Watlow Electric Computer Hardware Revision 5 User Manual

WATLOW ANAFAZE SYSTEM 32

HARDWARE

Installation And Operation Manua

Revision 5

December 21, 1988

Watlow Anafaze

344 Westridge DR

Watsonville, CA 95076

Phone: 831-724-3800

Fax: 831-724-0320

may be reproduced, stored in a retrieval system or transmitted in any form by any

means; electronic, mechanical, photo copying, recording, or otherwise, without

the prior written permission of Watlow Anafaze

Printed in U.S.A.

WARNING

ANAFAZE HAS MADE EFFORTS TO ENSURE THE RELIABILITY AND

SAFETY OF THE SYSTEM 32 AND PROVIDE RECOMMENDATIONS

FOR ITS SAFE USE IN SYSTEMS APPLICATIONS. PLEASE NOTE

THAT IN ANY APPLICATION, FAILURES CAN OCCUR THAT WILL

RESULT IN FULL CONTROL OUTPUTS OR OTHER OUTPUTS THAT

MAY CAUSE DAMAGE OR UNSAFE CONDITIONS IN THE

EQUIPMENT OR PROCESS CONNECTED TO THE ANAFAZE SYSTEM

32.

GOOD ENGINEERING PRACTICES, ELECTRICAL CODES, AND

INSURANCE REGULATIONS REQUIRE INDEPENDENT, EXTERNAL,

SAFETY DEVICES BE USED TO PREVENT POTENTIALLY

DANGEROUS OR UNSAFE CONDITIONS ASSUMING THAT THE

SYSTEM 32 CAN FAIL WITH OUTPUTS FULL ON, OR OUTPUTS

FULL OFF, OR OTHER CONDITIONS THAT WOULD BE

UNEXPECTED.

THE SYSTEM 32 INCLUDES A RESET CIRCUIT THAT WILL SET THE

CONTROL OUTPUTS TO THE DATA STORED IN THE EEROM IF THE

MICROPROCESSOR RESETS -- NORMALLY THE RESULT OF A

POWER FAILURE AND POWER RETURN. THE COMPUTER OR

OTHER HOST DEVICE SHOULD BE PROGRAMMED TO

AUTOMATICALLY

CONSTANTS, OR SAFE VALUES FOR THE PROCESS, UPON RETURN

OF SYSTEM POWER. THE COMPUTER CAN ALSO BE

RELOAD

THE

DESIRED

OPERATING

PROGRAMMED TO CHECK PROCESS DATA AND CAUSE ALARMS

INCLUDING CONTACT OUTPUTS FOR AUTOMATIC SHUT DOWN

TO ASSIST IN PREVENTING DANGEROUS OR UNSAFE CONDITIONS.

ANAFAZE WILL BE PLEASED TO PROVIDE APPLICATION

ASSISTANCE AND PROGRAMMING IF DESIRED. IN ANY EVENT,

THESE SAFETY FEATURES DO NOT ELIMINATE THE NEED TO

PROVIDE EXTERNAL, INDEPENDENT SAFETY DEVICES IN

POTENTIALLY DANGEROUS OR UNSAFE CONDITIONS.

ANAFAZE ALSO OFFERS AN OPTIONAL SOFTWARE PROGRAM

FOR IBM PC COMPATIBLE COMPUTERS THAT WILL RELOAD THE

SYSTEM 32 WITH THE CURRENT VALUES IN THE COMPUTER

MEMORY UPON A RESET. THE USER MUST INSURE THAT THIS

WILL BE SAFE FOR THE PROCESS. THIS FEATURE STILL DOES

NOT ELIMINATE THE NEED FOR APPROPRIATE EXTERNAL,

INDEPENDENT SAFETY DEVICES.

PLEASE CONTACT ANAFAZE IMMEDIATELY IF THERE ARE ANY

QUESTIONS ABOUT SYSTEM SAFETY

TABLE OF CONTENTS

1.0 INTRODUCTION_____________________________________________ 1

1.1 SYSTEM FEATURES _________________________________________1

1.2 PLUG IN SYSTEM 32 MODULES_______________________________2

1.3 ANASOFT 32 -- POWERFUL OPERATING SOFTWARE __________4

2.0 SPECIFICATIONS____________________________________________ 6

2.1 ANALOG INPUTS ____________________________________________6

2.2 OPERATING PARAMETERS __________________________________7

2.3 REPORTING PARAMETERS __________________________________7

2.4 COMMUNICATIONS _________________________________________7

2.5 CONTROL AND ALARM OUTPUTS____________________________8

2.6 DIGITAL INPUT OR OUTPUT _________________________________8

2.7 ANALOG OUTPUTS __________________________________________8

2.8 GENERAL___________________________________________________8

2.9 SUBASSEMBLY IDENTIFICATION ____________________________9

3.0 INSTALLATION ____________________________________________ 10

3.1 PHYSICAL CONSIDERATIONS_______________________________10

3.2 CONFIGURATION __________________________________________14

3.3 AC POWER INPUT __________________________________________16

4.0 COMMUNICATIONS SET-UP AND CONNECTIONS ____________ 17

4.1 RS-232 _____________________________________________________17

4.2 CURRENT LOOP____________________________________________18

4.3 RS-485 _____________________________________________________19

5.0 ANALOG INPUTS___________________________________________ 22

5.1 COMMON MODE VOLTAGE_________________________________22

5.2 NORMAL MODE VOLTAGE _________________________________22

5.3 GROUNDING _______________________________________________22

5.4 SOURCE IMPEDANCE ______________________________________22

5.5 ANALOG INPUT MODULES__________________________________23

5.6 A32-RRIAM -- REED RELAY ANALOG INPUT MODULE________23

5.7 A32-SSAIM -- SOLID STATE ANALOG INPUT MODULE ________26

5.8 SCALING AND CALIBRATION _______________________________27

5.9 DIAGRAMS OF TYPICAL INPUTS ____________________________28

5.10 ANALOG INPUT CONNECTIONS____________________________29

6.0 CONTROL OUTPUTS________________________________________ 31

6.1 PROCESSOR I/O MODULE __________________________________31

6.2 PROCESSOR I/O [A32-PIOM] PID OUTPUT CONNECTIONS ____34

6.3 ANALOG OUTPUT MODULE A32-AOM _______________________36

7.0 DETAILED MODULE DESCRIPTIONS ________________________ 38

7.1 PROCESSOR I/O MODULE -- A32-PIOM_______________________38

7.2 REED RELAY ANALOG INPUT MODULE -- A32-RRAIM________39

7.3 SOLID STATE ANALOG INPUT MODULE -- A32-SSAIM ________41

7.4 ANALOG OUTPUT MODULE -- A32-AOM _____________________41

7.5 PULSE INPUT MODULE -- A32-PIM___________________________42

7.6 POWER SUPPLY----PART NO. A32-PS_________________________42

7.7 OPERATOR STATION -- A32-OS______________________________42

8.0 PID CONTROL______________________________________________ 44

8.1 CONTROL LOOPS __________________________________________44

8.2 ADJUSTMENT OF PID CONSTANTS __________________________52

8.3 ANALOGY OF PID CONTROL TERMINOLOGY _______________55

9.0 SOFTWARE ________________________________________________ 57

9.1 ANASOFT-32 _______________________________________________57

9.2 CUSTOM APPLICATION PROGRAMS ________________________58

10.0 SOFTWARE COMMAND STRUCTURE _______________________ 59

10.1. Commands from Allen Bradley Programmable Controllers (CMD) _59

10.2. Error Checking (BCC / CRC)_________________________________59

10.3. Protocol ___________________________________________________59

10.4. Status Codes _______________________________________________59

10.5. Data Table Addresses _______________________________________60

10.6. Input Types________________________________________________61

10.7. Output Types ______________________________________________61

11.0 TROUBLE SHOOTING INFORMATION ______________________ 63

11.1 Computer Problems _________________________________________63

11.2 Computer Software__________________________________________63

11.3 Communications Problems ___________________________________64

11.4 SYSTEM 32 Problems _______________________________________64

1.0 INTRODUCTION

The ANAFAZE SYSTEM 32 is the key element used to form an innovative

measurement and control system. It combines its power with an IBM PC or

similar computer to deliver an extremely efficient data acquisition and process

control system. The SYSTEM 32 concentrates its power in analog measurement,

independent digital loop control, alarm monitoring, and signal processing. This

frees the computer to perform process control supervision including: graphic

process displays, operator data entry, data printout, data storage, and process

performance analysis.

The flexible ANAFAZE SYSTEM 32 is built upon a series of cost effective plug

in modules to handle a variety of diverse requirements. These plug in modules

make it easy to configure the SYSTEM 32 to specifically fit individual application

needs. Thus a tailored system can be obtained from off the shelf modules.

The SYSTEM 32 is an excellent choice for applications where multiple inputs

such as temperature, flow, speed, pressure, and others need to be measured or

controlled. This is because a mixture of different sensor types can be directly

connected to the SYSTEM 32. It is also well suited for processes with multiple

temperature zones and control methods including cascade, ramp and soak, and

adaptive control. The SYSTEM 32 is especially efficient since each controller

provides independent stand-alone PID control of up to 32 process loops and up to

96 channels of data acquisition.

The result is a powerful distributed process control system with the reliability of

independent loop control and the flexibility of computer supervision.

1.1 SYSTEM FEATURES

1.1.1 ACCURATE MEASUREMENT: Every process requires accurate

data measurement. The SYSTEM 32 assures this with optically-isolated

input modules.

Further noise rejection is achieved by an integrating

measurement technique. Input to input isolation is provided with reed relay

switching. This combination enables the SYSTEM 32 to deliver needed

accuracy in difficult process environments.

1.1.2 CONVENIENT INSTALLATION: Substantial savings in wiring

and installation costs can be achieved by locating SYSTEM 32 units

physically near the process. This is because the communication between the

SYSTEM 32 and the computer requires only four wires. A local or remote

system of up to 16 units [512 loops] can be connected on a single serial line

using RS-232, RS-485, or 20ma loop communication -- all optically-

isolated. Larger systems may utilize multiple communication lines.

1.1.3 PROCESS INTEGRITY: The ANAFAZE approach delivers high

integrity because the SYSTEM 32 independently controls and checks each

loop for alarms while it is in turn checked by the computer. Thus a

computer failure will not affect the process and a controller problem will be

detected by the computer. Further integrity is built in to the SYSTEM 32

since it has EEROM memory to protect control and alarm parameters. A

watchdog timer with digital output adds to process integrity.

1.1.4 MULTIPLE TYPES OF INPUTS AND CONTROL OUTPUTS:

Since there is a large variety of processes and sensor types the system 32 has

been designed to accept nearly any input and provide nearly any control

output. Measurements from thermocouples, RTD's, infrared sensors,

millivolt, milliamp, and other signals are directly connected the SYSTEM

32. Thermocouple reference junction compensation and linearization is

done by the SYSTEM 32. With plug in input modules, 16 to 96 inputs can

be accommodated in a single SYSTEM 32.

For control, each SYSTEM 32 includes, as standard, 32 digital outputs for

time proportioning or on/off control.

Additionally, 8 standard on/off

outputs can be used for global alarm shutdowns or process warnings.

Optional plug- in analog output modules provide open or closed loop

control. Each module contains 16 outputs which includes both 4 to 20ma

and 0 to 5Vdc outputs which can be selected individually for each output.

1.1.5 STANDARD [ALLEN BRADLEY] COMMUNICATION

PROTOCOL: The SYSTEM 32 utilizes a form of ANSI 3.28-1976

standard protocol for communication. Jumper selection of CRC or BCC,

and baud rate allow the system to matched to any host computer or other

device. This ANSI standard is also used by Allen Bradley enabling the

SYSTEM 32 to be connected directly to these programmable controllers.

1.1.6 COMPACT EASILY MAINTAINED PACKAGING: Front plug

in modules with removable screw terminal blocks provide high reliability

and convenient maintainability. A 3 and 6 slot housing is available and the

modules require a 5Vdc power supply which can be mounted internally or

externally.

1.2 PLUG IN SYSTEM 32 MODULES

The flexible ANAFAZE SYSTEM 32 design allows cost effective matching of

measurement and control capabilities to the process needs. By selecting a

combination of plug in modules the system will perform full PID control

processing, communications to a host computer, industrial sensor measurement,

and deliver precise control outputs.

Configurations can start with only the PROCESSOR I/O MODULE to provide 32

time proportioning or on/off open loop control outputs. For closed loop control,

simply add an ANALOG INPUT MODULE, either reed relay for 16 inputs, or

solid state for 32 inputs. A plug in ANALOG OUTPUT MODULE provides 16

analog control outputs.

Systems can be matched to different applications by combining the following

modules:

1.2.1 PROCESSOR I/O MODULE: The on board microprocessor

performs all necessary control calculations, on-line analog calibration,

system self test, thermocouple compensation and linearization, and

communication to the host computer.

This module contains the

communications interface, 32 time proportioning or on/off control outputs,

24 digital outputs, and 16 digital inputs.

Powerful Control: The SYSTEM 32 features a digital control algorithm

that allows each loop to be independently defined. Control outputs can be

set for closed loop or open loop with computer setting of the output level.

Switching between open loop and closed loop control can be initiated with

bumpless transfer. Closed loop control modes can be selected as: on/off,

proportional only [P], proportional with integral [PI], or full PID. In

addition, each output can be selected as reverse [heat] or direct [cool] acting

and a programmable digital output filter can be used to further match each

loop to the process conditions.

Unique Control Output Flexibility: Total control flexibility is assured

since each control output can be easily selected from the computer to match

individual process needs. The unique ANAFAZE design offers: on/off,

Cycle Time Proportioning, or Distributed Zero Crossing. Further flexibility

is included since each output can be set as reverse or direct acting. When a

process requires high power or the use of contactors, the SYSTEM 32 Cycle

Time Proportioning outputs are automatically balanced to minimize the

peak power consumption. For processes with solid-state power switching,

the Distributed Zero Crossing outputs provide the smoothest application of

control power.

Open Heater Detection: The SYSTEM 32 measures the current flowing in

each heater or other time proportioning output circuit to ensure that open

heaters and stuck relays are detected.

Protected Memory: Setpoints and other control parameters entered from

the computer are stored in non-volatile memory eliminating the need to re-

enter these parameters after a power failure.

Communication Monitor: A communications monitor can be enabled that

will turn off all control outputs after a selectable time period if no

communication is received form the host computer.

1.2.2 ANALOG INPUT MODULES: Two optically-isolated analog input

modules are available for the SYSTEM 32. A 16 channel reed relay

switching module and a 32 channel solid state switching module. The reed

relay module provides the highest level of input noise protection and the

solid state module is more economical. The two types of input modules can

be mixed in a single controller. Allowing up to 48 channels of reed relay

inputs, 96 channels of solid state inputs , or any combination such as 32

reed relay inputs with 32 solid state inputs. Both modules offer direct

connection of industrial sensors including thermocouples, RTD's, infrared

sensors, milliamp, and millivolt signals.

1.2.3 PULSE INPUT MODULE: Allows measurement of speed, RPM,

flow, and other inputs from sensor that produce pulse outputs. Each module

accepts up to 32 inputs and optical- isolation can be optionally added where

necessary. The pulse input module requires an expanded PROCESSOR I/O

MODULE, please contact ANAFAZE for additional information.

1.2.4 ANALOG OUTPUT MODULE: Provides 16 analog outputs for

open or closed loop control. Both 4 to 20ma and 0 to 5vdc are available for

each output [select one].

1.2.5 HOUSING: provides fully enclosed mounting for all modules and

includes a passive [no electrical components] interconnecting backplane. A

3 and 6 slot housing is offered. The 6 slot housing can be mounted in

standard relay racks. The six slot housing is 19" wide, 12.25" high, and

only 7.5" deep. The 3 slot housing is 10 5/8" wide, 12.25" high, and 7.5"

deep.

1.2.6 POWER SUPPLY: All the SYSTEM 32 modules operate from this

5vdc power supply. The power supply is furnished mounted to a standard

module front panel and occupies one slot in the housing. If desired the

power supply can be removed from the panel and externally mounted. This

frees the slot for an other module. The power supply connects to terminals

on the passive backplane.

1.3 ANASOFT 32 -- POWERFUL OPERATING SOFTWARE

Whether the process is simple or complex it must be defined and set up in order to

control it. Therefor, another essential element of a successful measurement and

control system is the application software. ANASOFT 32 is sophisticated menu

driven software program for the SYSTEM 32 that runs on IBM PC and compatible

computers. It is designed to be easily operated by inexperienced computer users

and it offers full flexibility for complex applications.

1.3.1 GRAPHIC PROCESS DISPLAYS: ANASOFT features a process

monitor screen that provides an overview of the system status at a glance.

Measured data can be displayed in either a graphic or numeric mode. On

line, real-time data for each input can be graphically plotted on the screen.

Data is continuously stored for every input to provide a history over user

selected time intervals. These on line plots enable quick analysis of process

conditions for optimizing performance, tuning control loops, determining

reasons for alarms, and other situations.

1.3.2 TUNING AND PROCESS SET UP: The password protected tune

menu displays necessary data for efficient tuning since it displays real time

process information. Key selectable sub menus are used to enter control

parameters, input scaling, trend plot scaling and time interval, warning

levels, and alarm setpoints.

1.3.3 DATA LOGGING: Hardcopy data is essential for record keeping,

quality control, required agency reporting, and production reports.

ANASOFT offers both automatic printer data logging, and disk data logging

in LOTUS compatible files. An available option for data recording when the

computer is not on line is the on-board memory option. This is 28.8k Bytes

of RAM memory for each A32-PIOM module in the system.

1.3.4 SYSTEM EXPANSION: ANAFAZE can provide complete turn key

systems for advanced control applications. Ramp and soak, adaptive

control, cascade control, and other types of systems can be designed and

installed by ANAFAZE engineering. Since many applications can be based

on ANASOFT, the cost and the time period for implementation is reduced.

ANASOFT is written in Microsoft QUICKBASIC and the source code is

provided for users that want to make their own modifications.

2.0 SPECIFICATIONS

2.1 ANALOG INPUTS

Number of channels:

32 for PID control, 48 total with reed multiplexer,

96 total with solid state.

Multiplexing:

three wire reed relay, guarded inputs. two wire solid

state.

A/D converter:

Loop update:

integrating voltage to frequency.

each loop 2 times per second, reed modules; 1 time

per second solid state.

Input isolation:

optical coupling.

Input resolution:

0.02% full scale [Approximately 12.7uv].

.005% per degree.

Temp. coefficient:

Measurement accuracy:

Thermocouple break:

Standard input types:

+0.1% full scale.

up scale standard.

All are present in every system: select by command

from host, any order, any mix:

Thermocouple ranges:

[200 ohms max.]

J: -350 to 1400 F K: -450 to 2500 F

T: -450 to 750 F E: -450 to 1450 F

R: 0 to 3200 F

S: 0 to 3200 F

SYSTEM 32 must be operating between 0 and 50

degrees C for full T/C ranges.

Thermocouple scaling:

Other Inputs:

Degrees F [convert to degrees C in computer].

-10mv to 60mv input range with provision for

scaling resistors and bridges for Voltage/Current

andRTD inputs.

Linear Scaling:

-16.7% to 100% for -10 to 60 mv

Voltage Ranges:100v max: Select resistors for 0 to 10v, 0 to 5v, 2 to 10v, etc.

as required.

Current Ranges:

Select resistors for 0 to 10ma, 4 to 20ma, 10 to

50ma, etc. as required.

Bridge Excitation:

Optional input types:

10v+.13%, at 50ma max [temperature coefficient

15ppm/degree C max].

Other T/C types, Non-contact infrared, 2, 3, or 4-

wire RTD, Carbon Potential.

2.2 OPERATING PARAMETERS

Independently set for each loop through serial interface.

Input type:

Gain:

any standard type (see above), any mix.

0 to 255 proportional; 0 to 510 on/off. Proportional

Band: Direct reading in engineering units of the

loop range.

Integral:

0 to 1020 seconds. Reset: .05 to 60 Repeats/Min. [4

sec. resolution].

Derivative:

0 to 255 sec. Rate: .01 to 4.25 Min.

Digital Filter:

Averages last 0 to 255 outputs. [0- 127.5 sec. time

constant].

Setpoint:

+span. Resolution: 0.01%; 0.1 for T/C.

ANASOFT resolution: 0.1%; 1 for T/C.

Deviation band alarm:

Control output level:

Manual output:

0 to +25% Full Scale; 0 to +250 T/C.

Direct or reverse acting, 0-100%.

0 to 100% (0.4% resolution).

2.3 REPORTING PARAMETERS

The computer can request any of the following for any loop:

Operating parameters:

Analog inputs:

Digital I/O:

all of the above

measured values

status

2.4 COMMUNICATIONS

Types:

RS-232 or 20ma current loop, factory set; optional

RS422 or RS485

Baud rate:

Protocol:

2400 or 9600, switch selectable

Form of ANSI X3.28-1976 [Allen Bradley

compatible]

Character set:

Error check:

Isolation:

ANSI X3.4

CRC or BCC, switch selectable.

optical for all types including RS-232.

LED indicates communication active.

Display:

2.5 CONTROL AND ALARM OUTPUTS

32 Individually selectable control outputs:

Digital Outputs:

Time proportioning, On/Off, Alarms: voltage

output: 5VDC at 6ma maximum for solid state or

other relays.

Analog:

voltage or current: selectable (4 to 20ma, or 0 to 5

volts).

2.6 DIGITAL INPUT OR OUTPUT

24 DigitalOutputs:

TTL Level:

true= < 0.4v @ 6ma false = > 3.9v

@ 6ma

16 Digital Inputs:

TTL Level:

2.7 ANALOG OUTPUTS

Types:

0 to 5Vdc at 5ma max.

4-20ma at 8Vdc max [maximum loop impedance

400 ohms].

Both are available at the output terminals of each

output. Either can be used -- no jumpers are

required. DO NOT USE BOTH ON SAME

OUTPUT.

Accuracy:

+3%

Resolution:

0.4%

2.8 GENERAL

Power input:

120VAC, 60Hz, to power supply.

modules require 5vdc @ 5A max [6 slot].

Operating ambient:

Humidity:

0 to 50 C.

10% to 90%, non-condensing.

NEMA 4, 12, 13 and others optional.

Enclosures:

Physical:

6 Slot Housing: 16.7" wide [19" standard rack

mount], 12.5" high, 7.5" deep.

3 Slot Housing: 10.7" wide.

Mounting:

Weight:

4 mounting holes for standard rack or panel

mounting -- see outline drawings.

maximum 20 pounds depends on plug modules

selected.

2.9 SUBASSEMBLY IDENTIFICATION

A32-PIOM:

PROCESSOR I/O MODULE includes factory selectable

communication interface [RS-232 or current loop], 32 control outputs, 24 digital

outputs, and 16 digital inputs.

A32-RRAIM: REED RELAY ANALOG INPUT MODULE for 16 mixed sensor

inputs including direct connection of thermocouples [J, K, or T] or millivolt [ -5 to

60mv]. Includes reference junction sensors for thermocouple inputs.

A32-SSAIM: SOLID STATE ANALOG INPUT MODULE for 32 mixed analog

inputs including direct connection of thermocouple or millivolt inputs. Includes

reference junction sensors for thermocouple inputs.

A32-IAIM-SIXX: SPECIAL INPUT SCALING for RRAIM or SSAIM to connect

milliamp, voltage, or RTD inputs. Consult ANAFAZE for details.

A32-AOM : ANALOG OUTPUT MODULE with 16 analog outputs set for both 0

to 5Vdc and 4 to 20ma. Consult ANAFAZE for other output levels.

A32-H6: 6 SLOT HOUSING including passive interconnection backplane and up

to three blank front panels. Can be mounted on a panel or in a standard 19 rack

[12.5" high, 19"wide, 7.5"deep].

A32-H3: 3 SLOT HOUSING including passive backplane and up to one blank

front panel. For panel mounting 12.5" high, 10.7" wide and 7.5" deep.

A32-PS: POWER SUPPLY: mounted on a blank front panel with wiring to

passive backplane. Supply can be externally mounted or plugged into a module

slot. Dimensions: 9" high, 2" wide and 5" deep.

A32-OS: OPERATOR STATION: allows for data display and setpoint entry away

from the system computer [requires ANASOFT].

ANASOFT-32: Software operating system for IBM PC and compatible computers.

CABLES: Interconnection cables with an RS-232 connector on one end and wires

at other for connection to SYSTEM 32 terminals:

CA-232M

CA-232F

25' RS-232 cable male computer connector

25' RS-232 cable female computer connector

3.0 INSTALLATION

There are some precautions that must be observed when installing SYSTEM 32:

WARNING: ELECTRICAL SHOCK DANGER

It is very important that all system power including the

be disconnected before servicing the ANAFAZE SYSTEM 32. HIGH

VOLTAGE MAY BE PRESENT EVEN WHEN POWER IS TURNED

OFF.

power input

To reduce the danger of electrical shock always mount the SYSTEM 32

in an enclosure that prevents personnel contact.

Since the ANAFAZE SYSTEM 32 can make measurements of input signals that

are not referenced to ground, the SYSTEM 32 ground and other signal lines can

have power line or other high voltage present even if the input power is turned off.

This could happen, for example, if a thermocouple was inadvertently shorted to the

AC power line.

WARNING: USE CORRECT INSULATION TRIM LENGTH AND

WIRE GAGE

The correct insulation trim length is 1/4" or 5mm. Care must be taken

to prevent contact between any wires and the case which is grounded.

The terminal manufacturer has UL approval for #14 to #30 AWG

(American Wire Gage). ANAFAZE recommends using #18 or #20

AWG.

To effectively use the plug-in terminals, the wire insulation should be trimmed so

that the wire fits inside the terminal with no bare wire exposed. Stranded wire

should be tinned.

WARNING: SUPPORT CABLES

Power, input, and output cables should be supported to reduce strain

on the connectors and to prevent them from being pulled out of the

terminal strips.

3.1 PHYSICAL CONSIDERATIONS

The ANAFAZE SYSTEM 32 consists of a number of plug in modules for a

housing with a passive backplane. Three or six slots are provided for plug-in

option boards.

3.1.1 MOUNTING [SEE DIAGRAMS ON NEXT 3 PAGES]

For optimum performance when directly connecting thermocouple inputs

the unit should be protected from thermal shocks whenever possible. This

will minimize any temperature gradients across the terminal strips and result

in the highest accuracy.

6 SLOT HOUSING DIMENSIONS

3 SLOT HOUSING DIMENSIONS

POWER SUPPLY DIMENSIONS

3.1.3 DETACHABLE TERMINAL BLOCKS

WARNING - ALWAYS CHECK TERMINAL LOCATION AND

ORIENTATION

All connections, except the Ac power supply, are made on removable

terminal strips. Terminal strip removal is achieved by removing the

retaining screws and pulling them directly away from the front panel. The

terminal strips must be carefully installed in the correct position and not up

side down.

3.2 CONFIGURATION

WARNING - TURN OFF POWER BEFORE CHANGING SWITCH

The unit configuration switch is located on the A32-PIOM PROCESSOR I/O

MODULE. It is a eight position DIP switch which is used to set the unit station

number, the baud rate, and the communications check character. The functions are:

_____________________________________________

| 1 | 1 | 1 | 1 |COMM | 9600| CRC | NOT | ON = 1

| 0 | 0 | 0 | 0 |Check| 2400| BCC | USED| OFF = 0

Station Number

3.2.1. STATION NUMBER (STN)

Four bit switches (Switch 1 - Switch 4) are provided on the SYSTEM 32 to

select controller addresses. These are read in hex format providing 16

addresses, 0000 to 1111. The base Station Number is 08 and the bit

switches select an address above that. Setting the bit switch in the on

position is considered a one by the processor.

Switch Number

4 3 2 1

Settings

Hex Address Octal Address Controller

0 0 0 0 [all off]

0 0 0 1

0 0 1 0

0 0 1 1

0 1 0 0

0 1 0 1

0 1 1 0

0 1 1 1

1 0 0 0

1 0 0 1

1 0 1 0

1 0 1 1

1 1 0 0

1 1 0 1

1 1 1 0

1 1 1 1 [all on]

010

011

012

013

014

015

016

017

020

021

022

023

024

025

026

027

3.2.2 COMMUNICATIONS WATCHDOG TIMER

The communications timer provides a method of turning off all control

outputs if there is a problem in the host computer that effects

communication. It operates by monitoring activity on the communication

line. If this controller has not been contacted within the time interval, it

automatically sets all control outputs to manual with zero outputs.

dedicated digital output is set when the watchdog times out.

WARNING: IF THE COMMUNICATIONS WATCHDOG IS

ENABLED, INSURE THAT THE HOST COMPUTER

COMMUNICATES WITH EACH SYSTEM 32 WITH IN THE TIME

LIMIT. IF NOT THE CONTROL OUTPUTS WILL BE SET TO

MANUAL WITH ZERO OUTPUT.

Switch Setting

Watchdog Status

Enabled

Off

Disabled

The hardware bit switch number 5 must be set to the "ON" position to

enable the communications watchdog timer. If the switch is ON at startup

then the controller constantly monitors the elapsed time between host

communication packets and takes action should the elapsed time overflow

the preset timeout period.

Furthermore, the option may be disabled by the host. If a value of -1 is

written into the timeout period counter then the controller disables the

option and ceases to monitor elapsed time. To re-enable the option via

software, the host must rewrite a valid timeout period to the watchdog

counter.

Timeout Period

The host computer may adjust the timeout period value within the range of

1 to 1092 seconds (or 18.2 minutes) with a resolution of one second. A 2-

byte number representing the length of the timeout period in seconds can be

written to the controller data table addresses 0290 and 0291 Hex.

The default timeout period (set by the controller on startup/reset) is 2

minutes (120 seconds).

Controller Action on Timeout

If the watchdog option is enabled and the elapsed time between

communication packets from the host exceeds the set timeout period, the

controller initiates a communications alarm sequence. This sequence

involves the following :

1. All control output types are set to MANUAL

2. All output values for control outputs are set to 0%.

3. Digital output 72 is set ON. This output is available at

TB2, pin 30.

4. The internal controller reset flag is set TRUE. (Hence the host

will receive

RESET status code upon re-establishing

communication).

3.2.3 BAUD RATE SELECTION

Switch 6 is used to set the baud rate at either 2400 or 9600. If

communication problems occur try 2400 baud.

Switch Setting Baud Rate

2400

9600

3.2.4 ERROR CHECKING

Switch 7 is used to select the method of error that is used by the SYSTEM

32. BCC is slightly faster and can be used for most applications. CRC

provides the highest data integrity and is recommended if communications

problems are noted.

Switch Setting Error Check

BCC

CRC

3.3 AC POWER INPUT

The ANAFAZE 32 PID requires 120VAC at 60Hz for power input to the power

supply. The power supply can be mounted to a module panel or externally if

desired.

3.3.1 POWER CONNECTIONS

The power must be connected according to the terminal labels. The

abbreviations are:

NEU

HOT

Third wire ground -- normally Green wire

110VAC Neutral -- normally white wire

110VAC Hot -- normally black wire

GND

+5Vdc input on back plane

GND on backplane

WARNING: DO NOT REVERSE THE +5 AND GND

CONNECTIONS IRREVERSIBLE DAMAGE TO THE 32 SYSTEM

WILL OCCUR

3.3.2 POWER FUSE

The SYSTEM 32 power supply is not fused. An external 1/2 AMP fuse in

the AC input line is recommended.

4.0 COMMUNICATIONS SET-UP AND CONNECTIONS

The ANAFAZE SYSTEM 32 is designed for three types of serial communications:

RS-232, RS-485, and 20ma current loop. Up to 16 units can be connected on one

communication line.

4.1 RS-232

The optically-isolated RS-232 interface is located on the processor module A32-

PIOM. Multiple SYSTEM 32 units are connected in parallel. Connections are

made on the upper terminal block TB1 as follows:

Computer

SYSTEM 32 [1]

TB1

SYSTEM 32 [2]

TB1

RX #3 ----------- TX- #2 ------------ TX- #2

TX #2 ----------- RX+ #3 ------------ RX+ #3

GND #7 ---------- RX- #4 ------------ RX- #4

The computer pins are for the normal 25 pin RS-232 connector. On some

computers transmit TX and receive RX may be reversed. Please check your

computer manual for details.

The ANAFAZE SYSTEM 32 RS-232 interface transmits data on TX- and receives

data on RX+. The host computer TXD output should be connected to the SYSTEM

32 RX+ input. The SYSTEM 32 TX- output should be connected to the host

computer RXD input. Host computer communication ground should be connected

to the SYSTEM 32 RX-.

Multiple SYSTEM 32 units are connected on the RS-232 line in parallel. The

SYSTEM 32 nearest to the computer is connected as described above. Then each

SYSTEM 32 is daisy chained wire for wire to the next unit. The next units' TX- is

connected to the first units' TX-, RX+ to RX+, and RX- to RX- etc.

WARNING: REMOVE JUMPER FOR MULTIPLE SYSTEM 32

INSTALLATIONS

Jumper JU18 must be removed on all but the farthest unit from the

computer when multiple units are on the same communications line.

4.1.1 Other RS-232 Lines

Some host computers or other RS-232 devices use additional communication lines

that are not required by the SYSTEM 32. These include:

RTS - Ready to Send

CTS - Clear To Send

DSR - Data Set Ready

DTR - Data Terminal Ready

If the host computer uses RTS and CTS or DSR and DTR, these lines should be

connected together in pairs [or as shown in the computer manual]. Normally this is

done in the RS-232 connector hood at the host computer. Alternately the effect of

these lines can be eliminated in software. The ANAFAZE SYSTEM 32 is ready to

receive data; therefore these lines are not required.

4.2 CURRENT LOOP

The current loop interface is located on the processor module A32-PIOM. Current

loop is recommended for longer cable runs and noisy environments. The

ANAFAZE SYSTEM 32 current loop is optically isolated. It uses an external

power supply for the current loop which is normally included in the device

communicating with the SYSTEM 32. Consult ANAFAZE for recommendations.

SINGLE UNIT:

Computer

RX+

SYSTEM 32

TX+ #1

TX- #2

RX+ #3

RX- #4

RX-

TX+

TX-

MULTIPLE UNITS:

Computer

RX+

SYSTEM 32 [1] SYSTEM 32 [2] Last SYSTEM 32

TX+ #1

TX- #2

TX+ #1

TX- #2

TX+ #1

TX- #2

RX-

TX+

TX-

RX+ #3

RX- #4

RX+ #3

RX- #4

RX+ #3

RX- #4

Multiple SYSTEM 32 units are connected in series. R+ is connected to the first

unit TX+ and TX- from the first unit is connected to TX+ of the next unit. These

serial connections are continued until the last unit is reached. The last unit TX- is

connected to the computer R-. T+ is connected to the first unit RX+ and the RX- is

connected to the next unit RX+. The last unit RX- is connected to the computer T-.

4.3 RS-485

The RS-485 is a voltage balance long distance multi-point transmission interface. It

may use 2 or 4 lines depending on system requirements.

4.3.1 RS-485 Description

The EIA Standard RS-485 specifies only the electrical characteristics of

generators (transmitters) and receivers for use in digital multi-point systems.

The specification of transmission lines, signaling rates, protocols, etc. is left

entirely up to the user. The transmitters and receivers selected by Anafaze

also meet the requirements of RS-422.

The following information is intended to make recommendations for the

application of the RS-485 interface to Anafaze equipment. This note covers

4 wire communication. Anafaze equipment will also support 2 wire

communication. Please contact the factory for recommendations.

The maximum signaling rate used by the Anafaze System 32 and associated

equipment is 9600 baud. Since this is far below the maximum signaling

rate covered by the specification, satisfactory performance may be expected

without strict adherence to all of the design rules. ANAFAZE has presented

conservative recommendations to insure reliable operation. If deviations

are necessary, please contact ANAFAZE.

4.3.2 Cable Selection

ANAFAZE recommends twisted shielded pairs for the RS-485 cables. The

transmitters and receivers specified in RS-485 are very tolerant of cable

characteristics, and some leeway is possible unless distances and signaling

rates push the specification limits.

One requirement is very important, as it impacts performance even down to

low frequency operation. The loop resistance of the transmission line [wire

only -- not terminating resistor] must not exceed 200 ohms for a properly

terminated line with a reasonable margin for noise. Thus the following

recommendations for distance and wire gauge should be observed:

Distance

Wire Gauge Recommended Cable

1500 ft.

4000 ft.

6000 ft.

28 AWG

24 AWG

22 AWG

Alpha 3492

Beldon 9729

Beldon 9184

The use of a shield depends on the noise environment and grounding

considerations [4.3.3]. The above cables are shielded.

4.3.3 Connections

Connection of the Anafaze controllers to a system computer requires an

interface at the computer to convert RS-232 levels to RS-485. Anafaze

recommends Black Box Model LD485A for this purpose. The LD485A

should be configured for DCE operation, with the RTS/CTS delay jumper in

the "on" position.

The RS-485 specification is for "balanced line" operation, and is not true

differential. Thus a common connection is required between all stations on

the communication line. This can be accomplished by either a 5th wire

(which could be shield) or a common ground connection. The Anafaze

system more conveniently supports the common ground connection,

although 5th wire can be supported if required due to common mode

voltages generated in a given installation. The 5th wire connection would be

required only if the "common mode" voltage between stations exceeds the

RS-485 specification of 7 volts peak. The power common in the Anafaze

controller has been wired to chassis ground. To make sure the

communication system works, the controller chassis must be electrically

tied to Earth ground, and the host computer communication must be tied to

Earth ground. If the host computer RS-232 communication is not referenced

to Earth ground, then install the 100 ohm resistor in W7 as recommended by

Black Box.

Figure 1 shows the only recommended system hookup. (Other hookups may

work fine). The transmitter from the host computer connects in parallel to

the controller receivers, and the host computer receiver hooks in parallel to

the controller transmitters. A single "daisy chain" is recommended. Octopus

connections or "spurs" are discouraged. A termination resistor is required at

each end of the transmission line. This is accomplished by applying a 200

ohm resistor across the line at the farthest point from the computer

transmitter, and by setting the Black Box SW2 to the "term" position to

terminate the computer receive line.

ANAFAZE SYSTEM 32 connections for a single unit are as follows:

Black Box

COMPUTER

LD485A

SYSTEM 32

+485 Output (Start bit +5v)

-485 Output (Start bit 0v)

+485 Input

TXA

RX+ #3

TXB

RX- #4

RXA

TX+ #1

-485 Input

RXB

TX- #2

Shield-------Earth Ground---------Shield

Do not Ground

Note: Connect the shields to earth ground only at the computer or other 485

interface. No shield connection is required at the SYSTEM 32. Connect a 200

ohm terminating resistor between RX- and RX+ at the SYSTEM 32.

For multiple units connect the system as follows:

Black Box

LD485A

SYSTEM 32

[1]

SYSTEM 32

[n]

TXA

RX+ #3

RX- #4

RX+ #3 ---|

200 ohms

RX- #4 ---|

TXB

Ground

RXB

TX+ #1

TX- #2

TX+ #1

TX- #2

RXA

Ground

5.0 ANALOG INPUTS

Connecting analog signals to the ANAFAZE SYSTEM 32 is normally

straightforward. Most signals, including thermocouples can

be directly

connected and mixed in any order. However, some problems may occur that could

reduce accuracy and possibly damage the unit. Sections 5.1 through 5.4 indicate

some of the potential areas for concern. [See typical input DIAGRAM in section

5.13].

5.1 COMMON MODE VOLTAGE

Common mode voltage is the voltage between the ground at

the ground at the ANAFAZE SYSTEM 32. It can be an

the sensor and

AC or DC voltage

and appears equally at the high and low

input terminals. Frequently it is

caused by large currents flowing in the ground path between the SYSTEM 32 and

the sensors. The effects are minimized by locating the SYSTEM 32 as close as

possible to the sensors. Do not exceed the maximum common mode voltage of

150 volts AC.

5.2 NORMAL MODE VOLTAGE

Normal mode voltage appears across the terminals of the input and is the signal

from the sensor plus any undesirable noise. The major cause of this noise is AC

power line pick-up. The effects are reduced by the ANAFAZE SYSTEM 32

capacity to integrate the signal over a multiple of the power line frequency.

Further reduction can be achieved by locating the SYSTEM 32 near the sensors

and by using twisted and shielded sensor wires. To ensure accurate readings, the

maximum of normal mode plus signal should not exceed -10mv to +65mv.

5.3 GROUNDING

For best accuracy, observe the grounding recommendations for connecting each

input and output signal. The analog signal grounds should be connected to the

low terminals on the analog input terminals. The communication and control

outputs should also be connected with their respective grounds. Do not mix the

grounds or connect them together. The analog input section is optically isolated

from the processing and control section. Connecting the grounds together will

negate this feature and could damage the unit. If possible, route the analog signal

cables separately from the communication, control and power cables.

5.4 SOURCE IMPEDANCE

Each sensor has a certain output impedance which is effectively connected across

the ANAFAZE SYSTEM 32 input amplifier when a measurement is made. To

reach the rated accuracy, the maximum source impedance should not exceed 300

ohms. Consult ANAFAZE for operation with higher source impedance.

5.5 ANALOG INPUT MODULES

Two types of analog input modules are available for the SYSTEM 32. The A32-

RRIAM -- REED RELAY ANALOG INPUT MODULE provides 16 analog

inputs with reed relay switching. The A32-SSAIM -- SOLID STATE ANALOG

INPUT MODULE provides 32 inputs with solid state switching. The A32-

SSAIM also provides 32 digital outputs for special systems. The primary

differences are:

The REED RELAY ANALOG INPUT MODULE provides 250Vdc

isolation between input channels and three wire switching: high, low, and

shield for each input. This module allows connection of three and four

wire RTD's and other special sensors. The REED RELAY ANALOG

INPUT MODULE is also recommended where high noise is present or

where grounded sensors are used and the ground potential difference will

exceed 10 Vdc.

The SOLID STATE ANALOG INPUT MODULE provides 32 inputs and

includes a high and low switch for each channel. The solid state switching

limits the channel to channel protection to 15Vdc. The SOLID STATE

ANALOG INPUT MODULE should be used with un-grounded sensors, or

sensors with the same ground potential [with-in 10Vdc].

5.6 A32-RRIAM -- REED RELAY ANALOG INPUT MODULE

The A32-RRAIM includes 16 analog inputs and a reference power supply. The

module can be plugged into any housing slot.

5.6.1 INPUT CIRCUITS

The ANAFAZE A32-RRAIM contains an isolated area that can be used to

install resistors to scale input voltages and connect inputs to match the -10

to 60mv (-16.7% to 100%) input range. The input circuit is designed to

enable connection of current inputs (such as 4 to 20ma), voltage inputs, and

for connection of transducers (RTD) in bridge configurations. ANAFAZE

will supply input scaling as needed -- order option A32-SI-XX. The input

circuit is shown below:

AUX O---------O---------O---------O

|RA

TERMINAL HI O-----------------------------O----HI

BLOCK

|RE

|RC

|RB

MEASUREMENT

INPUT

LO O-------------------O---------O----LO

|RD

SHLD O---------O-------------------O----SH

RA, RB, RC, RD and RE are selected separately for each input and are

labeled on the PC board for each loop. CH 1 (channel 1) is loop 1 etc.

Resistors should be 0.1% metal film, 1/4 watt. Other components such as

capacitors can be installed for signal conditioning. Please consult

ANAFAZE. The PC board silk screen shows the resistor locations.

5.6.2 USE OF THE SHIELD CONNECTION

The shield connection provides a third input which is switched as each

channel is measured. It is the ground reference for the measurement section.

By switching this reference with every channel, the effective measurement

ground can float to match the ground at the sensor, thus greatly reducing the

error caused by different ground potentials (common mode).

The system is factory set for use with non-shielded cables. Zero ohm

resistors in the RD position connect each low input to shield. Normally

when non-shielded cables are used, this will result in the lowest noise pick-

up.

If shielded cables are used, the shield should be connected to ground or the

low signal output at the sensor if possible. If this is done, the RD resistor for

that channel must be removed.

WARNING - USE SHIELD CORRECTLY

If the shield is used for any input always remove the factory installed

RD resistor.

5.6.3 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 mv. For scaling the positive input should be

connected to the AUX terminal and the negative input to the LOW terminal.

The scaling resistor RA is selected as the voltage dropping and/or current

limiting resistor. RB is selected for the 60 mv full scale dropping resistor. It

should normally be less then 300 ohms and should never be greater then

1000 ohms. Any value above 1000 ohms for RB will cause error due to the

upscale burnout circuit. Typical standard value scaling resistors are as

follows:

0-100mv 0-500mv 0-1v

RA= 499 ohms 5.49k 6.91k

0-5v

39.2k

0-10v

49.9k

RB= 750 ohms 750 ohms 442 ohms 475 ohms 301 ohms

ACC.= +.1% +.1% +.2% -.2% -.1%

Please note section 5.6.2 regarding the shield connection.

Please note section 5.8 regarding scaling and calibration.

The above values are standard metal film values and will give an accuracy

of +/- .25% when using .1% tolerance resistors.

Any possible error due to resistor tolerance may be corrected by using

scaling in ANASOFT.

5.6.4 DC CURRENT INPUTS

Current inputs from transmitters are accommodated by placing resistors in

the input section to convert the current input into a voltage. Different

current input ranges are accommodated by selecting the proper resistor

values. In general RC is selected to maintain a low source resistance. RA

and RC produce the input full scale of 60mv. The positive input should be

connected to the AUX terminal, and the negative input to the LOW

terminal. The following input values are suggested:

4 to 20 ma

RA = 93.1 ohms

0 to 10 ma

RA = 26.7 ohms

RB = 20.0 ohms

RC = 20.0 ohms

Load resistance=17 ohms

Load Resistance=14 ohms

A single 0.1% resistor may be used in place of the above resistors although

a small error may occur. This error can be corrected in using the scaling in

ANASOFT.

4 to 20 ma

0 to 10 ma

RB = 3.000 ohms

RB = 6.000 ohms

Please note section 5.6.2 regarding the shield connection.

Please note section 5.8 regarding scaling and calibration.

5.6.5 THERMOCOUPLE INPUTS

All thermocouple types may be directly connected to the ANAFAZE

SYSTEM 32. Types J,K,T,R,S,C, and B linearization and cold junction

compensation are provided standard in the ANAFAZE SYSTEM 32. For

other thermocouple types, optional input ranges are required.

Thermocouples should be connected with the positive lead to the HIGH

terminal and the negative lead to the LOW terminal. Note section 4.5 on

shielding.

5.6.6 RTD INPUTS

RTD's can be connected in different configurations including bridge

circuits, three wire and four wire -- please request a copy of the ANAFAZE

RTD application bulletin.

The standard industrial RTD is a 100 ohm Platinum three wire assmbly.

THE ANAFAZE SYSTEM 32 WILL BE CONFIGURED FOR THE

STANDARD THREE WIRE RTD INPUT UNLESS OTHERWISE

SPECIFIED.

ANAFAZE recommends using only the 3-wire or 4-wire RTD configuration

for high accuracy.

Due to multiple ranges, different RTD range resistors, and special

linearization of the RTD range for high accuracy, the RTD INPUT should

be factory installed. If less accuracy is acceptable, please request the

ANAFAZE RTD application bulletin to field install the RTD input.

5.6.7 INFRARED NON-CONTACT TEMPERATURE SENSORS

The ANAFAZE IRSM infrared sensing module is ideally suited for many

infrared non-contact temperature applications.

It can be supplied by

ANAFAZE as a fully integrated system with the SYSTEM 32 configured to

provide power for up to four IRSM sensing modules and for direct

connection of the IRSM output.

The following connections are required if the IRSM internal ambient sensor

is not used:

ANAFAZE SYSTEM 32

IRSM WIRES

Orange

Pin Color

Function

AUX -------------------- A

HIGH -- no connection --

LOW -------------------- B

SHLD ------------------- K

Signal out

[0-10madc]

Signal ground

Shield

White

Shield

No connection

REF GND ---------------- C

REF GND ---------------- J

Red

Black

Brown

+5vdc supply

power ground

no peak hold

+ REF ------------------ D

Green

Blue

Yellow

+15vdc supply

Ambient sensor

Track and hold

No connection

The range of the standard IRSM is 0-1000 degrees F with an output of 0-

10madc. The input of the ANAFAZE SYSTEM 32 configured for a 0-

10madc input. See section 5.6.4

To use more than the factory installed four IRSM with the SYSTEM 32, use

an external power supply of 8-15vdc.

If desired a second input can be used to monitor the IRSM internal ambient

temperature. Please consult ANAFAZE for additional IRSM information.

5.7 A32-SSAIM -- SOLID STATE ANALOG INPUT MODULE

The A32-SSAIM provides for 32 differential analog inputs. Analog input

connections are made on two terminal blocks and the module can be plugged into

any housing slot.

Only the -10 to +60mvdc range may be used with this module. If it is desired to

connect current signals to the input of this module then it will be necessary to use

the single loading resistor mounted on the plug in terminal block. See section

5.6.4 for resistor values.

5.8 SCALING AND CALIBRATION

Since a computer is used to display the reading and load the setpoints, a

mathematical step can be used to convert measurements and setpoints to

engineering units and correct for known sensor calibration errors.

For example, the ANAFAZE SYSTEM 32 does all thermocouple calculations in

degrees F since this provides almost twice the resolution of degrees C. If degrees

C display and setpoints are desired the computer makes the F to C conversion as

data is received from the ANAFAZE SYSTEM 32 and converts the setpoints from

C to F as they are sent to the controller.

In a similar manner, linear sensors can be converted to engineering units and

adjusted for known calibration errors with a conversion step. For a linear sensor

two outputs can be measured (x1 and x2) and converted into engineering units (y1

and y2) using the standard formula:

y = mx + b

where m = (y2 - y1)/(x2 - x1)

and b = y2 - mx2 or b = y1 - mx1

The same conversion formula can be used to convert the desired setpoint into a

percentage of full scale which allows the ANAFAZE SYSTEM 32 to control to

the actual measured signals while the computer displays the measurements and

setpoints in engineering units. This approach eliminates the need for

potentiometers and other analog adjustments on each input channel.

The ANASOFT-32 software for the IBM PC and compatible computers includes

these scaling functions as part of the menu driven program. Please consult

ANAFAZE for additional information.

5.9 DIAGRAMS OF TYPICAL INPUTS

SEE SECTION 5.6 FOR DETAILED INFORMATION.

Typical Thermocouple

AUX O

HIGH O-- + White -------------------------

LOW O-- - Red ----------------------------

SHLD O

Type J T/C

Shielded Thermocouple: To use shield remove jumper RD. Shield should be

grounded at probe [see 5.6.2].

AUX O

---------------------

HIGH O-- + Yellow -------------------------

LOW O-- - Red ------------------------------

SHLD O--------------------------------------

Type K T/C

DC Voltage Input: Use scaling resistors to reduce the full scale voltage to 0 to

60mv. SEE SECTION 5.6.3 FOR SCALING RESISTORS VALUES OF RA

AND RB.

AUX O------------ +

HIGHO DC VOLTAGE ABOVE

LOW O------------ - 60mv

SHLD 0

AUX O

HIGH O------------- +

LOW O------------- - 60mv

SHLD O DC VOLTAGE BELOW

Current Transmitter Inputs: Use scaling resistors to convert the current to a

voltage input scaled to 0 to 60mv. This will result in a 0 to 20ma full scale range,

and an Mx + B scaling can be in the computer to display the engineering units.

SEE SECTION 5.6.5 FOR SCALING VALUES OF RA, RB, AND RC.

SCALING RESISTORS MUST BE INSTALLED.

AUX O------------- +

HIGH O

DC CURRENT INPUTS

LOW O------------- -

SHLD O

RTD INPUTS: The input loop must be configured for the three wire RTD input

and must have the proper scaling resistors installed.

AUX O-------------

HIGH O-------------

RTD

LOW O-------------

SHLD O-------------

5.10 ANALOG INPUT CONNECTIONS

5.10.1 A32-RRAIM Analog Input Connections

Terminal 1 [Upper]

Terminal 2 [Lower]

Channel Assignment

Channel

Assignment | Pin

REF GND

| 1

| 2

+ REF

------------------------------| -----------------------------

AUX

| 3

| 4

| 5

| 6

AUX

SHLD

------------------------------| -----------------------------

| 7

AUX

| 8

| 9

AUX

SHLD

| 10SHLD

------------------------------| -----------------------------

AUX

| 11

| 12

| 13

| 14

AUX

SHLD

------------------------------| -----------------------------

AUX

| 15

| 16

| 17

| 18

AUX

SHLD

------------------------------| -----------------------------

AUX

| 19

| 20

| 21

| 22

AUX

SHLD

------------------------------| -----------------------------

AUX

| 23

| 24

| 25

| 26

AUX

SHLD

------------------------------| -----------------------------

AUX

| 27

| 28

| 29

| 30

AUX

SHLD

------------------------------| -----------------------------

AUX

| 31

| 32

| 33

| 34

AUX

SHLD

------------------------------| -----------------------------

+REF

| 35

| 36

REF GND

5.10.2 A32-SSAIM Analog Input Connections

UPPER TERMINAL BLOCK

Channel

Assignment | Pin

Channel

Assignment

| 2

| 4

| 6

| 8

| 10

| 12

| 14

| 16

| 18

| 20

| 22

| 24

| 26

| 28

| 30

| 32

| 34

| 36

LOWER TERMINAL BLOCK

Channel Assignment | Pin

Channel

Assignment

REF

RETN

| 2

| 4

| 6

| 8

| 10

| 12

| 14

| 16

| 18

| 20

| 22

| 24

| 26

| 28

| 30

| 32

| 34

| 36

REF

RETN

6.0 CONTROL OUTPUTS

Control outputs are provided from the A32-PIOM -- PROCESSOR I/O MODULE

for digital outputs and the A32-AOM -- ANALOG OUTPUT MODULE for

analog outputs. The A32-AOM is not required for systems that do not need

analog outputs. The A32-PIOM provides the digital control outputs, the serial

communication, and miscellaneous digital inputs and outputs.

WARNING -- GROUND LOOP POTENTIAL

The ground of every control output is connected to the ANAFAZE 32

PID logic ground. Use caution when connecting external devices that

may have their low side at a voltage other than controller ground,

since potential ground loops can be created. Use isolated relays or the

isolated control device inputs if possible grounding problems are

expected.

6.1 PROCESSOR I/O MODULE

Most PROCESSOR I/O MODULE [PIOM] connections are provided on plug in

terminal blocks. Additional inputs and outputs are provided on ribbon cable

connectors. The control outputs are also available on ribbon cable connectors to

simplify external wiring. The pins used on the ribbon cable connectors can be to

connect these inputs and outputs to external terminal strips or standard I/O

module boards such as the Gordos PCB24.

TB1 IS THE UPPER TERMINAL BLOCK and TB2 IS THE LOWER

TERMINAL BLOCK. J1, J2, and J3 ARE CONNECTORS FOR RIBBON

CABLES. These connectors can be used to reduce point to point wiring and must

be used for the additional input and output connections.

Output 65 is used by the controller to indicate a high deviation alarm and output

66 to indicate a low deviation alarm. Output 67 is used by ANASOFT 32 to

indicate a computer determined high process alarm and output 68 for the

corresponding low alarm.

Typical 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 50 amps

at 480vac. For larger currents these relays can be used to drive contactors.

Connections are made as follows:

Upper Terminal Block TB1

SSR 1

SSR 2

|--------|

| - + |

|--|--|--|

| |

|--------|

| - + |

|--|--|--|

Out 1

Out 2

+5V

5 O-----------------| |

| |

6 O--------------------|------------| |

11 O--------------------o---------------|

Alarm outputs are also used to activate SSR's when possible. The connections are

essentially the same.

Lower Terminal Block TB2

SSR 1

SSR 2

|--------|

| - + |

|--|--|--|

| |

|--------|

| - + |

|--|--|--|

Low Dev. Out 1

High Dev. Out 2

+5V

5 O--------------| |

| |

6 O-----------------|------------| |

11 O-----------------o---------------|

6.1.1 PROCESSOR READY

The processor READY is a Watchdog Timer Output from the PIOM and is

an indication that the microprocessor is running its program. This output is

available at READY Pin #33 of the TB2 on the PROCESSOR I/O

MODULE (PIOM).

This output is on [will sink current] whenever the microprocessor is

functioning properly. The READY output takes about 2 seconds upon

power up to indicate ready. The output is an open collector NPN transistor

to ground, capable of sinking 15ma. Maximum ratings of 24vdc at 25ma

should not be exceeded.

To use the READY output as a TTL signal, connect a 4.7Kohm resistor

from the +5v supply Pin #31 to READY Pin #33 of TB2. Pin #33 will be

TTL low(0v) with respect to ground Pin #32, when the processor is ready or

running. Pin #33 will be TTL high(5v), when the processor is not

functioning.

TTL output for Processor Ready

+ 5vdc 31 O------

Ground 32 O--------------------O TTL Output: 0v = OK

4.7 K

5v = Problem

Ready 33 O--------------------O

To use the READY output to energize a relay, an optically- isolated solid-

state relay [SSR] is recommended. The control signal is +5v. Connect the

positive terminal of the SSR to Pin #31 and the negative terminal to Pin

#33. When the microprocessor is ready, the relay will be energized. Upon

failure of the microprocessor, the relay would be de-energized. A Gordos

#OAC5A or #G280D10 equivalent is recommended.

Processor Ready output connected to SSR

|--------|

+ 5vdc 31 O-------------------O + |

Ready 33 O-------------------O -

| SSR |

|--------|

6.1.2 OUTPUTS ENABLE: A32-PIOM ONLY

The control outputs from the PIOM [TPV, ON-OFF, and DZC] for all 32

Loops are off, when Outputs ON Pin #35 of TB2 is TTL high or open. Also,

the outputs are off, whenever the microprocessor is not ready.

WARNING: If the outputs are not enabled through Pin 35, there will

be no control output from the PIOM. The Outputs enable has no

effect on the analog control outputs [A32- AOM].

To enable the outputs, Outputs ON Pin #35 must be tied to ground Pin #32

by a jumper. If so desired, a relay contact may be used that would enable the

outputs from some external circuit, such as a safety device. The outputs may

also be enabled or disabled by a TTL signal. A TTL low will turn the

outputs on and a TTL high will turn the outputs off. The TTL input should

be connected between ground pin 32, and the Outputs ON pin 35.

Jumper to keep

outputs enabled.

External Relay or Switch to

enable outputs when closed.

Ground

32 O-------

Ground

Relay or Switch

Outputs ON 35 O--------

32 O--------

Outputs ON 35 O-------

6.1.3 COMMUNCIATIONS WATCHDOG TIMER

The communciations watchdog timer output is on Pin #30 of TB2 the lower

block on the PIOM. The output will be ON upon communication failure.

|---------|

+5vdc 31 O------ 0v= no comm 31 O------------|--O+

5v= comm

GRD 32 O-------------O

TTL

SSR will

be on with

no comm

| SSR |

COMM 30 O-------------O

30 O---------------|--Ο-

|______|

6.2 PROCESSOR I/O [A32-PIOM] PID OUTPUT CONNECTIONS

6.2.1 SCREW TERMINAL CONNECTIONS

Pin # TB1 [UPPER BLOCK]

TB2 [LOWER BLOCK]

Tx+ COMPUTER COMMUNICATION PID OUT LOOP 25

Tx- SEE SECTION 4 PID OUT LOOP 26

Rx+ COMPUTER COMMUNICATION PID OUT LOOP 27

Rx- SEE SECTION 4

PID OUT LOOP 1 SEE SECTION

PID OUT LOOP 2

PID OUT LOOP 3

PID OUT LOOP 4

PID OUT LOOP 5

PID OUT LOOP 28

PID OUT LOOP 29

PID OUT LOOP 30

+5V LOGIC SUPPLY

PID OUT LOOP 31

PID OUT LOOP 32

DIGITAL OUT 57

+5V LOGIC SUPPLY

DIGITAL OUT 58

DIGITAL OUT 59

DIGITAL OUT 60

+5V LOGIC SUPPLY

DIGITAL OUT 61

DIGITAL OUT 62

DIGITAL OUT 63

+5V LOGIC SUPPLY

DIGITAL OUT 64

ALARM OUT65

6.1 FOR

WIRING

10 PID OUT LOOP 6

11 +5V LOGIC SUPPLY

12 PID OUT LOOP 7

13 PID OUT LOOP 8

14 PID OUT LOOP 9

15 +5V LOGIC SUPPLY

16 PID OUT LOOP 10

17 PID OUT LOOP 11

18 PID OUT LOOP 12

19 +5V LOGIC SUPPLY

20 PID OUT LOOP 13

21 PID OUT LOOP 14

22 PID OUT LOOP 15

23 +5V LOGIC SUPPLY

24 PID OUT LOOP 16

25 PID OUT LOOP 17

26 PID OUT LOOP 18

27 +5V LOGIC SUPPLY

28 PID OUT LOOP 19

29 PID OUT LOOP 20

30 PID OUT LOOP 21

31 +5V LOGIC SUPPLY

32 PID OUT LOOP 22

33 PID OUT LOOP 23

34 PID OUT LOOP 24

35 +5V LOGIC SUPPLY

36 LOGIC GROUND

NOTES!

HIGHDEVIATION

LOW DEVIATION

ALARM OUT 66

+5V LOGIC SUPPLY

ALARM OUT 67

HIGH PROCESS

LOW PROCESS

ALARM OUT 68

DIGITAL OUT 69

+5V LOGIC SUPPLY

DIGITAL OUT 70

DIGITAL OUT 71

COMM WATCH 72 COMMUNICATION TIMER

+5V LOGIC SUPPLY

LOGIC GROUND

CPU READY

I sense -

WATCHDOG TIMER

OPEN HEATER SENSOR

PID OUTPUTS ENABLE

OPEN HEATER SENSOR

Outputs ON

I sense +

1. TB2 PIN 35 OUTPUTS ON MUST BE CONNECTED TO LOGIC

GROUND PIN 32 OF TB2 BEFORE PID DIGITAL OUTPUTS WILL BE

ACTIVE.

2. THE PID OUTPUTS ARE NEGATIVE LOGIC WITH REFERENCE TO

THE +5V LOGIC.

3. THE I SENSE OF PINS 34 & 36 ARE INPUTS FOR A SENSOR SIGNAL

IN THE OPEN HEATER DETECTION CIRCUIT.

Spare digital outputs and digital inputs are not used in the standard SYSTEM 32.

6.2.2 A32-PIOM OUTPUTS 50 PIN FLAT RIBBON CABLE

CONNECTIONS

IN # J1 [TOP]

J2 [MIDDLE]

DIGITAL OUT 33

LOGIC GND

J3 [BOTTOM]

PID OUT LOOP 25

LOGIC GND

PID OUT LOOP 1

LOGIC GND

PID OUT LOOP 2

LOGIC GND

DIGITAL OUT 34

LOGIC GND

PID OUT LOOP 26

LOGIC GND

PID OUT LOOP 3

LOGIC GND

DIGITAL OUT 35

LOGIC GND

PID OUT LOOP 27

LOGIC GND

PID OUT LOOP 4

LOGIC GND

DIGITAL OUT 36

LOGIC GND

PID OUT LOOP 28

LOGIC GND

PID OUT LOOP 5

LOGIC GND

DIGITAL OUT 37

LOGIC GND

PID OUT LOOP 29

LOGIC GND

PID OUT LOOP 6

LOGIC GND

PID OUT LOOP 7

LOGIC GND

PID OUT LOOP 8

LOGIC GND

PID OUT LOOP 9

LOGIC GND

PID OUT LOOP 10

LOGIC GND

PID OUT LOOP 11

LOGIC GND

PID OUT LOOP 12

LOGIC GND

PID OUT LOOP 13

LOGIC GND

PID OUT LOOP 14

LOGIC GND

PID OUT LOOP 15

LOGIC GND

PID OUT LOOP 16

LOGIC GND

PID OUT LOOP 17

LOGIC GND

PID OUT LOOP 18

LOGIC GND

PID OUT LOOP 19

LOGIC GND

PID OUT LOOP 20

LOGIC GND

PID OUT LOOP 21

LOGIC GND

DIGITAL OUT 38

LOGIC GND

DIGITAL OUT 39

LOGIC GND

DIGITAL OUT 40

LOGIC GND

DIGITAL IN 9

LOGIC GND

DIGITAL IN 10

LOGIC GND

DIGITAL IN 11

LOGIC GND

DIGITAL IN 12

LOGIC GND

DIGITAL IN 13

LOGIC GND

DIGITAL IN 14

LOGIC GND

DIGITAL IN 15

LOGIC GND

DIGITAL IN 16

LOGIC GND

DIGITAL IN 1

LOGIC GND

DIGITAL IN 2

LOGIC GND

DIGITAL IN 3

LOGIC GND

DIGITAL IN 4

LOGIC GND

DIGITAL IN 5

LOGIC GND

PID OUT LOOP 30

LOGIC GND

PID OUT LOOP 31

LOGIC GND

PID OUT LOOP 32

LOGIC GND

DIGITAL OUT 57

LOGIC GND

DIGITAL OUT 58

LOGIC GND

DIGITAL OUT 59

LOGIC GND

DIGITAL OUT 60

LOGIC GND

DIGITAL OUT 61

LOGIC GND

DIGITAL OUT 62

LOGIC GND

DIGITAL OUT 63

LOGIC GND

DIGITAL OUT 64

LOGIC GND

ALARM HI DEV 65

LOGIC GND

ALARM LO DEV 66

LOGIC GND

ALARM HI PROC 67

LOGIC GND

ALARM LO PROC 68

LOGIC GND

DIGITAL OUT 69

LOGIC GND

PID OUT LOOP 22

LOGIC GND

PID OUT LOOP 23

LOGIC GND

PID OUT LOOP 24

LOGIC GND

+5V LOGIC SUPPLY

LOGIC GND

DIGITAL IN 6

LOGIC GND

DIGITAL IN 7

LOGIC GND

DIGITAL IN 8

LOGIC GND

+5V LOGIC SUPPLY

LOGIC GND

DIGITAL OUT 70

LOGIC GND

DIGITAL OUT 71

LOGIC GND

COMM WATCH 72

LOGIC GND

+5V LOGIC SUPPLY

LOGIC GND

6.3 ANALOG OUTPUT MODULE A32-AOM

Analog control outputs are provided for the SYSTEM 32 by using the A32-AOM.

Each module provides 16 analog outputs and up to two modules can be used in a

single SYSTEM 32 for 32 control outputs.

The AOM provides both 4 to 20ma with 400 ohms maximum load and 0- 5vdc at

5ma maximum. Both are available at the output terminals and either may be

selected.

WARNING: Both outputs may not used at the same time on the same

loop. THE OUTPUTS WILL BE IN ERROR.

WARNING: The grounds of all the analog outputs on a single

module are connected together. Ground loop problems and potential

damage can result if the outputs are connected to devices that have

common mode or other voltages on their terminals. Contact

ANAFAZE for isolated outputs.

6.3.1 Typical Connections

The output connections are designated as C for the positive terminal of the

current loops along with the loop number and the negative side of the

current loop is to any of the terminals labeled NEG.

The positive output connections for the voltage loops are V along with the

loop number and the negative side is to any of the terminals labeled NEG.

Typical Analog Output Connections are:

Function

TB1 Pin#

|--------------|

PID LOOP 1C [17C] POS 6 O----------------------- +

[4 to 20ma]

I/P

| Converter |

5 O----------------------- -

NEG

|--------------|

TB2 Pin#

|---------------|

PID LOOP 13V [29V] POS 20 O------------------ + Motor |

[0 to 5v]

Speed |

| Controller |

NEG

21 O------------------ -

|---------------|

6.3.2 A32-AOM ANALOG OUTPUT MODULE CONNECTIONS

Note the outputs are designated as follows:

LOOP #C Positive terminal for 4-20madc output.

LOOP #V Positive terminal for 0-5vdc output.

NEG

Negative terminals for both outputs.

TERMINAL BLOCK 1 [UPPER]

TERMINAL BLOCK 2 [LOWER]

CONNECTION

NEG

2 PID LOOP 9C

POS [25C]

NEG

4 PID LOOP 9V

POS [25V]

NEG

6 PID LOOP 1C

POS [17C]

NEG

6 PID LOOP 10C

POS [26C]

NEG

8 PID LOOP 1V

POS [17V]

NEG

8 PID LOOP 10V

POS [26V]

NEG

10 PID LOOP 2C

POS [18C]

NEG

10 PID LOOP 11C

POS [27C]

NEG

12 PID LOOP 2V

POS [18V]

NEG

12 PID LOOP 11V

POS [27V]

NEG

14PID LOOP 3C

POS [19C]

NEG

14 PID LOOP 12C

POS[28C]

NEG

16 PID LOOP 3V

POS [19V]

NEG

16 PID LOOP 12V

POS [28V]

NEG

18 PID LOOP 4C

POS [20C]

NEG

18 PID LOOP 13C

POS [29C]

NEG

20 PID LOOP 4V

POS [2OV]

NEG

20 PID LOOP 13V

POS [29V]

NEG

22 PID LOOP 5C

POS [21C]

NEG

22 PID LOOP 14C

POS [30C]

NEG

24 PID LOOP 5V

POS [21V]

NEG

24 PID LOOP 14V

POS [30V]

NEG

26 PID LOOP 6C

POS [22C]

NEG

26 PID LOOP 15C

POS [31C]

NEG

28 PID LOOP 6V

POS [22V]

NEG

28 PID LOOP 15V

POS [31V]

NEG

30 PID LOOP 7C

POS [23C]

NEG

30 PID LOOP 16C

POS [32C]

NEG

32 PID LOOP 7V

34 PID LOOP 8C

POS [23V]

NEG

POS [24C]

NEG

32 PID LOOP 16V

POS [32V]

NEG

36 PID LOOP 8V

POS [24V]

NOTE!OUTPUT LOOP NUMBERS ARE IN REFERENCE TO THE INPUT LOOP

NUMBERS AND ARE SELECTABLE BY ADDRESS JUMPER.

LOOPS 1-16 ARE MODULE #1 OR ADDRESS #1.

LOOPS [17-32] ARE MODULE #2 OR ADDRESS #2

7.0 DETAILED MODULE DESCRIPTIONS

7.1 PROCESSOR I/O MODULE -- A32-PIOM

The PIOM is the main processor for the SYSTEM 32 and is required in each

system. The only PIOM option available for standard systems is the type of

communications interface.

The PIOM has two microprocessors, an 8031 and 8088. These microprocessors

perform all the SYSTEM 32 software operations using programs stored in

PROM's. The 8031 primarily manages the I/O functions including

communications, while the 8088 performs the control calculations including PID

and linearization thermocouple and other inputs. Other software functions include

self-test of the system, on-line analog calibration, and open heater detection.

The PIOM is comprised of a two board set, the larger board is the 8031 processor

and the smaller piggy back board is the 8088.

The SYSTEM 32 microprocessor programs allow control parameters and other

operating conditions, such as input types, to be entered from an external computer

through the built in serial interface. Communications protocol is a form of ANSI

X3.28-1976, which is compatible with Allen-Bradley PLC's.

Up to 29 parameters, such as input type, control setpoint, deviation alarms, PID

constants, can be entered for each loop. These parameters can be stored by

command in EEROM, and the SYSTEM 32 will start according to these

parameters on application of power or after a microprocessor reset.

WARNING: Only a safe set of parameters should be stored in

EEROM, since the system will automatically start with these values.

7.1.1 Control Outputs and Digital Inputs and Outputs

The standard SYSTEM 32 PIOM has 32 digital control outputs, 8 alarm and

status outputs, an additional 16 digital outputs, and 16 digital inputs.

In the simplest SYSTEM 32 configuration, the PIOM may be used without

any other modules as an open loop controller with 32 manually set control

outputs. The outputs can be set to any level [percent of full scale] from the

system computer.

When used for closed loop control, the 32 control outputs correspond to the

first 32 analog inputs. Additional analog inputs up to 96 total per PIOM,

are used for data acquisition. A special version of the SYSTEM 32 is

available for 48 control loops.

The control outputs may be independently software set as on/off, or pulsed

dc outputs with a choice of Cycle Time Proportioning or Distributed Zero

Crossing. The control action can be independently set for Reverse [Heat] or

Direct [Cool]. The outputs are 5vdc at 16ma maximum and are normally

used to switch optically-isolated solid-state relays (SSR's).

The alarm and status outputs include a global high and low deviation and a

watchdog timer which are set by the SYSTEM 32. If ANASOFT-32 is used

in the system computer, a global high and low process alarm output is set

from the system computer. These outputs are also 5vdc and are designed to

connect to SSR's.

The additional digital I/O are used by special versions of ANASOFT-32.

Eight digital outputs are available on the terminal strips, and the remaining

8 digital inputs and 16 digital outputs are provided on a 50 pin ribbon cable

connector. The pin configuration is compatible with standard I/O modules

such as Gordos PB24.

7.1.2 Communication

The type of communication interface is determined by the distance the 32

System will be from the host computer. The communications interface type

is set at the factory. RS-232 is recommended up to 50 feet although it can

be used up to 500 feet with special cables in low electrical noise

environments. For longer distances either the 20ma Current Loop (up to

5000 ft.), or the RS-485 (up to 10,000 ft.) is recommended. The 20ma

current loop is a dual twisted pair serial connection and RS-485 is 4 or 2

wire balanced line parallel connection.

7.1.3 Address and Option Switch

An 8-position dip switch on the PIOM provides for the address selection.

The addresses allow up to 16 SYSTEM 32 PIOM's to be on the same

communication line. It also allows selection of the baud rate of 2400 or

9600 as well as other communication parameters.

7.1.4 Terminal Blocks

Push on, screw locked terminal blocks are provided on each module for

connection of field wiring. The blocks are large enough for most types of

input wiring. The blocks can be removed to service the modules without

the need to remove the field wiring. The blocks also include temperature

stabilization to improve the reference junction compensation when

thermocouples are directly connected.

7.2 REED RELAY ANALOG INPUT MODULE -- A32-RRAIM

The RRAIM provides the connections for up to 16 analog inputs to the SYSTEM

32. Analog inputs are sequentially switched to a frequency [V/F] converter

optical-isolator and to the PIOM where the pulses are counted and the readings are

determined. In addition to the analog inputs, two temperature sensors at each end

of the terminal blocks are measured for use as an electronic reference junction for

directly connected thermocouples.

7.2.1 Automatic Calibration

The RRAIM includes two additional inputs: a full scale and a zero signal

that are used by the PIOM for automatic full scale and zero calibration. The

zero input is read on one scan to calibrate the analog amplifier zero, on the

next scan the full scale input is read to calibrate the amplifier gain. The

next two scans are used to read the thermocouple reference temperatures

and then the calibration cycle starts again. Thus calibration is automatically

updated every two seconds.

7.2.2 Noise Rejection

The 16 channel reed relay input provides the highest level of protection

from input noise present in most industrial applications. By using a 3-pole

relay and switching both inputs for true differential measurement, and the

shield for noise rejection, up to 180vac of common mode voltage may be

present on an input without effecting calibration.

For further noise protection, the integration period for the voltage to

frequency converter is set at one period of the 60Hz power line frequency.

The provides high rejection of power line induced noise.

7.2.3 Resolution

The combination of the integration time period and the full scale frequency

output of the V/F results in a measurement resolution of one part in 5000, or

0.02%. This is slightly higher than 12 bit [one part in 4096] resolution.

The resolution of 0.02% full scale results in a measurement resolution of

better than 14 microvolts. This means that the typical thermocouple

resolution for a type J or T is 0.5 F, for a type K 0.75 F, and for type R or

S 2.0 F.

7.2.4 Scanning Speed

The SYSTEM 32 with the RRIAM, measures each input twice per second.

The PIOM performs the complete PID calculations for all loops in less than

this time, thus every loop is updated twice per second. The PIOM scans

each RRAIM in parallel so the addition of RRAIM's to the system will not

add to the scanning or loop update time.

7.2.5 Analog Input Range

The analog input range of the RRAIM is -10 to +60mv. To measure other

inputs, such as 4-20 ma, scaling resistors are used. The RRAIM contains an

isolated section for the purpose of mounting scaling resistors. These

resistors may be mounted by the factory [order A32-SI as needed] by the

user.

7.2.6 RTD Excitation Voltage

The excitation voltage for RTD's is 10vdc at 50ma max. When using RTD's,

a max current of 3ma per sensor is recommended to avoid self-heating of

the RTD as well as avoiding overloading the RRIAM power supply.

7.2.7 Open Thermocouple Detection

The RRIAM has upscale open thermocouple detection which is

accomplished by placing a small current through the thermocouple leads.

The input source impedance may go as high as 200 ohms before rated

accuracy is effected.

7.2.8 Address Selection

Each RRIAM has a jumper for address selection of the RRIAM in the

SYSTEM 32. As many as three RRAIM's may be used per system.

7.3 SOLID STATE ANALOG INPUT MODULE -- A32-SSAIM

The SSAIM is similar to the RRAIM except that the input channels are switched

with 2 wire solid state multiplexers instead of 3 pole reed relays. The result is less

voltage standoff [10volts maximum] between the inputs and the input grounds.

The number of input channels is increased to 32 at about the same cost of 16 reed

relay inputs.

The scan rate is still at 32 channels per second, thus each channel is updated every

second. The PIOM still scans the SSAIM's in parallel, thus additional SSAIM's

will not add to the scanning time.

The maximum number of SSAIM's per system is three. This gives a total of 96

inputs for a low cost data acquisition system.

Both RRAIM's and SSAIM's can be used in the same SYSTEM 32. The first 32

inputs are used for closed loop control.

7.4 ANALOG OUTPUT MODULE -- A32-AOM

The AOM is used when an analog output signal is required to control the final

control element. The 16 channel AOM provides a 4-20ma output [maximum load

400 ohms] or 0-5v output [5ma maximum]. Either output can be selected for each

loop on the terminal block.

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

Other outputs are available upon special order, contact ANAFAZE.

The 8-bit Digital/Analog (D/A) converter supplies the necessary signal to the output

transistors according to the PIOM control calculations. The analog control output

for a particular loop verses a digital control output on the PIOM is software

selected.

The output transistors have a compliance voltage of 8vdc and all outputs share a

common ground which is isolated from the system ground.

Warning: The analog outputs must not be connected to devices that

feedback power line AC or other voltages to the AOM. If there is

voltage present optical isolators must be used.

ANAFAZE for more information.

Please consult

Each AOM has an address Dip switch for address selection of the AOM in the 32

System. Up to two AOM's may be used in each SYSTEM 32.

7.5 PULSE INPUT MODULE -- A32-PIM

The PIM counts up to 32 pulse inputs at maximum pulse rates of 1kHz with 50%

duty cycle pulses. The A32-PIM can only be used in systems with an expanded

PROCESSOR I/O MODULE [A32-PIOM-EX].

7.6 POWER SUPPLY----PART NO. A32-PS

The power required by the SYSTEM 32 is 5 vdc at 5 amps. Each module of the

SYSTEM 32 has a DC to DC converter for isolation and to provide the regulated

voltages used. These voltages are typically +5vdc and +15vdc.

Since each module includes isolation and regulation, nearly any 5vdc supply can be

used. The SYSTEM 32 can be run from battery power since only a single voltage

is required.

The A32-PS includes a standard SYSTEM 32 front panel, and wiring to the

SYSTEM 32 backplane. The power supply is normally mounted in one module

slot. For systems that require all the slots for other modules, the power supply can

be mounted externally.

The rating of the A32-PS is 120 vac input with 5 vdc at 7 amp output. The power

supply has an adjustment for the 5 vdc.

For a spare supply, option A32-PSWOFP [Power Supply With Out Front Panel] is

available.

7.7 OPERATOR STATION -- A32-OS

The OPERATOR STATION is used to view the measured input value or Process

Variable (PV) for any loop of the SYSTEM 32. The OPERATOR STATION can

also be used to change the Setpoint (SP) of a loop at a remote location from the

computer.

The OPERATOR STATION is a panel mount 1/8 DIN LED readout instrument

utilizing the communication line from the computer to the 32 System. The

OPERATOR STATION front panel contains the function keys for the display

selection and setpoint changing.

The OPERATOR STATION requires ANASOFT-32 to be running in the system

computer. It obtains its readings and changes the setpoints through the computer.

The OPERATOR STATION can select any PIOM and any loop in the system for

display and changes. The SP may be viewed for any loop in the system and may, if

elected by the customer, be changed from the OPERATOR STATION. The ability

to change SP from the OPERATOR STATION is selected in ANASOFT-32 by the

user.

8.0 PID CONTROL

This section provides some common definitions of control terms and information

on control loop tuning.

8.1 CONTROL LOOPS

A control loop may consist of four or five elements depending upon the placement

of the functions of some elements. These elements are defined as follows:

PRIMARY ELEMENT: This senses the PROCESS VARIABLE (PV), a

thermocouple (T/C) measuring temperature is an example.

SIGNAL CONDITIONER ELEMENT: this may be required between the

PRIMARY ELEMENT and the CONTROLLER ELEMENT if the signal

cannot be directly connected to the CONTROLLER ELEMENT. An

example is a pH transmitter.

CONTROLLER ELEMENT: accepts the signal from the PRIMARY

ELEMENT and sends the appropriate control signal to the FINAL

CONTROL ELEMENT. An example is the SYSTEM 32.

FINAL CONTROL ELEMENT: accepts the control signal from the

CONTROLLER ELEMENT and controls the MANIPULATED

VARIABLE ELEMENT. An example is a motor positioning valve unit for

the control of natural gas into a burner system or a Solid State Relay (SSR)

controlling voltage into an electric load.

MANIPULATED VARIABLE ELEMENT: is the energy of the process

such as steam, natural gas, etc... needed by the process for the Process

Variable to reach Setpoint.

The FINAL CONTROL ELEMENT may be controlled in open loop, that is with

out feedback or direct measurement of the Process Variable. For open loop control

the control output from the CONTROLLER ELEMENT is set to some output level

to produce a desired effect. This assumes that the process is slow enough for

corrective action to be taken based on information from another source other than

the PRIMARY ELEMENT or the process characteristics are such that open loop

control will hold the Setpoint within desired limits.

Closed loop makes use of feedback from the process, comparing the Process

Variable to the Setpoint, and changing the control output automatically as required

to control the process.

OPEN LOOP is also known as MANUAL CONTROL, while CLOSED LOOP is

known as AUTOMATIC CONTROL.

8.1.2 CONTROL MODES

The control mode is the form of control function. In the SYSTEM 32 the

choices are: on/off, proportional [P], proportional and integral [PI], and

proportional with integral and differential [PID]. The control mode should

not be confused with with the type of control output signal: for example

pulsed DC voltage or analog output.

8.1.3 ON/OFF CONTROL

The simplest way to control the PROCESS VARIABLE (PV), for example

temperature on an oven, to a desired SETPOINT (SP), operating

temperature, is to use ON/OFF control. When the temperature is below the

setpoint the heat is turned fully on and when the temperature is above the

setpoint the heat is turned fully off. The result of ON/OFF control is usually

the cycling of the PV around the SP. The amount of PV deviation from the

SP is primarily due to the process dynamics rather then the controller gain.

Most ON/OFF controllers GAIN, [also known as DEADBAND,

HYSTERESIS, or SENSITIVITY] is a fixed percentage of the controller

input span. Thus, a gain of 1/2% of a 0-1400 F Type J span would be 7 F.

This means the controller will not switch the output on, until the PV falls

below SP by 3.5 F and will not switch the output off, until the PV rise

above SP by 3.5 F. Occasionally the deadband is too narrow for the

process and intermittent chattering of the Final Control Element may be

present. An adjustable gain on the ON/OFF controller function is very

useful for eliminating Final Control Element chatter. The SYSTEM 32

provides adjustable gain for ON/OFF control loops.

The Final Control Element most often used with ON/OFF control is the

relay. For example relays can be used for electrical heating loads, solenoid

valves, and two-position motor control.

8.1.4 PID CONTROL

PID or 3-mode control is used when ON/OFF control is not satisfactory for

the control requirements of the process. If cycling of the PV cannot be

tolerated, if process loading is a variable, and if the SP is changeable, then

PID would most likely be used in place of ON/OFF control.

The PID initials stand for PROPORTIONAL, INTEGRAL, and

DERIVATIVE. The SYSTEM 32 utilizes the ISA standard PID equation

to calculate the control output as follows:

U = 1

---

K (e + 1 edt + K de)

FSR

Where:

U is the control output in percent of output full scale. For a 4-20ma

output, 0% is 4ma, 50% is 12ma, and 100% is 20ma.

e is the error [the difference between the PV and SP].

FSR is the full scale range of the measured input. For a J thermocouple

the full scale range is -350 to 1400 F, or 1750 .

Kp is the proportional gain, and FSR/Kp is referred to as the

proportional band PB. The gain can be set from 0 to 255 for the

SYSTEM 32. Note that when gain is specified in the control equation

the output would be different for the same error if a different full scale is

used. If PB is used the FSR cancels out and the PB is independent of

the input range.

TI is the integral or reset time, and 1/TI is referred to as the reset rate.

For the SYSTEM 32, the integral or reset time can be set from 0 [off] to

1020 seconds with 4 second resolution. This corresponds to a reset rate

of 0.05 to 15 repeats per minute.

TD is the derivative time and the range for the SYSTEM 32 is 0 [off] to

255 seconds or 0.01 to 4.25 minutes.

8.1.5 PROPORTIONAL CONTROL [P]

Proportional control is when the control output signal is linearly

proportional to the error. In the above equation the integral and derivative

effects are zero. For the SYSTEM 32 this is accomplished by setting the

integral and derivative constants to zero. The proportional constant is also

known as gain.

As the gain of the controller is increased a small increase in error will cause

a large change in the control output. Since cycling of the PV can result

from high gain, reducing the gain is one way to improve stability.

In the control equation, once the error times the gain divided by the full

scale range reaches 100% [full control output] additional error cannot

increase the control output. If the error is less than this value a control

response proportional to the error is made. Thus if the error is less than

FSR/K it is said to be within the PROPORTIONAL BAND (PB). The PB

is equal to the full scale of the controller input divided by the gain. Thus a

gain of 100, for a thermocouple with a range of 0 to 1400 F, results in a

proportional band of 140 F.

Using ANASOFT-32 for the SYSTEM 32 allows the a choice of displays

for the proportional function. This function can be shown and entered as

either Gain or Proportional Band. If proportional band is selected, the

values can be entered IN THE ACTUAL ENGINEERING UNITS OF THE

INPUT regardless of the span of the instrument. Thus, a PB of 30 represents

30 F for any thermocouple input range in the SYSTEM 32.

Gain may also be used, but once again the input span of the controller

becomes critical. For the SYSTEM 32, a gain of 30 represents 48 F PB for

a Type J T/C, 87 F for a Type K T/C, and 29 F for a Type T T/C. To

obtain PB divide the span by the gain setting.

For temperature control, the most useful and easiest to use entry is the PB in

actual degrees for the SYSTEM 32. The nominal setting of the PB can be

between 5-20% of the SP. Thus, a SP of 300 F may require a PB of 15-60

F. To start use 10% of the SP.

A good way of establishing a PB setting is to start at a wide PB and then to

keep decreasing the PB [increasing gain] until the process cycles about the

SP. Take note of the PB at this point and double the figure. PB should be set

at this number. Reset should be set to a low value such as .3 [or set integral

to zero: off] and derivative should be at zero [off] before tuning PB.

The PB of 30 F with a SP of 300 F specifies that the output from the

controller will change proportionally from 0 to 100% over 30 degrees. The

output will be at 0% or 100%, if the PV is outside the PB of 30 F from the

SP of 300 F. Below 270 F [greater than a 30 error] the output will be at

100%, at 285 F it will be at 50% and at 300 F and above it will be at 0%.

All PID control functions take place within the PB, otherwise the controller

output is full on or full off with no Integral or Derivative action.

8.1.6 PROPORTIONAL AND INTEGRAL CONTROL [PI]

The Integral mode is also known as RESET action. Reset is the older of the

two terms and is descriptive of the control action that takes place. The

primary reason for for integral control is to reduce or eliminate steady state

errors, but this benefit typically comes at the cost of reduced stability.

With proportional only control the output will be zero when the PV is at SP

[error is zero]. Thus, in a heating system for example, the stable

temperature will always be below the setpoint. When the PV is stable at a

point above or below the SP, the deviation from the SP is known as

OFFSET. The control action that corrects for this offset, is integral or reset.

Reset is only active when the PV is not equal to the SP. The unit of Reset

most often used is called Repeats/Minute (R/M). This expresses the number

of times the PB response is repeated in one minute. This means with one

repeat per minute, that the control output would be exactly double the

proportional band [repeats the proportional band] only, if the error [SP-PV]

remained steady for the full minute. As long as reset is active, it will repeat

the PB response until the output has reached 0% or 100%.

MANUAL RESET is a manual biasing of the output, so that when the PV is

at SP, the output will be at the proper level to hold SP. It is more common

on older type controls. The newer controllers including the SYSTEM 32

provide AUTOMATIC RESET as described above. AUTOMATIC RESET

automatically makes the correction for offset errors, but the R/M value must

be set for the process.

Another way of viewing the reset action is to look at the integral term in the

control equation of section 8.1.4. The control output due to this term is the

error integrated over time. Thus a small offset over a long period of time

will increase the integral sum and consequently the control output until the

PV is equal to the SP. At this time, the proportional control output will be

zero and the system will be stable at setpoint due to the integral sum.

Consider again the above example, with the PB at 30 and the SP at 300 F,

50% of the output is obtained at 285 F, but zero output is obtained at SP.

Assuming 50% output is required to hold the temperature at 300 F, it

would be reasonable to assume that the PV would be stable at 285 F. This

results in an offset of 15 F from 300 F SP. To shift the PB so that 50% of

the output is at 300 oF, reset is used.

If, AUTOMATIC RESET is used with .5 R/M and assuming the last PB

response was 10% and the output is 50%. After the first minute, the output

will be at 55%. After the second minute, it will be at 60%. After the third,

65% and so until the output is at 100%. It would take ten minutes to do this,

assuming that there was no temperature rise. Since the temperature would

actually increase, the error would be reduced and the portion of the control

output due to proportional control would decrease. Since the value of the

integral sum is increasing with time, the effect of the reset output increases.

This interaction would continue until SP was reached, where reset holds the

temperature at setpoint and the proportional output becomes zero.

A .5 to 1 R/M would be a good starting point for most processes. A slow

process requires a slow reset (less then 1R/M). When too fast of a reset is

used, the PV may slowly cycle around the SP. When adding RESET to the

control mode of a controller, the addition of the RESET mode normally

requires widening of the PB from the PROPORTIONAL mode control only

setting.

8.1.7 PROPORTIONAL, INTEGRAL, AND DERIVATIVE

CONTROL [PID]

The Derivative mode is also known as RATE, ANTICIPATION, or

APPROACH. RATE is the more common term used. The function of

RATE is to prevent the overshoot or undershoot of PV at SP. It does this by

slowing the rate of approach of the PV to the SP.

When using PB with RESET, the PV will sometimes go past the SP when a

setpoint change or process disturbance occurs. This can happen since the

correct setting of the PB will cause a small damped oscillation around the

setpoint and the integral sum built up by the reset function cannot be

reduced until the PV is past the setpoint. Thus, a Two-Mode controller may

have overshoot, even if it is correctly set.

Most processes can tolerate an overshoot, but if the overshoot of the PV

relative to the SP cannot be tolerated, then the RATE function must be used.

RATE is also used to correct for rapid load changes, to slow large capacity

processes, and to overcome the slew rates of electric motor actuators.

The RATE function responds to the change in the error as a function of

time. Mathematically it is the first derivative of the error as a function of

time [see equation in section 8.1.4]. Thus if the error is steady the effect of

rate is zero. As the PV approaches the setpoint, the rate term will be

negative and reduce the control output. This will serve to slow the approach

to setpoint and reduce the tendency to overshoot. The higher the rate, the

faster the output is reduced, thus preventing overshoot. Too high a setting of

the rate will cause the PV to undershoot the setpoint and the approach will

be series of undershooting steps.

With PID control the output signal is a composite of the three control

functions and will vary as the constants for these functions are changed as

required to hold the PV to the SP. In general:

Increasing:

K and 1/T reduce system errors.

Decreasing: T reduces stability, but speeds the settling time.

Setting T = 0, turns off reset.

Increasing:

T improves stability. Setting T = 0, turns off rate.

8.1.8 ANAFAZE OUTPUT FILTER

The OUTPUT FILTER used by the ANAFAZE Controllers is a digital filter

on the output signal after the PID functions. It has a range of 0-255 levels

that gives a time constant of 0-127.5 seconds. It is used to filter out erratic

swings of the output due to extremely sensitive input signals, such as open

air T/C in a dry air gas oven or a turbine flow signal.

It can be used also to allow the SYSTEM 32 to function more effectively

than with PID alone. Some processes may be very sensitive, requiring a

wide PB, such that good control control is not possible. By increasing the

digital output filter to reduce the high and low output swings due to the

process, the PB may be narrowed (lower number -- higher gain) to obtain

good control.

The filter can also be used to forgive badly tuned PID loops and poorly

designed processes. It may also be used to reduce output noise [control

output cycling] when a large amount of derivative action is required.

8.1.13 REVERSE-DIRECT ACTION

The ACTION of the control OUTPUT with RESPECT to the PV is known

as REVERSE ACTION, if the OUTPUT INCREASES as the PV

DECREASES. If the OUTPUT INCREASES as the PV INCREASES, then

it is known as DIRECT ACTION.

Heating applications normally uses REVERSE ACTION and cooling

applications normally will use DIRECT ACTION. The selection may also

be dependent upon the application of two competing mediums of energy

such as in a HEAT/COOL or TEMPERATURE/HUMIDITY applications.

8.1.14 HEAT/COOL DUAL OUTPUTS

Certain processes such as plastic molding, plastic extrusion, refrigeration

systems, test chambers, and others require both heating and cooling control

loops. In many cases a single process variable is used for dual output, that

is, it controls both heating and cooling. To optimize the process it may be

necessary to have different setpoints with a deadband between them,

different PID or other control constants, and different output types for the

heat/cool loops. For example, a mold may be heated using PID control

through a phase angle fired power controller, while cooling is accomplished

using on/off control through a cooling water valve.

Dual outputs are provided by directing a single analog input to two control

loops. This approach is practical because of the low system cost. Two

configurations are available:

For systems with only a few heat/cool loops, a single sensor is

connected to two analog inputs. One loop is then used for heating

and the second for cooling. This is practical in the SYSTEM 32

since the cost per loop is reasonably low and fully isolated inputs are

available if needed.

For systems that are nearly all heat/cool, a single reed relay analog

input module can be jumper set to direct each analog input to two

independent loops.

In both cases each loop is fully independent and can have its own setpoint,

control mode, and output signal type. The separate setpoint allows for a

deadband adjustment not normally possible in many controllers. Three-

Position or Two-Position floating control can be implemented by selecting

the proper setpoints for the heating and cooling loops.

8.1.9 CONTROL OUTPUTS

The SYSTEM 32 provides two signal types for use as control outputs:

digital and analog. The type of output is selected from software. If the

system uses any analog outputs the optional A32-AOM ANALOG

OUTPUT MODULE is required.

8.1.10 DIGITAL OUTPUT

Digital outputs normally control the process using relays. Two types of

control are used: ON/OFF and TIME PROPORTIONING. Time

proportioning is also referred to as pulsed DC output.

On/off control has been described in section 8.1.3.

Time proportioning control is a method of using a digital output and an

on/off device such as a relay to essentially achieve an analog control signal.

When the controller calculates the required control signal, it converts the

percent output into a percent duty cycle and outputs this to the process

through the relay. The process itself integrates this output and responds as

if this percentage was applied in an analog manner.

For example, in a temperature process, if the controller requires 23% power

output, it will set a duty cycle for the relay such that it is fully on for 23% of

the time, and off for 77% of the time. If the time constants of the process

and the type of relay have been correctly determined, this will result in the

same temperature as if the heater could have been analog adjusted and the

power had been set to 23%. The advantage of this type of control is that a

relay is a relatively inexpensive way to control the heater power.

Different relay types may be used depending on the power and other process

requirements: ELECTRO-MECHANICAL or SOLID STATE [SSR].

Modern SSR's can switch up to 480vac at 75 amps.

The digital outputs of the SYSTEM 32 are designed to drive optically-

isolated SSR's. If electromechanical relays are required, an SSR should be

used to connect the SYSTEM 32 to the relay. This approach will protect the

controller from wiring errors and isolate every output from the others.

The ANAFAZE SYSTEM 32 offers two types of time proportioning

outputs: Cycle Time Proportioning and Distributed Zero Crossing. Cycle

time proportioning is normally used for electro-mechanical relays and

Distributed Zero Crossing is typically used for solid state relays

CYCLE TIME PROPORTIONING is the proportioning of a selected fixed

cycle time between an ON time versus an OFF time. With a cycle time of 10

seconds and a required control signal of 40% the on time would be 4

seconds and the OFF time would be 6 seconds. If the next control

calculation required 38% output the on time would be 3.8 seconds and the

off time 6.2 seconds. Thus as the PID control calculation changes the

output required the system responds exactly, and the output duty cycle is

adjusted to maintain the process at the setpoint.

Cycle Time Proportioning is primarily used on electrical energy type of

processes. Some applications may use solenoid valves in a time

proportioning mode, rather then ON/OFF. The general rule of thumb for

cycle time is no less then 10 seconds [20 recommended] for electro-

mechanical relays and no more then 5 seconds [2 recommended] for SSR's.

Normally the faster the cycle time, the closer the control and the more wear

on the relays.

8.1.11 DISTRIBUTED ZERO CROSSING

Distributed Zero Crossing [DZC] output is the other time proportioning

output available from the SYSTEM 32. This output is primarily for very fast

acting electrical heating loads using SSR's. The open air heater coil is an

example of a fast acting load. It should never be used with electro-

mechanical relays.

The combination of Distributed Zero Crossing and a solid state relay can

approach the effect of analog phase angle fired control at a reduced cost.

The DZC output is a TIME PROPORTIONING output where the controller

decides for each cycle of the AC line if the power should be on or off. There

is no fixed cycle time since the on/off decision is made for each AC cycle.

For example if the control output is 25% the power would be turned on for 1

AC cycle and off for the next 3 AC cycles. This pattern would repeat until

the output level changed, for example to 28%. The power would then be on

for 1 AC cycle and off for 3 cycles, then after repeating 1 on and 3 off

several times the power would be set on for 2 cycles and off for 2 cycles.

The result is after 100 cycles the power will have been on for 28 cycles and

off for 72 cycles.

Since the time period for 60Hz power is 16.6ms the switching interval is

very short and the power is applied very uniformly. Switching is still only

done at the zero crossing of the AC power reducing the generated electrical

noise.

8.1.12 ANALOG OUTPUTS

Analog outputs may be CURRENT or VOLTAGE and are continuously

proportional over the range of the output signal level. The SYSTEM 32

matches the standard industrial signal levels by providing 4 to 20 ma for the

CURRENT output and 0 to 5 vdc for the VOLTAGE output.

The analog signals drive many types of FINAL CONTROL ELEMENTS

such as electric proportioning motors for gas valve control of burner

systems, I/P transducers for pneumatic control of valves, and SCR controls

for phase angle control of electrical loads.

8.2 ADJUSTMENT OF PID CONSTANTS

The SYSTEM 32 is normally operated using ANASOFT-32 in a system computer.

For other installations the constants can be adjusted in a similar manner using the

software supplied.

ANASOFT offers a choice of displays for the control constants. For many people,

the use of Proportional Band is the most logical way to view these constants. If this

display is desired it must be selected in the ANASOFT-32 installation program

QINSTALL.

In addition the Plot History function should be set up to correctly display the PV of

the loops being tuned. The time base must be adjusted prior to the start of tuning,

and the full scale adjusted to match the expected PV range. The graphics of the

Plot will show the effect of the PID tuning in real time.

The understanding of PID functions would be useful in tuning loops, but not

essential to a successful application of PID constants to a control loop.

8.2.1 INITIAL VALUES FOR PID LOOPS

The following values may initially be used for the PID constants. They

have been used for many applications and will serve as a starting point for

tuning the controller. If ANASOFT is used be sure the SYSTEM 32 control

is set for AUTO.

ON/OFF CONTROL

PB = Minimum PB

Reset = 7.5 R/M

Rate = 0 Min.

Gain = 510

Integral = 8 Sec.

Derivative = 0 Sec.

Output Filter = 4

PROPORTIONAL BAND ONLY (P)

PB = 5% of SP Example SP = 450 PB = 22

Reset = .12 R/M

Rate = 0

Output Filter = 4

Gain = 79 [J T/C]

Integral = 500 Sec.

Derivative = 0 Sec.

Output Filter = 4

PB with Reset

(PI)

PB = 10% of SP Example SP = 450 PB = 45

Reset = .5 R/M

Rate = 0

Gain = 39 [J T/C]

Integral = 120 Sec.

Derivative = 0 Sec.

Output Filter = 4

PB with Reset with Rate (PID)

PB = 15% of SP Example SP = 450 PB = 67

Reset = 1 R/M

Rate = 0.2/Min.

Output Filter = 4

Gain = 44 [K T/C]

Integral = 60 Sec.

Derivative = 12 Sec.

Output Filter = 4

WARNING: never set the reset above 3 R/M or integral below 20

seconds for proportional control as cycling will occur.

In controlling a process to a SP, process engineering must design the system

to allow the controller to be within it's control capability. In most processes,

the controller element is the fine control, while the process itself is the

course control. If all of the variables could be defined and precisely

controlled, when engineering a process, then a predetermined reset could be

used. When sizing control valves, electrical loads or whatever the final

element might be, the correct sizing will be one that allows the controller

output to be in the 40-60% of it's output when PV is stable at SP at mid-

range of the process control span. If the process elements are not correctly

sized then it will be difficult and even impossible to tune the controller.

8.2.2 TUNING PID LOOPS

1. First set PB to 2% of the desired SP, Reset to .2 R/M, Rate to 0, Filter to

0. Set control in AUTO. Set the plot function for the proper range to record

the PV over an appropriate time base such as one hour.

2. The SP is set to the desired control point. If overshoot cannot be

tolerated, set the SP to a value below the final SP for tuning. Most heat

processes are slow reacting compared to many other types of control

systems. Usually 20 minutes are required between adjustments to see any

effective change. After a suitable wait, look at the Plot Function. If cycling

is not occurring, the PB is set correctly. If cycling is occurring, double the

PB. After a suitable interval [normally at least 20 minutes] if cycling is still

occurring, double the PB again. Repeat this process until the cycling stops.

The time between cycling peaks will usually be about 5 to 15 minutes. A

small amount of cycling may be removed by using the digital output filter

allowing a narrow PB without cycling.

3. With the PB at the Setting from Step 2, increase the reset in steps of .3

R/M. Keep increasing the reset until, by watching the Plot Function,

cycling is occurring at a slow rate. The time period between peaks will

probably be 20-40 minutes. Reduce the reset in .1 R/M steps until the

cycling stops. Remember to take the time between adjustments to allow the

process to settle out.

4. With the PB and RESET set according to Step #2 and #3, move the SP

upscale from the present SP by at least 20%. If the present SP is 450, the

new SP should be at least 540. If this cannot be done due to process

considerations, then allow the process to cool off. No matter the method, a

step change in SP is required. A ramp of the PV is needed to check the

overshoot of the PV, in order to adjust the RATE. Starting the system up in

the morning may be the only way to get a ramp of the PV. After seeing the

overshoot on the Plot Function, turn on RATE to a small number such as

.08, for a small overshoot and a larger number like .2, for a larger

overshoot. Keep increasing the number until there is no overshoot. If, the

RATE gets too large, the PV will undershoot. If undershooting occurs,

reduce the RATE setting in small steps until it is eliminated. This is the

RATE setting when little or no over or undershooting occurs.

The above steps may be time consuming, especially at first. With

experience the tuning process can be quick and straight forward.

Many processes have been controlled with the following values:

PB=40 RESET=.4 R/M [150 SEC.] RATE=0 [OFF] FILTER=4

8.2.3 OUTPUT FILTER

There is no tuning step for the Output Filter. Adjusting the PID without the

Filter gives the most accurate response of the control function of the PID

modes. The Output Filter may be turn on anytime so desired. The number is

increased as necessary to reduce cycling of the control output signal, thus

reducing the cycling of the PV. Some typical settings of the Output Filter is

2, 4, 8, 12, and 15. Use of the Output Filter is not reflected in the PV except

to make the PV more stable, the value of the PV is the actual response time

of the Primary Element and it's value.

8.3 ANALOGY OF PID CONTROL TERMINOLOGY

The terminology of PID may be confusing to technical, as well as non-technical

individuals, who have a need to have some understanding of PID control, due to

work requirements. The comparing of an unknown to the known has been a relative

easy way to explain a difficult subject for many years. The following analogy has

been used for many years and very successfully. The PID terms have been equated

to that of driving a car.

The little ole lady from Pasadena, the grandmother type, was out for a Sunday

drive. As she was waiting at a stop light for the light to turn green, a young man

who shall remain nameless, pulled up along side her. This young man had just

received his driver's license and had Daddy's car out for the first time by himself.

Pumping the gas pedal, he was gunning the engine and looking over at the little ole

lady. Needless to say, that when the light turn green, he stepped on the gas hard.

With burning tires, he squealed away, leaving the little ole lady behind. She in her

turn, gradually stepped on the gas, gently bringing the car up to the speed of 30

mph. The young man in the meantime had reached the next stop light and it was

red. He slammed on the brakes and came to a very quick stop.

While, waiting for the light to turn green, the young man was gunning the engine

and watching in his mirror, as the little ole lady gradually came up behind him. As

she approached the light, it turned green. She went through the light without

needing to change the car speed, while the young man once again, stepped on the

gas hard. They continued to repeat the same action over and over again. She

proportioned her speed to reach each light as it turned green, while the young man

was cycling between stepping on the gas or the brake. His gain was too high, as he

reacted too fast to changing conditions. This caused cycling of his car speed to a on-

off state, not to say anything about his Dad state, if he had known. The little ole

lady had proportional control over her car speed by reacting gradually to changing

conditions. This is known as the PROPORTIONAL FUNCTION.

Now, the little ole lady with proportional control was trying very hard to maintain

the 30 mph. This was the speed that the traffic lights were set for, thus allowing the

smooth flow of traffic. As she approached a fairly steep hill, her speed started to fall

off. Her initial response was a proportional push on the gas pedal. This was not

enough to hold the speed to the 30 mph and the speed was very slowly decreasing

from the 30 mph she wanted. She very gently increased the pressure on the gas

pedal, raising the speed back up to 30 mph. As she started to go down the hill, the

car speed started to slowly increase. She slowly backed off the pressure to the gas

pedal, trying to maintain the 30 mph. This is known as reset, as she was resetting

the engine speed to maintain 30 mph with changing load conditions. This is the

RESET FUNCTION.

The little ole lady now was very close to home and had turned off the highway she

was on. A couple of blocks in front of her, she could see the traffic light was green.

As she was watching, the light turned yellow and then went to red. Upon seeing the

light turn yellow, she took her foot off the gas pedal, because she had anticipated

that she was going to stop, as the light was soon to be red. Now, the rate of

approaching the light was too fast and she knew that she would coast into the

intersection, if she did not step on the brake. By gently stepping on the brake, she

could control the rate of approach of the car to the white line. If, upon stepping on

the brake too lightly, she could overshoot the white line and go into the intersection.

Then, by stepping on the brake too hard, she could undershoot, stopping way back

of the white line and then would need to creep up to the white line. By applying the

proper amount of braking, she was able to stop the car at the white line with no over

or undershooting. This is known as the RATE FUNCTION.

With the OUTPUT FILTER of the Anafaze System, a new function had to be added

to the analogy.

Remember the young man from the proportional section that had way too much

gain? It seems that Daddy did find out and started to look for ways to curb the

young man's appetite for rash action without cutting off his foot or waiting until he

was 40 years old. Daddy's car is an 8 cylinder engine with a 4 barrel carburetor

which reacted very fast to the young man's demand. Daddy acquired a 6 cylinder for

his son to drive and decided after a couple of tickets for squealing tires, to replace it

with a 4 cylinder.

The 8 cylinder is equivalent to no filter action, while the 6 cylinder is equivalent to

a low filter number. The 4 cylinder would be a high filter number. A single

cylinder engine would be equivalent to a very high filter number. By having a high

gain due to youth and a low horsepower due to engine size, a fast response would

not allow squealing of the tires. A response may be made, but not fast enough to

hurt anything. Thus, a high filter setting would reduce high reactions to changing

conditions. This is the OUTPUT FILTER FUNCTION.

9.0 SOFTWARE

ANAFAZE offers turn key software for IBM PC and compatible computers. The

present software includes:

ANASOFT-32 Measurement and Control

ANASOFT-32-RS Measurement and Control with Ramp and Soak

ANASOFT-32-CP Measurement and Control with Carbon Potential

9.1 ANASOFT-32

ANASOFT-32 is a menu driven program that operates up to 3 ANAFAZE

SYSTEM 32 units using an IBM PC or compatible computer. It provides a

summary screen with color graphic displays of system operating conditions. A

detailed, password protected, tuning screen allows entering of all control

parameters, names for control loops, engineering unit and calibration factors, and

other loop data. The program provides automatic data storage on diskette in

LOTUS compatible files and automatic printout at user selected intervals. It is

written in MICROSOFT QUICK BASIC and the source listings can be purchased

so it can be modified by users.

9.1.1 ANASOFT-32-RS: RAMP AND SOAK

For ramp and soak, ANAFAZE offers ANASOFT-32-RS, a software

package that includes the capability for multiple ramp and soak recipes.

ANASOFT-32-RS is a complete package that features convenient profile

entry, graphic displays, warnings and alarms. Some of the features are:

Independent Ramp and Soak: Any loop in the system can be

defined with a fully independent ramp and soak recipe. These

recipes can be started, stopped, or put on hold independently as

required.

16 Segment Recipes: Each profile can have up to 16 segments of

ramp and soak and can be set for unlimited repeats.

Easy Setup: Ramp and Soak recipes are entered through a profile

menu that includes a simple, fill in the blanks table of time verses

setpoint.

Recipe Storage: Once a recipe is entered it can be given a name or

number and stored on disk. The same recipe can then be for any

loop. Up to 100 different recipes can be stored on disk at one time.

Profile Storage: ANASOFT provides for up to 20 profiles or

control tasks to be stored on disk for the system. Each profile is a

completely independent set of all system parameters. These

parameters include setpoints, ramp and soak recipes, alarms

warnings, input types, scaling and all other selected data. The

desired profile can be selected from the initial system menu. When

the profile is selected the stored ramp and soak recipe for each loop

is automatically setup.

Accurate Recipe Tracking: The ramp and soak software provides special

alarms and warnings in addition to the standard features of ANASOFT.

Tolerance levels are used for guaranteed soak, process warnings, and

process alarms.

Guaranteed Soak: An independent tolerance band can be entered

for each recipe segment. If the temperature is not within this

tolerance band, the soak time is stopped and remains stopped until

the temperature is within the band.

Alarms: A guaranteed soak time alarm can also be entered for each

recipe. If the temperature is out of tolerance for longer than this

entered time an alarm will occur.

Data Storage: Process data can be stored in LOTUS compatible

files to analyze process performance.

9.1.2 ANASOFT-32-CP: CARBON POTENTIAL MEASUREMENT

AND CONTROL

The Anafaze 32 System may be used for heat treating applications to

measure and control Carbon Potential. A Carbon Potential Input Module is

added to the SYSTEM 32 to allow the connection of most carbon potential

probes. The SYSTEM 32 software is expanded to provide the carbon

potential measurement and control. ANASOFT-32-CP software is also

available for IBM PC and compatible computers.

The Carbon Potential Input Module allows up to four inputs from carbon

probes. The outputs may be dual time proportioning outputs for solenoid

valve control or analog proportioning for motor positioning control.

The software provides for direct reading of the carbon potential of .15 to 1.4

%. The controller output for adding carburizing gas will be off, when the

temperature is below the setpoint of the temperature probe. This will be

adjustable from the tune menu of ANASOFT-32-CP.

The ANASOFT-32-CP software will allow ramp soak programs of the

carbon and temperature setpoints for customer customized furnace profiles.

The standard ANASOFT-32-CP will hold up to 100 furnace profiles and

each profile may have up to 16 segments. The standard use of setpoints may

be used without the use of the ramp soak programs.

9.2 CUSTOM APPLICATION PROGRAMS

ANAFAZE maintains a staff of engineers that can provide assistance in generating

software for custom applications. In addition ANAFAZE will design and

implement your entire turn key hardware and software system. Please contact your

local representative or ANAFAZE directly for a quotation.

10.0 SOFTWARE COMMAND STRUCTURE

The SYSTEM 32 will respond to commands according to the following format.

The commands generally follow the specifications of ANSI X3.28-1976. The

structure is outlined below:

10.1. Commands from Allen Bradley Programmable Controllers (CMD)

The A32PID will respond only to Unprotected Block Read (CMD01) and

Unprotected Block Write (CMD 08) commands from the Allen Bradley PLC. Any

other command numbers received will return an error status code.

10.2. Error Checking (BCC / CRC)

Controller bit Switch 7 will select the method of error checking to be used. CRC is

recommended for highest data integrity, BCC can be used when higher speed is

necessary.

Switch Setting

Error Check

BCC

CRC

10.3. Protocol

Controller protocol is set for full duplex. Switch 8 is not used at this time.

10.4. Status Codes

Four Error Code numbers will be returned in the Status (STS) byte to denote the

following error conditions :

Error Code (Hex)

----------------

Status/Error Condition

----------------------

Processor Reset

Command Error

Data Boundary Error

[ Spare ]

10.4.1 Processor Reset

This Error Code is returned after :

ƒ Power-up reset

ƒ The watchdog timer resets the Master processor

ƒ The Master processor resets the Slave processor

10.4.2 Command Error

This Error Code is returned when the A32PID receives a command that is

not a Block Read or a Block Write.

10.4.3 Data Boundary Error

This Error Code is returned when:

ƒ A Read command attempts to read beyond the 32 byte boundary of

byte-size variables

ƒ A Read command attempts to read beyond the 64 byte boundary of

word-size variables

ƒ A Read command is received that specifies the number of bytes to read

as 0

ƒ AWritecommand attempts to write beyondthe32 byte boundary of

byte-size variables

ƒ A Write command attempts to write beyond the 64 byte boundary of

word-size variables

10.5. Data Table Addresses

Addresses

Variable

Prop. Gain

Rate

Reset

Number Size

32 Byte

32 Word

08 Byte

01 Byte

08 Byte

33 Byte

--- -----

64 Byte

Hex Byte Range Octal Word Range

0100 - 011F

0120 - 013F

0140 - 015F

0160 - 017F

0180 - 019F

01A0 - 01BF

01C0 - 01DF

01E0 - 01FF

0200 - 021F

0220 - 025F

0260 - 029F

02A0 - 02A7

02A8

200 - 217

220 - 237

240 - 257

260 - 277

300 - 317

320 - 337

340 - 357

360 - 377

400 - 417

420 - 457

460 - 517

520 - 523

524

Input Type

Output Value

Output Type

Output Filter

Cycle Time

Alarm Deviation

Setpoint

Measured Value

Ambients

Digital I/O's

Alarm Status

Heater Check

EEROM Save

DACQ Input Type

DACQ Meas. Val.

02B0 - 02B7

02BC

530 - 533

536

02BE

537

02C0 - 02FF

0300 - 037F

540 - 577

600 - 677

64 Word

10.6. Input Types

The following one byte codes designate the various input types accepted by the

SYSTEM 32:

Code

------------

Input Type

---------------

Linear (0-60 mV)

J Thermocouple

K Thermocouple

T Thermocouple

[ Spare ]

RTD

Frequency (Pulse Counter)

10.7. Output Types

Output type codes are one byte hexadecimal designations formed by setting the

individual bits, as explained below, to their proper state.

___7______6______5______4______3______2______1______0____

|Cntrl | On |

|Action| / |

|Auto |Digitl| DZC |

| / | / | / |

|Manual|Analog| TP |

| Off |

|______|______|______|______|______|______|______|______|

| 0 = Distributed

| Zero Crossing

| (DZC)

| 1 = Cycle Time

| Proportioned

0 = Digital Output

1 = Analog Output

0 = PID Control ON

1 = PID Control OFF

0 = ON/OFF Control Disabled

1 = ON/OFF Control Enabled

0 = Reverse Acting Output

1 = Direct Acting Output

The following examples show the output code for specific output types:

Output Configuration............................................................................ Hex Code

DZC Digital Output, Automatic control ............................................................... 00

Time Proportioned Digital Output, Automatic control ......................................... 01

Analog output, Automatic control......................................................................... 02

DZC Digital Output, Manual Control ................................................................... 04

Time Proportioned Digital Output, Manual control.............................................. 05

Analog output, Manual control ............................................................................. 06

ON/OFF Digital Output, Automatic control ......................................................... 40

ON/OFF Digital Output, Manual control.............................................................. 44

DZC Output, Automatic Control, Inverted Output ............................................... 80

Time Proportioned Output, Automatic Control, Inverted Output......................... 81

Analog Output, Automatic Control, Inverted Output............................................ 82

DZC Output, Manual Control, Inverted Output.................................................... 84

Time Proportioned Output, Manual Control, Inverted Output.............................. 85

Analog Output, Manual Control, Inverted Output ................................................ 86

ON/OFF Output, Automatic Control, Inverted Output .........................................C0

ON/OFF Output, Manual Control, Inverted Output..............................................C4

11.0 TROUBLE SHOOTING INFORMATION

These four items must work together to operate the SYSTEM 32:

The SYSTEM 32

The computer including the RS-232 or other serial interface

The communications link

The computer software

If the system does not work on initial start up check the SYSTEM 32 indicator

lights, the computer, and the serial link.

11.1 Computer Problems

The computer can be checked by running standard programs that use the display

and the printer. The serial interface must be functioning. This is harder to test

since most programs do not utilize the serial interface. Check any computer

problems with the computer supplier.

11.2 Computer Software

This can be divided into: ANASOFT-32 and user written software:

11.2.1 User Written Software

For user written software a simple routine that sends and receives a

command from the SYSTEM 32 should be written and tested initially. The

ideal routine sends and receives commands displaying both sets on the

computer monitor. Since the protocol includes all characters, the display

should show the hex numbers of the characters sent in both directions.

Once successful communications is established, this program can be used as

a check if problems arise in the operating software.

11.2.1 ANASOFT-32

ANASOFT-32 is a complete menu driven software program which includes

error detection and diagnostic messages. If ANASOFT-32 will not run at all

please see the ANASOFT-32 manual for detailed information. The

following can be checked:

1. Correct path for files -- run QINSTALL and check the disk drive and

path for the data files.

2. All files present -- check that all necessary files are present and on the

specified directory.

3 Sufficient memory free -- ANAFAZE-32 requires 512K memory free to

run. You can use the DOS command CHKDSK to view the free

memory. If there is insufficient memory check step 4.

3. Delete any memory resident programs -- check the AUTOEXEC.BAT to

insure no memory resident programs are automatically run on start-up.

Some memory resident programs may interfere with ANASOFT-32.

If ANASOFT-32 runs then the next step is to establish communications

with the SYSTEM 32. When ANASOFT-32 is started the program asks for

the Edit or Run mode. Select the Run mode. If the SYSTEM 32 does not

answer, a communications error message will appear on the display [see

11.3 and 11.4].

11.3 Communications Problems

If the computer is functioning properly [section 11.1] then the communication

interface, cables and connections must be checked. A number of problems have

been traced to bad cables or connections.

11.3.1 Serial Interface

The serial interface must be correctly installed in the computer and set

according to the manufacturers directions. ANASOFT-32 communicates

using Comm Port 1. Some multi-function interface cards allow setting of

the comm port -- this should be done correctly. In addition be careful that

only one communications channel is set as comm port 1.

When the communications interface is correctly installed a scope can be

used to check the transmit line to insure characters are being sent to the

SYSTEM 32.

If a scope is not available, a test program [contact ANAFAZE] can be used

that will display sent and received characters. The transmit line and the

receive line can be disconnected from the SYSTEM 32 and connected

together at the SYSTEM 32. The program can be run and characters typed

on the keyboard will be sent to the SYSTEM 32 and returned to the

computer directly on the communication line. If these characters are

displayed on the monitor, the communication card, and the wiring can be

assumed correct. Carefully re-connect the SYSTEM 32 and go to section

11.4.

11.4 SYSTEM 32 Problems

A preliminary check of the SYSTEM 32 can be accomplished using the indicator

lights on the Processor [A32-PIOM PROCESSOR I/O MODULE]. The lights

function as follows:

11.4.1 Processor: Ready Light -- Green, Communications -- Orange

The Green Processor Ready light is the most important SYSTEM 32

indicator. If the green light is not on, the PIOM is not running and the

SYSTEM 32 cannot operate.

If no other indicator lights are on, the power supply probably is not working.

If the orange light is on, or is flashing, but the green light is not on, then the

power supply is at least putting out a voltage.

But if the green light is not on, don't worry about what the computer is

doing, or about communication problems. If the green light is not on,

nothing will work.

If the green light is on, then the orange light light is a communications

indicator. The orange light will appear whenever the PIOM has decoded a

communication containing the address of the PIOM as set in the DIP switch.

Thus the conditions for establishing the orange light in the presence of the

green light are:

1) PIOM working.

2) Host and PIOM set at the same BAUD rate.

3) PIOM address switches set correctly.

4) Host sending out proper communication containing correct

address.

No other conditions are guaranteed to exist. For instance, this does not

guarantee proper communication error checking protocols.

If the green light and orange light are both on, first check error protocol as

set by the DIP switch and by Anasoft, then check the communication

wiring. If the green light comes on but the orange light does not, then check

the above in addition to checking the PIOM address switch and the BAUD

rate.

11.4.2 Process Ready Light is Off

If on applying power to the controller, the GREEN READY light

illuminated on the processor board mounting panel:

is not

Use a voltmeter to measure the 5 VDC supply to the controller backplane to

make sure that the voltage measures between 4.9 and 5.3 volts D.C. A low

voltage detect circuit on the processor board will prevent operation if the

supply voltage drops below 4.75 volts D.C. (+/- .1 volt).

If there is non power or a low supply check the AC input power, and the

power supply output at the power supply terminals.

If power is present at the proper voltage contact ANAFAZE as the probable

cause is PROCESSOR I/O MODULE problem.

11.4.3 Orange Communication Light Remains Off

Normally this will also cause a COMMUNICATION ERROR message

when running Anasoft. If this occurs and the Green Light is on:

Verify that the communications options specified in the Anasoft Installation

program (QINSTALL) match those specified by the option bit switch

settings on the processor board. These options include the baud rate and the

method of error checking to be used.

Verify that the controller address bit switch settings on the processor board

are correct. If you have only one controller in your communications circuit

it's address should be 0 (all address bit switches off).

Verify that you are using the COM 1 serial port on your computer. Anasoft

assumes this to be the active communications port.

Verify the wiring connections between your computer and the Anafaze

controller. For RS-232, only three wires are (Rx, Tx and Gnd) are necessary

to communicate with the controller.

Check the hardware communications option that was specified when you

ordered your controller. If your processor module was modified for current-

loop operation, it will not interface with a RS-232 circuit directly.

If all these items are checked and OK, contact ANAFAZE, the

PROCESSOR I/O MODULE probably has a problem.

11.4.5 No Control Outputs from PIOM

The Anasoft operating program displays proper output values for each loop

but the controller outputs remain off (0%).

Verify that the OUTPUTS ON input on the processor module is enabled. A

low level (0 volts) signal is necessary at this terminal to enable operation of

controller outputs. This connection is made at TB2, pin 35. NOTE: This

may be accomplished by connecting a jumper on TB2, between pin 32

(GND) and TB2, pin 35.

Chech the action of the communications watchdog timer. This may be

enabled and will set all control outputs to manual with zero output if

communications is not maintained by the host computer. Please see section

3.3.2 for details.

11.4.6 Measured Data Errors

If the input data does not appear to be correct or remains constant, check the

indicator lights on the analog input boards (RRAIM or SSAIM). The green

light indicates that the isolated supply is working properly, and a flashing

orange light indicates that the input module is scanning.

If the green light is not on and the PIOM has passed all the previous

conditions, then the most likely fault is in the input module. If the green

light is on and the orange light is not flashing, then the problem is probably

in the PIOM but could be in the input module. If the green light is on and

the orange light is flashing, then the problem is probably the input module,

the system wiring, or the transducers.

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