Watlow Revision 5 - Manuals

Page 2 - STATEMENT OF WARRANTY

STATEMENT OF WARRANTY ANAFAZE, Incorporated warrants that the Products furnished under thisAgreement will be free from material defects in material and workmanship for aperiod of 90 days from the date of shipment. The customer shall provide notice toANAFAZE, Incorporated of any such defect within on...

Page 3 - WARNING

WARNING ANAFAZE HAS MADE EFFORTS TO ENSURE THE RELIABILITY ANDSAFETY OF THE SYSTEM 32 AND PROVIDE RECOMMENDATIONSFOR ITS SAFE USE IN SYSTEMS APPLICATIONS. PLEASE NOTETHAT IN ANY APPLICATION, FAILURES CAN OCCUR THAT WILLRESULT IN FULL CONTROL OUTPUTS OR OTHER OUTPUTS THATMAY CAUSE DAMAGE OR UNSAFE CO...

Page 4 - TABLE OF CONTENTS

TABLE OF CONTENTS 1.0 INTRODUCTION _____________________________________________ 1 1.1 SYSTEM FEATURES _________________________________________11.2 PLUG IN SYSTEM 32 MODULES_______________________________21.3 ANASOFT 32 -- POWERFUL OPERATING SOFTWARE __________4 2.0 SPECIFICATIONS _________________...

Page 7 - PLUG IN SYSTEM 32 MODULES

2 1.1.3 PROCESS INTEGRITY: The ANAFAZE approach delivers high integrity because the SYSTEM 32 independently controls and checks eachloop for alarms while it is in turn checked by the computer. Thus acomputer failure will not affect the process and a controller problem will bedetected by the computer...

Page 13 - CONTROL AND ALARM OUTPUTS; 2 Individually selectable control outputs:; DIGITAL INPUT OR OUTPUT

8 2.5 CONTROL AND ALARM OUTPUTS 32 Individually selectable control outputs: Digital Outputs: Time proportioning, On/Off, Alarms: voltageoutput: 5VDC at 6ma maximum for solid state orother relays. Analog: voltage or current: selectable (4 to 20ma, or 0 to 5volts). 2.6 DIGITAL INPUT OR OUTPUT 24 Digit...

Page 14 - SUBASSEMBLY IDENTIFICATION

9 2.9 SUBASSEMBLY IDENTIFICATION A32-PIOM: PROCESSOR I/O MODULE includes factory selectable communication interface [RS-232 or current loop], 32 control outputs, 24 digitaloutputs, and 16 digital inputs. A32-RRAIM: REED RELAY ANALOG INPUT MODULE for 16 mixed sensor inputs including direct connection...

Page 15 - PHYSICAL CONSIDERATIONS

10 3.0 INSTALLATION There are some precautions that must be observed when installing SYSTEM 32: WARNING: ELECTRICAL SHOCK DANGERIt is very important that all system power including the power inputbe disconnected before servicing the ANAFAZE SYSTEM 32. HIGHVOLTAGE MAY BE PRESENT EVEN WHEN POWER IS TU...

Page 16 - SLOT HOUSING DIMENSIONS

Page 17 - SLOT HOUSING DIMENSIONS

Page 18 - POWER SUPPLY DIMENSIONS

Page 19 - WARNING - TURN OFF POWER BEFORE CHANGING SWITCH

14 3.1.3 DETACHABLE TERMINAL BLOCKS WARNING - ALWAYS CHECK TERMINAL LOCATION ANDORIENTATION All connections, except the Ac power supply, are made on removableterminal strips. Terminal strip removal is achieved by removing theretaining screws and pulling them directly away from the front panel. Thete...

Page 21 - All control output types are set to MANUAL

16 1. All control output types are set to MANUAL 2. All output values for control outputs are set to 0%. 3. Digital output 72 is set ON. This output is available at TB2, pin 30. 4. The internal controller reset flag is set TRUE. (Hence the hostwill receive a RESET status code upon re-establishingcom...

Page 22 - COMMUNICATIONS SET-UP AND CONNECTIONS

17 3.3.2 POWER FUSE The SYSTEM 32 power supply is not fused. An external 1/2 AMP fuse inthe AC input line is recommended. 4.0 COMMUNICATIONS SET-UP AND CONNECTIONS The ANAFAZE SYSTEM 32 is designed for three types of serial communications:RS-232, RS-485, and 20ma current loop. Up to 16 units can be ...

Page 23 - Computer SYSTEM 32

18 4.1.1 Other RS-232 Lines Some host computers or other RS-232 devices use additional communication linesthat are not required by the SYSTEM 32. These include: RTS - Ready to Send DSR - Data Set Ready CTS - Clear To Send DTR - Data Terminal Ready If the host computer uses RTS and CTS or DSR and DTR...

Page 25 - Distance Wire Gauge Recommended Cable

20 Distance Wire Gauge Recommended Cable 1500 ft. 28 AWG Alpha 3492 4000 ft. 24 AWG Beldon 9729 6000 ft. 22 AWG Beldon 9184 The use of a shield depends on the noise environment and groundingconsiderations [4.3.3]. The above cables are shielded. 4.3.3 Connections Connection of the Anafaze controllers...

Page 26 - ohm terminating resistor between RX- and RX+ at the SYSTEM 32.; For multiple units connect the system as follows:; Ground

21 ANAFAZE SYSTEM 32 connections for a single unit are as follows: Black BoxCOMPUTER LD485A SYSTEM 32 +485 Output (Start bit +5v) TXA RX+ #3 -485 Output (Start bit 0v) TXB RX- #4 +485 Input RXA TX+ #1 -485 Input RXB TX- #2 Shield-------Earth Ground---------Shield Do not Ground Note: Connect the shie...

Page 28 - ANALOG INPUT MODULES

23 5.5 ANALOG INPUT MODULES Two types of analog input modules are available for the SYSTEM 32. The A32-RRIAM -- REED RELAY ANALOG INPUT MODULE provides 16 analoginputs with reed relay switching. The A32-SSAIM -- SOLID STATE ANALOGINPUT MODULE provides 32 inputs with solid state switching. The A32-SS...

Page 29 - WARNING - USE SHIELD CORRECTLY

24 capacitors can be installed for signal conditioning. Please consultANAFAZE. The PC board silk screen shows the resistor locations. 5.6.2 USE OF THE SHIELD CONNECTION The shield connection provides a third input which is switched as eachchannel is measured. It is the ground reference for the measu...

Page 30 - The positive input should be; The following input values are suggested:

25 5.6.4 DC CURRENT INPUTS Current inputs from transmitters are accommodated by placing resistors inthe input section to convert the current input into a voltage. Differentcurrent input ranges are accommodated by selecting the proper resistorvalues. In general RC is selected to maintain a low source...

Page 32 - SCALING AND CALIBRATION

27 5.8 SCALING AND CALIBRATION Since a computer is used to display the reading and load the setpoints, amathematical step can be used to convert measurements and setpoints toengineering units and correct for known sensor calibration errors. For example, the ANAFAZE SYSTEM 32 does all thermocouple ca...

Page 33 - DIAGRAMS OF TYPICAL INPUTS; SEE SECTION 5.6 FOR DETAILED INFORMATION.; Typical Thermocouple; To use shield remove jumper RD. Shield should be; Current Transmitter Inputs:; Use scaling resistors to convert the current to a

28 5.9 DIAGRAMS OF TYPICAL INPUTS SEE SECTION 5.6 FOR DETAILED INFORMATION. Typical Thermocouple AUX OHIGH O-- + White ------------------------- Type J T/CLOW O-- - Red ----------------------------SHLD O Shielded Thermocouple: To use shield remove jumper RD. Shield should be grounded at probe [see 5...

Page 34 - ANALOG INPUT CONNECTIONS

29 5.10 ANALOG INPUT CONNECTIONS 5.10.1 A32-RRAIM Analog Input Connections Terminal 1 [Upper] | Terminal 2 [Lower] |Pin Channel Assignment | Pin Channel Assignment |1 REF GND | 1 + REF2 REF GND | 2 + REF------------------------------| -----------------------------3 LO | 3 LO4 1 AUX | 4 9 AUX5 HI | 5...

Page 35 - UPPER TERMINAL BLOCK; LOWER TERMINAL BLOCK; Pin Channel Assignment | Pin Channel Assignment

Page 36 - Upper Terminal Block TB1

31 6.0 CONTROL OUTPUTS Control outputs are provided from the A32-PIOM -- PROCESSOR I/O MODULEfor digital outputs and the A32-AOM -- ANALOG OUTPUT MODULE foranalog outputs. The A32-AOM is not required for systems that do not needanalog outputs. The A32-PIOM provides the digital control outputs, the s...

Page 42 - Note the outputs are designated as follows:; PIN

37 6.3.2 A32-AOM ANALOG OUTPUT MODULE CONNECTIONS Note the outputs are designated as follows: LOOP #C Positive terminal for 4-20madc output. LOOP #V Positive terminal for 0-5vdc output. NEG Negative terminals for both outputs. TERMINAL BLOCK 1 [UPPER] TERMINAL BLOCK 2 [LOWER] PIN CONNECTION PIN CONN...

Page 46 - Warning: Only one output may be used for each loop.

41 7.2.7 Open Thermocouple Detection The RRIAM has upscale open thermocouple detection which isaccomplished by placing a small current through the thermocouple leads.The input source impedance may go as high as 200 ohms before ratedaccuracy is effected. 7.2.8 Address Selection Each RRIAM has a jumpe...

Page 50 - The; PID; initials stand for; DERIVATIVE; . The SYSTEM 32 utilizes the ISA standard PID equation

45 not be confused with with the type of control output signal: for examplepulsed DC voltage or analog output. 8.1.3 ON/OFF CONTROL The simplest way to control the PROCESS VARIABLE (PV), for exampletemperature on an oven, to a desired SETPOINT (SP), operatingtemperature, is to use ON/OFF control. Wh...

Page 54 - TI reduces stability, but speeds the settling time.

49 RATE is also used to correct for rapid load changes, to slow large capacityprocesses, and to overcome the slew rates of electric motor actuators. The RATE function responds to the change in the error as a function oftime. Mathematically it is the first derivative of the error as a function oftime...

Page 57 - ADJUSTMENT OF PID CONSTANTS

52 8.1.11 DISTRIBUTED ZERO CROSSING Distributed Zero Crossing [DZC] output is the other time proportioningoutput available from the SYSTEM 32. This output is primarily for very fastacting electrical heating loads using SSR's. The open air heater coil is anexample of a fast acting load. It should nev...

Page 59 - Many processes have been controlled with the following values:

54 range of the process control span. If the process elements are not correctlysized then it will be difficult and even impossible to tune the controller. 8.2.2 TUNING PID LOOPS 1. First set PB to 2% of the desired SP, Reset to .2 R/M, Rate to 0, Filter to0. Set control in AUTO. Set the plot functio...

Page 60 - ANALOGY OF PID CONTROL TERMINOLOGY

55 8.2.3 OUTPUT FILTER There is no tuning step for the Output Filter. Adjusting the PID without theFilter gives the most accurate response of the control function of the PIDmodes. The Output Filter may be turn on anytime so desired. The number isincreased as necessary to reduce cycling of the contro...

Page 62 - Independent Ramp and Soak:

57 9.0 SOFTWARE ANAFAZE offers turn key software for IBM PC and compatible computers. Thepresent software includes: ANASOFT-32 Measurement and ControlANASOFT-32-RS Measurement and Control with Ramp and SoakANASOFT-32-CP Measurement and Control with Carbon Potential 9.1 ANASOFT-32 ANASOFT-32 is a men...

Page 63 - Accurate Recipe Tracking:; The ramp and soak software provides special; CUSTOM APPLICATION PROGRAMS

58 the profile is selected the stored ramp and soak recipe for each loopis automatically setup. Accurate Recipe Tracking: The ramp and soak software provides special alarms and warnings in addition to the standard features of ANASOFT.Tolerance levels are used for guaranteed soak, process warnings, a...

Page 64 - SOFTWARE COMMAND STRUCTURE

59 implement your entire turn key hardware and software system. Please contact yourlocal representative or ANAFAZE directly for a quotation. 10.0 SOFTWARE COMMAND STRUCTURE The SYSTEM 32 will respond to commands according to the following format.The commands generally follow the specifications of AN...

Page 65 - Addresses

60 10.4.1 Processor Reset This Error Code is returned after : Power-up reset The watchdog timer resets the Master processor The Master processor resets the Slave processor 10.4.2 Command Error This Error Code is returned when the A32PID receives a command that isnot a Block Read or a Block Wri...

Page 68 - TROUBLE SHOOTING INFORMATION; These four items must work together to operate the SYSTEM 32:; Computer Problems; This can be divided into: ANASOFT-32 and user written software:

63 11.0 TROUBLE SHOOTING INFORMATION These four items must work together to operate the SYSTEM 32: The SYSTEM 32 The computer including the RS-232 or other serial interface The communications link The computer software If the system does not work on initial start up check the SYSTEM 32 indicatorligh...

Page 69 - Communications Problems

64 the Edit or Run mode. Select the Run mode. If the SYSTEM 32 does notanswer, a communications error message will appear on the display [see11.3 and 11.4]. 11.3 Communications Problems If the computer is functioning properly [section 11.1] then the communicationinterface, cables and connections mus...

Page 70 - Orange Communication Light Remains Off

65 If the green light is on, then the orange light light is a communicationsindicator. The orange light will appear whenever the PIOM has decoded acommunication containing the address of the PIOM as set in the DIP switch.Thus the conditions for establishing the orange light in the presence of thegre...