Watlow MLS User Manual
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
Copyright © 1995
Watlow-Anafaze
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-
PM
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)
Contents
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
i
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
ii
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
iv
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
v
Contents MLS User’s Guide
vi
Overview
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
40 V
°
C
°
C, 0.01% per °C.
Introduction
Thermocouple Ranges
J
K
T
B
S
R
-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.
2
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.)
º
C
º
C
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
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
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