Watlow Controller Series D8 User Manual Download Page 141 | Manualshive

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D8 Series User’s Guide

Chapter 7: Troubleshooting and Reconfiguring

141

NOTE!

The controller retains its settings when powered. The battery is required to keep

the settings in memory only while the controller is not powered.

To replace the battery:

1. Contact your supplier to obtain a replacement battery.

2. See

Removing or Replacing the Battery on page 147.

If you must use the controller with the failed battery:

1. Acknowledge the Battery Dead alarm. This restores all setting to factory defaults.

2. Using your record of controller settings, re-enter your settings.

H/W Error: Gain or Offset

Gain and Offset alarms indicate that a hardware error is preventing accurate measurements. If a Gain
or Offset alarm occurs, the control outputs are turned off, an alarm message is displayed and the
global alarm output turns on. Acknowledging the alarm turns off the global alarm output. The error
clears when the condition no longer exists and the alarm has been acknowledged.

If the controller displays

H/W error: Gain

or

H/W error: Offset:

1. Switch the power to the controller off, then on again.

2. If the alarm persists, make a record of all controller settings, then clear the RAM.

See

Clearing the RAM on page 145.

3. If the alarm is not cleared, contact your supplier for further troubleshooting guidelines. See

Return Material Authorization (RMA) on page 3.

NOTE!

If the controller has failed, it is likely that it was damaged by excessive voltage or

noise. Before replacing the controller, troubleshoot for noise and ground loops.

H/W Error: Ambient

The

H/W error: Ambient

alarm indicates that the ambient sensor in the D8 is reporting that the

temperature around the controller is outside of the acceptable range of 0 to 50° C. This alarm can
also occur if there is a hardware failure.

If an

H/W Error: Ambient

alarm occurs, the control outputs are turned off, an alarm message is

displayed with the ambient temperature and the global alarm output turns on. Acknowledging the
alarm turns off the global alarm output. The error clears when the condition no longer exists and the
alarm has been acknowledged.

If the controller displays

H/W error: Ambient

:

1. Acknowledge the alarm and check the ambient air temperature near the controller. Adjust

ventilation, cooling or heating so that the temperature around the controller is 0 to 50°
C. If the unit is functioning correctly, the alarm will clear automatically when the ambient
temperature is within range.

2. If the ambient temperature is within range and the alarm persists, reseat the board

assembly:

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Summary of Contents for Controller Series D8

Page 1: ...D8 Series User s Guide...

Page 2: ...y Avertissements Attentions et Remarques AVERTISSEMENT Le r gulateur peut s av rer d faillant avec un r gime de puissance de sortie 0 ou 100 Pour viter tout risque de d c s blessure personnelle endomm...

Page 3: ...description of the problem Any special instructions Name and phone number of person returning the product 2 Prior approval and an RMA number from the customer service department is required when retur...

Page 4: ...igital Input Test 31 Sensor Wiring 31 Input Wiring Recommendations 33 Thermocouple Connections 33 RTD Input Connections 34 Voltage Input Connections 34 Current Input Connections 35 Wiring Control and...

Page 5: ...ple 0 to 5VDC Sensor 71 Autotuning 72 How Does Autotuning Work 72 Prerequisites 72 How to Autotune a Loop 73 Setting Up Alarms 73 Failed Sensor Alarms 73 Process Alarms 75 Global Alarm 76 Setting Up P...

Page 6: ...igh 110 Input High Signal 111 Input Range Low 111 Input Low Signal 111 Input Filter 112 Control Menu 112 Heat Cool Proportional Band 113 Heat Cool Integral 113 Heat Cool Derivative 114 Heat Cool Manua...

Page 7: ...rning 138 Failed Sensor Alarms 138 System Alarms 138 Other Behaviors 138 Reading the DeviceNet Indicator Lights 139 Corrective and Diagnostic Procedures 140 Low Power 140 Battery Dead 140 H W Error Ga...

Page 8: ...ith Mass Termination Option 28 Figure 2 13 Power Connections with the D8 Power Supply 30 Figure 2 14 Termocouple Connections 34 Figure 2 15 RTD Connections 34 Figure 2 16 Voltage Signal Connections 34...

Page 9: ...roportional Control 88 Figure 5 3 Proportional and Integral Control 89 Figure 5 4 Proportional Integral and Derivative Control 89 Figure 5 5 Time Proportioning and Distributed Zero Crossing Waveforms...

Page 10: ...2 Address Components 47 Table 3 3 Elementary Data Types 47 Table 3 4 Identity Class and Services 48 Table 3 5 Identity Instance Attributes 48 Table 3 6 Message Router Class and Services 48 Table 3 7...

Page 11: ...1 Table 4 7 Scaling Values 72 Table 4 8 Parameters Settings for Process Variable Retransmit Example 78 Table 4 9 Parameter Settings for the Primary Loop in the Cascade Example 81 Table 4 10 Parameter...

Page 12: ...le 7 6 Resistor Locations for Current Inputs 149 Table 7 7 Resistor Values for Voltage Inputs 149 Table 7 8 Resistor Locations for Voltage Inputs 150 Table 7 9 Resistor Locations for RTD Inputs 150 Ch...

Page 13: ...g by DeviceNet explains how to add the D8 controller to a network and how to access controller data via DeviceNet Chapter 4 Operation and Setup provides instructions about operating and setting up the...

Page 14: ...e two line 16 character display and touch keypad You can also use it as the key element in a computer supervised data acquisition and control system The D8 can be locally or remotely controlled via it...

Page 15: ...ontroller s battery backed memory Load a job through the keypad digital inputs or software Each job is a set of operating conditions including set points and alarm limits Nonlinear Output Curves Selec...

Page 16: ...sor and power inputs Mass Termination DB25 DB25 connection for sensor and power inputs Digital I O Termination Screw Terminals TB18 Screw terminals for digital inputs and outputs Mass Termination SCSI...

Page 17: ...al block TB50 The D8 is available with an 18 terminal block TB18 in place of the SCSI connector as shown in Figure 1 1 above Nonvolatile flash memory for storage of firmware Battery backed storage of...

Page 18: ...the D8 Figure 1 3 TB50 D8 Cabling Watlow provides optional cables to support installing the D8 A 50 pin SCSI cable connects the TB50 to the CLS200 Safety Watlow has made every effort to ensure the re...

Page 19: ...te To prevent death personal injury equipment damage or property damage install external safety shutdown devices that operate independently from the process control equipment With proper approval and...

Page 20: ...cent or 100 percent power output state To prevent death personal injury equipment damage or property damage install external safety shutdown devices that operate independently from the process control...

Page 21: ...ency interference can induce noise on sensor wiring Choose locations for the D8 and TB50 such that wiring can be routed clear of sources of interference such as high voltage wires power switching devi...

Page 22: ...of your system Ensure that there is enough clearance for mounting brackets terminal blocks and cable and wire connections 1 00 in 25 mm 1 98 in 50 mm 10 00 in 254 mm 2 44 in 62 mm Figure 2 2 Clearanc...

Page 23: ...3 in 92 mm as shown above Use caution the dimensions given here have 0 02 in 0 5 mm tolerances 4 Remove the brackets and collar from the controller if they are already in place 5 Slide the controller...

Page 24: ...to mount the board Standoffs DIN Rail Mount Figure 2 7 Mounting the TB50 DIN Rail Mounting Snap the TB50 on to the DIN rail by placing the hook side on the rail first then pushing the snap latch side...

Page 25: ...instructions for mounting information Choose a Class 2 power supply that supplies an isolated regulated 12 to 24VDC at 1A Mounting Environment Leave enough clearance around the power supply so that it...

Page 26: ...e Connect one end of the input and output wiring shield to earth ground Use copper wire for all connections other than thermocouple sensor inputs Table 2 1 Cable Recommendations FUNCTION MFR P N NO OF...

Page 27: ...ust place them in a panel with D8 series equipment use a 0 01 microfarad capacitor rated at 1000VAC or higher in series with a 47 0 5 watt resistor across the normally open contacts of the relay load...

Page 28: ...explains how to make power connections to the D8 and the TB50 J1 Sensor Inputs J2 Power Input SCSI to TB50 Digital Inputs Digital Outputs Figure 2 11 Power Input with Mass Termination Option TB1 Sens...

Page 29: ...sis ground This terminal is connected to the CLS200 chassis and must be connected to earth ground 5 Connect 120 240VAC power to the power supply NOTE Connect the dc common of the power supply used for...

Page 30: ...r 1 Turn on power to the D8 The display should read Calculating checksum then show the single loop display If you do not see these displays disconnect power and check wiring and power supply output 2...

Page 31: ...nt to test See See Table 2 7 TB18 Connections on page 39 or See Table 2 8 TB50 Connections on page 40 for connections a When the wire is connected only to the digital input terminal the digital input...

Page 32: ...CH3 Channel 3 positive input 8 CH3 Channel 3 negative input 9 Com Analog common 10 CH4 Channel 4 positive input 11 CH4 Channel 4 negative input 12 Com Analog common 13 Not used 14 CH5 Channel 5 posit...

Page 33: ...nalog Common 1 Terminals 11 to 18 are not used with a 4 loop controller Input Wiring Recommendations Use multicolored stranded shielded cable for analog inputs Watlow recommends that you use 20 AWG wi...

Page 34: ...D8 uses a floating analog common for sensor measurements The noise protection circuits on the sensor inputs function correctly only if the controller is correctly installed See Ground Loops on page 27...

Page 35: ...commendations When wiring output devices use multicolored stranded shielded cable for analog outputs and digital outputs connected to panel mounted solid state relays Analog outputs usually use a twis...

Page 36: ...Digital Output 2 Do not connect External Power TB50 or TB18 Loads Supply TB50 or TB18 to earth ground or equipment ground Figure 2 18 Digital Output Wiring Configuring Outputs As you choose outputs f...

Page 37: ...them to the negative side of solid state relays Figure 2 19 shows sample heat cool and alarm output connections Cool Output Alarm Output 5VDC SSR SSR SSR TB50 or TB18 Heat Output Figure 2 19 Sample He...

Page 38: ...ler common Table 2 6 Digital Input States and Values Stored in the Controller STATE VALUE1 DESCRIPTION Off 0 Open circuit On 1 Digital input connected to controller common 1 Read and write these value...

Page 39: ...store automatic control after a failed sensor has been repaired See Restore Automatic Mode on page 115 TB18 Connections Table 2 7 TB18 Connections TERMINAL FUNCTION CONTROL OUTPUT1 4 LOOP MODEL 8 LOOP...

Page 40: ...sed 15 Output 4 Loop 4 heat Loop 4 heat 16 Not used 17 Output 5 Loop 5 heat Loop 1 cool 18 Not used 19 Output 6 Loop 6 heat Loop 2 cool 20 Not used 21 Output 7 Loop 7 heat Loop 3 cool 22 Not used 23 O...

Page 41: ...requirements Also note in the specifications that the Dual DAC does not carry the same industry approvals as the Serial DAC Wiring the Serial DAC The Serial DAC provides a robust analog output signal...

Page 42: ...ft 125 Kbps Baud Rate Data Rate DeviceNet communications can use three different baud rates data rates 125k 250k and 500k baud When the switch is set to the PGM position the unit s baud rate is deter...

Page 43: ...ntroller s memory Set the controller s MAC ID with the two rotary switches on the side of the case Set the most significant digit MSD with the left switch and the least significant digit LSD with the...

Page 44: ...The device has not completed the duplicate MAC ID test yet The device may not be powered Look at Table 2 11 Module Status Indicator Light Green The device is online and has connections in the establi...

Page 45: ...b site and upon request from Watlow technical support NOTE There are several versions of the EDS file You must use the correct file for the number of loops in the controller d84 file version eds or d8...

Page 46: ...2 9 999 to 30 000 3 0 9999 to 3 0000 4 To determine the integer value to set in the controller move the decimal to the right the number of places specified For example If a loop has a process input wi...

Page 47: ...mines its scan list and sends commands accordingly Except for the Duplicate MAC ID Check a slave cannot initiate any communication before being told by the master to do so Addressing All data is refer...

Page 48: ...PTION 1 1 hex Get VendorID UINT Identification of each vendor by number Watlow has vendor ID 153 2 2 hex Get Product Type UINT Identification of general type of product for vender The D8 has type 0 3...

Page 49: ...T Baud Rate 0 to 2 3 3 hex Get Bus Off Counter USINT Number of times CAN went to the bs o state 0 to 255 4 4 hex Get Allocation Info STRUCT of BYTE USINT Allocation Information Allocation Choice Byte...

Page 50: ...of INTs array3 of UINTs Produced Static Input 1 Array size is equal to the number of loops in the controller 4 elements for four loops and 8 for eight loops 2 Array size is equal to the two times the...

Page 51: ...te Byte Byte Exception Status 1 byte Loop 1 Process Variable INT 2 bytes Loop 2 Process Variable INT 2 bytes Loop 3 Process Variable INT 2 bytes Loop 4 Process Variable INT 2 bytes Loop 5 Process Vari...

Page 52: ...hex Get Attribute Single 10 hex Set Attribute Single Table 3 15 Connection Instance Attributes ATTRIBUTE ACCESS NAME TYPE DESCRIPTION 1 1 hex Get State USINT State of the object 2 2 hex Get Instance...

Page 53: ...Get Attribute Single Instance Services 0E hex Get Attribute Single 10 hex Set Attribute Single Table 3 17 Input Class Attributes Instance 0 ATTRIBUTE ACCESS NAME TYPE DESCRIPTION 1 1 hex Get Revision...

Page 54: ...m instances of this object 8 3 3 hex Get Number of instances UINT Number of object instances Table 3 21 Output Instance Attributes Instances 1 to 4 or 8 ATTRIBUTE ACCESS NAME TYPE DESCRIPTION 100 64 h...

Page 55: ...e eight loop controller has eight additional instances each containing the attributes listed in Table 3 24 Instance 1 corresponds to loop 1 instance 2 corresponds to loop 2 and so on Table 3 22 Contro...

Page 56: ...nd so on Table 3 25 Alarm Class and Services Class Code 67 hex Class Services 0E hex Get Attribute Single Instance Services 0E hex Get Attribute Single 10 hex Set Attribute Single Table 3 26 Alarm Cla...

Page 57: ...ervices Class Code 68 hex Class Services 0E hex Get Attribute Single Instance Services 0E hex Get Attribute Single 10 hex Set Attribute Single Table 3 29 PV Retransmit Class Attributes Instance 0 ATTR...

Page 58: ...tes Instances 1 to 4 or 8 ATTRIBUTE ACCESS NAME TYPE DESCRIPTION 100 64 hex Get Set Ratio Master Loop USINT See page 129 101 65 hex Get Set Ratio Low Set Point INT See page 130 102 66 hex Get Set Rati...

Page 59: ...rovides read write access to all global parameters Instance 0 contains the class attributes listed in Table 3 38 Instance 1 contains the attributes listed in Table 3 39 Table 3 37 Global Class and Ser...

Page 60: ...16 MSB USINT See page 132 115 73 hex Get Set Digital Outputs 17 LSB and 18 and Global Alarm MSB USINT See page 132 116 74 hex Get Ambient Sensor INT See page 134 117 75 hex Get Battery Status BOOL OK...

Page 61: ...re 4 1 shows how to navigate from the loop display to other displays menus and parameters Loop Display Same Screen on the Next or Previous Loop Scanning Loop Display Hold 3 seconds 01 925 C 1000auto10...

Page 62: ...o to a different loop Save a change and go to a different loop Go to the scanning loop display hold for 3 seconds Save a change and go to the previous parameter Key Description Toggle between the loop...

Page 63: ...blank for that loop The scanning loop display sequentially displays the information for each loop The data for each loop displays for one second To activate the scanning loop display go to the loop d...

Page 64: ...igh deviation alarm Deviation Alarms on page 76 LD No message Low deviation alarm Deviation Alarms on page 76 AW No message Ambient Warning The controller is within 5 C of its operating temperature li...

Page 65: ...ead The RAM battery in the D8 is not functioning correctly and stored data has been corrupted Battery Dead on page 140 H W error Ambient The temperature around the controller is outside of the accepta...

Page 66: ...put of one loop to adjust the set point of another loop Setting Up Cascade Control on page 79 Ratio Control Use the process variable of one loop multiplied by a ratio as the set point of another loop...

Page 67: ...You should be back at the loop display The control mode is shown on the second line of the loop display Table 4 1 Control Modes on page 63 Accessing and Navigating the Setup Menus Use the setup menus...

Page 68: ...oller determines the appropriate output signal The controller calculates the output signal based on the feedback and the control algorithm Each loop may use either on off control or any combination of...

Page 69: ...automatic mode Changing the Control Mode and Output Power on page 66 For more information about the setup menus and parameters Chapter 6 Menu and Parameter Reference on page 95 Setting Up a Process I...

Page 70: ...per square inch PSI Setup Set the scaling parameters in the Input menu as follows For the Input type parameter choose process For the Disp format parameter choose 999 9to 3000 0 because the sensor mea...

Page 71: ...to 5VDC signal Independent calibration measurements of the flow in the pipe indicate that the sensor generates 0 5V at 3 gallons per minute GPM and 4 75V at 65 GPM The calibration instrument is accur...

Page 72: ...come constant to determine the integral term The controller mathematically derives the derivative term from the integral term When the controller finishes autotuning a loop it switches the loop to aut...

Page 73: ...ng limits of your system 5 Access the setup menus see page 67 Go to the Input filter parameter in the Input menu Write down the value and then change it to 0 scans Press to save the new setting 6 Pres...

Page 74: ...ouple Reversed Alarm The thermocouple reversed alarm occurs if the temperature goes in the opposite direction and to the opposite side of ambient temperature than expected for example a loop is heatin...

Page 75: ...teresis The alarm output deactivates when the process returns to normal Process Alarm Outputs Any digital output that is not used as a control output can be assigned to one or more process alarms The...

Page 76: ...pecified amount see Figure 4 7 above You can set separate high and low deviation values at the HiDeviation value and LoDeviation value parameters in the Alarms menu Upon power up or when the set point...

Page 77: ...h as a PLC Any available heat or cool output may be used as a retransmit output Any process variable may be retransmitted including the input from the same loop To get a 4 to 20mA or 0 to 5VDC signal...

Page 78: ...nput is a linear 4 to 20mA signal representing a range of 0 F to 1000 F so we will use a 0 percent output signal to represent 0 F PV retrans Ht retrans HighPV 1000 F This is the input value represente...

Page 79: ...and user specified cascade parameters If the primary loop has both heat and cool outputs then the set point of the secondary loop is equal to the Cascade low SP parameter when the cool output is at 10...

Page 80: ...so that the set point of the secondary loop has the desired relationship to the process variable of the primary loop See the example below How To Set Up Cascade Control 1 For the primary cascade loop...

Page 81: ...r T C Inner T C Figure 4 11 Example Application Using Cascade Control Table 4 9 Parameter Settings for the Primary Loop in the Cascade Example MENU PARAMETER VALUE COMMENT none Set point 150 F Desired...

Page 82: ...percent of 40 F is 4 F So when the temperature at loop 1 drops 1 F the set point of loop 2 increases by 4 F until the output of loop 1 is 100 percent and the set point of loop 2 is 190 F At this poin...

Page 83: ...loop for optimal performance before implementing the ratio setup 2 For the ratio loop set the parameters in the Ratio menu 3 Configure both the master loop and the ratio loop for inputs outputs and al...

Page 84: ...low SP 0 0 The minimum ratio loop set point is 0 0 gallons per second GPS Ratio Ratio high SP 7 0 The maximum ratio loop set point is 7 0 GPS Ratio Control ratio 0 5 The H2 0 flow rate 10 GPS is mult...

Page 85: ...Ratio Ratio low SP 300 0 F The lowest allowable set point for the ratio loop For this example we ll use 300 0 Ratio Ratio high SP 400 0 F The highest allowable set point for the ratio loop For this e...

Page 86: ...e full scale of 0 to 100 percent Input Input range low 0 F The 0VDC input signal represents 0 F Input Input low signal 0 0 The controller is equipped with a 0 to 5VDC input and the input signal is 0 t...

Page 87: ...rtional P Proportional and integral PI Proportional with derivative PD Proportional with integral and derivative PID P PI or PID control is necessary when process variable cycling is unacceptable or i...

Page 88: ...rtional to the process variable s deviation from the set point For example if the set point is 1000 F and the proportional band is 20 F the output power is as follows 0 percent when the process variab...

Page 89: ...that make the process very slow to reach set point and parameters that make the controller respond quickly but introduce some transient oscillations when the set point or load changes The extent to wh...

Page 90: ...a loop choose PID parameters that will best control the process This section gives PID values for a variety of heating and cooling applications NOTE Tuning is a slow process After adjusting a loop al...

Page 91: ...ttings The controller s derivative parameter is programmed in seconds Some other products use a derivative term called rate programmed in minutes Use the table or the formula to convert parameters fro...

Page 92: ...PID Set the proportional band to ten percent of the set point Example Set point 450 proportional band 45 Set the integral to 60 Set the derivative to 15 percent of the integral Example Integral 60 de...

Page 93: ...oportioned and it can be any value from 1 to 255 seconds For example if the output is 30 percent and the cycle time is ten seconds then the output will be on for three seconds and off for seven second...

Page 94: ...h gives a time constant of 0 to 85 seconds for an eight loop controller or 0 to 43 seconds for a four loop controller Use the output filter if you need to filter out erratic output swings due to extre...

Page 95: ...the operator parameters to change the set point control mode or output power level Cancel a change without saving Escape to the loop display Edit parameter values Save a value and go to the previous p...

Page 96: ...Table 6 1 Control Modes DISPLAY VALUE DeviceNet VALUE DESCRIPTION manual 0 The operator manually sets the output power for the loop auto 1 The controller automatically controls the outputs according t...

Page 97: ...Input 64 hex Overview of the Setup Menus The D8 has nine setup menus Table 6 2 provides a brief description of each menu Figure 6 2 lists all of the menus and parameters in the same order that they ap...

Page 98: ...rate Module LED Network LED Bus off count WATLOW D8x Vx xx cs xxxx Input Input type Loop name Input units Calibration offset Reversed T C detect Disp format Input range high Input high signal Input ra...

Page 99: ...mode automatic tune off or manual and output power levels if the loop is in manual control Alarm functions set points hysteresis and delay settings If you have enabled remote job selection BCD Job Loa...

Page 100: ...u have enabled remote job selection BCD Job Load on page 100 you will see the message below and you will not be able to use the controller keypad to save a job lSave setup as r not available Values 1...

Page 101: ...e which state is considered true for the digital inputs that are used for remote job selection If 1 true is selected then an input is true if connected to controller common and false for an open circu...

Page 102: ...o enabled by D I8 1 to 8 or disabled 0 Values in parentheses are for communications Default disabled 0 DeviceNet Object Global 6B hex WARNING Do not rely solely on the mode override feature to shut do...

Page 103: ...p Loop Mode lPower up loop r modeboff Choose the power up state of the control outputs Values See Table 6 5 Default off 0 DeviceNet Object Global 6B hex WARNING Do not set the controller to start from...

Page 104: ...process power is on but the temperature does not rise as expected If a thermocouple short is detected the controller puts the loop in manual mode at the output power level specified by the Sensor fai...

Page 105: ...ION on 0 Digital alarm outputs sink current to analog common when an alarm occurs off 1 Digital alarm outputs stop sinking current to analog common when an alarm occurs MAC ID lMAC ID r b63 The node a...

Page 106: ...DeviceNet Object N A Bus Off Count lBus off count r 0 Indicates the number of times the controller has gone to the bus off state Values 0 indicates the controller has not had a bus off error since th...

Page 107: ...ermocouple 350 to 1400 F 212 to 760 C K t c 2 Type K thermocouple 450 to 2500 F 268 to 1371 C T t c 3 Type T thermocouple 450 to 750 F 268 to 399 C S t c 4 Type S thermocouple 0 to 3200 F 18 to 1760 C...

Page 108: ...Degree symbol 223 Percent sign 37 Forward slash 47 Space 32 Pound sign 35 Input Units l01 Input unitsr b F For a thermocouple or RTD input choose the temperature scale For a process input enter a thr...

Page 109: ...x Table 6 9 Calibration Offset Ranges TYPE OF SENSOR OFFSET RANGE F C RTD 300 0 to 300 0 300 0 to 300 0 J Thermocouple K Thermocouple T Thermocouple 300 to 300 300 to 300 B Thermocouple S Thermocouple...

Page 110: ...99 to 300 00 2 99 99 300 00 9 999 to 30 000 3 9 999 30 000 0 9999 to 3 0000 4 0 9999 3 0000 Input Range High l01 Input ranger high b 1000 F For a process input enter the high process variable for inpu...

Page 111: ...isplayed when the input signal is at the level set for Input low signal This value and the value for Input low signal together define one of the points on the scaling function s conversion line Settin...

Page 112: ...within the specified number of scans One scan is 0 17 seconds for a four loop controller and 0 33 seconds for a eight loop controller Values 0 off to 255 Default 3 DeviceNet Object Input 64 hex Contr...

Page 113: ...Numeric Values on page 46 DeviceNet Object Control 66 hex Table 6 11 Proportional Band Values TYPE OF SENSOR VALUES IN F VALUES IN C J Thermocouple 1 to 1750 1 to 972 K Thermocouple 1 to 2950 1 to 163...

Page 114: ...his parameter enter the power level required to maintain set point to compensate for this offset Values 0 to 100 0 to 1000 Values in parentheses are for communications Default 0 0 Decimal Placement fo...

Page 115: ...nd Deviation Alarm Parameters INPUT TYPE DISPLAY FORMAT VALUES DEFAULT Thermocouple n a 0 to 500 5 RTD n a 0 to 500 0 5 0 Proess 999 to 3000 0 to 500 5 9999 to 30000 0 to 5000 50 999 9 to 3000 0 0 0 t...

Page 116: ...e Proportioning TP 2 The output is switched on and off once during a user selected cycle time Within each cycle the duration of on versus off time is proportional to the percent output power On Off on...

Page 117: ...es are for communications Default voltage 0 DeviceNet Object Output 65 hex Heat Cool SDAC Low Signal l01 Ht SDAC lowr signalb 00vdc For a Serial DAC output enter the low output signal level for the Se...

Page 118: ...Heat Cool Action l01 Heat actionr breverse Choose the control action for the output When the action is set to reverse the output goes up when the process variable goes down When the action is set to...

Page 119: ...Cool Output l01 Sensor failr heat outputb 0 A loop will switch to manual mode at the specified output power if one of the following conditions occurs while in automatic mode A failed sensor alarm occu...

Page 120: ...Object Output 65 hex Heat Cool Output Curve l01 Heat outputr curve blinear Choose an output curve If curve 1 or 2 is selected a PID calculation results in a lower actual output level than the linear...

Page 121: ...igh and Alarm Low on page 76 Values For a thermocouple or RTD input any value within the input range Table 6 7 Input Types and Ranges on page 107 For a process input any value between the Input range...

Page 122: ...igh Output l01 Alarm high r outputbnone Choose a digital output to activate when the high alarm occurs You cannot choose an output that is in use for closed loop control or for the Serial DAC clock Va...

Page 123: ...m occurs You cannot choose an output that is in use for closed loop control or for the Serial DAC clock Values none 0 or output 1 to 18 1 to 18 Values in parentheses are for communications Default non...

Page 124: ...control or for the Serial DAC clock Values none 0 or output 1 to 18 1 to 18 Values in parentheses are for communications Default none 0 DeviceNet Object Alarm 67 hex Alarm Low Set Point l01 Alarm low...

Page 125: ...t is in use for closed loop control or for the Serial DAC clock Values none 0 or output 1 to 18 1 to 18 Values in parentheses are for communications Default none 0 DeviceNet Object Alarm 67 hex Alarm...

Page 126: ...yr b 0 sec Use this parameter to delay a failed sensor process and deviation alarms until the alarm condition has been continuously present for longer than the delay time To delay alarms on powerup on...

Page 127: ...utput signal If the process variable falls below this value the output will stay at 0 percent Values Any value within the input sensor range see Table 6 7 Input Types and Ranges on page 107 Default Th...

Page 128: ...ions Default none 0 DeviceNet Object Cascade 6A hex Cascade Low Set Point l01 Cascade lowr SP b 25 C Enter the set point to use for the current loop when the output of the primary loop is at its minim...

Page 129: ...must be greater than the Cascade low SP parameter Default 25 for a thermocouple RTD or process input Decimal Placement for DeviceNet See Decimal Placement for Numeric Values on page 46 DeviceNet Obje...

Page 130: ...See Decimal Placement for Numeric Values on page 46 DeviceNet Object Ratio 69 hex Ratio High Set Point l01 Ratio high r SP b 25 C Enter the highest allowable set point for the current loop The set poi...

Page 131: ...cimal Placement for Numeric Values on page 46 DeviceNet Object Ratio 69 hex I O Tests Menu lI O tests r Other menus b Use the I O tests menu to test the following Digital inputs Digital outputs Keypad...

Page 132: ...Test lDisplay test r press d to begin Displays two screens with alternate pixels lit Press to enter test press or to switch pattern Press x to end the test DeviceNet Object None Test Digital Output 1...

Page 133: ...ged 1 or acknowledged 0 DeviceNet Object Alarm 67 hex Alarm Enable Enable or disable an alarm Table 6 16 below shows the bit to set or read for each alarm This parameter is available only via communic...

Page 134: ...the bit to read for each alarm This parameter is available only via communications Values Not active 0 or active 1 DeviceNet Object Alarm 67 hex Table 6 17 Bit Positions for Alarm Status and Alarm Ac...

Page 135: ...t Status Indicates whether the zero self calibration measurement falls within acceptable limits 0 In calibration 1 Out of calibration Global 6 Hardware Gain Status Indicates whether the full scale sel...

Page 136: ...help If you need to return the unit to Watlow for testing and repair Customer Service will issue you an RMA number See Return Material Authorization RMA on page 3 CAUTION Before trying to troubleshoot...

Page 137: ...ations similar issues cause high alarms In a heating application a high alarm or high deviation alarm may indicate one of the following The process set point and high alarm set point have been lowered...

Page 138: ...problem it displays an alarm message and with the exception of the Low Power alarm turns on the global alarm output The global alarm remains on until the alarm is acknowledged The message persists unt...

Page 139: ...ercent power Intermittent power Check wiring and service See Wiring the Power Supply on page 28 Use a separate dc supply for the controller Provide backup power uninterruptible power system In the Glo...

Page 140: ...er If the controller displays Low power or the display is not lit 1 Turn the power to the controller off then on again 2 If the Low power alarm message returns check that the power supplied to the con...

Page 141: ...e RAM See Clearing the RAM on page 145 3 If the alarm is not cleared contact your supplier for further troubleshooting guidelines See Return Material Authorization RMA on page 3 NOTE If the controller...

Page 142: ...heck whether there is an unacknowledged alarm The keys will not work for anything else until all alarms are acknowledged To acknowledge an alarm press x Checking Analog Inputs 1 If the process variabl...

Page 143: ...rical codes With ac power on measure for ac voltage that may be present between control panels chassis grounds Any ac voltage above 2VAC may indicate problems with the ac ground circuit With the heate...

Page 144: ...500 to 100 k resistor between the 5V terminal TB18 or TB50 terminal 1 and the output terminal you want to test 4 Connect the voltmeter s common lead to the output terminal and connect the voltmeter s...

Page 145: ...M power down the controller and remove the jumper wire from the keypad header before putting the controller back in service Replacing the EPROM Replacing the EPROM involves minor mechanical disassembl...

Page 146: ...that latch the two boards in the carrier at side with the ribbon cable and rotate the boards out of the carrier as shown in Figure 7 3 Figure 7 3 Unlatch Boards from Carrier 7 Remove the two plastic s...

Page 147: ...the Battery The lithium battery in the battery backed RAM module on the processor board should be removed and disposed of properly if decommissioning the controller It may also be replaced if needed d...

Page 148: ...ts on the D8 Inputs with signal ranges between 10 and 60mV use 0 resistors in the RC position only All other input signals require special input scaling resistors NOTE Scaling resistors cannot be chan...

Page 149: ...w Table 7 5 Resistor Values for Current Inputs INPUT RANGE RESISTOR VALUE RD 0 to 20mA 3 0 Resistor tolerance 0 1 RP RD Table 7 6 Resistor Locations for Current Inputs LOOP RESISTOR LOCATION RD LOOP R...

Page 150: ...RP3 4 R52 RP4 5 R50 RP5 6 R48 RP6 7 R46 RP7 8 R44 RP8 RTD Inputs Each RTD input has three scaling resistors installed one each at RA RB and RC for the input RA and RB are a matched pair of resistors...

Page 151: ...for thermocouple RTD and other fixed ranges and offset and span gain calibration for process inputs In order to scale the input signal you must 1 Have appropriate scaling resistors installed 2 Enter...

Page 152: ...D8 Series User s Guide Chapter 7 Troubleshooting and Reconfiguring 152...

Page 153: ...ller consists of a processor module with a 50 terminal block TB50 or a processor module with an 18 terminal block TB18 Table 8 1 Agency Approvals Compliance CE Directive Electromagnetic Compatibility...

Page 154: ...88 mm Figure 8 1 D8 Module Dimensions Without Cables Table 8 3 D8 with Standard SCSI Length 10 0 to 10 5 inches 254 to 267 mm Width 3 80 inches 96 mm Humidity 10 to 95 non condensing 50mm Exact requir...

Page 155: ...Power Terminal Torque TB2 4 4 to 5 3 in lb 0 5 to 0 6Nm Sensor Terminals TB1 Captive screw cage clamp Sensor Wire Gauge TB1 Thermocouple 20 AWG 0 5 mm2 Process 22 to 20 AWG 0 5 mm2 Communications 24 A...

Page 156: ...4 mm 0 92 in 23 mm Figure 8 5 TB50 Dimensions Table 8 6 TB50 Connections Screw Terminal Torque 4 4 to 5 3 in lb 0 5 to 0 6Nm SCSI Connector on Board SCSI 2 female Output Terminals Captive screw cage c...

Page 157: ...200ms at 50 Hz Eight loop models 3 Hz 333ms at 60Hz 2 5Hz 400ms at 50 Hz Miliampere Inputs 0 to 20mA 3 resistance with scaling resistors Voltage Input Ranges Available 0 to 10V 0 to 5V with scaling re...

Page 158: ...268 to 1 371 2 4 1 3 3 8 2 1 T 450 to 750 268 to 399 2 9 1 6 5 8 3 2 S 0 to 3 200 18 to 1 760 5 0 2 8 8 8 4 9 R 0 to 3 210 18 to 1 766 5 0 2 8 8 8 4 9 B 150 to 3 200 66 to 1 760 7 2 4 0 22 1 12 3 E 3...

Page 159: ...ded so that an external device can monitor the CPU state Analog Outputs Contact your supplier or Watlow for more information on these accessory products Contact your supplier or Watlow for more inform...

Page 160: ...utput Power to Operate Solid State Relays Voltage 5VDC Maximum Current 350mA Table 8 15 Communications Minimum Time Between Polled I O Requests 20ms Table 8 16 D8 Power Requirements Voltage 15 to 24 3...

Page 161: ...mbient Temperature The temperature of the air or other medium that surrounds the components of a thermal system American Wire Gauge AWG A standard of the dimensional characteristics of wire used to co...

Page 162: ...er DeviceNet classes define what attributes and services objects of that type have Class services are used to examine and change class attributes Closed Loop A control system that uses a sensor to mea...

Page 163: ...l action in which an increase in the process variable causes an increase in the output Usually used with cooling applications Direct Current DC An electric current that flows in one direction Distribu...

Page 164: ...within the numbers of scans that are set Frequency The number of cycles over a specified period of time usually measured G Gain The amount of amplification used in an electrical circuit Gain can also...

Page 165: ...s that can be stored and recalled in a controller s memory Also called a recipe Junction The point where two dissimilar metal conductors join to form a thermocouple K Keypad Lock A feature that preven...

Page 166: ...set point and process variable Output Type The form of control output such as time proportioning distributed zero crossing Serial DAC or analog Also the description of the electrical hardware that ma...

Page 167: ...n the output Heating applications usually use reverse action RTD See Resistance Temperature Detector S Serial Communications A method of transmitting information between devices by sending all bits se...

Page 168: ...ptable signal degradation U Undershoot The amount by which a process variable falls below the set point before it stabilizes V Volt V The unit of measure for electrical potential voltage or electromot...

Page 169: ...t temperature Ambient Sensor Reading 60 134 H W error Ambient alarm 141 operating range 21 153 Ambient Warning 138 analog output see also Dual DAC or Serial DAC 94 Application Objects 46 Assembly Obje...

Page 170: ...Action 54 118 Cool Cycle TIme 54 117 Cool Derivative 55 114 Cool Filter 56 114 Cool Integral 55 113 Cool Manual Reset 55 114 cool message on loop display 63 Cool Output Action for Watchdog 55 Cool Out...

Page 171: ...xplicit messages 44 47 49 52 54 140 external bridge circuit 34 external safety devices 18 F Fahrenheit 108 failed sensor alarms behavior of 138 codes 63 64 messages 63 64 output power if sensor alarm...

Page 172: ...ters 107 specifications 157 input scaling 69 Input Type 53 107 Input Units 53 108 installation 20 alarm wiring 37 clearance 22 154 controller 22 control output wiring 37 digital output wiring 35 envir...

Page 173: ...ital input Active 59 102 Modes 50 Module LED parameter see also Module status indicator 106 Module Status Indicator 41 44 106 139 N Network LED parameter see also Network status indicator 106 Network...

Page 174: ...50 proportional band description 88 guidelines for setting 90 setting a value 113 settings for various temperature ranges 90 settings from other controllers 91 PV Retransmit menu 126 PV Retransmit Obj...

Page 175: ...44 specifications 153 controller inputs 157 controller outputs 159 TB50 156 system alarms behavior of 138 messages 65 troubleshooting 140 T TB18 alarm outputs 37 connections 39 CPU watchdog timer outp...

Page 176: ...grounding problems 143 H W error Ambient alarm 141 H W error Gain alarm 141 H W error Offset alarm 141 keypad 132 139 142 low power alarm 140 process variable incorrect on display 138 142 RTDs 143 se...

Page 177: ...al Ratio master loop Bus off count Cl SDAC hi signal Ratio low SP WATLOW D8x Vx xx cs xxxx Cool action Ratio high SP Cool power limit Control ratio INPUT ClPwr limit time Ratio SP diff Input type Sens...

Page 178: ...D8 Series User s Guide 178 Declaration of Conformity...

Page 179: ...atlow co uk Website www watlow com From outside The United Kingdom Tel 44 0 115 964 0777 Fax 44 0 115 964 0071 Asia and Pacific Watlow Singapore Pte Ltd 20 Kian Teck Lane 4th Floor Singapore 627854 Te...

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