Home

Watlow Electric ANAFAZE SYSTEM 32 User`s guide

1. 27 Connecting Power Common to AIM TB 28 Testing Connections etate toes eene ral 28 Testing Your Systeme 30 MLS AIM Test ete eie atte 30 REB PCS Aces a 30 PID Output Test 30 31 PID Control and Alarm Output 33 KB 34 AIM Communications Failure esee 35 Inputs Ged tae hts 36 Input Wiring 37 Input Sealine eb 37 TBpUGS Pia Pao fiir poor 39 RED 40 LOS en Eu Vetro EN RIO eS RUNS 41 Voltage e o ee eui a uie adn estre eda 41 Unused 41 COMMMUMICAUONS fc 42 Changing Communications eee 42 Connecting RS 232 Communications 42 Connecting RS 485 Communications 43 Recommended Wire Gauges eene 45 Using the MLS 47 Front Panels petentis Das 48 Front Panel detienen en added 49 DISDIAVS 51 Viewing Several Loops Bar Graph Display 51 Viewing One Loop Single Loop Display 52 Interpreting Alarm Display esee
2. esses 91 High Process Alarm 91 High Process Alarm Output 91 Deviation Band Value ceni inte para 92 High Deviation Alarm 92 High Deviation Alarm Output Number 93 Low Deviation Alarm 93 Low Deviation Alarm Output Number 93 Low Process Alarm 94 Low Process Alarm Types eese ntes edi ey a deas 94 Low Process Alarm Output Number 94 Alarm Deadband ies teet et 95 Loop Alarm Delay iude eques utes e tot edere roce ae 95 Manual VO 96 Digital Input cie tete tieu 97 Test 97 Test Dip trae eee 97 Toggle Digital 98 Tuning and Control eee eee eere eene 99 Introduction 2 2 2 5 eke e RU RE 99 Control MOG eS coca Mete 99 On Off Control etse 99 Proportional Control eene 100 Proportional and Integral Control 101 Proportional Integral and Derivative Control 101 Digital Output Control Forms
3. A multimeter e A phone connector crimping tool made of metal optional Watlow Anafaze provides all the cabling for the Modular Loop System If you have special cabling requirements and you make your own RJ12 cable use a metal crimping tool for the connectors A metal tool makes better connections than a plastic tool The following additional hardware is also shipped to you e Four 6 screws for mounting the AIM TB 10 screws for mounting the optional MLS Power Supply MLS User s Guide 17 Installation Mounting the MLS PM This section tells you how to mount the MLS PM Sy NOTE Mount the MLS PM before you mount any other component of the MLS The processor module s placement affects placement and wiring for the MLS AIM MLS PS etc Mounting Environment Install the MLS PM in a location free from excessive gt 50 heat dust and unauthorized handling The MLS PM s 1 8 DIN package can mount in panels up to 0 2 thick Its dimensions are 1 89 x 3 78 x 6 1 48 x 96 x 156 mm as shown below MLS PM Side View 50 40 1 0 25 4 L 5412 130 mm ___ _ gt lt 6 1 155 mm 18 MLS User s Guide Installation MLS PM Mounting Steps 1 Use the template below to cut a hole in the panel Be careful the 0 02 0 5 mm tolerances don t allow much room for error Use a punch
4. 20 PSI Hi PV Process Variable Lo PV 0 PSI mv Rdg Rdg 60 mV Before you enter the values that determine the two points for the conversion line you must choose an appropriate display format The MLS has six characters available for process variable display select the setting with the desired number of decimal places before and after the decimal point Use a display format that matches the range and resolution of the process variable The display format you choose is used for the setpoint alarms deadband spread and proportional band The PV Process Variable range for the scaled input is between the PV values that correspond to the 16 6 and 100 input readings This PV range defines the limits for the setpoint and alarms as shown here HiPV Process Variable Range Lo PV aio 0 100 Hi Lin Input Reading RDG 60 2l RDG 2000 Hz Pulse input type IF NOTE See Linear Scaling Examples section in this manual MLS User s Guide 73 Setup Display Format Display Formats Use this menu to select a display format for a linear input Choose a format appropriate for your input range and accuracy LOOP PROCESS UNITS 05 DISP FORMAT 9999 TO 30000 ALARM SETPOINT STATUS _ OUT Selectable values The MLS has several available display formats as shown below this table shows also the high and low PV values High PV Default Low PV Default 99
5. Heat 14 36 DIG Output 21 Heat 21 Cool 5 37 DIG Output 15 Heat 15 38 DIG Output 20 Heat 20 Cool 4 39 DIG Output 16 Heat 16 40 DIG Output 19 Heat 19 Cool 3 41 DIG Output 17 Heat 17 Cool 1 42 DIG Output 18 Heat 18 Cool 2 43 DIG Input 1 44 DIG Input 2 45 DIG Input 3 46 DIG Input 4 47 DIG Input 5 48 DIG Input 6 49 DIG Input 7 50 DIG Input 8 Tf you install an Watlow Anafaze Serial Digital to Analog Converter SDAC the MLS uses digital output 34 for a clock line You cannot use output 34 for anything else when an SDAC is installed 34 MLS User s Guide Installation AIM Communications Failure The controller continuously checks communications between the MLS PM and the AIM If communication stops for more than five seconds the MLS PM display indicates AIM COMM FAIL the PID mode changes to manual and the controller sets every output to the output override percentage AN WARNING PID outputs remain in manual mode after an AIM communications failure After an AIM failure change the PID control status back to automatic mode for each control loop An AIM communications failure also activates the global alarm output If you have selected a digital output from the Global Parameters menu an AIM communications failure also activates the output MLS User s Guide 35 Installation Inputs This figure shows the AIM cards also known as the MUX cards and AIM TB with scaling resistor locations Scaling Resiste
6. eee 102 Setting Up and Tuning PID Loops 104 Proportional Band PB Settings 104 Integral Term ii eet rete 105 Derivative Term TD 105 General PID Constants 5 onec ete deis 106 Proportional Band Only P 106 Proportional with Integral PI 106 PI with Derivative 106 Troubleshooting aude oo tenue ken coi teu 109 Manual Controller Reset eese 109 Returning your Unit to 110 MLS User s Guide Contents Troubleshooting Stand Alone Systems 110 MLS PM Has No Power eese 110 Keys Don t 111 Controller Message AIM Comm Failure 111 Checking Analog Inputs 111 Checking PID Control Outputs esses 112 Checking Digital IE o nee teen e Rr ee 112 Checking Computer Supervised Systems 113 Computer Problems s o ovens tt er e ee EUER 113 Serial Interface Problems da pecia deed 113 Communications Problems eee 114 Software Problems nece deed tibia 115 Changing the BPROM 5 neben ether hte inet 116 Linear Sc
7. MLS User s Guide cal encoders R Ramp A programmed increase in the temperature of a setpoint system Range The area between two limits in which a quantity 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 con trol Solid State Relay SSR A switching device with no moving parts that com pletes or interrupts a circuit electrically Reset Control action that automatically eliminates off set or droop between setpoint and actual process temperature See also Integral Automatic Reset The integral function of a PI or PID temperature controller that adjusts the process temperature to the setpoint after the sys tem stabilizes The inverse of integral Automatic Power Reset A feature in latch ing limit controls that Resistance Opposition to the flow of electric current mea sured in ohms Resistance Temperature Detector RTD Glossary 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 ma
8. MLS User s Guide 21 Installation Mounting the RTB To mount the RTB slide it onto a DIN rail Watlow Anafaze recommends Phoenix Contact s NS32 perforated DIN rail part number 12 01 00 2 Mount the DIN rail according to Phoenix Contact s instructions and slide the RTB onto it AN WARNING Do not connect power to the MLS now Test the unit first as explained in the Power Wiring and Controller Test section 22 MLS User s Guide Installation Mounting the MLS PS Follow these instructions to mount the MLS PS If you use your own power supply for the MLS please refer to the power supply manufacturer s instructions for mounting information Choose a power supply that supplies a regulated 7 28 Vdc at 1 watt and isolated return line Mounting Environment The MLS PS measures 1 75 x 8 x 5 Leave enough clearance around the power supply that you can remove it later Mounting Steps The MLS PS has a bracket at each end of the unit Each bracket has three screw holes which will accept 6 or 10 screws To mount the MLS PS insert screws into the brackets and tighten them MLS User s Guide 23 Installation Wiring Your System 24 MLS User s Guide 12V DG Gom 45V Frame Ground AC N AC L NC S MLS PS Ajddng 2 IRSM if used puno45 owes This section explains how to wire the components of your system Below is the system connections diagram reprint
9. MLS User s Guide 25 Installation Cable Recommendations Use these cables or their equivalent Function MFR P N No of Wires AWG Analog Inputs Belden 9154 2 20 Belden 8451 2 22 RTD Inputs Belden 8772 3 20 Belden 9770 3 22 T C Inputs T C Ext Wire 2 20 Carbon Probe Input Belden 88760 2 18 Digital PID Outputs and Digital Belden 9539 9 24 Belden 9542 20 24 Ribbon Cable 50 Analog Outputs Belden 9154 2 20 Belden 8451 2 22 Computer Communication Belden 9729 4 24 RS232 RS422 RS485 or 20 Belden 9730 6 24 ma Belden 9842 4 24 Belden 9843 6 24 Noise Suppression 26 MLS User s Guide If the MLS outputs control dry contact EM relays with inductive loads like alarm horns and motor starters you may get Radio Frequency Interference RFI or noise This section explains how to avoid noise problems read it before you wire the MLS Symptoms of RFI The MLS display blanks out and then reenergizes as if power had been turned off for a moment The process value does not display correctly The MLS CPU may reset if it does it loses its PID output levels RFI may also damage the digital output circuit so digital outputs will not energize If the digital output circuit is damaged return the controller to Watlow Anafaze for repair Avoiding RFI Where possible use solid state relays SSRs instead of electrical mechanical EM relays If you must use EM relays tr
10. PB SP pen n Time A process using On Off control frequently cycles around the setpoint When process variable cycling is unacceptable or the process or setpoint are variable use proportional control Proportional control or Gain eliminates cycling by increasing or decreasing the output proportional to the process variable s distance from the setpoint The limits of proportional control are defined by the Proportional Band PB outside this band of control the output is either 100 or 0 For example using the same values from the example above and a PB of 20 the output is 50 when the process variable is 990 F 75 when the process variable is 985 F 100 when the process variable is 980 F or below However a process which uses only Proportional control may settle at a point above or below the setpoint it may never reach the setpoint at all This behavior is known as offset or droop This diagram shows a process under proportional control only PB SP PV Tuning and Control Proportional and Integral Control For Proportional and Integral control use the Integral term or Reset with Proportional control The Integral term corrects for offset by repeating the Proportional band s error correction until there is no error For example if a process tends to settle about 5 F below the setpoint use Integral control to bring it
11. Save to Job Load from Job 62 MLS User s Guide Use this menu to save the job information for every loop to one of eight jobs in the MLS battery backed RAM LOOP PROCESS UNITS SAVE SETUP TO JOB 1 Selectable Range 1 8 If you have enabled the remote job control function you will not be able to save a job when you try to do it you will see this message LOOP PROCESS UNITS CANNOT SAVE JOB REMOTE SELECT ALARM SETPOINT STATUS OUT Use this menu to load any one of eight saved jobs from the controller s front panel LOOP PROCESS UNITS LOAD SETUP FROM JOB 1 ALARM SETPOINT STATUS _ OUT Selectable values The last job number or job 1 The following parameters are loaded as part of a job 1 PID constants filter settings setpoints and spread values 2 Loop control status Automatic or Manual and output values If the loop is in Manual control 3 Alarm functions Off Alarm Control setpoints high low process setpoints high low deviation setpoints and deadband settings and loop alarm delay If you have enabled the remote job control function this menu is disabled Job Select Inputs Setup Use the Remote Job Control feature to run up to 8 jobs remotely The Job Select Inputs menu is the third menu under Setup Global Parameters It lets you set the number of job select inputs The controller uses these inputs as a binary code that specifies the job number to run
12. The number of inputs you choose in this menu controls the number of jobs you can select remotely The menu looks like this LOOP PROCESS _ UNITS JOB CONTROL DIG INPUTS NONE ALARM SETPOINT STATUS OUT Selectable values 1 2 3 or NONE Below is the truth table that tells you which input states select which jobs Digital Digital Input Digital Input You can choose 1 2 or 3 inputs or None These choices have the following effect Setting Enables 1 input Jobs 1 2 2 inputs Jobs 1 4 3 inputs Jobs 1 8 None no inputs Remote Select disabled MLS User s Guide 63 Setup Job Digital Input Polarity Use this menu to set the polarity of the digital outputs used for job selection You can set the Active state to closed Low or open High LOOP__ PROCESS UNITS JOB DIGITAL INPUT TRUE LOW ALARM SETPOINT STATUS _ OUT Selectable values Low or High Output Override Digital Input This menu lets you set a digital input that sets all loops in manual output at output levels you select in the Outputs menu This menu and the next one let you configure a panic button or kill switch that sets all outputs to the output override percentage you set in the Setup Loop Outputs main menu LOOP PROCESS _ UNITS OUTPUT OVERRIDE DIG INPUT NONE ALARM SETPOINT __STATUS__OUT Selectable values Input number 1 8 or NONE AN WARNING ANAFAZE recommends that you install
13. 0 100 mVdc 499 750 0 500 mVdc 5 49K 750 0 1 Vdc 6 91K 422 0 5 Vdc 39 2 475 0 10 Vdc 49 9K 301 0 12 Vdc 84 5K 422 Input Calibration The MLS provides offset calibration for T C RTD and other fixed ranges It also provides offset and span gain calibration for linear and pulse inputs Offset and span calibration convert linear analog inputs into engineering units using the Mx B function The offset range is 300 to 300 units the magnitude of the offset depends on the input type and span you select Follow these steps to use the MLS offset and span calibration 1 Install scaling resistors that will provide an appropriate full scale volt age If you have any doubts about your ability to install scaling resis tors contact Watlow Anafaze T C Inputs Installation 2 Select the of digits and decimal point location for the full scale PV display The smallest possible range is 0 9999 to 3 0000 the largest possible range is 9999 to 30000 3 Enter the zero and full scale values process variables you want dis played when the input signal is at zero and full scale AN WARNING Use ungrounded thermocouples thermocouples which have the T C junction isolated from the metal protection sheath Grounded thermocou ples will damage the MLS if voltage between the loops exceeds 10 volts If you are installing the MLS in an existing tem perature control system check all grounded T C assemblies in
14. It is a SINK output located on RTB terminal 6 Do not exceed the 10 mAdc rating for the System Safe output Its output is Low on when the CPU is operating when it stops operating the output goes High off de energizing the SSR Here s the recommended circuit for the System Safe output 5 Vdc RTB pin 2 SSR System safe RTB pin 6 MLS User s Guide 33 Installation RTB Connections Connect outputs to the RTB as shown in the table below Terminal Function PID Output Terminal Function PID Output 1 5 Vdc 2 5 Vdc 3 CTRL COM 4 CTRL COM 5 Spare 6 System Safe 7 Pulse input 8 Global Alarm 9 DIG Output 1 Heat 1 10 DIG Output 34 11 DIG Output 2 Heat 2 12 DIG Output 33 Pulse Loop Heat 13 DIG Output 3 Heat 3 14 DIG Output 32 Heat 32 Cool 16 15 DIG Output 4 Heat 4 16 DIG Output 31 Heat 31 Cool 15 17 DIG Output 5 Heat 5 18 DIG Output 30 Heat 30 Cool 14 19 DIG Output 6 Heat 6 20 DIG Output 29 Heat 29 Cool 13 21 DIG Output 7 Heat 7 22 DIG Output 28 Heat 28 Cool 12 23 DIG Output 8 Heat 8 24 DIG Output 27 Heat 27 Cool 11 25 DIG Output 9 Heat 9 26 DIG Output 26 Heat 26 Cool 10 27 DIG Output 10 Heat 10 28 DIG Output 25 Heat 25 Cool 9 29 DIG Output 11 Heat 11 30 DIG Output 24 Heat 24 Cool 8 31 DIG Output 12 Heat 12 32 DIG Output 23 Heat 23 Cool 7 33 DIG Output 13 Heat 13 34 DIG Output 22 Heat 22 Cool 6 35 DIG Output 14
15. MLS AIM before you connect inputs to it 1 w N p N e N Connect wire from the A terminal for loop to A terminal for loop 1 Turn on power to the MLS PM Press the ALARM ACK key to clear the alarm messages displayed on the MLS PM s screen Press the YES key to reach the single loop display for Loop 1 The MLS AIM TB contains an ambient temperature sensor so Loop 1 should display room temperature If it does not contact Watlow Anafaze Turn on power to the MLS Measure the 5Vdc supply at the A Connect the voltmeter s Common lead to RTB terminal 3 B Connect the voltmeter s Power lead to RTB screw terminal 1 The voltage should be 4 75 to 5 25 Vdc C Connect the Power lead to RTB screw terminal 2 The voltage should be 4 75 to 5 25 Vdc D Connect the Power lead to RTB screw terminal 4 The voltage should read 0 volts Connect the voltmeter power lead to RTB screw terminal 1 Connect the Common lead to the PID output pin If you have not connected a load to the output connect a 500 ohm to 100 Kohm resistor between RTB screw terminal 1 and the PID output pin Use the digital output test in the Manual I O Test menus to turn the digital output on and off When the output is off the output voltage should be less than 1 V When the output is on the output voltage should be between 3 75 and 5 5V Outputs Installation uy NOTE Your MLS
16. MUX card and the AIM 32 has two MUX cards These cards multiplex the 16 inputs each card receives Each 10 to 60 mVdc input is converted to a voltage that is transmitted to the Voltage Frequency V F card The MUX cards also automatically calibrate the zero and span of the analog amplifier and measure the cold junction compensation temperature for thermocouple T C inputs Both the AIM 16 and AIM 32 have a V F card which converts the input signal they receive from a voltage to a frequency The converted signal is then transmitted via the AIM COMM cable to the MLS PM for processing MLS User s Guide 13 Introduction Here s a picture of the MLS AIM 32 and terminal block MLS Cabling Technical Description Watlow Anafaze provides all the cables required to install your MLS The 50 pin ribbon cable which connects the RTB to the MLS PM is an 0 05 space conductor zoned 50 pin cable Pin 1 is at the red edge of the cable The cables which connect the MLS PM to the AIM TB the optional Smart I O Module SIOM and the computer are 6 conductor shielded cable These cables are also known as RJ12 cable they are available from Newark Electronics and other suppliers AN WARNING These cables are not standard phone cables stan dard cables are not shielded Watlow Anafaze pin numbering convention is also reversed 14 MLS User s Guide Installation Installation These installation instructions are written for
17. O Module MLS SIOM The System safe output is Low On when the CPU is running it keeps a solid state relay closed If the CPU stops working the output goes High Off and the SSR opens MLS User s Guide II Introduction The eight digital inputs are referenced to the MLS controller common an open input pulls them High Off When you short the input to controller common the input goes Low On Do not connect external power sources to the MLS digital inputs Front Panel Description The MLS PM s panel mounted LCD screen and touch keypad provide an intelligent way to operate the MLS The on board display driver operates the liquid crystal display The LCD has 16 alphanumeric or graphic characters per line it is backlit for viewing under low light conditions The 8 key keypad and on board keyboard scanner allow you to change the MLS operating parameters controller functions and displays The MLS information packed displays show process variables setpoints and output levels for each loop A bar graph display single loop display scanning display and an alarm display offer a real time view of process conditions Two access levels allow operator changes and supervisor changes The front panel looks like this ANAFAZE MLS LOOP PROCESS UNITS lt ALARM SETPOINT STATUS OUT MLS RTB Technical Description 12 MLS User s Guide Here s a picture of the RTB Introduction The RTB is a
18. Requirements eee 10 Environmental Specifications esses 10 Dimensions and Weight 10 Expanded Parts 11 MLS Processor Module Technical Description 11 MLS RTB Technical Description 13 MLS AIM and AIM TB Technical Description 13 MLS Cabling Technical Description 14 sco o rp irt ape E EE ie og eU 15 Read This Before Installation ined 16 Recommended Tools inei petii 17 Paniel Hole Cutters 17 Other POG TN 17 Additional Hardware 17 Mounting the MLS PM 18 Mounting Environment essere 18 MLS PM Mounting Steps eere 19 Mounting the MLS AIM eene 20 Mounting Environment esee 20 Mounting Steps oie dde cea eae 21 Mounting the REB 22 Mounting the MLS PS nie edente tbe 23 Mounting Environment eese 23 Gea 23 Wiring Y OUt System 24 Wiring Recommendations esee 25 Cable Recommendations eren reas 26 o odiee 26 Wiring and Testing Your System sess 27 Contents MLS User s Guide Connecting Power and RTB to MLS PM
19. Single Loop Display without saving the new setpoint Selecting Manual Automatic or Tune Control Press Man Auto If you set the output mode to Auto the MLS automatically controls the process according to the configuration information you give it If you set the output mode to Manual you need to set the output level f you set the output mode to Tune you can tune the PID parameters If the Loop is in Manual Mode Press Yes to toggle the mode e Press No to skip the mode change menu and set the output level See the Manual Output Levels section for instructions Press Back to return to the single loop display without saving the new mode setting Press Enter to save your changes and return to single loop display If the loop is in Automatic Mode Press Yes to toggle the mode Press Back or No to return to single loop display without saving your changes Press Enter to save your changes and if you have selected Manual Mode set the output level To learn how to set the output level see Manual Output Levels 56 MLS User s Guide Using the MLS e Press Enter then Back to store the new mode and return to Single Loop Display without setting an output level U 4 NOTE If the loop outputs are disabled you cannot toggle between Manual and Automatic output control If you try it the screen shows an error message tell ing you that the outputs are disabled as shown below Use the menus
20. User s Guide 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 Deriv ative 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 lowest value of the process range Proportional P Output effort proportional to the error from set point 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 Pulse Input Digital pulse signals from devices such as opti
21. alarm or set it to the alarm or control function LOOP PROCESS UNITS 01 HI PROC ALARM OFF ALARM SETPOINT STATUS OUT Selectable values Alarm Control Off High Process Alarm Output Number Use this menu to choose the digital output that activates when the loop is in high process alarm You can use this output to activate a second alarm horn or buzzer You can also use it to control your process For example you can set the output you have chosen to activate heating or cooling mechanisms or to turn off the system LOOP PROCESS UNITS 01 HI PROC ALARM DIG OUT NONE ALARM SETPOINT STATUS _ OUT Selectable values Any output number between 1 and 34 as long as it s not already used for control or the SDAC clock You may also select NONE MLS User s Guide 91 Setup Deviation Band Value All digital outputs are OR ed 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 Use this menu to set the deviation bandwidth a positive and negative alarm or control point relative to the setpoint If the setpoint changes the alarm or control points also change You can assign a separate digital output to the high and low deviation alarm control setpoints so that for example a high deviation alarm turns on a fan and a low deviation alarm turns on a heater LOOP PROCESS UNITS 02 DE
22. been subject to misuse accident negligence failure of electric power or modification by the Customer without the written approval of Watlow Anafaze Incorporated Final determination of warranty eligibility shall be made by Watlow Anafaze Incorporated If a warranty claim is considered invalid for any reason the Customer will be charged for services performed and expenses incurred by Watlow Anafaze Incorporated in handling and shipping the returned unit If replacement parts are supplied or repairs made during the original warranty period the warranty period for the replacement or repaired part shall terminate with the termination of the warranty period of the original product or part The foregoing warranty constitutes the sole liability of Watlow Anafaze Incorporated and the 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 Inc disclaims all warranties express or implied including any warranty of merchantability or fitness for a particular purpose Please Note External safety devices must be used with this equipment Addendum for MLS User s Guide 3 6 Addendum for MLS User s Guide 3 6 The following are changes to revision 3 6 of the MLS User s Guide The changes pertain to a new power supply that is being used with the MLS All changes are listed below by page number Shaded portions refer to the actual changed t
23. in the Setup Loop Outputs main menu to enable the outputs See Chapter 4 Setup for more information about the Setup menus LOOP PROCESS UNITS MAN AUTO CONTROL OUTPUTS DISABLED ALARM SETPOINT STATUS _ OUT Setting the Manual Output Levels You ll only see this menu if you set the current loop to Manual control Use this menu to set the manual heat and cool output levels The cool output level menu will only be present if the cool output for the current loop is enabled see Outputs Enabled Disabled in Chapter 4 Setup You should see a display like this LOOP PROCESS UNITS 01 SET HEAT OUTPUT 9096 ALARM SETPOINT STATUS OUT Press Yes to change the output power level If the MLS heat outputs are enabled you will be able to change the heat output power level If only the cool outputs are enabled you will be able to change only the cool output power level Then press Yes or No to select a new output power level When you are satisfied with the power level you have chosen press Enter to store your changes Then press No to advance to the cool output menu if the cool out puts on the MLS are enabled Press Back at any time to discard your changes and return to single loop display MLS User s Guide 57 Using the MLS 58 MLS User s Guide Automatically Tuning a Loop When you use the Autotune function the controller automatically sets the loop to Manual control 100 output If
24. lets you dampen the input response if inputs change unrealistically or change faster than the system can respond If the input filter is enabled the process variable responds to a step change by going to 2 3 of the actual value within the number of scans you set If all input loops are enabled none of them are set to SKIP the MLS scans each input loop 2 times per second The input filter applies to all input types except those set to SKIP LOOP PROCESS UNITS 01 LOW PASS FILTER VALUE 3 SCANS ALARM SETPOINT __STATUS__OUT Selectable range 0 255 scans Setup Setup Loop Control Parameters Use these menus to change control parameters for heat and cool outputs of the selected loop including Proportional Band PB Integral TI or Reset and Derivative TD or Rate settings Output Filter Spread between heat and cool outputs The Setup Loop Control Parameters menu looks like this LOOP PROCESS UNITS SETUP LOOP 01 CONTROL PARAMS ALARM SETPOINT STATUS __OUT SIF NOTE Both heat and cool outputs have the same menus so only one of each menu is explained in the text The controller shows both heat and cool menus even if the heat or cool output is disabled See Setup Loop Out puts for help in enabling or disabling the heat or cool output Refer to Tuning and Control section for help in selecting control parameter values Setup Loop Control Parameters Heat control PB 50 F C
25. makes full scale input 60 mV The next figure shows two resistors RA and RB are not loaded RC is the voltage reducing or current limiting resistor and RD is the 60 mV full scale dropping resistor RD is normally less than 500 ohms and it should never exceed 1000 ohms To Circuitry IN IN RC Unused Inputs Set the input type for unused inputs to SKIP to avoid the default T C break alarms MLS User s Guide 41 Installation Communications Changing Communications The MLS is factory configured for either RS 232 or RS 485 communications When you order your unit specify the type of communications you need If you use one MLS and you connect it to a computer less than 50 feet away you can use RS 232 communications e If you use more than one computer or if the computer and controller are more than 50 feet apart use RS 485 communications PC compatible computers typically use RS 232 communications If the MLS is configured for RS 232 communications you can connect it directly to the serial communications connector on an IBM PC or compatible computer If you use RS 485 communications attach an optically isolated RS 232 RS 485 converter to the computer You can use an internal converter card or an external plug in converter Follow these instructions to change the unit s communications between RS 485 and RS 232 Unplug any cables connected to the MLS PM N If you alre
26. nibbler or jigsaw file the edges of the hole 3 630 020 E m 0 500 REF 2 560 CLEARANCE 1 800 020 j 9 375 REF 1 AN WARNING Make sure bits of wire and debris do not lodge in the electronics or else make sure you clean the electronics before you connect power 2 Insert the MLS PM into the hole through the front of the panel 3 Screw the top and bottom clips in place If you expect much panel vibration use a rear support for the MLS and its interconnecting cables MLS User s Guide 19 Installation Mounting the MLS AIM This section contains mounting instructions and diagrams for the MLS AIM 4 NOTE If you plan to install scaling resistors mount them on the AIM TB before you mount the AIM TB in the panel If you mount the AIM TB in the panel before you mount the scaling resistors on it you will have to remove the AIM TB from the panel to install the scaling resistors If you ordered an MLS AIM TB with scaling inputs from Watlow Anafaze the scaling resistors are already installed Mounting Environment Install the MLS AIM in a location free from excessive gt 50 C heat dust and unauthorized handling The MLS AIM measures 6 5 x 5 x 7 165 x 127 x 178 mm Leave 6 of clearance above the MLS AIM so you can remove the entire unit or just the AIM cards if necessary The figure on the next page shows an overhead view of the AIM TB and M
27. nontechnical users If you are an electrician or you are technically proficient they may seem simple to you Please at least skim all of the instructions to make sure you don t miss anything vital If you have installed a Modular Loop System before you may wish to use the Quick Start foldout to install this system This section explains installation for the MLS Controller only If you are installing another Watlow Anafaze product such as a Relay Interface Board IRSM or an SDAC see the manual shipped with it to learn how to install it These symbols are used throughout this manual DANGER This symbol warns you about a hazard to human life AN WARNING This symbol warns you of possible damage to property or equipment NOTE This symbol denotes information you must know in order to proceed MLS User s Guide 15 Installation Read This Before Installation AN WARNING 16 MLS User s Guide During installation and wiring place temporary covers over the housing slots and the rear of the MLS so dirt and pieces of wire don t fall through the slots When you are finished with installation remove the covers Install the MLS so the airflow to the slots in the housing is not restricted after installation Make sure that other equipment does not block airflow to the housing slots Use 18 or 20 AWG wires and trim wire insula tion to 1 4 5 mm Wire should fit inside the terminal with no b
28. on the right as you re looking at the back of the MLS PM Colors vary depending on the manufacturer The figure below shows a back of an MLS PM 6 1 Connecting RS 485 Communications RS 485 specification is for balanced line operation it is not true differential so you must supply a common ground connection Use a fifth wire which should not be shield if possible or a common ground connection to establish the common ground Do not use the common ground connection unless the common mode voltage between stations at your installation exceeds the RS 485 specification of 7 volts peak in that case use a fifth wire The following diagram shows the recommended system hookup The transmitter from the host computer connects in parallel to the controller receivers and the host computer receiver connects in parallel to the controller transmitters Watlow Anafaze recommends that you use a single daisy chain rather than octopus connections or spurs In addition use a terminating resistor a 200 ohm resistor laid across the line at the furthest point from the transmitter at each end of the transmission line This figure shows the MLS RS 485 connections MLS User s Guide 43 Installation Black Box MLS T3A B MLS T3A B LD 485A 1 RJ12 n RJ12 TXA Red RX 43 RX 3 ae Blue White 1 TXB RX 1 BlueA
29. optional Serial Digital Analog Converter SCAC ON OFF On Off Output either full ON of full OFF 82 MLS User s Guide For an expanded description of these output types see Tuning and Control Heat Cool Cycle Time SDAC Menus SDAC Mode Setup Use this menu to set the Cycle Time for Time Proportioning outputs LOOP__ PROCESS UNITS 03 HEAT OUTPUT CYCLE TIME 10S ALARM SETPOINT STATUS __OUT Selectable range 1 255 seconds k NOTE The Cycle Time menu will only be present if the out put type for the current loop is Time Proportioning If you attach the optional SDAC to an output you must configure that output for the SDAC using the following series of menus The MLS will also assign digital output 34 as a clock line for the SDAC You won t be able to assign another function to output 34 while any loop s output is set to SDAC Use this menu to toggle the SDAC between current and voltage output The SDAC menus only appear if the output type for the loop is set to SDAC LOOP PROCESS UNITS 01 SDAC MODE VOLTAGE ALARM SETPOINT __ STATUS __ OUT Selectable values Current and Voltage MLS User s Guide 83 Setup SDAC High Value SDAC Low Value Heat Cool Output Action 84 MLS User s Guide Use this menu to set a high value for the SDAC output Set the high and low value to match the range of the output device For instance if the output device has a 4 20 mA r
30. replace the MLS with a spare unit the spare unit will break and you ll need to send both units to ANAFAZE for repair If you are certain that the controller is installed correctly you can try replacing the MLS with a spare controller one module at a time If the spare unit works correctly then the problem is specific to the MLS you replaced If you need to update the MLS Erasable Programmable Read Only Memory EPROM please refer to the third section Changing the EPROM If the instructions in this chapter tell you to perform a manual controller reset also called a No Key Reset follow these instructions e Disconnect power to the unit Press and hold the No key on the MLS front panel Reconnect power to the unit MLS User s Guide 109 Troubleshooting AN WARNING A manual controller reset clears the MLS memory and resets its parameters to their default values If you reset a stand alone system you cannot recover your original parameters If you have a computer supervised system ANASOFT stores a copy of your parameters Do not attempt to repair the MLS yourself There are no user repairable components in the MLS If the troubleshooting procedures in this chapter do not solve your system s problems you will need to return the unit to ANAFAZE for testing and repair see Returning the Unit to ANAFAZE below Returning your Unit to ANAFAZE If you need to return the MLS to ANAFAZE please call ANAFAZE
31. the front panel LOOP PROCESS UNITS SETUP LOOP 02 INPUT ALARM SETPOINT STATUS OUT Below is the menu tree for the Setup Loop Inputs menu Notice the default values inside the boxes Setup Loop Inputs T C or RTD Input Type Linear amp Pulse J T C pulse sample time Loop s name Loop s name Input units __ Input units Disp format 9999 to 30000 Input reading offset Input scaling Hi PV 10000 Input scaling Hi RDG 100 0 FS input scaling Lo PV 1660 Input scaling Lo RDG 16 6 FS Low pass filter value 3 MLS User s Guide 69 Setup Input Type 70 MLS User s Guide Use this menu to configure the input sensor for each loop as one of these input types Thermocouple types J K T S and B RTD Three ranges RTDI Platinum Class RTD2 Platinum Class B and RTD3 Nickel Linear and Pulse inputs Skip an input type available for unused channels The scanning dis play doesn t show loops you ve set to Skip LOOP PROCESS UNITS 06 INPUT TYPE Fahrenheit Celsius Range J 350 to 1400 212 to 760 K 450 to 2500 268 to 1371 T 450 to 750 268 to 399 5 0 to 3200 18 to 1760 R 0 to 3210 18 to 1766 B 150 to 3200 66 to
32. the system Make sure there is no voltage between T C leads You can connect all T C types directly to the MLS Watlow Anafaze provides J K T R S and B type linearization and cold junction compensation Other thermocouple types require custom input ranges contact Watlow Anafaze for more information about them Wiring Recommendations Follow these recommendations for thermocouple wiring Use 18 or 20 AWG thermocouple T C extension wire for all ther mocouple inputs Most T C wire is solid unshielded wire Use shielded wire if required at your installation ground one end only Use less than 500 of T C extension wire Longer wire runs exceed accuracy and source impedance specifications Install T C wiring in a separate conduit away from AC power the 120 Vac supply and high power 240 Vac or higher wiring MLS User s Guide 39 Installation Connecting Thermocouples Connect the positive T C lead to the A terminal Connect the negative T C lead to the A terminal of TB1 The figure below shows a typical thermocouple connection Use 20 gauge T C extension wire for all T C inputs e If you use shielded wire tie the shield to panel ground Install a jumper or zero ohm resistor in location RC on the AIM TB if it had been removed This figure shows a typical thermocouple connection White N 8 IN Shield RTD Inputs The standard industrial RTD is an 100
33. to the desired setting The next diagram shows a process under proportional and integral control PB SP PV Proportional Integral and Derivative Control For an improved level of control use Derivative control with Proportional or Proportional and Integral control Derivative control also called the Rate function corrects for overshoot by anticipating the behavior of the process variable and adjusting the output appropriately For example if the process variable is rapidly approaching the setpoint Derivative control reduces the output anticipating that the process variable will reach setpoint Use it to eliminate the process variable overshoot common to PI control This figure shows a process under full PID Proportional Integral and Derivative control PID PB SP MLS User s Guide 101 Tuning and Control Digital Output Control Forms 102 MLS User s Guide The next section explains different modes for control outputs On Off On Off output is very simple it turns the output on or off according to the control signal of the On Off control Time Proportioning TP Time Proportioning attempts to digitally simulate an analog output percentage by turning the output On or Off for each time step so that the cumulative average of the output is the desired setting You must enter a cycle time for TP outputs The cycle time is the time over which the outp
34. 1760 RTD1 148 0 to 572 0 100 0 to 300 0 RTD2 184 to 1544 120 to 840 RTD3 94 to 572 70 to 300 Pulse 0 2 KHz Skip Loop is not scanned or displayed Linear see the Linear Scaling section this chap ter and Appendix Pulse Sample Time Loop Name Input Units Setup You can connect a digital pulse signal of up to 2 KHz to the controller s pulse input Use this menu to specify the pulse sample period Every sample period the number of pulses the controller receives is divided by the sample time The controller scales this number and uses it as the pulse loop s PV LOOP PROCESS _ UNITS 06 INPUT PULSE SAMPLE TIME 1s ALARM SETPOINT STATUS _ OUT Selectable range 1 20 seconds Use this menu to name your loop You can choose any two characters from the set of characters used for the input units See table below LOOP PROCESS UNITS A5 LOOP SAM PLE A5 ALARM SETPOINT_ STATUS _ OUT Use this menu to choose a three character description of the loop s engineering units LOOP PROCESS UNITS 06 INPUT UNITS F ALARM SETPOINT STATUS _ OUT Selectable values This table shows the character set for input units Input Character Sets for Units thermocouples amp RTDs F or C degrees Linear and Pulse 0 9 A Z degrees space MLS User s Guide 71 Setup Input Reading Offset Linear Scaling Menus 72 MLS User s Guide Use this menu to m
35. 53 Displaying Loading and Saving Jobs 55 MOIS 56 Changing the Setpoint 56 Selecting Manual Automatic or Tune Control 56 CUED Sere ERA 59 How to enter the Setup menus 59 How to edit a ment 59 Setup Global Parameters Menu 61 ou ais 62 Load TOI JOD reote ife spe ees 62 Job Seleet DiIputs ic eoe oi ter qb iv hue ia tete 63 MLS User s Guide Contents Job Digital Input Polarity eee 64 Output Override Digital Input esse 64 Output Override Input Polarity ess 64 Startup Alarm 65 Keyboard Lock Status use teet rettet niea eae 65 Power Up Output Status 65 Controller Address e e oe s 66 Communications Error Checking 66 Communications Baud Rate esee 67 Allen Bradley Protocol cess 67 AC Dme Prequetney 67 Digital Output 68 AIM Communications Failure Output 68 EPROM Information out ears 68 Setup Loop Inp t ennen nininini 69 Inp t 70 Pulse Sample TIME 71 Loop NAIM 71 eph I boc vest ibi ee 71 Input Reading Offset inedite orte quce 72 Linear Scaling Menus
36. 99 to 30000 10000 0 999 to 3000 1000 0 99 to 300 100 0 9 to 30 10 0 9999 to 3 0000 1 0000 0000 9 999 to 30 000 10 000 000 99 99 to 300 00 100 00 00 999 9 to 3000 0 1000 0 0 High Process Value 74 MLS User s Guide Use this menu to enter a high process value The high process value and the high reading value together define one of the points on the linear scaling function s conversion line LOOP___PROCESS UNITS 01 INPUT SCALING HI PV 10000 F ALARM SETPOINT STATUS OUT Selectable values See table above High Reading Low Process Value Low Reading Setup Use this menu to enter the input level that corresponds to the high process value you entered in the previous menu For linear inputs the high reading is a percentage of the full scale input range For pulse inputs the high reading is expressed in Hz The 100 full scale input value is 60 mV for the linear input type LOOP PROCESS UNITS 09 INPUT SCALING HI RDG 100 096 FS ALARM SETPOINT STATUS _ OUT Selectable range Any value between 99 9 and 110 0 For pulse input the range is 0 2000 Hz and the default is 1000 Hz Use this menu to set a low process value for input scaling purposes The low process value and the low reading value together define one of the points on the linear scaling function s conversion line LOOP PROCESS UNITS 02 INPUT SCALING LO PV 0 F ALARM SETPOINT __STATUS__OUT Selectable v
37. DAC outputs Heat cool output cycle time 10 S For ON OFF DZC SDAC mode Voltage SDAC Lo value 0 00 SDAC Hi value 10 00 VDC Heat Cool output action Reverse Heat Cool output limit 100 Heat Cool output limit time CONT Sensor fail Heat Cool output 0 Outputs Heat Cool NLO OFF MLS User s Guide 81 Setup Enable Disable Heat and Cool Outputs Heat or Cool Output Type Display Output Use this menu to enable or disable the heat or cool output for the current loop If you want the loop to have PID control you must enable one output You can also disable a heat or cool control output and use the output pin for something else like an alarm LOOP PROCESS UNITS 05 HEAT CONTROL OUT ENABLED ALARM SETPOINT STATUS _ OUT Selectable values Enabled or Disabled The default setting enables the heat outputs and disables the Cool outputs Use this menu to set the output type LOOP PROCESS UNITS 14 HEAT OUTPUT TP ALARM SETPOINT STATUS _ OUT The next table shows the available output types Definition Code Type TP Time Percent output converted to a percent duty Proportioning cycle over the programmed cycle time DZC Distributed Output on off state calculated for every AC line Zero Crossing cycle SDAC Serial DAC Output type for
38. Loop is above setpoint If you enable the high or low devia tion alarm this symbol is scaled to it If you don t enable 1 il i these alarms these symbols are scaled to the setpoint 5 of the sensor s range Loop is at setpoint If you enable the high or low deviation n em alarm this symbol is scaled to it If you don t enable these alarms these symbols are scaled to the setpoint 5 of the sensor s range Loop is below setpoint If you enable the high or low devia tion alarm this symbol is scaled to it If you don t enable these alarms these symbols are scaled to the setpoint 5 of the sensor s range Blank Loop is set to SKIP F Sensor has failed The next table explains the symbols you see on the bottom line of the Bar Graph display and in the Single Loop display These symbols appear when the controller is in both dual output mode and single output mode If the process goes into alarm the controller automatically switches to Single Loop display and shows an alarm code MLS User s Guide 51 Using the MLS ingl Bar Graph js DisplaySy s Sy Description mbol mbol M MAN One or both outputs enabled Loop is in manual control A AUTO Only one output Heat or Cool is enabled Loop is in automatic control TUNE Indication that the loop is in Autotune mode F HEAT Both heat and cool outputs are enabled Loop is in Automatic control and heating s COOL Both heat
39. M Comm Failure Checking Analog Inputs If you power up the MLS PM and the message AIM COMM FAIL appears or if the LED on the AIM is not blinking check the following Make sure power supply connections are correct see the Power Wir ing and Controller Test section of the Installation chapter Make sure the AIM Communications cable is plugged into the AIM and the connector labeled TO AIM on the MLS PM If the AIM COMM FAIL message still appears perform a manual controller reset If the MLS still does not power up with the Bar Graph Display return the unit to ANAFAZE for repair If the number of inputs recognized by the MLS PM does not agree with the number of inputs in the MLS AIM perform a manual controller reset with the AIM connected to the processor module If the numbers still don t agree check the following Make sure the input wires are properly connected Every input on the MLS AIM has three screw terminals positive negative and auxiliary All T C milliamp and voltage inputs connect to the positive and negative terminals RTD inputs connect to all three terminals Check for high common mode voltage It is not uncommon for heaters to leak into the T C wires Use an AC Voltmeter for testing If the inputs are not reading properly make sure you have selected the correct input type from the Setup menus see Chapter 4 Setup Checking the Operation of an Input Disconnect the sensor wiring Set the in
40. MLS User s Guide Watlow Controls 1241 Bundy Blvd Winona MN 55987 Customer Service Phone 800 414 4299 Fax 800 445 8992 Technical Support Phone 507 494 5656 Fax 507 452 4507 Email wintechsupport watlow com Part No 11570 00 Revision 3 7 November 1995 Copyright 1995 Watlow Anafaze Information in this manual is subject to change without notice No part of this publication may be reproduced stored in a retrieval system or transmitted in any form without written permission from Watlow Anafaze Warranty Watlow Anafaze Incorporated warrants that the products furnished under this Agreement will be free from defects in material and workmanship for a period of one year from the date of shipment The customer shall provide notice of any defect to Watlow Anafaze Incorporated within one week after the Customer s discovery of such defect The sole obligation and liability of Watlow Anafaze Incorporated under this warranty shall be to repair or replace at its option and without cost to the Customer the defective product or part Upon request by Watlow Anafaze Incorporated the product or part claimed to be defective shall immediately be returned at the Customer s expense to Watlow Anafaze Incorporated Replaced or repaired products or parts will be shipped to the Customer at the expense of Watlow Anafaze Incorporated There shall be no warranty or liability for any products or parts that have
41. NOTE Most communications problems are due to incor rect wiring or improper communications parameters Therefore check the wiring and com munications parameters before you check anything else If your system has multiple MLS or other control units you must use RS 485 communications Therefore the internal RS 232 RS 485 selection jumper must be set to the correct position From the setup menus make sure that the communications parameters address error checking and baud rate are set correctly for each MLS in your system Every controller must have a separate address starting with 1 and increasing by 1 for each controller After you assign the controller addresses you must configure ANAINSTL with the same parameters In multiple controller systems ANASOFT indicates which controllers are communicating and which are not If you power down a controller in a multiple controller system ANASOFT should indicate a COMM FAILURE in that unit Disable communications to that unit until you power it up again Ground Loops During installation sometimes the MLS PM common wire is tied to earth ground and the computer s RS 232 common wire is tied to earth ground This arrangement creates a ground loop which may affect communications and other MLS functions To avoid ground loops either use an optically isolated communications adapter or disconnect the MLS from earth ground and tie an 0 1 microfarad capacitor from MLS DC common to earth gro
42. S User s Guide 45 Installation 46 MLS User s Guide Using the MLS Using the MLS This chapter explains how to use the front panel to operate the controller If you are using ANASOFT see the operation instructions in the ANASOFT User s Guide The next figure shows a map of the operator menus and displays accessible from the MLS Controller s front panel You don t need to enter a passkey sequence to reach these menus To make detailed changes to global parameters loop inputs control parameters outputs and alarms via the setup menus you must enter a special sequence of keys For more information about the Setup menus see Chapter 4 Setup Back Power Single Job gt loop Display Isplay display t gg cc D uiu Q 5 Bar graph Single loop Change scanning scanning setpoint display display or nem mode Heat Cool Ramp output Soak percentage Only in Manual Not available at this Mode time MLS User s Guide 47 Using the MLS Front Panel Man Auto Changes loop output control from Automatic to Manual or Tune Assigns output power level of manual loops 48 MLS User s Guide The MLS front panel provides a convenient interface with the controller You can use the front panel keys to program and operate the MLS or you can use ANASOFT a program designed specifically for ANAFAZE co
43. UTS HHHHHHHH ALARM SETPOINT STATUS __OUT Using This Menu Short the digital input you are testing to controller common When you do that the input s state should change to L Press Yes or No to advance to the next menu Press Back to return to the Manual I O test main menu Use this menu to test the keypad LOOP PROCESS UNITS KEYPAD TEST QUIT NO NO ALARM SETPOINT STATUS _ OUT Using This Menu Press any key to test the keypad The MLS will display the name of the key you have pressed Press No twice to advance to the next menu Use this menu to select one of the digital alarm outputs to test in the next menu LOOP PROCESS UNITS TEST DIGITAL OUTPUT 34 ALARM SETPOINT_ STATUS __ OUT MLS User s Guide 97 Setup Toggle Digital Output 98 MLS User s Guide Use this menu to manually toggle a digital output On or Off to test it You select the output to test in the previous menu On may be Low or High depending on the digital output polarity you set in the Output Polarity menu outputs are set to Off when you exit Manual I O Test menu LOOP PROCESS _ UNITS DIGITAL OUTPUT NUMBER 17 OFF ALARM SETPOINT STATUS _ OUT Selectable values On or Off Tuning and Control Tuning and Control Introduction Control Modes On Off Control SS y NOTE This chapter explains PID control and supplies some starting PID values and tuning instructions so th
44. UX cards with dimensions scaling resistor locations and hole locations It also shows the AIM communications port and the insertion of the MUX cards in the AIM Terminal Block 20 MLS User s Guide Installation AIM Communications Port Tel 1 Scaling Resisters QD BD SD WI s Te S OX EE 9 SII Sl s LESE c QS oW a L 2 JS gl eS p S c rt 2 S G gt D 7 Q lt D S S e o 2 2 gt H 00000000 fe A 00000000 Mounting Holes Mounting Steps 1 Choose an appropriate place to install the MLS AIM 2 Place the MLS AIM where you will mount it and use a pencil to trace around the plastic standoffs on the AIM If you wish you can use the AIM mounting template in the Quick Start foldout to position the holes 3 Drill four 6 or 8 holes in the chosen location 8 holes provide more clearance 4 Place the MLS AIM where you will mount it Insert the 6 screws in the plastic standoffs and tighten them You may use self tapping screws instead but be sure to remove any loose metal filings after you are finished mounting the MLS AIM Use 3 4 screws with internal star lock washers to ensure a good Frame Ground connac tion
45. VIATION ALARM VALUE 5 F ALARM SETPOINT STATUS _ OUT Selectable values You can set a value from 0 to 255 25 5 2 55 255 or 0255 depending on how you set up the input menus High Deviation Alarm Type 92 MLS User s Guide Use this menu to disable the high deviation alarm function or set it to the alarm or control function 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 LOOP PROCESS UNITS 07 HI DEVIATION ALARM TYPE OFF ALARM SETPOINT STATUS OUT Selectable values Alarm Control Off Setup High Deviation Alarm Output Number Use this menu to assign a digital output which activates when the loop is in high deviation alarm The digital output only activates if you have set the high deviation alarm type to Alarm or Control LOOP PROCESS _ UNITS 01 HI DEV ALARM DI OUT NONE ALARM SETPOINT STATUS __ OUT NOTE All digital outputs are OR ed 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 Selectable range Any output number between 1 and 34 as long as it isn t used for control or the SDAC clock You may also select NONE Low Deviation Alarm Type Use this menu to turn Off the low deviation alarm or set it to Alarm or Contr
46. additional external safety devices over temperature devices for emergency shutdowns Do not rely solely on the output override feature to shut down your process Output Override Input Polarity This menu lets you toggle the polarity of the Output Override digital input You can set the input to be active when Low or active when High LOOP PROCESS UNITS OVERRIDE DIG IN ACTIVE LOW ALARM SETPOINT STATUS OUT Selectable values Low or High 64 MLS User s Guide Startup Alarm Delay Keyboard Lock Status Power Up Output Status Setup Use this menu to set a startup delay for process and deviation alarms for all loops The controller does not report these alarm conditions for the specified number of minutes after the controller powers up The controller will always report failed sensor alarms no matter what startup delay you set LOOP PROCESS UNITS STARTUP ALARM DELAY 0 mins ALARM SETPOINT STATUS __OUT Selectable Range 0 60 minutes Use this menu to lock the front panel operator function keys Change SP Man Auto and Ramp Soak so that pressing these keys has no effect If you want to use these functions turn off the Keyboard Lock LOOP PROCESS UNITS KEYBOARD LOCK STATUS OFF ALARM SETPOINT STATUS _ OUT Selectable values On or Off Use this menu to set the initial power up state of the control outputs to Off or Memory If you choose Off all control outputs are init
47. ady installed the MLS PM in a panel remove it from the panel W Unscrew the screws on the PM s casing There are either two or four screws on the sides of the casing There are two additional screws on the top of the casing 4 Move jumpers JU2 JU4 and JU14 on the upper PC board 5 If you are changing communications for the last unit on the serial communications line also move jumper JU3 Installing this jumper places a 200 ohm impedance on the line 6 Reverse instructions 1 3 to reinstall the unit Connecting RS 232 Communications 42 MLS User s Guide The RS 232 interface is a standard phone cable with a 6 pin male phone connector on one end and a 9 or 25 pin D sub female connector on the computer end You can order this cable called an MLS COM cable from Watlow Anafaze If you order it specify the length of cable and the type of D sub miniature connector you need Installation 1 Plug the phone connector into the slot labeled RS 232 RS 485 on the rear of the MLS PM 2 Plug the D sub connector into the communications connector This table shows RS 232 connections for 25 pin and 9 pin connectors Computer Connector MLS RS 232 Pin DB 25 DB 9 Number RX Pin 3 RX Pin 2 TX Pin 5 Yellow TX Pin 2 TX Pin 3 RX Pin 1 Blue GND Pin 7 GND Pin 5 GND Pin 4 Green NOTE The pin numbers and colors are not industry stan dard Watlow Anafaze numbers the pins from right to left with 1
48. ake up for the input signal s inaccuracy For example at temperatures below 400 F a type J thermocouple may be inaccurate offset by several degrees Use independent thermocouple or your own calibration equipment to find the offset for your equipment To correct for offset errors change the factory default setting to a positive or negative value for the loop you are editing A positive value increases the reading and a negative value decreases it LOOP PROCESS _ UNITS 06 INPUT READING OFFSET 0 F ALARM SETPOINT STATUS _ OUT Selectable range 300 to 300 NOTE If the input type is Linear Pulse or Skip you will not see the Input Reading Offset menu The linear scaling menus appear under the Setup Loop Inputs main menu and they are available for Linear and Pulse inputs only It lets you scale the raw input readings readings in millivolts or hertz to the engineering units of the process variable You ll only see the linear scaling menus if you set the loop s input type to Linear or Pulse For linear inputs the input reading is in percent 16 6 to 100 representing the 10 60 mV input range of the MLS The scaling function is defined by two points on a conversion line It relates the high PV to the high reading and the low PV to the low reading to define the line The engineering units of the process variable can be any arbitrary units Setup The graph below shows pressure as an example
49. al open loop operation The control output does not change during the transfer 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 for mula 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 instruc tions and their execution Circuit Any closed path for electrical current A configu ration of electrically or electromagnetically con nected 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 metals and the electronic instrument Common Mode Rejection Ratio The 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 122 MLS User s Guide 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 heating as the process decreases below the setp
50. al 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 Glossary 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 pro cess deviation band deadband digital outputs 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 corresponding to the low process value For linear inputs the low reading is a per centage 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 control aspects The operator sets output levels Manual Reset See Reset Milliampere mA One thousandth of an ampere N No Key Reset A method for resetting the controller s memory for instance after an EPROM change Noise Unwanted electrical signals that usually produce signal interference in sensors and sens
51. alarm digital output Alarm deadband Loop alarm delay The setpoints deviation alarm values and deadband all use the same decimal format as the loop s process variable MLS User s Guide 89 Setup Alarm Delay You can set the MLS to delay normal alarm detection and alarm reporting There are two kinds of alarm delay The startup alarm delay delays process alarms but not failed sensor alarms for all loops for a time period you set in the Setup Global Parameters main menu The loop alarm delay delays failed sensor alarms and process alarms for one loop until the alarm condition is continuously present for longer than the loop alarm delay time you set J NOTE Failed sensor alarms are affected by the loop alarm delay even during the startup alarm delay time period 90 MLS User s Guide Setup High Process Alarm Setpoint High Process Alarm Type Use this menu to 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 deactivates when the PV goes below the high process setpoint minus the deadband value if you have set a deadband value LOOP PROCESS UNITS 04 HI PROC ALARM SETPT 1000 F ALARM SETPOINT STATUS __ OUT Selectable range Any point within the scaled sensor range Use this menu to turn off the high process
52. aling Examples e eeeeeeees 119 Example 1 Configuring a Pressure Sensor 119 Example 2 Configuring a Flow Sensor 120 GIOSSBEY 121 Contents MLS User s Guide vi Overview Overview This manual describes how to install setup and operate a 16 or 32 MLS controller Included are seven chapters and a glossary of terms Each chapter covers a different aspect of your control system and may apply to different users The following describes the chapters their purpose Introduction Gives a general description of the MLS and its related specifications Installation Describes how to install the MLS and its peripheral devices Using the MLS Provides an overview of operator displays used for system monitoring Setup Describes all the setup displays for the controller and how to access them Tuning and Control Explains PID control and provides tips for tuning your system Troubleshooting Gives some basic guidelines for solving control problems Linear Scaling Examples Provides an example configuring a pres sure sensor and one configuring a flow sensor MLS User s Guide 1 Overview System Diagram Parts List 2 MLS User s Guide The illustration below shows how the parts of the MLS are connected When unpacking your system use the diagram and parts list below to ensure all parts have been shipped Please don t hesitate t
53. alues See table on previous page Use this menu to enter the input level that corresponds to the low process value you selected in the previous menu For linear inputs the low reading is a percentage of the full scale input range For pulse inputs the low reading is expressed in Hz LOOP PROCESS _ UNITS 12 INPUT SCALING LO 16 6 FS ALARM SETPOINT __STATUS__OUT The full scale input range for the linear input type is 10 to 60 mV which corresponds to 16 6 to 100 0 Selectable range Any value between 99 9 and 110 0 For pulse inputs the range is 0 2000 Hz and the default is 0 MLS User s Guide 75 Setup Input Filter 76 MLS User s Guide Access this menu from the Setup Loop Inputs main menu The MLS has two different types of input filter noise rejection filter that rejects high frequency input signal noise This filter keeps a trend log of input readings If a reading is out side the filter s acceptance band and later readings are within the acceptance band the MLS ignores the anomalous reading The acceptance band for thermocouples is 5 degrees above and 5 degrees below the input reading For linear inputs it s 0 5 above and 0 5 below the input reading If later readings are also outside the acceptance band the MLS accepts the anomalous reading and calculates a new acceptance band This input filter does not require adjustment Astandard resistor capacitor RC filter that
54. and Tuning PID Loops To start your process after installation tune the control loops and set them to automatic control If the loop is already in automatic control mode and controlling the process set the loop to manual control Then you can tune it without upsetting the process However if you don t mind minor process fluctuations you can tune the loop in automatic control mode NS y NOTE Remember that tuning is a slow process After you change a PID parameter allow time 20 minutes for most processes before you make another change Proportional Band PB Settings 104 MLS User s Guide This table shows PB settings for several setpoints EX 100 to 99 20 1100 to 1199 75 2200 to 2299 135 100 to 199 20 1200 to 1299 80 2300 to 2399 140 200 to 299 30 1300 to 1399 85 2400 to 2499 145 300 to 399 35 1400 to 1499 90 2500 to 2599 150 400 to 499 40 1500 to 1599 95 2600 to 2699 155 500 to 599 45 1600 to 1699 100 2700 to 2799 160 600 to 699 50 1700 to 1799 105 2800 to 2899 165 700 to 799 55 1800 to 1899 110 2900 to 2999 170 800 to 899 60 1900 to 1999 120 3000 to 3099 175 900 to 999 65 2000 to 2099 125 3100 to 3199 180 1000 to 1099 70 2100 to 2199 130 3200 to 3299 185 Setting the PB a General Rule Set the PB to 10 of the setpoint below 1000 and 5 of the setpoint above 1000 This setting is useful as a starting value Tuning and Control Inte
55. and cool outputs are enabled Loop is in Automatic control and cooling blank blank Both outputs disabled or input type is set to SKIP Navigating in Bar Graph Display Press the Yes up or No down key to see a new group Press Enter twice to scan all groups The groups will display sequen tially for three seconds each This is called Scanning Mode Press Back Yes or No to go back to Bar Graph display From Bar Graph display press Back once to go to Single Loop dis play Viewing One Loop Single Loop Display Single Loop display below shows detailed information for only one loop If the heat and cool outputs are enabled Single Loop display looks like this Process Variable Loop Number BROCESS UNITS Engineering or Name 02 160 F Units 180 AUTO 100 Output Setpoint ALARM SETPOINT mae percentage Control Status The control status indicator shows HEAT or COOL if the loop is in automatic control and MAN or TUNE if the loop is in manual control 52 MLS User s Guide Using the MLS If only one output is enabled heat or cool but not both Single Loop display looks like this Process Variable Engineering Units Loop Number Output Percenta UMS 7 ge or Name 160 F Cool Setpoint 180 AUTO 100 Output Percentage ALARM A Heat Control Status Navigating in Single Loop Display From the single loop display Press the Back key once to get back
56. ange set the SDAC high value to 20 00 mA and the SDAC low value to 4 00 mA The controller converts 0 output to a 4 00 mA signal and 100 output to a 20 00 mA signal LOOP PROCESS UNITS 03 SDAC HI VALUE 10 00 VDC ALARM SETPOINT STATUS _ OUT Selectable values If the output is set to Voltage the default high value is 10 00 volts If the output is set to Current the default high value is 20 00 mA You cannot set the high value to be less than or equal to the low value Use this menu to set a low value for the SDAC output Set the high and low value to match the range of the output device For instance if the output device has a 0 00 10 00 Vdc range set the SDAC high value to 10 00 Vdc and the SDAC low value to 0 00 Vdc The controller converts 096 output to a 0 00 Vdc signal and 10046 output to a 10 00 Vdc signal LOOP PROCESS UNITS 04 SDAC LO VALUE 0 00 VDC ALARM SETPOINT STATUS _ OUT Selectable values If the output is set to Voltage the default low value is 0 00 volts If the output is set to Current the default value is 4 00 mA You cannot set the low value to be greater than or equal to the high value Use this menu to select the control action for the current output loop Normally heat outputs are set to reverse action and cool outputs are set to direct action LOOP PROCESS UNITS 01 HEAT OUTPUT ACTION REVERSE ALARM SETPOINT STATUS OUT Selectable values Reverse or Direct For H
57. ape key Press it to e Abort editing e Return to a previous menu Stop scanning mode MLS User s Guide 49 Using the MLS lt CHNG SP MAN AUTO RAMP SOAK ALARM ACK 50 MLS User s Guide e Switch between Bar Graph and Single Loop display Enter Press the Enter key to Store data or a menu choice after editing Goonto the next menu e Start scanning mode if pressed twice Chng SP Press this key to change the loop setpoint Man Auto Press the Man Auto key to Toggle a loop between manual and automatic control Adjust the output power level of manual loops Automatically tune the loop Ramp Soak Ramp Soak isn t available for the standard MLS When pressing this key a message appears OPTION UNAVAILABLE Alarm Ack Press Alarm Ack to e Acknowledge an alarm condition Resetthe global alarm digital output Using the MLS Displays This section describes the MLS displays Viewing Several Loops Bar Graph Display When you connect power to the MLS it displays general symbolic information for loops 1 8 This display is called Bar Graph mode The next figure shows a picture of the Bar Graph display LOOP PROCESS UNITS 01 gt gt lt 42088 This table explains the symbols on the top line of the Bar Graph display Symbol Symbol s Meaning lt Loop is in low process or low deviation alarm gt Loop is in high process or high deviation alarm
58. are wire exposed to prevent contact between wires and the grounded case Tin any stranded wire Support power input and output cables to reduce strain on the terminals and to prevent wire removal DANGER Shut off power to your process before you install the MLS High voltage may be present even when power is turned off Reduce the danger of electric shock after installation mount the MLS in an enclosure that prevents personal contact with elec trical components The MLS measures input signals that are not nor mally referenced to ground so the MLS inputs and other signal lines can have high voltage present even when power is turned off for example if you inadvertently short a thermocouple to the AC power line NOTE Choose a panel location that leaves enough clear ance to install and remove the MLS and its components Recommended Tools Panel Hole Cutters Other Tools Additional Hardware Installation This section lists the tools you will need to install the MLS Controller Use any of these tools to cut a hole in the panel jigsaw and metal file for stainless steel and other heavyweight panel doors A Greenlee 1 8 DIN rectangular punch Greenlee part 600 68 for most panel materials or thicknesses A nibbler and metal file for aluminum and other lightweight panel doors You ll also need these tools A Phillips head screwdriver e A flathead screwdriver for wiring
59. at you can use control parameters appropriate for your system If you would like more information on PID control consult the ANAFAZE Practical Guide to PID The control mode dictates how the controller responds to an input signal The control mode is different from the type of control output signal like analog or pulsed DC voltage There are several control modes available On Off Proportional P Proportional and Integral PD Proportional with Derivative and Proportional with Integral and Derivative PID P PI or PID control are necessary when process variable PV cycling is unacceptable or if the process or setpoint SP is variable For any of these control modes to function the loop must be in Automatic mode The next sections explain the different modes you can use to control a loop On Off control is the simplest way to control a process a controller using On Off control turns an output on or off when the process variable reaches a certain limit above or below the desired setpoint You can adjust this limit since ANAFAZE s controllers use an adjustable spread For example if your setpoint is 1000 F and your limit spread is 20 F the output switches On when the process variable goes below 980 F and Off when the process goes above 1000 F MLS User s Guide 99 Tuning and Control Proportional Control 100 MLS User s Guide The next diagram shows a process under On Off control On Off
60. by way of a two wire loop The loop has an external power supply The transmitter acts as a variable resistor with respect to its input signal Transmitters are desir able when long lead or extension wires produce unacceptable signal degradation U Upscale Break Protection A form of break detection for burned out thermo couples Signals the operator that the thermocou ple has burned out Undershoot The amount by which a process variable falls below the setpoint before it stabilizes MLS User s Guide V Volt V The unit of measure for electrical potential volt age 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 required to move one cou lomb 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 1 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 Glossary 129 130
61. cal Relays See Relay electromechanical Emissivity The ratio of radiation emitted from a surface compared to radiation emitted from a blackbody at the same temperature Engineering Units Selectable units of measure such as degrees Cel sius 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 123 Glossary 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 2 329 Failed Sensor Alarm Warns that an input sensor no longer produces a valid signal For example when there are thermo couple breaks infrared problems or resistance temperature detector RTD open or short fail ures 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 unreal istically 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 out pu
62. ch loop 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 loop s alarm delay during the startup alarm delay period LOOP PROCESS UNITS 04 ALARM DELAY 0 SECONDS ALARM SETPOINT STATUS OUT Selectable range 0 255 seconds MLS User s Guide 95 Setup Manual I O Test 96 MLS User s Guide Press Yes at this prompt to see menus which can help you test the digital inputs digital outputs and the MLS keypad LOOP PROCESS _ UNITS MANUAL I O TEST ALARM SETPOINT STATUS __ OUT The next figure shows the I O Test menu tree Notice the default values inside the boxes Manual I O Test Test digital inputs HHHHHHHH Test keypad Quit NO NO Test digital output one in use Toggle digital output Off Digital Input Testing Keypad Test Test Digital Output Setup Use this menu to view 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 The menu displays inputs 1 to 8 from left to right Since inputs are pulled High when they are not connected test an input by shorting it to controller common and making sure this menu shows the correct state for that input LOOP PROCESS UNITS DIGITAL INP
63. d under shoot 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 variable PV that decreases over the time of the derivative TD The TD is in units of seconds 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 signal 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 Zero Crossing DZC A form of digital output control Similar to burst fire Earth Ground Glossary 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 sys tem There are many possible causes such as switching ac power on inside the sine wave EMI can interfere with the operation of controls and other devices Electrical Mechani
64. de of a semiconductor material The wire RTD is a positive temperature coefficient sensor only while the thermistor 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 out put 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 single communication channel RS 232 An Electronics Industries of America EIA standard for interface between data termi nal equipment and data communications equip ment for serial binary data interchange This is usually for communications over a short distance 50 feet or less and to a single device RS 485 An Electronics Industries of America EIA standard for electrical characteristics of generators and receivers for use in balanced digi tal multipoint systems This is usually used to communicate with multiple devices over a com mon cable or where distances over 50 feet are required Setpoint SP The desired value programmed into a controller For example the temperature at which a system is to be maintained Shield A metallic foil or braided wire layer surrounding 127 Glossary conductors that is designed to prevent electro static or electromagnetic interference from exter nal sources Signal Any el
65. ded Parts List contains a technical description of each component of your MLS Controller MLS Processor Module Technical Description The MLS Processor Module MLS PM is housed in an eighth DIN panel mount package It contains the power supply circuits the CPU RAM with a built in lithium battery socket EPROM serial communications digital I O and the LCD screen and touch keypad Here s a side view of the MLS PM e Screw terminals connect the power inputs and outputs Input power is 10 28 Vdc at 1 amp The 5 Vdc 750 mAdc output power supply powers the MLS AIM 50 pin flat ribbon cable connects the digital inputs and outputs to the 50 pin terminal block TB 50 The MLS uses 6 pin telephone style connectors for internal and external communications The firmware s operating intelligence resides in the plug in EPROM so it s easy to update or change the MLS firmware The MLS stores its operating parameters in battery backed RAM so if there s a power loss the operating parameters are unchanged The battery has a ten year shelf life and it is not used when the unit is on The CPU microprocessor performs all calculations for input signal linearization PID control alarms and communications The telephone connectors on the rear of the MLS PM are used for Communications to the MLS AIM e RS 232 or RS 485 communications to an optional computer For OEM customers communications to the optional MLS Smart I
66. dig out NONE Alarm delay 0 Seconds MLS User s Guide 87 Setup Alarm Types The MLS has three different kinds of alarms failed sensor alarms global alarms and process alarms Failed Sensor Alarms Failed sensor alarms alert you to T C breaks and these RTD open or short failures e Open or input Short between and input When the loop is in Automatic or Tune mode and a failed sensor alarm occurs the MLS sets the loop to Manual control at the failed sensor percentage you set in the Setup Loop Outputs menus Global Alarms Global alarms occur when a loop alarm set to Alarm not Control is unacknowledged or when there are any unacknowledged failed sensor alarms If an alarm occurs the MLS front panel displays an appropriate alarm code see Chapter 4 Using the MLS for an explanation of these codes Even if the alarm condition goes away the global alarm stays on until you use the Alarm Ack key or ANASOFT to acknowledge it Process Alarms Process alarms include high and low deviation and high and low process alarms You can set each of these alarms to Off Alarm or Control as shown here Function Description Off No alarm or control function Alarm Standard alarm function Control Normal alarm function except that you don t have to ackowledge alarms High process and high deviation alarms activate when the process variable goes above a value you set They re
67. e MLS processor module s 1 8 DIN front panel has a Liquid Crystal Display LCD 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 and control system the MLS can be locally or remotely controlled via an RS 232 or RS 485 serial communications interface The MLS features include Direct Connection of Mixed Thermocouple Sensors Versatile analog inputs let you directly connect most thermocouples Thermocouple inputs feature reference junction compensation linearization PV offset calibration to correct for sensor inaccuracies T C upscale break detection and your choice of Fahrenheit or Celsius display Resistive Temperature Detector Sensors are Standard Inputs The standard three wire 100 W platinum DIN curve sensor is a standard input for the MLS as well as the Nickel RTD Automatic Scaling of Linear Analog Inputs The MLS automatically scales linear inputs used with other industrial process sensors To scale inputs simply enter any two measurement points For example to scale a pH sensor enter the endpoints the low PV is 2 0 pH while the high PV is 14 0 pH All subsequent values will be in pH Independently Selectable PID Output Modes You can set each loop s digital output to ON OFF Time Proportioning Serial DAC or Distributed Zero Crossing mode You can set each loop control mode for ON OFF P PI or PID control with reverse or direct acti
68. e MLS from electrical noise Connect one end of the input wiring shield to the MLS panel s 120 240 Vac panel ground and connect one end of the output wiring shield to the MLS panel s 120 240 Vac panel ground If your system requires a different shield configuration contact Watlow Anafaze for more informa tion For more information about noise suppression see Noise Suppression Connecting Power and RTB to MLS PM from page 27 Remove the temporary covers you placed on the MLS housing N Connect the power supply terminal labeled DC COM to the termi nal labeled GND on the Processor Module This terminal is DC common it is not frame chassis or earth ground W Connect the power supply terminal labeled 15V to the terminal labeled V the Processor Module 4 Connect the 50 pin ribbon cable to the Processor Module Plug it in so that the red stripe is on the left side under TB1 Connect the ribbon cable to Plug it in so that the red stripe is closest to screw terminal 1 IV MLS User s Guide 11570 00 rev 3 6 Contents CDV OV VIEW 1 eo Po SEU 2 2 ATELY 3 m 5 SPECIMCAL ONS s tesa J Analog Outputs 8 Digital Inputs amp Digita OU DU 9 Miscellaneous Specifications 10 Serial Interface bise is 10 System Power
69. e slot is on top of the V F card AN WARNING Do not turn on the AC power now Test the connec tions first as explained below 5 Connect AC power wires to the MLS PS 6 Connect 727 terminal on MLS AIM to frame Ground Testing Connections AN WARNING Reversed polarity or incorrect voltage to the PM or AIM will damage your MLS and you will need to return it to Watlow Anafaze for repair Please don t damage your unit Read this section com pletely and follow the steps below before you apply power to your MLS 1 Unplug TB1 the green block which contains the Ex GND and V terminals from the MLS PM 2 Unplug the AIM cards from the AIM TB e Carefully insert a screwdriver in the hole on the side of the AIM s metal jacket e Gently press the screwdriver blade against the metal standoffs which separate the AIM cards Continue pressing gently until the AIM cards pop loose from the plastic bracket that holds them in place Then carefully grasp the AIM cards by the edges and remove them from the metal bracket You have removed the parts of the MLS which will be damaged by excess voltage so turn on the AC power and use a voltmeter to check voltages 3 Touch the meter Common lead to the COM terminal on the MLS PM the green block with the wires The voltage on the V termi nal of the MLS PM should be 10 to 28 Vdc The voltage on the EX terminal of the MLS PM should read 0 Vdc 4 If the vo
70. eat outputs set to Reverse for Cool outputs set to Direct Heat Cool Output Limit Setup Use this menu to limit the maximum PID control output for a loop s heat and cool outputs This limit may be continuous or it may be in effect for a specified number of seconds see Output Limit Time on the next page If you choose a timed limit the output limit restarts when the controller powers up and when the output goes from Manual to Automatic control via the front panel when the controller changes jobs or from ANASOFT The output limit only affects loops under automatic control It does not affect loops under manual control LOOP PROCESS _ UNITS 01 HEAT OUTPUT LIMIT 100 ALARM SETPOINT STATUS OUT Selectable range 0 100 Heat Cool Output Limit Time Heat Cool Output Override Use this menu to set a time limit for the output limit LOOP PROCESS UNITS 04 HEAT OUTPUT LIMIT TIME CONT ALARM SETPOINT STATUS __OUT Selectable values 1 999 seconds or CONT continuous Use this menu to set an output override percentage You can configure a digital input for the output override in the Setup Global Parameters main menu If the current loop is in Automatic mode and a sensor failure occurs the loop switches to the output override percentage manual mode If you change the polarity of the override output to the active state for instance by flipping a kill switch you have set up every loop switches to t
71. ectrical transmittance that conveys infor mation Solid State Relay SSR See Relay Solid State Span The difference between the lower and upper lim its 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 out put 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 thermo couple 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 semicon ductor material that exhibits a large change in resistance for a small change in temperature Thermistors usually have negative temperature coefficients although they are also available with positive temperature coefficients Thermocouple T C A temperature sensing device made by joining two dissimilar metals This junction produces an electrical voltage in proportion to the difference 128 MLS User s Guide in temperature between the hot junction sensing junction and the lead wire connection to the instrument cold junction TI Timed Integral The Integral term Transmitter A device that transmits temperature data from either a thermocouple or RTD
72. ed here for your convenience See the next page for wiring instructions gt VO RS 232 To Exp AIM RS 485 SIOM a Ribbon 7 Cable Remote Terminal Block 9 qe WIV MLS AIM Terminal Block XL UON SN N CD LY ab iX 5V Y REF Wiring Recommendations Installation This section gives general wiring recommendations DANGER Never wire bundles of low power Watlow Anafaze circuits next to bundles of high power AC wiring Instead physically separate high power circuits from the controller If possible install high voltage AC power circuits in a separate panel Use stranded wire Use solid wire for fixed service it makes inter mittent connections when you move it for maintenance Use 18 or 20 AWG wire Larger or smaller sizes may be difficult to install may break easily or may cause intermittent connections Use shielded wire The electrical shield protects the MLS from electrical noise Connect one end of the input wiring shield to the MLS panel s 120 Vac panel ground and connect one end of the out put wiring shield to the MLS panel s 120 Vac panel ground If your system requires a different shield configuration contact Wat low Anafaze for more information For more information about noise suppression see Noise Suppression
73. egative values Ambient Temperature The temperature of the air or other medium that surrounds the components of a thermal system 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 electricity current in the circuit Units are one coulomb 6 25 x 1018 electrons per second Analog Output A continuously variable signal that is used to rep resent a value such as the process value or set point value Typical hardware configurations are 0 20mA 4 20mA or 0 5 Vdc 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 particular thermal 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 commu nications measured in bits per second 121 Glossary Block Check Character BCC A serial communications error checking method An acceptable method for most applications BCC is the default method See CRC Bumpless Transfer A smooth transition from Auto closed loop to Manu
74. erial DAC for precision open loop con trol 0 5 Vdc 4 20 mAdc jumper selectable Contact Watlow Anafaze for more information about the DAC and Serial DAC Digital Inputs Number 8 Input voltage protection Diodes to supply and common Absolute maximum input 10 mA current Voltage levels lt 1 3V Low gt 3 7V High Maximum input current 1 2 mA from MLS with input at zero volts tance Maximum switch resis 1 Kohm tance to pull input low Minimum switch off resis 11 Kohm 8 MLS User s Guide Introduction Digital Outputs Standard Digital Outputs Number 34 continuous 10 mA sink referenced to 5 Vdc of MLS for SSR operation 20 mA momentary peak sink User selectable outputs 34 PID control Alarm control or Events Two outputs are not PID programmable Number of PID loops 16 or 32 programmable loops 16 loop systems have dual outputs 32 loop systems have 32 single outputs and you can individually configure outputs 17 32 as a second out puts for loops 1 16 PID control outputs Time Proportioning Distributed Zero Crossing or On Off all independently selectable for each loop Cycle Time 1 255 seconds Control Action Reverse heat or Direct cool independently selectable for each loop Off State Leakage Current lt 01 mA to DC common System Digital Outputs Number of system digital 2 outputs Configuration 1 global alarm 5 Vdc a
75. everse values Gas heat with motorized val 100 240 40 8 DZC DAC NA Reverse ues SP gt 1200 F Extruders with cooling Heat 50 300 90 8 TP 3 Reverse with SSRs Spread set to zero cool with 10 OFF OFF 4 TP 20 Direct solenoid valve Cool with fans 10 OFF OFF 4 TP 60 Direct Electric heat with open heat 30 20 OFF 4 DZC NA Reverse coils Electric heat with SCR con 60 60 15 4 DZC DAC NA Reverse trollers 106 MLS User s Guide Tuning and Control MLS User s Guide 107 Tuning and Control 108 MLS User s Guide Troubleshooting Troubleshooting The next few sections describe general troubleshooting for the MLS Later sections describe specific procedures like checking an input changing the EPROM and testing the controller First Check your Installation The controller is only part of your control system Often what appears to be a problem with the MLS is really a problem with other equipment so check these things first Controller is installed correctly See Chapter 2 Installation for help e Inputs like thermocouples and RTDs are installed correctly with correct scaling resistors and working correctly Second Replace Unit AN WARNING Manual Controller Reset Check the installation before you replace the con troller If the controller wasn t installed correctly for instance if you have shorted sensor inputs to high voltage lines or a transformer is shorted out and you
76. ews and the power supply mounting bracket MLS User s Guide 11570 00 rev 3 6 Addendum for MLS User s Guide 3 6 Wiring Your System from page 24 This section explains how to wire the components of your system Below is the system connections diagram reprinted here for your convenience See the next page for wiring instructions VO To RS 232 To Exp Aim RS 485 SIOM v MLS AIM Terminal Block 50 Pin Flat Ribbon Cable Remote Terminal Block RTB Addng OWA ovz 0Z1 Addng OVA Orz 0Z 1 t 5 lt MLS PS MLS User s Guide 11570 00 rev 3 6 Addendum for MLS User s Guide 3 6 Wiring Recommendations from page 25 This section gives general wiring recommendations AN WARNING Never wire bundles of low power Watlow Anafaze circuits next to bundles of high power AC wiring Instead physically separate high power circuits from the controller If possible install high voltage AC power circuits in a separate panel Use stranded wire Use solid wire for fixed service it makes inter mittent connections when you move it for maintenance Use 18 or 20 AWG wire Larger or smaller sizes may be difficult to install may break easily or may cause intermittent connections Use shielded wire The electrical shield protects th
77. ext These changes will be incorporated in the next manual revision System Power Requirements from page 10 MLS PM supply input 10 28 Vdc at 1 amp MLS AIM supply input 4 75 to 5 25 Vdc at lt 0 5 amp supplied by MLS PM MLS PS system power supply Input 120 240 Vac at 0 75 amp Output 15 Vdc at 1 2 amp 5 Vdc at 4 amp Dimensions and Weight from page 10 MLS PM 1 75 lbs 1 89 x 3 78 x 6 75 0 8 kg 4 75 cm x 10 cm x 17 cm MLS AIM TB 1 50 Ibs 5 0 x 6 50 x 5 50 0 7 kg 12 5 cm x 16 25 cm x amp AIM cards 13 75 cm MLS PS 1 2 Ibs 1 40 x 8 0 x 3 9 0 6 kg 3 56 cm x 20 32 cm x 9 91 cm RTB 5 Ibs 5 0 x 3 0 x 2 25 227 kg 12 7 cm x 7 6 cm x 5 7 cm MLS User s Guide 11570 00 rev 3 6 I Addendum for MLS User s Guide 3 6 Mounting the MLS PS from page 23 Follow these instructions to mount the MLS PS If you use your own power supply for the MLS please refer to the power supply manufacturer s instructions for mounting information Choose a power supply that supplies a regulated 10 to 28 Vdc at 1 watt and isolated return line Mounting Environment The MLS PS measures 1 40 x 8 x 3 9 Leave enough clearance around the power supply that you can remove it later Mounting Steps The MLS PS has a mounting bracket The bracket has two screw holes which will accept 6 or 10 screws To mount the MLS PS attach the power supply to your panel with the two scr
78. f the multimeter to the MLS 5V and the negative lead to the control output The multimeter should read 0 Vdc when the output is 0 and 5 Vdc when the output is 100 If the control output is not connected to an output device like an SSR connect an LED in series with a 1K resistor from 5 V to the output Tie the anode of the LED to 5V The LED should be Off when the output is 0 and On when the output is 100 You can check digital inputs and outputs from the Setup menus see Chapter 4 Setup or you can use the techniques described above for PID control outputs Troubleshooting Checking Computer Supervised Systems Computer Problems Serial Interface Problems These four elements must work properly in a computer supervised system The MLS The computer and its RS 232 or RS 485 serial interface The RS 232 or RS 485 communication lines The computer software For MLS 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 If you suspect computer problems run ANASOFT in Edit mode to find out if the computer works correctly See the ANASOFT User s Guide for a description of correct operation If ANASOFT tells you that your computer is not functioning contact your computer service representative Check your ANAINSTL pr
79. for a Returned Materials Authorization RMA number The RMA number helps us track your equipment and return it to you as soon as possible Try to figure out if the problem is in the MLS PM or the MLS AIM and send only that part for repair Troubleshooting Stand Alone Systems MLS PM Has No Power 110 MLS User s Guide The MLS is self contained so there are very few things you can test if it is not functioning properly However the MLS is only part of a control system check other parts of the system like thermocouples before you assume that the unit is broken You may assume that there is a problem if e The LEDs on the Analog Input Module AIM are not blinking The MLS Processor Module s LCD screen is not lit The LCD screen does not display graphics or characters The rest of this section describes common problems and solutions for stand alone systems If you supply power to the MLS PM and the LCD screen does not light up check the power supply and its connections Follow the instructions in the Power Wiring and Controller Test section of the Installation chapter Keys Don t Respond Troubleshooting If the MLS seems to function perfectly but the Man Auto Chng SP Alarm Ack and Ramp Soak keys do not respond when you press them then you are probably locked out of the system Ask your supervisor to unlock the keyboard according to the instructions in the Setup Global Parameters section Controller Message AI
80. gral Term TI Settings This table shows Integral vs Reset repeats per minute TI Reset TI Reset secs repeat repeats min secs repeatO repeats min 600 10 Setting the A General Rule Use 60 120 180 or 240 as a starting value for the TI Derivative Term TD Settings This table shows Derivative term TD vs Rate Minutes RM Rate TD 60 TD Rate TD Rate secs repeat repeats min secs repeat repeats min 5 08 35 58 10 16 40 66 15 25 45 75 20 33 50 83 25 Al 55 91 30 50 60 1 0 Setting the TD A General Rule Set the TD to 15 of TI as a starting value MLS User s Guide 105 Tuning and Control General PID Constants This section gives general PID constants Proportional Band Only P Set the PB to 7 of the setpoint Example Setpoint 450 set the Proportional Band to 31 Proportional with Integral PI Set the PB to 10 of setpoint Example Setpoint 450 set PB to 45 Set TI to 60 Set TD to Off Set the Output Filter to 2 PI with Derivative PID Set the PB to 10 of the SP Set the TI to 60 Set the TD to 15 of the TI Example TI 60 so TD 9 Set the Output Filter to 2 PB TI TD FIL OUTPUT CT Action Electric heat with solid state 50 60 15 4 TP 3 Reverse relays Electric heat with mechani 50 60 15 6 TP 20 Reverse cal relays Gas heat with motorized 60 120 25 8 DZC DAC NA R
81. he output override percentage you set here LOOP PROCESS UNITS 03 SENSOR FAIL HT OUTPUT 096 ALARM SETPOINT STATUS OUT Selectable range 0 10096 MLS User s Guide 85 Setup Heat Cool Nonlinear Output Curve Use this menu to select one of two nonlinear output curves for nonlinear processes LOOP PROCESS _ UNITS 03 OUTPUTS HEAT NLO OFF ALARM SETPOINT STATUS _ OUT Selectable values Curve 1 Curve 2 or Off linear no curve The linear curves are shown in the figure below Calculated by PID Output 0 40 60 80 100 Calculated by PID 86 MLS User s Guide Setup Loop Alarms Setup Press Yes at the Setup Loop Alarms prompt to access menus which change alarm function parameters for the current loop The main alarms menu looks like this LOOP PROCESS UNITS SETUP LOOP 04 ALARMS ALARM SETPOINT STATUS OUT Below is the alarms menu tree Notice the default values inside the boxes Low deviation alarm type OFF Setup Loop Alarms High process alarm setpoint 1000 F High process alarm type OFF Low deviation alarm dig out NONE High process alarm dig out NONE Low process alarm setpoint ie Low process alarm type OFF Deviation alarm value 5 F Low process alarm dig out NONE High deviation alarm type OFF Alarm deadband 2 F High deviation alarm
82. hin the number of scans you set here LOOP PROCESS UNITS 07 HEAT CONTROL FILTER 2 ALARM SETPOINT STATUS __ OUT Selectable range 0 255 Setting the output filter to O turns it off Use this menu to set the spread between the heat and cool output and the spread of the On Off control action LOOP PROCESS UNITS 01 HEAT SPREAD 5 F ALARM SETPOINT STATUS OUT Selectable range The spread ranges from 0 to 255 25 5 2 55 255 or 0255 depending on the way you set up the input menus MLS User s Guide 79 Setup Setup Loop Outputs 80 MLS User s Guide Press Yes at this prompt to access menus to change loop output parameters for the current loop including Enable or disable outputs Output type Cycle time for TP outputs SDAC parameters for SDAC outputs Control action Output level limit and limit time Output override Nonlinear output curve Both heat and cool outputs have the same menus so only one of each menu is explained in this section The next page shows a menu tree Here s the main menu LOOP PROCESS UNITS SETUP LOOP 03 OUTPUTS ALARM SETPOINT STATUS _ OUT The figure on the next page shows the menu tree for the output setup menus Notice the default values inside the boxes For TP outputs Setup Loop Outputs Heat Cool control out Output disabled Setup Output Enabled Heat Cool output type For S
83. ially set to Manual mode at 0 output level If you choose Memory the outputs are restored to the last output state stored in memory LOOP PROCESS UNITS POWER UP OUTPUT STATUS OFF ALARM SETPOINT STATUS _ OUT Selectable values Off or Memory AN WARNING Do not set the MLS to start from memory if a memory based restart is unsafe for your process MLS User s Guide 65 Setup Controller Address Use this menu to set the MLS controller address The controller address is used for multiple controller communications on a single RS 485 cable so each MLS must have a different address Begin with address 1 for the first controller and assign each subsequent controller the next higher address LOOP PROCESS _ UNITS CONTROLLER ADDRESS ALARM SETPOINT STATUS OUT Selectable Range a number between 1 and 32 Communications Error Checking 66 MLS User s Guide Use this menu to set the data check algorithm used in the ANAFAZE communications protocol to Block Check Character BCC or to Cyclic Redundancy Check CRC CRC is a more secure error checking algorithm than BCC but it requires more calculation time and slows the MLS communications BCC ensures a high degree of communications integrity so ANAFAZE recommends that you use BCC unless your application specifically requires CRC LOOP PROCESS UNITS COMMUNICATIONS ERR CHECK BCC ALARM SETPOINT STATUS _ OUT Selectable values BCC o
84. ing instrument is precise to fil gallon per minute so the appropriate display format is 999 to 3000 This table shows the input readings PV Displayed Sensor Input Reading FS 65 GPM 4 75 4 75 5 00V x 1009629596 3 GPM 0 5 0 5V 5 00V x 100 10 Based on these input readings use these scaling values Parameter Low Value High Value Process Value PV 3 GPM 65 GPM Input Reading RDG 10 0 95 0 120 MLS User s Guide Glossary A AC See Alternating Current AC Line Frequency The frequency of the AC power line measured in Hertz Hz usually 50 or 60 Hz Accuracy Closeness between the value indicated by a mea suring instrument and a physical constant or known standards Action The response of an output when the process vari able 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 or 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 inter vals and alternates positive and n
85. is shipped with heat outputs enabled and cool outputs disabled You can disable any PID output and use it for other digital output functions All digital outputs and PID outputs are sink out puts referenced to the 5Vdc supply These outputs are Low when they are On All digital inputs are Transistor Transistor Logic TTL level inputs referenced to control common This section discusses the MLS PID control and alarm outputs AN WARNING Control outputs are connected to the MLS s logic ground when the control output is On Low Be careful when you connect external devices that may have a low side at voltage other than control ler ground since you may create ground loops If you expect grounding problems use isolated solid state relays and isolate the control device inputs The MLS provides dual PID control outputs for each loop These outputs are on the 50 pin ribbon cable connector which connects to the RTB You can enable or disable them e The default setting is heat outputs enabled cool outputs disabled e You can program each output for on off TP or DZC control You can program each output for direct or reverse action e You can program a deadband for heat cool within that deadband both outputs will be Off Output Wiring Recommendations When you wire output devices to the RTB use multicolored stranded shielded cable for analog outputs and PID digital outputs connected to panel mount SSRs Analog o
86. l inputs job alarm setpoint ime Load setup from pue sample time Heat control TI p m Hiat Keypad test job alarm type Loop name Heat output Test digital Job control Heat control TD cycle time TP High process true 1 nput reading Cool control PB offset T C amp Output override RTD dig input Cool control TI Disp format Linear amp Pulse Override dig in active Cool control TD Input scaling Startup alarm Hi pv Linear amp Cool control filter delay Pulse Keyboard lock Input scaling pare status Hi rdg Linear amp Pulse Power up output Input scaling status Lo pv Linear amp Pulse Controller Input scaling address Lo RDG Linear amp Pulse Communications err check Lo pass filter Communications value Allen Bradley protocol Press Enter Alarm Ack Change Setpoint to reach these menus AC line freq Press Yes to use a menu Press Up or Down to change a Digout outputs value or select an option active Press Enter to store the value you AIM comm h h d failure output es Press Back to escape a menu EPROM without changing it information 60 MLS User s Guide SDAC Heat output action Heat output limit Heat output limit time Sensor fail Ht output Outputs heat NLO Cool c
87. l temperature control protection where a potential hazard exists could result in damage to equipment and property and injury to personnel The MLS includes a reset circuit that sets the control outputs off or to the data stored in memory if the microprocessor resets normally the result of a power failure and power return If a memory based restart will be unsafe for your process program the MLS Controller to restart with outputs off For additional safety program the computer or other host device to automatically reload the desired operating constants or process values on return of operating power However these safety features do not eliminate the need for external independent safety devices in potentially dangerous or unsafe conditions Watlow Anafaze also offers ANASOFT an optional software program for IBM AT or IBM PC compatible computers In the event of a reset ANASOFT will reload the MLS Controller with the current values in computer memory The user must ensure that this reset will be safe for the process Again use of ANASOFT does not eliminate the need for appropriate external independent safety devices Contact Watlow Anafaze immediately if you have any questions about system safety or system operation MLS User s Guide 3 Overview 4 MLS User s Guide Introduction Introduction The MLS is a modular control system with 32 fully independent loops of PID control It can function as a stand alone controller th
88. ltages are within the limits described above e Turn off the power Plug TB1 the green block which contains the screw terminals back into the MLS PM 28 MLS User s Guide Installation Turn the power back on The Processor Module s display should light up and after about a second the Bar Graph display should appear followed by the message AIM COMM FAIL 5 Connect the Common lead of the voltmeter to TB3 and the power lead of the voltmeter to the AIM TB terminal labeled 5V The voltage on the 5V terminal should be between 4 75 and 5 25 Vdc 6 If the voltages are within the limits described above A Turn off the power B Carefully insert the AIM cards back into the AIM Terminal Block C If you have unplugged the AIM COMM cable plug it back in D Press and hold the No key While pressing it turn the power back on This procedure is known as a manual controller reset or No Key reset The green LEDs on the AIM should blink which means that the unit is working normally If they do not blink contact Watlow Anafaze E The MLS PM will display a T C Break alarm message for each channel These messages are normal to clear them press Alarm Ack once for each control loop MLS User s Guide 29 Installation Testing Your System MLS AIM Test RTB Test PID Output Test 30 MLS User s Guide This section explains how to test the controller after installation Use this procedure to test the
89. lug this board to access the bottom board processor board The next figure shows the screws to remove 116 MLS User s Guide Troubleshooting 5 Locate the EPROM on the circuit board The EPROM is a 28 pin socketed chip which may have an ANAFAZE label on top of it If there is no label a small window will be visible in the middle of the top of the chip Do not confuse the EPROM with the RAM the RAM also has 28 pins but it is in a high profile socket and it does not have a label or a window The component designation U2 is printed on the processor board next to the EPROM socket The next figure shows the EPROM and the RAM chip 6 Remove the existing EPROM from its socket by prying it out with a small flathead screwdriver as shown below 7 Carefully bend the legs of the new EPROM against a flat surface until they line up with the holes in the EPROM socket 8 Carefully insert the new EPROM into the EPROM socket Make sure that the chip is oriented so that its notch faces the same way as the part outline on the board 9 Reverse steps 2 through 4 to reassemble the unit 10 Perform a manual controller reset The reset reinitializes the battery backed RAM You must perform a manual controller reset for the unit to operate properly MLS User s Guide 117 Troubleshooting 118 MLS User s Guide Linear Scaling Examples Linear Scaling Examples Example 1 Configuring a P
90. main active until the process variable goes below that value minus the deadband See the diagram on the next page If you don t use a digital output for PID control you can assign it to one or more process variable alarms The output is active if any of its alarms are active All alarm outputs are active Low or active High depending on the global alarm output polarity setting Low process and low deviation alarms activate when the process variable goes below a value you set They remain active until the process variable goes above that value plus the deadband The dia gram below shows these alarms 66 MLS User s Guide Setup When the controller 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 Alarm Limit SP Deviation Setpoint SP Deviation Low Alarm Limit High process alarm on High process alarm off Deadband High deviation alarm on Deadband High deviation alarm off cas Low deviation alarm off _ Ve eee alee oe EP rad oe ES a Ce he dde Deadband Low deviation alarm on Deadband Low process alarm on Low process alarm off Use menus to set the following process alarm parameters for each loop High and low process alarm type setpoint and digital output High and low deviation alarm type deviation alarm value and
91. ns the Alarm display switches to the next loop in alarm Acknowledge all alarms to clear the global alarm digital output The keyboard and display won t work for anything else until you acknowledge each alarm The alarm symbols are displayed as long as the alarm condition is valid Using the MLS Displaying Loading and Saving Jobs Job display appears only if You have turned on the Remote Job Select function This function is explained in Chapter 4 Setup You have selected a job from the job load menu When you load a job Job display shows you the following screen LOOP PROCESS UNITS JOB 3 RUNNING If you remotely loaded the job Job display looks like this LOOP PROCESS UNITS JOB 3 RUNNING REMOTELY LOADED ALARM SETPOINT STATUS __OUT If you modify a job s parameters while the job is running you ll see this job message LOOP PROCESS UNITS JOB 3 RUNNING DATA MODIFIED ALARM SETPOINT STATUS __ OUT If an alarm occurs the controller switches to Single Loop Display MLS User s Guide 55 Using the MLS Operator Menus You can perform these tasks from Single Loop Display Changing the Setpoint Press Chng SP from the loop you want to change this display appears LOOP PROCESS UNITS 01 SETPOINT Press Yes to change the setpoint Press Yes or No to change the setpoint value Press Enter to save your changes and return to Single Loop Display Press No or Back to return to
92. nternal Accuracy 0 1 at 25 C Calibration Automatic zero and full scale Temperature coefficient Less than 100 ppm C 0 01 per Analog Ground to frame Ground Max 40 V potential DC Common to frame Ground Max poten 40 V tial Thermocouple Ranges 350 to 1400 F 212 to 760 C 450 to 2500 F 268 to 1371 C 450 to 750 F 268 to 399 C 150 to 3200 F 66 to 1760 C 0 to 3200 F 18 to 1760 C 0 to 3210 F 18 to 1766 C mu tc Hau mi MLS User s Guide 7 Introduction RTD Ranges RTD1 148 0 to 572 F 100 0 to 300 0 C 0 1 C RTD2 184 to 1544 F 120 to 840 C 1 0 C RTD3 94 to 572 F 70 to 300 C 1 0 C Miscellaneous Specifications T C break detection Pulse type for upscale break detection and thermocouple alarm display Milliamp inputs 0 10 mA 0 20 mA 4 20 mA etc with scal ing resistors Infrared inputs power supply included with scaling resistors for IRSM Source impedance Measurements are within specification with up to 500 ohms source resistance Analog Outputs The Watlow Anafaze Digital to Analog Converter DAC is an optional module for MLS and CLS controllers It lets you convert a distributed zero crossing output signal to an analog process control signal You can purchase 4 20 mAdc 0 5 Vdc and 0 10 Vdc versions of the DAC Watlow Anafaze also offers the S
93. ntrollers See the ANASOFT User s Guide for more information about ANASOFT or contact ANAFAZE This figure shows the MLS front panel Ramp Soak Not available ANAFAZE MLS at this time PROCESS UNITS Alarm Ack Acknowledges ALARM SETPOINT STATUS OUT i Enter Stores data or menu choices amp advances to yes Back the next menu Selects a menu Aborts editing Starts scanning mode Change Setpoint Answers Yes and returns Gf pressed twice Changes process to Yes No prompts to a previous Setpoint Increases a number menu or choice No Skips a menu Answers No to Yes No prompts Decreases a number or choice you are editing Front Panel Keys Yes Up Using the MLS Press Yes to do these things Select a menu e Answer Yes to Yes No prompts Increase a number or choice you re editing e Stop scanning mode No Down Press No to do these things Skip a menu when the prompt is blinking Answer No to Yes No prompts Decrease a number or choice when editing Stop scanning mode Perform a manual controller No Key reset see next page AN WARNING Back A manual controller No Key reset clears the con troller s RAM and reinitializes the MLS PM s factory default values A manual controller reset is appropriate in these situations e After you change the PROM In some cases when troubleshooting see Chapter 6 Troubleshoot ing The Back key works like an esc
94. o call Watlow Anafaze s Technical Service Department if you have problems with your shipment or if the MLS components are missing or damaged cn eget Power Wires Signal Inputs PM to AIM Power Wires 50 Pin to Power Supply X Ribbon Cable MLS PM Outputs Control Alarm 50 Pin RTB MLS Processor Module PM Controller Mounting Kit MLS AIM Module 16 or 32 e AIM Cable 4 foot e RS 232 or RS 485 Com Cable optional Terminal Block 50 Ribbon Cable Power Supply optional Safety Overview Watlow Anafaze has made efforts to ensure the reliability and safety of the MLS Controller and to recommend safe usage practices in systems applications Please note that in any application failures can occur These failures may result in full control outputs or other outputs which may cause damage to or unsafe conditions in the equipment or process connected to the MLS Controller Good engineering practices electrical codes and insurance regulations require that you use independent external safety devices to prevent potentially dangerous or unsafe conditions Assume that the Watlow Anafaze MLS Controller can fail with outputs full on outputs full off or that other unexpected conditions can occur Install high or low temperature protection in systems where an overtemperature or undertemperature fault condition could present a fire hazard or other hazard Failure to instal
95. o use it set the output type for the appropriate loop to SDAC Tuning and Control ANAFAZE also offers the DAC another optional analog output module for the MLS It converts two DZC outputs to two 4 20 mA current outputs Output Digital Filter The output filter digitally filters the PID control output signal It has a range of 0 255 levels which gives a time constant of 0 127 5 seconds Use the output filter if you need to filter out erratic output swings due to extremely sensitive input signals like a turbine flow signal or an open air thermocouple in a dry air gas oven The output filter can also enhance PID control Some processes are very sensitive and require a high PB so normal control methods are ineffective You can use a smaller PB and get better control if you use the digital filter to reduce the high and low process output swings You can also use the filter to reduce output noise when a large derivative is necessary or to make badly tuned PID loops and poorly designed processes behave properly Reverse and Direct Action Reverse action is an output control action in which an increase in the process variable causes a decrease in the output Direct action is an output control action in which an increase in the process variable causes an increase in the output Heating applications normally use reverse action and cooling applications usually use direct action MLS User s Guide 103 Tuning and Control Setting Up
96. ogram to make sure that ANASOFT and the MLS are set for the same serial communications port ANA SOFT can use either COMI or COM2 Make sure that you have set the same error checking method either BCC or CRC in ANASOFT and in the processor module Check that the communications baud rate is also set to the same value either 2400 or 9600 in ANASOFT and in the processor module Make sure you are using DOS 5 0 or a later version of DOS Set the serial interface according to the manufacturer s instructions To test an RS 232 interface buy an RS 232 troubleshooter from Radio Shack Attach the troubleshooter between the MLS and the computer When ANASOFT sends data to the MLS the troubleshooter s TX LED should blink When it receives data from the MLS the RX LED should blink MLS User s Guide 113 Troubleshooting Communications Problems 114 MLS User s Guide Y 5 If you use the Black Box RS 485 interface make sure you have set it up correctly See the Communications section in Chapter 2 for RS 485 setup instructions The LEDs on the unit should blink but should not stay lit For either type of interface you can connect an oscilloscope to the transmit or receive line to see whether data is being sent or received If the serial interface does not function contact your computer service representative If you are experiencing communications problems check the communications interface cables and connections
97. ohm three wire platinum assembly as shown in the next figure Watlow Anafaze highly recommends that you use the three wire RTD to prevent reading errors due to cable resistance f you order an RTD1 RTD2 or RTD3 configuration we will con figure your MLS for the standard three wire RTD If you must use a two wire RTD jumper A to AUX f you must use a four wire RTD do not connect the fourth wire Watlow Anafaze offers three standard DIN 385 curve RTD input ranges as shown in the table below RTD Type MPU Renee Resolution RTDI 100 0 to 300 0 C 0 1C 148 0 to 572 0 F 0 1 F RTD2 120 to 840 C 1C 184 to 1544 F 1 F RTD3 70 to 300 C 1C 94 to 572 F 1 F This figure shows a typical 3 wire RTD connection 40 MLS User s Guide Installation Rear Terminal Block Connections Black IN 100 Ohm RTD Black IN Red Analog Common Current Inputs To install current milliamp inputs place resistors in the input section which convert the milliamp input into a voltage You can get different current input ranges if you select different resistor values The input connections for these inputs are the same as the input connections for voltage inputs Voltage Inputs Connect the side of the voltage input to the A terminal Connect the side of the input to the A terminal The voltage input range is 10 to 60 mV Scale signals larger than 60 mV with a scaling resistor which
98. oint the out put increases For direct action usually cooling as the process increases above the setpoint the output increases Control Mode The type of action that a controller uses For example On Off time proportioning PID Auto matic 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 Charac ter 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 the deadband specific conditions can be placed on control output actions Operators select the MLS User s Guide deadband It is usually above the heating propor tional 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 process and compensates to minimize overshoot an
99. ol mode LOOP PROCESS _ UNITS 12 LO DEVIATION ALARM OFF ALARM SETPOINT STATUS __OUT Selectable values Alarm Control Off Low Deviation Alarm Output Number Use this menu to assign a digital output that activates when the loop is in low deviation alarm LOOP PROCESS UNITS 12 LO DEV ALARM DIG OUT NONE ALARM SETPOINT STATUS __ OUT Selectable values Any output number between 1 and 34 as long as it isn t used for control or the SDAC clock You may also select NONE MLS User s Guide 93 Setup J NOTE All digital outputs are OR ed 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 Low Process Alarm Setpoint Low Process Alarm Type Use this menu 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 LOOP PROCESS UNITS 01 LO PROC ALARM SETPT 0 F ALARM SETPOINT STATUS __OUT Selectable range Any value within the input sensor s range Use this menu to turn off the low process alarm or set it to the Alarm or Control function LOOP PROCESS UNITS 01 LO PROC ALARM TYPE OFF ALARM SETPOINT STATUS OUT Selectable values Alarm Control Off Low Process Alarm Output N
100. on output Flexible Alarm Outputs You can set independent high low process alarms and a high low deviation band alarm for each loop Each alarm can activate an individual digital output or it can be grouped with other alarms to activate a single digital output Alarm or Control Outputs You can set high low deviation and high low process setpoints to operate separate digital outputs as on off control functions instead of as alarms The control function will not have alarm notification or global alarm output Global Alarm Output When any alarm is triggered the Global Alarm Output is also triggered and it stays on until you acknowledge it Watchdog Timer The MLS watchdog timer System Safe output provides a digital output which notifies you if the system fails MLS User s Guide 5 Introduction 6 MLS User s Guide Front Panel or Computer Operation You can set up and run the MLS Controller from the processor module s front panel or from a local or remote computer Watlow Anafaze offers ANASOFT our IBM AT or IBM PC compatible software you can use to operate the MLS ANASOFT has these features e Graphic Trend Plotting Process Overviews Printouts e Data Archiving in Lotus Compatible Files Multiple Job Storage You can store up to 8 jobs in protected memory and access them by entering a single job number Each job is a set of operating conditions including setpoints and alarms so if a single oven produces multiple p
101. ontrol out alarm value High deviation alarm type Alarm dig out Low deviation alarm type Low deviation alarm dig out Low process alarm setpoint Low process alarm type Cool output type Low process alarm dig out Cool output cycle time SDAC menus SDAC Cool output action Cool output limit Cool output limit time Sensor fail Cl output Outputs cool NLO Alarm dead band Alarm delay Setup Setup Global Parameters Menu The setup global parameters menu looks like this LOOP___PROCESS UNITS SETUP GLOBAL PARAMETERS ALARM SETPOINT STATUS __OUT Below is the setup global parameters menu tree Notice the default values inside the boxes Setup Global Parameters Power up output status OFF Save setup to job 1 Controller address 1 Load setup from job 1 Communications err Job control digital inputs check BCC NONE Communications baud rate 9600 Job digital input true LOW Allen Bradley protocol Output override dig input NONE AC line freq 60 HERTZ Override dig in active LOW Digout outputs active LOW Startup alarm delay ae 0 ae AIM communications failure output NONE Keyboard lock status OFF EPROM information MLS User s Guide 61 Setup
102. ool control TI 60 Sec R Heat control TI 60 Sec R Cool control TD 0 Sec Heat control TD 0 Sec Cool control filter Heat control filter 2 L2 Soe Er eat Coo Cool control PB 50 F spread 5 F MLS User s Guide 77 Setup Heat Cool Control PB Use this menu to set the Proportional Band LOOP PROCESS UNITS 01 HEAT CONTROL PB 50 F ALARM SETPOINT STATUS __ OUT J NOTE Heat Cool Control TI Heat Cool Control TD 78 MLS User s Guide The MLS internally represents the proportional band PB as a gain value When you edit the PB you ll see the values change in predefined steps small steps for narrow PB values and large steps for wide PB values The controller calculates the default PB for each input type according to the following equation Default PB High Range Low Range Gain Use this menu to set the Integral term or Reset LOOP PROCESS UNITS 01 HEAT CONTROL TI 180 SEC R ALARM SETPOINT_ STATUS __OUT Selectable range 0 6000 seconds Use this menu to set the derivative constant LOOP PROCESS UNITS 15 HEAT CONTROL TD 0 SEC ALARM SETPOINT STATUS _ OUT Selectable range 0 255 seconds Heat Cool Output Filter Heat Cool Spread Setup Use this menu to dampen the heat or cool output s response The output responds to a step change by going to approximately 2 3 of its final value wit
103. or circuits 125 Glossary See Electromagnetic Interference Noise Suppression The use of components to reduce electrical inter ference 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 Offset 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 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 con tinuity between the two networks Output Control signal action in response to the difference between setpoint and process variable 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 126 MLS
104. p Display select the loop you wish to edit 2 While still in Single Loop Display enter the pass sequence below Press Enter Alarm Ack Change Setpoint ALAAM ASK 3 The first setup menu appears NOTE For your protection MLS reverts to Single Loop Dis play If you don t make any changes for three minutes Press Yes to select this menu or No to advance to the next menu press Yes No to toggle between the options in your menu Press Enter to store the value you have selected If you decide not to edit the menu press Back to stop editing and return to the main menu In the next sections you will find detailed information about the submenus for each of the six main menus Each display contains the default value for that specific menu and below each display you will see the range of choices for that menu The next page shows a diagram describing the six main menus and all the submenus in each one of them MLS User s Guide 59 Setup dig inputs Input units Job digital input Heat control filter SDAC menus alarm dig out Deviation Digital output number Setup Global Setup Loop xx Setup Loop x Setup Setup Manual I O Parameters Input Control Params Outputs xx Alarms save setup to Input type Heat control PB Heat control out High process Digita
105. put sensor to type J T C from the Setup menus Place a short across the input The process variable should indicate ambient temperature If it does not call ANAFAZE for an RMA number and return the unit for repair If the process variable indicates ambient temperature then the MLS is working correctly and the problem lies in the sensor or sensor wiring You can test T C or RTD sensors with a Multimeter MLS User s Guide 111 Troubleshooting check thermocouple inputs unplug the AIM module and measure between the A and A terminals of the AIM TB Thermocouple inputs should not read above 200 ohms To check RTD inputs unplug the AIM module and measure between the A and A terminals Then measure between the A and A COM terminals of the AIM TB RTD inputs should read between 20 and 250 ohms Both readings should be the same Make sure other inputs operate within the AIM s full scale voltage 60 mVdc If they do not install scaling resistors on the MLS AIM TB see Chapter 2 Installation Checking PID Control Outputs Checking Digital I O 112 MLS User s Guide To check control outputs Set the loop you want to check to Manual mode Set the output power percentage to the desired level Set the output type to On Off or TP see Chapter 4 Setup Testing Control Output Devices To test a control output device like an SSR use a digital multimeter set to DC voltage Connect the positive lead o
106. r CRC NOTE If you are using ANASOFT be sure to configure ANAINSTL for the same error checking method that you set in this menu Setup Communications Baud Rate Use this menu to set the Communications Baud Rate to 2400 or 9600 baud LOOP PROCESS _ UNITS COMMUNICATIONS BAUD RATE 9600 ALARM SETPOINT STATUS __ OUT Selectable values 9600 or 2400 Allen Bradley Protocol AC Line Frequency NOTE If you use ANASOFT be sure to set ANAINSTL to the same baud rate that you set in this menu Use this menu to set the protocol type to either Allen Bradley or ANAFAZE LOOP PROCESS UNITS ALLEN BRADLEY PROTOCOL NO ALARM SETPOINT STATUS __ OUT Selectable values Yes or No Use this menu to configure the controller to match an AC line frequency of 50 or 60 Hz This function is provided for international users who require 50 Hz lines Since the controller reduces the effect of power line noise on the analog measurement by integrating the signal over the period of the AC line frequency the controller s noise rejection will suffer if the line frequency is not set correctly LOOP PROCESS UNITS AC LINE FREQ 60 HERTZ ALARM SETPOINT STATUS __OUT Selectable values 60 Hz or 50 Hz NOTE If you change the AC line frequency you must switch power to the MLS on and off for the change to take effect MLS User s Guide 67 Setup Digital Output Polarity Use thi
107. ressure Sensor You re using a pressure sensor that generates a 4 20 milliamp signal The sensor generates 4 milliamps at 0 0 PSI and 20 mA at 50 0 PSI Setup You connect the sensor to a loop input set up with a resistor scaling network to produce 60 millivolts at 20 mA See the Inputs section of Chapter 2 Installation for more information on scaling networks The sensor measures PSI in tenths so the appropriate display format is 999 9 to 3000 0 This table shows the input readings PV T9 Displayed Sensor Input Reading FS 50 0 PSI 20 100 0 0 PSI 4 100 x 4ma 20 ma 20 Based on these input readings use these scaling values Parameter Low Value High Value Process Value PV 0 0 PSI 50 0 PSI Input Reading RDG 20 0 100 0 MLS User s Guide 119 Linear Scaling Example 2 Configuring a Flow Sensor You connect a flow sensor to the MLS to measure the flow in a pipe The sensor generates a 0 5V signal The sensor s output depends on its installation Measurements of the flow in the pipe indicate that the sensor generates 0 5 volts at three gallons per minute GPM and 4 75 volts at 65 GPM The calibration instruments are precise to 1 gallon per minute Setup The sensor is connected to a loop input set up with a resistor voltage divider network to produce 60 millivolts at 5 volts See the Inputs section of the Installation chapter for information on scaling networks The calibrat
108. roducts simply enter one job number to set up every loop Dual Outputs Standard for 16 Loops The 16 loop MLS Controller includes dual control outputs for each loop and a second set of control constants for heating and cooling applications Flexible Outputs Standard for 32 Loops The 32 loop MLS Controller is factory set for a single heat output for each input Outputs for loops 17 32 can be assigned as second outputs for loops 1 16 Introduction Specifications This section shows specifications for the MLS including inputs outputs serial interface information system power requirements and environmental and physical specifications Analog Inputs Number of control loops 16 dual output or 32 single output plus one pulse loop Number of analog inputs 16 with AIM 16 or 32 with AIM 32 Input switching Differential solid state MUX switching Input sampling rate 16 loops per second Analog over voltage protection between 70 V peak to peak maximum inputs Maximum analog input voltage 10 V from or input to analog common Common mode voltage 500 Vac maximum analog common to MLS PM or MLS AIM power supply common CMR Common Mode Rejection gt 85 dB at 60 Hz 110 dB typical A D converter Integrates voltage to frequency Integration time per loop 33 3 ms at 60 Hz line frequency Input range 10 to 60 mV or 0 to 25 V with scaling resis tors Resolution 0 02 greater than 12 bits i
109. rs AIM Communications Port Tel 1 CO GGG GOP VPOOY PLOY 0000000000000000 SSSSSSSSSG a Se OOS ia DC 8V LA J REF The loop input number is marked on the terminal block the number 1 indicates an input for loop 1 the number 2 an input for loop 2 etc The A terminal is the positive input of the analog signal The A terminal is the negative input of the analog signal 36 MLS User s Guide Installation The AUX terminal is the Auxiliary input This is analog common used for RTD inputs AN WARNING Do not exceed 10 Vdc between loops Excess volt age may damage the Analog Input Module AIM Input Wiring Recommendations Input Scaling Use multicolored stranded shielded cable for analog inputs Watlow Anafaze recommends that you use 20 AWG wire If the sensor manufacturer requires it you can also use 22 or 24 AWG wiring Most inputs use a shielded twisted pair some require a 3 wire input You can connect thermocouples 4 20 mA current inputs voltage inputs and 2 or 3 wire RTD inputs to the MLS If you need to scale input voltages or convert milliamp inputs to match the 10 to 60 mV 16 7 to 100 input range install scaling resistors Watlow Anafaze can supply factory installed input scaling resi
110. rtup they may interfere with ANASOFT Thesoftware key is properly installed on the printer port It should plug into the printer port with the female end toward the computer and the male end toward the printer Do not remove the screws on the software key to connect it If after you check these things ANASOFT still does not work correctly consult the ANASOFT User s Guide for more troubleshooting information MLS User s Guide 115 Troubleshooting Changing the EPROM Changing the EPROM involves minor mechanical disassembly and reassembly of the controller but you don t need any soldering or electrical expertise You ll need a Phillips head screwdriver and a small flathead screwdriver Cun Y If you change the EPROM you must perform a manual controller reset for the EPROM change to take effect A manual controller reset changes all controller parameters back to their default values so you must reenter the desired values from ANA SOFT or from the controller s front panel after you change the EPROM 1 Power down the controller Be sure to take antistatic precautions 2 Remove the two or four screws from the sides of the controller front panel and remove the two screws from the top of the case as shown below 3 Remove the electronics assembly from the case as shown below 4 Unscrew the four screws at the corners of the top board and carefully unp
111. s menu to set the polarity of the digital outputs used for alarms The output can be active High or active Low LOOP PROCESS _ UNITS DIGOUT OUTPUTS ACTIVE LOW ALARM SETPOINT STATUS _ OUT Selectable values High or Low AIM Communications Failure Output EPROM Information 66 MLS User s Guide Use this menu to select the digital output that activates if communications fail between the MLS AIM and the MLS PM You can use this output along with the Global Alarm output to power an alarm horn or buzzer that sounds if communications fail between the AIM and the PM The global alarm will activate if there is an AIM communications failure and will reset automatically when the problem is corrected The controller will revert to manual mode during an AIM communications failure LOOP PROCESS UNITS AIM COMM FAILURE OUTPUT NONE ALARM SETPOINT STATUS _ OUT Selectable values any output from 1 to 34 as long as it s not used for control or for SDAC clock or NONE Use this last menu of the Setup Global Parameters main menu to see the controller s EPROM version and checksum LOOP PROCESS _ UNITS MLS Press any key from this menu to return to the Setup Parameters menu Setup Loop Input Setup The Setup Loop Input main menu lets you access menus which change loop input parameters Input type Input scaling and calibration Input filtering The next section explains how to configure inputs via
112. screw terminal interface for control wiring which allows you to easily connect external real world wiring to the MLS The RTB connects a 50 pin flat ribbon cable to a screw terminal block which accepts 18 or 20 AWG wires The ribbon cable receptacle has a locking latch which keeps the cable in place The RTB s 34 digital outputs are sink outputs referenced to the 5 Vdc power supply of the MLS Controller They are Low when the output is On The firmware allows you to globally change the alarm and control outputs default state no alarms from On to Off for System Safe output The outputs are rated at a continuous 10 mAdc if all outputs are On at the same time Initial power up current should not exceed 20 mAdc MLS AIM and AIM TB Technical Description The MLS Analog Input Module MLS AIM containing the AIM TB AIM Terminal Board and AIM s plug in cards receive input signals from sensors and pass them to the MLS PM The MLS AIM TB contains the power supply terminals input signal wiring screw terminals input signal conditioning circuits and terminal connections for the AIM s plug in cards It also contains a cold junction temperature sensor and room for the input scaling resistors if required RTDs inputs greater than 60 mVdc and mAdc current inputs require input scaling resistors The AIM TB has three slots for the plug in AIM cards There are two versions of the MLS AIM the AIM 16 and AIM 32 The AIM 16 has one multiplexer
113. ss Variable PV See Process Variable PV High Reading An input level that corresponds to the high pro cess value For linear inputs the high reading is a percentage of the full scale input range For pulse inputs the high reading is expressed in cycles per second Hz Infrared A region of the electromagnetic spectrum with wavelengths ranging from one to 1 000 microns These wavelengths are most suited for radiant MLS User s Guide 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 1 Control action that automatically eliminates off set or droop between setpoint and 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 mem ory also called a Recipe Junction The point where two dissimilar metal conductors join to forma thermocouple L Lag The delay between the output of a signal and the response of the instrument to which the signal is sent Linear Input A process input that represents a straight line function Linearity The deviation in response from an expected or theoretic
114. stors order option MLS SI XX See the next table for standard scaling resistor values or special input kits MLS SIK XX call Watlow Anafaze for XX number Scaling Values Scaling values for mVdc ranges are standard metal film values with 0 25 accuracy if 0 1 tolerance resistors are used e Scaling values for mAdc ranges 0 1 tolerance with 0 10 accuracy Scaling values for RTD ranges are 0 05 tolerance Use these values to remain within factory specifications for the RTD inputs Use 0 1 metal film 1 4 watt resistors Higher tolerances may cause significant errors Use the MLS built in linear scaling to correct any errors due to resistor tolerance You can also install other com ponents like capacitors for signal conditioning please consult Watlow Anafaze for more information This figure shows an input circuit RA RB RC and RD refer to the scaling resistor locations printed on the MLS AIM s terminal board MLS User s Guide 37 Installation 38 MLS User s Guide Analog To Input MLS AIM Terminal Circuitry IN Internal RA 42 5 Vdc i Reference RD RB RC A IN 47 uF A COM ae C 47 uF 77 This table shows scaling resistor values Input Range RB RC RD All T C 0 60 mVdc Jumper RTD1 100 0 to 300 0 5 49K 5 49K 80 RTD3 70 to 300 C 11 0K 11 0K 100 0 10 mAdc 450 to Jumper 6 0 0 20 mAdc 4 20 mA 2500 Jumper 3 0
115. structions are written for non electricians If you are an experienced electrician they may seem elementary to you If so feel free to skim them When you have connected each component of your system install and connect input and output devices For help with inputs and outputs see the Outputs and the Inputs sections in this chapter Connecting Power and RTB to MLS PM Remove the temporary covers you placed on 5 housing n Connect the power supply terminal labeled DC COM to the termi nal labeled GND on the Processor Module This terminal is DC common it is not frame chassis or earth ground Connect the power supply terminal labeled 12 to the terminal labeled V on the Processor Module 4 Connect the 50 pin ribbon cable to the Processor Module Plug it in so that the red stripe is on the left side under TB1 5 Connect the ribbon cable to the RTB Plug it in so that the red stripe is closest to screw terminal 1 Connecting Power and Common to AIM TB 1 Connect the terminal labeled EX on TB1 of the MLS PM to the ter minal labeled 5V on the MLS AIM 2 Connect the terminal labeled COM on TB1 of the MLS PM to the MLS AIM terminal labeled DC COMMON MLS User s Guide 27 Installation 3 Plug the AIM communications cable into the slot on the MLS PM labeled To AIM 4 Plug the other end of the AIM communications cable into the slot on the MLS AIM labeled Tel 1 Th
116. t The output responds to a step change by going to approximately 2 3 its final value within the numbers of scans that are set 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 electrical circuit Gain can also refer to the Proportional P mode of PID Global Alarm Alarm associated with a global digital output that 124 MLS User s Guide 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 poten tial as the surrounding earth Electrical systems are usually grounded to protect people and equip ment from shocks due to malfunctions 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 24 VAC or Vdc and any current level above 50 mAac 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 Proce
117. t 10 mA sink 1 System Safe CPU Watch dog Timer 5 Vdc at 10 mA sink MLS User s Guide 9 Introduction Miscellaneous Specifications Serial Interface Type RS 232 3 wire or RS 485 4 wire Isolation RS 232 None RS 485 To EIA RS 485 specification Baud Rate 2400 or 9600 user selectable Error Check BCC or CRC user selectable Number of Controllers 1 with RS 232 communications 32 with RS 485 communications 16 with open frame units Protocol Form of ANSI X3 28 1976 D1 F1 compatible with Allen Brad ley PLC full duplex System Power Requirements MLS PM supply input 10 28 Vdc at 1 amp MLS AIM supply input 4 75 to 5 25 Vdc at lt 0 5 amp supplied by MLS PM MLS PS system power supply Input 120 Vac at 0 5 amp Output 12 Vdc at 1 amp Environmental Specifications Storage Temperature 20 to 70 C Operating Temperature 0 to 50 Humidity Conditions 10 to 95 non condensing Dimensions and Weight MLS PM 1 75 Ibs 1 89 x 3 78 x 6 75 0 8 kg 4 75 cm x 10 cm x 17 cm MLS AIM TB 1 50 Ibs 5 0 x 6 50 x 5 50 0 7 kg 12 5 cm x 16 25 cm x amp AIM cards 13 75 cm MLS PS 1 50 Ibs 1 90 x 8 10 x 4 90 0 7 kg 4 75 cm x 20 25 cm x 12 25 cm RTB Ibs 5 0 x 3 0 x 2 25 227 kg 12 7 cm x 7 6 cm x 5 7 cm 10 MLS User s Guide Introduction Expanded Parts List The Expan
118. to Bar Graph display Press Enter twice to get to the Single Loop Scanning display The Single Loop Scanning display shows information for each loop in sequence Data for each loop displays for one second Press Back Yes or No to return to the Single Loop display Interpreting Alarm Display If an alarm occurs the alarm interrupts any other display and switches to the alarm display as shown in the next figure If the MLS is in Bar Graph display it switches to Bar Graph Alarm display If it is in Single Loop display it switches to Single Loop Alarm display Loop Number LOOP PROCESS UNITS or Name Ol gt gt A a 88 AAAA MAMA ALARM SETPOINT __STATUS__OUT Alarm Symbols Loop Status Process Variable 02 180 oF 180 AUTO 0 Alarm Symbols Engineering Units Loop number or Name Output Percentage Setpoint MLS User s Guide 53 Using the MLS 54 MLS User s Guide This table shows the symbols used in each form of the alarm display Bar Graph Single Loo ET Gabel corel i gt High Process Alarm gt HD High Deviation Alarm lt LP Low Process Alarm lt LD Low Deviation Alarm B T C Break Open Input Error S RTD Short RTD Short Alarm RTD Open RTD Open Alarm Aim Comm Aim Fail MLS AIM Failure Communications Failure Acknowledging an Alarm Press Alarm Ack to acknowledge the alarm If there are other loops with alarm conditio
119. ud eer 72 Display Format uti Reo set erst 74 High Process Value a den tae detecte tado 74 Hish tdeo 75 Leow Process etta dees 75 Low Meam cA nans 75 qu 76 Setup Loop Control Parameters eese 77 Heat Cool Control PB nete 78 Heat Cool Control LE us notte tle hd 78 Heat Cool Control TD nitet 78 Heaut ool Output Filter eere etes 79 beau COOL STAG sica adt iae uaa ie Been hs 79 Setup Loop OUtpuls 80 Enable Disable Heat and Cool Outputs 82 Heat or Cool Output Type isse 82 Heat Cool Cycle Time 83 SIXAC Mens uei itu eed 83 83 SDAC High Value 84 SID AC Low oie Gg tt rene cect tari 84 Heat Cool Output Action iiie ioa Servo tdeo 84 Heat Cool Output Limit eene 85 Heat Cool Output Limit Time sss 85 iii Contents MLS User s Guide Heat Cool Output Override esses 85 Heat Cool Nonlinear Output Curve 86 Setup Loop Alaris car c dead iets 87 Apnd SU WISE Soo 88 Alarm Delay tuii ast tr a REIS Ge t ie ha Re Ee ui 90 High Process Alarm Setpoint
120. umber 94 MLS User s Guide Use this menu to assign the digital output that activates when the loop is in low process alarm LOOP PROCESS UNITS 04 LO PROC ALARM DIG OUT 31 ALARM SETPOINT STATUS _ OUT Selectable values Any output number between 1 and 34 as long as it isn t used for control or the SDAC clock You may also select NONE Alarm Deadband Loop Alarm Delay Setup J NOTE All digital outputs are OR ed 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 Use this menu to set an alarm deadband This deadband value applies to the high process low process high deviation and low deviation alarms for the loop you are editing Use the Alarm Deadband to avoid repeated alarms as the PV cycles slightly around an alarm value LOOP PROCESS UNITS 03 ALARM DEADBAND 2 F ALARM SETPOINT STATUS _ OUT Selectable values The default range is 0 to 255 25 5 2 55 255 or 0255 depending on how you set up the input menus Use this menu to set a loop alarm delay There are two types of alarm delay the startup alarm delay and loop 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 loops for a specified time after the controller powers up The loop alarm delay in contrast is set separately for ea
121. und Software Problems Troubleshooting This section gives some solutions for software problems User Written Software If you don t want to use ANASOFT as your software interface to the MLS you are responsible for the correct operation of the software you buy or write You can request the ANAFAZE Communications Specification if you want to write your own software ANAFAZE will answer any technical questions that arise during your software development process but ANAFAZE does not otherwise support user software in any way If you write your own software first write a routine that sends and receives display commands to and from the MLS The protocol includes all characters so the display should show the hexadecimal values of the data sent in both directions If you have problems with the software you write you can use this program to test your communications ANASOFT If ANASOFT is not working check these things first e ANAINSTL the ANASOFT installation program has the cor rect path for the program and data files e All the necessary files exist in the directory specified by the path Your computer has enough memory ANASOFT requires up to 640K of free memory to run To maximize the amount of free mem ory available use a memory manager like HIMEM from DOS 5 0 Your computer is not running memory resident programs Check your AUTOEXEC BAT file to make sure that no memory resident programs automatically run on sta
122. ut is proportioned and it can be any value from 1 to 255 seconds For example if the output is 30 and the Cycle Time is 10 seconds then the output will be on for 3 seconds and off for 7 The figure below shows typical TP and DZC graphs TP 30 DZC 33 Off 0 3 10 0 3 4 6 Seconds Cycle Time 10 AC Cycle Distributed Zero Crossing DZC DZC output is essentially a Time Proportioning output However for each AC line cycle the controller decides whether the power should be On or Off There is no Cycle Time since the decision is made for each line cycle Since the time period for 60 Hz power is 16 6 ms the switching interval is very short and the power is applied uniformly Switching is done only at the zero crossing of the AC line which helps reduce electrical noise DZC output is primarily used for very fast acting electrical heating loads using Solid State Relays SSRs For instance the open air heater coil is an example of a fast acting load Do not use DZC output for electromechanical relays The combination of DZC output and a solid state relay can inexpensively approach the effect of analog phase angle fired control Analog Outputs The Serial DAC is an optional analog output module for the CLS It lets the controller output precision analog voltages or currents typically for precision open loop control motor or belt speed control or phase angle fired control T
123. utputs usually use a twisted pair Digital outputs have 9 to 20 conductors depending on wiring tech nique MLS User s Guide 31 Installation 32 MLS User s Guide Ribbon Cable Recommendations Use the 50 pin connector for both ends of the 50 pin flat ribbon cable Do not connect either end to a screw terminal the cable wire is too small to withstand much flexing Do not exceed 15 of 50 conductor cable Using the Cable Tie Wraps When you have wired outputs to the TB 50 install the cable tie wraps shipped with it This diagram shows the cable tie wrap holes Each row of terminals has a cable tie wrap hole at one end Thread the cable tie wrap through the cable tie wrap hole Then wrap the cable tie wrap around the wires attached to that terminal block Installation PID Control and Alarm Output Connections Typical digital control outputs use external optically isolated solid state relays SSRs The SSRs use 3 to 32 Vdc input for control and you can size them to switch up to 100 amps at 480 Vac For larger currents use these optically isolated relays to drive contactors NS y NOTE Control outputs are sink outputs They are Low when the output is On Connect them to the nega tive side of Solid State Relays The next figure shows sample heat cool and alarm output connections PID Heat 1 PID Cool 1 DIG Output 32 Alarm 5 Vdc System Safe Watchdog Timer constantly monitors the MLS CPU
124. white Lpy 1 RXA Black TX 2 Black TX 2 RXB Ti TX 5 eN TX 5 Ground Silver 6 Silver 6 SY NOTE Connect the shields to earth ground only at the computer or other 485 interface Do not connect the shield at the MLS Connect a 200 ohm termi nating resistor between RX and RX at the last MLS Ju3 The loop resistance of the transmission line wire only not terminating resistor must not exceed 200 ohms This table shows RS 485 connections RS 485 Connection TXB RX Pin 1 Blue White TXA RX Pin 3 Red RXB TX Pin 5 Yellow RXA TX Pin 2 Black Ground Pin 4 Green Shield Shield Pin 6 Not jumpered internally EIA Standard RS 485 specifies the electrical characteristics of transmitters and receivers for digital multi point systems Watlow Anafaze equipment meets RS 485 and RS 422 standards However RS 485 does not specify transmission lines signaling rates protocols etc Watlow Anafaze recommends the following e Maximum signaling rate 9600 baud Twisted shielded pairs for the RS 485 cables 44 MLS User s Guide Installation Recommended Wire Gauges This table shows maximum distances and wire gauges for communications wiring Distance Wire Gauge Recommended Cable 4000 ft 24 AWG Belden 9729 Belden 9842 6000 ft 22 AWG Belden 9184 You may wish to use a shield depending on your noise environment and grounding problems These cables are shielded ML
125. y to avoid mounting them in the same panel as Watlow Anafaze equipment Separate the 120 Vac power leads from the low level input and output leads connected to the MLS Don t run the digital output or PID control output leads in bundles with 120 Vac wires Never run input leads in bundles with high power leads see the General Wiring section Installation If you must use EM relays and you must place them in a panel with Watlow Anafaze equipment use a 01 microfarad capacitor rated at 1000 Vac or higher in series with a 47 ohm 1 2 watt resistor across the normally open NO contacts of the relay load This network is known as an arc suppressor or snubber network You can use other voltage suppression devices but they are not usually required For instance you can place a metal oxide varistor MOV rated at 130 Vac for 120 Vac control circuits across the load which limits the peak AC voltage to about 180 Vac You can also place a transorb back to back zener diodes across the digital output which limits the digital output loop to 5 Vdc You can get these parts from Watlow Anafaze The above steps will eliminate most noise problems If you have further problems or questions please contact Watlow Anafaze Wiring and Testing Your System After you install each component of the MLS use this section to connect them If these instructions are not clear to you refer to the system connections diagram for more information These in
126. you selected a continuous output limit the controller sets the loop to the output limit The autotune function calculates the appropriate PID constants for the loop and puts the loop in automatic control with the calculated PID values The Autotune function will abort if The process variable goes over 75 of the setpoint Remember the controller is at 100 output or at the output limit you set The controller has not calculated PID constants after 10 minutes due to heater failure sensor failure etc If the autotune function aborts it puts the loop into its previous control state Automatic or Manual control at the previous output percentages To automatically tune a loop follow these steps 1 Make sure the process is cold or stable and well below setpoint 2 Initiate Autotune 1 Use the front panel keypad to go to Single Loop Display 2 Press the Man Auto key 3 Choose Tune 4 Press Enter The Tune indicator will flash and the controller will return to Single Loop Display The Tune indicator will flash as long as the loop is tuning Setup The Setup menus let you change the MLS detailed configuration information If you have not set up a Modular Loop System before or if you don t know what values to enter please read first the next chapter Tuning and Control which contains PID tuning constants and useful starting values How to enter the Setup menus How to edit a menu 1 In Single Loo

Watlow Electric ANAFAZE SYSTEM 32 User`s guide

Contents

Download Pdf Manuals

Related Search

Related Contents