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Watlow MLS-PM User Manual

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Watlow MLS-PM User Manual

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  • Page 1 Artisan Technology Group is your source for quality new and certified-used/pre-owned equipment SERVICE CENTER REPAIRS WE BUY USED EQUIPMENT • FAST SHIPPING AND DELIVERY Experienced engineers and technicians on staff Sell your excess, underutilized, and idle used equipment at our full-service, in-house repair center We also offer credit for buy-backs and trade-ins •...
  • Page 2 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...
  • Page 3 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.
  • Page 4 These changes will be incorporated in the next manual revision. System Power Requirements (from page 10) MLS-PM supply input 10-28 Vdc at <1 amp MLS-AIM supply input 4.75 to 5.25 Vdc at <0.5 amp, supplied by MLS- MLS-PS system power supply Input: 120/240 Vac at 0.75 amp...
  • Page 5 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.
  • Page 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.) MLS User’s Guide (11570-00 rev.
  • Page 7 For more information about noise suppression, see Noise Suppression . Connecting Power and RTB to MLS-PM (from page 27) 1. Remove the temporary covers you placed on the MLS' housing. 2. Connect the power supply terminal labeled "DC COM" to the termi- nal labeled "GND"...

  • Page 8: Table Of Contents

    Read This Before Installation ..........16 Recommended Tools ............17 Panel Hole Cutters ............17 Other Tools ..............17 Additional Hardware............. 17 Mounting the MLS-PM ............18 Mounting Environment..........18 MLS-PM Mounting Steps..........19 Mounting the MLS-AIM ............ 20 Mounting Environment..........20 Mounting Steps .............
  • Page 9 Contents MLS User’s Guide Connecting Power and RTB to MLS-PM..... 27 Connecting Power and Common to AIM-TB....28 Testing Connections ............. 28 Testing Your System ............30 MLS-AIM Test ............. 30 RTB Test............... 30 PID Output Test ............30 Outputs................31 PID Control and Alarm Output Connections....
  • Page 10 MLS User’s Guide Contents Job Digital Input Polarity..........64 Output Override Digital Input........64 Output Override Input Polarity ........64 Startup Alarm Delay ............. 65 Keyboard Lock Status........... 65 Power-Up Output Status ..........65 Controller Address ............66 Communications Error Checking ......... 66 Communications Baud Rate .........
  • Page 11 Contents MLS User’s Guide Heat/Cool Output Override........... 85 Heat/Cool Nonlinear Output Curve ......86 Setup Loop Alarms ............. 87 Alarm Types ..............88 Alarm Delay..............90 High Process Alarm Setpoint........91 High Process Alarm Type..........91 High Process Alarm Output Number......91 Deviation Band Value...........
  • Page 12 MLS User’s Guide Contents Troubleshooting Stand-Alone Systems ......110 MLS-PM Has No Power..........110 Keys Don't Respond............111 Controller Message: AIM Comm Failure ..... 111 Checking Analog Inputs ..........111 Checking PID Control Outputs........112 Checking Digital I/O............. 112 Checking Computer Supervised Systems ......113 Computer Problems ............
  • Page 13 Contents MLS User’s Guide...

  • Page 14: Overview

    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 and their purpose.

  • Page 15: System Diagram

    The illustration below shows how the parts of the MLS are connected. When unpacking your system, use the diagram and parts list below to ensure all parts have been shipped. Please don't hesitate to call Watlow- Anafaze's Technical Service Department if you have problems with your shipment, or if the MLS' components are missing or damaged.

  • Page 16: Safety

    Overview Safety 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.
  • Page 17 Overview 4 MLS User’s Guide...

  • Page 18: Introduction

    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; the 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;...
  • Page 19 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.

  • Page 20: Specifications

    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) >85 dB at 60 Hz, 110 dB typical.

  • Page 21: Analog Outputs

    4-20 mAdc, 0-5 Vdc, and 0-10 Vdc versions of the DAC. Watlow-Anafaze also offers the Serial DAC for precision open-loop con- trol. 0-5 Vdc / 4-20 mAdc jumper selectable. Contact Watlow-Anafaze for more information about the DAC and Serial DAC.

  • Page 22: Digital Outputs

    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.

  • Page 23: Miscellaneous Specifications

    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 <0.5 amp, supplied by MLS-PM MLS-PS system power supply Input: 120 Vac at 0.5 amp...

  • Page 24: Expanded Parts List

    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.
  • Page 25 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;...

  • Page 26: Mls Rtb 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.

  • Page 27: Mls Cabling Technical Description

    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.

  • Page 28: Installation

    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.

  • Page 29: Read This Before Installation

    Installation Read This Before Installation WARNING During installation and wiring, place temporary covers over the housing slots and the rear of the MLS so dirt and pieces of wire don't fall through the slots. When you are finished with installation, remove the covers.

  • Page 30: Recommended Tools

    • 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.)

  • Page 31: Mounting The Mls-Pm

    MLS-AIM, MLS-PS, etc. Mounting Environment º Install the MLS-PM in a location free from excessive (>50 C) 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"...

  • Page 32: Mls-Pm Mounting Steps

    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.

  • Page 33: Mounting The Mls-Aim

    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 º...

  • Page 34: Mounting Steps

    Installation Scaling Resisters AIM Communications Port (Tel. 1) 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.

  • Page 35: Mounting The Rtb

    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.

  • Page 36: Mounting The Mls-Ps

    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.

  • Page 37: Wiring Your System

    Installation Wiring Your System 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.) 24 MLS User’s Guide...

  • Page 38: Wiring Recommendations

    Installation Wiring Recommendations 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.

  • Page 39: Cable Recommendations

    Where possible, use solid state relays (SSRs) instead of electrical- mechanical (EM) relays. If you must use EM relays, try 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.

  • Page 40: Wiring And Testing Your System

    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".

  • Page 41: Testing Connections

    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.
  • Page 42 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.

  • Page 43: Testing Your System

    MLS-PM's screen. 4. 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. RTB Test 1.

  • Page 44: Outputs

    Installation NOTE Your MLS 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.
  • Page 45 Installation 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.

  • Page 46: Pid Control And Alarm Output Connections

    Installation PID Control and Alarm Output Connections Typical digital control outputs use external optically-isolated solid-state relays (SSRs). The SSRs use a 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.

  • Page 47: Rtb Connections

    DIG Input 7 DIG Input 8 * If 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.

  • Page 48: 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.

  • Page 49: Inputs

    Installation Inputs This figure shows the AIM cards (also known as the MUX cards) and AIM-TB, with scaling resistor locations. Scaling Resisters AIM Communications Port (Tel. 1) • 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.

  • Page 50: Input Wiring Recommendations

    Analog Input Module (AIM). Input Wiring Recommendations 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;...
  • Page 51 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.) 38 MLS User’s Guide...

  • Page 52: T/C Inputs

    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;...

  • Page 53: Rtd Inputs

    – Shield RTD Inputs The standard industrial RTD is an 100 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. • If you order an RTD1, RTD2, or RTD3 configuration, we will con- figure your MLS for the standard three-wire RTD.

  • Page 54: Current Inputs

    Installation Rear Terminal Block Connections Black IN + 100 Ohm RTD Black – 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.

  • Page 55: Communications

    RS-485 and RS-232: 1. Unplug any cables connected to the MLS-PM. 2. If you already installed the MLS-PM in a panel, remove it from the panel. 3. Unscrew the screws on the PM's casing. (There are either two or four screws on the sides of the casing.

  • Page 56: Connecting Rs-485 Communications

    The pin numbers and colors are not industry stan- dard. Watlow-Anafaze numbers the pins from right to left with 1 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.
  • Page 57 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.

  • Page 58: Recommended Wire Gauges

    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.
  • Page 59 Installation 46 MLS User’s Guide...

  • Page 60: Using The Mls

    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.

  • Page 61: Front Panel

    Using the MLS Front Panel 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 controllers. (See the ANASOFT User's Guide for more information about ANASOFT, or contact ANAFAZE.) This figure shows the MLS' front panel.

  • Page 62: Front Panel Keys

    • Perform a manual controller (No Key) reset (see next page). WARNING 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: •...
  • Page 63 Using the MLS • Switch between Bar Graph and Single Loop display. Enter Press the "Enter" key to: • Store data or a menu choice after editing. • Go on to the next menu. • Start scanning mode (if pressed twice). Chng SP •...

  • Page 64: Displays

    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...

  • Page 65: Viewing One Loop: Single Loop Display

    Using the MLS Single Bar Graph Loop DisplaySy Description DisplaySy mbol mbol One or both outputs enabled. Loop is in manual control. AUTO Only one output (Heat or Cool) is enabled. Loop is in automatic control. TUNE Indication that the loop is in Autotune mode. HEAT Both heat and cool outputs are enabled.

  • Page 66: Interpreting Alarm Display

    Using the MLS If only one output is enabled (heat or cool, but not both), Single Loop display looks like this: Engineering Units Process Variable Loop Number Output Percentage LOOP PROCESS UNITS or Name Cool º 180 AUTO 100 Setpoint Output Percentage Heat ALARM SETPOINT...
  • Page 67 Using the MLS This table shows the symbols used in each form of the alarm display. Bar Graph Single Loop Description Symbol Symbol > High Process Alarm > High Deviation Alarm < Low Process Alarm < Low Deviation Alarm T/C Break Open Input Error RTD Short RTD Short Alarm...

  • Page 68: Displaying, Loading, And Saving Jobs

    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...

  • Page 69: Operator Menus

    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 ? ALARM SETPOINT STATUS OUT% •...
  • Page 70 Using the MLS • Press Enter, then Back to store the new mode and return to Single Loop Display without setting an output level. 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.
  • Page 71 Using the MLS Automatically Tuning a Loop When you use the Autotune function, the controller automatically sets the loop to Manual control, 100% output. (If 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.

  • Page 72: Setup

    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.
  • Page 73 Setup Setup Loop xx Setup loop xx Setup Loop Setup Loop xx Setup Global Manual I/O Control Params? Outputs? xx Alarms? Input? Parameters? Test? save setup to Heat control out? High process Input type? Heat control PB? Digital inputs? job? alarm setpoint? Pulse sample time? Heat control TI?

  • Page 74: Setup Global Parameters Menu

    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? Save setup to job? 1 Controller address?

  • Page 75: Save To Job

    Setup Save to Job 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 ALARM SETPOINT STATUS OUT% Selectable Range: 1-8. If you have enabled the remote job control function, you will not be able to save a job;...

  • Page 76: Job Select Inputs

    Setup Job Select Inputs 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.

  • Page 77: Job Digital Input Polarity

    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%...

  • Page 78: Startup Alarm Delay

    Setup Startup Alarm Delay 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...

  • Page 79: Controller Address

    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.

  • Page 80: Communications Baud Rate

    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. NOTE If you use ANASOFT, be sure to set ANAINSTL to the same baud rate that you set in this menu.

  • Page 81: Digital Output Polarity

    AIM Communications Failure Output 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.

  • Page 82: Setup Loop Input

    Setup Setup Loop Input 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 the front panel. LOOP PROCESS UNITS...

  • Page 83: Input Type

    Setup Input Type Use this menu to configure the input sensor for each loop as one of these input types: • Thermocouple types (J, K, T, S, R and B). • RTD. Three ranges: RTD1 (Platinum Class A), RTD2 (Platinum Class B), and RTD3 (Nickel).

  • Page 84: Pulse Sample Time

    Setup Pulse Sample Time 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.

  • Page 85: Input Reading Offset

    Setup Input Reading Offset Use this menu to make up for the input signal's inaccuracy. For º example, at temperatures below 400 F, a type J thermocouple may be inaccurate ("offset") by several degrees F. Use an independent thermocouple or your own calibration equipment to find the offset for your equipment.
  • Page 86 Setup The graph below shows pressure as an example. 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.

  • Page 87: Display Format

    Setup Display Format 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.

  • Page 88: High Reading

    Setup High Reading 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.

  • Page 89: Input Filter

    Setup Input Filter Access this menu from the Setup Loop Inputs main menu. The MLS has two different types of input filter: • A 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.

  • Page 90: Setup Loop Control Parameters

    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.

  • Page 91: Heat/Cool Control Pb

    Setup Heat/Cool Control PB Use this menu to set the Proportional Band. LOOP PROCESS UNITS 01 HEAT CONTROL º PB? 50 ALARM SETPOINT STATUS OUT% NOTE 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.

  • Page 92: Heat/Cool Output Filter

    Setup Heat/Cool Output Filter 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 within the number of scans you set here. LOOP PROCESS UNITS 07 HEAT CONTROL...

  • Page 93: Setup Loop Outputs

    Setup Setup Loop Outputs 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) •...
  • Page 94 Setup Setup Loop Outputs? Output disabled Heat/Cool control out? Output Enabled For TP outputs For SDAC outputs Heat/Cool output type? Heat/cool output SDAC mode? Voltage cycle time? 10 S SDAC Lo value? 0.00 SDAC Hi value? 10.00 VDC Heat/Cool output action? Reverse Heat/Cool output limit? Heat/Cool output limit...

  • Page 95: Enable/Disable Heat And Cool Outputs

    Setup Enable/Disable Heat and Cool Outputs 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.

  • Page 96: Heat/Cool Cycle Time

    Setup Heat/Cool Cycle Time 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. NOTE The Cycle Time menu will only be present if the out- put type for the current loop is Time Proportioning.

  • Page 97: Sdac High Value

    Setup SDAC High Value 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 range, set the SDAC high value to 20.00 mA and the SDAC low value to 4.00 mA.

  • Page 98: Heat/Cool Output Limit

    Setup Heat/Cool Output Limit 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).

  • Page 99: Heat/Cool Nonlinear Output Curve

    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.

  • Page 100: Setup Loop Alarms

    Setup Setup Loop Alarms 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.

  • Page 101: Alarm Types

    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: • Open + or - input. •...
  • Page 102 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 process alarm on High process alarm off High Alarm Limit Deadband...

  • Page 103: Alarm Delay

    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.

  • Page 104: High Process Alarm Setpoint

    Setup High Process Alarm Setpoint 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.

  • Page 105: Deviation Band Value

    Setup 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. Deviation Band Value Use this menu to set the deviation bandwidth, a positive and negative alarm or control point relative to the setpoint.

  • Page 106: High Deviation Alarm Output Number

    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...

  • Page 107: Low Process Alarm Setpoint

    Setup 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 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.

  • Page 108: Alarm Deadband

    Setup 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. Alarm Deadband 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.

  • Page 109: Manual I/O Test

    Setup Manual I/O Test Press Yes at this prompt to see menus which can help you test the digital inputs, digital outputs and the 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.

  • Page 110: Digital Input Testing

    Setup Digital Input Testing 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.

  • Page 111: Toggle Digital Output

    Setup Toggle Digital Output 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.

  • Page 112: Tuning And Control

    Tuning and Control Tuning and Control Introduction This chapter explains PID control and supplies some starting PID values and tuning instructions, so that 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.

  • Page 113: Proportional Control

    Tuning and Control The next diagram shows a process under On/Off control. Proportional Control 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.

  • Page 114: Proportional And Integral Control

    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. º For example, if a process tends to settle about 5 F below the setpoint, use Integral control to bring it to the desired setting.

  • Page 115: Digital Output Control Forms

    Tuning and Control Digital Output Control Forms 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.
  • Page 116 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.

  • Page 117: Setting Up And Tuning Pid Loops

    Tuning and Control Setting Up 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.

  • Page 118: Integral Term (Ti) Settings

    Tuning and Control Integral Term (TI) Settings This table shows Integral vs. Reset repeats per minute. Reset Reset (secs./repeat) (repeats/min) (secs./repeat0 (repeats/min) 0.28 Setting the TI: 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.

  • Page 119: General Pid Constants

    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.
  • Page 120 Tuning and Control MLS User’s Guide 107...
  • Page 121 Tuning and Control 108 MLS User’s Guide...

  • Page 122: Troubleshooting

    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.

  • Page 123: Returning Your Unit To Anafaze

    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.

  • Page 124: Keys Don't Respond

    Display, return the unit to ANAFAZE for repair. Checking Analog Inputs 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.

  • Page 125: Checking Pid Control Outputs

    Troubleshooting • To 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.

  • Page 126: Checking Computer Supervised Systems

    Troubleshooting Checking Computer Supervised Systems 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.

  • Page 127: Communications Problems

    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.

  • Page 128: Software Problems

    Troubleshooting Software Problems 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.

  • Page 129: Changing The Eprom

    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. NOTE If you change the EPROM, you must perform a manual controller reset for the EPROM change to take effect.
  • Page 130 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.
  • Page 131 Troubleshooting 118 MLS User’s Guide...

  • Page 132: Linear Scaling Examples

    Linear Scaling Examples Linear Scaling Examples Example 1: Configuring a Pressure 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.

  • Page 133: Example 2: Configuring A Flow Sensor

    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.

  • Page 134: Glossary

    Glossary surrounds the components of a thermal system. American Wire Gauge (AWG) See Alternating Current. A standard of the dimensional characteristics of wire used to conduct electrical current or signals. AC Line Frequency AWG is identical to the Brown and Sharpe The frequency of the AC power line measured in (B&S) wire gauge.
  • Page 135 Glossary MLS User’s Guide Block Check Character (BCC) See Baud Rate. A serial communications error checking method. Control Action An acceptable method for most applications, The response of the PID control output relative to BCC is the default method. See CRC. the error between the process variable and the Bumpless Transfer setpoint.
  • Page 136 MLS User’s Guide Glossary deadband. It is usually above the heating propor- A metal rod, usually copper, that provides an tional band and below the cooling proportional electrical path to the earth, to prevent or reduce band. the risk of electrical shock. Default Parameters Electrical Noise The programmed instructions that are perma-...
  • Page 137 Glossary MLS User’s Guide is cleared directly from a controller or through a user interface. Fahrenheit The temperature scale that sets the freezing point Global Digital Outputs º º of water at 32 F and its boiling point at 212 F at A pre-selected digital output for each specific standard atmospheric pressure.
  • Page 138 MLS User’s Guide Glossary heating and infrared (noncontact) temperature changes reflectance or transmittance when an sensing. electrical field is applied to it. Input Load Process variable information that is supplied to The electrical demand of a process, expressed in the instrument. power (watts), current (amps), or resistance (ohms).
  • Page 139 Glossary MLS User’s Guide See Electromagnetic Interference. Overshoot The amount by which a process variable exceeds Noise Suppression the setpoint before it stabilizes. The use of components to reduce electrical inter- ference that is caused by making or breaking electrical contact, or by inductors. Panel Lock Non Linear A feature that prevents operation of the front...
  • Page 140 MLS User’s Guide Glossary cal encoders. A sensor that uses the resistance temperature characteristic to measure temperature. There are two basic types of RTDs: the wire RTD, which is usually made of platinum, and the thermistor which is made of a semiconductor material. The Ramp wire RTD is a positive temperature coefficient A programmed increase in the temperature of a...
  • Page 141 Glossary MLS User’s Guide conductors that is designed to prevent electro- in temperature between the hot junction (sensing static or electromagnetic interference from exter- junction) and the lead wire connection to the nal sources. instrument (cold junction). Signal TI (Timed Integral) Any electrical transmittance that conveys infor- The Integral term.
  • Page 142 MLS User’s Guide Glossary 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.
  • Page 143 Glossary MLS User’s Guide...
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