Watlow MLS Uživatelský manuál

MLS User’s Guide Part No. 11570-00. Revision 3.7 November 1995Watlow Controls1241 Bundy Blvd.Winona, MN 55987Customer ServicePhone: (800) 414-4299

Contents MLS User’s GuideivHeat/Cool Output Override... 85Heat/Cool Nonlinear Output Curve ...

88 MLS User’s GuideSetup Alarm TypesThe MLS has three different kinds of alarms: failed sensor alarms,global alarms, and process alarms. Fail

SetupMLS User’s Guide 89When the controller powers up or the setpoint changes, deviation alarmsdo not activate until the process goes inside the devia

90 MLS User’s GuideSetup Alarm DelayYou can set the MLS to delay normal alarm detection and alarmreporting. There are two kinds of alarm delay

SetupMLS User’s Guide 91High Process Alarm SetpointUse this menu to select the setpoint (temperature or other value withinthe scaled sensor range) at

92 MLS User’s GuideSetup NOTEAll digital outputs are "OR'ed" together (combined).Therefore you can assign more than one alarm t

SetupMLS User’s Guide 93High Deviation Alarm Output NumberUse this menu to assign a digital output which activates when the loop isin high deviation a

94 MLS User’s GuideSetup NOTEAll digital outputs are "OR'ed" together (combined).Therefore you can assign more than one alarm t

SetupMLS User’s Guide 95NOTEAll digital outputs are "OR'ed" together (combined).Therefore you can assign more than one alarm to thesame

96 MLS User’s GuideSetup Manual I/O TestPress Ye s at this prompt to see menus which can help you test the digitalinputs, digital outputs and

SetupMLS User’s Guide 97Digital Input TestingUse this menu to view the logic state of the 8 digital inputs as H (High--the input is at 5 volts or is n

MLS User’s Guide Contents vTroubleshooting Stand-Alone Systems ... 110MLS-PM Has No Power...

98 MLS User’s GuideSetup Toggle Digital OutputUse this menu to manually toggle a digital output On or Off to test it.(You select the output to

Tuning and ControlMLS User’s Guide 99Tuning and ControlIntroductionThis chapter explains PID control and supplies some starting PID valuesand tuning i

100 MLS User’s GuideTuning and Control The next diagram shows a process under On/Off control.Proportional ControlA process using On/Off contro

Tuning and ControlMLS User’s Guide 101Proportional and Integral ControlFor Proportional and Integral control, use the Integral term, or Reset,with Pro

102 MLS User’s GuideTuning and Control Digital Output Control FormsThe next section explains different modes for control outputs.On/OffOn/Of

Tuning and ControlMLS User’s Guide 103ANAFAZE also offers the DAC, another optional analog output modulefor the MLS. It converts two DZC outputs to tw

104 MLS User’s GuideTuning and Control Setting Up and Tuning PID LoopsTo start your process after installation, tune the control loops and set

Tuning and ControlMLS User’s Guide 105 Integral Term (TI) Settings This table shows Integral vs. Reset repeats per minute. Setting the TI: A General

106 MLS User’s GuideTuning and Control General PID ConstantsThis section gives general PID constants. Proportional Band Only (P)Set the PB to

Tuning and ControlMLS User’s Guide 107

Contents MLS User’s Guidevi

108 MLS User’s GuideTuning and Control

TroubleshootingMLS User’s Guide 109TroubleshootingThe next few sections describe general troubleshooting for the MLS.Later sections describe specific

110 MLS User’s GuideTroubleshooting WARNINGA manual controller reset clears the MLS memoryand resets its parameters to their default values. I

TroubleshootingMLS User’s Guide 111Keys Don't RespondIf the MLS seems to function perfectly, but the Man/Auto, Chng SP,Alarm Ack, and Ramp/Soak k

112 MLS User’s GuideTroubleshooting • To check thermocouple inputs, unplug the AIM module and measure between the A+ and A- terminals of the A

TroubleshootingMLS User’s Guide 113Checking Computer Supervised SystemsThese four elements must work properly in a computer-supervisedsystem:• The MLS

114 MLS User’s GuideTroubleshooting If you use the Black Box RS-485 interface, make sure you have set it upcorrectly. (See the Communications

TroubleshootingMLS User’s Guide 115Software ProblemsThis section gives some solutions for software problems.User-Written SoftwareIf you don't wan

116 MLS User’s GuideTroubleshooting Changing the EPROMChanging the EPROM involves minor mechanical disassembly andreassembly of the controller

TroubleshootingMLS User’s Guide 1175. Locate the EPROM on the circuit board. The EPROM is a 28-pin socketed chip which may have an ANAFAZE label on to

OverviewMLS User’s Guide 1OverviewThis manual describes how to install, setup, and operate a 16 or 32 MLScontroller. Included are seven chapters and a

118 MLS User’s GuideTroubleshooting

Linear Scaling ExamplesMLS User’s Guide 119 Linear Scaling Examples Example 1: Configuring a Pressure Sensor You’re using a pressure sensor that gener

120 MLS User’s GuideLinear Scaling Example 2: Configuring a Flow Sensor You connect a flow sensor to the MLS to measure the flow in a pipe.The sensor g

121GlossaryAACSee Alternating Current.AC Line FrequencyThe frequency of the AC power line measured inHertz (Hz), usually 50 or 60 Hz.AccuracyCloseness

Glossary MLS User’s Guide122Block Check Character (BCC)A serial communications error checking method.An acceptable method for most applications,BCC

MLS User’s Guide Glossary123deadband. It is usually above the heating propor-tional band and below the cooling proportionalband.Default ParametersThe

Glossary MLS User’s Guide124FFahrenheitThe temperature scale that sets the freezing pointof water at 32ºF and its boiling point at 212ºF atstandard

MLS User’s Guide Glossary125heating and infrared (noncontact) temperaturesensing.InputProcess variable information that is supplied tothe instrument.I

Glossary MLS User’s Guide126See Electromagnetic Interference. Noise SuppressionThe use of components to reduce electrical inter-ference that is caus

MLS User’s Guide Glossary127cal encoders.RRampA programmed increase in the temperature of asetpoint system. RangeThe area between two limits in which

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

Glossary MLS User’s Guide128conductors that is designed to prevent electro-static or electromagnetic interference from exter-nal sources.SignalAny e

MLS User’s Guide Glossary129VVolt (V)The unit of measure for electrical potential, volt-age or electromotive force (EMF).See Voltage.Voltage (V)The di

Glossary MLS User’s Guide130

OverviewMLS User’s Guide 3SafetyWatlow-Anafaze has made efforts to ensure the reliability and safety ofthe MLS™ Controller and to recommend safe usage

4 MLS User’s GuideOverview

IntroductionMLS User’s Guide 5IntroductionThe MLS is a modular control system with 32 fully independent loops of PID control. It can function as a sta

6 MLS User’s GuideIntroduction Front Panel or Computer Operation: You can set up and run the MLS Controller from the processor module's f

IntroductionMLS User’s Guide 7Specifications This section shows specifications for the MLS, including inputs, outputs, serial interface information, s

Copyright © 1995Watlow-Anafaze Information in this manual is subject to change without notice. No part of this publication may bereproduced, stored

8 MLS User’s GuideIntroduction RTD RangesMiscellaneous SpecificationsAnalog OutputsDigital InputsRTD1-148.0 to 572°F (-100.0 to 300.0°C)0.1°CR

IntroductionMLS User’s Guide 9Digital Outputs Standard Digital OutputsSystem Digital OutputsNumber 34 continuous 10 mA sink referenced to +5 Vdc of ML

10 MLS User’s GuideIntroduction Miscellaneous SpecificationsSerial InterfaceSystem Power RequirementsEnvironmental SpecificationsDimensions a

IntroductionMLS User’s Guide 11Expanded Parts List The Expanded Parts List contains a technical description of each component of your MLS Controller.

12 MLS User’s GuideIntroduction The eight digital inputs are referenced to the MLS controller common; an open input pulls them High (Off). Whe

IntroductionMLS User’s Guide 13The RTB is a screw terminal interface for control wiring which allows you to easily connect external "real world&q

14 MLS User’s GuideIntroduction Here's a picture of the MLS-AIM-32 and terminal block:MLS Cabling Technical Description Watlow-Anafaze pr

InstallationMLS User’s Guide 15InstallationThese installation instructions are written for nontechnical users. If you are an electrician or you are te

16 MLS User’s GuideInstallation Read This Before InstallationWARNINGDuring installation and wiring, place temporarycovers over the housing slo

InstallationMLS User’s Guide 17Recommended Tools This section lists the tools you will need to install the MLS Controller.Panel Hole Cutters Use any o

Addendum for MLS User’s Guide (3.6)MLS User’s Guide (11570-00 rev. 3.6) I Addendum for MLS User’s Guide (3.6) The following are changes to revision

18 MLS User’s GuideInstallation Mounting the MLS-PM This section tells you how to mount the MLS-PM. NOTEMount the MLS-PM before you mount any

InstallationMLS User’s Guide 19MLS-PM Mounting Steps1. Use the template below to cut a hole in the panel. Be careful; the 0.02" (0.5 mm) toleranc

20 MLS User’s GuideInstallation Mounting the MLS-AIM This section contains mounting instructions and diagrams for the MLS-AIM.NOTEIf you plan

InstallationMLS User’s Guide 21Mounting Steps 1. Choose an appropriate place to install the MLS-AIM.2. Place the MLS-AIM where you will mount it and u

22 MLS User’s GuideInstallation Mounting the RTB To mount the RTB, slide it onto a DIN rail. Watlow-Anafaze recommends Phoenix Contact’s NS32

InstallationMLS User’s Guide 23Mounting the MLS-PS Follow these instructions to mount the MLS-PS. If you use your own power supply for the MLS, please

24 MLS User’s GuideInstallation Wiring Your SystemThis section explains how to wire the components of your system.Below is the system connecti

InstallationMLS User’s Guide 25Wiring Recommendations This section gives general wiring recommendations.DANGERNever wire bundles of low power Watlow-A

26 MLS User’s GuideInstallation Cable Recommendations Use these cables or their equivalent.Noise Suppression If the MLS outputs control dry-co

InstallationMLS User’s Guide 27If you must use EM relays and you must place them in a panel with Watlow-Anafaze equipment, use a .01 microfarad capaci

II MLS User’s Guide (11570-00 rev. 3.6) Addendum for MLS User’s Guide (3.6) Mounting the MLS-PS (from page 23) Follow these instruction

28 MLS User’s GuideInstallation 3. Plug the AIM communications cable into the slot on the MLS-PM labeled "To AIM".4. Plug the other

InstallationMLS User’s Guide 29• Turn the power back on. The Processor Module's display should light up, and after about a second the Bar Graph d

30 MLS User’s GuideInstallation Testing Your SystemThis section explains how to test the controller after installation.MLS-AIM Test Use this p

InstallationMLS User’s Guide 31NOTEYour MLS is shipped with heat outputs enabledand cool outputs disabled. You can disable any PIDoutput and use it fo

32 MLS User’s GuideInstallation Ribbon Cable Recommendations Use the 50-pin connector for both ends of the 50 pin flat ribbon cable. (Do not c

InstallationMLS User’s Guide 33PID Control and Alarm Output Connections Typical digital control outputs use external optically-isolated solid-state re

34 MLS User’s GuideInstallation RTB ConnectionsConnect outputs to the RTB as shown in the table below. Terminal Function PID Output Terminal F

InstallationMLS User’s Guide 35AIM Communications Failure The controller continuously checks communications between the MLS-PM and the AIM. If communi

36 MLS User’s GuideInstallation Inputs This figure shows the AIM cards (also known as the MUX cards) and AIM-TB, with scaling resistor locatio

InstallationMLS User’s Guide 37• The A COM (AUX) terminal is the Auxiliary input. This is analog common used for RTD inputs. WARNINGDo not exceed 10 V

Addendum for MLS User’s Guide (3.6)MLS User’s Guide (11570-00 rev. 3.6) III Wiring Your System (from page 24) This section explains how to wire the

38 MLS User’s GuideInstallation This table shows scaling resistor values.Input Calibration The MLS provides offset calibration for T/C, RTD, a

InstallationMLS User’s Guide 392. Select the # of digits and decimal point location for the full scale PV display. The smallest possible range is -0.9

40 MLS User’s GuideInstallation Connecting Thermocouples Connect the positive T/C lead to the A+ terminal. Connect the negativeT/C lead to the

InstallationMLS User’s Guide 41Current Inputs To install current (milliamp) inputs, place resistors in the input section which convert the milliamp i

42 MLS User’s GuideInstallation Communications The MLS is factory-configured for either RS-232 or RS-485 communications. When you order your u

InstallationMLS User’s Guide 431. Plug the phone connector into the slot labeled "RS-232/RS-485" on the rear of the MLS-PM. 2. Plug the D-su

44 MLS User’s GuideInstallation NOTEConnect the shields to earth ground only at thecomputer or other 485 interface. Do not connectthe shield a

InstallationMLS User’s Guide 45Recommended Wire GaugesThis table shows maximum distances and wire gauges for communications wiring:You may wish to use

46 MLS User’s GuideInstallation

Using the MLSMLS User’s Guide 47Using the MLSThis chapter explains how to use the front panel to operate thecontroller. (If you are using ANASOFT, see

IV 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 g

48 MLS User’s GuideUsing the MLS Front PanelThe MLS front panel provides a convenient interface with thecontroller. You can use the front pane

Using the MLSMLS User’s Guide 49Front Panel KeysPress Yes to do these things:• Select a menu. • Answer Yes to Yes/No prompts.• Increase a number or ch

50 MLS User’s GuideUsing the MLS • Switch between Bar Graph and Single Loop display.Press the "Enter" key to:• Store data or a menu

Using the MLSMLS User’s Guide 51DisplaysThis section describes the MLS' displays. Viewing Several Loops: Bar Graph DisplayWhen you connect power

52 MLS User’s GuideUsing the MLS Navigating in Bar Graph DisplayPress the Ye s (up) or No (down) key to see a new group.• Press Enter twice t

Using the MLSMLS User’s Guide 53If only one output is enabled (heat or cool, but not both), Single Loopdisplay looks like this:Navigating in Single Lo

54 MLS User’s GuideUsing the MLS This table shows the symbols used in each form of the alarm display.Acknowledging an AlarmPress Alarm Ack to

Using the MLSMLS User’s Guide 55Displaying, Loading, and Saving JobsJob display appears only if:• You have turned on the Remote Job Select function. (

56 MLS User’s GuideUsing the MLS Operator Menus You can perform these tasks from Single Loop Display. Changing the SetpointPress Chng SP from

Using the MLSMLS User’s Guide 57• Press Enter, then Back to store the new mode and return to Single Loop Display without setting an output level.NOTEI

iContentsOverview ...1System Diagram...

58 MLS User’s GuideUsing the MLS Automatically Tuning a LoopWhen you use the Autotune function, the controller automatically setsthe loop to M

MLS User’s Guide 59 Setup The Setup menus let you change the MLS' detailed configurationinformation.If you have not set up a Modular Loop System

60 MLS User’s Guide Setup Setup GlobalParameters?Setup Loop xxInput?Setup Loop xx Setup loop xxOutputs?Setup Loop xx Alarms?Manual I/OTest?sa

SetupMLS User’s Guide 61 Setup Global Parameters Menu The setup global parameters menu looks like thisBelow is the setup global parameters menu tree.

62 MLS User’s Guide Setup Save to Job Use this menu to save the job information for every loop to one of eightjobs in the MLS’ battery-backe

SetupMLS User’s Guide 63 Job Select Inputs Use the Remote Job Control feature to run up to 8 jobs remotely. TheJob Select Inputs menu is the third me

64 MLS User’s Guide Setup Job Digital Input Polarity Use this menu to set the polarity of the digital outputs used for jobselection. You can

SetupMLS User’s Guide 65 Startup Alarm Delay Use this menu to set a startup delay for process and deviation alarms forall loops. The controller does

66 MLS User’s Guide Setup Controller Address Use this menu to set the MLS controller address. The controller addressis used for multiple con

SetupMLS User’s Guide 67 Communications Baud Rate Use this menu to set the Communications Baud Rate to 2400 or 9600baud. Selectable values: 9600 or

Contents MLS User’s GuideiiConnecting Power and RTB to MLS-PM... 27Connecting Power and Common to AIM-TB... 28Testing Co

68 MLS User’s Guide Setup Digital Output Polarity Use this menu to set the polarity of the digital outputs used for alarms.The output can be

SetupMLS User’s Guide 69 Setup Loop Input The Setup Loop Input main menu lets you access menus which changeloop input parameters: • Input type • In

70 MLS User’s Guide Setup Input Type Use this menu to configure the input sensor for each loop as one of theseinput types: • Thermocouple

SetupMLS User’s Guide 71 Pulse Sample Time You can connect a digital pulse signal of up to 2 KHz to the controller’spulse input. Use this menu to spe

72 MLS User’s Guide Setup Input Reading Offset Use this menu to make up for the input signal's inaccuracy. Forexample, at temperatures

SetupMLS User’s Guide 73 The graph below shows pressure as an example.Before you enter the values that determine the two points for theconversion li

74 MLS User’s GuideSetup Display Format Use this menu to select a display format for a linear input. Choose aformat appropriate for your input

SetupMLS User’s Guide 75High ReadingUse this menu to enter the input level that corresponds to the highprocess value you entered in the previous menu.

76 MLS User’s GuideSetup Input FilterAccess this menu from the Setup Loop Inputs main menu. The MLS hastwo different types of input filter: • A

SetupMLS User’s Guide 77Setup Loop Control ParametersUse these menus to change control parameters for heat and cool outputsof the selected loop, inclu

MLS User’s Guide Contents iiiJob Digital Input Polarity... 64Output Override Digital Input...

78 MLS User’s GuideSetup Heat/Cool Control PB Use this menu to set the Proportional Band.NOTEThe MLS internally represents the proportional ba

SetupMLS User’s Guide 79Heat/Cool Output FilterUse this menu to dampen the heat or cool output's response. The outputresponds to a step change by

80 MLS User’s GuideSetup Setup Loop OutputsPress Yes at this prompt to access menus to change loop outputparameters for the current loop, in

SetupMLS User’s Guide 81Setup Loop Outputs?Heat/Cool control out?Output disabledOutputEnabledHeat/Cool output type?For SDAC outputsFor TP outputsHeat/

82 MLS User’s GuideSetup Enable/Disable Heat and Cool Outputs Use this menu to enable or disable the heat or cool output for the currentloop.

SetupMLS User’s Guide 83Heat/Cool Cycle TimeUse this menu to set the Cycle Time for Time Proportioning outputs.Selectable range: 1-255 seconds.NOTETh

84 MLS User’s GuideSetup SDAC High ValueUse this menu to set a high value for the SDAC output. Set the high andlow value to match the range of

SetupMLS User’s Guide 85Heat/Cool Output LimitUse this menu to limit the maximum PID control output for a loop's heatand cool outputs. This limit

86 MLS User’s GuideSetup Heat/Cool Nonlinear Output CurveUse this menu to select one of two nonlinear output curves for nonlinearprocesses.Sel

SetupMLS User’s Guide 87Setup Loop AlarmsPress Ye s at the Setup Loop Alarms prompt to access menus whichchange alarm function parameters for the curr