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Chapter 7: Troubleshooting and Reconfiguring Series D8 User’s Guide
158 Watlow Anafaze Doc. 0600-3120-2000
CAUTION! Before trying to troubleshoot a problem by
replacing your controller with another one,
first check the installation. If you have short-
ed sensor inputs to high voltage lines or a
transformer is shorted out, and you replace
the controller, you will risk damage to the
new controller.
If you are certain the installation is correct, you can try replac-
ing the controller. If the second unit works correctly, then the
problem is specific to the controller you replaced.
Returning a Unit
Before returning a controller, contact your supplier or call
Watlow (see page 1) for technical support.
Controllers purchased as part of a piece of equipment must be
serviced or returned through the equipment manufacturer.
Equipment manufacturers and authorized distributors should
call customer service at Watlow to obtain a return materials
authorization (RMA) number. Shipments without an RMA
will not be accepted. Other users should contact their suppli-
ers for instructions on returning products for repair.
Troubleshooting the Controller
A problem may be indicated by one or more of several types
of symptoms:
• A process alarm
• A failed sensor alarm
• A system alarm
• Unexpected or undesired behavior
The following sections list symptoms in each of these catego-
ries and suggest possible causes and corrective actions.
- Series D8 1
- User’s Guide 1
- Warranty 2
- Table of Contents 3
- 4 Operation and Setup 77 5
- 5 Tuning and Control 111 6
- 8 Specifications 179 8
- Glossary 197 9
- Index 205 9
- Menu Structure 213 9
- List of Figures 11
- List of Tables 15
- 8 Specifications 17
- System Overview 19
- Getting Started 20
- Product Features 20
- D8 Parts List 23
- D8x0-0000-xx0x 23
- Technical Description 24
- D8SI _ _ - _ _ - _ _ 24
- Front Panel Description 25
- Figure 1.4 D8 Front Panel 25
- D8 Cabling 26
- External Safety Devices 26
- Power-Fail Protection 27
- Installation 29
- Typical Installation 30
- Recommended Tools 31
- Mounting the Controller 31
- Figure 2.3 Wiring Clearances 32
- Figure 2.4 Mounting Bracket 33
- Mounting the TB50 34
- Mounting with Standoffs 35
- Mounting the Power Supply 36
- Mounting 37
- Dimensions 37
- System Wiring 38
- Noise Suppression 39
- Ground Loops 40
- Power Connections 41
- Table 2.2 Power Connections 42
- Connecting the TB50 to the D8 43
- Testing the System 44
- Sensor Wiring 45
- Input Wiring Recommendations 46
- Thermocouple Connections 47
- RTD Input Connections 48
- Voltage Input Connections 48
- Current Input Connections 48
- Output Wiring Recommendations 49
- Cable Tie Wraps 49
- Digital Outputs 49
- Stored in the Controller 50
- Configuring Outputs 51
- Output Connections 51
- External Power Supply 52
- CPU Watchdog Timer 52
- TB18 Connections 54
- TB50 Connections 55
- Wiring the Serial DAC 57
- Connector Type 58
- Figure 2.28 Pinout 59
- Table 2.8 DeviceNet Connector 59
- Network Length 60
- Baud Rate (Data Rate) 60
- Node Address (MAC ID) 60
- Status Indicators 61
- Indicator Light Description 62
- Communicating by DeviceNet 63
- Found Devices 65
- Table 3.1 Number of Bytes 66
- Mapping Polled I/O Data 68
- Assigning PLC Addresses 69
- Sample Ladder Logic 71
- Size of the message 75
- Non-Numeric Settings 76
- Bit-Wise Values 77
- D8 DeviceNet Overview 78
- DeviceNet Objects 79
- Message Router Object 80
- DeviceNet Object 81
- Assembly Object 81
- Poll Connection 82
- Connection Object 84
- Input Object 85
- Output Object 86
- (Instances 1 to 4 or 8) 87
- Control Object 88
- Alarm Object 89
- PV Retransmit Object 90
- Ratio Object 91
- Cascade Object 92
- Global Object 93
- (Instance 1) 94
- Operation and Setup 95
- Figure 4.2 Keypad Navigation 97
- Displays 98
- Alarm Displays 99
- How to Acknowledge an Alarm 100
- System Alarm Messages 100
- Job Display 101
- Changing the Set Point 102
- How to Access the Setup Menus 104
- How to Edit a Setup Parameter 104
- Control Algorithm 105
- Control Output Signal Forms 105
- Heat and Cool Outputs 105
- Feedback 105
- Setting Up a Process Input 106
- Figure 4.6 Input Scaling 107
- Situation 107
- Table 4.4 Input Readings 108
- Table 4.5 Scaling Values 108
- Autotuning 109
- Prerequisites 110
- How to Autotune a Loop 110
- Setting Up Alarms 111
- Thermocouple Open Alarm 112
- Thermocouple Reversed Alarm 112
- Thermocouple Short Alarm 112
- RTD Open and RTD Fail Alarms 112
- Process Alarms 113
- Alarm High and Alarm Low 114
- Deviation Alarms 114
- Global Alarm 115
- Variable Retransmit 117
- Variable Retransmit Example 117
- Setting Up Cascade Control 118
- Loop Has Heat Output Only 119
- How To Set Up Cascade Control 120
- Setting Up Ratio Control 122
- How to Set Up Ratio Control 123
- Loop (Loop 2) in the Example 124
- Loop (Loop 2) for the Example 125
- Loop (Loop 1) in the Example 126
- Tuning and Control 129
- On/Off Control 130
- Proportional Control (P) 130
- Proportional 131
- Proportional Band Settings 133
- Integral Settings 133
- Derivative Settings 134
- Proportional Band Only (P) 135
- Control Outputs 136
- Analog Outputs 137
- Output Filter 138
- Reverse and Direct Action 138
- Menu and Parameter Reference 139
- Set Point 140
- Heat/Cool Output 140
- Overview of the Setup Menus 141
- >< 142
- Global Setup Menu 143
- BCD Job Load 144
- BCD Job Load Logic 144
- Mode Override 145
- Power Up Alarm Delay 146
- Power Up Loop Mode 146
- Keypad Lock 147
- AC Line Frequency 147
- Digital Output Alarm Polarity 147
- Baud Rate 148
- Module LED 148
- Network LED 148
- Bus Off Count 148
- Input Menu 149
- Loop Name 150
- Input Units 150
- Calibration Offset 150
- Display Format 151
- Input Range High 152
- Input High Signal 152
- Input Range Low 153
- Input Low Signal 153
- Input Filter 153
- Control Menu 154
- Heat/Cool Integral 155
- Heat/Cool Derivative 155
- Heat/Cool Manual Reset 155
- Heat/Cool Filter 155
- Hysteresis 156
- Restore Automatic Mode 156
- Output Menu 157
- Heat/Cool Cycle Time 158
- Heat/Cool SDAC Signal 158
- Heat/Cool SDAC Low Signal 158
- Heat/Cool SDAC High Signal 158
- Heat/Cool Action 159
- Heat/Cool Power Limit 159
- Heat/Cool Power Limit Time 159
- Sensor Fail Heat/Cool Output 160
- Alarms Menu 161
- Alarm High Output 162
- Alarm High Function 162
- High Deviation Value 163
- High Deviation Function 163
- High Deviation Output 163
- Low Deviation Value 163
- Low Deviation Function 163
- Low Deviation Output 164
- Alarm Low Set Point 164
- Alarm Low Function 164
- Alarm Low Output 164
- Alarm Hysteresis 165
- Alarm Delay 165
- Heat/Cool Output Retransmit 166
- Cascade Menu 167
- Ratio Menu 168
- I/O Tests Menu 169
- Digital Inputs 170
- Keypad Test 170
- Display Test 170
- Test Digital Output 1 to 20 171
- Alarm Acknowledge 171
- Alarm Enable 171
- Alarm Function 172
- Alarm Status 172
- Ambient Sensor Reading 173
- Inactivity Fault 174
- When There is a Problem 175
- Returning a Unit 176
- Ambient Warning 178
- Failed Sensor Alarms 178
- System Alarms 178
- Other Behaviors 179
- Descriptions 180
- Low Power 181
- Battery Dead 181
- H/W Error: Gain or Offset 182
- H/W Error: Ambient 183
- Keys Do Not Work 184
- Checking Analog Inputs 184
- Earth Grounding 185
- Testing the TB18 and TB50 186
- Clearing the RAM 187
- Installing Scaling Resistors 190
- Current Inputs 191
- Voltage Inputs 192
- RTD Inputs 193
- SERIAL DAC 194
- Configuring Dual DAC Outputs 195
- Specifications 197
- 96 mm (3.78 in) 198
- Table 8.4 D8 Connections 199
- Figure 8.3 TB50 Dimensions 200
- Table 8.6 TB50 Connections 200
- SCSI Cable 201
- Table 8.9 Analog Inputs 203
- Resolution 204
- Table 8.13 Digital Inputs 205
- Power Supply 207
- Dual DAC Specifications 209
- Dual DAC Inputs 210
- Dual DAC Analog Outputs 210
- Serial DAC Specifications 211
- Serial DAC Inputs 212
- Serial DAC Analog Outputs 213
- Declaration of Conformity 214
- Glossary 215
- — A po wer switching 220
- 68, 132 223
- 83, 164 225
- Index Series D8 User’s Guide 230
- Menu Structure 231
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