WATLOWCAS200 User’s GuideSystem Overview

This manual describes how to install, setup, and operate a 

CAS200. Included are six chapters and a glossary of terms. 

Each chapter covers a different aspect of the alarm scanner 

and may apply to different users. The following describes 

the chapters and their purpose.

• Chapter 1: System Overview provides a component 

list and summary of features for the CAS200 series 

alarm scanners.

• Chapter 2: Installation provides detailed 

instructions on installing the CAS200 and its 

peripherals.

• Chapter 3: Using the CAS200 provides an overview 

of operator displays used for system monitoring and 

job selection.

• Chapter 4: Setup provides detailed descriptions of all 

menus and parameters for scanner setup.

• Chapter 5: Troubleshooting and 

Reconfiguration provides some basic guidelines for 

solving operational problems and provides procedures 

for changing some of the hardware options (e.g. 

installing special input resistors and changing EIA/

TIA-232 to EIA/TIA-485).

• Chapter 6: Linear Scaling Examples provides 

three examples where linear scaling is used.

• Chapter 7: Specifications lists detailed 

specifications of the scanner and optional components.

Product Features

The CAS200 is a modular monitoring system with 16 

analog inputs. It can function as a stand-alone system; the 

CAS200 1/8 DIN front panel has a Vacuum Fluorescent 

Display (VFD) and touch keypad for local display and local 

parameter entry. You can also use it as the key element in 

a computer supervised data acquisition system; the 

CAS200 can be locally or remotely controlled via an EIA/

TIA-232 or EIA/TIA-485 serial communications interface.

Features include:

Direct Connection of Mixed Thermocouple Sensors:

Connect most thermocouples to the scanner with no 

hardware modifications. Thermocouple inputs feature 

reference junction compensation, linearization, process 

variable offset calibration to correct for sensor 

inaccuracies, detection of broken, shorted or reversed 

thermocouples, and a choice of Fahrenheit or Celsius 

display.

Automatic Scaling for Linear Analog Inputs: The 

CAS200 series automatically scales linear inputs used with 

industrial process sensors. Enter two points and all input 

values are automatically scaled in your units. Scaling 

resistors must be installed.

Flexible Alarm Outputs: Independently set high/low 

process alarms and a high/low deviation band alarm for 

each channel. Alarms can activate a digital output by 

themselves, or they can be grouped with other alarms to 

activate an output. 

Alarm Outputs: You can set high/low deviation and high/

low process alarm setpoints to operate digital outputs as 

latched or unlatched functions. 

Global Alarm Output: When any alarm is triggered, the 

global alarm output is also triggered, and it stays on until 

you acknowledge it.

CPU Watchdog: The CAS200 series CPU watchdog timer 

output notifies you of system failure. Use it to hold a relay 

closed while the system is running, so you are notified if the 

microprocessor shuts down.

Front Panel or Computer Operation: Set up and run 

the scanner from the front panel or from a local or remote 

computer. Watlow Anafaze offers WatView, a Windows® 

compatible Human Machine Interface (HMI) software 

package that includes data logging and graphing features 

in addition to process monitoring and parameter setup 

screens.

Multiple Job Storage: Store up to eight jobs in protected 

memory, and access them locally by entering a single job 

number or remotely via digital inputs. Each job is a set of 

alarm conditions.

Pulse Counter Input: Use the pulse counter input for 

precise monitoring of motor or belt speed.

 System Diagram

The illustration below shows how the parts of the CAS200 

are connected. When unpacking your system, use the 

diagram and parts list below to ensure all parts have been 

shipped. Please don't hesitate to call Watlow Anafaze if you 

have problems with your shipment, or if any CAS200 

components are missing or damaged. 

Figure 1.1 System Components

• CAS200 Scanner

• Mounting Kit

• TB50 Terminal Board

• 50-Pin SCSI Cable

• DC Power Supply

Mounting Scanner Components

Install the scanner in a location free from excessive heat 

(>50°C), dust, and unauthorized handling. 

Electromagnetic and radio frequency interference can 

induce noise on sensor wiring. Select locations for the CAS 

200 and TB50 such that wiring can be routed clear of 

sources of interference such as high voltage wires, power 

switching devices and motors.

∫

WARNING! To reduce the risk of fire or electric shock, install 

CAS200 in a controlled environment, relatively 

free of contaminants.

 Safety

Watlow Anafaze has made efforts to ensure the reliability 

and safety of the CAS200 and to recommend safe uses in 

systems applications. Note that in any application failures 

can occur. 

Good engineering practices, electrical codes, and insurance 

regulations require that you use independent external 

safety devices to prevent potentially dangerous or unsafe 

conditions. Assume that the CAS200 can fail or that other 

unexpected conditions can occur.

Install high or low temperature protection in systems 

where an overtemperature or undertemperature fault 

condition could present a fire hazard or other hazard. 

Failure to install temperature control protection where a 

potential hazard exists could result in damage to 

equipment and property, and injury to personnel.

For additional process safety, program a computer or other 

host device to automatically reload your desired operating 

parameters after a power failure. However, this safety 

feature does not eliminate the need for other external, 

independent safety devices in dangerous conditions.

The CAS200 should never be used as a safety 

shutdown device. It should only be used with 

other approved independent safety shutdown 

devices.

Contact Watlow Anafaze immediately if you have any 

questions about system safety or system operation.

This chapter describes how to install the CAS200 series 

scanner and its peripherals. Installation of the scanner 

involves the following procedures:

• Determining the best location for the scanner

• Mounting the scanner and TB50

• Power Connection

• Input Wiring

• Communications Wiring (EIA/TIA-232 or EIA/TIA485)

• Output Wiring

Typical Installation

The illustrations below show typical installations of the 

scanner with the TB50 terminal block. Observe the 

illustration below to determine potential space 

requirements.

We recommend that you read this entire chapter first 

before beginning the installation procedure. This will help 

you to carefully plan and assess the installation. 

Figure 2.1 System Components

Safety

∫

WARNING! Ensure that power has been shut off to your entire 

process before you begin installation of the 

scanner

Watlow Anafaze has made every effort to ensure the 

reliability and safety of this product. In addition, we have 

provided recommendations that will allow you to safely 

install and maintain this scanner. 

∫

WARNING! In any application, failures can occur. These 

failures can result in full control output (100% 

power), or the occurrence of other output failures 

which can cause damage to the scanner, or to the 

equipment or process connected to the scanner. 

Therefore, always follow good engineering 

practices, electrical codes, and insurance 

regulations when installing and operating this 

equipment. 

 External Safety Devices

External safety devices should be used to prevent 

potentially dangerous and unsafe conditions upon 

equipment failure. Always assume that this device can fail 

with outputs full-On, or full-Off, by the occurrence of an 

unexpected external condition.

∫

WARNING! Always install high or low temperature protection 

in installations where an overtemperature or 

undertemperature fault will present a potential 

hazard. Failure to install external protection 

devices where hazards exist can result in damage 

to equipment, property, or human life.

Mounting 

We recommend you mount the scanner in a panel not more 

than 0.2 inches thick. 

∫

WARNING! To reduce the risk of fire or electric shock, install 

the CAS200 in a controlled environment, 

relatively free of contaminants.

 Location

Install the scanner in a location free from excessive (>50°C) 

heat, dust, and unauthorized handling. 

Ensure there is enough clearance for mounting brackets, 

terminal blocks, and cable and wire connections; the 

scanner extends 7.0 in. behind the panel face and the screw 

brackets extend 0.5 in. above and below it. Allow an 

additional 1 to 3 inches for the SCSI cable.

Figure 2.2 Clearance Recommendations

Other Tools: 

You will also need these tools:

• Phillips head screwdriver

• Flathead screwdriver for wiring

• Multimeter

 Mounting the Scanner

Mount the scanner before you mount the TB50 or do any 

wiring. The scanner's placement affects placement and 

wiring considerations for the other components of your 

system.

You receive one of two types of mounting brackets with 

your scanner, the mini-bracket or the collar bracket. Refer 

to the corresponding sections below for instructions.

 Steps Using the Mini-Bracket

1. Cut a hole in the panel to the dimensions shown in the 

illustration below. To do this, use a punch, nibbler, or 

jigsaw, and file the edges of the hole.

2. Insert the scanner into the hole through the front of 

the panel.

3. Screw the top and bottom clips in place: insert the 

clip’s lip into the cutout in the scanner’s metal housing 

just behind the front panel. Tighten the screws. 

4. If you expect much panel vibration, use a rear support 

for the scanner and its interconnecting cables.

Figure 2.3 Mounting with the Mini-Bracket

Steps Using the Collar Bracket

Installing and mounting requires access to the back of the 

panel. 

NOTE! Removing the scanner chassis from its case

makes mounting easier.

1. Make a panel cutout. Refer to Figure 2.3 on page 11 for 

dimensions of the cutout.

2. Slide the scanner into the panel cutout. 

3. Slide the mounting collar over the back of the scanner, 

making sure the mounting screw indentations face 

toward the back of the scanner.

4. Loosen the mounting bracket screws enough to allow 

for the mounting collar and panel thickness. Place 

each mounting bracket into the mounting slots (head 

of the screw facing the back of the scanner). Push each 

bracket backward then to the side to secure it to the 

scanner case. 

5. Make sure the case is seated properly. Tighten the 

installation screws firmly against the mounting collar 

to secure the unit. Ensure that the end of the mounting screws fit into the indentations on the mounting 

collar.

Figure 2.4 Mounting with the Collar Bracket

Mounting the TB50

There are two ways you can mount the TB50, by using the 

pre-installed DIN rail mounting brackets provided or by 

using the plastic standoffs. Follow the procedures for each 

to mount the board.