Watlow Electric 987, 986, 989, 988 User Manual

Name: Watlow Electric 987
Brand: Watlow Electric
SKU: 741037
Rating: 4.5 (2 reviews)

4.5 (2)

Series 988

1/8 DIN Microprocessor-Based Temperature/Process Controller

0600-0009-0001 Rev W

March 1999

Supersedes: 0600-0009-0001 Rev V

$10.00

Made in the U.S.A.

Printed on Recycled Paper 10% Postconsumer Waste

User’s Manual

Includes 986, 987, 988 and 989

User Levels:

• New User........................... go to Introduction

• Experienced User................... go to page 4.1

Installers:

• Set-up..................................... go to page 1.1

• Wiring & Installation................ go to page 2.1

Watlow Controls

1241 Bundy Blvd., P.O. Box 5580, Winona, Minnesota USA 55987-5580

Phone: (507) 454-5300, Fax: (507) 452-4507 http://www.watlow.com

Registered Company

Winona, Minnesota USA

ISO 9001

TOTAL

3 Year Warranty

WATLOW Series 988 User’s ManualTable of Contents

Table of Contents

Introduction to the Watlow Series 988

Controllers

ii Using this Manual

ii Document Every Step

iii Notes, Cautions and Warnings

iii Technical Assistance

iii We Value Your Feedback

Chapter 1

Hardware Setup

1.1 Dip Switch Locations and Functions

Chapter 2

Installation and Wiring

2.1 Panel Cutout and Dimensions

2.2 Installing the Series 988

2.4 Wiring the Series 988

2.4 Input-to-output Isolation

2.4 Power Wiring

2.5 Sensor Installation Guidelines

2.6 Wiring Example

2.8 Input 1 Wiring

2.9 Input 2 Wiring

2.11 Event Input 1 Wiring

2.12 Output 1 Wiring

2.13 Output 2 Wiring

2.14 Output 3 Wiring

2.15 Output 4 Wiring

Chapter 3

Front Panel and Display Loop

3.1 Keys and Displays

3.2 Display Loop

Chapter 4

The Setup Menus

4.1 Navigating the Setup Menus

4.2 Input Menu

4.18 Output Menu

4.34 Global Menu

4.44 Communications Menu

Chapter 5

The Operation Menus

5.1 Navigating the Operation Menus

5.2 System Menu

5.9 PID A and PID B Menus

Chapter 6

The Factory Menus

6.1 Navigating the Factory Menus

6.2 Panel Lockout Menu

6.7 Diagnostics Menu

6.13 Calibration Menu

Chapter 7

Tuning, Manual Operation,

Alarms and Error Codes

7.1 Auto-tuning (Heat and/or Cool)

7.2 Manual Tuning

7.4 Manual and Automatic Operation

7.5 Changing the Output 3 Alarm Jumper

7.6 Using Alarms

7.8 Error Code E1 and E2 Messages

7.9 Error Code Actions

Chapter 8

General Software

8.2 Burst Fire

8.4 Communications

8.6 Dead Band

8.8 Digital Events

8.10 Heater Current

8.12 Input Filter

8.14 Input Linearization

8.16 Ramp to Set Point

8.18 Remote Set Point

8.20 Retransmit

8.22 Slidewire Feedback

Appendix

A.2 Glossary

A.4 Specifications

A.5 Warranty and Returns

A.6 Index

A.10 Menu Overview

A.11 Model Number – Ordering Information

A.12 Declaration of Conformity

WATLOW Series 988 User’s Manual i

Introduction

Introduction to the

W atlow Series 988 Controllers

Figure Int.1 -

The Series 988

Controllers.

Watlow’s Series 988 controllers set a new standard in the controller indus-

try by packing an impressive array of features into an 1/8-DIN package.

No other controller offers the flexibility, compact size and durability of the

Series 988. It can control a wide variety of temperature and process appli-

cations, with a broad range of input and output options that allow control

of virtually any process variable.

The Series 988 is the only 1/8 DIN controller that can provide single-unit

cascade control of a process. Its other features include heater current

monitoring, remote set point input, ratio control and valve control through

slidewire feedback. The Series 988 also delivers expanded auto-tuning

capabilities, increased alarm functionality and several unique control algo-

rithms.

When we refer to the “Series 988” controller, we refer also to the horizontal

and low-voltage versions of the Series 988: the 986, 987, 988 and 989. We

recommend that you read all of this manual’s introduction to familiarize

yourself with the conventions and content of this manual and the steps to

setting up a Series 988 controller. Make sure you understand the

“Caution” and “Warning” symbols we use in the book.

ii WATLOW Series 988 User’s Manual

Introduction

Using this Manual

This manual provides the information you will need to install and operate

a Series 988 controller.

If you need information about Series 988 configurations and model num-

bers, refer to the Appendix of this manual or, for more detailed informa-

tion, to Optimizing Your Process System with the Series 988 Controller: An

Application Guide for the Watlow Series 988 Family.

If your Series 988 controller will be used for data communications, you

will also need our communications manual, Data Communications with the

Watlow Series 988 Family of Controllers (green cover).

Series 988 controllers are calibrated in the factory, but if you need to do

periodic calibration you will need our calibration manual, Calibrating

Watlow Process Controllers, (blue cover).

This manual explains the five steps of setting up a Series 988 controller:

1. Set and document all of the DIP switches, if applicable: Chapter 1.

2. Mount the controller: Chapter 2.

3. Wire and document the controller wiring: Chapter 2.

4. Configure and document the controller software: Chapters 3-6.

5. Run, test and adjust your application. Update documentation.

Chapters 7 and 8 and the Appendix provide detailed advice, definitions

and specifications along with application examples to help you optimize

the safety and performance of your application. Use the Table of Contents

and Index to find specific information.

Document Every Step

The Series 988 provides powerful and complex features. Carefully docu-

ment each step of the setup and any subsequent changes. This will make

it much easier to change, adjust and troubleshoot your application.

Make the configuration documentation available to engineers and techni-

cians, on all shifts, who may need to work with the Series 988. We provide

space in this manual to record configurations. You may prefer to photo-

copy the blank forms and keep them in a separate binder. However you

maintain your documentation, be sure to replace all old copies of the doc-

umentation with updated versions whenever the controller configuration is

changed.

NOTE:

The Menu Overview

in the Appendix

shows all the

menus and

prompts.

NOTE:

The 12-digit number

is printed on the top

of the stickers on

each side of the

controller’s case

and on the right-

hand or top circuit

board.

Introduction

WATLOW Series 988 User’s Manual iii

Introduction

Notes, Cautions and Warnings

We use note, caution and warning symbols throughout this book to draw

your attention to important operational and safety information.

A bold text “NOTE” marks a short message in the margin to alert you to

an important detail.

A bold text “CAUTION” safety alert appears with information that is

important for protecting your equipment and performance. Be especially

careful to read and follow all cautions that apply to your application.

A bold text “WARNING” safety alert appears with information that is

important for protecting you, others and equipment from damage. Pay

very close attention to all warnings that apply to your application.

The ç symbol (an exclamation point in a triangle) precedes a general

CAUTION or WARNING statement.

The Ó symbol (a lightning bolt in a triangle) precedes an electric shock

hazard CAUTION or WARNING safety statement.

Technical Assistance

If you encounter a problem with your Watlow controller, review all of your

configuration information for each step of the setup to verify that your

selections are consistent with your applications.

If the problem persists after checking all the steps, you can get technical

assistance by calling Watlow Controls at (507) 454-5300, between 7 a.m.

and 5 p.m. CST, and asking for an applications engineer. When you call

have the following information on hand: the controller’s model number

(the 12-digit number is printed on the top of the stickers on each side of

the controller’s case and on the right-hand or top circuit board); your

user’s manual; all configuration information; and the Diagnostics Menu

readings.

We Value Your Feedback

Your comments and suggestions on this manual are welcome. Please send

them to, Technical Writer, Watlow Controls, 1241 Bundy Blvd., P.O. Box

5580, Winona, MN 55987-5580 or call (507) 454-5300 or fax (507) 452-

4507. The Series 988 User’s Manual is copyrighted by Watlow Winona,

WATLOW Series 988 User’s Manual 1.1

Hardware Setup, Chapter 1

Chapter 1 Hardware Setup

DIP Switch Locations and Functions

The Watlow Series 988 has at least one and as many as six dual in-line

package (DIP) switches inside the controller, depending on the model

number. They allow users to configure the controller for a variety of input

sensors, to provide power for external signal conditioners or to lockout

front panel access to some functions.

To set any DIP switch:

• Remove the controller from the case by pressing firmly on the two release

tabs on one side or the top of the bezel until they unsnap. Then firmly

press the two release tabs on the opposite side or the bottom of the con-

trol until they unsnap. You will need to gently rock the bezel back and

forth to release it from the chassis.

• Use the illustrations on the following pages to locate and set each DIP switch.

PROCESS

L1 L2 L3 L4

DEV

% OUT

DISPLAY

SERIES 988

MODE

AUTO

MAN

Release

Tabs

Release

Tabs

PROCESS

L1 L2 L3 L4

DEV

% OUT

MODE

SERIES 989

DSPY

AUTO

MAN

Release

Tabs

Release

Tabs

Figure 1.1 - Press

the release tabs to

remove the con-

troller chassis.

1.2 WATLOW Series 988 User’s Manual

Hardware Setup, Chapter 1

DIP Switches

Figure 1.2 -

Input DIP switches.

Input 1 Input 2

(98 _ _-2_ _ _-_ _ _ _)(98 _ _-_2_ _-_ _ _ _)

RTD (100 Ω)

thermocouple: R, S or B

thermocouple: J, K, T, N, E, C, D, Pt2

or 0-50mV (high impedance)

0-20 or 4-20mA; 0-5, 1-5 or 0-10V

↑

123

↑

123

↑

123

↑

123

↑

123

↑

123

↑

123

↑

123

Controller Chassis

Rear View

Input 1 DIP

Input 2 DIP

1. Set the input DIP

switches to match the

sensors you are using

in your application.

Only controllers with

model number 98_ _-

2_ _ _-_ _ _ _ or 98_ _-

_2_ _-_ _ _ _ have an

input DIP switch.

NOTE:

The Input 2 DIP

switch is mounted

upside down.

NOTE:

Only controllers

with the indicated

model numbers

have these DIP

switches.

DIP Switches

WATLOW Series 988 User’s Manual 1.3

Hardware Setup, Chapter 1

Output 2

Option B oa r d a nd D IP

Output 4

Option B oa r d a nd D IP

Con t ro ller Chassis

Top View (986 & 988)

Left-side View (987 & 989)

Output 3

Option B oa r d a nd D IP

Output 1

Option Board

offon

off

Figure 1.3 -

External signal con-

ditioner power sup-

ply DIPs.

Output 2 Output 3 Output 4

(98 _ _-_ _ _T-_ _ _ _) (98 _ _-_ _ _ _-T_ _ _) (98 _ _-_ _ _ _-_T_ _)

20V ± 5% @ 30mA

12V ± 5% @ 30mA

5V ± 5% @ 30mA

↑

2. Set DIP switches for

outputs equipped with

an external signal con-

ditioner power supply.

Only controllers with

model number 98_ _-_

_ _T-_ _ _ _, 98_ _-_ _ _

_-T_ _ _ or 98_ _-_ _ _

_-_T_ _ have an exter-

nal signal conditioner

power supply.

NOTE:

For other voltages

or current settings

contact the factory.

3. When the DIP switches are set, gently insert the controller chassis into

the case and push it firmly into place until all four tabs snap into place.

NOTE:

Only controllers

with the indicated

model numbers

have these DIP

switches.

1.4 WATLOW Series 988 User’s Manual

Hardware Setup, Chapter 1

DIP Switches

Figure 1.4 -

Lockout DIP switch.

no hardware lockout or

(Switch 1 has no effect.)

lockout Setup and Factory menus or

(Switch 1 has no effect.)

↑

4. The lockout DIP switch

hides the Setup Menus

(Input, Output, Global and

Communications) and the

Factory Menus (Panel

Lockout, Diagnostics and

Calibration). All units have

a lockout DIP switch.

CAUTION:

The lockout DIP

switch makes the

Setup and Factory

menus unavailable.

Configure all the

Setup and Factory

menus before lock-

ing them out.

Failure to do so

could result in dam-

age to equipment in

the event of a setup

error.

Input

Output Global

Panel

Lockout

Diagnostics Calibration

Commu-

nications

[InPt]

[`SEt]



[OtPt]

[`SEt]



[PLOC]

[Fcty]

[diAG]

[Fcty]

[`CAL]

[Fcty]

[GLbL]

[`SEt]



[CO

[`SEt]



WATLOW Series 988 User’s Manual 2.1

Installation and Wiring, Chapter 2

Chapter 2 Installation and Wiring

Panel Cutout

Maximum Panel

Thickness

0.38" (9.65mm)

3.62" + 0.03 -0.00

(92mm + 0.8)

1.77 + 0.02 -0.00

(45mm + 0.6)

4.03"

(102mm)

2.18"

(55 mm)

PROCESS

L1 L2 L3 L4

DEV

% OUT

DISPLAY

SERIES 988

MODE

AUTO

MAN

4.03"

(102mm)

2.18"

(55 mm)

PROCESS

L1 L2 L3 L4

DEV

% OUT

MODE

SERIES 989

DSPY

AUTO

MAN

Figure 2.1 -

Series 988 and

Series 989

dimensions and

terminal number

layout.

Panel

Adjustable

Mounting Bracket

4.06"

(103 mm)

0.68"

(17 mm)

NOTE:

Adjustable mount-

ing brackets can be

side-mounted.

NOTE:

Space panel

cutouts at least 1.66

inches (42.2mm)

apart.

NOTE:

Holes can be cut in

the panel using a

Greenlee 1/8 DIN

Hydraulic Kit

#60068 (punch

#60069, die #60070).

98765432

19 18 17 16 15 14 13 12

2.2 WATLOW Series 988 User’s Manual

Installation and Wiring, Chapter 2

Installation

Installing the Series 988

Installing and mounting requires access to the back of the panel.

1. Make a panel cutout using the panel cutout dimensions from the previ-

ous page.

2. To remove the controller chassis from its case, press in firmly on the two

tabs on one side or the top of the bezel until they unsnap, then unsnap

the two tabs on the opposite side or the bottom. Pull the chassis out of

the case by gently rocking it.

3. Slide the case into the panel cutout. Check to see that the gasket is not

twisted, and is seated within the case bezel flush with the panel. Slide

Panel

Adjustable

Mounting Bracket

Bezel

External Gasket

Mounting Collar

Release Tabs

Top and Bottom (986 or 988)

or Side (987 or 989) View

Mounting Slots

Side (986 or 988)

or Top and Bottom (987 or 989) View

NOTE:

Removing the con-

troller chassis from

its case makes

mounting easier.

Figure 2.2 -

Side and top view.

WATLOW Series 988 User’s Manual 2.3

Installation and Wiring, Chapter 2

the mounting collar over the back of the control.

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 controller).

Push each bracket backward then down to secure it to the control

case. To guarantee a proper NEMA 4X seal, Series 986 and 988

units (vertical) must have the mounting brackets located on either

side of the unit. When installing Series 987 and 989 units (horizon-

tal) the brackets must be on the top and bottom of the unit.

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

firmly against the mounting collar to secure the unit. To ensure a

NEMA 4X seal, there should be no space between the bezel and

panel. Overtightening the screws will distort the case and make it diffi-

cult to remove or replace the controller.

6. Make sure the inside gasket is seated properly and not twisted.

Insert the controller chassis into its case and press the bezel until all

four tabs snap.

7. To release the mounting brackets, loosen the mounting bracket screws

and push the brackets forward, then pull it up and out.

CAUTION:

Follow the installa-

tion procedure

exactly to guarantee

a proper NEMA 4X

seal. Make sure the

gasket between the

panel and the rim of

the case is not

twisted and is seat-

ed properly. Failure

to do so could

result in damage to

equipment.

Installation

2.4 WATLOW Series 988 User’s Manual

Installation and Wiring, Chapter 2

Wiring

Wiring the Series 988

Wiring options depend on the model number and DIP switch settings.

Check the terminal designation stickers on either side of the controller

and compare your model number to those shown here and with the model

number breakdown on the inside back cover of this manual.

Input-to-output Isolation

The Series 988 uses optical isolation between the analog inputs and the

controller outputs/digital input. This isolation provides a 500VÅ (ac) bar-

rier to prevent ground loops when using grounded sensors and/or periph-

eral equipment.

Here is a breakdown of the isolation barriers:

• Analog inputs 1 and 2 are grouped together.

• Outputs 1 through 4 and the standard event input are grouped together.

This does not apply to Output 4 when configured as communications.

• The digital communications output (4) is separate from the above

groups.

Power Wiring

100 to 240V

‡‡

(ac/dc) nominal, (85 to 264 actual)

Vertical Package 98 8 _ - _ _ _ _ - _ _ _ _

Horizontal Package 98 9 _ - _ _ _ _ - _ _ _ _

24 to 28 V

‡‡

(ac/dc) nominal, (20 to 30 actual)

Vertical Package 98 6

_ - _ _ _ _ - _ _ _ _

Horizontal Package 98 7

_ - _ _ _ _ - _ _ _ _

fuse

earth ground

L2L1

∫

WARNING:

To avoid potential

electric shock, use

National Electric

Code (NEC) safety

practices when

wiring and connect-

ing this unit to a

power source and

to electrical sensors

or peripheral

devices. Failure to

do so could result

in injury or death.

NOTE:

Input-to-output iso-

lation is defeated

when the external

signal conditioner

power supply is

used to power a

transmitter con-

nected to input 1 or

input 2.

Figure 2.4 -

Power wiring.

WATLOW Series 988 User’s Manual 2.5

Installation and Wiring, Chapter 2

Wiring

Sensor Installation Guidelines

Maintain isolation between input 1 and input 2 to prevent a ground loop.

A ground loop may cause incorrect readings, dashes across the upper dis-

play or the display of error codes.

Thermocouple input: Extension wire for thermocouples must be of the

same alloy as the thermocouple itself to limit errors.

Using grounded thermocouples for both input 1 and input 2 may create

ground loop problems. To correct this problem, replace at least one of the

grounded thermocouples with an ungrounded thermocouple. If the appli-

cation requires grounded thermocouples, use an isolated transmitter,

such as a Watlow Gordon 5702 isolated transmitter.

RTD (100 Ω) input: Each 1Ω of lead wire resistance can cause a +2°C

error when using a two-wire RTD. A three-wire RTD sensor overcomes this

problem. All three wires must have the same electrical resistance (i.e.,

same gauge, same length, multi-stranded or solid, same metal).

Process input: Isolation must be maintained between input 1 and input

2. If both input 1 and input 2 are used as process inputs, a separate

power supply and transmitter must be used for each input. Output option

T (external signal conditioner power supply) can be used to supply power

for only one input.

CAUTION:

The Series 988 will

not function with

two grounded ther-

mocouple inputs.

Avoid using a

grounded thermo-

couple for both

input 1 and input 2.

Failure to follow this

guideline could

result in damage to

equipment.

NOTE:

Input-to-output iso-

lation is defeated

when the external

signal conditioner

power supply is

used to power a

transmitter connect-

ed to input 1 or

input 2.

2.6 WATLOW Series 988 User’s Manual

Installation and Wiring, Chapter 2

Wiring Example

Figure 2.6 -

System wiring

example.

988A-10CA-AARR

rear view

(+)

2221

(-)

120VÅ (ac)

fuse

92A3-1DJ1-0000

limit control

heater

process sensor limit sensor

optional

normally open

momentary switch

red

high-limit

mechanical

contactor

earth ground

(+)

dc input

SSR

SSR-240-10A-DC1

out

13 14

high-temperature

light

coil

120VÅ (ac)

1 2

(+)

(-)

1CR

high-temperature light

SSR-240-10A-DC1

solid-state relay, dc input

heater

out

24-240VÅ (ac)

(+)

(-)

3-32VÎ (dc)

1 CR-1

910

12 13

21 22

limit control

Series 988

988A-10CA-AARR

temperature control

Series 92

92A3-1DJ1-0000

(+)

(-)

∫

WARNING:

To avoid potential

electric shock, use

National Electric

Code (NEC) safety

practices when

wiring and connect-

ing this unit to a

power source and

to electrical sen-

sors or peripheral

devices. Failure to

do so could result

in injury or death.

WARNING:

Install high or low

temperature limit

control protection

in systems where

an over tempera-

ture fault condition

could present a fire

hazard or other haz-

ard. Failure to

install temperature

limit control protec-

tion where a poten-

tial hazard exists

could result in dam-

age to equipment,

property and injury

to personnel.

WARNING:

To avoid damage to

property and equip-

ment, and/or injury

of loss of life, use

National Electric

Code (NEC) stan-

dard wiring prac-

tices to install and

operate the Series

988. Failure to do

so could result in

such damage,

and/or injury or

death.

WATLOW Series 988 User’s Manual 2.7

Installation and Wiring, Chapter 2

Wiring Notes

L1 L2

power

earth ground

21 22

WARNING:

To avoid damage to

property and equip-

ment, and/or injury

of loss of life, use

National Electric

Code (NEC) stan-

dard wiring prac-

tices to install and

operate the Series

988. Failure to do

so could result in

such damage,

and/or injury or

death.

Figure 2.7 -

Wiring notes.

NOTE:

Sketch in your

application on this

page or a copy of it.

See wiring exam-

ples in this chapter

and in the Appen-

dix.

2.8 WATLOW Series 988 User’s Manual

Installation and Wiring, Chapter 2

Input 1 Wiring

Figure 2.8c — 0-5V

ÎÎ

, 1-5V

ÎÎ

or 0-10V

ÎÎ

(dc) Process

Universal signal conditioner

98 _ _ - 2 _ _ _ - _ _ _ _

Input impedance: 10KΩ

Figure 2.8a — Thermocouple or 0-50mV (high impedance)

Thermocouple only

98 _ _ - 1 _ _ _ - _ _ _ _ (no DIP switches)

Universal signal conditioner

98 _ _ - 2 _ _ _ - _ _ _ _

Input impedance: 20MΩ

Figure 2.8b — RTD (2- or 3-wire) (100 Ω)

Universal signal conditioner

98 _ _ - 2 _ _ _ - _ _ _ _

0-50mV

Figure 2.8d — 0-20mA or 4-20mA Process

Universal signal conditioner

98 _ _ - 2 _ _ _ - _ _ _ _

Input impedance: 7Ω

DIP Switch

Setting

R, S, B

DIP Settings

J, K, T, N, C, E, D, Pt2,

0-50mV DIP Settings

DIP Switch

Setting

DIP Switch

Setting

NOTE:

Successful installa-

tion requires five

steps:

• Model number and

software choice

(Appendix);

• DIP switch set-

tings (Chapter 1);

• Sensor match

(Chapter 2 and

Appendix);

• Sensor installation

(Chapter 2); and

• Wiring (Chapter 2).

↑

123

↑

123

↑

123

↑

123

↑

123

Jumper

#9 to #10

for 2-wire

RTD

Figure 2.9d — 0-20mA or 4-20mA Process

Universal signal conditioner

98 _ _ - _ 2 _ _ - _ _ _ _

Input impedance: 7Ω

Figure 2.9c —

0-5V

ÎÎ

, 1-5V

ÎÎ

or 0-10V

ÎÎ

(dc) Process

Universal signal conditioner

98 _ _ - _ 2 _ _ - _ _ _ _

Input impedance: 10KΩ

Figure 2.9b — RTD (2- or 3-wire) (100 Ω)

Universal signal conditioner

98 _ _ - _ 2 _ _ - _ _ _ _

WATLOW Series 988 User’s Manual 2.9

Installation and Wiring, Chapter 2

Input 2 Wiring

Figure 2.9a — Thermocouple or 0-50mV (high impedance)

Thermocouple only

98 _ _ - _ 1 _ _ - _ _ _ _ (no DIP switches)

Universal signal conditioner

98 _ _ - _ 2 _ _ - _ _ _ _

Input impedance: 20MΩ

Jumper

#19 to #20

for 2-wire

RTD

DIP Switch

Setting

R, S, B

DIP Settings

J, K, T, N, C, E, D, Pt2,

0-50mV DIP Settings

DIP Switch

Setting

↑

123

↑

123

↑

123

↑

123

DIP Switch

Setting

↑

123

0-50mV

NOTE:

Successful installa-

tion requires five

steps:

• Model number and

software choice

(Appendix);

• DIP switch set-

tings (Chapter 1);

• Sensor match

(Chapter 2 and

Appendix);

• Sensor installation

(Chapter 2); and

• Wiring (Chapter 2).

Figure 2.10b — Current Transformer Input

98 _ _ - _ 4 _ _ - _ _ _ _

The current transformer must be purchased separately. Watlow current

transformer part number 16-0246 (up to 50 amps).

Systems that use more than 50 Amps need an interstage transformer.

For example, if you use a 300A current transformer, part #16-0073, and

an interstage transformer, part #16-0176, the 300A current transformer

provides a 5A signal to the interstage transformer. In turn, the trans-

former sends a 20mA maximum signal to the controller.

Phase

dot

2.10 WATLOW Series 988 User’s Manual

Installation and Wiring, Chapter 2

Input 2 Wiring

Load wire

Center leg not used

Figure 2.10a — Slidewire Feedback or Potentiometer Input

98 _ _ - _ 3 _ _ - _ _ _ _

CCW

Wiper

NOTE:

See Chapter 8 for

information on

slidewire feedback.

NOTE:

A process output

cannot be installed

on output 1 when

using a current

transformer input.

NOTE:

Successful installa-

tion requires five

steps:

• Model number and

software choice

(Appendix);

• DIP switch set-

tings (Chapter 1);

• Sensor match

(Chapter 2 and

Appendix);

• Sensor installation

(Chapter 2); and

• Wiring (Chapter 2).

AC Load

0 to 5A

0 to

20mA

Red

Wh Bk

Bk Wh

16-0176

Transformer

20mA

Single-phase Single-phase current sensing up to 300 amps

3-phase using 2 current transformers 3-phase current sensing up to 300 amps.

WATLOW Series 988 User’s Manual 2.11

Installation and Wiring, Chapter 2

Figure 2.10c — Digital Event Input 2

98 _ _ - _ 5 _ _ - _ _ _ _

open 0-3VÎ (dc) Event Input 2 off

closed 14-36VÎ (dc) Event Input 2 on

Figure 2.11a — Digital Event Input 1

Available on all units.

open 14-36VÎ (dc) Event Input 1 off

closed 0-3VÎ (dc) Event Input 1 on

+5VÎ (VDC)

100Ω

750Ω

4.7KΩ

1KΩ

.01µf

Internal Circuitry

23 24

+24VÎ (dc)

10KΩ

4.99KΩ

OPTO

ISOLATOR

750Ω

.01µf

4.99KΩ

Internal Circuitry

NOTE:

Successful installa-

tion requires five

steps:

• Model number and

software choice

(Appendix);

• DIP switch set-

tings (Chapter 1);

• Sensor match

(Chapter 2 and

Appendix);

• Sensor installation

(Chapter 2); and

• Wiring (Chapter 2).

Event Input 1 Wiring

2.12 WATLOW Series 988 User’s Manual

Installation and Wiring, Chapter 2

Figure 2.12a — AC Outputs

Solid-state Relay

with

Contact Suppression

98 _ _ - _ _ B _ - _ _ _ _

0.5 amps, minimum off-state impedance: 20KΩ

Electromechanical Relay

with

Contact Suppression

(Suppression between NO and COM contacts only)

98 _ _ - _ _ D _ - _ _ _ _

Form C, 5 amps, minimum off-state impedance: 20KΩ

Electromechanical Relay

without

Contact Suppression

98 _ _ - _ _ E _ - _ _ _ _

Form C, 5 amps off-state impedance: 31MΩ

Solid-state Relay

without

Contact Suppression

98 _ _ - _ _ K _ - _ _ _ _

0.5 amps, off-state impedance: 31MΩ

Output 1 Wiring

Figure 2.12b — Switched DC, Open Collector

98 _ _ - _ _ C _ - _ _ _ _

Maximum voltage: 42V

ÎÎ

(dc)

Maximum current: 1A

External

Load

COM

Fuse

(#14 for D & E outputs only)

External

Load

COM

Figure 2.12d — 0-5V

ÎÎ

, 1-5V

ÎÎ

and 0-10V

ÎÎ

(dc) Process

98 _ _ - _ _ F _ - _ _ _ _

Minimum load impedance: 1KΩ

Figure 2.12c — 0-20mA and 4-20mA Process

98 _ _ - _ _ F _ - _ _ _ _

Maximum load impedance: 800Ω

Internal Circuitry

790Ω

19 to 32VÎ (dc)

NOTE:

Successful installa-

tion requires five

steps:

• Model number and

software choice

(Appendix);

• DIP switch set-

tings (Chapter 1);

• Sensor match

(Chapter 2 and

Appendix);

• Sensor installation

(Chapter 2); and

• Wiring (Chapter 2).

NOTE:

Switching inductive

loads (relay coils,

solenoids, etc.) with

the mechanical

relay or solid state

relay output options

requires using an

R.C. suppressor.

Watlow carries the

R.C. suppressor

Quencharc brand

name, which is a

trademark of ITW

Paktron. Watlow

Part No. 0804-0147-

0000.

WATLOW Series 988 User’s Manual 2.13

Installation and Wiring, Chapter 2

Output 2 Wiring

Figure 2.13b — Switched DC, Open Collector

98 _ _ - _ _ _ C - _ _ _ _

Maximum voltage: 42V

ÎÎ

(dc)

Maximum current: 1A

External

Load

COM

Figure 2.13d — 0-5V

ÎÎ

, 1-5V

ÎÎ

and 0-10V

ÎÎ

(dc) Process

98 _ _ - _ _ _ F - _ _ _ _

Minimum load impedance: 1KΩ

Figure 2.13c — 0-20mA and 4-20mA Process

98 _ _ - _ _ _ F - _ _ _ _

Maximum load impedance: 800Ω

Figure 2.13e — External Signal Conditioner Power Supply

98 _ _ - _ _ _ T - _ _ _ _

-V

Transmitter

4-20mA out

Input

1 or 2

Figure 2.13a — AC Outputs

Solid-state Relay

with

Contact Suppression

98 _ _ - _ _ _ B - _ _ _ _

0.5 amps, minimum off-state impedance: 20KΩ

Electromechanical Relay

with

Contact Suppression

(Suppression between NO and COM contacts only)

98 _ _ - _ _ _ D - _ _ _ _

Form C, 5 amps, minimum off-state impedance: 20KΩ

Electromechanical Relay

without

Contact Suppression

98 _ _ - _ _ _ E - _ _ _ _

Form C, 5 amps off-state impedance: 31MΩ

Solid-state Relay

without

Contact Suppression

98 _ _ - _ _ _ K - _ _ _ _

0.5 amps, off-state impedance: 31MΩ

External

Load

COM

Fuse

(#17 for D & E outputs only)

Internal Circuitry

790Ω

19 to 32VÎ (dc)

NOTE:

Successful installa-

tion requires five

steps:

• Model number and

software choice

(Appendix);

• DIP switch set-

tings (Chapter 1);

• Sensor match

(Chapter 2 and

Appendix);

• Sensor installation

(Chapter 2); and

• Wiring (Chapter 2).

NOTE:

Input-to-output iso-

lation is defeated

when the external

signal conditioner

power supply is

used to power a

transmitter connect-

ed to input 1 or

input 2.

NOTE:

Switching inductive

loads (relay coils,

solenoids, etc.) with

the mechanical

relay or solid state

relay output options

requires using an

R.C. suppressor.

Watlow carries the

R.C. suppressor

Quencharc brand

name, which is a

trademark of ITW

Paktron. Watlow

Part No. 0804-0147-

0000.

Loop powered

Figure 2.14c — Process Retransmit

0-20mA, 4-20mA, Load impedance: 600Ω max.

98 _ _ - _ _ _ _ - M _ _ _

0-5V

ÎÎ

, 1-5V

ÎÎ

, 0-10V

ÎÎ

(VDC), Load impedance: 500Ω min.

98 _ _ - _ _ _ _ - N _ _ _

2.14 WATLOW Series 988 User’s Manual

Installation and Wiring, Chapter 2

NOTE:

Input-to-output iso-

lation is defeated

when the external

signal conditioner

power supply is

used to power a

transmitter con-

nected to input 1 or

input 2.

NOTE:

Successful installa-

tion requires five

steps:

• Model number and

software choice

(Appendix);

• DIP switch set-

tings (Chapter 1);

• Sensor match

(Chapter 2 and

Appendix);

• Sensor installation

(Chapter 2); and

• Wiring (Chapter 2).

Figure 2.14d — External Signal Conditioner Power Supply

98 _ _ - _ _ _ _ - T _ _ _

Figure 2.14a — AC Outputs

Solid-state Relay

with

Contact Suppression

98 _ _ - _ _ _ _ - B _ _ _

0.5 amps, minimum off-state impedance: 20KΩ

Electromechanical Relay

without

Contact Suppression

98 _ _ - _ _ _ _ - J _ _ _ _

Form A or B, 5 amps, off-state impedance: 31MΩ

Solid-state Relay

without

Contact Suppression

98 _ _ - _ _ _ _ - K _ _ _ _

0.5 amps, off-state impedance: 31MΩ

External

Load

COM

Fuse

NO Form A

NC Form B

Figure 2.14b — Switched DC

98 _ _ - _ _ _ _ - C _ _ _

Minimum load resistance: 500Ω

External

Load

-V

Transmitter

4-20mA out

Input

1 or 2

Form B

Form A

Form A or B

alarm jumper

settings (98__-

____-J___ only)

NOTE:

See Chapter 1 for

power supply DIP

switch information.

Internal Circuitry

790Ω

19 to 32VÎ (dc)

Output 3 Wiring

NOTE:

Switching inductive

loads (relay coils,

solenoids, etc.) with

the mechanical

relay or solid state

relay output options

requires using an

R.C. suppressor.

Watlow carries the

R.C. suppressor

Quencharc brand

name, which is a

trademark of ITW

Paktron. Watlow

Part No. 0804-0147-

0000.

Loop powered

WATLOW Series 988 User’s Manual 2.15

Installation and Wiring, Chapter 2

Figure 2.15b — Switched DC, Open Collector

98 _ _ - _ _ _ _ - _ C _ _

Maximum voltage: 42V

ÎÎ

(dc)

Maximum current: 1A

Figure 2.15a — AC Outputs

Solid-state Relay

with

Contact Suppression

98 _ _ - _ _ _ _ - _ B _ _

0.5 amps, minimum off-state impedance: 20KΩ

Electromechanical Relay

with

Contact Suppression

(Suppression between NO and COM contacts only)

98 _ _ - _ _ _ _ - _ D _ _ _

Form C, 5 amps, minimum off-state impedance: 20KΩ

Electromechanical Relay

without

Contact Suppression

98 _ _ - _ _ _ _ - _ E _ _ _

Form C, 5 amps, off-state impedance: 31MΩ

Solid-state Relay

without

Contact Suppression

98 _ _ - _ _ _ _ - _ K _ _ _

0.5 amps, off-state impedance: 31MΩ

Output 4 Wiring

External

Load

COM

Fuse

(#7 for D & E outputs only)

External

Load

COM

Figure 2.15c — External Signal Conditioner Power Supply

98 _ _ - _ _ _ _ - _ T _ _

-V

Transmitter

4-20mA out

Input

1 or 2

Controllers with Output 4 (R, S, or U)

For data communications wiring refer to “

Data Communications

with the Watlow Series 988 Family of Controllers”

manual. This

manual can be downloaded from Watlow’s website at

www.watlow.com

, Product Techical Information - Controls.

NOTE:

Input-to-output iso-

lation is defeated

when the external

transmitter power

supply is used to

power a signal con-

ditioner connected

to input 1 or input 2.

NOTE:

See Chapter 1 for

power supply DIP

switch information.

NOTE:

Successful installa-

tion requires five

steps:

• Model number and

software choice

(Appendix);

• DIP switch set-

tings (Chapter 1);

• Sensor match

(Chapter 2 and

Appendix);

• Sensor installation

(Chapter 2); and

• Wiring (Chapter 2).

Internal Circuitry

790Ω

19 to 32VÎ (dc)

NOTE:

Switching inductive

loads (relay coils,

solenoids, etc.) with

the mechanical

relay or solid state

relay output options

requires using an

R.C. suppressor.

Watlow carries the

R.C. suppressor

Quencharc brand

name, which is a

trademark of ITW

Paktron. Watlow

Part No. 0804-0147-

0000.

Loop powered

WATLOW Series 988 User’s Manual 3.1

Front Panel and Display Loop, Chapter 3

Chapter 3 Front Panel and Display Loop

Upper Display

Indicates the actual process value,

prompt parameter value or error

code.

DEV LED

When lit, the lower display shows

the most recent deviation unit from

the set point.

% OUT LED

When lit, the lower display shows

the current percent output.

Up-arrow Key

Increases the value or changes the

parameter in the upper display

(except for set point changes in the

Display Loop, which occur in the

lower display). Hold the key down

to increase the value rapidly. New

data takes effect in five seconds or

when the Mode key or Display key

is pressed.

Up + Down Keys

Press simultaneously for three sec-

onds to go to the Setup Menu.

Continue to press both keys for

another three seconds to go to the

Factory Menu. Access to the Setup

and Factory menus can be dis-

abled with lockout DIP switch.

Lower Display

Indicates the set point, deviation,

percent power, temperature unit,

menu prompt name or alarm code.

L1, L2, L3, L4

These LED’s indicate when output

1, 2, 3 or 4 are active. Outputs can

be configured as:

Ot1 Control

Ot2 Control or Alarm

Ot3 Alarm or Retransmit

Ot4 Alarm or Communications

(flashes on transmit and

receive)

Display Key

Pressing this key enters the

Display Loop. Press the Display

key at any time to return to this

loop. The next page has more

information on the Display Loop.

Auto/Man Key

In Manual mode the lower display

shows percent output. Pressed

once, it clears any latched alarm. If

pressed again within five seconds

it will toggle between Auto and

Manual mode.

Auto/Man LED

Lit when the control is in Manual

operation. Press the Auto/Man key

twice to enter Automatic operation.

When blinking, press the Auto/Man

key to toggle between Auto and

Manual. After five seconds without

pressing the Auto/Man key, the

LED stops blinking and returns to

its previous state.

PROCESS

L1 L2 L3 L4

DEV

% OUT

DISPLAY

SERIES 988

MODE

AUTO

MAN

Mode Key

Enters new data and steps to

the next prompt in the current

menu.

Mode + Up-arrow Keys

Hold the Mode key then press

the Up-arrow key to move

backwards through the cur-

rent menu. Scrolling stops

when you reach the top of the

menu.

Figure 3.1 -

Series 988 Keys and Displays

Down-arrow Key

Decreases the value or changes

the parameter in the upper display

(except for set point changes in the

Display Loop, which occur in the

lower display). Hold the key down

to decrease the value rapidly. New

data takes effect in five seconds or

when the Mode key or Display key

is pressed.

Keys and Displays

3.2 WATLOW Series 988 User’s Manual

Front Panel and Display Loop, Chapter 3

Display Loop

The Display Loop is the “home” state of the Series 988 controller. Pressing

the Display key ∂ returns the controller to the Display Loop from any

prompt in any menu. The controller automatically returns to the Display

Loop from any menu when a minute passes without any keys being

pressed.

Figure 3.2 -

The Display Loop

DISPLAY

units selected (units, °F or °C)

set point 1 (change with Up-arrow > or Down-arrow < key)

input 2 process (appears only if controller equipped with input 2 hardware)

deviation from set point, process 1 minus set point 1 (DEV light on)

percent output (%OUT light on)

DISPLAY

current input 1 reading

current input 2 reading

current input 1 reading

DISPLAY

[`988]

[`988]

[`988]

[Pr`2]

[`988]

[`988]

[`988]

[`100]

[`988]

[``°C]

NOTE:

If [``no] is selected

for [`In2], in the

Input Menu, the

[Pr`2] prompt will

not appear.

NOTE:

For information on

input 1 [`In1] and

input 2 [`In2]

ranges, refer to

Chapter 4.

PROCESS

L1 L2 L3 L4

DEV

% OUT

DISPLAY

SERIES 988

MODE

AUTO

MAN

WATLOW Series 988 User’s Manual 4.1

Setup Menus, Chapter 4

Navigating the Setup Menus

To reach the Setup Menus, begin in the Display Loop and press both the Up-

arrow > and Down-arrow < keys for three seconds. The Setup Menu

prompt [`SEt] will appear in the lower display, and the Input Menu prompt

[InPt] will appear in the upper display. The four Setup Menus are: Input

[InPt]; Output [OtPt]; Global [GLbL]; and Communications [COM]. Use the

Up-arrow > or Down-arrow < key to select a menu and the Mode key µ

to step through a menu. The Communications Menu appears only on units

equipped with the data communications option.

You will not see every prompt in any of these menus. The unit’s configuration

and model number determine which prompts appear. After stepping through

each menu, the Series 988 returns to the Setup Menu prompt [`SEt]. Use

the Up-arrow > and Down-arrow < keys to select the next menu, or use

the Mode key µ to advance through the same menu again. To move back-

wards through the menu hold the Mode key µ down and press the Up-

arrow key >. Use the Up-arrow > or Down-arrow < key to change the

prompt setting.

Refer to the Appendix for model number options. For information about

communications and the communications prompts, refer to the supple-

mental manual Data Communications with the Watlow Series 988 Family of

Controllers.

Chapter 4 The Setup Menus

Figure 4.1 -

Navigating the

Setup Menus.

Input

p. 4.2

Output

p. 4.18

Global

p. 4.34

Communications

p. 4.44

[Inpt]

[`Set]

[`Set] [`Set]

[`Set]

[OtPt] [gLbL] [COm]

❶ Begin in the Display Loop, and press the Up-arrow

> and Down-arrow < keys simultaneously to

reach the Setup Menus.

❷ Press the Up-arrow key > to select one of the

Setup Menus.

PROCESS

L1 L2 L3 L4

DEV

% OUT

DISPLAY

SERIES 988

MODE

AUTO

MAN

NOTE:

The lockout DIP

switch hides the

Setup Menus. See

Chapter 1.

NOTE:

Press the Display

key ∂ to return to

the Display Loop

from any point in

any menu.

NOTE:

When navigating

through menus,

outputs will be dis-

abled.

4.2 WATLOW Series 988 User’s Manual

Setup Menus, Chapter 4

MODE

*Slidewire Hysteresis

*Hunt

*Linearization 2

*Software Filter 2

*RTD Calibration Curve 2

*Calibration Offset 2

*Learn High

*Learn Low

*Range High 2

*Range Low 2

*Decimal 2

*Remote Set Point

*Input 2

*Linearization 1

Software Filter 1

*RTD Calibration Curve 1

Range High 1

Calibration Offset 1

Setup Prompt

Input 1

*Decimal 1

Range Low 1

Enter your settings,

from the controller's

upper display.

MODE

Input 2 (p. 4.9)

Input 1 (p. 4.3)

Slidewire (p. 4.16)

[Inpt]

[`Set]



[`In1]

[deC1]

[`rL1]

[`rH1]

[CAL1]

[rtd1]

[Ftr1]

[Lin1]

[`ln2]

[`rSp]

[deC2]

[`RL2]

[`RH2]

[LrnL]

[LrnH]



[CAL2]

[rtd2]

[Ftr2]

[Lin2]

[Hunt]

[SHYS]

Figure 4.2 -

The Input Menu.

Setup-Input

❸ Select the Input Menu, then press

the Mode key µ to step through the

prompts.

PROCESS

L1 L2 L3 L4

DEV

% OUT

DISPLAY

SERIES 988

MODE

AUTO

MAN

❹ Press the Up-arrow key > or the

Down-arrow key < to select one of

the prompt values.

…

[Ftr1] [Ftr1] [Ftr1] [Ftr1]

[```0] [```1] [```2] [``60]

[root]

[Lin1]

[``no]

[Lin1]

*Prompts may not appear,

depending on controller

configuration.

Reaching the Input Menu

Input Prompts

When you are in the Setup menus, the Series 988 displays the menu selec-

tion ( [InPt], [OtPt], [GLbL] or [COM] ) in the upper display, and [`SEt] in

the lower display.

The Up-arrow > or Down-arrow key < selects another menu. Press the

Mode key µ to display the prompt in the lower display and its value in the

upper display. Use the Up-arrow > or Down-arrow < key to change the

value in the upper display. The new value will not take effect until after a

five-second delay or until you press the Mode key µ.

Input 1

Select sensor type for input 1. This selection must match the sensor type

connected to terminals 8, 9 and 10. See Appendix for more information

about sensors.

• Changing the value of [`In1] changes all other prompts to the factory

default values, except the Communications and Lockout menus, the

[`C_F] prompt in the Global Menu and the [`dFL] prompt in the

Calibration Menu. If you change the value, the default warning [dFLt]

will flash in the upper display.

• Changes do not take effect automatically after five seconds; you must

press the Mode key µ to enter the sensor type change and advance to

the next prompt.

[`In1] This prompt always appears.

If Default

↓ ↓

98_ _-1_ _ _-_ _ _ _

no DIP J K T N E W5 W3 Pt2 0-50mV

[```J] [```H] [```t] [```n] [```E] [```C] [```d] [`Pt2] [0-50]

thermocouple [`In1] [`In1] [`In1] [`In1] [`In1] [`In1] [`In1] [`In1] [`In1]

only

98_ _-2_ _ _-_ _ _ _

Input 1 DIP J K T N E W5 W3 Pt2 0-50mV

[```J] [```H] [```t] [```n] [```E] [```C] [```d] [`Pt2] [0-50]

[`In1] [`In1] [`In1] [`In1] [`In1] [`In1] [`In1] [`In1] [`In1]

thermocouple

Input 1 DIP RSB

[```r] [```S] [```b]

[`In1] [`In1] [`In1]

thermocouple

↑

123

↑

123

WATLOW Series 988 User’s Manual 4.3

Setup Menus, Chapter 4

Setup-Input

NOTE:

Decimal points may

not always be in the

position specified

below depending on

the the settings in

the Decimal 1

[dEC1] and Decimal

2 [dEC2] parame-

ters in the Input

Menu.

CAUTION:

Changing the value

of [`In1] changes

most other prompts

to the factory

default values.

Document all set-

tings before chang-

ing sensor type.

Verify the correct

sensor type before

making a change.

Failure to follow

this guideline could

result in damage to

equipment or prop-

erty. Document all

settings before

changing sensor

type.

[`In1]

Input 1 continued

on next page.

[`In1]

4.4 WATLOW Series 988 User’s Manual

Setup Menus, Chapter 4

[`In1]

Input 1 continued

from previous

page.

Setup-Input

If Default

↓↓

Input 1 DIP RTD RTD(0.1°)

[`rtd] [`r†d]

[`In1] [`In1]

RTD

Input 1 DIP 4-20mA 0-20mA 0-5VÎ 1-5VÎ 0-10VÎ (dc)

[4-20] [0-20] [`0-5] [`1-5] [0-10]

[`In1] [`In1] [`In1] [`In1] [`In1]

process

Decimal 1

Select the decimal point location for process type input 1 data. This

prompt, in conjunction with the Range Low and Range High prompts,

allows you to format and limit units of measure for process 1.

• All prompts with units of measure related to input 1 will display in the

selected decimal format.

• This affects propbands, alarm set points, process set points, calibration

offsets, deadbands and ranges.

[dEC1] This prompt appears only if you have set input 1 [`In1] to a

process input or to a thermocouple input set to 0-50mV.

Default

↓

[```)] [``)0] [`)00] [)000]

[dEC1] [DEC1] [dEC1] [dEC1]

↑

123

↑

123

[dEC1]

+ 119 hidden pages