of the MLS and its

related specifications.

•

Installation: Describes how to install the MLS and its peripheral

devices.

•

Using the MLS: Provides an overview of operator displays used for

system monitoring.

•

Setup: Describes all the setup displays for the controller, and how to

access them.

•

Tuning and Control: Explains PID control and provides tips for

tuning your system.

•

Troubleshooting: Gives some basic guidelines for solving control

problems.

•

Linear Scaling Exa mples: Provides an example configuring a pres-

sure sensor, and one configuring a fl ow sensor.

MLS User’s Guide 1

Overview

System Diagram

The illustration below shows how the parts of the MLS are connected.

When unpacking your system, use the diagram and parts list below to

ensure all parts have been shipped. Please don't hesitate to call Watlow-

Anafaze's Technical Service Department if you have problems with

your shipment, or if the MLS' components are missing or damaged.

Parts List

•

MLS Processor Module (PM)

•

Controller Mounting Kit

•

MLS AIM Module (16 or 32)

•

AIM Cable, 4 foot.

•

RS-232 or RS-485 Com Cable (optional)

•

RTB Terminal Block

•

50-Pin Ribbon Cable

•

Power Supply (optional)

2 MLS User’s Guide

Safety

Overview

Watlow-Anafaze has made efforts to ensure the reliability and safety of

the MLS™ Controller and to recommend safe usage practices in

systems applications. Please note that, in any application, failures can

occur. These failures may result in full control outputs or other output s

which may cause damage to or unsafe conditions in the equipment or

process connected to the MLS Controller.

Good engineering practices, electrical codes, and insurance regulations

require that you use independent external safety devices to prevent

potentially dangerous or unsafe conditions. Assume that the Watlow-

Anafaze MLS Controller can fail with outputs full on, outputs full off,

or that other unexpected conditions can occur.

Install high or low temperature protection in systems where an

overtemperature or undertemperature fault condition co uld present a fire

hazard or other hazard. Failure to install temperature control protection

where a potential hazard exists could result in damage to equipment and

property, and injury to person nel.

The MLS includes a reset circuit that sets the control outputs off or to

the data stored in memory if the microprocessor resets--normally the

result of a power failure and power return. If a memory-based restart

will be unsafe for your process, program the MLS Controller to restart

with outputs off. For additional safety, program the computer or other

host device to automa tically reload the desired operating constants or

process values on return of operating power. However, these safety

features do not eliminate the need for external, independent safety

devices in potentially dangerous or unsafe conditions.

Watlow-Anafaze also offers ANASOFT

program for IBM-AT

event of a reset, ANASOFT will reload the MLS Controller with the

current values in computer memory. The user must ensure that this reset

will be safe for the process. Again, use of ANASOFT does not eliminate

the need for appropriate external, independent safety devices.

Contact Watlow-Anafaze immediately if you have any questions about

system safety or system operation.

or IBM-PC® compatible computers. In the

, an optional software

MLS User’s Guide 3

Overview

4 MLS User’s Guide

Introduction

The MLS is a modular control system with 32 fully indepe ndent loops

of PID control. It can function as a stand-alone controller; the MLS

processor module's 1/8 DIN front panel has a Liquid Crystal Display

(LCD) and touch keypad for local display and local p arameter entry.

You can also use it as the key element in a computer-supervised data

acquisition and control system; the MLS can be locally or remotely

controlled via an RS-232 or RS-485 serial communications interface.

The MLS features include:

Direct Connection of Mixed Thermocouple Sensors: V ersatile analog

inputs let you directly connect most thermocouples. Thermocouple

inputs feature reference junction compensation, linearization, PV offset

calibration to correct for sensor inaccuracies, T/C upscale break

detection, and your choice of Fahrenheit or Celsius display.

Introduction

Resistive Temperature Detector Sensors are Standard Inputs: The

standard three-wire 100 W platinum DIN curve sensor is a standard

input for the MLS, as well as the Nickel RT D.

Automatic Scaling of Linear Analog Inputs: The MLS automatically

scales linear inputs used with other industrial process sensors. To scale

inputs, simply enter any two measurement points. For example, to scale

a pH sensor enter the endpoints: the low PV is 2.0 pH, while the high

PV is 14.0 pH. All subsequent values will be in pH.

Independently Selectable PID Output Modes: Y ou can set each loop's

digital output to ON/OFF, Time Proportionin g, Serial DAC, or

Distributed Zero Crossing mode. You can set each loop control mode

for ON/OFF, P, PI, or PID control with reverse or direct action output.

Flexible Alarm Outputs: You can set independent high/low process

alarms and a high/low deviation band alarm for each loop. Each alarm

can activate an individual digital output or it can be grouped with other

alarms to activate a single digital output.

Alarm or Control Outputs: You can set high/low deviation and high/

low process setpoints to operate separate dig ital outputs as on/off

control functions instead of as alarms. (The control function will not

have alarm notification or global alarm output.)

Global Alarm Output: When any alarm is triggered, the Global Alarm

Output is also triggered, and it st ays on until you acknowledge it.

Watchdog Timer: The MLS watchdog timer (System Safe) output

provides a digital output which notifies you if the system fails.

MLS User’s Guide 5

Introduction

Front Panel or Computer Operation: You can set up and run the MLS

Controller from the processor module's front panel or from a local or

remote computer. Watlow-Anafaze offers ANASOFT, our IBM-AT or

IBM-PC compatible software you can use to operate the MLS.

ANASOFT has these features:

•

Graphic Trend Plotting

•

Process Overviews

•

Printouts

•

Data Archiving in Lotus-Compatible Files

Multiple Job Storage: You can store up to 8 jobs in protected memory

and access them by entering a single job number. Each job is a set of

operating conditions, in cluding setpoi nts an d alarms- -so if a si ngle oven

produces multiple products, simply enter one job number to set up every

loop.

Dual Outputs Standard for 16 Loops: The 16-loop MLS Controller

includes dual control outputs for each loop, and a second set of control

constants for heating and cooling applications.

Flexible Outputs Standard for 32 Loops: The 32-loop MLS

Controller is factory set for a single heat output for each input. Outputs

for loops 17-32 can be assigned as second outputs for loops 1-16.

6 MLS User’s G uide

Specifications

This section shows specifications for the MLS, including inputs,

outputs, serial interface information, system power requirements, and

environmental and physical specifications.

Analog Inputs

Number of control loops 16 dual output or 32 singl e output plus one pulse

loop. Number of analog inputs 16 (with AIM-16) or 32 (with AIM-32). Input switching Differential solid state MUX switching. Input sampling rate 16 loops per second. Analog over-voltage protection between

inputs Maximum analog input voltage +10 V from + or - input to analog common. Common mode voltage 500 Vac maximum analog common to MLS-PM

CMR (Common Mode Rejection) >85 dB at 60 Hz, 110 dB typical. A/D converter Integrates voltage to frequency. Integration time per loop 33.3 ms at 60 Hz line frequency. Input range -10 to +60 mV, or 0 to 25 V with s caling resis-

Resolution 0.02%, greater than 12 bits (intern a l) Accuracy

Calibration Automatic zero and full scale. Temperature coefficient

Analog Ground to frame Ground Max. potential

DC Common to frame Ground Max. potential

70 V peak to peak maximum.

or MLS-AIM power supply common.

tors.

0.1% at 25

Less than 100 ppm/

40 V

C, 0.01% per °C.

Introduction

Thermocouple Ranges

J K T B

-350 to 1400

-450 to 2500

-450 to 750

150 to 3200

0 to 3200 0 to 3210

F (-212 to 760°C)

F (-268 to 1371°C)

F (-268 to 399°C)

F (+66 to 1760°C)

F (-18 to 1760°C)

F (-18 to 1766°C)

MLS User’s Guide 7

Introduction

RTD Ranges

RTD1 RTD2 RTD3

T/C break detection Pulse type for upscale break detection and

Milliamp inputs 0-10 mA, 0-20 mA (4-20 mA), etc., with scal-

Infrared inputs power supply included, with scaling resistors

Source impedance Measurements are within specification with

Analog Outputs

The Watlow-Anafaze Digital to Analog Converter (DAC) is an optional

module for MLS and CLS control le rs . It l et s y ou co nver t a dis t ri bu ted zero

crossing output si gnal to an analog pr ocess contro l sig nal. You can purchase

Watlow-Anafaze also offers the Serial DAC for precision open-loop con-

trol. 0-5 Vdc / 4-20 mAdc jumper selectable. Contact Watlow-Anafaze for

-148.0 to 572

-184 to 1544

-94 to 572

F (-100.0 to 300.0°C)0.1

F (-120 to 840°C)1.0

F (-70 to 300°C)1.0

Miscellaneous Specifications

thermocouple alarm display.

ing resistors.

for IRSM.

up to 500 ohms source resistance.

4-20 mAdc, 0-5 Vdc, and 0-10 Vdc versions of the DAC.

more information about the DAC and Serial DAC.

°C °C °C

Digital Inputs

Input voltage protection Diodes to supply and common

Absolute maximum input

Maximum input current 1.2 mA from MLS with input at zero volts

Maximum switch resis-

tance to pull input low

Minimum switch off resis-

Number 8

10 mA

current

Voltage levels <1.3V=Low; >3.7V=High

1 Kohm

11 Kohm

tance

8 MLS User’s G uide

Digital Outputs

Standard Digital Outputs

Number 34 continuous 10 mA sink referenced to +5 Vdc of MLS

for SSR operation; 20 mA momentary peak sink.

User selectable outputs 34 PID control, Alarm/control, or Events. T wo outputs are

not PID programmable.

Number of PID loops 16 or 32 programmable loops. 16-loop systems have dual

outputs. 32-loop systems have 32 sing le outputs, and you can individually configure outputs 17-32 as a second out-

puts for loops 1-16.

PID control outp uts Time Proportioning, Distributed Zero Crossing, or On/

Off--all independently selectable for each loop.

Cycle Time 1-255 seconds.

Control Action Reverse (heat) or Direct (cool), independently selectable

for each loop.

Off State Leakage Current <.01 mA to DC common.

Introduction

System Digital Outputs

Number of system digital

outputs

Configuration 1 global alarm, 5 Vdc at 10 mA sink; 1 System Safe (CPU Watch-

dog Timer), 5 Vdc at 10 mA sink.

MLS User’s Guide 9

Introduction

Miscellaneous Specifications

Serial Interface

Number of Controllers 1 with RS-232 communicati ons, 32 with RS -485 co mmuni cations ,

System Power Requirements

Type RS-232 3-wire or RS-485 4-wire.

Isolation RS-232: None

RS-485: To EIA RS-485 specification.

Baud Rate 2400 or 9600, user selectable.

Error Check BCC or CRC, user selectable.

16 with open frame units.

Protocol Form of ANSI X3.28-1976, (D1, F1) compatible with Allen-Brad-

ley PLC, full duplex.

MLS-PM supply input 10-28 Vdc at <1 amp

MLS-AIM supply input 4.75 to 5.25 Vdc at <0.5 amp, supplied by

MLS-PM

MLS-PS system power supply Input: 120 Vac at 0.5 amp

Output: 12 Vdc at 1 amp

Environmental Specifications

Storage Temperature

Operating Temperature

Humidity Conditions 10 to 95% non-condensing

Dimensions and Weight

MLS-PM 1.75 lbs., 1.89" x 3.78" x 6.75" (0.8 kg, 4.75 cm x 10 cm x 17

MLS-AIM-TB

& AIM cards

MLS-PS 1.50 lbs., 1.90" x 8.10" x 4.90" (0.7 kg, 4.75 cm x 20.25 cm x

RTB .5 lbs, 5.0’’ x 3.0’’ x 2.25’’ (.227 kg, 12.7 cm x 7.6 cm x 5.7 cm.)

1.50 lbs., 5.0" x 6.50" x 5.50" (0.7 kg, 12.5 cm x 16.25 cm x

-20 to 70 0 to 50

cm.)

13.75 cm.)

12.25 cm.)

10 MLS User’s Guide

Expanded Parts List

The Expanded Parts List contains a technical description of each component of your MLS Controller.

MLS Processor Module Technical Description

The MLS Processor Module (MLS-PM) is housed in an eighth-DIN panel mount package. It contains the power supply circuits, the CPU, RAM with a built-in lithium battery socket, EPROM, serial communications, digital I/O, and the LCD screen and touch keypad.

Here's a side view of the MLS-PM:

Introduction

•

Screw terminals connect the power inputs and outpu t s.

•

Input power is 10-28 Vdc at 1 amp.

•

The +5 Vdc, 750 mAdc output po wer s upp ly po wer s th e MLS- A IM.

•

A 50-pin flat ribbon cable connects the digital inputs and outputs to

the 50-pin terminal block (TB-50).

•

The MLS uses 6-pin telephone-style connectors for internal and

external communications.

The firmware's operating intelligence resides in the plug-in EPROM, so it's easy to update or change the MLS' firmware. The MLS stores its operating parameters in battery-backed RAM, so if there's 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 CPU microprocessor performs all calculations for input signal linearization, PID control, alarms, and communications.

The telephone connectors on the rear of the MLS-PM are used for:

•

Communications to the MLS-AIM.

•

RS-232 or RS-485 communications to an optional computer.

•

For OEM customers, communications to the optional MLS Smart I/

O Module (MLS-SIOM).

The System safe output is Low (On) when the CPU is running; it keeps a solid state relay closed. If the CPU stops working, the output goes High (Off) and the SSR opens.

MLS User’ s Guide 11

Introduction

The eight digital inputs are referenced to the MLS controller common; an open input pulls them High (Off). When you short the input to controller common the input goes Low (On). Do not connect external power sources to the MLS' digital inputs.

Front Panel Description

The MLS-PM's panel mounted LCD screen and touch keypad provide an intelligent way to operate the MLS. The on-board display driver operates the liquid crystal display. The LCD has 16 alphanumeric or graphic characters per line; it is backlit for viewing under low light conditions. The 8-key keypad and on-boar d keyboard scanner allo w you to change the MLS' operating parameters, controller functions, and displays.

The MLS' 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. The front panel looks like this:

MLS RTB Technical Description

12 MLS User’s Guide

Here's a picture of the RTB:

The RTB is a screw terminal interface for control wiring which allows you to easily connect external "real world" wiring to the MLS. The RTB connects a 50-pin flat ribbon cable to a screw terminal block which accepts #18 or #20 AWG wires. The ribbon cable receptacle has a locking latch which keeps the cable in place.

The RTB's 34 digital outputs are sink outputs referenced to the +5 Vdc power supply of the MLS Controller. They are Low when the output is On. The firmware allows you to globally change the alarm and control outputs' default state (no alarms) f rom On to Of f for System Safe outpu t. The outputs are rated at a continuous 10 mAdc if all outputs are On at the same time. Initial power up current should not exceed 20 mAdc.

MLS-AIM and AIM-TB Technical Description

The MLS Analog Input Module (MLS-AIM), containing the AIM-TB (AIM Terminal Board) and AIM’s plug-in cards, receive input signals from sensors and pass them to the MLS-PM.

Introduction

The MLS-AIM-TB contains the power supply terminals, input signal wiring screw terminals, input signal cond itioning circuits, and terminal connections for the AIM's plug-in cards. It also contains a cold junction temperature sensor and room for the input scaling resistors, if required. (RTDs, inputs greater than 60 mVdc, and mAdc current inputs require input scaling resistors.) The AIM-TB has three slots for the plug-in AIM cards.

There are two versions of the MLS-AIM: the AIM-16 and AIM-32. The AIM-16 has one multiplexer (MUX) card, and the AIM-32 has two MUX cards. These cards multiplex the 16 inputs each card receives. Each -10 to 60 mVdc input is converted to a voltage that is transm itted to the Voltage/Frequency (V/F) card. (The MUX cards also automatically calibrate the zero and span of the analog amplifier and measure the cold junction compensation temperature for thermocouple (T/C) inputs.) Both the AIM-16 and AIM-32 have a V/F card, which converts the input signal they receive from a voltage to a frequency . The converted signal is then transmitted via the AIM COMM cable to the MLS-PM for processing.

MLS User’s Guide 13

Introduction

MLS Cabling Technical Description

Here's a picture of the MLS-AIM-32 and terminal block:

Watlow-Anafaze provides all the cables required to install your MLS.

The 50 pin ribbon cable which connects the RTB to the MLS-PM is an

0.05 space conductor-zoned 50 pin cable. Pin #1 is at the red edge of the cable.

The cables which connect the MLS-PM to the AIM-TB, the optional Smart I/O Module (SIOM) and the computer are 6-conductor shielded cable. (These cables are also known as RJ12 cable; they are available from Newark Electronics and other suppliers.)

WARNING

These cables are not standard phone cables; standard cables are not shielded. Watlow-Anafaze pin numbering convention is also reversed.

14 MLS User’s Guide

Installation

These installation instructions are written for nontechnical users. If you are an electrician or you are technically proficient, they may seem simple to you. Please at least skim all of the instructions, to make sure you don't miss anything vital. (If you have installed a Modular Loop System before, you may wish to use the Quick Start foldout to install this system.)

This section explains installation for the MLS Controller only. If you are installing another Watl ow-Anafaze product (such as a Relay Interface Board, IRSM, or an SDAC), see the manual shipped with it to learn how to install it.

These symbols are used throughout this manual:

DANGER

This symbol warns you a bout a hazard to hu man life.

WARNING

This symbol warns you of possible damage to property or equipment.

NOTE

This symbol denotes information you must know in order to proceed.

MLS User’s Guide 15

Installation

Read This Before Installation

WARNING

During installation and wiring, place temporary covers over the housing slots and the rear of the MLS so dirt and pieces of wire don't fall through the slots. When you are finished with installation, remove the covers.

Install the MLS so the airflow to the slots in the housing is not restricted after installation. Make sure that other equipment does not block airflow to the housing slots.

Use #18 or #20 AWG wires and trim wire insulation to 1/4" (5 mm). Wire should fit inside the terminal with no bare wire exposed, to prevent contact between wires and the grounded case. Tin any stranded wire.

Support power, input and output cables to reduce strain on the terminals and to prevent wire removal.

DANGER

Shut off power to your process before you install the MLS. High voltage may be present even when power is turned off! Reduce the dan ger of electri c shock after installa tion--mount the MLS in an enclosure that prevents personal contact with electrical components.

The MLS measures input signals that are not normally referenced to ground, so the MLS inputs and other signal lines can have high voltage present even when power is turned off--for example, if you inadvertently short a thermocouple to the AC power line.

NOTE

Choose a panel location that leaves enough clearance to install and remove the MLS and its components.

16 MLS User’s Guide

Recommended Tools

Panel Hole Cutters

Other Tools

Installation

This section lists the tools you will need to install the MLS Controller.

Use any of these tools to cut a hole in the panel:

•

A jigsaw and metal file--for stainless steel and other heavyweight

panel doors.

•

A Greenlee 1/8 DIN rectangular punch (Greenlee part #600-68)--for

most panel materials or thicknesses.

•

A nibbler and metal file--for aluminum and other lightweight panel

doors.

Additional Hardware

You'll also need these tools:

•

A Phillips head screwdriver.

•

A flathead screwdriver for wiring.

•

A multimeter.

•

A phone connector crimping tool made of metal (optional).

W atlow-Anafaze pro vides all the cabling for the Modular Loop System. If you have special cabling requirements and you make your own RJ12 cable, use a metal crimping tool for the connectors. (A metal too l makes better connections than a plastic tool.)

The following additional hardware is also shipped to you:

•

Four #6 screws for mounting the AIM-TB.

•

#10 screws for mounting the optional MLS Power Supply.

MLS User’s Guide 17

Installation

Mounting the MLS-PM

Mounting Environment

This section tells you how to mount the MLS-PM.

NOTE

Mount the MLS-PM before you mount any other component of the MLS. Th e processor module's placement affects placement and wiring for the MLS-AIM, MLS-PS, e tc.

Install the MLS-PM in a location free from excessive (>50 ºC) heat, dust, and unauthorized handling. The MLS-PM's 1/8 DIN package can mount in panels up to 0.2" thick . Its dimen sions are 1.8 9" x 3.78" x 6.1" (48 x 96 x 156 mm), as shown below.

18 MLS User’s Guide

MLS-PM Mounting Steps

Installation

1. Use the template below to cut a hole in the panel. Be careful; the

0.02" (0.5 mm) tolerances don't allow much room for error. Use a punch, nibbler, or jigsaw; file the edges of the hole.

WARNING

Make sure bits of wire and debris do not lodge in the electronics, or else make sure you clean the electronics before you connect power.

2. Insert the MLS-PM into the hole through the front of the panel.

3. Screw the top and bottom clips in place. If you expect much panel vibration, use a rear support for the MLS and its interconnecting cables.

MLS User’s Guide 19

Installation

Mounting the MLS-AIM

This section contains mounting instructions and diagrams for the MLSAIM.

NOTE

If you plan to install scaling resistors, mount them on the AIM-TB before you mount the AIM-TB in the panel. (If you mount the AIM-TB in the panel before you mount the scaling resistors on it, you will have to remove the AIM-TB from the panel to install the scaling resistors.)

If you ordered an MLS-AIM-TB with scaling inputs from Watlow-Anafaze, the scaling resistors are already installed.

Mounting Environment

Install the MLS-AIM in a location free from excessive (>50ºC) heat, dust, and unauthorized handling.

The MLS-AIM measures 6.5" x 5 " x 7" (165 x 127 x 1 78 mm). Leave 6 " of clearance above the MLS-AIM, so yo u can remove the entire unit (or just the AIM cards) if necessary.

The figure on the next page shows an overhead view of the AIM-TB and MUX cards, with dimensions, scaling resistor locations and hole locations. It also shows the AIM communications port and the insertion of the MUX cards in the AIM Terminal Block.

20 MLS User’s Guide

Scaling Resisters AIM Communications Port (Tel. 1)

Installation

Mounting Holes

Mounting Steps

1. Choose an appropriate place to install the MLS-AIM.

2. Place the MLS-AIM where you will mount it and use a pen cil to trace around the plastic standoffs on the AIM. (If you wish, you can use the AIM mounting template in the Quick Start foldout to po sitio n the holes.)

3. Drill four #6 or #8 holes in the chosen location. (#8 holes provide more clearance.)

4. Place the MLS-AIM where you will mount it. Insert the #6 screws in the plastic standoffs and tighten them. You may use self-tapping screws instead, but be sure to remove any loose metal filings after you are finished mounting the MLS-AIM. Use 3/4" screws with internal star lock washers to ensure a good Frame Ground connaction.

MLS User’s Guide 21

Installation

Mounting the RTB

To mount the RTB, slide it onto a DIN rail. Watlow-Anafaze recommends Phoenix Contact’s NS32 perforated DIN rail (part number 12-01-00-2). Mount the DIN rail according to Phoenix Contact’s instructions and slide the RTB onto it.

WARNING

Do not connect power to the MLS now. Test the unit first, as explained in the Power Wiring and Controller Test section.

22 MLS User’s Guide

Mounting the MLS-PS

Mounting Environment

Mounting Steps

Installation

Follow these instructions to mount the MLS-PS.

If you use your own power supply for the MLS, please refer to the power supply m anufacturer's instructions for mounting informati on. Choose a power supply that s upplies a regul ated 7 -28 Vdc at 1 wat t, and isolated return line.

The MLS-PS measures 1.75" x 8" x 5". Leave enough clearance ar oun d the power supply that you can remove it later.

The MLS-PS has a bracket at each end of the unit. Each bracket has three screw holes which will accept #6 or #10 screws. To mount the MLS-PS, insert screws into the brackets and tighten them.

MLS User’s Guide 23

Installation

Wiring Your System

This section explains how to wire the components of your system.

Below is the system connections diagram reprinted here for your

convenience. (See the next page for wiring instructions.)

24 MLS User’s Guide

Wiring Recommendations

Installation

This section gives general wiring recommendations.

DANGER

•

Use stranded wire. (Use solid wire for fixed service; it makes inter-

mittent connections when you move it for maintenance.)

•

Use #18 or #20 AWG 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 MLS from

electrical noise.) Connect one end of the MLS panel's 120 Vac panel ground, and connect one end of the

put wiring shield

your system requires a different shield configuration, contact Watlow-Anafaze for more information.)

For more information about noise supp res sion , see

to the MLS panel's 120 Vac panel ground. (If

input wiring shield

Noise Suppression

to the

out-

MLS User’s Guide 25

Installation

Cable Recommendations

Use these cables or their equivalent.

Function MFR P/N No. of Wires AWG

Analog Inputs Belden #9154

Belden #8451

RTD Inputs Belden #8772

Belden #9770 T/C Inputs T/C Ext. Wire 2 20 Carbon Probe Input Belden #88760 2 18 Digital PID Outputs and Digital

I/O

Analog Outputs Belden #9154

Computer Communication: RS232, RS422, RS485, or 20 ma

Belden #9539

Belden #9542

Ribbon Cable

Belden #8451

Belden #9729

Belden #9730

Belden #9842

Belden #9843

2 2

3 3

9 20 50

2 2

4 6 4 6

20 22

24 24

20 22

24 24 24 24

Noise Suppression

If the MLS outputs control dry-contact EM relays with inductive loads-like alarm horns and motor starters--you may get Radio-Frequency Interference (RFI, or "noise") This section explains how to avoid noise problems; read it before you wire the MLS.

Symptoms of RFI

•

The MLS display blanks out and then reenergizes, as if power had

been turned off for a moment.

•

The process value does not display correctly.

•

The MLS CPU may reset; if it does, it loses its' PID output levels.

RFI may also damage the di gital output circuit--so digital outputs will not energize. If the digital output circuit is damaged, return the controller to Watlow-Anafaze for repair.

Avoiding RFI

Where possible, use solid state relays (SSRs) instead of electricalmechanical (EM) relays. If you must use EM relays, try to avoid mounting them in the same panel as Watlow-Anafaze equipment.

Separate the 120 Vac power leads from the low level input and output leads connected to the MLS. Don't run the digital output or PID control output leads in bundles with 120 Vac wires. (Never run input leads in bundles with high power leads--see the

General Wiring

section.)

26 MLS User’s Guide

If you must use EM relays and you must place them in a panel with Watlow-Anafaze equipment, use a .01 microfarad capacitor rated at

1000 Vac (or higher) in series with a 47 ohm, normally open (NO) contacts of the relay load. This network is known as an arc suppressor or snubber network.

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 130 Vac for 120 Vac control circuits across the load, which limits the peak AC voltage to about 180 Vac. You can also place a transorb (back to back zener diodes) across the digital output, which limits the digital output loop to 5 Vdc. (You can get these parts from Watlow-Anafaze.)

The above steps will eliminate most noise problems . If you have fu rther problems or questions, please contact Watlow-Anafaze.

Wi ring and Testing Your System

Installation

watt resistor across the

After you install each component of the MLS, use this section to connect them. If these instructions are not clear to you, refer to the system connections diagram for more information. (These instructions are written for non-electricians. If you are an experienced electrician, they may seem elementary to you. If so, feel free to skim them.)

When you have connected each component of your system, install and connect input and output devices. For help with inputs and outputs, see the Outputs and the Inputs sections in this chapter.

Connecting Power and RTB to MLS-PM

1. Remove the temporary covers you placed on the MLS' housing.

2. Connect the power supply terminal labeled "DC COM" to the terminal labeled "GND" on the Processor Module. This terminal is DC common; it is not frame, chassis or earth ground.

3. Connect the power supply terminal labeled "+12V" to the terminal labeled "+V" on the Processor Module.

4. Connect the 50-pin ribbon cable to the Processor Module. Plug it in so that the red stripe is on the left side, under TB1.

5. Connect the ribbon cable to the RTB. Plug it in so that the red stripe is closest to screw terminal 1.

Connecting Power and Common to AIM-TB

1. Connect the terminal labeled "EX" on TB1 of the MLS-PM to the terminal labeled "+5V" on the MLS-AIM.

2. Connect the terminal labeled "COM" on TB1 of the MLS-PM to the MLS-AIM terminal labeled "DC COMMON".

MLS User’s Guide 27

Installation

Testing Connections

3. Plug the AIM communications cable into the slot on the MLS-PM labeled "To AIM".

4. Plug the other end of the AIM communications cable into the sl ot on the MLS-AIM labeled "Tel 1". (The slot is on top of the V/F card.)

WARNING

Do not turn on the AC power now. Test the connections first, as explained below.

5. Connect AC power wires to the MLS-PS.

6. Connect " " terminal on MLS AIM to frame Ground.

WARNING

Reversed polarity or incorrect voltage to the PM or AIM will damage your MLS, and y ou will need to return it to Watlow-Anafaze for repair. Please don't damage your unit! Read this section completely and follow the steps below before you apply power to your MLS.

1. Unplug TB 1 (the green block which contains the Ex, GND, and +V terminals) from the MLS-PM.

2. Unplug the AIM cards from the AIM-TB:

•

Carefully insert a screwdriver in the hole on the side of the AIM's

metal jacket.

•

Gently press the screwdriver blade against the metal standoffs which

separate the AIM cards.

•

Continue pressing gently until the AIM cards pop loose from the

plastic bracket that holds them in place. Then, carefully grasp the AIM cards by the edges and remove them from the metal bracket.

You have removed the parts of the MLS which will be damaged by excess voltage, so turn on the AC power and use a voltmeter to check voltages:

3. Touch the meter Common lead to the "COM" terminal on the MLSPM (the green block with the wires). The voltage on the "+V" terminal of the MLS-PM should be +10 to 28 Vdc. The voltage on the "EX" terminal of the MLS-PM should read 0 Vdc.

4. If the voltages are within the limits described above:

•

Turn off the power.

•

Plug TB1 (the green block which contains the screw terminals) back

into the MLS-PM.

28 MLS User’s Guide

Installation

•

Turn the power back o n. The Processor Mo dule's display should light

up, and after about a second the Bar Graph display should appear, followed by the message "AIM COMM FAIL".

5. Connect the Common lead of the voltmeter to TB3 and the power lead of the voltmeter to the AIM-TB terminal labeled "+5V". The voltage on the "+5V" terminal should be between +4.75 and +5.25 Vdc.

6. If the voltages are within the limits described above:

A. Turn off the power. B. Carefully insert the AIM cards back into the AIM Terminal

Block. C. If you have unplugged the AIM COMM. cable, plug it back in. D. Press and hold the No key. While pressing it, turn the power

back on. (This procedure is known as a manual controller reset

or No Key reset.)

The green LEDs on the AIM should blink, which means that the

unit is working normally. If they do not blink, contact Watlow-

Anafaze. E. The MLS-PM will display a "T/C Break" alarm message for

each channel. These messages are normal; to clear them, press

Alarm Ack once for each control loop.

MLS User’s Guide 29

Installation

Testing Your System

MLS-AIM Test

This section explains how to test the controller after installation.

Use this procedure to test the MLS-AIM before you connect inputs to it.

1. Connect a wire from the A+ terminal for loop 1 to the A- terminal for loop 1.

2. Turn on power to the MLS-PM.

3. Press the on the MLS-PM's screen.

4. Press the MLS-AIM-TB contains an ambient temperature sensor, so Loop 1 should display room temperature. If it does not, contact WatlowAnafaze.

ALARM ACK

YES

key to reach the single loop display for Loop 1. The

key to clear the alarm messages displayed

RTB Test

PID Output Test

1. Turn on power to the MLS.

2. Measure the +5Vdc supply at the RTB:

A. Connect the voltmeter's Common lead to RTB terminal #3. B. Connect the voltmeter's Power lead to RTB screw terminal #1.

The voltage should be 4.75 to 5.25 Vdc.

C. Connect the Power lead to RTB screw terminal #2. The voltage

should be 4.75 to 5.25 Vdc.

D. Connect the Power lead to RTB screw terminal #4. The voltage

should read 0 volts.

1. Connect the voltmeter power lead to RTB screw terminal #1.

2. Connect the Common lead to the PID output pin.

3. If you have not connected a load to the output, connect a 500 ohm to 100 Kohm resistor b etween RTB screw terminal 1 and the PID output pin.

4. Use the digital output test (in the Manual I/O Test menus) to turn the digital output on and off. When the output is off, the output voltage should be less than 1V. When the output is on, the output voltage should be between 3.75 and 5.5V.

30 MLS User’s Guide

Outputs

Installation

NOTE

Your ML S is shipped wit h heat outputs e nabled and cool outputs disabled. You can disable any PID output and use it for other digital output functions.

All digital outputs and PID outputs are sink outputs referenced to the 5Vdc supply. These outputs are Low when they are On.

All digital inputs are Transistor-Transistor Logic (TTL) level inputs referenced to control common.

This section discusses the MLS' PID control and alarm outputs.

WARNING

Control outputs are connected to the MLS's logic ground when the control output is On (Low). Be careful when you connect external devices that may have a low side at voltage other than controller ground, since you may create ground loops.

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

The MLS provides dual PID control outputs for each loop. These outputs are on the 50 pin ribbon cable connector which connects to the RTB. You can enable or disable them.

•

The default setting is heat outputs enabled, co ol outputs disabled.

•

You can program each output for on/off, TP, or DZC control.

•

You can program each output for direct or reverse action.

•

You can program a deadband for heat/cool; within that deadband

both outputs will be Off.

Output Wiring Recommendations

When you wire output devices to the RTB, use multicolored stranded shielded cable for analog outputs and PID digital outputs connected to panel mount SSRs.

•

Analog outputs usually use a twisted pair.

•

Digital outputs have 9 to 20 conductors, depending on wiring tech-

nique.

MLS User’s Guide 31

Installation

Ribbon Cable Recommendations

Use the 50-pin connector for both ends of the 50 pin flat ribbon cable. (Do not connect either end to a screw terminal; the cable wire is too small to withstand much flexing.) Do not exceed 15' of 50-conductor cable.

Using the Cable Tie Wraps

When you have wired outputs to the TB-50, ins tall the cable tie wraps shipped with it. This diagram shows the cable tie wrap holes.

Each row of terminals has a cable tie wrap hole at one end. Thread the cable tie wrap through the cable tie wrap hole. Then wrap the cable tie wrap around the wires attached to that terminal block.

32 MLS User’s Guide

PID Control and Alarm Output Connections

T ypical digital control outputs use external optically-isolated solid-state relays (SSRs). The SSRs use a 3 to 32 Vdc input for control, and you can size them to switch up to 100 amps at 480 Vac. For larger currents, use these optically-isolated relays to drive contactors.

NOTE

Control outputs are sink outputs. They are Low when the output is O n. Connec t them t o the neg ative side of Solid State Relays.

The next figure shows sample heat/cool and alarm output connections.

Installation

System Safe (Watchdog Timer) constantly monitors the MLS CPU. It is a SINK output located on RTB terminal #6. (Do not exceed the 10 mAdc rating for the System Safe output.) Its output is Low (on) when the CPU is operating; when it stops operating, the output goes High (off), de-energizing the SSR.

Here's the recommended circuit for the System Safe output:

+5 Vdc

(RTB pin 2)

SSR

System safe

(RTB pin 6)

MLS User’s Guide 33

Installation

RTB Connections

Connect outputs to the RTB as shown in the table below.

Terminal Function PID Output Terminal Function PID Output

1 +5 Vdc 2 +5 Vdc 3 CTRL COM 4 CTRL COM 5 Spare 6 System Safe 7 Pulse input 8 Global Alarm 9 DIG Output 1 Heat 1 10 DIG Output 34* 11 DIG Output 2 Heat 2 12 DIG Output 33 Pulse Loop Heat 13 DIG Output 3 Heat 3 14 DIG Output 32 Heat 32/Cool 16 15 DIG Output 4 Heat 4 16 DIG Output 31 Heat 31/Cool 15 17 DIG Output 5 Heat 5 18 DIG Output 30 Heat 30/Cool 14 19 DIG Output 6 Heat 6 20 DIG Output 29 Heat 29/Cool 13 21 DIG Output 7 Heat 7 22 DIG Output 28 Heat 28/Cool 12 23 DIG Output 8 Heat 8 24 DIG Output 27 Heat 27/Cool 11 25 DIG Output 9 Heat 9 26 DIG Output 26 Heat 26/Cool 10 27 DIG Output 10 Heat 10 28 DIG Output 25 Heat 25/Cool 9 29 DIG Output 11 Heat 11 30 DIG Output 24 Heat 24/Cool 8 31 DIG Output 12 Heat 12 32 DIG Output 23 Heat 23/Cool 7 33 DIG Output 13 Heat 13 34 DIG Output 22 Heat 22/Cool 6 35 DIG Output 14 Heat 14 36 DIG Output 21 Heat 21/Cool 5 37 DIG Output 15 Heat 15 38 DIG Output 20 Heat 20/Cool 4 39 DIG Output 16 Heat 16 40 DIG Output 19 Heat 19/Cool 3 41 DIG Output 17 Heat 17/Cool 1 42 DIG Output 18 Heat 18/Cool 2 43 DIG Input 1 44 DIG Input 2 45 DIG Input 3 46 DIG Input 4 47 DIG Input 5 48 DIG Input 6 49 DIG Input 7 50 DIG Input 8 * If you install an Watlow-Anafaze Serial Digital to Analog Converter (SDAC), the MLS uses digital output #34

for a clock line. You cannot use output #34 for anything else when an SDAC is installed.

34 MLS User’s Guide

AIM Communications Failure

The controller continuously checks communications between the MLSPM and the AIM. If communication stops for more than five seconds, the MLS-PM display indicates AIM COMM FAIL, the PID mode changes to manual, and the controller sets every output to the output override percentage.

WARNING

PID outputs remain in manual mode after an AIM communications failure. After an AIM failure, change the PID control status back to automatic mode for each control loop.

An AIM communications failure also activates the global alarm output. If you have selected a digital output from the Global Parameters menu, an AIM communications failure also activates the output.

Installation

MLS User’s Guide 35

Installation

Inputs

This figure shows the AIM cards (also known as the MUX cards) and AIM-TB, with scaling resistor locations.

Scaling Resisters AIM Communications Port (Tel. 1)

36 MLS User’s Guide

•

The loop input number is marked on the terminal block: the number

1 indicates an input for loop 1, the n umber 2 an input for loop 2, etc.

•

The A+ terminal is the positive input of the analog signal.

•

The A- terminal is the negative input of the analog signal.

•

The A COM (AUX) terminal is the Auxiliary input. This is an alog

WARNING

Do not exceed 10 Vdc between loops. Excess voltage may damage the Analog Input Module (AIM).

Input Wiring Recommendations

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

Input Scaling

Installation

common used for RTD inputs.

Y ou can co nnect thermocouples, 4-20 mA current inputs, vo ltage inputs, and 2- or 3- wire RTD inputs to the MLS. If you need to scale input voltages or convert milliamp inputs to match the -10 to 60 mV (-16.7% to 100%) input range, install scaling resistors. Watlow-Anafaze can supply factory-installed input scaling resistors--order option MLS-SIXX (See the next table for standard scaling resistor values), or special input kits MLS-SIK-XX (call Watlow-Anafaze for XX number).

Scaling Values

•

Scaling values for mVdc ranges are standard metal film values with

0.25% accuracy if 0.1% tolerance resistors are used.

•

Scaling values for mAdc ranges are 0.1% tolerance with +0.10%

accuracy.

•

Scaling values for RTD ranges are 0.05% tolerance. Use these values

to remain within factory specifications for the RTD inputs.

•

Use 0.1% metal film, 1/4 watt resistors. Higher tolerances may cause

significant errors. Use the MLS' built-in linear scaling to correct any errors due to resistor tolerance. You can also install other components (like capacitors) for signal conditioning; please consult Watlow-Anafaze for more information.

This figure shows an input circuit. RA, RB, RC, and RD refer to the scaling resistor locations printed on the MLS-AIM's terminal board.

MLS User’s Guide 37

Installation

To MLS-AIM

Circuitry

C .47 uF

A +

A -

A COM

Analog Input Terminal

Internal

+2.5 Vdc Reference

C .47 uF

This table shows scaling resistor values.

Input Range RA RB RC RD

All T/C, 0-60 mVdc Jumper RTD1 -100.0 to 300.0

RTD2, -120 to 840 RTD3, -70 to 300

0-10 mAdc 0-20 mAdc (4-20 mA)

0-100 mVdc 0-500 mVdc 0-1 Vdc 0-5 Vdc 0-10 Vdc 0-12 Vdc

5.49K

11.0K

-450 to 2500

5.49K

11.0K

80 100 100

Jumper Jumper

499

5.49K

6.91K

39.2K

49.9K

84.5K

IN +

IN -

6.0

3.0 750

750 422 475 301 422

38 MLS User’s Guide

Input Calibration

The MLS provides offset calibration for T/C, RTD, and other fixed ranges. It also provides offset and span (gain) calibration for linear and pulse inputs. (Offset and span calibration convert linear analog inputs into engineering units using the Mx+B function.) The offset range is 300 to +300 units; the magn itude of the of fs et depen ds on the inp ut ty pe and span you select.

Follow these steps to use the MLS' offset and span calibration:

1. Install scaling resistors that will provide an appropriate full scale voltage. (If you have any doubts about your ability to install scaling resistors, contact W atlow-An afaze.)

T/C Inputs

Installation

2. Select the # of digits and decimal point location for the full scale PV display. The smallest possible range is -0.9999 to +3.0000; the largest possible range is -9999 to 30000.

3. Enter the zero and full scale values (process variables) you want displayed when the input signal is at zero and full scale.

WARNING

Use ungrounded thermocouples (thermocouples which have the T/C junction isolated from the metal protection sheath). Grounded thermocouples will damage the MLS if voltage between the loops exceeds 10 volts.

If you are installing the MLS in an existing temperature control system, check all grounded T/C assemblies in the system. Make sure there is no voltage between T/C leads.

You can connect all T/C types directly to the MLS. Watlow-Anafaze provides J, K, T, R, S, and B type linearization and cold junction compensation. (Other thermocouple types require custom input ranges; contact Watlow-Anafaze for more information about them.)

Wiring Recommendations

Follow these recommendations for thermocouple wiring:

•

Use 18 or 20 AWG thermocouple (T/C) extension wire for all ther-

mocouple inputs.

•

Most T/C wire is solid unshielded wire. Use shielded wire if required

at your installation; ground one end only.

•

Use less than 500' of T/C extension wire. Longer wire runs exceed

accuracy and source impedance specifications.

•

Install T/C wiring in a separate conduit away from AC power (the

120 Vac supply) and high power (240 Vac or higher) wiring.

MLS User’s Guide 39

Installation

Connecting Thermocouples

Connect the positive T/C lead to the A+ terminal. Connect the negative T/C lead to the A- terminal of TB1. The figure below shows a typical thermocouple connection.

•

Use 20 gauge T/C extension wire for all T/C inputs.

•

If you use shielded wire, tie the shield to panel ground.

•

Install a jumper or zero ohm resistor in location RC on the AIM-TB

if it had been removed.

This figure shows a typical thermocouple connection.

RTD Inputs

White

Type J T/C

The standard industrial RTD is an 100 ohm, three-wire, platinum assembly as shown in the next figure. Watlow-Anafaze highly recommends that you use the three-wire RTD to prevent reading errors due to cable resistance.

•

If you order an RTD1, RTD2, or RTD3 configuration, we will con-

figure your MLS for the standard three-wire RTD.

•

If you must use a two-wire RTD, jumper A- to AUX.

•

If you must use a four-wire RTD, do not connect the fourth wire.

Watlow-Anafaze offers three standard DIN 385 curve RTD input ranges, as shown in the table below:

Red Shield

IN +

–

40 MLS User’s Guide

RTD Type

RTD1 -100.0 to 300.0 C

RTD2 -120 to 840 C

RTD3 -70 to 300 C

This figure shows a typical 3-wire RTD connection.

Input Range

-148.0 to 572.0 F

-184 to 1544 F

-94 to 572 F

Resolution

0.1 C

0.1 F 1 C

1 F 1 C

1 F

Display

Current Inputs

Voltage Inputs

Installation

Rear Terminal Block Connections

Black

100 Ohm RTD

Black Red

IN +

–

IN Analog Common

To install current (milliamp) inputs, place resistors in the input section which convert the milliamp input into a voltage. (You can get different current input ranges if you select different resistor values.) The input connections for these inputs are the same as the input connections for voltage inputs.

Unused Inputs

Connect the + side of the voltage input to the A+ terminal. Connect the side of the input to the A- terminal. The voltage input range is -10 to 60 mV. Scale signals larger than 60 mV with a scaling resistor which makes full scale input 60 mV.

The next figure shows two resistors. RA and RB are not loaded. RC is the voltage reducing or current limiting resistor, and RD is the 60 mV full scale dropping resistor. RD is normally less than 500 ohms, and it should never exceed 1000 ohms.

Circuitry

IN +

–

Set the input type for unused inputs to "SKIP" to avoid the default T/C break alarms.

MLS User’s Guide 41

Installation

Communications

The MLS is factory-configured for either RS-232 or RS-485 communications. When you order your un it, specify the type of communications you need.

•

If you use one MLS and you connect it to a computer less than 50

feet away, you can use RS-232 communications.

•

If you use more than one comp uter, or if the computer and controller

are more than 50 feet apart, use RS-485 communications.

PC-compatible computers typically use RS-232 communications. If the MLS is configured for RS-232 communications, you can connect it directly to the serial communications connector on an IBM-PC or compatible computer.

If you use RS-485 communications, attach an optically isolated RS-232/ RS-485 converter to the computer. You can use an internal converter card or an external plug-in converter.

Changing Communications

Follow these instructions to change the unit's communications between RS-485 and R S -232:

1. Unplug any cables connected to the MLS-PM.

2. If you already installed the MLS-PM in a panel, remove it from the panel.

3. Unscrew the screws on the PM's casing. (There are either two or four screws on the sides of the casing. There are two additional screws on the top of the casing.)

4. Move jumpers JU2, JU4, and JU14 on the upper PC board.

5. If you are changing communications for the last unit on the serial communications line, also m ov e jumper JU3. Installing this jumper places a 200 ohm impedance on the line.

6. Reverse instructions 1-3 to reinstall the unit.

Connecting RS-232 Communications

The RS-232 interface is a standard phone cable with a 6-pin male phone connector on one end and a 9- or 25-pin D-sub female connector on the computer end. (You can order this cable--called an MLS COM cable-from Watlow-Anafaze. If you order it, specify the length of cable and the type of D-sub miniature connector you need.)

42 MLS User’s Guide

Installation

1. Plug the phone connector into the slot labeled "RS-232/RS-485" on the rear of the MLS-PM.

2. Plug the D-sub connector into the communications connector.

This table shows RS-232 connections for 25-pin and 9-pin connectors.

Computer Connector

DB 25 DB 9

RX Pin 3 RX Pin 2 TX Pin 5 Ye llow TX Pin 2 TX Pin 3 RX Pin 1 Blue GND Pin 7 GND Pin 5 GND Pin 4 Green

MLS RS-232 Pin

Number

NOTE

The pin numbers and colors are not industry standard. Watlow-Anafaze numbers the pins from right to left with 1 on the right as you’re looking at the back of the MLS-PM. Colors vary depending on the manufacturer. The figure below shows a back of an MLS-PM.

Connecting RS-485 Communications

RS-485 specification is for "balanced line" operation; it is not true differential, so you must supply a common ground connection. Use a fifth wire (which should not b e shi eld, i f pos sible) or a commo n groun d connection to establish the common ground.

Do not use the common ground connection unless the common mode voltage between stations at your installation exceeds the RS-485 specification of 7 volts peak; in that case, use a fifth wire.

The following diagram shows the recommended system hookup. The transmitter from the host computer connects in parallel to the controller receivers, and the host computer receiver connects in parallel to the controller transmitters. Watlow-Anafaze recommends that you use a single "daisy chain" rather than "octopus connections" or "spurs". In addition, use a terminating resistor (a 200 ohm resistor lai d acros s the line at the furthest point from the transmitter) at each end of the transmission line.

This figure shows the MLS RS-485 connections.

MLS User’s Guide 43

Installation

Black Box LD 485

TXA TXB

RXA RXB

Ground

MLS T3A/B

[n] RJ12

RX+ #3 RX- #1

TX+ #2 TX- #5

Red Blue/White

Black Yello w

Silver

MLS T3A/B [1] RJ12

RX+ #3 RX- #1

TX+ #2 TX- #5

Red Blue/White Black

Yello w Silver

NOTE

Connect the shields to earth ground only at the computer or other 485 interface. Do not connect the shield at the MLS. Connect a 200 ohm terminating resistor between RX- and RX+ at the last MLS (Ju3).

The loop resistance of the transmission line (wire only, not terminating resistor) must not exceed 200 ohms.

200

Ω

This table shows RS-485 connections.

Line RS-485 Connection Color

TXB RX+Pin 1 Blue/White TXA RX-Pin 3 Red RXB TX+Pin 5 Yellow RXA TX-Pin 2 Black

Ground Pin 4 Green

Shield Shield Pin 6

(Not jumpered internally)

EIA Standard RS-485 specifies the electrical characteristics of transmitters and receivers for digital multi-point systems. WatlowAnafaze equipment meets RS-485 and RS-422 standard s. Ho wever, RS485 does not specify transmission lines, signaling rates, protocols, etc. Watlow-Anafaze recommends the following:

•

Maximum signaling rate: 9600 baud.

•

Twisted shielded pairs for the RS-485 cab les.

44 MLS User’s Guide

Recommended Wire Gauges

Installation

This table shows maximum distances and wire gauges for communica tions wiring:

Distance Wire Gauge Recommended Cable

4000 ft. 24 AWG Belden #9729

Belden #9842

6000 ft. 22 AWG Belden #9184

You may wish to use a shield, dependin g on your noi se envi ronment and grounding problems. These cables are shielded.

MLS User’s Guide 45

Installation

46 MLS User’s Guide

Using the MLS

This chapter explains how to use the front panel to operate the controller. (If you are using ANASOF T, see the operation instructions in the ANASOFT User's Guide.) The next figure shows a map of the operator menus and displays accessible from the MLS Controller's front panel. You don't need to enter a passkey sequence to reach these menus.

To make detailed changes to global parameters, loop inputs, control parameters, outputs, and alarms via the setup menus, you must enter a special sequence of keys. (F or m ore i n form at io n about the Setup menus ,

Chapter 4: Setup

see

Using the MLS

MLS User’s Guide 47

Using the MLS

Front Panel

Man/Auto

Changes loop output control from Automatic to Manual or Tune Assigns output power level of manual loops

Change Setpoint

Changes process Setpoint

The MLS front panel provides a convenient interface with the controller. You can use the front panel keys to program and operate the MLS, or you can use ANASOFT, a program designed specifically for ANAFAZE controllers. (See the

ANASOFT User's Guide

for more

information about ANASOFT, or contact ANAFAZE.)

This figure shows the MLS' front panel.

Ramp/Soak

Not available at this time

Alarm Ack

Acknowledges

Enter

Stores data or me nu

yes

Selects a menu Answers Yes

to Ye s/No prompts Increases a number or choice

Back

Aborts editing and returns to a previous menu

choices & advances to the next menu Starts scanning mode (if pressed twice)

Skips a menu Answers No to Yes/No prompts Decreases a number or choice you are editing

48 MLS User’s Guide

Front Panel Keys

Yes (Up)

No (Down)

Yes

Press

•

to do these things:

Select a menu. Answer Yes to Yes/No prompts. Increase a number or choice you're editing. Stop scanning mode.

Using the MLS

Back

Press No to do these things:

•

Skip a menu when the prompt is blinking.

•

Answer No to Yes/No prompts.

•

Decrease a number or choice when editing.

•

Stop scanning mode.

•

Perform a manual controller (No Key) reset (see next page).

WARNING

A manual controller (No Key) reset clears the controller's RAM and reinitializes the MLS-PM's factory default values.

A manual controller reset is appropriate in these situations:

•

After you change the PROM.

•

In some cases when troubleshooting (see

ing

Chapter 6: Troubleshoot-

Back

The

•

key works like an "escape" key. Press it to:

Abort editing. Return to a previous menu. Stop scanning mode.

MLS User’s Guide 49

Using the MLS

Enter

Chng SP

Man/Auto

•

Switch between Bar Graph and Single Loop display.

Press the "Enter" key to:

•

Store data or a menu choice after editing.

•

Go on to the next menu.

•

Start scanning mode (if pressed twice).

•

Press this key to change the loop setpoint.

Ramp/Soak

Alarm Ack

Press the Man/Auto key to:

•

Toggle a loop between manual and automatic control.

•

Adjust the output power level of manual loops.

•

Automatically tune the loop.

Ramp/Soak isn't available for the standard MLS. When pressing this key, a message appears: OPTION UNAVAILABLE.

Press Alarm Ack to:

•

Acknowledge an alarm condition.

•

Reset the global alarm digital output.

50 MLS User’s Guide

Displays

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

This section describes the MLS' displays.

Viewing Several Loops: Bar Graph Display

When you connect power to the MLS, it displays general symbolic information for loops 1-8. This display is called Bar Graph mode. The next figure shows a picture of the Bar Graph display.

01 08 AAAA MAMA

This table explains the symbols on the to p line of the Bar Graph display.

Using the MLS

Symbol Symbol’s Meaning

< >

Loop is in low process or low deviation alarm. Loop is in high process or high deviation alarm. Loop is above setpoint. If you enable the high or low devia-

tion alarm, this symbol is scaled to it. If you don’t enable these alarms, these symbols are scaled to the setpoint + the sensor’s range.

Loop is at setpoint. If you enable the high or low deviation alarm, this symbol is scaled to it. If you don’t enable these alarms, these symbols are scaled to the setpoint +

5% of the

sensor’s range. Loop is below setpoint. If you enable the high or low devia-

tion alarm, this symbol is scaled to it. If you don’t enable these alarms, these symbols are scaled to the setpoint + the sensor’s range.

Blank

(

) Loop is set to SKIP.

Sensor has failed.

The next table explains the symbols you see on the bottom line of the Bar Graph display and in the Single Loop display. These symbols appear when the controller is in bot h dual ou tput mode and s ingle ou tput mode. If the process goes into alarm, the controller automatically switches to Single Loop display and shows an alarm code.

5% of

MLS User’s Guide 51

Using the MLS

Bar Graph DisplaySy

mbol

Single

Loop

DisplaySy

mbol

Description

M MAN One or both outputs enabled. Loop is in manual control.

A AUTO Only one output (Heat or Cool) is enabled. Loop is in automatic

control.

T TUNE Indication th at the loop is in Autotune mode.

H T

C L

(blank) (blank)

HEAT

COOL

Both heat and cool outputs are enabled. Loop is in Automatic

control and heating.

Both heat and cool outputs are enabled. Loop is in Automatic

control and cooling.

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

Navigating in Bar Graph Display

Press the Yes (up) or No (down) key to see a new group.

•

Press Enter twice to scan al l gr oups. The g roups will disp lay s equen -

tially for three seconds each. This is called Scanning Mode.

•

Press Back, Yes or No to go back to Bar Graph display.

•

From Bar Graph display, press Back once to go to Single Loop dis-

play.

Viewing One Loop: Single Loop Display

Single Loop display (below) shows detailed information for only one loop. If the heat and co ol o utput s ar e enabled, Single Loop di s pla y lo oks like this:

Process Variable

Loop Number or Name

Setpoint

The control status indicator shows HEAT or COOL if the loop is in automatic control, and MAN or TUNE if the loop is in manual control.

LOOP PROCESS UNITS

02 160

180 AUTO 100

ALARM SETPOINT STATUS OUT%

Control Status

Engineering Units Output percentage

52 MLS User’s Guide

Using the MLS

If only one output is enabled (heat or cool, but not both), Single Loop display looks like this:

Interpreting Alarm Display

Engineering Units

F 0

Output Percentage Cool

Output Percentage Heat

Loop Number or Name

Setpoint

Process Variable

LOOP PROCESS UNITS

02 160 180 AUTO 100

ALARM SETPOINT STATUS OUT%

Control Status

Navigating in Single Loop Display

From the single loop display,

•

Press the Back key once to get back to Bar Graph display.

•

Press Enter twice to get to the Single Loop Scanning display. (The

Single Loop Scanning display shows information for each loop in sequence. Data for each loop displays for one second.)

•

Press Back, Yes, or No to return to the Single Loop display.

If an alarm occurs, the alarm interrupts any other display and switches to the alarm display, as shown in the next figure. If the MLS is in Bar Graph display, it switches to Bar Graph Alarm display. If it is in Single Loop display, it switches to Single Loop Alarm display.

Loop Number or Name

Alarm Symbols Loop Status

Process Variable

Loop number or Name

Alarm Symbols

LOOP PROCESS UNITS

01 08 AAAA MAMA

ALARM SETPOINT STATUS OUT%

LOOP PROCESS UNITS

02 180

LP 180 AUTO 0

ALARM SETPOINT STATUS OUT%

Setpoint

Engineering Units

Output Percentage

MLS User’s Guide 53

Using the MLS

This table shows the symbols used in each form of the alarm display.

Bar Graph

Symbol

> HP High Process Alarm > HD High Deviation Alarm < LP Low Process Alarm < LD Low Deviation Alarm

B T/C Break Open Input Error

Aim Comm

Failure

Single Loop

Symbol

RTD Short RTD Open

Aim Fail MLS-AIM

Description

RTD Short Alarm RTD Open Alarm

Communications Failure

Acknowledging an Alarm

Press Alarm Ack to acknowledge the alarm. If there are other loops with alarm conditions, the Alarm display s witches to the next loop in alarm. Acknowledge all alarms to clear the global alarm digital output (The keyboard and display won't work for anything else until you acknowledge each alarm). The alarm symbols are displayed as long as the alarm condition is valid.

54 MLS User’s Guide

Displaying, Loading, and Saving Jobs

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

Job display appears only if:

•

Y ou have turned on t he Remote Job Sel ect function. (This functi on is

explained in

•

You have selected a job from the job load menu.

When you load a job, Job display shows you the following screen:

JOB 3 RUNNING

If you remotely loaded the job, Job display looks like this:

Chapter 4: Setup

Using the MLS

JOB 3 RUNNING REMOTELY LOADED

If you modify a job's parameters while the job is running, you 'll see thi s job message:

JOB 3 RUNNING DATA MODIFIED

If an alarm occurs, the controller switches to Single Loop Display.

MLS User’s Guide 55

Using the MLS

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

Operator Menus

Changing the Setpoint

You can perform these tasks from Single Loop Display.

Chng SP

Press

01 SETPOINT ? 25

from the loop you want to change. this display appears:

•

Yes

Press Press Press Press No or

the new setpoint.

to change the setpoint.

Yes

or No to change the setpoint value.

Enter

to save your changes and return to Single Loop Display.

Back

to return to Single Loop Display without saving

Selecting Manual, Automatic, or Tune Control

Man/Auto

Press

•

If you set the output mode to

the process according to the configuration information you give it.

•

If you set the output mode to

level.

•

If you set the output mode to

If the Loop is in Manual Mode

•

Yes

Press

Press No to skip the mode change menu and set the output level. (See

the

Press

new mode setting.

Press

to toggle the mode.

Manual Output Levels

Back

to return to the single loop display w ithout saving the

Enter

to save your changes and return to single loop display.

Auto

, the MLS automatically controls

Manual

Tune

section for instructions.)

, you need to set the output

, you can tune the PID parameters.

56 MLS User’s Guide

If the loop is in Automatic Mode

•

Yes

Press

changes.

Press

Mode, set the output level. (To learn how to set the output level, see

Manual Output Levels

to toggle the mode.

Back

Enter

to return to single loop display without saving your

to save your changes and if you have selected Manual

Using the MLS

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

•

Press Enter, then Back to store the new mode and return to Single

Loop Display without setting an output level.

NOTE

If the loop outputs are disabled, you cannot toggle between Manual and Automatic output control. If you try it, the screen shows an error message telling you that the outputs are disabled, as shown below.

Use the menus in the Setup Loop Outputs main menu to enable the outputs. (See Chapter 4: Setup for more information about the Setup menus.)

MAN/AUTO CONTROL

OUTPUTS DISABLED

Setting the Manual Output Levels

You'll only see this menu if you set the current loop to Manual control. Use this menu to set the manual heat and cool output levels. (The cool output level menu will only be presen t if the cool output for th e current loop is enabled; see Outputs Enabled/Disabled in Chapter 4: Setup). You sh ould see a display like this:

01 SET HEAT OUTPUT ? 90%

•

Press Yes to change the output power level. (If the MLS' heat outputs

are enabled, you will be able to change the heat output power level. If only the cool outputs are enabled, you will be able to change only the cool output power level.)

•

Then press Yes or No to select a new output power level.

•

When you are satisfied with the power level you have chosen, press

Enter to store your changes.

•

Then press No to advance to the cool output menu (if the cool out-

puts on the MLS are enabled).

•

Press Back at any time to discard your changes and return to single

loop display.

MLS User’s Guide 57

Using the MLS

Automatically Tuning a Loop

When you use the Autotune function, the contro ller automatically sets the loop to Manual control, 100% output. (If you selected a continuous output limit, the controller sets the loop to the output limit.) The autotune function calculates the appropriate PID constants for the loop and puts the loop in automatic control with the calculated PID values.

The Autotune function will abort if:

•

The process variable goes over 75% of t he setp oi nt. (R ememb e r, the

controller is at 100% output or at the output limit you set.)

•

The controller has not cal culated PI D constant s after 10 minutes (d ue

to heater failure, sensor failure, etc.).

If the autotune function aborts, it puts the loop into its previous contro l state (Automatic or Manual control) at the previous output percentages.

To automatically tune a loop, follow these steps:

1. Make sure the process is cold (or stable and well below setpoint).

2. Initiate Autotune:

1. Use the front panel keypad to go to Single Loop Display.

2. Press the Man/Auto key.

3. Choose Tune.

4. Press Enter.

The Tune indicator will flash and the controller will return to Single Loop Display. The Tune indicator will flash as long as the loop is tuning.

58 MLS User’s Guide

Setup

The Setup menus let you change the MLS' detailed conﬁguration information.

If you have not set up a Modular Loop System before, or if you don't know what values to enter , please read ﬁrst the ne xt chapter,

Control

How to enter the Setup menus?

1. In Single Loop Display, select the loop you wish to edit.

2. While still in Single Loop Display, enter the pass sequence below:

which contains PID tuning constants and useful starting values.

Press

Enter, Alarm Ack, Change Setpoint

Tuning and

How to edit a menu?

3. The ﬁrst setup menu appears.

NOTE

For your protection, MLS reverts to Single Loop Display If you don't make any changes for three minutes.

•

Press

Yes

to select this menu or No to advance to the next menu.

•

press

Yes

or No to toggle between the options in your menu.

•

Press Enter to store the value you have selected. If you decide not to edit the menu, press Back to stop editing and

•

return to the main menu.

In the next sections you will ﬁnd detailed information about the submenus for each of the six main menus.

Each display contains the default value for that speciﬁc menu, and below each display you will see the range of choices for that menu.

The next page shows a diagram describing the six main menus and all the submenus in each one of them.

MLS User’s Guide 59

Setup

Setup Global Parameters?

save setup to

job?

Load setup from job?

Job control dig inputs?

Job digital input true?

Output override dig input?

Override dig in active?

Startup alarm delay?

Keyboard lock status?

Power up output status?

Controller address?

Communications err check?

Communications

baud rate?

Allen Bradley protocol?

AC line freq?

Digout outputs active?

AIM comm. failure output?

EPROM information

Setup Loop xx Input?

Input type?

Pulse sample time?

Loop name?

Input units?

Input reading

offset (T/C & RTD)?

Disp format (Linear & Pulse)?

Input scaling Hi pv? (Linear & Pulse)

Input scaling Hi rdg? (Linear & Pulse)

Input scaling Lo pv? (Linear & Pulse) Input scaling Lo RDG? (Linear & Pulse)

Lo pass filter value?

Setup Loop xx Setup loop xx

Control Params?

Heat control PB?

Heat control TI?

Heat control TD?

Heat control filter?

Cool control PB?

Cool control TI?

Cool control TD?

Cool control filter?

Heat/Cool

spread?

Press Enter, Alarm Ack, Change Setpoint to reach these menus. Press Yes to use a menu. Press Up or Down to change a value or select an option. Press Enter to store the value you have changed. Press Back to escape a menu without changing it.

Outputs?

Heat control out?

Heat output type?

Heat output cycle time? (TP)

SDAC menus (SDAC)

Heat output action?

Heat output limit?

Heat output limit time?

Sensor fail Ht output?

Outputs heat NLO?

Cool control out?

Cool output

type?

Cool output cycle time?

SDAC menus (SDAC)

Cool output action?

Cool output

limit?

Cool output limit time?

Sensor fail Cl output?

Outputs cool NLO?

Setup Loop

xx Alarms?

High process

alarm setpoint?

High process alarm type?

High process alarm dig out?

Deviation alarm value?

High deviation alarm type?

Alarm dig out?

Low deviation alarm type?

Low deviation alarm dig out?

Low process alarm setpoint?

Low process alarm type?

Low process alarm dig out?

Alarm deadband?

Alarm delay?

Manual I/O Test?

Digital inputs?

Keypad test?

Test digital output?

Digital output number?

60 MLS User’s Guide

Setup Global Parameters Menu

The setup global parameters menu looks like this

LOOP PROCESS UNITS

Below is the setup global parameters menu tree. Notice the default values inside the boxes.:

Setup

SETUP GLOBAL PARAMETERS?

ALARM SETPOINT STATUS OUT%

Setup Global Parameters?

Save setup to job? 1

Load setup from job? 1

Job control digital inputs?

NONE

Job digital input true?

LOW

Output override dig input? NONE

Override dig in active? LOW

Startup alarm delay? 0 MINS

Keyboard lock status? OFF

Power up output status? OFF

Controller address? 1

Communications err check? BCC

Communications baud rate? 9600

Allen Bradley protocol? NO

AC line freq.? 60 HERTZ

Digout outputs active? LOW

AIM communications failure output? NONE

EPROM information

MLS User’s Guide 61

Setup

Save to Job

Use this menu to save the job information for every loop to one of eight jobs in the MLS’ battery-backed RAM.

LOOP PROCESS UNITS

SAVE SETUP TO JOB? 1

ALARM SETPOINT STATUS OUT%

Selectable Range: 1-8.

If you have enabled the remote job control function, you will not be able to save a job; when you try to do it, you will see this message:

LOOP PROCESS UNITS

CANNOT SAVE JOB REMOTE SELECT

ALARM SETPOINT STATUS OUT%

Load from Job

Use this menu to load any one of eight saved jobs from the controller’s front panel.

LOOP PROCESS UNITS

LOAD SETUP FROM JOB? 1

ALARM SETPOINT STATUS OUT%

Selectable values: The last job number or job 1.

The following parameters are loaded as part of a job:

1. PID constants, ﬁlter settings, setpoints, and spread values.

2. Loop control status (Automatic or Manual), and output values (If the loop is in Manual control).

3. Alarm functions (Off, Alarm, Control), setpoints, high/low process setpoints, high/low deviation setpoints and deadband settings, and loop alarm delay.

If you have enabled the remote job control function, this menu is

disabled .

62 MLS User’s Guide

Job Select Inputs

Setup

Use the Remote Job Control feature to run up to 8 jobs remotely. The Job Select Inputs menu is the third menu under Setup Global Parameters. It lets you set the number of job select inputs. The controller uses these inputs as a binary code that speciﬁes the job number to run. The number of inputs you choose in this menu controls the number of jobs you can select remotely. The menu looks like this:

LOOP PROCESS UNITS

JOB CONTROL DIG INPUTS? NONE

ALARM SETPOINT STATUS OUT%

Selectable values: 1, 2, 3 , or NONE.

Below is the truth table that tells you which input states select which jobs.

Digital

Input 3

FF F 1 FF T 2 FT F 3 FT T 4 TF F 5 TF T 6 TT F 7 TT T 8

Digital Input 2 Digital Input

Job #

You can choose 1, 2, or 3 inputs, or None. These choices have the following effect:

Setting Enables

1 input Jobs 1-2 2 inputs Jobs 1-4 3 inputs Jobs 1-8

None (no inputs) Remote Select disabled

MLS User’s Guide 63

Setup

Job Digital Input Polarity

Output Override Digital Input

Use this menu to set the polarity of the digital outputs used for job selection. You can set the Active state to closed (Low) or open (High).

LOOP PROCESS UNITS

JOB DIGITAL INPUT TRUE? LOW

ALARM SETPOINT STATUS OUT%

Selectable values: Low or High.

This menu lets you set a digital input that sets all loops in manual output at output levels you select in the Outputs menu. This menu, and the next one, let you conﬁgure a "panic button" or "kill switch" that sets all outputs to the output override percentage you set in the Setup Loop

Outputs main menu.

OUTPUT OVERRIDE DIG INPUT? NONE

Selectable values: Input number 1-8, or NONE.

WARNING

ANAFAZE recommends that you install additional external safety devices or over-temperature devices for emergency shutdowns. Do not rely solely on the output override feature to shut down your process.

Output Override Input Polarity

This menu lets you toggle the polarity of the Output Override digital input. You can set the input to be active when Low or active when High.

LOOP PROCESS UNITS

OVERRIDE DIG IN ACTIVE? LOW

LOOP PROCESS UNITS

ALARM SETPOINT STATUS OUT%

64 MLS User’s Guide

Selectable values: Low or High.

Startup Alarm Delay

Keyboard Lock Status

Setup

Use this menu to set a startup delay for process and deviation alarms for all loops. The controller does not report these alarm conditions for the speciﬁed number of minutes after the controller powers up. (The controller will always report failed sensor alarms, no matter what startup delay you set.)

LOOP PROCESS UNITS

ST AR TUP ALARM DELAY? 0 mins

ALARM SETPOINT STATUS OUT%

Selectable Range: 0-60 minutes.

Power-Up Output Status

Use this menu to lock the front panel operator function keys Change SP, Man/Auto, and Ramp/Soak so that pressing these keys has no effect. If you want to use these functions, turn off the Keyboard Lock.

LOOP PROCESS UNITS

KEYBOARD LOCK STATUS? OFF

ALARM SETPOINT STATUS OUT%

Selectable values: On or Off.

Use this menu to set the initial power-up state of the control outputs to Off or Memory. If you choose Off, all control outputs are initially set to Manual mode at 0% output level. If you choose Memory, the outputs are restored to the last output state stored in memory.

LOOP PROCESS UNITS

POWER UP OUTPUT STATUS? OFF

ALARM SETPOINT STATUS OUT%

Selectable values: Off or Memory.

WARNING

Do not set the MLS to start from memory if a memory-based restart is unsafe for your process.

MLS User’s Guide 65

Setup

Controller Address

Communications Error Checking

Use this menu to set the MLS controller address. The controller address is used for multiple controller communications on a single RS-485 cable, so each MLS must have a different address. Begin with address 1 for the ﬁrst controller and assign each subsequent controller the next higher address.

LOOP PROCESS UNITS

CONTROLLER ADDRESS? 1

ALARM SETPOINT STATUS OUT%

Selectable Range: a number between 1 and 32.

Use this menu to set the data check algorithm used in the ANAFAZE communications protocol to Block Check Character (BCC) or to Cyclic Redundancy Check (CRC).

CRC is a more secure error checking algorithm than BCC, but it requires more calculation time and slows the MLS communications. BCC ensures a high degree of communications integrity, so ANAFAZE recommends that you use BCC unless your application speciﬁcally requires CRC.

LOOP PROCESS UNITS

COMMUNICATIONS ERR CHECK? BCC

ALARM SETPOINT STATUS OUT%

Selectable values: BCC or CRC.

NOTE

If you are using ANASOFT, be sure to conﬁgure ANAINSTL for the same error checking method that you set in this menu.

66 MLS User’s Guide

Communications Baud Rate

Setup

Use this menu to set the Communications Baud Rate to 2400 or 9600 baud.

LOOP PROCESS UNITS

COMMUNICATIONS BAUD RATE? 9600

ALARM SETPOINT STATUS OUT%

Selectable values: 9600 or 2400.

NOTE

If you use ANASOFT, be sure to set ANAINSTL to the same baud rate that you set in this menu.

Allen Bradley Protocol

AC Line Frequency

Use this menu to set the protocol type to either Allen Bradley or ANAFAZE.

LOOP PROCESS UNITS

ALLEN BRADLEY PROTOCOL? NO

ALARM SETPOINT STATUS OUT%

Selectable values: Yes or No.

Use this menu to conﬁgure the controller to match an AC line frequency of 50 or 60 Hz. (This function is provided for international users who require 50 Hz lines.) Since the controller reduces the effect of power line noise on the analog measurement by integrating the signal over the period of the AC line frequency, the controller's noise rejection will suffer if the line frequency is not set correctly.

LOOP PROCESS UNITS

AC LINE FREQ ? 60 HERTZ

ALARM SETPOINT STATUS OUT%

Selectable values: 60 Hz or 50 Hz.

NOTE

If you change the AC line frequency, you must switch power to the MLS on and off for the change to take effect.

MLS User’s Guide 67

Setup

Digital Output Polarity

AIM Communications Failure Output

Use this menu to set the polarity of the digital outputs used for alarms. The output can be active High or active Low.

LOOP PROCESS UNITS

DIGOUT OUTPUTS ACTIVE? LOW

ALARM SETPOINT STATUS OUT%

Selectable values: High or Low.

Use this menu to select the digital output that activates if communications fail between the MLS-AIM and the MLS-PM. You can use this output, along with the Global Alarm output, to power an alarm horn or buzzer that sounds if communications fail between the AIM and the PM.

EPROM Information

The global alarm will activate if there is an AIM communications failure, and will reset automatically when the problem is corrected. The controller will revert to manual mode during an AIM communications failure.

LOOP PROCESS UNITS

AIM COMM FAILURE OUTPUT? NONE

ALARM SETPOINT STATUS OUT%

Selectable values: any output from 1 to 34 as long as it’s not used for

control or for SDAC clock, or NONE.

Use this last menu of the Setup Global Parameters main menu to see the controller's EPROM version and checksum.

LOOP PROCESS UNITS

MLS VO 2.60

ALARM SETPOINT STATUS OUT%

Press any key from this menu to return to the Setup Parameters menu.

68 MLS User’s Guide

Setup Loop Input

Setup

The Setup Loop Input main menu lets you access menus which change loop input parameters:

•

Input type

•

Input scaling and calibration Input ﬁltering

•

The next section explains how to conﬁgure inputs via the front panel.

LOOP PROCESS UNITS

SETUP LOOP 02 INPUT?

ALARM SETPOINT STATUS OUT%

Below is the menu tree for the Setup Loop Inputs menu. Notice the default values inside the boxes.

Setup Loop Inputs?

Linear & PulseT/C or RTD

pulse sample time?

Loop’s name?

Input units? __

Disp format?

-9999 to 30000

Input scaling Hi PV? 10000

Input scaling Hi

RDG? 100.0% FS

Loop’s name?

Input units?

Input reading offset? 0

ºF

Input T ype? J T/C

Low pass filter value? 3

input scaling Lo PV? -1660

Input scaling Lo RDG? -16.6%FS

MLS User’s Guide 69

Setup

Input Type

Use this menu to conﬁgure the input sensor for each loop as one of these input types:

Thermocouple types (J, K, T, S, R and B).

•

RTD. Three ranges: RTD1 (Platinum Class A), RTD2 (Platinum

•

Class B), and RTD3 (Nickel).

•

Linear and Pulse inputs.

•

Skip (an input type available for unused channels.) The scanning dis-

play doesn't show loops you've set to Skip.

LOOP PROCESS UNITS

06 INPUT TYPE? J T/C

ALARM SETPOINT STATUS OUT%

The next table shows the MLS' input types and ranges.

Input

Type

J -350 to +1400 -212 to +760 K -450 to +2500 -268 to +1371 T -450 to +750 -268 to +399 S 0 to +3200 -18 to +1760 R 0 to +3210 -18 to +1766

B +150 to +3200 +66 to +1760 RTD1 -148.0 to +572.0 -100.0 to +300.0 RTD2 -184 to +1544 -120 to +840 RTD3 -94 to 572 -70 to 300 Pulse 0-2 KHz

Skip Loop is not scanned or displayed.

Linear see the

Fahrenheit

Range

Linear Scaling section

ter) and

Celsius Range

(this chap-

Appendix

70 MLS User’s Guide

Pulse Sample Time

Setup

You can connect a digital pulse signal of up to 2 KHz to the controller’s pulse input. Use this menu to specify the pulse sample period. Every sample period, the number of pulses the controller receives is divided by the sample time. The controller scales this number and uses it as the pulse loop’s PV.

LOOP PROCESS UNITS

06 INPUT PULSE SAMPLE TIME? 1s

ALARM SETPOINT STATUS OUT%

Selectable range: 1-20 seconds .

Loop Name

Input Units

Use this menu to name your loop. You can choose any two characters from the set of characters used for the input units.( See table below).

LOOP PROCESS UNITS

A5 LOOP SAMPLE NAME? A5

ALARM SETPOINT STATUS OUT%

Use this menu to choose a three-character description of the loop's engineering units.

LOOP PROCESS UNITS

06 INPUT UNITS? º F

ALARM SETPOINT STATUS OUT%

Selectable values:

This table shows the character set for input units.

Input Character Sets for Units

thermocouples & RTDs F or C degrees

Linear and Pulse 0-9, A-Z, %, degrees, /, space

MLS User’s Guide 71

Setup

Input Reading Offset

Use this menu to make up for the input signal's inaccuracy. For example, at temperatures below 400 ºF, a type J thermocouple may be inaccurate ("offset") by several degrees F. Use an independent

thermocouple or your own calibration equipment to ﬁnd the offset for your equipment. To correct for offset errors, change the factory default setting to a positive or negative value for the loop you are editing. (A positive value increases the reading and a negative value decreases it.)

LOOP PROCESS UNITS

06 INPUT READING OFFSET? 0 º F

ALARM SETPOINT STATUS OUT%

Linear Scaling Menus

Selectable range:

-300 to +300.

NOTE

If the input type is Linear, Pulse, or Skip, you will not see the Input Reading Offset menu.

The linear scaling menus appear under the Setup Loop Inputs main menu, and they are available for Linear and Pulse inputs only. It lets you scale the "raw" input readings (readings in millivolts or hertz) to the engineering units of the process variable.

You'll only see the linear scaling menus if you set the loop's input type to Linear or Pulse.

For linear inputs, the input reading is in percent (-16.6 to 100%) representing the -10-60 mV input range of the MLS. The scaling function is deﬁned by two points on a conversion line. It relates the high PV to the high reading and the low PV to the low reading to deﬁne the line. The engineering units of the process variable can be any arbitrary units.

72 MLS User’s Guide

Setup

The graph below shows pressure as an example.

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

Hi PV

Proces s Varia ble

Range

Lo PV

The PV (Process Variable) range for the scaled input is between the PV values that correspond to the -16.6% and 100% input readings. This PV range deﬁnes the limits for the setpoint and alarms, as shown here.

0PSI

0% 0mV 0Hz

Lo RDG

Input Reading

Hi RDG

100%

}Line a r input type

60 mV

} Pulse input type

2000 Hz

NOTE

See Linear Scaling Examples section in this manual.

MLS User’s Guide 73

Setup

Display Format

Use this menu to select a display format for a linear input. Choose a format appropriate for your input range and accuracy.

LOOP PROCESS UNITS

05 DISP FORMAT

-9999 TO 30000

ALARM SETPOINT STATUS OUT%

Selectable values: The MLS has several available display formats, as shown below. this table shows also the high and low PV values. .

Display Formats High PV Default Low PV Default

-9999 to +30000 10000 0

-999 to +3000 1000 0

-99 to +300 100 0

-9 to +30 10 0

-.9999 to +3.0000 1.0000 .0000

-9.999 to +30.000 10.000 .000

-99.99 to +300.00 100.00 .00

-999.9 to +3000.0 1000.0 .0

High Process Value

Use this menu to enter a high process value. The high process value and the high reading value together deﬁne one of the points on the linear scaling function's conversion line.

LOOP PROCESS UNITS

01 INPUT SCALING HI PV? 10000 º F

ALARM SETPOINT STATUS OUT%

Selectable values: See table above.

74 MLS User’s Guide

High Reading

Low Process Value

Setup

Use this menu to enter the input level that corresponds to the high process value you entered in the previous menu. For linear inputs, the high reading is a percentage of the full scale input range. For pulse inputs, the high reading is expressed in Hz.

The 100% full scale input value is 60 mV for the linear input type.

LOOP PROCESS UNITS

09 INPUT SCALING HI RDG = 100.0% FS

ALARM SETPOINT STATUS OUT%

Selectable range: Any value between -99.9 and 110.0. For pulse input, the range is 0-2000 Hz, and the default is 1000 Hz.

Low Reading

Use this menu to set a low process value for input scaling purposes. The low process value and the low reading value together deﬁne one of the points on the linear scaling function's conversion line.

LOOP PROCESS UNITS

02 INPUT SCALING LO PV? 0 º F

ALARM SETPOINT STATUS OUT%

Selectable values: See table on previous page.

Use this menu to enter the input level that corresponds to the low process value you selected in the previous menu. For linear inputs, the low reading is a percentage of the full scale input range. For pulse inputs, the low reading is expressed in Hz.

LOOP PROCESS UNITS

12 INPUT SCALING LO RDG ? .-16.6%FS

ALARM SETPOINT STATUS OUT%

The full scale input range for the linear input type is -10 to 60 mV, which corresponds to -16.6 to 100.0%.

Selectable range: Any value between - 99.9 and 110.0. For pulse inputs, the range is 0-2000 Hz, and the default is 0.

MLS User’s Guide 75

Setup

Input Filter

Access this menu from the Setup Loop Inputs main menu. The MLS has two different types of input ﬁlter:

• A noise rejection ﬁlter that rejects high frequency input signal noise.

This ﬁlter keeps a "trend log" of input readings. If a reading is outside the ﬁlter's "acceptance band", and later readings are within the acceptance band, the MLS ignores the anomalous reading. (The acceptance band for thermocouples is 5 degrees above and 5 degrees below the input reading. For linear inputs, it's 0.5% above and 0.5% below the input reading.) If later readings are also outside the acceptance band, the MLS accepts the anomalous reading and calculates a new acceptance band. (This input ﬁlter does not require adjustment.)

• A standard resistor-capacitor (RC) ﬁlter that lets you dampen the

input response if inputs change unrealistically or change faster than the system can respond. If the input ﬁlter is enabled, the process variable responds to a step change by going to 2/3 of the actual value within the number of scans you set.

If all input loops are enabled (none of them are set to SKIP) the MLS scans each input loop 2 times per second. The input ﬁlter applies to all input types except those set to SKIP.

LOOP PROCESS UNITS

01 LOW PASS FILTER VALUE? 3 SCANS

ALARM SETPOINT STATUS OUT%

Selectable range: 0-255 scans.

76 MLS User’s Guide

Setup Loop Control Parameters

Use these menus to change control parameters for heat and cool outputs of the selected loop, including:

• Proportional Band (PB), Integral (TI or Reset), and Derivative (TD

or Rate) settings.

• Output Filter.

• Spread between heat and cool outputs.

The Setup Loop Control Parameters menu looks like this:

LOOP PROCESS UNITS

SETUP LOOP 01 CONTROL PARAMS?

ALARM SETPOINT STATUS OUT%

Setup

NOTE

Both heat and cool outputs have the same menus, so only one of each menu is explained in the text. The controller shows both heat and cool menus even if the heat or cool output is disabled. (See Setup Loop Out- puts for help in enabling or disabling the heat or cool output.) Refer to Tuning and Control section for help in selecting control parameter values.

Setup Loop Control Parameters?

Heat control PB?

ºF

Heat control TI? 60 Sec/R

Heat control TD? 0 Sec.

Heat control filter?

Cool control PB?

ºF

Cool control TI? 60 Sec/R

Cool control TD?

0 Sec.

Cool control filter?

Heat / Cool spread? 5

ºF

MLS User’s Guide 77

Setup

Heat/Cool Control PB

Use this menu to set the Proportional Band.

LOOP PROCESS UNITS

01 HEAT CONTROL PB? 50 ºF

ALARM SETPOINT STATUS OUT%

NOTE

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

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

Heat/Cool Control TI

Heat/Cool Control TD

Default PB =

(High Range - Low Range)

Gain

Use this menu to set the Integral term, or Reset.

LOOP PROCESS UNITS

01 HEAT CONTROL TI ? 180 SEC/R

ALARM SETPOINT STATUS OUT%

Selectable range: 0-6000 seconds.

Use this menu to set the derivative constant.

LOOP PROCESS UNITS

15 HEAT CONTROL TD ? 0 SEC

ALARM SETPOINT STATUS OUT%

78 MLS User’s Guide

Selectable range: 0-255 seconds.

Heat/Cool Output Filter

Heat/Cool Spread

Setup

Use this menu to dampen the heat or cool output's response. The output responds to a step change by going to approximately 2/3 of its ﬁnal value within the number of scans you set here.

LOOP PROCESS UNITS

07 HEAT CONTROL FILTER ? 2

ALARM SETPOINT STATUS OUT%

Selectable range: 0-255. Setting the output ﬁlter to 0 turns it off.

Use this menu to set the spread between the heat and cool output and the spread of the On/Off control action.

LOOP PROCESS UNITS

01 HEAT SPREAD ? 5 ºF

ALARM SETPOINT STATUS OUT%

Selectable range: The spread ranges from 0 to 255, 25.5, 2.55, .255 or .0255, depending on the way you set up the input menus.

MLS User’s Guide 79

Setup

Setup Loop Outputs

Press Yes at this prompt to access menus to change loop output parameters for the current loop, including:

• Enable or disable outputs

• Output type

• Cycle time (for TP outputs)

• SDAC parameters (for SDAC outputs)

• Control action

• Output level limit and limit time

• Output override

• Nonlinear output curve

Both heat and cool outputs have the same menus, so only one of each menu is explained in this section. (The next page shows a menu tree.)

Here's the main menu:

LOOP PROCESS UNITS

SETUP LOOP 03 OUTPUTS ?

ALARM SETPOINT STATUS OUT%

The ﬁgure on the next page shows the menu tree for the output setup menus. Notice the default values inside the boxes

80 MLS User’s Guide

Setup Loop Outputs?

Heat/Cool control out?

Output Enabled

Heat/Cool output type?

Setup

Output disabled

For SDAC outputsFor TP outputs

Heat/cool output cycle time? 10 S

For ON/OFF DZC

Heat/Cool output action? Reverse

Heat/Cool output limit? 100%

Sensor fail Heat/Cool output? 0%

SDAC mode? Voltage

SDAC Lo value?

0.00

SDAC Hi value?

10.00 VDC

Heat/Cool output limit time? CONT

Outputs Heat/Cool NLO? OFF

MLS User’s Guide 81

Setup

Enable/Disable Heat and Cool Outputs

Heat or Cool Output Type

Use this menu to enable or disable the heat or cool output for the current loop. If you want the loop to have PID control, you must enable one output. You can also disable a heat or cool control output and use the output pin for something else, like an alarm.

LOOP PROCESS UNITS

05 HEAT CONTROL OUT? ENABLED

ALARM SETPOINT STATUS OUT%

Selectable values: Enabled or Disabled. The default setting enables the heat outputs and disables the Cool outputs.

Use this menu to set the output type. .

LOOP PROCESS UNITS

14 HEAT OUTPUT TYPE = TP

ALARM SETPOINT STATUS OUT%

The next table shows the available output types.

Display

Code

TP Time

DZC Distributed

SDAC Serial DAC Output type for optional Serial Digital-Analog

ON/OFF On / Off Output either full ON of full OFF.

Output

Type

Proportioning

Zero Crossing

Deﬁnition

Percent output converted to a percent duty cycle over the programmed cycle time.

Output on/off state calculated for every AC line cycle.

Converter (SCAC)

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

82 MLS User’s Guide

Heat/Cool Cycle Time

Setup

Use this menu to set the Cycle Time for Time Proportioning outputs.

LOOP PROCESS UNITS

03 HEAT OUTPUT CYCLE TIME ? 10S

ALARM SETPOINT STATUS OUT%

Selectable range: 1-255 seconds.

NOTE

The Cycle Time menu will only be present if the output type for the current loop is Time Proportioning.

SDAC Menus

SDAC Mode

If you attach the optional SDAC to an output, you must conﬁgure that output for the SDAC using the following series of menus. The MLS will also assign digital output #34 as a clock line for the SDA C. You won't be able to assign another function to output #34 while any loop's output is set to SDAC.

Use this menu to toggle the SDAC between current and voltage output. The SDAC menus only appear if the output type for the loop is set to SDAC .

LOOP PROCESS UNITS

01 SDAC MODE ? VOLTAGE

ALARM SETPOINT STATUS OUT%

Selectable values: Current and Voltage.

MLS User’s Guide 83

Setup

SDAC High Value

SDAC Low Value

Use this menu to set a high value for the SDAC output. Set the high and low value to match the range of the output device. For instance, if the output device has a 4-20 mA range, set the SDAC high value to 20.00 mA and the SDAC low value to 4.00 mA. The controller converts 0% output to a 4.00 mA signal and 100% output to a 20.00 mA signal.

LOOP PROCESS UNITS

03 SDAC HI VALUE ?

10.00 VDC

ALARM SETPOINT STATUS OUT%

Selectable values: If the output is set to Voltage, the default high value is 10.00 volts. If the output is set to Current, the default high value is

20.00 mA. You cannot set the high value to be less than or equal to the low value.

Heat/Cool Output Action

Use this menu to set a low value for the SDAC output. Set the high and low value to match the range of the output device. For instance, if the output device has a 0.00-10.00 Vdc range, set the SDAC high value to

10.00 Vdc and the SDAC low value to 0.00 Vdc. The controller converts 0% output to a 0.00 Vdc signal and 100% output to a 10.00 Vdc signal.

LOOP PROCESS UNITS

04 SDAC LO VALUE ?

0.00 VDC

ALARM SETPOINT STATUS OUT%

Selectable values: If the output is set to Voltage, the default low value is

0.00 volts. If the output is set to Current, the default value is 4.00 mA. You cannot set the low value to be greater than or equal to the high value.

Use this menu to select the control action for the current output loop. Normally, heat outputs are set to reverse action and cool outputs are set to direct action.

LOOP PROCESS UNITS

01 HEAT OUTPUT ACTION ? REVERSE

ALARM SETPOINT STATUS OUT%

84 MLS User’s Guide

Selectable values: Reverse or Direct. For Heat outputs, set to Reverse; for Cool outputs, set to Direct.

Heat/Cool Output Limit

Use this menu to limit the maximum PID control output for a loop's heat and cool outputs. This limit may be continuous, or it may be in effect for a speciﬁed number of seconds (see Output Limit Time on the next page). If you choose a timed limit, the output limit restarts when the controller powers up and when the output goes from Manual to Automatic control (via the front panel, when the controller changes jobs, or from ANASOFT.) The output limit only affects loops under automatic control. It does not affect loops under manual control.

Selectable range: 0-100%

Heat/Cool Output Limit Time

Setup

LOOP PROCESS UNITS

01 HEAT OUTPUT LIMIT ? 100%

ALARM SETPOINT STATUS OUT%

Heat/Cool Output Override

Use this menu to set a time limit for the output limit.

LOOP PROCESS UNITS

04 HEAT OUTPUT LIMIT TIME ? CONT

ALARM SETPOINT STATUS OUT%

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

Use this menu to set an output override percentage. (You can conﬁgure a digital input for the output override in the Setup Global Parameters main menu.) If the current loop is in Automatic mode and a sensor failure occurs, the loop switches to the output override percentage, manual mode. If you change the polarity of the override output to the active state--for instance, by ﬂipping a "kill switch" you have set up--every loop switches to the output override percentage you set here.

LOOP PROCESS UNITS

03 SENSOR FAIL HT OUTPUT ? 0%

ALARM SETPOINT STATUS OUT%

Selectable range: 0-100%

MLS User’s Guide 85

Setup

Heat/Cool Nonlinear Output Curve

Use this menu to select one of two nonlinear output curves for nonlinear processes.

LOOP PROCESS UNITS

03 OUTPUTS HEAT NLO ? OFF

ALARM SETPOINT STATUS OUT%

Selectable values: Curve 1, Curve 2, or Off (linear/no curve).

The linear curves are shown in the ﬁgure below. Calculated by PID

100

Output

100

Line ar

Calculated by PID

86 MLS User’s Guide

Setup Loop Alarms

Setup

Press Yes at the Setup Loop Alarms prompt to access menus which change alarm function parameters for the current loop. The main alarms menu looks like this:

LOOP PROCESS UNITS

SETUP LOOP 04 ALARMS ?

ALARM SETPOINT STATUS OUT%

Below is the alarms menu tree. Notice the default values inside the boxes.

Setup Loop Alarms?

High process alarm setpoint?

ºF

1000 High process

alarm type? OFF

High process alarm dig out? NONE

Deviation alarm value? 5

ºF

High deviation alarm type? OFF

High deviation alarm dig out? NONE

Low deviation alarm type? OFF

Low deviation alarm dig out? NONE

Low process alarm setpoint?

ºF

Low process alarm type? OFF

Low process alarm dig out? NONE

Alarm deadband?

ºF

Alarm delay? 0 Seconds

MLS User’s Guide 87

Setup

Alarm Types

The MLS has three different kinds of alarms: failed sensor alarms, global alarms, and process alarms.

Failed Sensor Alarms

Failed sensor alarms alert you to T/C breaks and these RTD open or short failures:

• Open + or - input.

• Short between + and - input.

When the loop is in Automatic or Tune mode and a failed sensor alarm occurs, the MLS sets the loop to Manual control at the failed sensor percentage you set in the Setup Loop Outputs menus.

Global Alarms

Global alarms occur when a loop alarm, set to Alarm (not Control), is unacknowledged, or when there are any unacknowledged failed sensor alarms. (If an alarm occurs, the MLS front panel displays an appropriate alarm code--see Chapter 4: Using the MLS for an explanation of these codes.) Even if the alarm condition goes away, the global alarm stays on until you use the Alarm Ack key (or ANASOFT) to acknowledge it.

Process Alarms

Process alarms include high and low deviation and high and lo w process alarms. You can set each of these alarms to Off, Alarm, or Control, as shown here.

Function Description

Off No alarm or control function

Alarm Standard alarm function

Control Normal alarm function, except that you

don’t have to ackowledge alarms

• High process and high deviation alarms activate when the process

variable goes above a value you set. They remain active until the process variable goes below that value minus the deadband. (See the diagram on the next page.)

• If you don’t use a digital output for PID control, you can assign it to

one or more process variable alarms. The output is active if any of its alarms are active. All alarm outputs are active Low or active High, depending on the global alarm output polarity setting.

• Low process and low deviation alarms activate when the process

variable goes below a value you set. They remain active until the process variable goes above that value plus the deadband. (The diagram below shows these alarms.)

88 MLS User’s Guide

Watlow MLS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

System Power Requirements (from page 10)

Dimensions and Weight (from page 10)

Mounting Environment

Mounting Steps

Wiring Your System (from page 24)

Contents

Overview

System Diagram

Parts List

Safety

Introduction

Specifications

Analog Inputs

Thermocouple Ranges

RTD Ranges

Analog Outputs

Miscellaneous Specifications

Digital Inputs

Standard Digital Outputs

System Digital Outputs

Miscellaneous Specifications

Serial Interface

System Power Requirements

Environmental Specifications

Dimensions and Weight

Expanded Parts List

MLS Processor Module Technical Description

MLS RTB Technical Description

MLS-AIM and AIM-TB Technical Description

MLS Cabling Technical Description

Installation

Read This Before Installation

Recommended Tools

Panel Hole Cutters

Other Tools

Additional Hardware

Mounting the MLS-PM

Mounting Environment

MLS-PM Mounting Steps

Mounting the MLS-AIM

Mounting Environment

Mounting Steps

Mounting the RTB

Mounting the MLS-PS

Mounting Environment

Mounting Steps

Wiring Your System

Wiring Recommendations

Cable Recommendations

Noise Suppression

Symptoms of RFI

Avoiding RFI

Wi ring and Testing Your System

Connecting Power and RTB to MLS-PM

Connecting Power and Common to AIM-TB

Testing Connections

Testing Your System

MLS-AIM Test

RTB Test

PID Output Test

Outputs

Output Wiring Recommendations

Ribbon Cable Recommendations

Using the Cable Tie Wraps

PID Control and Alarm Output Connections

RTB Connections

AIM Communications Failure

Inputs

Input Wiring Recommendations

Input Scaling

Scaling Values

Input Calibration

T/C Inputs

Wiring Recommendations

Connecting Thermocouples

RTD Inputs