Watlow 8LS Controller Bedienungsanleitung

8LSUser’s Guide Part No. 10585-00. Revision 9.2July 1996Watlow Controls1241 Bundy Blvd.Winona, MN 55987Customer ServicePhone: (800) 414-4299Fax: (800)

2 8LS User’s GuideOverview System DiagramThe illustration below shows how the parts of the 8LS are connected.When unpacking your system, use t

92 8LS User’s GuideAppendix A: Ramp Soak Copying the Setup from Another ProfileUse this menu to setup similar profiles quickly, by copying a p

Appendix A: Ramp Soak8LS User’s Guide 93Editing the Ready SetpointWhen you assign a profile to a loop, the profile doesn’t startimmediately; instead,

94 8LS User’s GuideAppendix A: Ramp Soak Choosing an External Reset InputUse this menu to select an external reset input. Toggle the input to

Appendix A: Ramp Soak8LS User’s Guide 95Setting a Segment SetpointUse this menu to set a setpoint for the segment you are editing. Theprocess will go

96 8LS User’s GuideAppendix A: Ramp Soak Editing Event OutputsThis menu appears only if you answered YES to the previous menu. Useit to assign

Appendix A: Ramp Soak8LS User’s Guide 97Assigning an Input to a TriggerThis menu appears only if you answered YES to the Edit SegmentTriggers menu. Us

98 8LS User’s GuideAppendix A: Ramp Soak Setting Segment ToleranceUse this menu to set a positive or negative tolerance value for eachsegment.

Appendix A: Ramp Soak8LS User’s Guide 99Using Ramp/SoakThis section explains how to assign a profile to a loop, how to put aprofile in Run, Continue,

100 8LS User’s GuideAppendix A: Ramp Soak Assigning a profile the first timeTo assign a profile to a loop that doesn’t have a profile, follow

Appendix A: Ramp Soak8LS User’s Guide 101Running several profiles simultaneouslyTo run several profiles simultaneously, follow these steps:1. Setup th

Overview8LS User’s Guide 3SafetyWatlow Anafaze has made efforts to ensure the reliability and safety ofthe 8LS controller and to recommend safe usage

102 8LS User’s GuideAppendix A: Ramp Soak Bar graph displayLoops that are running R/S profiles have different Bar Graph displaycodes. For thes

Appendix A: Ramp Soak8LS User’s Guide 103How many times has it cycled?From Single Loop display, press the RAMP/SOAK key twice. The nextmenu will appea

104 8LS User’s GuideAppendix A: Ramp Soak Continuing a profileIf a profile is holding and you want it to run, you can put it in Continuemode.•

Appendix B: 8LS-CP8LS User’s Guide 105Appendix B: 8LS-CP The 8LS-CP controller with a Zirconia Carbon Probe assembly cancontrol and record the Dew poi

106 8LS User’s GuideAppendix B: 8LS-CP System ConfigurationThe 8LS-CP uses a modified input with discreet components per carboninput. Each CP

Appendix B: 8LS-CP8LS User’s Guide 107The 8LS-CP is not only ordered for the number of carbon input loopsdesired, but the CPU DIP Switch on the CPU bo

108 8LS User’s GuideAppendix B: 8LS-CP SpecificationsThe standard specifications listed in the Introduction section of thismanual apply to the

Appendix B: 8LS-CP8LS User’s Guide 109CP ControlThe temperature control may be accomplished by using a standardAnalog Input/Output loop or it may be i

110 8LS User’s GuideAppendix B: 8LS-CP Recommended CP Trim Gas Alarm for Continuous ApplicationsWhen using the 8LS-CP for controlling the gas

Appendix B: 8LS-CP8LS User’s Guide 111Carbon ProbeIn general practice, follow the probe manufacturer’s recommendationsas to installation and maintenan

4 8LS User’s GuideOverview

112 8LS User’s GuideAppendix B: 8LS-CP Probe Burn OffCarbon Probe Burn Off Requirements:1. To burn off carbon, excess fresh air is supplied to

Appendix B: 8LS-CP8LS User’s Guide 113The figure below describes the typical installation of a carbon burn offsystem. Burn Off FunctionThe carbon pr

114 8LS User’s GuideAppendix B: 8LS-CP If you want to disable the enrichment gas during the burn off period, aNormally Open solenoid valve sho

Appendix B: 8LS-CP8LS User’s Guide 115CO+CO2% and % of HydrogenUpon selecting CP as the input type, the following menu is available.Use it to adjust t

116 8LS User’s GuideAppendix B: 8LS-CP Offset CalibrationIf the carbon probe input type is set to CP or DP, a menu is available forediting an

Appendix B: 8LS-CP8LS User’s Guide 117typically used in continuous furnace applications. Setting the start modeto Input means the burn off procedure w

118 8LS User’s GuideAppendix B: 8LS-CP Burn Off Time PeriodThis menu is displayed if the start mode is set to either Input or Time.Use it to e

Appendix B: 8LS-CP8LS User’s Guide 119Setup AlarmsCP Gas AlarmThis menu is available from the Setup Alarms main menu. Use it to setthe digital output

120 8LS User’s GuideAppendix B: 8LS-CP

Appendix C: 8LS Cascade8LS User’s Guide 121Appendix C: 8LS CascadeIntroductionThe Cascade control feature allows the output percentage of one controll

Introduction8LS User’s Guide 5Introduction The 8LS is a powerful 1/4 DIN controller that delivers 8 fullyindependent loops of PID control. It can fun

122 8LS User’s GuideAppendix C: 8LS Cascade Choosing the Primary LoopUse this selection to choose the primary loop for cascade control. Thislo

123 8LS User’s GuideGlossaryAACSee Alternating Current.AC Line FrequencyThe frequency of the AC power line measured inHertz (Hz), usually 50 or 60 Hz.

Glossary 124 8LS User’s GuideBumpless TransferA smooth transition from Auto (closed loop) toManual (open loop) operation. The control outputdoes not

Glossary

Glossary 126 8LS User’s GuideFilterFilters are used to handle various electrical noiseproblems. Digital Filter (DF) — A filter that allows therespons

Glossary

Glossary 128 8LS User’s GuideOOffsetThe difference in temperature between the set-point and the actual process temperature. Offsetis the error in the

Glossary

Glossary 130 8LS User’s GuideSpanThe difference between the lower and upper lim-its of a range expressed in the same units as therange.SpreadIn heat/

Glossary

6 8LS User’s GuideIntroduction Dual Output Standard: The 8LS includes dual control outputs foreach loop with a second set of control constant

Glossary 132 8LS User’s Guide

Introduction8LS User’s Guide 7SpecificationsAnalog InputsThermocouple RangesRTD RangesAnalog inputs 8, solid state, differentialOptical isolation 120

8 8LS User’s GuideIntroduction Control CapabilityDigital OutputsDigital InputsPulse Counting InputSerial InterfacePower SupplyNumber of loops

Installation8LS User’s Guide 9InstallationThis section explains how to install the 8LS. The instructions are writtenfor nontechnical users. If you are

10 8LS User’s GuideInstallation Read This Before InstallationDANGERShut off power to your process before you installthe 8LS. High voltage may

Installation8LS User’s Guide 11Mounting The 8LSThe 8LS consists of a 1/4 DIN housing with a front plug in electronicsmodule. The 8LS-OF (Open Frame) i

Copyright © 1996Watlow AnafazeInformation in this manual is subject to change without notice. No part of this publication may bereproduced, stored in

12 8LS User’s GuideInstallation .1234 56 78LOOP PROCESS UNITSALARM SETPOINT STATUS OUTPUT%YESNOBACKENTERALARM ACKCHNG SPMANAUTORAMPSOAKFr

Installation8LS User’s Guide 13External WiringDuring wiring, it is recommended that the 8LS electronics be removedor that temporary covers be put over

14 8LS User’s GuideInstallation 2. Use 20 or 22 AWG size wire. The use of 16,18,20,22, or 24 AWG ispermissible also. The power requirement is

Installation8LS User’s Guide 15Wiring bundles of low power Watlow Anafaze circuits next to bun-dles of high power AC wiring should never be done. The

16 8LS User’s GuideInstallation Noise Suppression When using the digital outputs from Watlow Anafaze multiloopcontrollers to energize dry cont

Installation8LS User’s Guide 17The above steps should eliminate any noise problems that might bepresent with using E-M relays. If, problems persists a

18 8LS User’s GuideInstallation Terminal Block And Connector LayoutThe 8LS terminal blocks and connectors are assigned according to thefollowi

Installation8LS User’s Guide 19RTB ConnectionsThe RTB provides the control outputs and additional digital inputs andoutputs as follows:All digital out

20 8LS User’s GuideInstallation NOTEWhen using the RTB, proper polarity of the flatribbon cable is necessary for correct pin termina-tions. In

Installation8LS User’s Guide 21Source ImpedanceEach sensor has a certain output impedance which is effectivelyconnected across the 8LS input amplifier

8LS User’s Guide iContentsOverview 1System Diagram...2Parts List ...

22 8LS User’s GuideInstallation Resistor Installation For scaling resistors the body of the resistor goes vertically into the holewith the whi

Installation8LS User’s Guide 23Voltage InputsDC Voltage inputs should be connected with the positive side to theHigh terminal and the negative side to

24 8LS User’s GuideInstallation RTD Inputs The standard industrial RTD is a 100 ohm Platinum three wireassembly. We highly recommend using the

Installation8LS User’s Guide 25The range of the standard IRSM is 0-1000 degrees F with an output of0-10ma dc. The input of the Watlow Anafaze 8LS is c

26 8LS User’s GuideInstallation The Belden cable part number 88760 is highly recommended for theconnection of the carbon probe to the 8LS. An

Installation8LS User’s Guide 27Control Outputs WARNINGControl outputs are connected to the 8LS logicground. Be careful when you connect externaldevice

28 8LS User’s GuideInstallation Pid Control Relay Outputs Typical ON/OFF, TP, DZC control outputs utilize external optically-isolated solid-st

Installation8LS User’s Guide 29Digital Outputs On The Screw Terminal BlocksNOTEAlarms and events outputs are sinking +5vdc toground when the output is

30 8LS User’s GuideInstallation second is down, the output is in current mode. Thus if switch 3 is downand 4 is up on the dip switch package n

Installation8LS User’s Guide 31CPU Dip SwitchWARNINGNormal mode of operation is for all positions to beOff. Positions that are On will effect the 8LS

ii 8LS User’s GuidePID Control Relay Outputs...28Primary Screw Terminal Outputs ...

32 8LS User’s GuideInstallation Connections are made as follows:SSR 1SSR 2+-+-Remote Terminal Block OrRibbon Cable Pin9111PID Ctl

Installation8LS User’s Guide 33Communications Set-up and ConnectionsThe 8LS offers two types of serial communications: RS- 232 and RS-485. Up to 32 ad

34 8LS User’s GuideInstallation RS-485 Description And ConnectionsThe RS-485 is a voltage balanced long distance multi-pointtransmission inter

Installation8LS User’s Guide 35RS-485 ConnectionsConnection of Watlow Anafaze controllers to a system computerrequires an interface at the computer to

36 8LS User’s GuideInstallation A termination resistor is required at each end of the transmission line.This is accomplished by applying a 200

Using the 8LS8LS User’s Guide 37Using the 8LSThis Chapter will show you how to use the 8LS from the front panel.Front PanelThe 8LS front panel provide

38 8LS User’s GuideUsing the 8LS Front Panel KeysPress Yes to• Select a menu when prompt is blinking• Answer Yes to Yes/No prompts• Increase a

Using the 8LS8LS User’s Guide 39Press Chng SP to• Adjust the setpoint on displayed loopPress Man/Auto to• Toggle loop status between Manual and Auto•

40 8LS User’s GuideUsing the 8LS DisplaysThe next section discusses the 8LS displays:• Bar Graph display• Single Loop display• Scanning displa

Using the 8LS8LS User’s Guide 41The table below shows the status symbols for the Ramp and Soakoption.If an acknowledged alarm exists, the Bar Graph is

8LS User’s Guide iiiInput Type...54Pulse Sample Time ...

42 8LS User’s GuideUsing the 8LS The table below shows the alarm symbols.The Alarm display interrupts any system display. If more than one ala

Using the 8LS8LS User’s Guide 43Operator MenusYou can perform these tasks from Single Loop display.Changing the SetpointPress CHNG SP from the loop yo

44 8LS User’s GuideUsing the 8LS If you have set the current loop to Manual control, this display appearsafter you press Enter:• Press Ye s t

Setup8LS User’s Guide 45SetupThe Setup menus let you change the 8LS detailed configurationinformation.If you have not set up a modular system before,

46 8LS User’s GuideSetup Setup Setup Setup Globals? control?SetupOutputs?SetupAlarms?SetupR/S Pro?Save asjob# ?RestoreJob# ?Alarmdelay?R/S ti

Setup8LS User’s Guide 47Setup Global Parameters MenuThe Setup global parameters menu looks like this:Answering Yes to this prompt gets you into the gl

48 8LS User’s GuideSetup Save as JobUse this menu to save the job information for every loop to one of eightjobs in the battery-backed memory.

Setup8LS User’s Guide 49Set R/S Time BaseUse This menu to set the global ramp and soak time base to units ofhours and minutes or minutes and seconds.

50 8LS User’s GuideSetup WARNINGSet safe start up conditions. Do not use memorystartup if there is any chance the process couldstart in an uns

Setup8LS User’s Guide 51Communication Baud RateUse this menu to set the communications baud rate.Selectable values: 2400 or 9600.NOTEIf you are using

iv 8LS User’s GuideSetting Up and Tuning PID Loops ...80General PID Constants by Application...

52 8LS User’s GuideSetup EPROM VersionUse this menu to see the controller’s EPROM version and checksum.1234 56 78LOOP PROCESS UNITSALARMSETPOI

Setup8LS User’s Guide 53Setup Inputs MenuThe Setup input main menu lets you access menus which change loopinput parameters:• Input type• Engineering u

54 8LS User’s GuideSetup Input TypeUse this menu to configure the input sensor for each loop as one of theseinput types:• Thermocouple types (

Setup8LS User’s Guide 55Pulse Sample TimeYou can connect a digital pulse signal of 20 KHz to the controller’spulse input. Use this menu to specify the

56 8LS User’s GuideSetup Linear Scaling MenusNOTEThe next four menus appear only for Linear orPulse loops.For all inputs automatic scaling is

Setup8LS User’s Guide 57Low RDG DisplaySelectable range: 0-9999.The low input reading is referenced to 60mV and is calculated using thisequation:Linea

58 8LS User’s GuideSetup Input OffsetNOTEThe next menu appears only for Thermocouple orRTD loops.Use this menu to make up for the input signal

Setup8LS User’s Guide 59Setup Control MenuThe Setup Control menu allows you to set control parameters for bothheat and cool outputs of the selected lo

60 8LS User’s GuideSetup Heat/Cool PBUse this menu to set the Proportional Band.Heat/Cool TIUse this menu to set the Integral Term.Selectable

Setup8LS User’s Guide 61Heat/Cool SpreadUse this menu to set the spread between the heat and cool output and thespread of the On/Off control action. S

8LS User’s Guide vHolding a Profile or Continuing from Hold...103Resetting a Profile...

62 8LS User’s GuideSetup Setup Outputs MenuThe Setup Outputs Menu allows you to edit output parameters such as:• Output type• Cycle time• Cont

Setup8LS User’s Guide 63Output TypeUse this menu to to set the output type.Selectable values: The next table shows the available output types.Cycle Ti

64 8LS User’s GuideSetup Output ActionUse this menu to select the control action for the current output loop.The default is Reverse for heat o

Setup8LS User’s Guide 65Output Limit TimeUse this menu to set the time limit for the output limit.Selectable values: 1-999 seconds or C (Continuous).N

66 8LS User’s GuideSetup Heat OutputUse this menu to select the Terminal Block or the Flat Ribbon for theheat output termination. The heat out

Setup8LS User’s Guide 67Setup AlarmsThe Setup Alarms main menu lets you access menus which change thealarm functions for the selected loop.You can edi

68 8LS User’s GuideSetup Alarm TypesGlobal AlarmsGlobal alarms occur when a loop alarm, set to Alarm, isunacknowledged, or when there are any

Setup8LS User’s Guide 69High Process Alarm Setpoint Use this menu to select the setpoint at which the high process alarmactivates. The high process al

70 8LS User’s GuideSetup Deviation Band AlarmUse this menu to set the deviation bandwidth, a positive and negativealarm point relative to the

Setup8LS User’s Guide 71Low Deviation Alarm Output NumberUse this menu to assign a digital output which activates when the loop isin low diviation ala

vi 8LS User’s Guide

72 8LS User’s GuideSetup Low Process Alarm Output NumberUse this menu to assign the digital output that activates when the loop isin low proce

Setup8LS User’s Guide 73Test I/OThe Test I/O main menu lets you view menus which can help you testthe digital inputs and the digital outputs.The main

74 8LS User’s GuideSetup Test OutputUse this menu to select one of the 30 digital outputs for manualoperation.Selectable values: 1-30.Digital

Tuning and Control8LS User’s Guide 75Tuning and ControlIntroductionThis chapter explains PID control and supplies some starting PID valuesand tuning i

76 8LS User’s GuideTuning and Control Control ModesThe next sections explain the different modes you can use to control aloop.On/Off ControlOn

Tuning and Control8LS User’s Guide 77However, a process which uses only Proportional control may settle at apoint above or below the setpoint; it may

78 8LS User’s GuideTuning and Control Proportional, Integral and Derivative ControlFor an improved level of control, use Derivative control wi

Tuning and Control8LS User’s Guide 79Distributed Zero Crossing (DZC) DZC output is essentially a Time Proportioning output. However, foreach AC line c

80 8LS User’s GuideTuning and Control Setting Up and Tuning PID LoopsAfter you have installed your control system, tune each control loop andt

Tuning and Control8LS User’s Guide 81Integral Term (TI) SettingsThis table shows TI settings vs. Reset settings.As a general rule, use 60, 120, 180, o

Overview8LS User’s Guide 1OverviewThis manual describes how to install, setup, and operate an 8LScontroller. Included are six chapters, Appendixes des

82 8LS User’s GuideTuning and Control General PID Constants by ApplicationThis section gives PID values for many applications. They are useful

Tuning and Control8LS User’s Guide 83

84 8LS User’s GuideTuning and Control

Troubleshooting8LS User’s Guide 85TroubleshootingNOTEIf you need to return the 8LS to Watlow-Anafaze,please call first for a Returned Materials Author

86 8LS User’s GuideTroubleshooting Computer Supervised SystemsThese four items must work together to operate the 8LS:1. The 8LS2. Th

Troubleshooting8LS User’s Guide 87If you write your own software, first write a routine that sends andreceives display commands to and from the 8LS. T

88 8LS User’s GuideTroubleshooting

Appendix A: Ramp Soak8LS User’s Guide 89Appendix A: Ramp Soak IntroductionThis Appendix will teach you how to set up and use Ramp/Soak profilesin 8LS

90 8LS User’s GuideAppendix A: Ramp Soak SpecificationsConfiguring Ramp/SoakThis section will teach you how to set up R/S profiles. The follow

Appendix A: Ramp Soak8LS User’s Guide 91Setting the R/S Time BaseThe R/S time base menu is in the Setup Globals main menu.Use this menu to set the tim