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CAS200 User`s Guide

1. Watlow Anafaze Table 6 3 Input Readings and Calculations ee Sensor Reading Percent of O Displayed Input Full Scale FS 65 GPM 4 75 4 75V 5 00V x 100 95 3 GPM 0 5 0 5V 5 00V x 100 10 Table 6 4 Scaling Values Parameter Prompt Value High Process Variable HIGH PV 65 GPM High Sensor Reading HIGH RDG 95 0 FS Low Process Variable LO PV 0 0 GPM Low Sensor Reading LO RDG 10 0 FS 89 Chapter 6 Linear Scaling Examples CAS200 User s Guide Example 3 Pulse Encoder Situation A pulse encoder which measures the movement of a conveyor is connected to the scanner The encoder generates 900 pulses for every inch the conveyor moves You want to measure conveyor speed in feet per minute FPM Setup The encoder input is connected to the scanner s pulse input The INPUT TYPE for the loop is set to PULSE A one second sample time gives adequate resolution of the conveyor s speed The resolution is 1 pulse 60 seconds linch 1 foot x x x 0 006FPM 1 second 1 minute 900 pulses 12 inches A DISPLAY FORMAT of 99 99 TO 300 00 is appropriate The input readings are as follows e At 0Hz the input reading will be 0 00 FPM e At the maximum pulse rate of the CAS200 2000Hz 200 pulses 60 seconds linch 1 foot x x x 11 11FPM 1 second 1 minute 900 pulses 12 inches Table 6 5 Scaling Values Parameter Prompt Value High Process Variable HIGH PV 11 11
2. 3 SCANS CHANNEL NAME ALARM STATUS Selectable values 0 to 255 scans Watlow Anafaze 57 Chapter 4 Setup 58 CAS200 User s Guide Setup Channel Alarms The Setup Channel Alarms menu lets you access menus which change alarm function parameters for the current channel The main alarms menu looks like this CHANNEL PROCESS __UNITS SETUP CHANNEL 01 ALARMS CHANNEL NAME ALARM STATUS The CAS200 has three different kinds of alarms failed sensor alarms global alarms and process alarms Failed Sensor Alarms Global Alarms Process Alarms Failed sensor alarms alert you to thermocouple breaks Global alarms occur when a channel alarm is active and unacknowledged or when there are any unacknowledged failed sensor alarms If an alarm occurs the CAS200 front panel displays an appropriate alarm code see Chapter 3 Using the CAS200 on page 35 Even if the alarm condition goes away the global alarm stays on until you use the front panel Alarm Ack key to acknowledge it Process alarms include high and low deviation and high and low process alarms You can set each of these alarms to Off Latched or Unlatched as shown here Function Description Off No alarm Alarm is only cleared if it is in a Non Alarming state and the ALARM RESET key is pressed If ALARM ACKNOWL EDGE has not been previously pressed the ALARM RESET will acknowledge the global alarm as well Latched Digital output ac
3. 1 2 3 Make a record of system parameters Power down the scanner Remove the four screws from the sides of the scanner front panel Remove the electronics assembly from the case as shown in Watlow Anafaze 79 Chapter 5 Troubleshooting and Reconfiguring CAS200 User s Guide Figure 5 1 Removal of Electronics Assembly from Case 5 Unscrew the four screws at the corners of the top board and carefully unplug this board to access the bottom board processor board Figure 5 2 shows the screws to remove Figure 5 2 Screws Locations on PC Board 6 Locate the EPROM on the circuit board The EPROM is a 32 pin socketed chip that is labeled with the mod el version and checksum 80 Watlow Anafaze CAS200 User s Guide Chapter 5 Troubleshooting and Reconfiguring Figure 5 3 EPROM Location EPROM Detail vung cae a B ePin 1 SRAM E Notch 7 Remove the existing EPROM from its socket with an IC extraction tool or a jeweler s flathead screwdriver Figure 5 4 Remove EPROM 8 Carefully insert the new EPROM into the EPROM socket Make sure that the chip is oriented so that its notch fits in the corresponding corner of the socket 9 Reverse steps 2 through 4 to reassemble the unit 10 Power up the scanner 11 Re enter parameters Changing Communications To switch between EIJA TIA 232 and EIA TIA 485 change the jumpers as
4. 10 to 60mV or 0 to 25V with MPU mange scaling resistors Resolution 0 006 greater than 14 bits internal 0 03 of full scale 60mV at 25 C Accuracy 0 08 of full scale 60mV at 0 50 C Calibration Automatic zero and full scale Analog Ground to Frame Ground 40V Maximum DC Common to Frame Ground 40V Maximum Potential Thermocouple Break Detection Pulse type for upscale break detection Milliampere Inputs 0 20mA 30 resistance or 0 10mA 6Q resistance with scaling resistors Linear Voltage Input Ranges Available 0 12V 0 10V 0 5V 0 1V 0 500mV 0 100mV with scaling resistors Source Impedance For 60mV thermocouple measurements are within specification with up to 500Q source resistance For other types of analog signals the maximum source impedance is 5000Q Watlow Anafaze CAS200 User s Guide Chapter 7 Specifications Table 7 12 Pulse Inputs Parameter Description Number 1 Frequency Range 0 2000Hz Input Voltage Protection Diodes to supply and common lt 1 3 V Low Voltage Levels 53 7 V High TTL Maximum Switch Resistance to Pull Input Low Minimum Switch Off Resistance 30kQ 2kQ Table 7 13 Thermocouple Range and Resolution Accuracy at Accuracy at aO Pups Range in F Range in C 25 C Ambient 0 50 C Ambient ype oF C oF C J 350 to 1400 212 to 760 2 2
5. Belden 9154 2 20 0 5 mur Belden 8451 2 22 0 5 Belden 8772 3 20 0 5 BND anputs Belden 9770 3 22 0 5 Thermocouple Inputs T C Ext Wire 2 20 0 5 _ Belden 9539 9 24 0 2 a Outputs and Dig Belden 9542 20 24 0 2 Ribbon Cable 50 22 14 0 5 2 5 Belden 9154 2 20 0 5 eee a Belden 8451 2 22 0 5 Belden 9729 4 24 0 2 4000 ft 1219 m Computer Communica Belden 9730 6 24 0 2 tion EIA TIA 232 422 or Belden 9842 4 24 0 2 4000 ft 1219 m 485 or 20 mA Belden 9843 6 24 0 2 Belden 9184 4 22 0 5 6000 ft 1829 m Noise Suppression The CAS200 s outputs are typically used to drive solid state relays These relays may in turn operate more inductive types of loads such as electromechanical relays alarm horns and motor starters Such devices may generate electromagnetic interference EMI or noise If the scanner is placed close to sources of EMI it may not function correctly Below are some tips on how to recognize and avoid problems with EMI For earth ground wire use a large gauge and keep the length as short as possible Additional shielding may be achieved by connecting a chassis ground strap from the panel to CAS200 case Symptoms of RFI EMI If your scanner displays the following symptoms suspect EMI e The scanner s display blanks out and then reenergizes as if power had been turned off for a moment e The process variable does not display correctly EMI may also damage the digital output circuit so digital outputs will
6. 1 2 3 3 1 8 K 450 to 2500 268 to 1371 2 4 1 3 3 8 2 1 T 450 to 750 268 to 399 2 9 1 6 5 8 3 2 S 0 to 3200 18 to 1760 5 0 2 8 8 8 4 9 R 0 to 3210 18 to 1766 5 0 2 8 8 8 4 9 B 150 to 3200 66 to 1760 7 2 4 0 22 1 12 3 E 328 to 1448 200 to 787 1 8 1 0 2 9 1 6 N 450 to 2370 268 to 1299 2 7 1 5 5 0 2 8 PL Il 50 to 2012 10 to 1100 1 9 1 0 3 1 1 7 True for 10 to 100 of span except type B which is specified for 800 F to 3200 F Watlow Anafaze 99 Chapter 7 Specifications CAS200 User s Guide Table 7 14 Input Resistance for Voltage Inputs Range Input Resistance 0 12V 85kQ 0 10V 50kQ 0 5V 40kQ 0 1V 7 4kQ 0 500mV 6 2kQ 0 100mV 1 2kQ Table 7 15 Digital Inputs Parameter Description Number 8 8 selectable for output override remote job Configuration selection Input Voltage Protection Diodes to supply and common Source must limit current to 10 mA for override conditions Voltage Levels lt 1 3V Low gt 3 7V High TTL 5V maximum OV minimum Maximum Switch Resistance to Pull Input Low 1kQ Minimum Switch Off Resistance 11kQ Update Rate 6kQ 100 Watlow Anafaze CAS200 User s Guide Outputs Digital Outputs Chapter 7 Specifications The scanner provides open collector outputs These outputs are typically used to control SSRs or other power switching devices which in turn may
7. 16 6 to 100 representing the 10 to 60mV input range of the CAS200 For pulse inputs the input reading is in hertz cycles per second The scaling function is defined by two points on a conversion line the high PV and the low PV High PV is the high end of the input in engineering units and the low PV is the low end The engineering units of the process variable can be any arbitrary units The example below shows a high PV of 20 psi and a low PV of 0 psi The high reading is the high end of the input signal where 60mV 100 20 PSI Hi PV Process Variable 0 PSI OmV Rdg Rd Input Reading GSO Before you enter the values that determine the two points for the conversion line you must choose an appropriate display format The CAS200 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 and alarm deviation Watlow Anafaze CAS200 User s Guide Chapter 4 Setup The PV Process Variable range for the scaled input is between the PV values that correspond to the 0 and 100 input readings For the pulse input it is between the 0Hz and 2000Hz readings This PV range defines the limits for the setpoint and alarms as shown here Hi PV Process Variable
8. 0 5Vdc Sensor 89 Situation 89 Setup 89 Example 3 Pulse Encoder 90 Situation 90 Setup 90 Specifications 91 CAS200 System Specifications 91 CAS200 Processor Physical Specifications 92 TB50 Physical Specifications 95 Inputs 98 Outputs 101 CAS200 Power Supply 103 Glossary 105 Watlow Anafaze Contents vi Watlow Anafaze CAS200 User s Guide List of Figures 1 System Overview 1 Figure 1 1 System Components 4 2 Installation 7 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 2 8 Figure 2 9 Figure 2 10 Figure 2 11 Figure 2 12 Figure 2 13 Figure 2 14 Figure 2 15 Figure 2 16 Figure 2 17 Figure 2 18 Figure 2 19 Figure 3 1 Figure 3 2 5 Troubleshooti System Components 8 Clearance Recommendations 10 Mounting with the Mini Bracket 11 Mounting with the Collar Bracket 12 Mounting 13 Mounting Dimensions 14 CAS200 Series Scanner 19 Power Connections with the CAS200 Power Supply 20 Sensor Connections 22 Wiring Thermocouple Inputs 23 Wiring Voltage Input Connections 24 Wiring Current Input Connections 24 Connecting One CAS200 to a Computer Using EIA TIA 232 26 EIA TIA 485 Wiring 27 Recommended System Connections 28 Wiring Digital Outputs 31 Wiring Alarm Output Connections 31 Wiring Watchdog Timer Output 32 Wiring Digital Inputs 33 3 Using the CAS200 35 Navigating with a Single Channel Display 35 Fro
9. 2 15 If necessary for servicing instead of connecting each scanner directly to the next install a terminal strip or connector as close as possible to each CAS200 run a communications cable from one terminal strip to the next and connect the scanners to the bus with short lengths of cable To avoid unacceptable interference use less than 10 feet 3 m of cable from the terminal or connector to the CAS200 serial port Some systems may experience problems with sensor signal readings if the commons of multiple scanners are connected See Signal Common on page 28 for more information Refer to Termination on page 28 for more on terminating resistors Connect the shield drain to earth ground only at the computer or host end 27 Chapter 2 Installation 28 232 Communications CAS200 User s Guide Figure 2 15 Recommended System Connections 485 Communications Serial Port C Optically Isolatin 232 to 485 Converter Signal Common Termination Shielded Twisted Pair Cable Se First CAS200 Second CAS200 Last CAS200 For usual installations do not connect the de commons of the scanners together or to the converter or host device Use an optically isolating 232 to 485 converter to prevent problems with sensor readings For EIA TIA 485 signals to be transmitted properly each pair must be properly terminated The value of the termination resistor should be equal to the impedance of the c
10. Anafaze 67 Chapter 5 Troubleshooting and Reconfiguring CAS200 User s Guide 68 A CAUTION Returning Your Unit Before trying to troubleshoot a problem by replac ing your scanner with another one first check the installation If you have shorted sensor inputs to high voltage lines or a transformer is shorted out and you replace the scanner you will risk damage to the new scanner If you are certain the installation is correct you can try replacing the scanner If the second unit works correctly then the problem is specific to the scanner you replaced Before returning a scanner contact your supplier or call Watlow Anafaze at 1 831 724 3800 for technical support Scanners purchased as part of a piece of equipment must be serviced or returned through the equipment manufacturer Equipment manufacturers and authorized distributors should call customer service at Watlow Anafaze to obtain a return materials authorization RMA number Shipments without an RMA will not be accepted Other users should contact their suppliers for instructions on returning products for repair Troubleshooting Scanners A problem may be indicated by one or more of several types of symptoms e A process or deviation alarm e A failed sensor alarm e Asystem alarm e Unexpected or undesired behavior The following sections list symptoms in each of these categories and suggest possible causes and corrective actions Process and Devia
11. CH CH C CH CH 5V CH CH Gnd TX INTHE 0 9 10 o 11712 0 13 14 Ref 15 16 USA m INH N m IN IN m IN ING IN IN TXB TXA Follow the instructions pertaining to the type s of input s you are installing Watlow Anafaze CAS200 User s Guide Chapter 2 Installation The scanner accepts the following inputs without any special scaling resistors e J K T S R and B thermocouples e Linear inputs with ranges between 10 and 60 mV Any unused inputs should be set to SKIP or jumpered to avoid thermocouple break alarms Connect signal inputs to TB1 as shown below Note that some inputs require scaling resistors that are generally factory installed Thermocouple Connections Use 18 or 20 AWG thermocouple T C extension wire for all the thermocouple inputs Most thermocouple wire is solid unshielded wire Use shielded wire if required at your installation ground one end only Figure 2 10 Wiring Thermocouple Inputs White Ch IN e Type J T C Com e Red Shield if present Earth Ground at Process End Since the CAS200 has single ended inputs it has little protection from common mode voltage sources Therefore Watlow Anafaze highly recommends that you use ungrounded thermocouples with the external thermocouple sheath electrically connected to earth ground You
12. Low Process Value 56 Input Scaling Low Reading 57 Input Filter 57 Setup Channel Alarms 58 Failed Sensor Alarms 58 Global Alarms 58 Process Alarms 58 Alarm Delay 60 High Process Alarm Setpoint 60 High Process Alarm Type 60 High Process Alarm Output Number 61 Deviation Alarm Value 61 High Deviation Alarm Type 61 High Deviation Alarm Output Number 62 Low Deviation Alarm Type 62 Low Deviation Alarm Output Number 62 Watlow Anafaze Contents Low Process Alarm Setpoint 63 Low Process Alarm Type 63 Low Process Alarm Output Number 63 Alarm Deadband 64 Alarm Delay 64 Manual I O Test 65 Digital Input Testing 65 Digital Output Selection 65 Digital Output Test 66 Keypad Test 66 Troubleshooting and Reconfiguring 67 When There is a Problem 67 Returning Your Unit 68 Troubleshooting Scanners 68 Process and Deviation Alarms 68 Thermocouple Break Alarm 69 System Alarms 69 Other Behaviors 70 Corrective and Diagnostic Procedures 71 Additional Troubleshooting for Computer Supervised Systems 76 Computer Problems 76 Communications 77 Ground Channels 78 Software Problems 78 NO Key Reset 78 Replacing the EPROM 79 Changing Communications 81 Installing Scaling Resistors 82 CAS200 Input Circuit 82 CAS200 Current Inputs 83 CAS200 Voltage Inputs 84 Scaling and Calibration 85 Watlow Anafaze CAS200 User s Guide CAS200 User s Guide Contents Linear Scaling Examples 87 Example 1 4 20mA Sensor 88 Situation 88 Setup 88 Example 2
13. PROCESS _ UNITS 01 ALARM DELAY 0 SECONDS CHANNEL NAME ALARM STATUS Selectable values 0 to 255 seconds Watlow Anafaze CAS200 User s Guide Chapter 4 Setup Manual I O Test Press Yes at this prompt to see menus which can help you test the digital inputs digital outputs and the CAS200 keypad CHANNEL PROCESS UNITS CHANNEL NAME ALARM STATUS Digital Input Testing This is a read only menu that shows the logic state of the 8 digital inputs as H High the input is at 5 volts or is not connected or L Low the input is at zero volts Inputs 1 to 8 are displayed from left to right Since inputs are pulled High when they are not connected test an input by shorting it to scanner common and making sure this menu shows the correct state for that input CHANNEL PROCESS _ UNITS DIGITAL INPUTS HHLLHHHH CHANNEL NAME ALARM STATUS Digital Output Selection This menu lets you select one of the digital alarm outputs to test in the next menu CHANNEL PROCESS _ UNITS EST DIGITAL OUTPUT 34 CHANNEL NAME ALARM STATUS Watlow Anafaze 65 Chapter 4 Setup Digital Output Test Keypad Test 66 CAS200 User s Guide This menu lets you manually toggle a digital output On or Off to test it Select the output to test in the previous menu On may be Low or High depending on the digital output polarity you set All outputs are set to Off when you exit this menu CHANNEL PROCESS _UNITS
14. a large change in resistance for a small change in tem perature Thermistors usually have negative temperature coefficients although they are also available with positive temperature coeffi cients Thermocouple T C A temperature sensing device made by joining two dissimilar metals This junction produces an electrical voltage in proportion to the differ ence in temperature between the hot junction sensing junction and the lead wire connection to the instrument cold junction 111 Glossary TI Timed Integral The Integral term Transmitter A device that transmits temperature data from either a thermocouple or RTD by way of a two wire loop The loop has an external power sup ply The transmitter acts as a variable resistor with respect to its input signal Transmitters are desirable when long lead or extension wires produce unacceptable signal degrada tion U Upscale Break Protection A form of break detection for burned out ther mocouples Signals the operator that the ther mocouple has burned out Undershoot The amount by which a process variable falls below the setpoint before it stabilizes V Volt V The unit of measure for electrical potential voltage or electromotive force EMF See Voltage Voltage V The difference in electrical potential between two points in a circuit It s the push or pressure behind current flow through a circuit One volt V is the difference in potential re
15. back of the scanner 4 Loosen the mounting bracket screws enough to allow for the mounting collar and panel thickness Place each mounting bracket into the mounting slots head of the screw facing the back of the scanner Push each bracket backward then to the side to secure it to the scanner case 5 Make sure the case is seated properly Tighten the installation screws firmly against the mounting collar to secure the unit Ensure that the end of the mount ing screws fit into the indentations on the mounting collar Figure 2 4 Mounting with the Collar Bracket i Panel Adjustable quam e ee j D Mounting De SSS EE Brackets ammm H top and bottom H of scanner De A D z 6 m w ae az Li mg n T D e DO D H Bezel Y Mounting Collar Watlow Anafaze CAS200 User s Guide Mounting the TB50 NOTE DIN Rail Mounting Chapter 2 Installation There are two ways you can mount the TB50 by using the pre installed DIN rail mounting brackets provided or by using the plastic standoffs Follow the procedures for each to mount the board Figure 2 5 Mounting TB50 Mounted to DIN Rail TB50 Mounted with Standoffs Seoseosobseo If you choose to use the standoffs you will need to remove the DIN rail brackets before you can mount the board Attach the SCS
16. be used to signal another device of an alarm condition An open collector CPU watchdog output is also provided so that an external device may monitor the CPU state Table 7 16 Digital Outputs Control Alarm Parameter Description Number 35 Operation Open collector output ON state sinks to logic common Function 34 may be used to signal an alarm on one or more channels 1 global alarm output Off State Leakage Current lt 0 01mA to dc common Maximum Current 60mA for each output 5V power supply from the processor module can supply up to 350mA total to all outputs Maximum Voltage Switched 24Vdc Table 7 17 CPU Watchdog Output Parameter Description Number 1 Operation Open collector output ON state sinks to logic common Function Monitors the processor module microprocessor Maximum Current 10mA 5V power supply in the processor module can supply up to 35mA total to all outputs Maximum Voltage Switched 5Vdc Watlow Anafaze 101 Chapter 7 Specifications CAS200 User s Guide Table 7 18 5Vdc Output Power to Operate Solid State Relays Parameter Description Voltage Maximum Current 5Vdc 350mA Table 7 19 Reference Voltage Output Power to Operate Bridge Circuit Sensors Parameter Description Voltage 5Vdc Maximum Current 100mA Table 7 20 Processor Serial Inte
17. eeoe O lto signal supply 5 EAA AAAA np ls AAA ooocoocooocooocooo0oo0000000 o ahd O ee eee ee er m SCSI Port WATLOW ANAFAZE ASSY NO 30540 REV TB BOARD S N D C to TB50 COMPONENT SIDE P Wiring the Power Supply A CAUTION Use a power supply with a Class 2 rating only UL approval requires a Class 2 power supply Connect power to the scanner before any other connections This allows you to ensure that the scanner is working before any time is taken installing inputs and outputs Watlow Anafaze Chapter 2 Installation 120 240 Vac Supply CAS200 User s Guide Figure 2 8 Power Connections with the CAS200 Power Supply Power Supply 5V CG e Add jumper Y F SVCOM o CAS200 E 15V SSR SSR e gt _ D o a SSR SSR 15V e e Ground e AC Line e AC Neutral e white H black green 77 If using 5Vdc for outputs jumper 5V common to 15V common Connect terminals to ac panel ground 20 Table 2 2 Power Connections Function Power Supply CAS200 TB2 DC Power 12 to 24Vdc DC Common Peat Earth Ground Ground mn and tighten Watlow Anafaze 1 determine polarity 2 the scanner 3 tighten 4 Plug in and test the voltage of your power
18. ground loops EIA TIA 232 may be used to connect a computer through a 232 to 485 converter to an EIA TIA 485 communications network with up to 32 CAS200 scanners Table 2 3 EIA TIA 232 Connections Wire CAS200 DB 9 DB 25 Color TB1 Connector Connector White TX Pin 26 RX Pin 2 RX Pin 3 Red RX Pin 25 TX Pin 3 TX Pin 2 Black GND Pin 23 GND Pin 5 GND Pin 7 Green GND Pin 24 N U Pin 9 N U Pin 22 Shield N C GND Pin 5 GND Pin 7 Jumpers in EIA TIA 232 Connectors Watlow Anafaze Some software programs and some operator interface terminals require a clear to send CTS signal in response 25 Chapter 2 Installation CAS200 User s Guide to their request to send RTS signal or a data set ready DSR in response to their data terminal ready DTR The CAS200 is not configured to receive or transmit these signals To use such software with the CAS200 jumper the RTS to the CTS and the DTR to the DSR in the DB connector Table 2 4 lists the standard pin assignments for DB 9 and DB 25 connectors Table 2 4 RTS CTS and DSR DTR Pins in DB 9 and DB 25 Connectors DB 9 DB 25 RTS 7 4 CTS 8 5 DTR 4 20 DSR 6 6 Cables manufactured by Watlow Anafaze for EIA TIA 232 communications include these jumpers WATVIEW does not require these jumpers Figure 2 13 Connecting One CAS200 toa Computer Using EIA TIA 232 EIA TIA 232 o EIA TIA 485 Interface 26 To c
19. ls j co co co S co co co co ae co R e co co cols IS ja SY co 1 5 in 37 mm 96 Watlow Anafaze CAS200 User s Guide Chapter 7 Specifications Table 7 10 TB50 with Right Angle SCSI Length 5 4 inches 137 mm Width 4 0 inches 102 mm Height 1 5 inches 37mm Figure 7 6 TB50 Dimensions with Right Angle SCSI Cable YA 5 4 in 137 mm a ROR S08 088 808008 A yey BEBRBBEBRRRBE RE 4 0 in 102 mm Q 1 5 in 37 mm Watlow Anafaze 97 Chapter 7 Specifications 98 Inputs CAS200 User s Guide The scanner accepts analog sensor inputs which are measured and may be used as feedback for control loops It also accepts digital TTL inputs which may be used to trigger certain firmware features Table 7 11 Analog Inputs Parameter Description Number of Channels 17 Number of Analog Inputs 16 with full range of input types plus one pulse Input Switching Single ended solid state multiplexer Input Sampling Rate 1 5Hz 667ms at 60Hz 1 25Hz 800ms at 50Hz Analog Over Voltage Protection 20V referenced to digital ground Common Mode Rejection CMR For inputs that do not exceed 5V gt 60dB dc to 1kHz and 120dB at selected line frequency A D Converter Integrates voltage to frequency
20. n the power to the scanner off b Remove the boards from the CAS200 housing c Reseat the boards and turn power on 3 If the error persists make a record of the settings then perform a NO key reset See NO Key Reset on page 78 4 Ifthe error is not cleared contact your supplier for fur ther troubleshooting guidelines See Returning Your Unit on page 68 NOTE If the scanner has failed it is likely that it was damaged by excessive voltage or noise Before replacing the scanner troubleshoot for noise and ground channels HW Gain or Offset Failure If the scanner displays HW FAILURE GAIN or HW FAILURE OFFSET 1 Turn the power to the scanner off the on again 2 Ifthe error persists make a record of the settings us ing software then perform a NO key reset See NO Key Reset on page 78 3 Ifthe error is not cleared contact your supplier for fur ther troubleshooting guidelines See Returning Your Unit on page 68 72 Watlow Anafaze CAS200 User s Guide Chapter 5 Troubleshooting and Reconfiguring NOTE If the scanner has failed it is likely that it was damaged by excessive voltage or noise Before replacing the scanner troubleshoot for noise and ground channels Keys Do Not Respond If the CAS200 seems to function but the CHNG SP key does not respond when you press it the keypad is probably locked Unlock the keypad according to the instructions in Keyboard Lock Status on page 47 Checking Analo
21. not turn on If the digital output circuit is damaged return the scanner to Watlow Anafaze for repair Watlow Anafaze CAS200 User s Guide Avoiding RFI EMI Chapter 2 Installation To avoid or eliminate most RFI EMI noise problems Connect the CAS200 case to earth ground The CAS200 system includes noise suppression circuitry This circuitry requires proper grounding Separate the 120 or 240 Vac power leads from the low level input and output leads connected to the CAS200 series scanner Do not run the digital I O or alarm output leads in bundles with ac wires Where possible use solid state relays SSRs instead of electromechanical EM relays If you must use EM relays try to avoid mounting them in the same panel as the CAS200 series equipment If you must use EM relays and you must place them in a panel with CAS200 series equipment use a 0 01 microfarad capacitor rated at 1000 Vac or higher in series with a 47Q 0 5 watt resistor across the N O contacts of the relay load This is known as a snubber network and can reduce the amount of electrical noise 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 Watlow Anafaze part number 26 130210 00 You can also place a transorb back to back zener diodes across the digit
22. on page 72 HW FAILURE OFFSET Hardware failed due to exces See HW Gain or Offset Failure sive voltage on inputs on page 72 Watlow Anafaze 69 Chapter 5 Troubleshooting and Reconfiguring CAS200 User s Guide Other Behaviors The following table indicates potential problems with the system or scanner and recommends corrective actions Table 5 2 Other Symptoms Symptom Possible Causes Recommended Action Scanner not communicating Indicated tempera ture not as expected Sensor wiring incorrect See Checking Analog Inputs on page 73 Noise Check wiring and service See Wiring the Power connection incorrect Powersupply onpil 19 CAS200 display is Replace the EPROM See Replacing the not lit RP EEE EPROM on page 79 Return the CAS200 for repair See Return CAS200 damaged or failed ina Your Union pace en CAS200 display is Keypad is locked See Keys Do Not Respond on page 73 Ub Dub eye 20 not Return the CAS200 for repair See Return work CAS200 damaged or failed ine Your Unit gn paze 8 Set JOB SELECT DIG INPUTS TO NONE Digital job select feature is This parameter is only accessible using the Alarm limits or other enabled and has changed scanner s keypad and display See Job settings change jobs Select Inputs on page 45 Check wiring and service See Wiring the Power Supply on page 19 Poweris intermitent Use a separate dc supply for the scanner Acknowledged Pr
23. resistor location Table 5 3 Resistor Values for CAS200 Current Inputs Input Range Resistor Value RD 0 10mA 6 0Q 0 20mA 3 0Q Resistor tolerance 0 1 Watlow Anafaze 83 Chapter 5 Troubleshooting and Reconfiguring CAS200 User s Guide 84 Table 5 4 Resistor Locations for CAS200 Current Inputs Resistor Resistor Channel Location Channel Location RD RD 1 R42 9 R41 2 R40 10 R39 3 R38 11 R37 4 R36 12 R35 5 R34 13 R33 6 R32 14 R31 7 R30 15 R29 8 R28 16 R27 CAS200 Voltage Inputs For each voltage input on a CAS200 scanner you must install two resistors The resistance must be correct for the expected input range Install the resistors in the listed locations Table 5 5 Resistor Values for CAS200 Voltage Inputs Resistor Values Input Range RC RD 0 100mVdc 499Q 750Q 0 500mVdc 750Q 0 Vdc 422 02 0 5Vdc 475 02 0 10Vdc 301 02 0 12Vdc 422 0Q Resistor tolerance 0 1 Watlow Anafaze CAS200 User s Guide Chapter 5 Troubleshooting and Reconfiguring Table 5 6 Resistor Locations for CAS200 Voltage Inputs Resistor Locations Resistor Locations Channel Channel RC RD 1 R58 R42 9 R57 R41 2 R56 R40 10 R55 R39 3 R54 R38 11 R53 R37 4 R52 R36 12 R51 R35 5 R50 R34 13 R49 R33 6 R48 R32 14 R47 R31 7 R46 R30 15 R45 R29 8 R44 R28 16 R43 R27 Scaling and Calibration Th
24. s Guide Chapter 4 Setup Input Reading Offset Watlow Anafaze NOTE This menu lets you set an input reading offset function to make up for the input signal s inaccuracy at any given point For example at temperatures below 400 F 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 channel you are editing A positive value increases the reading and a negative value decreases it CHANNEL PROCESS _ UNITS 01 INPUT READING OFFSET O F CHANNEL NAME ALARM STATUS Selectable values 300 to 300 for thermocouples with the following exceptions when Input Units are set to F Offset Range If the input type is set to Linear Pulse or Skip you will not see this menu 53 Chapter 4 Setup 54 CAS200 User s Guide Linear Scaling Menus NOTE The linear scaling menus appear under the Setup Channel Inputs main menu Linear scaling is 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 The linear scaling menus will only be present if you set the channel s input type to Linear or for channel 17 to Pulse For linear inputs the input reading is in percent
25. scanning mode if pressed twice Alarm Ack e Press Alarm Ack to e Acknowledge an alarm condition and reset the global alarm e Stop the scanning display Alarm Reset e Press Alarm Reset to e Clear an alarm when the process is in a non alarming state e Acknowledge an alarm if the process is in an alarming state Watlow Anafaze 37 Chapter 3 Using the CAS200 38 CHNG SP Single Channel Job Display CAS200 User s Guide Change SP Press Change SP to change the setpoints Func The FUNC key is not used in normal operation It is reserved for future enhancement Display Single Channel display below shows detailed information for one channel Process Variable Engineering Units CHANNEL PROCESS _ UNI Channel Number a 02 347 F CHAN 01 CHANNEL NAME ALARM STATUS Default Channel Name From Single Channel Display e Press Yes to go to the next channel e Press No to go to the previous channel e Press the Back key once to go to Job display if it is enabled e Press Enter twice to start Single Channel Scanning display The Single Channel Scanning Display shows information for each channel for one second e Press any key to stop scanning mode Job display appears only if e You have turned on the Remote Job Select function This function is explained in Chapter 4 Setup e You have selected a job from the job load menu Watlow Anafaze
26. serial communications interface Features include Direct Connection of Mixed Thermocouple Sensors Connect most thermocouples to the scanner with no hardware modifications Thermocouple inputs feature reference junction compensation linearization process variable offset calibration to correct for sensor inaccuracies detection of broken shorted or reversed thermocouples and a choice of Fahrenheit or Celsius display Automatic Scaling for Linear Analog Inputs The CAS200 series automatically scales linear inputs used with industrial process sensors Enter two points and all input values are automatically scaled in your units Scaling resistors must be installed Flexible Alarm Outputs Independently set high low process alarms and a high low deviation band alarm for each channel Alarms can activate a digital output by themselves or they can be grouped with other alarms to activate an output Alarm Outputs You can set high low deviation and high low process alarm setpoints to operate digital outputs as latched or unlatched functions Global Alarm Output When any alarm is triggered the global alarm output is also triggered and it stays on until you acknowledge it CPU Watchdog The CAS200 series CPU watchdog timer output notifies you of system failure Use it to hold a relay closed while the system is running so you are notified if the microprocessor shuts down Front Panel or Computer Operation Set up and run the sca
27. shown in Figure 5 5 Figure 5 5 Jumper Configurations JU1 ba e g pa JU2 ea e epa e pa JU3 Ba e epa pa JU4 boa o opb 4 opb d JU5 B o opb g ebd A B A B A B Configured for Configured for Last scanner in EIA TIA 232 EIA TIA 485 system configured for EIA TIA 485 Watlow Anafaze 81 Chapter 5 Troubleshooting and Reconfiguring CAS200 User s Guide 82 You will need tweezers and a Phillips head screwdriver to switch between EIA TIA 232 and EJA TIA 485 Follow these steps 1 Power down the unit 2 Remove the scanner s metal casing See Replacing the EPROM on page 79 for step by step instructions 3 Find jumpers JU2 JU3 JU4 and JU5 on the board 4 Use tweezers to carefully grasp the jumpers and gen tly slide them off the pins 5 Use tweezers to gently slide jumpers JU2 JU3 JU4 and JU5 onto the correct pins see Figure 5 5 6 Ifyou are configuring the scanner as the last device on an EJA TIA 485 network move JU1 to the B position 7 Reassemble the scanner Installing Scaling Resistors A CAUTION Resistors are installed for all inputs on the CAS200 Inputs with signal ranges between 10 and 60mV use 0Q resistors in the RC position only All other input signals require special input scaling resistors Scaling resistors are soldered to the circuit board Only qualified technicians should attempt to install or remove these components Imp
28. supply to Locate the and connectors at the left on the back of Attach the positive wire to the connector on TB2 and Attach the negative wire to the COM connector on TB2 CAS200 User s Guide Chapter 2 Installation 5 Athird Ground connector on TB2 is available for chas sis ground This terminal is connected to the CAS200 chassis and must be connected to earth ground NOTE Connect the dc common of the power supply used for loads to the dc common of the supply powering the scanner If the supplies are not ref erenced to one another the scanner s outputs will not be able to switch the loads NOTE When making screw terminal connections tight en to 4 5 5 4 inch pound 0 5 0 6 Nm CAUTION Without proper grounding the CAS200 may not operate properly or may be damaged CAUTION To prevent damage from incorrect connections do not turn on the ac power before testing the connections as explained in Testing Power to the Scanner on page 21 NOTE Do not connect the scanner s dc common COM to earth ground 4 Doing so will defeat the noise protection circuitry making measurements less stable Testing Power to the Scanner 1 Perform a no key reset by holding the NO key while applying power to the CAS200 The no key reset sets all parameters to their defaults 2 When powered up the following screen should be displayed on the scanner If it is not try repeating the no key reset CHANNEL PROCE
29. the deadband specific conditions can be placed on control output actions Opera tors select the deadband It is usually above the heating proportional band and below the cooling proportional band Default Parameters The programmed instructions that are perma nently stored in the microprocessor software Derivative Control D The last term in the PID algorithm Action that anticipated the rate of change of the pro cess and compensates to minimize overshoot and undershoot Derivative control is an instantaneous change of the control output in the same direction as the proportional error This is caused by a change in the process vari able PV that decreases over the time of the derivative TD The TD is in units of seconds 106 Watlow Anafaze CAS200 User s Guide Deutsche Industrial Norms DIN A set of technical scientific and dimensional standards developed in Germany Many DIN standards have worldwide recognition Deviation Alarm Warns that a process has exceeded or fallen below a certain range around the setpoint Digital to Analog Converter DAC A device that converts a numerical input sig nal to a signal that is proportional to the input in some way Direct Action An output control action in which an increase in the process variable causes an increase in the output Cooling applications usually use direct action Direct Current DC An electric current that flows in one direction Distributed Zer
30. the pulse input as follows a Disconnect the sensor wiring b Set the INPUT TYPE to J thermocouple in the SETUP LOOP INPUT menu c Place a short across the input The scanner should indicate the ambient temperature on the channel you are testing Earth Grounding If you suspect a problem with the ac ground or a ground channel e Measure for ac voltage between ac neutral and panel chassis ground If ac voltage above 2Vac is observed then there may be a problem with the ac power wiring This should be corrected per local electrical codes e With ac power on measure for ac voltage that may be present between control panels chassis grounds Any ac voltage above 2Vac may indicate problems with the ac ground circuit e Check for ac voltage on thermocouples with the heater power on A control output providing power to the heaters will increase the ac voltage if there is heater leakage and an improper grounding circuit Measure from either positive or negative thermocouple lead to ac ground AC voltage above 2Vac may indicate the ground lead is not connected to the CAS200 TB2 ground terminal If the above tests indicate proper ac grounding but the scanner is indicating incorrect temperatures or process readings e Verify which type of sensor is installed and that the INPUT TYPE parameter is set accordingly e For a linear voltage or current input check that the correct input scaling resistors are installed page 82 and c
31. 0 C heat dust and unauthorized handling Ensure there is enough clearance for mounting brackets terminal blocks and cable and wire connections the scanner extends 7 0 in behind the panel face and the screw brackets extend 0 5 in above and below it Allow an additional 1 to 3 inches for the SCSI cable Figure 2 2 Clearance Recommendations 7 00 in 2 00 in v A 1 00 in ii mm 0 50 in 13 mm 178 mm 51 mm Jp Bezel freee ae Terminals a Steel Case I L A 0 50 in SCSI Cable 13 mm 4 00 in with right angle SCI cable Recommended Tools Panel Hole Cutters Use these tools to install the CAS200 series scanner and TB50 Use any of the following tools to cut a hole of the appropriate size in the panel e Jigsaw and metal file for stainless steel and heavyweight panel doors e Greenlee 1 8 DIN rectangular punch Greenlee part 600 68 for most panel materials and thicknesses e Nibbler and metal file for aluminum and lightweight panel doors Watlow Anafaze CAS200 User s Guide Chapter 2 Installation Other Tools You will also need these tools e Phillips head screwdriver e Flathead screwdriver for wiring e Multimeter Mounting the Scanner Mount the scanner before you mount the TB50 or do any wiring The scanner s plac
32. 00 User s Guide The following sections provide information regarding product features technical descriptions safety requirements and preparation for operation These symbols are used throughout this manual Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury or property damage Indicates pertinent information or an item that may be useful to document or label for later refer ence Contacting Watlow Anafaze To contact Watlow Anafaze send correspondence to Watlow Anafaze Inc 314 Westridge Drive Watsonville CA 95076 Our technical support and customer service departments may be reached Monday Friday 8 a m to 5 p m Pacific time Telephone 1 831 724 3800 Email anafazetechsupport watlow com Be sure to specify CAS200 when asking for technical support Watlow Anafaze CAS200 User s Guide Chapter 1 System Overview Product Features The CAS200 is a modular monitoring system with 16 analog inputs It can function as a stand alone system the CAS200 1 8 DIN front panel has a Vacuum Fluorescent Display VFD and touch keypad for local display and local parameter entry You can also use it as the key element in a computer supervised data acquisition system the CAS200 can be locally or remotely controlled via an EIA TIA 232 or EIA TIA 485
33. 1 DEV ALARM ALUE 25 F CHANNEL NAME ALARM STATUS Selectable values 0 to 255 25 5 2 55 255 or 0255 depending on the way you set up the Input menus High Deviation Alarm Type This menu lets you disable the high deviation alarm function or set it to the alarm functions The high deviation alarm activates if the process value PV rises above the deviation band value and remains active until the PV goes below the deviation band value minus the deadband value CHANNEL PROCESS 01 HI DEV ALARM YPE LATCHED CHANNEL NAME ALARM STATUS Selectable values Latched Unlatched or Off Watlow Anafaze 61 Chapter 4 Setup CAS200 User s Guide High Deviation Alarm Output Number This menu assigns a digital output which activates when the channel is in high deviation alarm The digital output only activates if you have set the high deviation alarm to On CHANNEL PROCESS UNITS 01 HI DEV ALARM OUTPUT NONE CHANNEL NAME ALARM STATUS Selectable values 1 to 34 None NOTE All digital outputs are combined Therefore you can assign more than one alarm to the same out put number and that output will be On if any of those alarms are On Low Deviation Alarm Type This menu turns off the low deviation alarm or set it to the alarm function CHANNEL PROCESS __UNITS 01 LO DEV ALARM YPE LATCHED CHANNEL NAME ALARM STATUS Selectable values Off Latched or Unlatched Low Deviation Al
34. 6 Nm Output Terminals TB18 Captive screw cage clamp Output Wire Gauge TB18 Multiconductor cables 24 AWG 0 2 mm Single wire 22 to 18 AWG 0 5 to 0 75 mm Output Terminal Torque TB18 4 4 to 5 3 in lb 0 5 to 0 6 Nm SCSI Connector SCSI 2 female Watlow Anafaze CAS200 User s Guide TB50 Physical Specifications Chapter 7 Specifications Table 7 7 TB50 Physical Dimensions Weight 0 32 Ib 0 15 kg Length 4 1 inches 104 mm Width 4 0 inches 102 mm Height 1 5 inches 37mm Figure 7 4 TB50 Dimensions 4 1 in 8 104 mm 228008 008008 ino nn HEHBEYRE Oo Cc YJ B 1 5 in 37 mm Table 7 8 TB50 Connections Screw Terminal Torque 4 4 to 5 3 in lb 0 5 0 6 Nm SCSI Connector on Board SCSI 2 female Output Terminals Captive screw cage clamp Output Wire Gauge Multiconductor cables 24 AWG 0 2 mm Single wire 22 to 18 AWG 0 5 to 0 75 mm Output Terminal Torque 4 4 to 5 3 in Ib 0 5 to 0 6 Nm Watlow Anafaze 95 Chapter 7 Specifications CAS200 User s Guide Table 7 9 TB50 with Straight SCSI Length 6 4 inches 163 mm Width 4 0 inches 102 mm Height 1 5 inches 37mm Figure 7 5 TB50 Dimensions with Straight SCSI Cable S 6 4 in 163 mm N SNE Q co co co co co o co o
35. CAS200 User s Guide WATLOW 1241 Bundy Boulevard Winona MN 55987 Phone 1 507 454 5300 Fax 1 507 452 4507 Document No 0600 3050 2400 Revision A November 2008 Copyright 2001 Watlow Anafaze Information in this manual is subject to change without notice No part of this publi cation may be reproduced stored in a retrieval system or transmitted in any form without written permission from Watlow Anafaze Warranty Watlow Anafaze Incorporated warrants that the products furnished under this Agree ment will be free from defects in material and workmanship for a period of three years from the date of shipment The customer shall provide notice of any defect to Watlow Anafaze within one week after the Customer s discovery of such defect The sole obli gation and liability of Watlow Anafaze 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 Replaced or repaired products or parts will be shipped to the Customer at the expense of Watlow Anafaze 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 Cus tomer without the written approval of Watlow Anafaze Final determin
36. CAS200 User s Guide Chapter 3 Using the CAS200 When you load a job Job display shows you this screen CHANNEL PROCESS __UNITS JOB 3 RUNNING CHANNEL NAME ALARM STATUS If you remotely loaded the job Job display looks like this CHANNEL PROCESS _ UNITS JOB 3 RUNNING REMOTELY LOADED CHANNEL NAME ALARM STATUS If you modify a job s parameters while the job is running you ll see this message CHANNEL PROCESS _ UNITS JOB 3 RUNNING DATA MODIFIED CHANNEL NAME ALARM STATUS If an alarm occurs the scanner switches to Single Channel Display Change Setpoint To change the set point go to the Single Channel Display of the channel you want to change and press the Change Setpoint key the set point is the desired temperature pH et cetera for the process You should see a display like this CHANNEL PROCESS _ UNITS 03 SETPOINT 500 F CHANNEL NAME ALARM STATUS e Press Yes to change the set point e Then press Yes or No to change the set point value e When you are satisfied with the set point value you have chosen press Enter to save your changes and return to Single Channel Display or e To return to Single Channel Display without saving your changes press No or Back Watlow Anafaze 39 Chapter 3 Using the CAS200 40 Alarms CAS200 User s Guide If an alarm occurs an eight character alarm code is displayed in the lower right section of the display Process Variabl
37. DIGITAL OUTPUT NUMBER 34 OFF CHANNEL NAME ALARM STATUS Press Yes or No to toggle the output state between On and Off This menu lets you test the keypad Press any key on the keypad to test the response The CAS200 will display the name of the key you have pressed CHANNEL PROCESS _ UNITS EYPAD TEST QUIT NO NO CHANNEL NAME ALARM STATUS Watlow Anafaze Troubleshooting and Reconfiguring The first sections of this chapter describe general troubleshooting for the CAS200 Later sections describe specific procedures such as checking an input changing the EPROM and testing the scanner When There is a Problem Even in stand alone systems the CAS200 is only part of your control system Often what appears to be a problem with the CAS200 is really a problem with other equipment so check these things first e Scanner is installed correctly See Chapter 2 Installation on page 7 for help Inputs like thermocouples are installed correctly and working NOTE If you suspect your scanner has been damaged do not attempt to repair it yourself or you may void the warranty If the troubleshooting procedures in this chapter do not solve your system s problems call the Technical Services department for additional troubleshooting help If you need to return the unit to Watlow Anafaze for testing and repair Customer Services will issue you an RMA number See Returning Your Unit on page 68 Watlow
38. FPM High Sensor Reading HIGH RDG 2000Hz Low Process Variable LO PV 0 FPM Low Sensor Reading LO RDG OHz 90 Watlow Anafaze Specifications This chapter contains specifications for the CAS200 series scanners TB50 terminal board and the CAS200 power supply CAS200 System Specifications This section contains CAS200 series scanner specifications for environmental specifications and physical dimensions inputs outputs the serial interface and system power requirements The scanner described consists of a processor module and a 50 terminal block TB50 Table 7 1 Agency Approvals Compliance CE Directive Electromagnetic Compatibility EMC Directive 89 336 EEC UL and C UL UL 916 Standard for Energy Manage ment Equipment File E177240 Watlow Anafaze 91 Chapter 7 Specifications CAS200 User s Guide CAS200 Processor Physical Specifications Table 7 2 Environmental Specifications Storage Temperature 20 to 60 C Operating Temperature 0 to 50 C Humidity 10 to 95 non condensing Environment The scanner is for indoor use only Table 7 3 Physical Dimensions Weight 1 98 Ibs 0 9 kg Length 8 0 inches 203 mm Width 3 78 inches 96 mm Height 1 96 inches 50 mm Without SCSI connector or with TB18 option Figure 7 1 CAS200 Processor Module Dimensions 92 Watlow Anafaze CAS200 U
39. I connector to the TB50 Snap the TB50 to the DIN rail To remove the TB50 from the rail use a screw driver to unsnap the bracket from the rail with a flat head screw driver Mounting with Standoffs Watlow Anafaze 1 Remove the DIN rail mounting brackets from the TB50 Select a location with enough clearance to safely remove the TB50 its SCSI cable and the scanner itself Place the TB50 where you will mount it and use a pen cil to trace around the standoffs Drill and tap 6 32 holes in the locations you marked Place the TB50 where you will mount it Insert the 6 screws in the standoffs and tighten them There are also four smaller holes on the terminal board for mounting with tie wraps Use these holes to secure wiring to the terminal block Chapter 2 Installation System Wiring A WARNING CAS200 User s Guide Figure 2 6 Mounting Dimensions Standoffs 4 places for use with 6 32 screws Successful installation and operation of the alarm scanner can depend on placement of the components and on selection of the proper cables sensors and peripheral components Routing and shielding of sensor wires and proper grounding of components can insure a robust system This section includes wiring recommendations instructions for proper grounding and noise suppression and considerations for avoiding ground loops To reduce the risk of electrical shock fire and equipment damage follow all local
40. IA 485 An Electronics Industries of America EIA standard for electrical charac teristics of generators and receivers for use in balanced digital multipoint systems This is usually used to communicate with multiple devices over a common cable or where dis tances over 50 feet are required Setpoint SP The desired value programmed into a control ler For example the temperature at which a system is to be maintained Shield A metallic foil or braided wire layer surround ing conductors that is designed to prevent elec trostatic or electromagnetic interference from external sources Watlow Anafaze Glossary Signal Any electrical transmittance that conveys information Solid State Relay SSR See Relay Solid State Span The difference between the lower and upper limits of a range expressed in the same units as the range Spread In heat cool applications the difference between heat and cool Also known as process deadband See deadband Stability The ability of a device to maintain a constant output with the application of a constant input T T C Extension Wire A grade of wire used between the measuring junction and the reference junction of a ther mocouple Extension wire and thermocouple wire have similar properties but extension wire is less costly TD Timed Derivative The derivative function Thermistor A temperature sensing device made of semi conductor material that exhibits
41. ModBus RTU MOD Communications Error Checking This selection allows you 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 CAS200 communications BCC ensures a high degree of communications integrity so we recommend that you use BCC unless your application specifically requires CRC Also if using Anascan ensure that the same error checking algorithm has been set through the scaninst program CHANNEL PROCESS _ UNITS COMMUNICATIONS ERR CHECK BCC CHANNEL NAME ALARM STATUS Selectable values BCC or CRC 48 Watlow Anafaze CAS200 User s Guide Chapter 4 Setup AC Line Frequency This menu lets you configure the scanner to match an AC line frequency of 50 or 60Hz This function is provided for international users who require 50Hz lines Since the scanner reduces the effect of power line noise on the analog measurement by integrating the signal over the period of the AC line frequency the scanner s noise rejection will suffer if the line frequency is not set correctly Cycle power to enable this change CHANNEL PROCESS _ UNITS AC LINE FREQ 60 HERTZ CHANNEL NAME ALARM STATUS Selectable values 50 or 60Hz Digital Output Polarity This menu lets you set the state of the digital outputs used for al
42. NNEL PROCESS _ UNITS SETUP GLOBAL PARAMETERS CHANNEL NAME ALARM STATUS Load a Job CHANNEL PROCESS _ UNITS LOAD SETUP FROM JOB 1 CHANNEL NAME ALARM STATUS Selectable values 1 to 8 The following parameters are loaded as part of a job e Set points and spread values e Alarm functions Off and Alarm set points high low process set points high low deviation set points and deadband settings and channel alarm delay A CAUTION All current job settings will be overwritten if you select a job from memory Save your current programming to a job number if you want to keep it CHANNEL PROCESS _ UNITS CANNOT LOAD JOB REMOTE SELECT ON CHANNEL NAME ALARM STATUS 44 Watlow Anafaze CAS200 User s Guide Save Setup to Job Job Select Inputs Watlow Anafaze Chapter 4 Setup Use this menu to save job information for every channel to one of eight jobs in the CAS200 battery backed RAM CHANNEL PROCESS _ UNITS SAVE SETUP O JOB 1 CHANNEL NAME ALARM STATUS If you have not enabled the remote job control function you will not be able to save a job If you try it you will get this message CHANNEL PROCESS _ UNITS CANNOT SAVE JOB REMOTE SELECT ON CHANNEL NAME ALARM STATUS Use this menu to run up to eight jobs remotely It lets you set the number of job select inputs The CAS200 uses these inputs as a binary code that specifies the job number to run The number of inputs you cho
43. Range Lo PV 0 PSI fo ay 100 Linear input type Omv Rdg Input Reading 60mV l 0 Hz 2000 Hz Pulse input type NOTE For example linear scaling calculations see Chapter 6 Linear Scaling Examples on page 87 Display Format Watlow Anafaze This menu lets you select a display format for a linear or pulse input Choose a format appropriate for your input range and accuracy You will only see the Display Format menu if you are editing a linear or pulse input CHANNEL PROCESS UNITS CHANNEL NAME ALARM STATUS The CAS200 has several available display formats the display format you choose determines the default values for the rest of the linear scaling menus Display Format Default High PV Default Low PV 9999 to 30000 10000 0 999 to 3000 1000 0 99 9 to 3000 0 1000 0 0 99 99 to 300 00 100 00 00 9 999 to 30 000 10 000 000 9999 to 3 0000 1 0000 0000 55 Chapter 4 Setup 56 High Process Value CAS200 User s Guide From this menu you can 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 CHANNEL PROCESS _UNITS 01 INPUT SCALING HI PV 1000 CHANNEL NAME ALARM STATUS Selectable Values The CAS200 displays the process value based on the table above Input Scaling High Reading Use this menu to enter the input level that corresponds to the
44. SS _ UNITS RESET WITH DEFAULTS CHANNEL NAME ALARM STATUS Watlow Anafaze Chapter 2 Installation 22 CAS200 User s Guide 3 Press Y for Yes to reset all the parameters When all parameters are reset the scanner will display the following CHANNEL PROCESS _ UNITS 01 70 F CHAN 01 CHANNEL NAME ALARM STATUS Connecting the TB50 to the CAS200 For a CAS200 scanner with the TB50 option 1 Connect the SCSI cable to the scanner 2 Connect the SCSI cable to the TB50 Input Wiring Sensor Connection This section describes how to properly install inputs to your scanner Inputs refer to thermocouples current and voltage Inputs The scanner can accept any mix of available input types Some input types require that special scaling resistors be installed generally done by Watlow Anafaze before the scanner is delivered All inputs are installed at the channel input connectors TB1 at the back of the scanner The illustrations below show the connector locations for the CAS216 scanner A WARNING Never run input leads in bundles with high power leads Figure 2 9 Sensor Connections rc Tai 1 3 5 7 J9 11 13 15 17 19 21 23 25 H CH C CH CH H CH Ref CH CH Gnd Rx CLS216 c c enfe C CHIC ef CH CH fana RX Ce m 5 7 TB2 IN IN IN IN m IN IN IN IN RXB RXA gt 2 4 6 s8 10 12 14 16 18 20 22 24 26 MADE V C Gnd CH CH C
45. a controller These menus allow operators to set or change various control actions or features Optical Isolation Two electronic networks that are connected through an LED Light Emitting Diode and a photoelectric receiver There is no electrical continuity between the two networks Output Control signal action in response to the differ ence between setpoint and process variable 109 Glossary Output Type The form of PID control output such as Time Proportioning Distributed Zero Crossing SDAC or Analog Also the description of the electrical hardware that makes up the output Overshoot The amount by which a process variable exceeds the setpoint before it stabilizes P Panel Lock A feature that prevents operation of the front panel by unauthorized people PID Proportional Integral Derivative A control mode with three functions Proportional action dampens the system response Integral corrects for droops and Derivative prevents overshoot and undershoot Polarity The electrical quality of having two opposite poles one positive and one negative Polarity determines the direction in which a current tends to flow Process Variable The parameter that is controlled or measured Typical examples are temperature relative humidity pressure flow fluid level events etc The high process variable is the highest value of the process range expressed in engineering units The low process variable is the lo
46. actual process temperature See Auto reset J Job A set of operating conditions for a process that can be stored and recalled in a controller s memory also called a Recipe Junction The point where two dissimilar metal conduc tors join to form a thermocouple L Lag The delay between the output of a signal and the response of the instrument to which the signal is sent 108 Watlow Anafaze CAS200 User s Guide Linear Input A process input that represents a straight line function Linearity The deviation in response from an expected or theoretical straight line value for instruments and transducers also called Linearity Error Liquid Crystal Display LCD A type of digital display made of a material that changes reflectance or transmittance when an electrical field is applied to it Load The electrical demand of a process expressed in power watts current amps or resistance ohms The item or substance that is to be heated or cooled Loop Alarm Any alarm system that includes high and low process deviation band deadband digital out puts and auxiliary control outputs Low Deviation Alarm Warns that the process is below the setpoint but above the low process variable It can be used as either an alarm or control function Low Process Alarm A signal that is tied to a set minimum value that can be used as either an alarm or control function Low Reading An input level correspondin
47. al output which limits the digital output voltage Additional Recommendations for a Noise Immune System It is strongly recommended that you Watlow Anafaze Isolate outputs through solid state relays where possible Isolate RTDs or bridge type inputs from ground Isolate digital inputs from ground through solid state relays If this is not possible then make sure the digital input is the only connection to earth ground other than the chassis ground If you are using ETA TIA 232 from a non isolated host either 1 do not connect any other power common point to earth ground or 2 use an optical isolator in the communications line Chapter 2 Installation Ground Loops CAS200 User s Guide Ground loops occur when current passes from the process through the scanner to ground This can cause instrument errors or malfunctions A ground loop may follow one of these paths among others e From one sensor to another e From a sensor to the communications port e From a sensor to the dc power supply The best way to avoid ground loops is to minimize unnecessary connections to ground Do not connect any of the following terminals to each other or to earth ground e Power supply dc common e TB1 terminals 5 6 11 12 analog common e TB1 terminal 17 reference voltage common e TB1 terminals 23 24 communications common e TB2 terminal 2 dc power common The CAS200 has single ended inputs All the negati
48. an input type available for unused channels The scanning display doesn t show channels you ve set to Skip CHANNEL PROCESS __UNITS 01 INPUT TYPE J T C CHANNEL NAME ALARM STATUS 50 Watlow Anafaze CAS200 User s Guide Display Resolution Watlow Anafaze NOTE Chapter 4 Setup If you set the input type to Skip you won t see any of the other submenus in the Setup Channel Input menu Channel 17 toggles between pulse and skip If you set the input type to any thermocou ple you will see the Offset menu If you set the in put type to Linear or you are editing the Pulse channel 17 you will see the Input Scaling sub menus Selectable values The table shows the input types and ranges Input Type pii Celsius Range J 350 to 1400 212 to 760 K 450 to 2500 268 to 1371 T 450 to 750 18 to 1766 S 0 to 3200 18 to 1760 R 0 to 3210 18 to 1765 B 150 to 3200 66 to 1760 PL II 50 to 2012 10 to 1100 N 450 to 2370 268 to 1299 Pulse 0 2KHz Channel 17 only Skip Channel is not scanned or displayed ie See the Linear Scaling section this chapter and appendix When type T thermocouples are selected the display may be in tenths of a degree or whole number CHANNEL PROCESS _ UNITS 01 DISP RES 999 to 999 CHANNEL NAME ALARM STATUS Selectable values 999 to 999 or 999 0 to 999 0 51 Chapter 4 Setup Pulse Sample Time Channel Na
49. and national electrical codes Correct wire sizes fuses and thermal breakers are essential for safe operation of this equipment Watlow Anafaze CAS200 User s Guide A CAUTION Chapter 2 Installation Do not wire bundles of low voltage signal and control circuits next to bundles of high voltage ac wiring High voltage may be inductively coupled onto the low voltage circuits which may damage the scanner or induce noise and cause poor control Physically separate high voltage circuits from low voltage circuits and from CAS200 hardware If possible install high voltage ac power circuits in a separate panel Wiring Recommendations Follow these guidelines for selecting wires and cables Watlow Anafaze Use stranded wire Solid wire can be used for fixed service it makes intermittent connections when you move it for maintenance Use 20 AWG 0 5 mm thermocouple extension 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 signals and the CAS200 from electrical noise Connect one end of the input and output wiring shield to earth ground Use copper wire for all connections other than thermocouple sensor inputs Chapter 2 Installation CAS200 User s Guide Table 2 1 Cable Recommendations No of 2 Maximum Function Mfr P N Wires AWG mm Length Analog houi
50. ange Setpoint ba ACK SP 3 The first setup menu appears CHANNEL PROCESS __UNITS SETUP GLOBAL PARAMETERS CHANNEL NAME ALARM STATUS NOTE If you are in the Setup menus and you don t make any changes for three minutes the CAS200 re verts to Single Channel Display for your protec tion Watlow Anafaze 41 Chapter 4 Setup 42 How to Edit a Menu CAS200 User s Guide e Press Yes to select the menu or No to advance to the next menu e Press Yes or No to toggle between the option in your menu e Press Enter to store the value you have selected e If you decide not to edit the menu press Back to stop editing and return to the main menu 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 following sections tell more about the submenus for each of the four main menus The next page shows the setup menus accessible from Single Channel Display Watlow Anafaze CAS200 U ser s Guide Single Channel Display Passkey Sequence 4 i ALARM CHNG ACK sP Setup Global Parameters D Setup Chan Q Load Job 1 8 m Input type DISP RES Save Job 1 8 999 or 999 0 T T C only Jo
51. any output wiring on the output to be test ed 3 Connect a 500Q to 100kQ resistor between the 5V terminal TB18 or TB50 screw terminal 1 and the output terminal you want to test 4 Connect the voltmeter s common lead to the output terminal and connect the voltmeter s positive lead to the 5V terminal 5 Restore power to the scanner 6 Ifyou are testing a digital output use the MANUAL IO TEST menu to turn the output on and off See Manual I O Test on page 65 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 25V Watlow Anafaze 75 Chapter 5 Troubleshooting and Reconfiguring Testing Digital Inputs 1 CAS200 User s Guide Turn off power to the scanner Disconnect any system wiring from the input to be tested Restore power to the scanner Go to the DIGITAL INPUTS parameter in the MANUAL O TEST menu This parameter shows whether the digital inputs are H high or open or L low or closed Attach a wire to the terminal of the digital input to test When the wire is connected only to the digital in put terminal the DIGITAL INPUTS parameter should show that the input is H high When you connect the other end of the wire to scanner common TB50 termi nal 3 the DIGITAL INPUTS parameter should show that the input is L low Additional Troubleshooting for Computer Supervised Systems These four elements
52. arm Output Number This menu is used to assign a digital output that activates when the channel is in low deviation alarm CHANNEL PROCESS _ UNITS 01 LO DEV ALARM OUTPUT NONE CHANNEL NAME ALARM STATUS Selectable values 1 to 34 None NOTE All digital outputs are OR d together combined Therefore you can assign more than one alarm to the same output number and that output will be On if any of those alarms is On 62 Watlow Anafaze CAS200 User s Guide Chapter 4 Setup Low Process Alarm Setpoint This menu is used to set a low process alarm setpoint The low process alarm activates when the process variable goes below the low process alarm setpoint It deactivates when the process variable goes above the low process alarm setpoint plus the deadband CHANNEL PROCESS UNITS 01 LO PROC ALARM SETPT O CHANNEL NAME ALARM STATUS Selectable values Any value within the input sensor s range Low Process Alarm Type This menu lets you turn off the low process alarm or set it to the alarm function CHANNEL PROCESS _ UNITS 01 LO PROC ALARM YPE OFF CHANNEL NAME ALARM STATUS Selectable values Off Latched Unlatched Low Process Alarm Output Number This menu lets you assign the digital output that activates when the channel is in low process alarm CHANNEL PROCESS _ UNITS 01 LO PROC ALARM OUTPUT NONE CHANNEL NAME ALARM STATUS Selectable values NONE 1 to 34 NOTE All
53. arms When set to CLOSED the output closes the circuit when an alarm occurs This setting does not affect the function of the Global Alarm CHANNEL PROCESS _ UNITS DIG OUT POLARITY ON ALARM CLOSED CHANNEL NAME ALARM STATUS Selectable values Closed or Open External Alarm Acknowledge Input Active An external alarm reset or acknowledge button can be wired to the CAS200 at input 8 When activated it performs the same function as if the ALARM ACK key was pressed CHANNEL PROCESS _ UNITS EXTRN ALARM ACK INPT ACTIVE LOW CHANNEL NAME ALARM STATUS Selectable values High or Low Watlow Anafaze 49 Chapter 4 Setup CAS200 User s Guide EPROM Information This view only display shows the scanner s EPROM version and checksum CHANNEL PROCESS _ UNITS CAS200 1 00 CS 2233 CHANNEL NAME ALARM STATUS Setup Channel Inputs The Setup Channel Input main menu lets you access menus which change parameters related to the channel input e Input type e Input units e Input scaling and calibration The next section explains how to use the Input menus to configure your scanner CHANNEL PROCESS _ UNITS ETUP CHANNEL 02 INPUT CHANNEL NAME ALARM STATUS Input Type This is the first menu of the Setup Channel Inputs menu It lets you configure the input sensor for each channel as one of these input types e Thermocouple types J K T S R B PL II and N e Linear inputs e Skip
54. ation of war ranty eligibility shall be made by Watlow Anafaze If a warranty claim is considered invalid for any reason the Customer will be charged for services performed and expenses incurred by Watlow Anafaze 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 and the cus tomer 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 disclaims all war ranties express or implied including any warranty of merchantability or fitness for a particular purpose Please Note External safety devices must be used with this equipment List of Figures ix List of Tables xiii System Overview 1 Manual Contents 1 Getting Started 2 Safety symbols 2 Contacting Watlow Anafaze 2 Product Features 3 System Diagram 4 Parts List 4 Mounting Scanner Components 5 Safety 5 Installation 7 Typical Installation 8 Safety 9 External Safety Devices 9 Mounting 10 Location 10 Recommended Tools 10 Mounting the Scanner 11 Mounting the TB50 13 System Wiring 14 Wiring Recommendations 15 Noise Suppression 16 Ground Loops 18 Power Connections 19 Watlow Anafa
55. b Select Inputs Channel Name None 3 Job Select Input Input Units F RC Pol Startup Alarm Del Pulse Sample Time 0 60 min 0 20 sec Keyboard Lock Input Reading Stat Offset ad Controller Address Disp Formt Linear 1 32 amp Plse 999 3000 Com Baud Rate High PV Linear amp 9600 2400 Pulse 10000Hz If Com Protocol Mod High RDG Linear amp Ana AB Mod Pulse 10000Hz Comm ERR Low PV Linear amp Chckng Pulse 0Hz AC Line Freq Low RDG Linear amp 60 50Hz Pulse 0Hz Digital Output Pol Input Filter Low High aes 3 Scans Ext Alarm Ack Inp EPROM Informa gt tion Default settings are shown in BOLD typeface Watlow Anafaze a Hi Proc alarm Set 1000 Hi Proc Alarm Type OFF UNL LCH Hi Proc Alarm Outp Dev Alarm Value 25 IHi Dev Alarm type Chapter 4 Setup UNL LCH OFF None Lo Dev Alarm Type UNL LCH OFF Lo Dev Alarm Out None Lo Proc Alarm Setp ILo Proc Alarm Type OFF UNL LCH Lo Proc Alarm Outp None Alarm Deadband 2 Alarm Delay 0 255 Hi Dev Alarm Out gt Manual I O Test Test Digital Inputs Test Digital Outputs Digital Output Test Keypad 43 Chapter 4 Setup CAS200 User s Guide Setup Global Parameters Menu The setup global parameters menu looks like this CHA
56. be used with other approved independent safety shutdown devices Contact Watlow Anafaze immediately if you have any questions about system safety or system operation Watlow Anafaze 5 Chapter 1 System Overview CAS200 User s Guide 6 Watlow Anafaze Watlow Anafaze Installation This chapter describes how to install the CAS200 series scanner and its peripherals Installation of the scanner involves the following procedures e Determining the best location for the scanner e Mounting the scanner and TB50 e Power Connection e Input Wiring e Communications Wiring EIA TIA 232 or EIA TIA 485 e Output Wiring Chapter 2 Installation CAS200 User s Guide Typical Installation The illustrations below show typical installations of the scanner with the TB50 terminal block Observe the illustration below to determine potential space requirements We recommend that you read this entire chapter first before beginning the installation procedure This will help you to carefully plan and assess the installation Figure 2 1 System Components CSI Cable TB50 Digital inputs P and outputs B fe and pulse input 8 Watlow Anafaze CAS200 User s Guide Safety A WARNING A WARNING Chapter 2 Installation Ensure that power has been shut off to your entire process before you begin installation of the scanner Watlow Anafaze has made every effort to ensure the reliability and safety of this
57. can use 400 to 500 feet of thermocouple extension wire depending on wire type and size and keep to accuracy and source impedance specifications Always install thermocouple wiring in separate conduit away from AC power the 120Vac control supply and high power 240Vac or higher wiring Watlow Anafaze 23 Chapter 2 Installation nN WARNING CAS200 User s Guide The scanner uses a floating ground system Therefore isolate input devices or host computers connected through communications cables like EIA TIA 232 from earth ground Use ungrounded thermocouples with the thermocouple sheath electrically connected to earth ground Use optically isolated EIA TIA 232 devices to isolate earth grounded host computers from the scanners When you use grounded thermocouples tie the thermocouple sheaths to a common earth ground in one place Otherwise any common mode voltages that exceed 5 volts may cause incorrect readings or damage to the scanner Voltage Input Connections This input type requires scaling resistors Special input resistors installed at Watlow Anafaze divide analog input voltages such that the scanner sees a 20 to 60mV signal on the channel Figure 2 11 Wiring Voltage Input Connections Ch IN Device with Voltage Com Output Current Input Connections 24 This input type requires special input resistors Resistors installed at Watlow Anafaze for analog current signals are such that the scann
58. digital outputs are combined Therefore you can assign more than one alarm to the same out put number and that output will be On if any of those alarms is On Watlow Anafaze 63 Chapter 4 Setup Alarm Deadband Alarm Delay 64 CAS200 User s Guide This menu lets you set an alarm deadband This deadband value applies to the high process low process high deviation and low deviation alarms for the channel you are editing The alarm deadband sets the hysteresis of the alarm action which is used to avoid intermittent alarms as the PV returns to a normal state CHANNEL PROCESS _UNITS 01 ALARM DEAD BAND 2C CHANNEL NAME ALARM STATUS Selectable values 0 to 255 25 5 2 55 255 or 0255 depending on your input menu setup This menu sets a channel alarm delay There are two types of alarm delay the startup alarm delay and channel alarm delay Startup alarm delay which you can set in the Setup Global Parameters main menu delays process alarms but not failed sensor alarms for all channels for a specified time after the CAS200 powers up The channel alarm delay in contrast is set separately for each channel It delays failed sensor and process alarms until the alarm condition has been continuously present for longer than the alarm delay time Failed sensor alarms are not subject to the startup alarm delay but they are affected by the channel s alarm delay during the startup alarm delay period CHANNEL
59. e 2 6 TB18 Connections Terminal Function 1 5 Vdc 2 CTRL COM 3 Watchdog timer 4 Global alarm 5 Output 1 6 Output 2 7 Output 3 8 Output 4 9 Output 5 10 Output 6 11 Output 7 12 Output 8 13 Output 9 14 Output 10 15 Output 34 16 Input 1 17 Input 2 18 Input 3 Pulse input Watlow Anafaze Using the CAS200 Introduction This chapter will show you how to use the CAS200 from the front panel The next diagram shows how to reach the operator menus from Single Channel display To change global parameters channel inputs and alarms from the setup menus you must enter a special sequence of keys To learn how see Chapter 4 Setup on page 41 Figure 3 1 Navigating with a Single Channel Display Single channel display Single channel Change Power ON Job Display scanning Setpoint display Watlow Anafaze 35 Chapter 3 Using the CAS200 CAS200 User s Guide Front Panel The front panel provides a convenient interface with the CAS200 system You can program and operate the CAS200 with the front panel keys shown below or you can use WatView or ANASCAN software Figure 3 2 Front Panel Display WATLOW ANAFAZE CAS200 Alarm Reset CHANNEL PROCESS UNITS ra Resets alarms when the process is safe CHANNEL NAME ALARM STATUS N Alarm Ack Turns off global alarm digital alarm stays active FUNC A Enter No func
60. e Chapter 4 Setup Keyboard Lock Status This selection lets you lock the front panel operator function key Change SP so that pressing this key has no effect If you want to use this function turn off the Keyboard Lock CHANNEL PROCESS _ UNITS KEYBOARD LOCK STATUS OFF CHANNEL NAME ALARM STATUS Selectable values On or Off Scanner Address This menu allows you to set the CAS200 scanner address The scanner address is used for multiple scanner communications on a single EIA TIA 485 cable so each CAS200 must have a different address Begin with address 1 for the first scanner and assign each subsequent scanner the next higher address CHANNEL PROCESS _ UNITS CONTROLLER ADDRESS 1 CHANNEL NAME ALARM STATUS Selectable values 1 32 Communications Baud Rate This menu allows you to set the Communications Baud Rate If using Anascan ensure that the program has the same baud rate set through the scaninst program CHANNEL PROCESS _UNITS COMMUNICATIONS BAUD RATE 9600 CHANNEL NAME ALARM STATUS Selectable values 19200 2400 or 9600 Watlow Anafaze 47 Chapter 4 Setup CAS200 User s Guide Communications Protocol This menu is located under the Setup Global Parameters main menu It allows you to select the Communications Protocol CHANNEL PROCESS _ UNITS COMMUNICATIONS PROTOCOL ANA CHANNEL NAME ALARM STATUS Selectable values Anafaze ANA Allen Bradley AB
61. e Engineering Units Channel Number Channel Name HTR1 HIGH PRC CHANNEL NAME ALARM STATUS A Alarm Message These alarm codes and messages are shown in the table below Alarm Message Alarm Type TC BREAK Thermocouple Break HIGH PRC High process alarm HIGH DEV High deviation alarm LOW DEV Low deviation alarm LOW PRC Low process alarm Acknowledging an Alarm Resetting an Alarm Press the Alarm Acknowledge key to acknowledge an alarm If there are other channels with alarm conditions the Alarm display switches to the next channel in alarm Acknowledge all alarms to clear the global alarm The Alarm Acknowledge key operates differently in latched and unlatched modes In latched mode an alarm can only be cleared when the process is in a non alarming state and the Alarm Reset key is pressed In un latched mode the alarm clears automatically when the Alarm Acknowledge key is pressed and the system is in a non alarming state Pressing the Alarm Reset key clears an alarm only if the system in a non alarming state Otherwise the key will operate the same as the Alarm Acknowledge key Watlow Anafaze Setup CAS200 Menus The Setup menus let you change detailed configuration information How to Enter the Setup Menus 1 In Single Channel Display select the channel you wish to edit 2 While still in Single Channel Display enter the pass sequence below Press Enter Alarm Ack Ch
62. e ability of an instrument to reject electrical noise with relation to ground from a common voltage Usually expressed in decibels dB Communications The use of digital computer messages to link components See Serial Communications See Baud Rate Control Action The response of the PID control output relative to the error between the process variable and the setpoint For reverse action usually heat ing as the process decreases below the set point the output increases For direct action usually cooling as the process increases above the setpoint the output increases CAS200 User s Guide Control Mode The type of action that a controller uses For example On Off time proportioning PID Automatic or manual and combinations of these Current The rate of flow of electricity The unit of mea sure is the ampere A 1 ampere 1 coulomb per second Cycle Time The time required for a controller to complete one on off on cycle It is usually expressed in seconds Cyclic Redundancy Check CRC An error checking method in communications It provides a high level of data security but is more difficult to implement than Block Check Character BCC See Block Check Character D Data Logging A method of recording a process variable over a period of time Used to review process perfor mance Deadband The range through which a variation of the input produces no noticeable change in the output In
63. e repaired or replaced Most communications problems are due to incorrect wiring or incorrectly set communications parameters Therefore when there is a problem check the wiring and communications settings first Verify the following Communications port Software must be configured to use the communications port to which the scanner is connected Software protocol Set the scanner to MOD Modbus for WatView ANA Anafaze for ANASCAN Scanner address Configure software to look for the scanner at the correct address In a multiple scanner installation each scanner must have a unique address Baud rate Software and scanner must be set the same Error checking ANA protocol only Software and scanner must be set the same CRC or BCC Hardware protocol PC and scanner must use the same protocol or a converter must be used The scanner is typically configured for EIA TIA 232 when it is shipped See Changing Communications on page 81 to change between EJA TIA 232 and ETA TIA 485 To communicate with more than one scanner or when more than 50 feet of cable is required use EIA TIA 485 Even for a single scanner you may use EIA TIA 485 and an optically isolating converter to eliminate ground channels Converter Make sure that the EIA TIA 232 to 485 converter is powered configured and wired correctly Cables Check continuity by placing a resistor across each pair of wires and measuring the resistance with an ohmmeter at the ot
64. e scanner provides offset calibration for thermocouples and offset and span gain calibration for linear and pulse inputs In order to scale linear input signals you must 1 3 Install appropriate scaling resistors Contact Watlow Anafaze s Customer Service Department for more information about installing scaling resistors Select the display format The smallest possible range is 9999 to 3 0000 the largest possible range is 9999 to 30000 Enter the appropriate scaling values for your process See Chapter 6 Linear Scaling Examples on page 87 Watlow Anafaze 85 Chapter 5 Troubleshooting and Reconfiguring CAS200 User s Guide 86 Watlow Anafaze Linear Scaling Examples This chapter provides three linear scaling examples The examples describe e A pressure sensor generating a 4 to 20mA signal e A flow sensor generating a 0 to 5V signal e A pulse encoder generating 900 pulses per inch of movement Watlow Anafaze 87 Chapter 6 Linear Scaling Examples Example 1 4 20mA Sensor Situation CAS200 User s Guide A pressure sensor that generates a 4 20 milliamp signal is connected to the scanner The specifications of the sensor state that it generates 4mA at 0 0 pounds per square inch psi and 20mA at 50 0 psi Setup The sensor is connected to a loop input set up with a resistor scaling network to produce 60 millivolts at 20mA The INPUT TYPE for the loop is let to LINEAR The sens
65. ed to control common The digital I O are located on the EIA TIA 232 remote TB50 The CAS200 outputs are typically used to drive solid state relays These relays may in turn operate more inductive loads such as electromechanical relays and alarm horns These devices may generate electromagnetic interference EMI or noise If the scanner is placed near sources of EMI it may not function correctly Below are some tips on how to recognize and avoid problems with EMI Symptoms of RFI EMI Watlow Anafaze If your scanner displays the following symptoms suspect EMI e The scanner s display blanks out and then reenergizes as if power had been turned Off for a moment e The process variable does not display correctly EMI may also damage the digital output circuit so digital outputs will not energize If the digital output circuit is damaged return the scanner to Watlow Anafaze for repair 29 Chapter 2 Installation CAS200 User s Guide Avoiding Noise Problems Digital Outputs 30 To avoid noise problems be sure ground wire terminal on TB2 is connected to earth ground Where possible use solid state relays SSRs instead of electromechanical EM relays If you must use EM relays try to avoid mounting them in the same panel as the CAS200 series equipment Separate the 120 240Vac power leads from the low level input and output leads connected to the CAS200 series scanner Don t run the digital output or contro
66. ement affects placement and wiring considerations for the other components of your system You receive one of two types of mounting brackets with your scanner the mini bracket or the collar bracket Refer to the corresponding sections below for instructions Steps Using the Mini Bracket 1 Cuta hole in the panel to the dimensions shown in the illustration below To do this use a punch nibbler or jigsaw and file the edges of the hole 2 Insert the scanner into the hole through the front of the panel 3 Screw the top and bottom clips in place insert the clip s lip into the cutout in the scanner s metal housing just behind the front panel Tighten the screws 4 Ifyou expect much panel vibration use a rear support for the scanner and its interconnecting cables Figure 2 3 Mounting with the Mini Bracket eS Maximum Panel ee R 0 2 in 5mm Z N 1 80 in 0 02 in 45 7mm 0 5mm 3 63 in 0 02 in 92 2mm 0 5mm Watlow Anafaze 11 Chapter 2 Installation CAS200 User s Guide Steps Using the Collar Bracket NOTE Installing and mounting requires access to the back of the panel Removing the scanner chassis from its case makes mounting easier 1 Make a panel cutout Refer to Figure 2 3 on page 11 for dimensions of the cutout Slide the scanner into the panel cutout Slide the mounting collar over the back of the scanner making sure the mounting screw indentations face toward the
67. er sees a 10 to 60mV signal across its inputs for the channel Figure 2 12 Wiring Current Input Connections Ch IN Device with Current Com Ref Com Output Do not use the scanner s power supply to power sensors transmitters or output devices Watlow Anafaze CAS200 User s Guide NOTE Chapter 2 Installation When mixing current inputs with low voltage in puts thermocouples or voltage inputs less than one volt connect the current signal to the IN and Ref Com terminals When no low voltage sen sors are used the current inputs can be wired to the IN and Com terminals on the TB1 Serial Communications The CAS200 series scanners are factory configured for EIA TIA 232 communications unless otherwise specified when purchased However the communications are jumper selectable so you can switch between EJA TIA 232 and EJA TIA 485 See Changing Communications on page 81 EIA TIA 232 Interface EIA TIA 232 provides communication to the serial port of an IBM PC or compatible computer It is used for single scanner installations where the cable length does not exceed 50 feet 15 m The EIA TIA 232 interface is a standard three wire interface Table 2 3 shows EIA TIA 232 connections for 25 pin and 9 pin connectors or cables that are supplied by the factory If you are using EIA TIA 232 communications with grounded thermocouples use an optical isolator between the scanner and the computer to prevent
68. g Inputs NOTE If the process variable displayed in the software and on the scanner do not agree 1 Verify that the scanner is communicating 2 Ifthe process variable indicated on the scanner dis play is incorrect a Verify that you have selected the correct input type for the affected channels b Verify that sensors are properly connected 3 Ifthe sensors are correctly connected with power on to the heaters check for high common mode voltage a Set a voltmeter to measure volts ac b Connect the negative lead to a good earth ground c One by one check each input for ac voltage by con necting the positive lead on the voltmeter to the positive and negative sensor input connections The process variable should indicate ambient tem perature If it does not contact your supplier to re turn the unit for repair See Returning Your Unit on page 68 Noise in excess of 1Vac should be eliminated by correctly grounding the CAS200 See Wiring the Power Supply on page 19 4 Verify the sensors e For thermocouples remove the thermocouple leads and use a digital voltmeter to measure the resistance between the positive and negative thermocouple leads A value of 2 to 20Q is normal Readings in excess of 200Q indicate a problem with the sensor Watlow Anafaze 73 Chapter 5 Troubleshooting and Reconfiguring CAS200 User s Guide 5 To verify that the scanner hardware is working correctly check any input except
69. g to the low pro cess value For linear inputs the low reading is a percentage of the full scale input range For pulse inputs the low reading is expressed in cycles per second Hz M Manual Mode A selectable mode that has no automatic con trol aspects The operator sets output levels Manual Reset See Reset Milliampere mA One thousandth of an ampere Watlow Anafaze Glossary N No Key Reset A method for resetting the controller s memory for instance after an EPROM change Noise Unwanted electrical signals that usually pro duce signal interference in sensors and sensor circuits See Electromagnetic Interference Noise Suppression The use of components to reduce electrical interference that is caused by making or breaking electrical contact or by inductors Non Linear Through ANAFAZE software the Non Linear field sets the system to linear control or to one of two non linear control options Input 0 for Linear 1 or 2 for non linear O Offset The difference in temperature between the set point and the actual process temperature Off set is the error in the process variable that is typical of proportional only control On Off Control A method of control that turns the output full on until setpoint is reached and then off until the process error exceeds the hysteresis Open Loop A control system with no sensory feedback Operator Menus The menus accessible from the front panel of
70. heck the input scaling parameter settings page 54 e Ifreadings are erratic look for sources of electrical noise SeeNoise Suppression on page 29 e Eliminate possible ground channels SeeConnecting the TB50 to the CAS200 on page 22 e Contact your supplier for further troubleshooting guidance SeeReturning Your Unit on page 68 74 Watlow Anafaze CAS200 User s Guide Chapter 5 Troubleshooting and Reconfiguring Testing Output Devices Connect the solid state relay SSR control terminals to the CAS200 control output and connect a light bulb or other load that can easily be verified to the output terminals on the SSR Put the channel in manual mode and set the output to 100 The ac load should turn on Do not attempt to measure ac voltage at the SSR s output terminals Without a load connected the SSR s output terminals do not turn off This makes it difficult to determine whether the SSR is actually working Measure the voltage across a load or use a load that can be visually verified such as a light bulb Testing the TB18 and TB50 1 Turn on power to the scanner 2 Measure the 5Vdc supply at the TB18 or TB50 The voltage should be 4 75 to 5 25 Vdc a Connect the voltmeter s common lead to the TB18 screw terminal 2 or TB50 screw terminal 3 b Connect the voltmeter s positive lead to the TB18 or TB50 screw terminal 1 Testing Digital Outputs 1 Turn off power to the scanner 2 Disconnect
71. her end Watlow Anafaze 77 Chapter 5 Troubleshooting and Reconfiguring CAS200 User s Guide 78 Ground Channels Software Problems WatView ANASCAN Many PC communications ports have their common wires connected to chassis ground Once connected to the scanner this can provide a path to ground for current from the process that can enter the scanner through a sensor such as a thermocouple This creates a ground channel that can affect communications and other scanner functions To eliminate a ground channel either use an optically isolated communications adapter or take measures to ensure that sensors and all other connections to the scanner are isolated and not conducting current into the unit If the scanner and serial communications connections seem to be working correctly but you are still not getting the result you expect consult the resources you have available for the software program you are using Consult the ANASCAN User s Guide for help with the user interface WatView comes with a context sensitive help explaining operation of the software Context sensitive means that you can press the F1 key to get help related to the part of the program you are using User Written Software NO Key Reset You can request a communications specification from Watlow Anafaze if you want to write your own software Watlow Anafaze will answer technical questions that arise during your software development process For user
72. 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 the pulse input the high reading is in Hertz The full scale range of the linear input type is 10 to 6 0mV where OmV corresponds to 0 and 60mV corresponds to 100 The actual signal is scaled to be within this range with scaling resistors For pulse inputs it is 0 to 2000Hz CHANNEL PROCESS _ UNITS 01 INPUT SCALING HI RDG 100 0 CHANNEL NAME ALARM STATUS Selectable values Depends on the Input Type 99 9 to 999 9 when Input Type is set to Linear 1 to 2000 Hz when Input Type is set to Pulse Input Scaling Low Process Value 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 CHANNEL PROCESS UNITS 01 INPUT SCALING LO PV O F CHANNEL NAME ALARM STATUS The default low PV is determined by the display format you selected refer to Display Format table Watlow Anafaze CAS200 User s Guide Chapter 4 Setup Input Scaling Low Reading Use this menu to enter the input level that corresponds to the low process value you entered in the previous menu For linear inputs the low reading is a percentage of the full scale input range For the pulse input the low reading is in Hertz The full scale range of the linear input t
73. icular ther mal system B Bandwidth A symmetrical region above and below the set point in which proportional control occurs Baud Rate The rate of information transfer in serial com munications measured in bits per second Block Check Character BCC A serial communications error checking method An acceptable method for most appli cations BCC is the default method See CRC Bumpless Transfer A smooth transition from Auto closed loop to Manual open loop operation The control out put does not change during the transfer 105 Glossary C Calibration The comparison of a measuring device an unknown against an equal or better standard Celsius Centigrade Formerly known as Centigrade A temperature scale in which water freezes at 0 C and boils at 100 C at standard atmospheric pressure The formula for conversion to the Fahrenheit scale is F 1 8x C 32 Central Processing Unit CPU The unit of a computing system that includes the circuits controlling the interpretation of instructions and their execution Circuit Any closed path for electrical current A config uration of electrically or electromagnetically connected components or devices Closed Loop A control system that uses a sensor to measure a process variable and makes decisions based on that feedback Cold Junction Connection point between thermocouple met als and the electronic instrument Common Mode Rejection Ratio Th
74. ide The CPU watchdog monitors the microprocessor Its sink output is located on TB50 terminal 6 Do not exceed the 5Vdc 10mAdc rating for the watchdog timer The output is Low On when the microprocessor is operating when it stops operating the output goes High Off which de energizes the SSR The figure below shows the recommended circuit for the watchdog timer output Figure 2 18 Wiring Watchdog Timer Output TB50 5Vdc pin 1 SSR CPU Watchdog pin 6 All digital inputs are transistor transistor logic TTL level inputs referenced to control common and the internal 5V power supply of the CAS200 The eight digital inputs are pulled up to 5Vdc with respect to the scanner common by internal 10kW resistors when not pulled low by an external device In this high state the input is considered off When an input is connected to the scanner common the input is pulled low and considered on Features that use the digital inputs can be user configured to activate when an input is either high or low To insure the inputs are reliably switched use a switching device with the appropriate impedances in the on and off states and do not connect the inputs to external power sources When off the switching device must provide an impedance of at least 11kW in order to ensure the voltage will rise to greater than 3 7Vdc When on the switch must provide not more than 1kW impedance in order to insure the voltage dro
75. in its settings when powered e battery is required to keep the settings in memory only when the scanner is powered down If the scanner displays BATTERY DEAD 1 Verify that the parameters are set as desired 2 Make a record of all scanner settings before continu ing When you power off the scanner in the next step parameter settings may return to their default set tings if the battery is dead 3 Turn the power to the scanner off then on again 4 Ifthe error message returns when power is restored perform a NO key reset See NO Key Reset on page 78 5 Ifthe error is not cleared contact your supplier for fur ther troubleshooting guidelines See Returning Your Unit on page 68 Watlow Anafaze 71 Chapter 5 Troubleshooting and Reconfiguring CAS200 User s Guide HW Ambient Failure The hardware failure ambient alarm indicates that the ambient sensor in the CAS200 is reporting that the temperature around the scanner is outside of the acceptable range of 0 50 C This error can also occur when there is a hardware failure If the scanner displays HW AMBIENT FAILURE 1 Check the ambient air temperature near the scanner Adjust ventilation cooling or heating to ensure that the temperature around the scanner is 0 50 C If the unit is functioning correctly the error will clear automatically when the ambient temperature is within range 2 Ifthe ambient temperature is within range and the er ror persists a Turn
76. ion alarm on Deadband Low Alarm Limit Low process alarm on Low process alarm off Use menus to set the following process alarm parameters for each channel e High and low process alarm type setpoint and digital output e High and low deviation alarm type deviation alarm value and digital output e Alarm deadband e Alarm delay The set points deviation alarm values and deadband all use the same decimal format as the channel s process variable Watlow Anafaze 59 Chapter 4 Setup 60 Alarm Delay NOTE CAS200 User s Guide You can set the CAS200 to delay normal alarm detection and alarm reporting There are two kinds of alarm delay e Startup alarm delay delays detection of process alarms but not failed sensor alarms for all channels for a time period you set in the Setup Global Parameters main menu e Channel alarm delay delays failed sensor alarms and process alarms for one channel until the alarm condition is continuously present for longer than the channel alarm delay time you set Failed sensor alarms are detected at startup They are affected by the channel alarm delay not the startup alarm delay time High Process Alarm Setpoint This menu lets you select the setpoint temperature or other value within the scaled sensor range at which the high process alarm activates The high process alarm activates when the process variable PV goes above the high process setpoint It deactivate
77. l output leads in bundles with 120 240Vac wires Never run input leads in bundles with high power leads If you must use EM relays and you must place them in a panel with CAS200 series equipment use a 0 01 microfarad capacitor rated at 1000Vac or higher in series with a 47Q watt resistor across the 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 130Vac for 120Vac control circuits across the load which limits the peak AC voltage to about 180Vac Watlow Anafaze P N 26 130210 00 You can also place a transorb back to back zener diodes across the digital output which limits the digital output voltage The above steps will eliminate most noise problems If you have further problems or questions please contact Watlow Anafaze The CAS200 scanner provides 35 digital outputs The digital outputs sink current from a load connected to the scanner s internal power supply or from an external power supply referenced to the scanner analog common e Ifyou use an external power supply do not exceed 24 volts e Ifyou tie the external load to ground or if you cannot connect it as shown on the following page then use a solid state relay e Ifyou connect an external supply to earth or equipment ground use solid state relays to avoid ground loop c
78. lems or resistance temperature detector RTD open or short failures Filter Filters are used to handle various electrical noise problems Digital Filter DF A filter that allows the response of a system when inputs change unrealistically or too fast Equivalent to a standard resistor capacitor RC filter Digital Adaptive Filter A filter that rejects high frequency input signal noise noise spikes Heat Cool Output Filter A filter that slows the change in the response of the heat or cool output The output responds to a step change by going to approximately 2 3 its final value within the numbers of scans that are set 107 Glossary Frequency The number of cycles over a specified period of time usually measured in cycles per second Also referred to as Hertz Hz The reciprocal is called the period G Gain The amount of amplification used in an electri cal circuit Gain can also refer to the Propor tional P mode of PID Global Alarm Alarm associated with a global digital output that is cleared directly from a controller or through a user interface Global Digital Outputs A pre selected digital output for each specific alarm that alerts the operator to shut down critical processes when an alarm condition occurs Ground An electrical line with the same electrical potential as the surrounding earth Electrical systems are usually grounded to protect people and equipment from shocks due to
79. malfunc tions Also referred to a safety ground H Hertz Hz Frequency measured in cycles per second High Deviation Alarm Warns that the process is above setpoint but below the high process variable It can be used as either an alarm or control function High Power As defined by ANAFAZE Any voltage above 24Vac or Vde and any current level above 50mAac or mAdc High Process Alarm A signal that is tied to a set maximum value that can be used as either an alarm or control function High Process Variable PV See Process Variable PV CAS200 User s Guide High Reading An input level that corresponds to the high process value For linear inputs the high read ing is a percentage of the full scale input range For pulse inputs the high reading is expressed in cycles per second Hz I Infrared A region of the electromagnetic spectrum with wavelengths ranging from one to 1 000 microns These wavelengths are most suited for radiant heating and infrared noncontact temperature sensing Input Process variable information that is supplied to the instrument Input Scaling The ability to scale input readings readings in percent of full scale to the engineering units of the process variable Input Type The signal type that is connected to an input such as thermocouple RTD linear or process Integral Control D Control action that automatically eliminates offset or droop between setpoint and
80. me Input Units 52 CAS200 User s Guide You can connect a digital pulse signal of up to 2KHz to the scanner s pulse input In this menu you specify the pulse sample period This is the second menu of the Setup Channel Inputs menu for the pulse input channel only Every sample period the number of pulses the scanner receives is divided by the sample time The scanner scales this number and uses it as the pulse channel s process variable CHANNEL PROCESS _UNITS 05 INPUT PULSE SAMPLE TIME 1s CHANNEL NAME ALARM STATUS Selectable values 1 to 20 seconds This menu lets you enter a channel name up to seven characters from this menu If no name is entered the CAS200 will default to the current channel number CHANNEL PROCESS CHANNEL NAME ALARM STATUS Selectable values A Z 0 9 space The Input Units menu lets you choose a three character description of the channel s engineering units Thermocouples can only be F or C e Ifyou have selected a linear or pulse input type you can choose any available character for each character position For example you can use GPM or psi or for a linear input s units CHANNEL PROCESS _UNITS 02 INPUT UNITS F CHANNEL NAME ALARM STATUS The table below shows the character set for input units Character Sets for Units Thermocouple F or C Linear amp Pulse 0 9 A Z space Watlow Anafaze CAS200 User
81. mptoms 70 Resistor Values for CAS200 Current Inputs 83 Resistor Locations for CAS200 Current Inputs 84 Resistor Values for CAS200 Voltage Inputs 84 Resistor Locations for CAS200 Voltage Inputs 85 Linear Scaling Examples Input Readings 88 Scaling Values 88 Input Readings and Calculations 89 Scaling Values 89 Scaling Values 90 Specifications Agency Approvals Compliance 91 Environmental Specifications 92 Physical Dimensions 92 Processor with Straight SCSI 93 Processor with Right Angle SCSI 93 Processor Connections 94 TB50 Physical Dimensions 95 TB50 Connections 95 TB50 with Straight SCSI 96 Table 7 10 TB50 with Right Angle SCSI 97 Table 7 11 Analog Inputs 98 Table 7 12 Pulse Inputs 99 Table 7 13 Thermocouple Range and Resolution 99 Watlow Anafaze List of Tables Table 7 14 Table 7 15 Table 7 16 Table 7 17 Table 7 18 Table 7 19 Table 7 20 Table 7 21 Table 7 22 Table 7 23 Table 7 24 Table 7 25 Table 7 26 Table 7 27 CAS200 User s Guide Input Resistance for Voltage Inputs 100 Digital Inputs 100 Digital Outputs Control Alarm 101 CPU Watchdog Output 101 5Vdc Output Power to Operate Solid State Relays 102 Reference Voltage Output Power to Operate Bridge Circuit Sensors 102 Processor Serial Interface 102 Processor Power Requirements 102 Power Supply Environmental Specifications 103 Power Supply Agency Approvals Compliance 103 Power Sup
82. must work properly in a computer supervised system The scanner The computer and its EIA TIA 232 or EIA TIA 485 serial interface The EIA TIA 232 or EIA TIA 485 communication lines The computer software For troubleshooting disconnect the communications line from the computer and follow the troubleshooting steps in the first section of this chapter The next few sections explain troubleshooting for the other elements of computer supervised systems Computer Problems If you are having computer or serial interface problems check the following 76 Check your software manual and make sure your computer meets the software and system requirements Check the communications interface cables and connections Make sure the serial interface is set according to the manufacturer s instructions Watlow Anafaze CAS200 User s Guide Communications Chapter 5 Troubleshooting and Reconfiguring To test an EIA TIA 232 interface purchase an EIA TIA 232 tester with LED indicators Attach the tester between the scanner and the computer When the computer sends data to the scanner the tester s TX LED should blink When the computer receives data from the scanner the RX LED should blink You can also connect an oscilloscope to the transmit or receive line to see whether data is being sent or received If the serial port does not appear to be working the software setup may need to be modified or the hardware may need to b
83. nner from the front panel or from a local or remote computer Watlow Anafaze offers WatView a Windows compatible Human Machine Interface HMI software package that includes data logging and graphing features in addition to process monitoring and parameter setup screens Multiple Job Storage Store up to eight jobs in protected memory and access them locally by entering a single job number or remotely via digital inputs Each job is a set of alarm conditions Watlow Anafaze 3 Chapter 1 System Overview System Diagram Parts List CAS200 User s Guide Pulse Counter Input Use the pulse counter input for precise monitoring of motor or belt speed The illustration below shows how the parts of the CAS200 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 if you have problems with your shipment or if any CAS200 components are missing or damaged Figure 1 1 System Components a SCSI Cable TB50 Digital inputs and outputs and pulse input 5 CAS200 Scanner Mounting Kit TB50 Terminal Board 50 Pin SCSI Cable DC Power Supply Watlow Anafaze CAS200 User s Guide Chapter 1 System Overview Mounting Scanner Components Install the scanner in a location free from excessive heat gt 50 C dust and unauthorized handling Electromagnetic and radio frequency interference can induce noise on sensor
84. nt Panel Display 36 ng and Reconfiguring 67 Figure 5 1 Removal of Electronics Assembly from Case 80 Figure 5 2 Screws Locations on PC Board 80 Figure 5 3 EPROM Location 81 Figure 5 4 Remove EPROM 81 Figure 5 5 Jumper Configurations 81 Figure 5 6 CAS200 Input Circuit 83 Watlow Anafaze vii List of Figures 7 Specifications 91 viii Figure 7 1 CAS200 Processor Module Dimensions 92 Figure 7 2 CAS200 Clearances with Straight SCSI Cable 93 Figure 7 3 CAS200 Clearances with Right Angle SCSI Cable 93 Figure 7 4 TB50 Dimensions 95 Figure 7 5 TB50 Dimensions with Straight SCSI Cable 96 Figure 7 6 TB50 Dimensions with Right Angle SCSI Cable 97 Figure 7 7 Power Supply Dimensions Bottom View 104 Watlow Anafaze CAS200 User s Guide Es Installation Table 2 1 Table 2 2 Table 2 3 Table 2 4 Table 2 5 Table 2 6 Table 5 1 Table 5 2 Table 5 3 Table 5 4 Table 5 5 Table 5 6 Table 6 1 Table 6 2 Table 6 3 Table 6 4 Table 6 5 Table 7 1 Table 7 2 Table 7 3 Table 7 4 Table 7 5 Table 7 6 Table 7 7 Table 7 8 Table 7 9 List of Tables Cable Recommendations 16 Power Connections 20 EIA TIA 232 Connections 25 RTS CTS and DSR DTR Pins in DB 9 and DB 25 Connectors 26 TB50 Connections for CAS200 33 TB18 Connections 34 Troubleshooting and Reconfiguring Hardware Error Messages 69 Other Sy
85. o Crossing DZC A form of digital output control Similar to burst fire E Earth Ground A metal rod usually copper that provides an electrical path to the earth to prevent or reduce the risk of electrical shock Electrical Noise See Noise Electromagnetic Interference EMI Electrical and magnetic noise imposed on a system There are many possible causes such as switching ac power on inside the sine wave EMI can interfere with the operation of con trols and other devices Electrical Mechanical Relays See Relay electromechanical Emissivity The ratio of radiation emitted from a surface compared to radiation emitted from a black body at the same temperature Watlow Anafaze Glossary Engineering Units Selectable units of measure such as degrees Celsius and Fahrenheit pounds per square inch newtons per meter gallons per minute liters per minute cubic feet per minute or cubic meters per minute EPROM Erasable Programmable Read Only Memory inside the controller Error The difference between the correct or desired value and the actual value F Fahrenheit The temperature scale that sets the freezing point of water at 32 F and its boiling point at 212 F at standard atmospheric pressure The formula for conversion to Celsius is C 5 9 F 32 F Failed Sensor Alarm Warns that an input sensor no longer produces a valid signal For example when there are thermocouple breaks infrared prob
86. omatic Reset The integral function of a PI or PID temperature controller that adjusts the process temperature to the set point after the system stabilizes The inverse of integral Automatic Power Reset A feature in latching limit controls that Resistance Opposition to the flow of electric current mea sured in ohms 110 Watlow Anafaze CAS200 User s Guide Resistance Temperature Detector RTD A sensor that uses the resistance temperature characteristic to measure temperature There are two basic types of RTDs the wire RTD which is usually made of platinum and the thermistor which is made of a semiconductor material The wire RTD is a positive tempera ture coefficient sensor only while the ther mistor can have either a negative or positive temperature coefficient Reverse Action An output control action in which an increase in the process variable causes a decrease in the output Heating applications usually use reverse action RTD See Resistance Temperature Detector S Serial Communications A method of transmitting information between devices by sending all bits serially over a sin gle communication channel EIA TIA 232 An Electronics Industries of America EIA standard for interface between data terminal equipment and data communi cations equipment for serial binary data inter change This is usually for communications over a short distance 50 feet or less and to a single device EIA T
87. ommunicate with more than one CAS200 series scanner on a scanner network or to use communication cable lengths greater than 50 feet 15 m from PC to scanner you must use EIA TIA 485 communications When using EIA TIA 485 communications you must attach an optically isolated 232 to 485 converter to the computer Figure 2 13 and Figure 2 15 show the recommended system wiring To avoid ground loops use an optically isolated 232 to 485 converter between the computer and the EIA TIA 485 network Watlow Anafaze CAS200 User s Guide Chapter 2 Installation Figure 2 14 EIA TIA 485 Wiring Personal Computer 232 to 485 Converter First CAS200 Last CAS200 JU1 JU1 eA eA TXA TDA TX RXA 25 el hra 25 Ptg TXB TDB TX RXB 23 RXB 23 RXA RDA RX TXA 26 TXA 26 RXB RDB RX TXB 24 TXB 24 Do not connect shield to CAS200 Cable Recommendations Watlow Anafaze recommends Belden 9843 cable or its equivalent This cable includes three 24 AWG 0 2 mm shielded twisted pairs It should carry signals of up to 19200 baud with acceptable losses for up to 4000 feet 1220 m EIA TIA 485 Network Connections Watlow Anafaze Watlow Anafaze recommends that you use a single daisy chain configuration rather than spurs Run a twisted pair cable from the host or converter to the first CAS200 and from that point run a second cable to the next CAS200 and so on See Figure
88. ommunications cable used Values are typically 150 to 200Q The receive lines at the converter or host device should be terminated in the converter the connector to the host device or the device itself Typically the converter documentation provides instructions for termination Use a terminating resistor on the receive lines on the last scanner on the 485 line Set jumper JU1 in position B to connect a 200Q resistor across the receive lines See Changing Communications on page 81 Watlow Anafaze CAS200 User s Guide Chapter 2 Installation EIA TIA 485 Converters and Laptop Computers For a 232 to 485 converter to optically isolate the computer from the 485 network the 232 and 485 sides must be powered independently Many 232 to 485 converters can be powered by the computer s communications port Some computers laptops in particular do not automatically provide the appropriate voltages These computer converter combinations can usually be used by connecting an external power supply to the 232 side of the converter Not all converters have power inputs for the 232 side however Wiring Digital I O Noise Suppression This section describes how to wire and configure the alarm outputs for the CAS200 series scanner All digital outputs are sink outputs referenced to the CAS200 common These outputs are Low pulled to common when they are On All digital inputs are Transistor Transistor Logic TTL level inputs referenc
89. or measures psi in tenths so the DISP FORMAT is set to 999 9 TO 3000 0 Table 6 1 Input Readings Process Sensor Variable Ihb t Displayed P Reading Percent of Full Scale FS 50 0 psi 20mA 100 FS 0 0 psi 4mA 100 x 4mA 20mA 20 FS The scaling values set up in the SETUP LOOP INPUT menu are shown in Table 9 2 Table 6 2 Scaling Values Parameter Prompt Value High Process Variable High Sensor Reading Low Process Variable Low Sensor Reading 88 Watlow Anafaze HIGH PV 50 0 psi HIGH RDG 100 0 FS LO PV 0 0 psi LO RDG 20 0 FS CAS200 User s Guide Chapter 6 Linear Scaling Examples Example 2 0 5Vdc Sensor Situation A flow sensor connected to the scanner measures the flow in a pipe The sensor generates a 0 5V signal The sensor s output depends on its installation Independent calibration measurements of the flow in the pipe indicate that the sensor generates 0 5V at three gallons per minute GPM and 4 75V at 65 GPM The calibration instruments are accurate to within one gallon per minute Setup The sensor is connected to a loop input set up with a resistor voltage divider network to produce 60mV at 5V The INPUT TYPE for the loop is set to LINEAR The calibrating instrument is precise to 1 GPM so the DISP FORMAT is set to 999 TO 3000 This table shows the input readings and percentage calculation from the 60mV full scale input
90. ose in this menu controls the number of jobs you can select remotely CHANNEL PROCESS __UNITS OB SELECT DIG INPUTS NONE CHANNEL NAME ALARM STATUS Below is the truth table that tells you which input states select which jobs Digital Digital Digital Input 3 Input 2 Input 1 yop F F F 1 F F T 2 F T F 3 F T T 4 T F F 5 T F T 6 T T F 7 T T T 8 45 Chapter 4 Setup CAS200 User s Guide Selectable values 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 Job Select Input Polarity This menu lets you set the polarity of the digital inputs used for job selection You can set the Active state to closed low or open high CHANNEL PROCESS UNITS OB SEL DIG INS ACTIVE LO CHANNEL NAME ALARM STATUS Selectable values High or Low Startup Alarm Delay Use this menu to set a startup delay for process and deviation alarms for all channels The scanner does not report these alarm conditions for the specified number of minutes after the scanner powers up The scanner will always report failed sensor alarms no matter what startup delay you set CHANNEL PROCESS _ UNITS STARTUP ALARM DELAY 0 MINS CHANNEL NAME ALARM STATUS Selectable values 0 60 minutes 46 Watlow Anafaze CAS200 User s Guid
91. ovide backup power UPS alarms reoccur or alarms fail to be indi Analog reference voltage is Disconnect any wiring from the 5V Ref cated overloaded connection on TB1 Check the scanner front panel for a hard Hardware failure ware alarm See System Alarms on page 69 Scanner does not Corrupt or incorrect values in Perform a NO key reset See NO Key behave as expected RAM Reset on page 78 70 Watlow Anafaze CAS200 User s Guide Chapter 5 Troubleshooting and Reconfiguring Corrective and Diagnostic Procedures Low Power Battery Dead NOTE The following sections detail procedures you may use to diagnose and correct problems with the scanner If the scanner displays LOW POWER or the display is not lit 1 2 Th Turn the power to the scanner off then on again If the error message returns check that the power supplied to the scanner is at least 12 0Vdc 1 A See Wiring the Power Supply on page 19 If the error message returns again make a record of the settings if possible using software Then perform a NO key reset see NO Key Reset on page 78 If the error is not cleared contact your supplier for fur ther troubleshooting guidance See Returning Your Unit on page 68 e dead battery alarm indicates that the CAS200 battery is not functioning correctly or has low power or no power Parameter settings may return to the default settings Th Th e scanner will reta
92. ply Physical Specifications 103 Power Supply with Mounting Bracket 103 Power Supply Inputs 104 Power Supply Outputs 104 Watlow Anafaze System Overview Manual Contents Watlow Anafaze This manual describes how to install setup and operate a CAS200 Included are six chapters and a glossary of terms Each chapter covers a different aspect of the alarm scanner and may apply to different users The following describes the chapters and their purpose Chapter 1 System Overview provides a component list and summary of features for the CAS200 series alarm scanners Chapter 2 Installation provides detailed instructions on installing the CAS200 and its peripherals Chapter 3 Using the CAS200 provides an overview of operator displays used for system monitoring and job selection Chapter 4 Setup provides detailed descriptions of all menus and parameters for scanner setup Chapter 5 Troubleshooting and Reconfiguration provides some basic guidelines for solving operational problems and provides procedures for changing some of the hardware options e g installing special input resistors and changing EIA TIA 232 to EIA TIA 485 Chapter 6 Linear Scaling Examples provides three examples where linear scaling is used Chapter 7 Specifications lists detailed specifications of the scanner and optional components Chapter 1 System Overview Getting Started Safety symbols A WARNING A CAUTION NOTE CAS2
93. product In addition we have provided recommendations that will allow you to safely install and maintain this scanner In any application failures can occur These failures can result in full control output 100 power or the occurrence of other output failures which can cause damage to the scanner or to the equipment or process connected to the scanner Therefore always follow good engineering practices electrical codes and insurance regulations when installing and operating this equipment External Safety Devices A WARNING Watlow Anafaze External safety devices should be used to prevent potentially dangerous and unsafe conditions upon equipment failure Always assume that this device can fail with outputs full On or full Off by the occurrence of an unexpected external condition Always install high or low temperature protection in installations where an overtemperature or undertemperature fault will present a potential hazard Failure to install external protection devices where hazards exist can result in damage to equipment property or human life Chapter 2 Installation Mounting A WARNING Location CAS200 User s Guide We recommend you mount the scanner in a panel not more than 0 2 inches thick To reduce the risk of fire or electric shock install the CAS200 in a controlled environment relatively free of contaminants Install the scanner in a location free from excessive gt 5
94. ps below 1 3Vdc To install a switch as a digital input connect one lead to the common terminal on the TB50 terminals 3 and 4 Connect the other lead to the desired digital input terminal on the TB50 terminals 43 50 Digital inputs are used to activate various functions See Chapter 4 Setup on page 41 Watlow Anafaze CAS200 User s Guide Chapter 2 Installation Figure 2 19 Wiring Digital Inputs TB50 Digital Input Input Device Control Com Watlow Anafaze Table 2 5 TB50 Connections for CAS200 Terminal Function Terminal Function 1 5Vdc 2 5Vdc 3 CTRL COM 4 CTRL COM 5 Not Used 6 Watchdog Timer 7 Pulse Input 8 Global Alarm 9 DIG output 1 10 DIG output 34 11 DIG output 2 12 DIG output 33 13 DIG output 3 14 DIG output 32 15 DIG output 4 16 DIG output 31 17 DIG output 5 18 DIG output 30 19 DIG output 6 20 DIG output 29 21 DIG output 7 22 DIG output 28 23 DIG output 8 24 DIG output 27 25 DIG output 9 26 DIG output 26 27 DIG output 10 28 DIG output 25 29 DIG output 11 30 DIG output 24 31 DIG output 12 32 DIG output 23 33 DIG output 13 34 DIG output 22 35 DIG output 14 36 DIG output 21 37 DIG output 15 38 DIG output 20 39 DIG output 16 40 DIG output 19 41 DIG output 17 42 DIG output 18 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 aries A Alarm 33 Chapter 2 Installation 34 CAS200 User s Guide Tabl
95. quired to move one coulomb of charge between two points in a circuit consuming one joule of energy In other words one volt V is equal to one ampere of current I flowing through one ohm of resistance R or V IR Z Zero Cross Action that provides output switching only at or near the zero voltage crossing points of the ac sine wave 112 Watlow Anafaze CAS200 User s Guide
96. r fallen below a certain range around the setpoint For example an alarm may indicate that a process is too hot or too cold See also Deviation Alarm Failed Sensor Alarm Global Alarm High Deviation Alarm High Process Alarm Loop Alarm Low Deviation Alarm Low Process Alarm Alarm Delay The lag time before an alarm is activated Alternating Current AC An electric current that reverses at regular intervals and alternates positive and negative values Ambient Temperature The temperature of the air or other medium that surrounds the components of a thermal system Watlow Anafaze American Wire Gauge AWG A standard of the dimensional characteristics of wire used to conduct electrical current or signals AWG is identical to the Brown and Sharpe B amp S wire gauge Ammeter An instrument that measures the magnitude of an electric current Ampere Amp A unit that defines the rate of flow of electric ity current in the circuit Units are one cou lomb 6 25 x 1018 electrons per second Analog Output A continuously variable signal that is used to represent a value such as the process value or setpoint value Typical hardware configura tions are 0 20mA 4 20mA or 0 5Vdc Automatic Mode A feature that allows the controller to set PID control outputs in response to the Process Vari able PV and the setpoint Autotune A feature that automatically sets temperature control PID values to match a part
97. rface Parameter Description Type EIA TIA 232 3 wire or EIA TIA 485 4 wire Isolation None Baud Rate 2400 9600 or 19200 user selectable Error Check BCC or CRC user selectable Number of Scanners 1 with EIA TIA 232 communications up to 32 with ElA TIA 485 communications depending upon protocol Form of ANSI X3 28 1976 D1 F1 compatible with Protocol Allen Bradley PLC full duplex or Modbus RTU Table 7 21 Processor Power Requirements Parameter Description Voltage 15 24Vdc 3Vdc Maximum Current 1A 102 Watlow Anafaze CAS200 User s Guide CAS200 Power Supply Watlow Anafaze Chapter 7 Specifications 103 Chapter 7 Specifications CAS200 User s Guide 104 Watlow Anafaze Glossary A AC See Alternating Current AC Line Frequency The frequency of the AC power line measured in Hertz Hz usually 50 or 60Hz Accuracy Closeness between the value indicated by a measuring instrument and a physical constant or known standards Action The response of an output when the process variable is changed See also Direct action Reverse action Address A numerical identifier for a controller when used in computer communications Alarm A signal that indicates that the process has exceeded o
98. roper techniques tools or materials can result in dam age to the scanner that is not covered by the war ranty CAS200 Input Circuit The CAS200 can accept single ended thermocouple mVdc Vdc and mA dc inputs Unless ordered with special inputs the scanner accepts only signals within the standard range 10 to 60 mVdc To accommodate other signals the input circuit must be modified When configured for thermocouple inputs 0 Q resistors are installed in all RC locations To accommodate milliamp current signals or voltage signals outside the standard range resistors are added or replaced to scale the signals to the standard range These resistor can be installed by Watlow Anafaze or by a qualified electronics technician using scaling resistors supplied by Watlow Anafaze Watlow Anafaze CAS200 User s Guide Chapter 5 Troubleshooting and Reconfiguring Figure 5 6 shows the schematic for one single ended sensor input to the CAS200 See CAS200 Current Inputs on page 83 and CAS200 Voltage Inputs on page 84 for specific instructions and resistor values for voltage and current inputs Figure 5 6 CAS200 Input Circuit Voltage only To CAS200 IN Measurement gee RC Circuitry npu Terminals RD Voltage and Current Com e CAS200 Current Inputs For each current input on a CAS200 scanner you must install one resistor The value of the resistor must be correct for the expected input range Install the resistor in the listed
99. s when the PV goes below the high process setpoint minus the deadband value if you have set a deadband value CHANNEL PROCESS __UNITS 01 HI PROC ALARM SETPT 1000 F CHANNEL NAME ALARM STATUS Selectable values Any point within the scaled sensor range High Process Alarm Type This menu lets you turn off the high process alarm or set it to one of the alarm functions See the previous description for an explanation of these choices CHANNEL PROCESS UNITS 01 HI PROC ALARM YPE OFF CHANNEL NAME ALARM STATUS Selectable values Off Latched Unlatched Watlow Anafaze CAS200 User s Guide Chapter 4 Setup High Process Alarm Output Number This menu lets you choose the digital output that activates when the channel isin high process alarm You can use this output to activate a second alarm horn or buzzer CHANNEL PROCESS _ UNITS 01 HI PROC ALARM OUTPUT NONE CHANNEL NAME ALARM STATUS Selectable values 1 to 34 None NOTE All digital outputs are combined Therefore you can assign more than one alarm to the same out put number and that output will be On if any of those alarms is On Deviation Alarm Value This menu lets you set the deviation bandwidth a positive and negative alarm point relative to the setpoint If the setpoint changes the alarm points also change You can assign a separate digital output to the high and low deviation alarm set points CHANNEL PROCESS __UNITS 0
100. ser s Guide Chapter 7 Specifications Table 7 4 Processor with Straight SCSI Length 9 6 inches 244 mm Width 3 78 inches 96 mm Height 1 96 inches 50 mm Figure 7 2 CAS200 Clearances with Straight SCSI Cable 1 0 in 7 0 in 1 6 in 25 mm 178 mm 41 mm ii gt lt i gt lt p ih 0 5 in 13 mm 1 96 in i 50 mm gt A i AD Table 7 5 Processor with Right Angle SCSI Length 8 6 inches 218mm Width 3 78 inches 96 mm Height 1 96 inches 50 mm Figure 7 3 CAS200 Clearances with Right Angle SCSI Cable 1 0 in 7 0 in 0 60 in 25 mm 178 mm 15 mm pe 4 lt gt SDF 0 5 in 13 mm e eee 1 96 in J 50 mm e ml Watlow Anafaze 93 Chapter 7 Specifications 94 Table 7 6 CAS200 User s Guide Processor Connections Power Terminals TB2 Captive screw cage clamp Power Wire Gauge TB2 22 to 18 AWG 0 5 to 0 75 mm Power Terminal Torque TB2 4 4 to 5 3 in lb 0 5 to 0 6 Nm Sensor Terminals TB1 Captive screw cage clamp Sensor Wire Gauge TB1 Thermocouples 20 AWG 0 5 mm Linear 22 to 20 AWG 0 5 mm Communications 24 AWG 0 2 mm Sensor Terminal Torque TB1 4 4 to 5 3 in lb 0 5 to 0
101. tion Alarms When a process or deviation alarm occurs the scanner switches to the single channel display for the channel with the alarm and displays the alarm code on the screen Software such as ANASCAN or WatView displays a message on the alarm screen and logs the alarm in the event log See Alarms on page 40 for a description of alarm behavior and how to respond to alarms Watlow Anafaze CAS200 User s Guide Chapter 5 Troubleshooting and Reconfiguring Thermocouple Break Alarm System Alarms When a thermocouple break alarm occurs the scanner switches to the single channel display for the channel with the alarm and displays an alarm code on the screen ANASCAN or WatView displays a message on the alarm screen and logs the alarm in the event log A failed sensor alarm clears once it has been acknowledged and the sensor is repaired If the scanner detects a hardware problem it displays a message The message persists until the condition is corrected Table 5 1 Hardware Error Messages Message Possible Cause Recommended Action LOW POWER Power supply failed See Low Power on page 71 BATTERY DEAD RAM battery is dead See Battery Dead on page 71 HW FAILURE AMBIENT Cold junction is too hot See HW Gain or Offset Failure Hardware failed due to exces on page 72 sive voltage on inputs HW FAILURE GAIN Hardware failed due to exces See HW Gain or Offset Failure sive voltage on inputs
102. tion in the Yes Aborts editing and Stores data or menu choices CAS200 mpts Selects a menu returns to a previous menu amp advances to the next menu Answers Yes to Yes No pro Starts scanning mode Increases a number or choice if pressed twice Change Setpoint Skips a menu Used for changing setpoints Answers No to Yes No prompts Decreases a number or choice you are editing Front Panel Keys Yes Press Yes to e Select a menu e Answer Yes to Yes No questions e Increase a number or choice you re editing No Press No to e Skip a menu you don t want to edit when the prompt is blinking e Answer No to Yes No prompts e Decrease a number or choice when editing e Perform a NO key reset to clear the memory 36 Watlow Anafaze CAS200 User s Guide WARNING A ALARM ACK ALARM RESET Chapter 3 Using the CAS200 The NO key reset clears the system s memory and reinitializes the CAS200 factory defaults To do a Manual System Reset power down the CAS200 press and hold the No key during power up This is required during installation after changing the EPROM or when troubleshooting Back The Back key works like an escape key Press it to e Abort editing e Return to a previous menu e Switch between single channel and job control displays Enter e Press the Enter key to e Store data or menu choices after editing and go to the next menu e Start
103. tivates on alarm and deactivates when channel is in a Non Unlatched Alarming state The ALARM ACK key must be pressed to shut off the global alarm e 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 below Watlow Anafaze CAS200 User s Guide Chapter 4 Setup e Any digital output can be assigned 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 Digital Output Polarity On Alarm parameter setting e 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 When the scanner powers up or the setpoint changes deviation alarms do not activate until the process goes inside the deviation alarm band preventing deviation alarms during a cold start High and low process alarms are always enabled High process alarm on High process alarm off High Alarm Limit ee ee ee Be Ne Poh fo HE Rent Pa OE Deadband yen Ly High deviation alarm on P D SP Deviation 7 Deadband High deviation alarm off Set Point Ee i ff ow deviation alarm o a Deadband SP Deviation Low deviat
104. urrents Ground loop currents may degrade analog measurements in the scanner The outputs conduct current when they are LOW or ON The maximum current sink capability is 6 0mA at 24Vdc They cannot source current to a load Watlow Anafaze CAS200 User s Guide Chapter 2 Installation Figure 2 16 Wiring Digital Outputs TB50 External 5Vde Power Supply A Load Digital Output 1 Digital Output 2 Using Internal Power Supply Do not connect to earth Ta ground or equipment ground Control Common Digital Output 1 Digital Output 2 Using External Power Supply Alarm Output Connections Typical alarm outputs use external optically isolated solid state relays SSRs The SSRs use a 3 to 32Vdc input for control and you can size them to switch up to 100A at 480Vac For larger currents you can use SCR power controls or optically isolated SSRs to drive contactors NOTE Alarm outputs are SINK outputs They are Low when the output is On Connect them to the nega tive side of Solid State Relays The figure below shows sample alarm output connections Figure 2 17 Wiring Alarm Output Connections TB50 SSR SSR SSR a ap Alarm Output 1 Alarm Output 2 D Alarm Output 3 5Vdc Watlow Anafaze 31 Chapter 2 Installation 32 CPU Watchdog Digital Inputs CAS200 User s Gu
105. ve sensor leads are tied to the analog common That means there is no sensor to sensor isolation Proper grounding is critical for this unit Take these precautions e Use all ungrounded or all well grounded thermocouples not a mix e Ifusing a mixture of thermocouples or low voltage inputs lt 500 mV and current inputs connect the negative leads of the current transmitters to terminal 17 Ref Com on TB1 e Ifusing voltage transmitters use only sourcing models or configuration Sinking configurations will not work e Isolate the scanner s communication port if used by using an optically isolated 232 to 485 converter Personal Computers and Ground Loops Many PC communications ports connect the communications common to chassis ground When such a PC is connected to the scanner this can provide a path to ground for current from the process that can enter the scanner through a sensor such as a thermocouple This creates a ground loop that can affect communications and other scanner functions To eliminate a ground loop either use an optically isolated communications adapter or take measures to ensure that sensors and all other connections to the scanner are isolated and not conducting current into the unit Watlow Anafaze CAS200 User s Guide Chapter 2 Installation Power Connections Figure 2 7 CAS200 Series Scanner TB2 S TB1 Se AAAA e
106. west value of the process range Proportional P Output effort proportional to the error from setpoint For example if the proportional band is 20 and the process is 10 below the setpoint the heat proportioned effort is 50 The lower the PB value the higher the gain Proportional Band PB A range in which the proportioning function of the control is active Expressed in units degrees or percent of span See PID Proportional Control A control using only the P proportional value of PID control CAS200 User s Guide Pulse Input Digital pulse signals from devices such as optical encoders R Ramp A programmed increase in the temperature of a setpoint system Range The area between two limits in which a quan tity or value is measured It is usually described in terms of lower and upper limits Recipe See Job Reflection Compensation Mode A control feature that automatically corrects the reading from a sensor Relay A switching device Electromechanical Relay A power switching device that completes or interrupts a circuit by physically moving electrical contacts into contact with each other Not recommended for PID control Solid State Relay SSR A switching device with no moving parts that completes or interrupts a circuit electrically Reset Control action that automatically eliminates offset or droop between setpoint and actual process temperature See also Integral Aut
107. wiring Select locations for the CAS 200 and TB50 such that wiring can be routed clear of sources of interference such as high voltage wires power switching devices and motors A WARNING To reduce the risk of fire or electric shock install CAS200 in a controlled environment relatively free of contaminants Safety Watlow Anafaze has made efforts to ensure the reliability and safety of the CAS200 and to recommend safe uses in systems applications Note that in any application failures can occur 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 CAS200 can fail or that other unexpected conditions can occur Install high or low temperature protection in systems where an overtemperature or undertemperature fault condition could 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 personnel For additional process safety program a computer or other host device to automatically reload your desired operating parameters after a power failure However this safety feature does not eliminate the need for other external independent safety devices in dangerous conditions A WARNING The CAS200 should never be used as a safety shutdown device It should only
108. written Windows interfaces use WatConnect the Modbus RTU dynamic link library software from Watlow Performing a NO key reset returns all scanner settings to their defaults All recipes are also cleared To perform a NO key reset 1 Make a record of the scanner s settings 2 Turn off power to the unit 3 Press and hold the NO key on the keypad 4 Turn on power to the scanner still holding the NO key 5 When prompted RESET WITH DEFAULTS release the NO key and press the YES key Watlow Anafaze CAS200 User s Guide 7 Chapter 5 Troubleshooting and Reconfiguring If you do not see the RESET WITH DEFAULTS prompt or do not get a chance to press YES repeat the proce dure Restore the scanner settings If you have a stand alone system there is no way to recover your original parameters If you have a computer supervised system with WatView or ANASCAN a copy of your parameters can be saved to a job file Replacing the EPROM Replacing the EPROM involves minor mechanical disassembly and reassembly of the scanner You will need a Phillips screwdriver and a small flathead screwdriver A CAUTION NOTE The EPROM and other components are sensitive to damage from electrostatic discharge ESD To prevent ESD damage use an ESD wrist strap or other antistatic device Replacing the EPROM with another version re sults in full erasure of RAM Make a record of all parameters before changing the EPROM
109. ype is 10 to 6 0mV where OmV corresponds to 0 and 60mV corresponds to 100 The actual signal is scaled to be within this range with scaling resistors For pulse inputs it is 0 to 2000Hz CHANNEL PROCESS UNITS 01 INPUT SCALING LO RDG 0 0 FS CHANNEL NAME ALARM STATUS Selectable values Depends on the Input Type 99 9 to 999 9 when Input Type is set to Linear 1 to 2000Hz when Input Type is set to Pulse Input Filter The CAS200 has two different types of input filter e A noise rejection filter that rejects high frequency input signal noise This filter keeps a trend log of input readings Ifa reading is outside the filter s acceptance band and later readings are within the acceptance band the CAS200 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 CAS200 accepts the anomalous reading and calculates a new acceptance band You cannot adjust this input filter e 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 CHANNEL PROCESS _ UNITS 01 INPUT FILTER
110. ze Contents Contents Wiring the Power Supply 19 Testing Power to the Scanner 21 Connecting the TB50 to the CAS200 22 Input Wiring 22 Sensor Connection 22 Thermocouple Connections 23 Voltage Input Connections 24 Current Input Connections 24 Serial Communications 25 EIA TIA 232 Interface 25 EIA TIA 485 Interface 26 EIA TIA 485 Converters and Laptop Computers 29 Wiring Digital I O 29 Noise Suppression 29 Digital Outputs 30 Alarm Output Connections 31 CPU Watchdog 32 Digital Inputs 32 Using the CAS200 35 Introduction 35 Front Panel 36 Front Panel Keys 36 Single Channel Display 38 Job Display 38 Change Setpoint 39 Alarms 40 Setup 41 CAS200 Menus 41 How to Enter the Setup Menus 41 How to Edit a Menu 42 Setup Global Parameters Menu 44 Load a Job 44 Save Setup to Job 45 Job Select Inputs 45 ii Watlow Anafaze CAS200 User s Guide CAS200 User s Guide Contents Job Select Input Polarity 46 Startup Alarm Delay 46 Keyboard Lock Status 47 Scanner Address 47 Communications Baud Rate 47 Communications Protocol 48 Communications Error Checking 48 AC Line Frequency 49 Digital Output Polarity 49 External Alarm Acknowledge Input Active 49 EPROM Information 50 Setup Channel Inputs 50 Input Type 50 Display Resolution 51 Pulse Sample Time 52 Channel Name 52 Input Units 52 Input Reading Offset 53 Linear Scaling Menus 54 Display Format 55 High Process Value 56 Input Scaling High Reading 56 Input Scaling

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