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Watlow Controls 8LS User Manual

Summary of 8LS

  • Page 1

    8ls user’s guide part no. 10585-00. Revision 9.2 july 1996 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.

  • Page 2

    Copyright © 1996 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 ...

  • Page 3: Contents

    8ls user’s guide i contents overview 1 system diagram.....................................................................2 parts list ..........................................................................2 safety .....................................................................................

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    Ii 8ls user’s guide pid control relay outputs ..............................................28 primary screw terminal outputs ....................................28 digital outputs on the screw terminal blocks.............29 primary analog outputs ..................................................29...

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    8ls user’s guide iii input type........................................................................54 pulse sample time ..........................................................55 input units .......................................................................55 linear scaling menus ...........

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    Iv 8ls user’s guide setting up and tuning pid loops ........................................80 general pid constants by application..................................82 troubleshooting 85 stand alone systems .............................................................85 checking control outputs .......

  • Page 7

    8ls user’s guide v holding a profile or continuing from hold.....................103 resetting a profile ............................................................104 appendix b: 8ls-cp 105 key features ....................................................................105 system configuration .....

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    Vi 8ls user’s guide.

  • Page 9: Overview

    Overview 8ls user’s guide 1 overview this manual describes how to install, setup, and operate an 8ls controller. Included are six chapters, appendixes describing the 8ls-cp (carbon potential) and the 8ls-rs (ramp/soak), and a glossary of terms. Each chapter covers a different aspect of your control ...

  • Page 10

    2 8ls user’s guide overview system diagram the illustration below shows how the parts of the 8ls 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 h...

  • Page 11

    Overview 8ls user’s guide 3 safety watlow anafaze has made efforts to ensure the reliability and safety of the 8ls 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 ...

  • Page 12

    4 8ls user’s guide overview.

  • Page 13: Introduction

    Introduction 8ls user’s guide 5 introduction the 8ls is a powerful 1/4 din controller that delivers 8 fully independent loops of pid control. It can function as a stand alone controller and as the key element in a computer supervised data acquisition and control system. An led front panel display an...

  • Page 14

    6 8ls user’s guide introduction dual output standard: the 8ls includes dual control outputs for each loop with a second set of control constants for heating and cooling applications. Optional ramp and soak: the 8ls is available with a built in powerful ramp and soak programmer for batch processing. ...

  • Page 15

    Introduction 8ls user’s guide 7 specifications analog inputs thermocouple ranges rtd ranges analog inputs 8, solid state, differential optical isolation 120 vac between inputs; 175 vac from input to ground a/d converter integrating voltage to frequency dc voltage range -10 to 60 mv. You can change i...

  • Page 16

    8 8ls user’s guide introduction control capability digital outputs digital inputs pulse counting input serial interface power supply number of loops 8, dual output control outputs cycle time proportioning, distributed zero crossing, on/off or ana- log; all independently selectable for each loop cont...

  • Page 17: Installation

    Installation 8ls user’s guide 9 installation this section explains how to install the 8ls. The instructions are written for nontechnical users. If you are technically proficient and they seem simple, at least skim all of the instructions, so you don’t miss anything vital. These symbols are used thro...

  • Page 18

    10 8ls user’s guide installation read this before installation danger shut off power to your process before you install the 8ls. High voltage may be present even when power is turned off! Reduce the danger of electric shock after installation--mount the 8ls in an enclosure that prevents personal con...

  • Page 19

    Installation 8ls user’s guide 11 mounting the 8ls the 8ls consists of a 1/4 din housing with a front plug in electronics module. The 8ls-of (open frame) is suitable for sub-plate mounting inside an enclosure without a front panel. An 8ls-dk will supply the front panel keyboard with a 10-foot plug- i...

  • Page 20

    12 8ls user’s guide installation . 1 2 3 4 5 6 7 8 loop process units alarm setpoint status output% yes no back enter alarm ack chng sp man auto ramp soak front 3.78’’ 96 mm 3.78’’ 96 mm 3.58 ’’ 90.9 mm 3.58 ’’ 90.9 mm pio tb2 tb3 tb1 tb4 rear 3.78’’ 96 mm 3.58’’ 90.9 mm 9.4’’ 238.7mm 10.5’’ 266.7mm...

  • Page 21

    Installation 8ls user’s guide 13 external wiring during wiring, it is recommended that the 8ls electronics be removed or that temporary covers be put over the housing slots to ensure pieces of wire do not enter the housing and lodge in the electronics. Always ensure that the housing is clean when th...

  • Page 22

    14 8ls user’s guide installation 2. Use 20 or 22 awg size wire. The use of 16,18,20,22, or 24 awg is permissible also. The power requirement is not a factor in the wire size. Only the mechanical strength and the ohmage of the wire may be factors to consider. Smaller or larger sizes are not easily in...

  • Page 23

    Installation 8ls user’s guide 15 wiring bundles of low power watlow anafaze circuits next to bun- dles of high power ac wiring should never be done. The physical separation of the high power circuits from the controllers should be of prime importance. In fact, most ac voltage high power circuits are...

  • Page 24

    16 8ls user’s guide installation noise suppression when using the digital outputs from watlow anafaze multiloop controllers to energize dry contact electrical-mechanical relays with inductive loads, generation of rfi may become a problem. This may cause the 8ls display to blank out and then re-energ...

  • Page 25

    Installation 8ls user’s guide 17 the above steps should eliminate any noise problems that might be present with using e-m relays. If, problems persists and/or any questions about the above steps arises, please call watlow anafaze technical service department at (408) 724 3800. L 1 120 vac l 2 mov ho...

  • Page 26

    18 8ls user’s guide installation terminal block and connector layout the 8ls terminal blocks and connectors are assigned according to the following two pages. Subsequent sections provide detailed connection descriptions. Communications terminal block 4 1 2 3 4 5 6 com rx com tx rs-232 connections te...

  • Page 27

    Installation 8ls user’s guide 19 rtb connections the rtb provides the control outputs and additional digital inputs and outputs as follows: all digital outputs and the pid outputs on this ribbon connection are sink outputs. They are in reference to the 5vdc supply. The outputs will be low when they ...

  • Page 28

    20 8ls user’s guide installation note when using the rtb, proper polarity of the flat ribbon cable is necessary for correct pin termina- tions. Install the red marker indicating pin #1 to the left when terminal #1 of the rtb is to the left. The flat ribbon cable should have the red marker down when ...

  • Page 29

    Installation 8ls user’s guide 21 source impedance each sensor has a certain output impedance which is effectively connected across the 8ls input amplifier when a measurement is made. To reach the rated accuracy, the maximum source impedance should not exceed 500 ohms. Consult watlow anafaze for oper...

  • Page 30

    22 8ls user’s guide installation resistor installation for scaling resistors the body of the resistor goes vertically into the hole with the white silk screen. The lead on the top then goes into the adjacent indicated hole. The resistor positions are highlighted. Rc1 rb1 rc2 rb2 rc3 rb3 rc4 rb4 rc5 ...

  • Page 31

    Installation 8ls user’s guide 23 voltage inputs dc voltage inputs should be connected with the positive side to the high terminal and the negative side to the low terminal. The input range is -10 to +60 mv. Signals greater than 60 mv must be scaled with resistors to match the input full scale to 60 ...

  • Page 32

    24 8ls user’s guide installation rtd inputs the standard industrial rtd is a 100 ohm platinum three wire assembly. We highly recommend using the 3-wire rtd. The8ls will be configured for the standard three wire rtd input. Watlow anafaze offers two standard din 385 curve rtd input ranges, as shown in...

  • Page 33

    Installation 8ls user’s guide 25 the range of the standard irsm is 0-1000 degrees f with an output of 0-10ma dc. The input of the watlow anafaze 8ls is configured for a 0- 10madc input. To use more than four irsm's with the 8ls, use an external power supply of 8-15vdc. If desired, a second input may...

  • Page 34

    26 8ls user’s guide installation the belden cable part number 88760 is highly recommended for the connection of the carbon probe to the 8ls. An equivalent cable may be used. Probe cable belden #88760. Connect shield to tb4-6 chassis ground. No. Of cp loops t/c input loop number carbon probe input lo...

  • Page 35

    Installation 8ls user’s guide 27 control outputs warning control outputs are connected to the 8ls logic ground. Be careful when you connect external devices that may have a low side at voltage other than controller ground, since you may create ground loops. If you expect grounding problems, use isol...

  • Page 36

    28 8ls user’s guide installation pid control relay outputs typical on/off, tp, dzc control outputs utilize external optically- isolated solid-state relays. These relays use a 3 to 32vdc input for control and can be sized to switch up to 100amps at 480vac. For larger currents these relays can be used...

  • Page 37

    Installation 8ls user’s guide 29 digital outputs on the screw terminal blocks note alarms and events outputs are sinking +5vdc to ground when the output is on. They should be connected to the minus (-) side of ssrs. Connections are made as follows: see terminal block and connector layout. Primary an...

  • Page 38

    30 8ls user’s guide installation second is down, the output is in current mode. Thus if switch 3 is down and 4 is up on the dip switch package near the rear panel, then channel 3 is set for voltage. Output switches are set to voltage mode; in cpu switch all special features are set to off. Analog ou...

  • Page 39

    Installation 8ls user’s guide 31 cpu dip switch warning normal mode of operation is for all positions to be off. Positions that are on will effect the 8ls nor- mal operation mode. Position 1 on--clears the battery backed ram and re-initializes the factory default values into the ram. 1. Turn off pow...

  • Page 40

    32 8ls user’s guide installation connections are made as follows: ssr 1 ssr 2 + - + - remote terminal block or ribbon cable pin 9 11 1 pid ctl out 1 pid ctl out 2 +5vdc supply.

  • Page 41

    Installation 8ls user’s guide 33 communications set-up and connections the 8ls offers two types of serial communications: rs- 232 and rs- 485. Up to 32 addresses can be set in the 8ls for one communication line. Rs-232 can not be used for more than 1 controller. Unless otherwise specified in the pur...

  • Page 42

    34 8ls user’s guide installation rs-485 description and connections the rs-485 is a voltage balanced long distance multi-point transmission interface. It may use 2 or 4 lines depending on system requirements. The 8ls uses four lines [two lines can be accommodated on special order -- contact watlow a...

  • Page 43

    Installation 8ls user’s guide 35 rs-485 connections connection of watlow anafaze controllers to a system computer requires an interface at the computer to convert rs-232 levels to rs- 485. Watlow anafaze recommends two options: • b&b electronics 485oic with 485ps2 or 485oispr with 485ps. • black box...

  • Page 44

    36 8ls user’s guide installation a termination resistor is required at each end of the transmission line. This is accomplished by applying a 200 Ω resistor across the line at the farthest point from the computer transmitter. Check with watlow anafaze for setting the black box sw2 to the "term" posit...

  • Page 45: Using The 8Ls

    Using the 8ls 8ls user’s guide 37 using the 8ls this chapter will show you how to use the 8ls from the front panel. Front panel the 8ls front panel provides a convenient interface with the controller for both viewing the process conditions and operating the controller. You can program and operate th...

  • Page 46

    38 8ls user’s guide using the 8ls front panel keys press yes to • select a menu when prompt is blinking • answer yes to yes/no prompts • increase a number or choice you are editing press no to • skip a menu when prompt is blinking • answer no to yes/no prompts • decrease a number or choice you are e...

  • Page 47

    Using the 8ls 8ls user’s guide 39 press chng sp to • adjust the setpoint on displayed loop press man/auto to • toggle loop status between manual and auto • adjust output power level of loops in manual mode press ramp/soak to • assign a ramp/soak profile to selected loop • perform operations on profi...

  • Page 48

    40 8ls user’s guide using the 8ls displays the next section discusses the 8ls displays: • bar graph display • single loop display • scanning display • alarm display bar graph display this is the default display on power-up. It provides a system overview by displaying a deviation bar graph for each l...

  • Page 49

    Using the 8ls 8ls user’s guide 41 the table below shows the status symbols for the ramp and soak option. If an acknowledged alarm exists, the bar graph is replaced by an alarm symbol. Press back to see the single loop display. Single loop display this display shows the detailed information for one l...

  • Page 50

    42 8ls user’s guide using the 8ls the table below shows the alarm symbols. The alarm display interrupts any system display. If more than one alarm is present, the first one is shown. When you press the alarm ack key, the flashing stops but the alarm indicator remains as long as the alarm condition e...

  • Page 51

    Using the 8ls 8ls user’s guide 43 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: • press yes to change the setpoint. • press yes or no to change the setpoint value. • press enter to save...

  • Page 52

    44 8ls user’s guide using the 8ls if you have set the current loop to manual control, this display appears after you press enter: • press yes to change the output power. • press yes or no to select a new power output level. • press enter to store your choice and go back to single loop display autotu...

  • Page 53: Setup

    Setup 8ls user’s guide 45 setup the setup menus let you change the 8ls detailed configuration information. If you have not set up a modular system before, or if you don’t know what values to enter, please read the next section first, tuning and control, which contains pid tuning constants and useful...

  • Page 54

    46 8ls user’s guide setup setup setup setup globals? Control? Setup outputs? Setup alarms? Setup r/s pro? Save as job# ? Restore job# ? Alarm delay? R/s time base? Panel lock? Power up outs? Contrllr addr? Comm err chk? Comm baud? Comm ptcl? Ac line? Prom info input type? Input smplt? (only pulse) i...

  • Page 55

    Setup 8ls user’s guide 47 setup global parameters menu the setup global parameters menu looks like this: answering yes to this prompt gets you into the globals submenus. Below is the setup global parameters menu tree. Notice the default values inside the boxes. 1 2 3 4 5 6 7 8 loop process units ala...

  • Page 56

    48 8ls user’s guide setup save as job use this menu to save the job information for every loop to one of eight jobs in the battery-backed memory. Selectable range: 1-8. Restore a job use this menu to load a job from the memory . Selectable range: the last job number or job 1. Set alarm delay use thi...

  • Page 57

    Setup 8ls user’s guide 49 set r/s time base use this menu to set the global ramp and soak time base to units of hours and minutes or minutes and seconds. All time entries in r/s profiles will assume the units you set here. Selectable values: hours and minutes or minutes and seconds. Note this prompt...

  • Page 58

    50 8ls user’s guide setup warning set safe start up conditions. Do not use memory startup if there is any chance the process could start in an unsafe state. Controller address use this menu to set the 8ls controller address. This address is used for communications and each 8ls in a system must have ...

  • Page 59

    Setup 8ls user’s guide 51 communication baud rate use this menu to set the communications baud rate. Selectable values: 2400 or 9600. Note if you are using anasoft, be sure to set anain- stl to the same baud rate you set in this menu. Communication protocol use this menu to set the protocol type to ...

  • Page 60

    52 8ls user’s guide setup eprom version use this menu to see the controller’s eprom version and checksum. 1 2 3 4 5 6 7 8 loop process units alarm setpoint status output% 8ls-rs v3.20

  • Page 61

    Setup 8ls user’s guide 53 setup inputs menu the setup input main menu lets you access menus which change loop input parameters: • input type • engineering units • scaling the setup inputs menu looks like this: answering yes to this prompt, gets you into the inputs submenus. Below is the setup inputs...

  • Page 62

    54 8ls user’s guide 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, b, and n) • rtd. Two ranges: rtd1 (platinum class a: din 43760-1980, alpha=.00385), and rtd2 (platinum class b: din 43760-1980, alpha=.0038...

  • Page 63

    Setup 8ls user’s guide 55 pulse sample time you can connect a digital pulse signal of 20 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 ...

  • Page 64

    56 8ls user’s guide setup linear scaling menus note the next four menus appear only for linear or pulse loops. For all inputs automatic scaling is provided. To set the scaling enter a high process variable in engineering units and a corresponding high reading. Then enter a low process variable in en...

  • Page 65

    Setup 8ls user’s guide 57 low rdg display selectable range: 0-9999. The low input reading is referenced to 60mv and is calculated using this equation: linear input scaling example: problem: you want to connect a pressure sensor to be able to read pressure directly in psi. The sensor has an output of...

  • Page 66

    58 8ls user’s guide setup input offset note the next menu appears only for thermocouple or rtd loops. Use this menu to make up for the input signal’s inaccuracy. For example, at temperatures below 400 º f , a type j thermocouple may be inaccurate ("offset") by several degrees. To correct for offset ...

  • Page 67

    Setup 8ls user’s guide 59 setup control menu the setup control menu allows you to set control parameters for both heat and cool outputs of the selected loop. These are the parameters you can edit. • proportional band • integral • rate • output filter • spread between heat and cool outputs the setup ...

  • Page 68

    60 8ls user’s guide setup heat/cool pb use this menu to set the proportional band. Heat/cool ti use this menu to set the integral term. Selectable range: 0-5000 seconds. Heat/cool td use this menu to set the derivative constant. Selectable range: 0-255 seconds. Heat/cool output filter use this menu ...

  • Page 69

    Setup 8ls user’s guide 61 heat/cool spread use this menu to set the spread between the heat and cool output and the spread of the on/off control action. Selectable range: 0-255 engineering units. 1 2 3 4 5 6 7 8 loop process units alarm setpoint status output% 1 control spr? 10

  • Page 70

    62 8ls user’s guide setup setup outputs menu the setup outputs menu allows you to edit output parameters such as: • output type • cycle time • control action • output level limit • output limit duration • heat/cool nonlinear output curve • terminal block or ribbon the setup outputs menu looks like t...

  • Page 71

    Setup 8ls user’s guide 63 output type use this menu to to set the output type. Selectable values: the next table shows the available output types. Cycle time use this menu to set the cycle time for the tp outputs. Selectable values: 1-255 seconds. Note this menu appears only if you set the output ty...

  • Page 72

    64 8ls user’s guide setup output action use this menu to select the control action for the current output loop. The default is reverse for heat outputs and direct for cool outputs. Selectable values: reverse or direct. Output limit the output from each loop's dual heat/cool output may be limited to ...

  • Page 73

    Setup 8ls user’s guide 65 output limit time use this menu to set the time limit for the output limit. Selectable values: 1-999 seconds or c (continuous). Nonlinear output curve use this menu to select one of two nonlinear output curves for nonlinear processes. Selectable values: 1 (curve 1), 2 (curv...

  • Page 74

    66 8ls user’s guide setup heat output use this menu to select the terminal block or the flat ribbon for the heat output termination. The heat output is usually defaulted to the screw terminals of tb2, while the cool output is on the 50 pin flat ribbon connections of p10. However, you can switch the ...

  • Page 75

    Setup 8ls user’s guide 67 setup alarms the setup alarms main menu lets you access menus which change the alarm functions for the selected loop. You can edit these parameters: • high process alarm • deviation band alarm • low process alarm • alarm deadband the setup alarms main menu looks like this: ...

  • Page 76

    68 8ls user’s guide setup alarm types global alarms global alarms occur when a loop alarm, set to alarm, is unacknowledged, or when there are any unacknowledged failed sensor alarms. (if an alarm occurs, the 8ls front panel displays an appropriate alarm code). Even if the alarm condition goes away, ...

  • Page 77

    Setup 8ls user’s guide 69 high process alarm setpoint use this menu to select the setpoint 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 ...

  • Page 78

    70 8ls user’s guide setup deviation band alarm use this menu to set the deviation bandwidth, a positive and negative alarm point relative to the setpoint. If the setpoint changes, the alarm points also changes. You can assign a separate digital output to the high and low deviation alarm setpoints. (...

  • Page 79

    Setup 8ls user’s guide 71 low deviation alarm output number use this menu to assign a digital output which activates when the loop is in low diviation alarm. Selectable values: 0-30. Low process alarm setpoint use this menu to set a low process alarm setpoint. The low process alarm activates when th...

  • Page 80

    72 8ls user’s guide setup low process alarm output number use this menu to assign the digital output that activates when the loop is in low process alarm. Selectable values: 0-30. Alarm deadband use this menu to set an alarm deadband. This deadband value applies to the high process, low process, hig...

  • Page 81

    Setup 8ls user’s guide 73 test i/o the test i/o main menu lets you view menus which can help you test the digital inputs and the digital outputs. The main menu looks like this: answering yes to this prompt gets you into the i/o test submenus. Below is the menu tree. Notice the default values in the ...

  • Page 82

    74 8ls user’s guide setup test output use this menu to select one of the 30 digital outputs for manual operation. Selectable values: 1-30. Digital output test use this menu to toggle the state of a digital output between on and off. Selectable values: on, off. Note before leaving this menu, turn off...

  • Page 83: Tuning and Control

    Tuning and control 8ls user’s guide 75 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 w...

  • Page 84

    76 8ls user’s guide tuning and control control modes the next sections explain the different modes you can use to control a loop. On/off control 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 ce...

  • Page 85

    Tuning and control 8ls user’s guide 77 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.) pro...

  • Page 86

    78 8ls user’s guide tuning and control proportional, integral and derivative control for an improved level of control, use derivative control with proportional or proportional and integral control. Derivative control corrects for overshoot by anticipating the behavior of the process variable and adj...

  • Page 87

    Tuning and control 8ls user’s guide 79 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...

  • Page 88

    80 8ls user’s guide tuning and control setting up and tuning pid loops after you have installed your control system, tune each control loop and then set the loop to automatic control. (when you tune a loop, you choose pid parameters that will best control the process.) if you don't mind minor proces...

  • Page 89

    Tuning and control 8ls user’s guide 81 integral term (ti) settings this table shows ti settings vs. Reset settings. As 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) versus rate minutes (rm); rate=td/60. As...

  • Page 90

    82 8ls user’s guide tuning and control general pid constants by application this section gives pid values for many applications. They are useful as control values or as starting points for pid tuning. Proportional band only (p) pb: set the pb to 7% of the setpoint (sp) (example: setpoint = 450, so p...

  • Page 91

    Tuning and control 8ls user’s guide 83.

  • Page 92

    84 8ls user’s guide tuning and control.

  • Page 93: Troubleshooting

    Troubleshooting 8ls user’s guide 85 troubleshooting note if you need to return the 8ls to watlow-anafaze, please call first for a returned materials authori- zation (rma) number. This number helps us track your equipment and return it to you as soon as possible. Stand alone systems if the unit has n...

  • Page 94

    86 8ls user’s guide troubleshooting computer supervised systems these four items must work together to operate the 8ls: 1. The 8ls 2. The computer including the rs-232 or other serial interface 3. The communications link 4. The computer software if the system does not work on initial startup, check ...

  • Page 95

    Troubleshooting 8ls user’s guide 87 if you write your own software, first write a routine that sends and receives display commands to and from the 8ls. The protocol includes all characters, so the display should show the hexadecimal values of the data sent in both directions. If you have problems wi...

  • Page 96

    88 8ls user’s guide troubleshooting.

  • Page 97: Appendix A: Ramp Soak

    Appendix a: ramp soak 8ls user’s guide 89 appendix a: ramp soak introduction this appendix will teach you how to set up and use ramp/soak profiles in 8ls controllers. The ramp/soak feature turns your 8ls into a powerful and flexible batch controller. The ramp/soak feature lets you program the contro...

  • Page 98

    90 8ls user’s guide appendix a: ramp soak specifications configuring ramp/soak this section will teach you how to set up r/s profiles. The following diagram shows the r/s configuration menu tree. Number of possible profiles 8 number of times to repeat a profile 1-99 or con- tinuous number of segment...

  • Page 99

    Appendix a: ramp soak 8ls user’s guide 91 setting the r/s time base the r/s time base menu is in the setup globals main menu. Use this menu to set the time base in all your r/s profiles. Selectable values: h/m (hours/mins) or m/s (mins/secs). Editing r/s parameters you can reach the rest of the menu...

  • Page 100

    92 8ls user’s guide appendix a: ramp soak copying the setup from another profile use this menu to setup similar profiles quickly, by copying a profile to another one. Selectable values: a to h. Editing the tolerance alarm time use this menu to set a tolerance time that applies to the entire profile....

  • Page 101

    Appendix a: ramp soak 8ls user’s guide 93 editing the ready setpoint when you assign a profile to a loop, the profile doesn’t start immediately; instead, it goes to the ready segment (segment 0) and stays there until you put the profile in start mode. You can set a setpoint, assign events, and set e...

  • Page 102

    94 8ls user’s guide appendix a: ramp soak choosing an external reset input use this menu to select an external reset input. Toggle the input to reset a profile to ready state when it is in run, hold, or wait mode. You can make any of the eight digital inputs the external reset input. Selectable valu...

  • Page 103

    Appendix a: ramp soak 8ls user’s guide 95 setting a segment setpoint use this menu to set a setpoint for the segment you are editing. The process will go to this setpoint by the end of the segment time. Selectable values: -999 to 9999, or off (no segment setpoint). Configuring segment events you can...

  • Page 104

    96 8ls user’s guide appendix a: ramp soak editing event outputs this menu appears only if you answered yes to the previous menu. Use it to assign a digital output to each event. Assign digital outputs that are not being used for pid control. Selectable values: 1-30, except those in use, or no (no ev...

  • Page 105

    Appendix a: ramp soak 8ls user’s guide 97 assigning an input to a trigger this menu appears only if you answered yes to the edit segment triggers menu. Use it to assign one of the controller’s eight digital inputs to a segment trigger. You can assign any digital input to ant trigger. You can also as...

  • Page 106

    98 8ls user’s guide appendix a: ramp soak setting segment tolerance use this menu to set a positive or negative tolerance value for each segment. This value is displayed in the engineering units of the process and is a deviation from the setpoint. • if you enter a positive tolerance, the process is ...

  • Page 107

    Appendix a: ramp soak 8ls user’s guide 99 using ramp/soak this section explains how to assign a profile to a loop, how to put a profile in run, continue, or hold mode, how to reset a profile, and how to display profile statistics. The next figure shows the ramp/soak key menus. From the ramp/soak res...

  • Page 108

    100 8ls user’s guide appendix a: ramp soak assigning a profile the first time to assign a profile to a loop that doesn’t have a profile, follow these steps: 1. In single loop display, switch to the loop you want to edit. 2. Press the ramp/soak key. The assigning menu appears. (see menu in previous p...

  • Page 109

    Appendix a: ramp soak 8ls user’s guide 101 running several profiles simultaneously to run several profiles simultaneously, follow these steps: 1. Setup the profiles so that segment 1 of each profile has the same latched trigger. 2. Assign the profiles to the appropriate loops. The loops will go to t...

  • Page 110

    102 8ls user’s guide appendix a: ramp soak bar graph display loops that are running r/s profiles have different bar graph display codes. For these loops, you will see the first letter of each mode where the controller would normally display m (for manual control) or a (for automatic control). The ne...

  • Page 111

    Appendix a: ramp soak 8ls user’s guide 103 how many times has it cycled? From single loop display, press the ramp/soak key twice. The next menu will appear. This menu displays the number of times the profile has run out of the total number of cycles. Holding a profile or continuing from hold use the...

  • Page 112

    104 8ls user’s guide appendix a: ramp soak continuing a profile if a profile is holding and you want it to run, you can put it in continue mode. • press ramp/soak key repeatedly until you see the r/s mode menu • while the profile is holding, the only mode you will be able select is cont (continue). ...

  • Page 113: Appendix B: 8Ls-Cp

    Appendix b: 8ls-cp 8ls user’s guide 105 appendix b: 8ls-cp the 8ls-cp controller with a zirconia carbon probe assembly can control and record the dew point of atmosphere generators or the percentage of carbon potential of hardening and sintering furnaces. The 8ls-cp can accept direct connection of o...

  • Page 114

    106 8ls user’s guide appendix b: 8ls-cp system configuration the 8ls-cp uses a modified input with discreet components per carbon input. Each cp input requires two loops. The 8ls-cp is factory configured to contain between 1 to 4 cp loops. The unit must be ordered for the number of cp inputs require...

  • Page 115

    Appendix b: 8ls-cp 8ls user’s guide 107 the 8ls-cp is not only ordered for the number of carbon input loops desired, but the cpu dip switch on the cpu board must be set correctly to reflect the number of carbon inputs. The figure below presents a typical 8ls-cp control system. Number of carbon loops...

  • Page 116

    108 8ls user’s guide appendix b: 8ls-cp specifications the standard specifications listed in the introduction section of this manual apply to the 8ls-cp with the following additions: analog inputs each cp input: • 1 loop selectable type n, k, r, or s t/c reference temperature for cp • 1 loop selecta...

  • Page 117

    Appendix b: 8ls-cp 8ls user’s guide 109 cp control the temperature control may be accomplished by using a standard analog input/output loop or it may be installed so that the t/c reference loop of the cp input is the temperature control for the system. A standard pid control and output function is a...

  • Page 118

    110 8ls user’s guide appendix b: 8ls-cp recommended cp trim gas alarm for continuous applications when using the 8ls-cp for controlling the gas atmosphere, it is required to prevent gas from being introduced by the control system until the temperature is above 1400ºf (760ºc). The 8ls-cp has a digita...

  • Page 119

    Appendix b: 8ls-cp 8ls user’s guide 111 carbon probe in general practice, follow the probe manufacturer’s recommendations as to installation and maintenance schedule. General guidelines 1. The probe must be exposed to the same atmosphere as the work load. 2. Be sure of the physical location as to le...

  • Page 120

    112 8ls user’s guide appendix b: 8ls-cp probe burn off carbon probe burn off requirements: 1. To burn off carbon, excess fresh air is supplied to the end of the probe. 2. The excess fresh air burning off the carbon will cause the temperature of the probe to increase. The temperature must be monitore...

  • Page 121

    Appendix b: 8ls-cp 8ls user’s guide 113 the figure below describes the typical installation of a carbon burn off system. Burn off function the carbon probe burn off function of the 8ls-cp is designed to supply excess fresh reference air to the outside of the probe assembly. When the excess air is ex...

  • Page 122

    114 8ls user’s guide appendix b: 8ls-cp if you want to disable the enrichment gas during the burn off period, a normally open solenoid valve should be installed in the enriching gas line and powered from the same ssr that is supplying power to the burn off air solenoid valve. In both modes, the cont...

  • Page 123

    Appendix b: 8ls-cp 8ls user’s guide 115 co+co2% and % of hydrogen upon selecting cp as the input type, the following menu is available. Use it to adjust the amount of co+co2% in the atmosphere. Selectable range: 1-30%. Upon selecting dp as the input type, the following menu is available. Use it to a...

  • Page 124

    116 8ls user’s guide appendix b: 8ls-cp offset calibration if the carbon probe input type is set to cp or dp, a menu is available for editing an offset calibration of the probe input in the engineering units of the process variable. The mv input is in direct reading of the millivolt output of the ca...

  • Page 125

    Appendix b: 8ls-cp 8ls user’s guide 117 typically used in continuous furnace applications. Setting the start mode to input means the burn off procedure will be started based on a digital input signal. This is typically used in batch furnace applications. Selectable values: off, time, input. Burn off...

  • Page 126

    118 8ls user’s guide appendix b: 8ls-cp burn off time period this menu is displayed if the start mode is set to either input or time. Use it to edit the time period of the burn off. This is the time that the burn off air flow output will be set on to allow air flow to the probe burn off port. Select...

  • Page 127

    Appendix b: 8ls-cp 8ls user’s guide 119 setup alarms cp gas alarm this menu is available from the setup alarms main menu. Use it to set the digital output number for the cp trim gas alarm output. This output is on when the temperature of the t/c reference loop is between 1400 to 2400ºf and off when ...

  • Page 128

    120 8ls user’s guide appendix b: 8ls-cp.

  • Page 129: Appendix C: 8Ls Cascade

    Appendix c: 8ls cascade 8ls user’s guide 121 appendix c: 8ls cascade introduction the cascade control feature allows the output percentage of one control loop to be used as the setpoint of a second control loop. The loop providing the output is called the master or primary loop. The loop that is usi...

  • Page 130

    122 8ls user’s guide appendix c: 8ls cascade choosing the primary loop use this selection to choose the primary loop for cascade control. This loop provides the output for the secondary loop, which is the current loop as it appears on the upper line of the display. Setting the high end of the second...

  • Page 131: Glossary

    123 8ls 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 ...

  • Page 132

    Glossary 124 8ls user’s guide bumpless transfer a smooth transition from auto (closed loop) to manual (open loop) operation. The control output does not change during the transfer. C calibration the comparison of a measuring device (an unknown) against an equal or better standard. Celsius (centigrad...

  • Page 133

    Glossary 8ls user’s guide 125 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 and under- shoot. Derivative control is an instantaneous change of the control output in the same direction as the...

  • Page 134

    Glossary 126 8ls user’s guide 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...

  • Page 135

    Glossary 8ls user’s guide 127 integral control (i) 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 call...

  • Page 136

    Glossary 128 8ls user’s guide 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...

  • Page 137

    Glossary 8ls user’s guide 129 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 switchin...

  • Page 138

    Glossary 130 8ls user’s guide 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 m...

  • Page 139

    Glossary 8ls user’s guide 131.

  • Page 140

    Glossary 132 8ls user’s guide.