Watlow MLS-PM User manual

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MLS
User’s Guide
Part No. 11570-00. Revision 3.7
November 1995
Watlow Controls
1241 Bundy Blvd.
Winona, MN 55987
Customer Service
Phone: [phone]
Fax: [phone]
Technical Support
Phone: [phone]
Fax: [phone]
Email: [e-mail]

Copyright
©
1995
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 the products furnished under this Agreement will be
free from defects in material and workmanship for a period of one year from the date of shipment.
The customer shall provide notice of any defect to Watlow-Anafaze, Incorporated within one week
after the Customer's discovery of such defect. The sole obligation and liability of Watlow-Anafaze,
Incorporated under this warranty shall be to repair or replace, at its option and without cost to the
Customer, the defective product or part.
Upon request by Watlow-Anafaze, Incorporated, the product or part claimed to be defective shall
immediately be returned at the Customer's expense to Watlow-Anafaze, Incorporated. Replaced or
repaired products or parts will be shipped to the Customer at the expense of Watlow-Anafaze,
Incorporated.
There shall be no warranty or liability for any products or parts that have been subject to misuse,
accident, negligence, failure of electric power or modification by the Customer without the written
approval of Watlow-Anafaze, Incorporated. Final determination of warranty eligibility shall be
made by Watlow-Anafaze, Incorporated. If a warranty claim is considered invalid for any reason,
the Customer will be charged for services performed and expenses incurred by Watlow-Anafaze,
Incorporated in handling and shipping the returned unit.
If replacement parts are supplied or repairs made during the original warranty period, the warranty
period for the replacement or repaired part shall terminate with the termination of the warranty
period of the original product or part.
The foregoing warranty constitutes the sole liability of Watlow-Anafaze, Incorporated and the cus-
tomer's sole remedy with respect to the products. It is in lieu of all other warranties, liabilities, and
remedies. Except as thus provided, Watlow-Anafaze, Inc. disclaims all warranties, express or
implied, including any warranty of merchantability or fitness for a particular purpose.
Please Note : External safety devices must be used with this equipment.

Addendum for MLS User’s Guide (3.6)
MLS User’s Guide (11570-00 rev. 3.6) I
Addendum for MLS User’s
Guide (3.6)
The following are changes to revision 3.6 of the MLS User’s Guide. The
changes pertain to a new power supply that is being used with the MLS.
All changes are listed below by page number. Shaded portions refer to
the actual changed text.
These changes will be incorporated in the next manual revision.
System Power Requirements (from page 10)
Dimensions and Weight (from page 10)
MLS-PM supply input 10-28 Vdc at <1 amp
MLS-AIM supply input 4.75 to 5.25Vdc at <0.5 amp, supplied by MLS-
PM
MLS-PS system power supply Input: 120/240 Vac at 0.75 amp
Output: 15 Vdc at 1.2 amp, 5 Vdc at 4 amp
MLS-PM 1.75 lbs., 1.89" x 3.78" x 6.75" (0.8 kg, 4.75 cm x 10 cm x 17
cm.)
MLS-AIM-TB
& AIM cards 1.50 lbs., 5.0" x 6.50" x 5.50" (0.7 kg, 12.5 cm x 16.25 cm x 13.75 cm.)
MLS-PS 1.2 lbs., 1.40" x 8.0" x 3.9" (0.6 kg, 3.56 cm x 20.32 cm x 9.91
cm.)
RTB .5 lbs, 5.0’’ x 3.0’’x 2.25’’ (.227 kg, 12.7 cm x 7.6 cm x 5.7 cm.)

II MLS User’s Guide (11570-00 rev. 3.6)
Addendum for MLS User’s Guide (3.6)
Mounting the MLS-PS (from page 23)
Follow these instructions to mount the MLS-PS.
If you use your own power supply for the MLS, please refer to the
power supply manufacturer's instructions for mounting information.
Choose a power supply that supplies a regulated 10 to 28 Vdc at 1 watt,
and isolated return line.
Mounting Environment
The MLS-PS measures 1.40" x 8" x 3.9". Leave enough clearance
around the power supply that you can remove it later.
Mounting Steps
The MLS-PS has a mounting bracket. The bracket has two screw holes
which will accept #6 or #10 screws. To mount the MLS-PS, attach the
power supply to your panel with the two screws and the power supply
mounting bracket.

Addendum for MLS User’s Guide (3.6)
MLS User’s Guide (11570-00 rev. 3.6) III
WiringYour System (from page 24)
This section explains how to wire the components of your system.
Below is the system connections diagram reprinted here for your
convenience. (See the next page for wiring instructions.)

IV MLS User’s Guide (11570-00 rev. 3.6)
Addendum for MLS User’s Guide (3.6)
Wiring Recommendations (from page 25)
This section gives general wiring recommendations.
WARNING
Never wire bundles of low power Watlow-Anafaze
circuits next to bundles of high power AC wiring.
Instead, physically separate high power circuits
from the controller. If possible, install high voltage
AC power circuits in a separate panel.
•
Use stranded wire. (Use solid wire for fixed service; it makes inter-
mittent connections when you move it for maintenance.)
•
Use #18 or #20AWG wire. Larger or smaller sizes may be difficult to
install, may break easily, or may cause intermittent connections.
• Use shielded wire. (The electrical shield protects the MLS from
electrical noise.) Connect one end of the input wiring shield to the
MLS panel's 120/240Vac panel ground, and connect one end of the
output wiring shield to the MLS panel's
120/240 Vac panel ground. (If your system requires a different
shield configuration, contact Watlow-Anafaze for more informa-
tion.)
For more information about noise suppression, see Noise Suppression .
Connecting Power and RTB to MLS-PM (from page 27)
1. Remove the temporary covers you placed on the MLS' housing.
2. Connect the power supply terminal labeled "DC COM" to the termi-
nal labeled "GND" on the Processor Module. This terminal is DC
common; it is not frame, chassis or earth ground.
3. Connect the power supply terminal labeled "+15V" to the terminal
labeled "+V" on the Processor Module.
4. Connect the 50-pin ribbon cable to the Processor Module. Plug it in
so that the red stripe is on the left side, under TB1.
5. Connect the ribbon cable to the RTB. Plug it in so that the red stripe is
closest to screw terminal 1.

i
Contents
Overview .....................................................................1
System Diagram..................................................................2
Parts List .. ..........................................................................2
Safety ....... ..........................................................................3
Introduction................................................................5
Specifications......................................................................7
Analog Outputs.............................................................8
Digital Inputs ................................................................8
Digital Outputs..............................................................9
Miscellaneous Specifications............................................. 10
Serial Interface..............................................................10
System Power Requirements........................................10
Environmental Specifications.......................................10
Dimensions and Weight................................................10
Expanded Parts List ............................................................11
MLS Processor Module Technical Description............11
MLS RTB Technical Description.................................13
MLS-AIM and AIM-TB Technical Description...........13
MLS Cabling Technical Description............................14
Installation..................................................................15
Read This Before Installation ............................................. 16
Recommended Tools ..........................................................17
Panel Hole Cutters........................................................17
Other Tools ...................................................................17
Additional Hardware.....................................................17
Mounting the MLS-PM ......................................................18
Mounting Environment.................................................18
MLS-PM Mounting Steps.............................................19
Mounting the MLS-AIM ....................................................20
Mounting Environment.................................................20
Mounting Steps.............................................................21
Mounting the RTB..............................................................22
Mounting the MLS-PS........................................................23
Mounting Environment.................................................23
Mounting Steps.............................................................23
Wiring Your System...........................................................24
Wiring Recommendations ............................................25
Cable Recommendations ..............................................26
Noise Suppression.........................................................26
Wiring and Testing Your System ....................................... 27

Contents MLS User’s Guide
ii
Connecting Power and RTB to MLS-PM.....................27
Connecting Power and Common to AIM-TB............... 28
Testing Connections ..................................................... 28
Testing Your System ..........................................................30
MLS-AIM Test ............................................................. 30
RTB Test.......................................................................30
PID Output Test............................................................ 30
Outputs..... ..........................................................................31
PID Control and Alarm Output Connections................ 33
RTB Connections.......................................................... 34
AIM Communications Failure......................................35
Inputs ....... ..........................................................................36
Input Wiring Recommendations...................................37
Input Scaling.................................................................37
T/C Inputs .....................................................................39
RTD Inputs ...................................................................40
Current Inputs ............................................................... 41
Voltage Inputs...............................................................41
Unused Inputs ...............................................................41
Communications.................................................................42
Changing Communications...........................................42
Connecting RS-232 Communications ..........................42
Connecting RS-485 Communications ..........................43
Recommended Wire Gauges ........................................45
Using the MLS............................................................47
Front Panel.......................................................................... 48
Front Panel Keys...........................................................49
Displays ... ..........................................................................51
Viewing Several Loops: Bar Graph Display ................51
Viewing One Loop: Single Loop Display ....................52
Interpreting Alarm Display...........................................53
Displaying, Loading, and Saving Jobs................................55
Operator Menus ..................................................................56
Changing the Setpoint...................................................56
Selecting Manual, Automatic, or Tune Control............56
Setup ...........................................................................59
How to enter the Setup menus? .................................... 59
How to edit a menu?.....................................................59
Setup Global Parameters Menu .......................................... 61
Save to Job....................................................................62
Load from Job...............................................................62
Job Select Inputs...........................................................63

MLS User’s Guide Contents
iii
Job Digital Input Polarity..............................................64
Output Override Digital Input.......................................64
Output Override Input Polarity..................................... 64
Startup Alarm Delay.....................................................65
Keyboard Lock Status...................................................65
Power-Up Output Status...............................................65
Controller Address........................................................66
Communications Error Checking .................................66
Communications Baud Rate .........................................67
Allen Bradley Protocol ................................................. 67
AC Line Frequency....................................................... 67
Digital Output Polarity.................................................. 68
AIM Communications Failure Output.......................... 68
EPROM Information.....................................................68
Setup Loop Input .......................................................... 69
Input Type.....................................................................70
Pulse Sample Time .......................................................71
Loop Name ...................................................................71
Input Units ....................................................................71
Input Reading Offset.....................................................72
Linear Scaling Menus...................................................72
Display Format ............................................................. 74
High Process Value.......................................................74
High Reading................................................................75
Low Process Value ....................................................... 75
Low Reading.................................................................75
Input Filter ....................................................................76
Setup Loop Control Parameters.......................................... 77
Heat/Cool Control PB................................................... 78
Heat/Cool Control TI....................................................78
Heat/Cool Control TD ..................................................78
Heat/Cool Output Filter ................................................ 79
Heat/Cool Spread..........................................................79
Setup Loop Outputs ............................................................80
Enable/Disable Heat and Cool Outputs ........................ 82
Heat or Cool Output Type ............................................82
Heat/Cool Cycle Time.................................................. 83
SDAC Menus......................................................................83
SDAC Mode .................................................................83
SDAC High Value ........................................................84
SDAC Low Value.........................................................84
Heat/Cool Output Action.............................................. 84
Heat/Cool Output Limit................................................85
Heat/Cool Output Limit Time.......................................85

Contents MLS User’s Guide
iv
Heat/Cool Output Override........................................... 85
Heat/Cool Nonlinear Output Curve..............................86
Setup Loop Alarms............................................................. 87
Alarm Types ................................................................88
Alarm Delay..................................................................90
High Process Alarm Setpoint........................................ 91
High Process Alarm Type.............................................91
High Process Alarm Output Number............................91
Deviation Band Value................................................... 92
High Deviation Alarm Type ......................................... 92
High Deviation Alarm Output Number ........................ 93
Low Deviation Alarm Type.......................................... 93
Low Deviation Alarm Output Number......................... 93
Low Process Alarm Setpoint ........................................94
Low Process Alarm Type .............................................94
Low Process Alarm Output Number ............................94
Alarm Deadband........................................................... 95
Loop Alarm Delay ........................................................ 95
Manual I/O Test..................................................................96
Digital Input Testing.....................................................97
Keypad Test..................................................................97
Test Digital Output .......................................................97
Toggle Digital Output................................................... 98
Tuning and Control....................................................99
Introduction.........................................................................99
Control Modes ....................................................................99
On/Off Control..............................................................99
Proportional Control.....................................................100
Proportional and Integral Control.................................101
Proportional, Integral and Derivative Control.............. 101
Digital Output Control Forms.......................................102
Setting Up and Tuning PID Loops .....................................104
Proportional Band (PB) Settings...................................104
Integral Term (TI) Settings........................................... 105
Derivative Term (TD) Settings..................................... 105
General PID Constants........................................................ 106
Proportional Band Only (P)..........................................106
Proportional with Integral (PI)...................................... 106
PI with Derivative (PID)............................................... 106
Troubleshooting..........................................................109
Manual Controller Reset...............................................109
Returning your Unit to ANAFAZE.............................. 110

MLS User’s Guide Contents
v
Troubleshooting Stand-Alone Systems .............................. 110
MLS-PM Has No Power...............................................110
Keys Don't Respond......................................................111
Controller Message: AIM Comm Failure..................... 111
Checking Analog Inputs ...............................................111
Checking PID Control Outputs.....................................112
Checking Digital I/O.....................................................112
Checking Computer Supervised Systems...........................113
Computer Problems ......................................................113
Serial Interface Problems..............................................113
Communications Problems...........................................114
Software Problems........................................................115
Changing the EPROM..................................................116
Linear Scaling Examples...........................................119
Example 1: Configuring a Pressure Sensor ........................ 119
Example 2: Configuring a Flow Sensor.............................. 120
Glossary ......................................................................121

Contents MLS User’s Guide
vi

Overview
MLS User’sGuide 1
Overview
This manual describes how to install, setup, and operate a 16 or 32 MLS
controller. Included are seven chapters and a glossary of terms. Each
chapter covers a different aspect of your control system and may apply
to different users. The following describes the chapters and their
purpose.
•
Introduction: Gives a general description of the MLS and its
related specifications.
• Installation: Describes how to install the MLS and its peripheral
devices.
• Using the MLS: Provides an overview of operator displays used for
system monitoring.
• Setup: Describes all the setup displays for the controller, and how to
access them.
• Tuning and Control: Explains PID control and provides tips for
tuning your system.
• Troubleshooting: Gives some basic guidelines for solving control
problems.
• Linear Scaling Examples: Provides an example configuring a pres-
sure sensor, and one configuring a flow sensor.

2MLS User’sGuide
Overview
System Diagram
The illustration below shows how the parts of the MLS are connected.
When unpacking your system, use the diagram and parts list below to
ensure all parts have been shipped. Please don't hesitate to call Watlow-
Anafaze's Technical Service Department if you have problems with
your shipment, or if the MLS' components are missing or damaged.
Parts List
• MLS Processor Module (PM)
• Controller Mounting Kit
• MLS AIM Module (16 or 32)
• AIM Cable, 4 foot.
• RS-232 or RS-485 Com Cable (optional)
• RTB Terminal Block
• 50-Pin Ribbon Cable
• Power Supply (optional)

Overview
MLS User’sGuide 3
Safety
Watlow-Anafaze has made efforts to ensure the reliability and safety of
the MLS™ Controller and to recommend safe usage practices in
systems applications. Please note that, in any application, failures can
occur. These failures may result in full control outputs or other outputs
which may cause damage to or unsafe conditions in the equipment or
process connected to the MLS Controller.
Good engineering practices, electrical codes, and insurance regulations
require that you use independent external safety devices to prevent
potentially dangerous or unsafe conditions. Assume that the Watlow-
Anafaze MLS Controller can fail with outputs full on, outputs full off,
or that other unexpected conditions can occur.
Install high or low temperature protection in systems where an
overtemperature or undertemperature fault condition could present a fire
hazard or other hazard. Failure to install temperature control protection
where a potential hazard exists could result in damage to equipment and
property, and injury to personnel.
The MLS includes a reset circuit that sets the control outputs off or to
the data stored in memory if the microprocessor resets--normally the
result of a power failure and power return. If a memory-based restart
will be unsafe for your process, program the MLS Controller to restart
with outputs off. For additional safety, program the computer or other
host device to automatically reload the desired operating constants or
process values on return of operating power. However, these safety
features do not eliminate the need for external, independent safety
devices in potentially dangerous or unsafe conditions.
Watlow-Anafaze also offers ANASOFT®, an optional software
program for IBM-AT®or IBM-PC®compatible computers. In the
event of a reset, ANASOFT will reload the MLS Controller with the
current values in computer memory. The user must ensure that this reset
will be safe for the process. Again, use of ANASOFT does not eliminate
the need for appropriate external, independent safety devices.
Contact Watlow-Anafaze immediately if you have any questions about
system safety or system operation.

4MLS User’sGuide
Overview

Introduction
MLS User’s Guide 5
Introduction
The MLS is a modular control system with 32 fully independent loops
of PID control. It can function as a stand-alone controller; the MLS
processor module's 1/8 DIN front panel has a Liquid Crystal Display
(LCD) and touch keypad for local display and local parameter entry.
You can also use it as the key element in a computer-supervised data
acquisition and control system; the MLS can be locally or remotely
controlled via an RS-232 or RS-485 serial communications interface.
The MLS features include:
Direct Connection of Mixed Thermocouple Sensors: Versatile analog
inputs let you directly connect most thermocouples. Thermocouple
inputs feature reference junction compensation, linearization, PV offset
calibration to correct for sensor inaccuracies, T/C upscale break
detection, and your choice of Fahrenheit or Celsius display.
Resistive Temperature Detector Sensors are Standard Inputs: The
standard three-wire 100 W platinum DIN curve sensor is a standard
input for the MLS, as well as the Nickel RTD.
Automatic Scaling of Linear Analog Inputs: The MLS automatically
scales linear inputs used with other industrial process sensors. To scale
inputs, simply enter any two measurement points. For example, to scale
a pH sensor enter the endpoints: the low PV is 2.0 pH, while the high
PV is 14.0 pH. All subsequent values will be in pH.
Independently Selectable PID Output Modes: You can set each loop's
digital output to ON/OFF, Time Proportioning, Serial DAC, or
Distributed Zero Crossing mode. You can set each loop control mode
for ON/OFF, P, PI, or PID control with reverse or direct action output.
Flexible Alarm Outputs: You can set independent high/low process
alarms and a high/low deviation band alarm for each loop. Each alarm
can activate an individual digital output or it can be grouped with other
alarms to activate a single digital output.
Alarm or Control Outputs: You can set high/low deviation and high/
low process setpoints to operate separate digital outputs as on/off
control functions instead of as alarms. (The control function will not
have alarm notification or global alarm output.)
Global Alarm Output: When any alarm is triggered, the Global Alarm
Output is also triggered, and it stays on until you acknowledge it.
Watchdog Timer: The MLS watchdog timer (System Safe) output
provides a digital output which notifies you if the system fails.

6 MLS User’s Guide
Introduction
Front Panel or Computer Operation: You can set up and run the MLS
Controller from the processor module's front panel or from a local or
remote computer. Watlow-Anafaze offers ANASOFT, our IBM-AT or
IBM-PC compatible software you can use to operate the MLS.
ANASOFT has these features:
•Graphic Trend Plotting
•Process Overviews
•Printouts
•Data Archiving in Lotus-Compatible Files
Multiple Job Storage: You can store up to 8 jobs in protected memory
and access them by entering a single job number. Each job is a set of
operating conditions, including setpoints and alarms--so if a single oven
produces multiple products, simply enter one job number to set up every
loop.
Dual Outputs Standard for 16 Loops: The 16-loop MLS Controller
includes dual control outputs for each loop, and a second set of control
constants for heating and cooling applications.
Flexible Outputs Standard for 32 Loops: The 32-loop MLS
Controller is factory set for a single heat output for each input. Outputs
for loops 17-32 can be assigned as second outputs for loops 1-16.

Introduction
MLS User’s Guide 7
Specifications
This section shows specifications for the MLS, including inputs,
outputs, serial interface information, system power requirements, and
environmental and physical specifications.
Analog Inputs
Thermocouple Ranges
Number of control loops 16 dual output or 32 single output plus one pulse
loop.
Number of analog inputs 16 (with AIM-16) or 32 (with AIM-32).
Input switching Differential solid state MUX switching.
Input sampling rate 16 loops per second.
Analog over-voltage protection between
inputs 70 V peak to peak maximum.
Maximum analog input voltage +10 V from + or - input to analog common.
Common mode voltage 500 Vac maximum analog common to MLS-PM
or MLS-AIM power supply common.
CMR (Common Mode Rejection) >85 dB at 60 Hz, 110 dB typical.
A/D converter Integrates voltage to frequency.
Integration time per loop 33.3 ms at 60 Hz line frequency.
Input range -10 to +60 mV, or 0 to 25 V with scaling resis-
tors.
Resolution 0.02%, greater than 12 bits (internal)
Accuracy 0.1%at25°C
Calibration Automatic zero and full scale.
Temperature coefficient Lessthan100 ppm/°C,0.01%per°C.
Analog Ground to frame Ground Max.
potential 40 V
DC Common to frame Ground Max. poten-
tial 40 V
J-350to1400°F(-212 to 760°C)
K-450to 2500°F(-268to 1371°C)
T-450 to750°F(-268to 399°C)
B150 to3200°F(+66to 1760°C)
S0to3200°F(-18 to1760°C)
R0to3210°F(-18 to1766°C)