HeatWave Labs, Inc.
HeatWave Labs
Model 101303-50
Temperature Controller
S/N 10262
User’s Manual
Important Safety Notice
Warning: This instrument operates from and delivers potentially
lethal voltages. Observe all precautions when using this
device, and particularly be sure that all devices connected
to the instrument are safely wired and properly grounded.
Always disconnect power to the instrument before
opening the enclosure or making any wiring changes.
Caution: Additionally, this device is intended to control heaters and
thermal systems, which may be hot and/or dangerous.
Beware that damage to heaters and other equipment,
possibly resulting in personal injury or death may result
from improper use or control of thermal systems.
Understand the safety implications of your system and
take proper precautions to avoid damage to property or
injury to personnel.
Where to Get More Information
This owner’s manual represents the most current information at the time it was published;
for the latest information, please visit our website: www.cathode.com.
We may also be reached in the following ways:
HeatWave Labs, Inc.
195 Aviation Way, Suite 100
Watsonville, CA 95076-2069
Warranty and Repair Information
Our products are warranted against defects in materials or workmanship according to our
Standard Product Warranty, TB-166.
Tel: 831-722-9081
Fax: 831-722-5491
Email: techsales@cathode.com
ii Important Safety Notice
Model 101303-50
Model 101303-50 Specifications
• Ramp and soak programmability
with storage for 2 profiles, with
up to 8 steps per profile
• Autotuning PID control; also
supports manual tuning and other
control modes, including alarm
mode
• Solid-state control utilizing an
oversized solid-state relay for
long-life and precise control
• Phase-angle fired SCR for use
with tungsten heating elements
• Over-temperature protection
utilizing a separately controlled
alarm setpoint and an independent
mechanical relay in series with the
solid state control relay
• Internal SCR is short-circuit
protected by a back-panel
accessible semiconductor fuse
(HWL p/n 101960-01, FWH020A6F)
• Over-current protection using a
front panel circuit breaker
• Open loop protection, shutting
down output if open loop
operation is detected (factory
preset with open loop off)
• Dual LED displays on control
module for simultaneous indication
of process temperature and setpoint
in Fahrenheit or Celsius (default)
• Input power: 100-130 VAC, 50/60
Hz. See Factory Configuration in
Appendix A
• Output power:
• See Factory Configuration in
Appendix A
• Display resolution: 1°
• Absolute accuracy: ±1°
• Heater connector: 3-pin screw
terminal, including ground conductor
• Type K thermocouple sensor input
• range: 0 to 1370°C
• ambient rejection: <0.1°C/°C
• connector: standard Type-K
• Enclosure: standard EIA 19” EIA
rackmount, 7.0” tall (5 rack units),
14” deep, 12 lbs.
• Ambient temperature range: 0 to
60°C, non-condensing
Watlow is a registered trademark of Watlow Electric Manufacturing Co.
iii Model 101303-50 Specifications Model 101303-50
Table of Contents
Important Safety Notice ........................................................................................ ii
Where to Get More Information............................................................................ ii
Warranty and Repair Information ......................................................................... ii
Model 101303-50 Specifications ......................................................................... iii
Overview................................................................................................................2
Control Module Displays and Menu Navigation ...................................................3
Limit Module Displays and Menu Navigation.......................................................3
Limit Module Displays and Menu Navigation.......................................................4
Getting Started .......................................................................................................4
Getting Started .......................................................................................................5
Programming and Executing Profiles ....................................................................9
Programming a Profile.......................................................................................9
Running a Profile.............................................................................................11
Resuming a Halted Profile...............................................................................11
Using the Wait-for Process Deviation Function..............................................11
Advanced Features and Settings ..........................................................................12
Setting the autotune point to a lower value......................................................12
Switching between Celsius and Fahrenheit .....................................................12
Changing the resolution (decimal point) .........................................................12
Power limiting .................................................................................................13
Other features...................................................................................................14
Error Messages and Troubleshooting...................................................................15
Error messages.................................................................................................15
Troubleshooting...............................................................................................15
Appendix A: Default Factory Configuration.......................................................17
Input voltage settings ...........................................Error! Bookmark not defined.
Output voltage settings .................................... Error! Bookmark not defined.
8V output with 120V input................................... Error! Bookmark not defined.
Appendix B: Model 101303-50 Electrical Schematic.........................................19
Appendix C: User Worksheet .............................................................................20
Model 101303-50
Overview
The HeatWave Labs Model 101303-50 is a full featured, high quality rackmount
temperature controller designed for low-voltage tungsten heater control applications
requiring precise, reliable control and ramp/soak programmability.
Over-temperature protection is provided by a completely independent limit
controller and sensor. The alarm will disable power to the heater if the alarm
setpoint is exceeded. Alarm switching is provided by an independent, internal
mechanical relay in series with the solid-state control relay. This alarm scheme
provides protection against system runaway if the solid-state relay should fail in the
closed position. In addition to over-temperature protection, the Model 101303-50
provides other mechanisms like open loop and open sensor detection to assist in
system protection. The phase-angle fired SCR is protected by a semiconductor fuse
that can be replaced via back-panel access.
2 Overview
Model 101303-50
4.
Not used.
Control Module Displays and Menu Navigation
The Watlow® Series 96 Controller with the ramping software option allows
programming of 2 temperature vs. time profiles (called “files) that can each have up
to eight distinct steps programmed into them. Upon power-up, the unit starts at the
“Home Page” and indicates the process temperature in the upper display and the
setpoint (or ) in the lower display. While not running a profile, the setpoint
can be directly adjusted with the up and down arrow keys. The setpoint is registered
about 2 seconds after the last pressing of either up or down arrow.
Management, programming, and execution of temperature vs. time profiles are
explained in the Programming and Executing Profiles section.
Upper Display:
Indicates process
temperature, or
parameter value
when in menus.
Lower Display:
Indicates process
setpoint, or
parameter name
when in menus.
Advance Key:
When at the home page, pressing this
key will open the programming menu.
If in other menus, this key selects the
menu choice in the upper display,
scrolls through menu selections, or
will scroll through parameter values in
the lower display.
LEDs 1 to 4:
1. Illuminated when heater output is active. For example, it will be
on continuously when the heater is at 100% power, and on half
the time when the heater is at 50% power.
2. Not used.
3. Illuminated when the over-temperature alarm has been activated.
Infinity/Home Key:
From the home page, pressing once opens
the Pre-run menu; pressing again starts
the profile and opens the Run menu.
If not at the home page, pressing this key
will exit the menu system and return to the
home page.
Profile Indicator:
Illuminated when controller
has been set to manual
mode, where Upper Display
indicates percent output.
Up and Down Keys:
Pressing up or down alone
changes the setpoint or
parameter value.
Pressing them
simultaneously for 3 seconds
accesses Operations Page.
If held for 3 more seconds,
accesses Setup Page. See
Watlow Series 96 User’s
Manual for full description of
Operations and Setup Pages.
Figure 1 Control module keys and displays
Watlow is a registered trademark of Watlow Electric Manufacturing Co.
3 Control Module Displays and Menu Navigation
Model 101303-50
Limit Module Displays and Menu Navigation
The Watlow® Series SD Limit Controller monitors the Limit sensor and will shut
down output power if the limit controller’s alarm setpoint is exceeded. Upon
power-up the limit sensor’s process temperature is indicated in the upper display.
The alarm setpoint is set by pressing the blue Advance key until “A1.hi” is
displayed in the lower (right) display. The value of the alarm setpoint should be
visible in the upper (left) display. Use the up and down arrows to adjust the alarm
setpoint value. The setpoint is registered about 2 seconds after the last pressing of
either up or down arrow. The limit has been factory preset. See Appendix A for
factory configuration.
Upper Display:
Indicates process
temperature, or
parameter value
when in menus.
Advance Key:
When at the home page, pressing this
key will open the programming menu.
If in other menus, this key selects the
menu choice in the upper display,
scrolls through menu selections, or
will scroll through parameter values in
the lower display.
LED 2:
Illuminated when the overtemperature alarm has been
activated.
Infinity/Home Key:
From the home page, pressing once opens
the Pre-run menu; pressing again starts
the profile and opens the Run menu.
If not at the home page, pressing this key
will exit the menu system and return to the
home page.
Lower Display:
Indicates process setpoint,
or parameter name when
in menus (not on during
normal operation).
Up and Down Keys:
Pressing up or down alone
changes the setpoint or
parameter value.
Pressing them
simultaneously for 3 seconds
accesses Setup Page.
Figure 2 Limit module keys and displays
Watlow is a registered trademark of Watlow Electric Manufacturing Co.
4 Limit Module Displays and Menu Navigation
Model 101303-50
Getting Started
Getting started using your new HeatWave Labs Temperature Controller should be
quick and easy. The Error Messages and Troubleshooting section of this manual
describes errors that may be encountered during this process. For more details about
the operation of the control module, consult the attached Watlow® Series 96 user’s
manual.
This manual is also available for download at the HeatWave labs web site,
www.cathode.com or at http://www.cathode.com/pdf/series96man.pdf.
To ensure the quickest and most reliable startup, please follow the eight steps
below in the order shown.
1. Unpack the instrument
Be sure that you received the following items in good condition. If there was any
damage in shipping, please keep your shipping containers and contact the factory
immediately.
• Model 101303-50 instrument chassis
• Power Cord
• HeatWave Labs p/n 101960-01 (FWH-020A6F) 20A, Fast Acting
Semiconductor Fuse (Installed)
• Quencharc 102660-03 (not installed)
• Manuals: HeatWave Labs Model 101303-50, Watlow® Series 96, and
Watlow® Series SD user’s manuals
• HeatWave Labs Catalog
2. Connect the instrument
Warning: This instrument is designed for use with input
voltage, current and frequency as specified in the
Factory Configuration in Appendix A only; serious
equipment damage and/or injury will occur if it is
connected to improper power.
Caution: Air vents are located on top, bottom and rear of the
instrument. Airflow must not be restricted at these
locations.
1. Make sure the switch on the front panel is in the off position.
2. Plug your process thermocouple, Type K, into the control sensor receptacle
on the rear panel. (If you need to add connectors to your sensors, do it now.
Remember thermocouples are polarity sensitive, for Type-K the yellow wire
is positive.)
5 Getting Started
Model 101303-50
Warning: This unit is designed to deliver maximum output
voltage and amperage to the load at 100% controller
output. If the load is designed to run at lower than
the maximum output capability, the controller must
be adjusted to limit the voltage to this load. The
factory has limited the output of this controller as per
the controller settings listed in the Factory
Configuration in Appendix A.
It is likely that the user will need to change these
settings to reach desired operating temperatures and
ramping rates. Consult the Series 96 Manual for
necessary settings.
3. Plug the unit into a power receptacle.
4. Do not connect the system heater at this time.
Warning: This instrument is designed for use with input
voltage, current and frequency as specified in the
Factory Configuration in Appendix A only; serious
equipment damage and/or injury will occur if it is
connected to improper power.
3. Power up the instrument
1. Turn the instrument on using the front panel switch.
2. After a few seconds the sensor temperature will be visible in the upper
display of the control module (in Celsius) and the setpoint will be visible in
the lower display. Verify that this sensor temperature appears reasonable.
4. Set over-temperature alarm set point
The over-temperature alarm setpoint of the limit module must be set. For more
information about the user interface, see Limit Module Displays and Menu
Navigation above.
6 Getting Started
Model 101303-50
Note: The module will exit the menu system and return to the
main display in 60 seconds if no keys are pressed.
If the limit sensor reaches this setpoint for any reason the heater output will be shut
off until the user resets the instrument manually (by pressing the infinity key on the
limit module after the temperature has dropped more than 2 °C below this alarm
limit). On the LIMIT module:
1. Press Advance key until “A1hi” is displayed in the lower (right) display.
2. The alarm setpoint may now be set with the arrow keys.
3. Return to the main display by pressing the infinity key.
5. Set the setpoint
1. The setpoint can be adjusted using the up and down arrow keys from the
home page (not while inside any other menus). At this point, adjust the
setpoint to a value below the current process temperature to avoid applying
power to the output. The lower display shows if the setpoint is
adjusted to its lowest permissible value (0° C).
6. Verify proper system performance
1. If your system will be damaged by 100% output power, set the power limits
on the control module as described in the Advanced Features section. In
Appendix A, the Power Limit Parameters factory preset is shown.
2. Turn the unit off, plug in the heater, and turn the unit back on again.
3. Set the setpoint a few degrees above the present process temperature so that
output power will be applied.
Verify that:
a. LED #1 illuminates or begins to flash intermittently, indicating
heater output is activated, and
b. The temperature begins to rise.
4. If the system temperature does not begin rising, shut off power and
investigate sensor and heater connections and integrity. If the circuit
breaker trips, or any errors are displayed, refer to the Error Messages and
Troubleshooting section of this manual.
7. Autotune the system
DO NOT RUN AUTOTUNE
unit without first consulting the Factory. Autotuning
will allow the power supply to apply its maximum
voltage to the load. This may seriously damage the
heater. PLA and PLB power limit setting will be
ignored during Autotune.
on any heater with this
7 Getting Started
Model 101303-50
Excellent thermal control is normally attained by automatically tuning the control
parameters (described below) to the specific thermal system. The controller should
be autotuned the first time it is used and whenever the thermal properties of the
system being controlled change significantly.
Warning: For systems that cannot tolerate the overshoot that
can occur during the autotuning process, change the
ATSP parameter (as described in the advanced
features) to a lower value so that the system
autotunes around a lower value. The default
autotuning point is 90% of the setpoint. This may
also be set to 100% to tune the controller at the
setpoint if your system allows.
Be aware that the autotuning algorithm turns power
on at 100% to measure system response. Operating
at 100% duty cycle may damage some types of
heaters, especially those used in high temperature
furnaces. Do not autotune the system if it will be
damaged by 100% output power. If this is the case,
refer to the Watlow® Series 96 manual for the manual
tuning procedure.
1. Set the control setpoint to a safe operating value for your system.
2. On the control module, press the two arrows keys simultaneously until
appears in the lower display.
3. Scroll up or down with the arrow keys until appears in the upper
display.
4. Press the blue advance key once to select this user menu.
5. Press the blue advance key once or until is displayed in the lower
display of the control module. Use one of the arrow keys to change the
upper display from to .
6. Press the infinity key to return to the main display and initiate the autotune
sequence. The upper display will flash alternately with the
temperature until it is done autotuning. This process typically takes from a
few minutes for small systems to over an hour for larger systems.
8. Verify safe alarm conditions
Your temperature controller is now configured for your system and ready to use.
During normal operation, the current process temperature will be visible in the
upper display and the setpoint temperature in the lower display.
If the over-temperature alarm setpoint is exceeded (optional feature), the message
will flash in the upper display of the limit module and heater output will be
disabled. This alarm can be cleared by pressing the infinity key after the process
temperature has fallen more than 2 °C below the alarm setpoint.
8 Getting Started
Model 101303-50
Programming and Executing Profiles
This section outlines how to manage and execute temperature vs. time profiles.
Detailed explanation of the menu structure and profile parameters can be found in
the Watlow® Series 96 User’s Manual.
Note: The default settings of the HeatWave Labs Model 101303-
50 allow for only a subset of step parameters that are
available in the Watlow Series 96 Controller. For example,
by default, the “program type” parameter found in the
Global Menu is set to “time based”, which means setpoint
steps are specified in time durations as opposed to being
specified as a ramp rate in degrees per unit time. In
addition, event inputs and outputs are not used. Therefore,
the event handling functions and “wait for event” features
are not implemented.
Three menus are used to manage and execute profiles: the Pre-run Menu, the Run
Menu, and the Programming Menu. They can be accessed from the Home Page of
the system. The Home Page is essentially the main display, where process
temperature and setpoint are displayed, and when the unit is not in another menu.
Menu Function
Programming Allows the user to program the steps that are stored in the
two profiles. Use the blue Advance key to scroll through
parameters and press the Infinity key to exit the menu.
Pre-Run The Pre-Run menu allows the user to select a file and
step number from which to begin execution, or to resume
a previously halted profile. Enter the Pre-Run menu by
pressing the Infinity key from the Home Page. Scroll
through the menu using the blue Advance key. While in
the Pre-Run menu, the Profile Indicator will be flashing.
Run The Run menu is available while a profile is running,
allowing the user to view the setpoint and time remaining
for the currently running step. Enter the Run menu (and
start the selected file and step) by pressing the Infinity key
from the Pre-Run menu. Scroll through the menu using
the blue Advance key. While in the Run menu, the Profile
Indicator will be continuously illuminated.
Programming a Profile
Two separate and distinct profiles, each containing up to eight steps may be stored
in the controller. The step type can be any one of four step types available: set point
step, soak step, jump loop step, or end step. Various parameters will need to be
specified for each step, the number and types of which will depend on the step type
chosen.
9 Programming and Executing Profiles
Model 101303-50
The general procedure for programming a profile is to
1. Enter the programming menu on the control module by pressing the blue
Advance key once from the Home Page while the program is on hold or not
running.
2. Select the file number by choosing number 1 or 2 while the
parameter is shown in the lower display, and pressing the blue Advance key.
3. Select the step number within the selected file while the parameter is
visible in the lower display, and press the blue Advance key.
4. Select the step type (as described below) for each step in the profile. After
specifying a step type, select type-specific parameter values.
5. Repeat above procedure for each step in the profile.
Step Types
The step type can be any one of four step types available: set point step, soak step,
jump loop step, or end step. Various parameters will need to be specified for each
step, the number and types of which will depend on the step type chosen. The
purpose of each step type and the parameters that need to be specified are detailed
below.
Step Type Available Parameters
Set Point Step:
ramp to a
setpoint in a
specified amount
of time
Soak Step:
remain at a
setpoint for a
specified amount
of time
Jump Loop Step:
allows for
jumping and
looping to other
steps in either of
the two profiles
End Step:
specifies
end of profile and
the state of control
when the profile is
ended
Set point value (0 to 1370°C)
Hours (0 to 99)
Jump File (1 or 2)
Jump Count (0 to 255): the number
Minutes (0 to 59)
Seconds (0 to 59)
Hours (0 to 99)
Minutes (0 to 59)
Seconds (0 to 59)
Wait-for deviation value (if a value
is entered, the profile will wait until the
process values falls within the range
defined by the setpoint ± this value)
Jump Step (1 to 8)
of time the jump is to be executed; a value
of zero specifies an infinite loop
End state ( or ): If
is selected, the controller will
maintain the same setpoint as that
specified in the previous step. If is
selected, the controller output is set to zero
and
is shown in the lower display.
10 Programming and Executing Profiles
Model 101303-50
Running a Profile
The user can start executing a program at any step within either profile.
To run a profile:
1. Enter the Pre-Run menu on the control module by pressing the Infinity key
once from the Home Page (while a profile is not already running). The
Profile Indicator will begin flashing.
2. The upper display shows the file number to be run and is shown in
the bottom display. Use the up and down arrow keys to select which file
number to run.
3. Press the blue Advance key to accept the file number and advance to the
step selection.
4. Use the arrow keys to select the step number at which to begin running the
profile.
5. Press the Infinity key and the profile will begin executing from the specified
step, and the Profile Indicator will change from flashing to continuous
illumination.
6. You may view the currently running step parameters by pressing the blue
Advance key multiple times.
7. To stop the profile, press the Infinity key when the profile is running.
Resuming a Halted Profile
If no changes are made to the profiles after a profile has been halted, the profile can
be resumed from the same step from which it was halted.
To resume the halted profile:
1. Press the Infinity key on the control module once to enter Pre-run Menu.
2. Press the blue Advance key twice until appears in the lower display.
The upper display will show the file and step number at which the profile
was halted and will be resumed. Note the parameter only appears in
the Pre-Run menu if a profile had been previously halted.
3. Press the Infinity key to resume the profile.
Using the Wait-for Process Deviation Function
For each soak step in a profile, a Wait-for Process Deviation value ( ) can be
entered. If a value is entered, the controller will wait until the process value falls
within the deviation band defined by that step’s setpoint value ± the Wait-for
deviation value. The controller will begin decrementing the time left in that step
only after the Wait-for condition has been met, and will continue to do so regardless
of the condition or process changes during the remainder of the step.
11 Programming and Executing Profiles
Model 101303-50
Advanced Features and Settings
There are numerous advanced features supported on the control module that may be
useful in specific circumstances. The most common ones are listed below. Consult
the Watlow® Series 96 User’s Manual for more details on these and other options.
Setting the autotune point to a lower value
1. On the control module, press the two arrows keys simultaneously until
appears in the lower display
2. Use the arrow keys to scroll until appears in the upper display.
3. Press the advance key once to select this user menu.
4. Press the advance key three times or until appears in the lower
display.
5. Use the arrow keys to adjust the value (in the upper display) to the desired
percentage of setpoint at which to autotune. For example, if is set to
80, and the setpoint is set to 750 degrees, it will autotune at 600 degrees.
6. Press the infinity key to return to the main display.
Switching between Celsius and Fahrenheit
The instrument is shipped with each module configured to display temperature in
Celsius. To change to Fahrenheit or back to Celsius:
1. On the control module, press the up and down arrows simultaneously. After
three seconds the word will be visible in the lower display. Continue
pressing both keys until appears in the lower display
2. Use the arrow keys to scroll through the parameters until the upper display
shows .
3. Press the advance key to select the global menu.
4. Press the advance key twice, until the lower display reads . Use the
arrow keys to select either or .
5. Press the infinity key to return to the main display.
Changing the resolution (decimal point)
The instrument can be configured to display tenths of a degree, but if tenths are
displayed, the maximum temperature that can be reached is 1000 degrees.
To change the resolution of the control module:
1. On the control module, press the up and down arrows simultaneously. After
three seconds the word will be visible in the lower display. Continue
pressing both keys until appears in the lower display
2. Use the arrow keys to scroll through the parameters until the upper display
shows .
3. Press the advance key to select the Input 1 menu.
12 Advanced Features and Settings
Model 101303-50
4. Press the advance key five times, until the lower display reads and
the upper display reads 0.0. Use the arrow keys to toggle this to 0.
5. Press the infinity key to return to the main display.
Power limiting
Some heaters, especially those used in furnaces, must be controlled quite carefully.
Heaters with a negative temperature coefficient of resistance may be damaged if
operated at full power at low temperatures. Metal film radiative heaters may not
tolerate large duty cycle at high temperatures. The Model 101303-50 allows for two
independent power limits and a temperature breakpoint to be set.
Warning: This unit is designed to deliver maximum output
voltage and amperage to the load at 100% controller
output. If the load is designed to run at lower than
the maximum output capability, the controller must
be adjusted to limit the voltage to this load. The
factory has limited the output of this controller as per
the controller settings listed in the Factory
Configuration in Appendix A.
It is likely that the user will need to change these
settings to reach desired operating temperatures and
ramping rates. Consult the Series 96 Manual for
necessary settings.
To enable power limiting in the control module:
1. On the control module, press the up and down arrows simultaneously. After
three seconds the word will be visible in the lower display. Continue
pressing both keys until appears in the lower display
2. Use the arrow keys to scroll through the parameters until the upper display
shows .
3. Press the advance key to select the global menu.
4. Press the advance key five times, until the lower display reads . Use
the arrow keys to adjust the upper display to the desired temperature
breakpoint where the controller will switch to the power limits set below.
5. Press the advance key once so that the lower display shows . Use the
arrow keys to select the power limit, in percent, for temperatures above the
temperature breakpoint set in step 4.
6. Press the advance key once so that the lower display shows . Use the
arrow keys to select the power limit, in percent, for temperatures below the
temperature breakpoint set in step 4.
7. Press the infinity key to return to the main display.
13 Advanced Features and Settings
Model 101303-50
Caution: The autotune algorithm overrides these power limits
during its execution. Do not autotune your system if
it can be damaged by 100% duty cycle.
Other features
There are number of other features which are supported on the controller, but are
typically only useful under very special circumstances. These are described briefly
here. Please consult the Watlow® Series 96 user’s manual for more information.
Caution: There may be subtle intricacies and implications for
system operation when implementing these
advanced features. These alternate modes are not
recommended except for use by expert users in
special applications.
1. Bumpless Failure Mode: the controller output may be configured to keep
outputting a fixed percent power rather than shutting off after a sensor fault.
2. Additional alarm configurations: The over-temperature alarm may be
configured to be non-latching (default is latching, meaning it must be
manually reset even when the process is back in the safe region). The alarm
may be configured to be two-sided, silenceable (ability to be overridden),
and/or triggered by a deviation from setpoint. These other alarm modes
should be very well understood before being implemented and are not
recommended for general use.
3. Calibration: Sensor input and analog output may be manually calibrated to
change offsets or gains. This is rarely necessary since incorrect offsets and
scaling are almost always caused by improper grounds, faulty wiring, or
other pathological problems. The controller should not be recalibrated
unless it is certain that there are no other problems.
4. PID parameters: PID parameters may be manually adjusted. Note that
control can rarely be improved upon, and danger of adversely affecting
control performance is eminent.
14 Advanced Features and Settings
Model 101303-50
Error Messages and Troubleshooting
Error messages
The control module is capable of displaying a number of errors and alarm
conditions. These messages are described below. For more details, consult the
Watlow® Series 96 Manual.
Message Meaning and Corrective Action
flashing in upper
display
flashing in upper
display
flashing in upper
display
, , , or
in upper display
through in
upper display
Recorded process temperature has exceeded alarm
limit (over-temperature setpoint). Check value of
alarm limit and integrity of sensor. When the process
temperature falls more than 2 °C below the alarm
limit, clear the error by pressing the reset key.
Alternatively, this alarm may be cleared by cycling
power to the instrument once the process temperature
has fallen below the alarm limit.
Open loop error. The controller has been outputting
100% power but its sensor temperature is not
changing. Verify that the sensor is located properly
and that the heater is connected and functioning
properly. This error is cleared by cycling power to
the unit. This error indicates a thermal system
malfunction -- do not ignore it!
System is autotuning (this only occurs when initiated
manually by the user). No action is necessary,
although autotuning sequence may be terminated by
setting parameter to in main menu.
Sensor errors. Verify sensor connections and
continuity. Unit will continue to display error
condition until power is cycled or error is cleared by
pressing the infinity key
Internal module errors, not normally seen. Cycle
power to unit, and if problem persists call factory.
Troubleshooting
Below are some tips to resolve problems not identified by the standard error
messages:
Symptom Possible causes
Displayed temperature goes
down when heaters turn on.
Circuit Breaker trips Check that heater is sized properly. The Model
15 Error Messages and Troubleshooting
Thermocouple leads reversed. Shut off power
immediately and check wiring of sensor.
101303-50 will not deliver more than 15 Amps.
Check that the heater power is not shorted to ground
anywhere in the system.
Model 101303-50
Symptom Possible causes
Heater never heats; open
loop errors cannot be
avoided.
Over-temperature alarm will
not clear.
Temperature fluctuates by
more than 1 degree.
Unit does not control. It
heats regardless of setpoint,
until alarm limit trips.
Control module does not
display anything, or displays
but is not functioning
properly.
Check that heater is sized properly. If so, internal
transformer may have failed. Call factory.
This alarm limit has a two-degree hysteresis. The
process temperature must fall more than 2 °C below
the alarm set point before it can be cleared with the
reset key. This hysteresis may be overridden by
cycling power to the instrument once the process
temperature has fallen below the alarm limit.
Verify the unit has been autotuned in the current
thermal configuration and near the setpoint
temperature. If not do so.
The solid-state relay may have failed. This is
unlikely unless the output has been shorted and the
semiconductor fuse did not properly function (blow).
Call factory.
Check that circuit breaker is on, and line voltage is
present.
If so, disconnect power, remove cover, and ensure all
connectors on the back of the control module are
securely in place.
16 Error Messages and Troubleshooting
Model 101303-50
Appendix A: Default Factory Configuration
If for any reason the instrument settings become corrupted, the instrument must be
reconfigured with the values listed below. Additionally, it will then be necessary to
reset the setpoint, alarm limit, autotune the controller, and reset any other advanced
configurations that have been changed for your system. Refer to the Watlow® Series
96 User’s Manual for more information.
Warning: This unit is designed to deliver up to 120 Volts and 20
Amps to the load at 100% controller output. If the
load is designed to run at lower than 120 Volts, the
controller must be adjusted to limit the Voltage to this
load. The factory has limited the output of this
controller as follows:
Power Limit Set Point (PLSP) 300°°°°C
Power Limit Above (PL A) 50%
Power Limit Below (PL B) 30%
It is likely that the user will need to change these
settings to reach desired operating temperatures and
ramping rates. Consult the Series 96 Manual for
necessary settings.
17 Appendix A: Default Factory Configuration
Model 101303-50
Table A1: Power input and output (Load) settings
This unit can be internally configured by the factory for 120VAC or 240VAC and
50 Hz or 60 Hz input. The output can be set to 32V/47A, 16V/94A or 8V/94A.
This unit has been configured at the factory as follows:
I/O Setting Units Value as shipped
Input Voltage Volts, AC 120
Output Voltage Volts, AC 120
Output Current Amps, AC 20, max
Line Frequency Hertz, Hz 50 or 60
Table A2: Control Module Settings
Menu Location Parameter Value as shipped
Oper>ALM A1hi 1000
Set>glbl C_F C
Set>glbl Err Lat
Set>glbl Fail Off
Set>glbl PLSP 300C
Set>glbl PL A 50%
Set>glbl PL B 30%
Set>glbl OPLP On
Set>InP1 In 1 H
Set>InP1 Dec1 0.0
Set>Out1 Prc1 4-20
Set>Out3 Ot 3 Al
Set>Out3 Lat3 Yes
Set>Out3 Sid3 Hi
18 Appendix A: Default Factory Configuration
Model 101303-50
Front panel
circuit breaker
H
N
G
Inlet receptacle
13
14
8 9
76
Control
Module
19
21
+
-
Control
Out
0
1
4
6
Outlet
GndL2
Solid State
Relay
Mechanical
Relay
Red
Red/White
Yellow
Black
Black
W hite
Black
Control
Sensor
Receptacle
-
+
AT Firing Card
+
-
L1
24V trans-
former
24VAC power
Control
Signal
Phase
Output
120 or 240VAC
Output 4
RS-485
Output 1
4-20mA
Input 1 AC Power
Very fast-acting
semiconductor
fuse: 20 Amp
Bussmann p/n
FW H-020A6F
24VAC
coil
12VAC
12VAC
120VAC
120VAC
1
2
3
4
5
6
7
8
Orange
W hite
Brown
Black
Black
Black
W hite
Grey
Red
Jumpers
T+
T-
Limit
Module
Limit Sensor
Receptacle
+
-
1 2 5 6
11 10
20
Com
T+ T-
3 4
T+
T-
Com
1 2 3 4 5
6 7 8 9
Digital Comm s
RS-485
fem ale
9-pin d
-sub
Blue
Red/Black
Green Blue
Appendix B: Model 101303-50 Electrical Schematic
19 Appendix B: Model 101303-50 Electrical Schematic
Model 101303-50
Appendix C: User Worksheet
Keeping an accurate record of any changes to the controller parameters is
encouraged. This is particularly helpful when allowing a colleague to use the
temperature controller or in the event you should need to troubleshoot operation
with the factory.
Menu Location Parameter Value
Oper>ALM A1hi 1000
Set>glbl C_F C
Set>glbl Err Lat
Set>glbl Fail Off
Set>glbl PLSP 300C
Set>glbl PL A 50%
Set>glbl PL B 30%
Set>glbl OPLP On
Set>InP1 In 1 H
Set>InP1 Dec1 0.0
Set>Out1 Prc1 4-20
Set>Out3 Ot 3 Al
Set>Out3 Lat3 Yes
Set>Out3 Sid3 Hi
Date Date Date Date Date Date Date
20 Appendix C: User Worksheet
Model 101303-50
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