Watlow 920 User Manual
Series 920
Microprocessor-Based
Ramping Control
User’s Manual
Watlow
Controls, 1241 Bundy Blvd., Winona, MN 55987, Phone:
W920-MA60-9302
January, 1993
Supersedes:
W920-MC5A-8944
507/454-5300,
Made in the U.S.A.
0
Printed
0
Fax:
507-452-4507
$10.00
on
Recycled
Paper
First...
This manual will
tion is a good way to become familiar with the Series 920. Here’s an overview:
make
your
job
easier.
Reading it and applying the
informa-
Starting
Front Panel
Running a Program
lnstall/Wire
Tune
Programming
Alarms
Appendix
Quick Reference
Out
Introduction, Chapter 1.
Keys and Displays, Chapter 2.
Sample Program, Chapter 3.
Installation and Wiring, Chapter 4.
How to Tune, Chapter 5.
How to Program, Chapter 6.
How to Use Alarms, Chapter 7.
Specifications
Glossary
Calibration
Warranty
Series 920 error codes and prompts, inside and outside back covers.
Notes
The user’s manual contains informational notes to alert you to important details. When you
see a note
icon,
look for an explanation in the margin.
J
or fl NOTE:
Details of a
appear here, in the
narrow box on the
outside of each page.
f
0
n
Details of a “Caution”
appear here, in the
narrow box on the
outside of each page.
0
Details of a “Warning”
appear here, in the
narrow box on the
outside of each page.
2
“Note”
CAUTION:
WARNING:
WATLOW
Series 920
Safety Information
Boldface safety information protects both you and your equipment.
them. Here are explanations:
The CAUTION symbol (exclamation point) in the wide text column alerts you to a
TION”,
a safety or functional hazard which could affect your
A full explanation is in the narrow column on the outside of the page.
equipment
Please be attentive to
‘CAU-
or its performance.
0
The WARNING symbol (lightning bolt) in the wide text column alerts you to a ‘WARNING”,
A full explanation is in the
P.0. Box
.
5580,
Winona,
Techni-
MN 55987-5580,
are
bir
0193
a safety hazard which could affect you and the equipment.
narrow
column
on the outside of the page.
Your comments or suggestions on this manual are welcome, please send them to:
cal Writer,
or phone
copyrighted by Watlow Winona, Inc.,© 1987 with all rights reserved.
User's
Watlow
507/454-5300.
Manual
Controls, 1241 Bundy Blvd.,
The Watlow Series 920 User’s Manual and integral software
Page
Item
6
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Starting out with the Watlow Series 920 - Chapter 1
General Description
Packing List
Put Your Control to Work-Three Steps
How to Open the 920
How to Set the DIP Switches
Changing the Position of a DIP Switch
Overview of the Three Operating Modes
Where To Go From Here
How to Use the Keys and Displays - Chapter 2
Display, Key and LED-Location and Explanation
Front Panel Information
Actual and Alphanumeric Display Area
Keyboard Area
Where To Go From Here
-
Learning the Series 920
A Brief
Overview
Chapter 3
Clear Memory, Set DIP Switches
Enter Real Time of Day
Before Entering Your Program
Programming File 1
Running Your Program
Editing Your Program
Adding an
LIN
King Files
The
AUTOSTART
WAITFOR
Step Type
Step
Running Your Series 920
Where To Go From Here
Starting Out
Front Panel
Sample Program
20
20
20
21
22
22
22
24
24
25
26
27
27
28
30
32
Contents
How to Install and Wire the Series 920 - Chapter 4
Sensor Installation Guidelines
Input Power Wiring
The Do’s and
Don’ts
of Clean Input Power
How to Check for Ground Loops
Noise Suppression Devices Available from Watlow
Line Filtering Configurations For Controls
Installation Information
Installation Procedure
How to Wire the Series 920
Power Wiring
Input Wiring
Auxiliary Output Wiring
Output 1 Wiring
Output 2 Wiring
System Wiring Example
Install and Wire
WATLOW Series 920 User’s Manual
3
Page
Item
Tuning
Programming
Alarms
33
33
33
33
34
35
35
36
36
36
36
37
37
38
39
40
42
49
54
54
54
55
56
57
58
58
58
How to Tune the Series 920 - Chapter
5
Recommended Tuning Reference
Using a Chart Recorder
Load
LEDs
Tuning
The LOPWR and
HIPWR
Parameters
Where To Go From Here
H
OW
to Program the Series 920 - Chapter
6
Write Out Your Program
Programming in General
Select the Proper DIP Switch Settings
Event Ouputs
Guaranteed Soak
The Four
JUMPLOOP
Types
Rules to Follow
SYSTEM Menu
SETUP Menu
PROGRAM Menu
How to Use the Series 920 Alarms - Chapter
Alarm
Relay Configuration
Number of Alarms
Alarm Types
The Operating Band
Alarm
Limits
Alarm
Function, Latching or Non-Latching
Clearing an Alarm Message
An Alarm And The State Of The Alarm Relay
7
Appendix
Terminology
Quick Reference
WATLOW Series 920 User’s
59
59
60
62
63
64
66
67
75
77
77
77
78
80
Appendix
Specifications
Model Number Information
J, K, & T Thermocouple Field Calibration Procedure
R, S, &
B Thermocouple Field Calibration Procedure
RTD Field Calibration Procedure
Process Field Calibration Procedure
Glossary
Index
Warranty
Returning Merchandise
Shipping Claims
Series 920 Error Codes/Alarms
Series 920 Quick Reference
Manual
Contents
Figures, Tables and Charts
Page
.
6
8
9
10
12
12
13
19
23
23
23
24
25
25
26
27
27
28
28
29
29
30
30
30
31
31
32
37
40
42
49
55
55
57
57
62
63
64
66
Item
Series 920 Input and Output Overview
How to Open the Series
920
DIP Switch Location and Orientation
Overview
of the Three Operating Modes
Series 920 Front Panel Information
Actual and Alphanumeric Display Front Panel Information
Keyboard Front Panel Information
RUN Key Flow Diagram
Differential Mode Filter Diagram
Common Mode Filter Diagram
Combination Differential-common Mode Filter Diagram
Series 920 Faceplate Dimensions
Series 920 Dimensions (side view)
Series 920 Panel Cutout Dimensions
Series 920 Power Wiring
Input Options Wiring Diagram
Auxiliary Wiring Diagram
Output 1, S.S. Relay, Wiring Diagram
Output 1, S.S. Switch, Wiring Diagram
Output 1,
Output 1,
Output
Mech.
Relay, Wiring Diagram
Triac,
Wiring Diagram
1,4-20mA,
Wiring Diagram
No Output 2
Output 2, S.S. Relay, Wiring Diagram
Output 2, S.S. Switch, Wiring Diagram
Output 2,
Mech. Relay,
Wiring Diagram
System Wiring Example
Guaranteed Soak (GS) Example
SYSTEM Key Flow
SETUP Key Flow
PROGRAM Key Flow
Alarm Type for
Alarm 1
is “process” alarm
Alarm Type for Alarm 1 is a “deviation” alarm
Alarm limits for Alarms 1 and 2 with “process” type alarm
Alarm limits for Alarms 1 and 2 with “deviation” type alarm
J, K, T Reference Compensator to 920 Connection Diagram
“R"
Reference Compensator to 920 Connection Diagram
Decade Resistance Box to Series 920 Connection Diagram
Voltage/Current Source to Series 920 Connection Diagram
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
Figure
24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
Figure 36
Figure 37
Figure 38
Figure 39
9
16
17
17
18
18
22
41
43
50
56
65
53
Contents
DIP Switch Selection
Series 920 Ramp and Soak Program
Editing Your Program, Steps 4-7
Adding the AUTOSTART Step
LlNKing
The
to Another File
WAITFOR
Step
Noise Suppression Device Ratings
SYSTEM Prompts and Description
SETUP Prompts and Description
Table 1
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
Table 8
Table 9
PROGRAM Prompts and Description Table 10
Operating Band Limits and Ranges
RTD Calibration Settings for
JIS
Master Step Chart
Table 11
Table 12
Chart 1
WATLOW Series
920
User’s
Manual
5
Figure
Series
output
l-
920 Input
Overview
Selectab
RTD,
T/C
Process
and
Chapter 1
Starting out with the
Watlow Series 920:
A Microprocessor-Based Control
or
Dual
PID
or
ON/OFF
outputs
FF
Two Auxiliary Outputs
RS-422A
Optional Computer Interface
or
RS-423A (RS-232C
Compatible)
General Description
Congratulations, you’re about to become a fully-qualified user of the Watlow
Series
simple to learn. A ramp progresses from one set point to another set point over a
period of time.
920 and its operation.
Figure 1 is a simplified view of the Series
microprocessor-based, 1/4 DIN-sized ramping temperature control. The 920
accepts a single, front panel-selectable input. This includes Type
or B thermocouple input, a 1° or 0.1°
has a full control temperature range, offset calibration, and a front panel lock-out
feature.
6
WATLOW Series 920
User’s
920!
This versatile microprocessor-based ramping control is powerful, yet
In this chapter of the user’s manual, you’ll get an overview of the
920’s
capabilities. It is a dual output,
J,
K, T, R, S,
RTD
input, or one of two process inputs. It
Starting
Out,
Chapter
Manual
1
The Series 920 is a
PID
controller. You may input two complete sets of
PID
parameters on the front panel for heat/cool applications. This includes rate,
reset, proportional band and cycle time. By setting the proportional band(s) to
zero, the Series 920 becomes a simple
ON/OFFcontrol
with a
3°F
or
1.7°C
switching differential.
The 920s auxiliary outputs may be alarms or events. An event is an ON/OFF
auxiliary output relay signal. You can use events, based on time, temperature,
or other process variables, to trigger peripheral equipment or processes.
Operator-friendly features include automatic entry codes or “prompts” to aid in
setup. When there’s a power outage, the Watlow Series 920 stores all information in a non-volatile memory.
When you first apply power, the unit will “come up” with default values for set
points, alarm points and control
parameter.
These default values provide
minimum operating information for the control until you program in the desired
data. The default values are listed in the Master Step Menus and Charts,
pp.
41-50.
Remove the Series 920 carefully from its shipping container. Be sure to set
this literature aside where it will not be discarded.
Packing List
Included with your Watlow Series 920 are two mounting brackets with integral
screws, and this manual.
If your unit has communications, the “How to Use
Data Communications with the Watlow Series 922” manual is also included.
Put Your Control to Work-Three Steps
Once your control is installed and wired, getting the Series 920 “up and run-
ning” is a three-part process:
l
First, match the control’s “personality”, to your system in what we call the
SETUP menu; input type, units of measure, range, calibration offset, output
action, alarm type, lock-out.
l
Second, tune the control making final
l
Third, enter up to ten separate profiles in the PROGRAM menu.
PID
entries.
WATLOW Series 920 User’s Manual
7
How to Open the 920
7
0
A
The front panel
screw turns
only. Do not apply
excessive force or
turn the screw more
than
CAUTION:
90°
90°.
Before going further, open the Series
case. Here’s how:
The control chassis fastens to the case with a single screw located on the
lower front panel. See Figure
Three or four strip connector
power and signals through the back of the casing to the triple terminal strip.
These plugs will let go as you pull.
f
l
A
When removing the Series
When returning the control to the case, be sure you have the top up to match
the plugs with the case. The 920 will not fit in to the case upside down. Always check to see that it is oriented correctly.
the front panel screw clockwise to secure it.
2.
plugs, in the rear of
920
control from its case, pull firmly but gently.
920
and pull the control chassis from its
Turn the screw counterclockwise to loosen it.
the control chassis, feed
Press the unit in firmly, then turn
Figure 2
How to Open the
Series 920.
-
How to Set the DIP Switches
The Watlow Series 920 has a Dual In-line Package (DIP) switch inside the
control on circuit board
appear in Figure 3. The switches are clearly numbered from left to right. You
will use DIP switches #1 and 3 - 8; #2 is not used. Table 1 on the next page
shows the DIP switch selections.
AOO7-1699.
The locations of the board and switch
8
WATLOW Series 920 User’s Manual
Starting Out Chapter 1
Figure 3
DIP Switch Location
and
-
Orientation.
DIP
SW#
ON
1
2
3
4
5
6
7
8
Cold Start
Not Used
Tenths of units displayed
0-5VDC/0-20mA
Primary output is
LEDs
are load indicators
Selected SPCLFUNC promts
Factory Test/Calibrate
DIP switch #1 determines a warm or cold start. A
grammed information in the 920s memory back-up protection. A “cold” start is a
“clean” startup condition; all user-programmed information is lost. The Series
920 leaves the factory programmed for a warm start.
DIP switch #2 is not used.
DIP switch #3 determines if the decimal point is displayed in tenths of units for
process inputs.
DIP switch #4 is for
DIP switch #5 is for units with
set switch #5 ON for the Primary output.
DIP switch #6 determines the function of the front panel
actual display. When ON, these
or system troubleshooting, see Page 12 and 33.
DIP switch #7 is OFF, all SPCLFUNC prompts are displayed, when ON,
factory selected prompts appear. See Page 42. DIP switch #8 is a factory
calibrate switch.
Function
input
4-20mA
0-5VDC/0-20mA
4-20mA
LEDs
Normal
Operating
OFF
Warm Start
Not Used
No decimal displayed
l-5VDC/4-20mA
Primary output is not 4-20
LEDs
are °F or
All SPCLFUNC prompts
Normal
input or
output.
can be used as a diagnostic tool for tuning
Operation
l-5VDC/4-20mA
input
°C
“warm”
If your unit has
LEDs
Position
OFF
OFF
Choose
Choose
Model #
Choose
Choose
OFF
start saves all pro-
input selection.
4-20mA
to the right of the
Dep,
output,
only
test/
Changing the Position of a Switch
Whenever you change the position of a DIP switch, follow this procedure:
1.
Remove power from the 920. Turn the front panel screw
2.
Grip the front panel bezel and pull it straight out from the control case.
The control chassis will come out of the case as you pull the bezel.
90°counterclockwise.
Table 1
DIP Switch
Selection.
J
For units with
process input only.
If
have process input,
DIP Switch #3
should be in the OFF
position.
n
Dokg
will cause all setup
parameters and files
to be lost. DO NOT
put DIP switch #1 in
the ON position
unless all
programmed
information is to be
cleared.
-
NOTE:
your unit does not
T
WARNING:
a cold start
user-
3.
Set the DIP switch to the position you want.
4.
Return the control chassis to the case. Be sure you have it oriented correctly. It will not fit in upside down, but check just the same. Press
firmly, but gently, to seat the chassis.
Secure the front
5.
Starting
Out,
Chapter 1
panel
screw and re-apply power to the 920.
WATLOW Series 920
User’s Manual
9
Overview of the Three Operating Modes
Operating
Before getting into the details of the Series 920s keys and displays, take a look
at Figure 4 showing the three different modes. After you feel comfortable with
the names of the modes and their functions, go ahead to learn the keys and
displays.
Figure
Overview of the
Series 920
O
perating
4
-
Series 920: Three Mode Types
Manually
Control
outputs
Enter
Program
Steps & View
Program
Set Up
Your
System
SYSTEM
PROGRAM
SETUP
SYSTEM
Generates a
ramping set point
(fixed), and can
manipulate events,
clear alarms and
error codes.
Mode
non-
PROGRAM Mode
Enter or view step type,
program loops,
wait for...
points, auxiliary
(event) outputs ON/OFF,
and step duration.
conditions,
set
SETUP Mode
Set up or change
system-operating
parameters such as
real time, high/low
range,
alarm points,
settings, RS-422
address.
alarm
types,
PID
10 WATLOW
Where To Go From Here:..
You are now ready to find out more about the Series 920s keys and displays.
Continue to Chapter 2.
Series
920 User’s Manual
Chapter
2
How to Use the Keys and Displays
This chapter will show you the Series 920 front panel, and the function of each
display, key and LED. Figures 6
Display, Key and LED-Location and Explanation
The
Watlow
ACTUAL display at the top of the unit, and the smaller alphanumeric display
below. You set up the Series 920s characteristics in the alphanumeric display
window. On the right of the ACTUAL display there is a red OF LED and a red
°C
LED, indicating the temperature scale ACTUAL is displaying. If neither of
these
Units
The 920 has five touch-membrane keys along the bottom edge of the front
panel: (from left to right) a MODE key, an UP key, a DOWN key, an ENTER
key, and a RUN/HOLD key.
Series 920 Ramping Control has two main displays, the process
LEDs
are showing, the ACTUAL display is showing Process Variable
(PVU’s).
and 7
explain the 920 front panel.
The MODE key steps the processor through the entry prompts.
The UP and DOWN keys increase and decrease or change values in the
alphanumeric display. A single touch to either of these keys will change the
least significant digit by one. Continuous pressure will change the value in the
alphanumeric display at an increased rate. The ENTER key places the value,
in the alphanumeric display, into the processor’s memory.
An alphanumeric display value will flash (when changed with the UP or DOWN
keys) until you press ENTER, placing the value in the processor
The RUN/HOLD key will execute or halt a program.
memory.
Front Panel Information
Use Figures 6 and 7 to assist you in learning the locations and functions of the
front panel components.
How
to Use Keys and Displays, Chapter 2
WATLOW Series 920
User’s
Manual
11
Use the following figures to learn the nature and function of the Series 920s
keys and displays.
Figure 5
Series 920 Front
Panel Information.
ACTUAL Display
-
X,
Shows the actual value
of the process variable
up to four digits.
Figure 6
Actual and
Alphanumeric
Display
Front Panel
lnformation.
-
Actual and Alphanumeric Display Area
°F
LED
When DIP switch #6 is
OFF, it indicates the value
in the ACTUAL display is
temperature in degrees
Fahrenheit. When DIP
switch #6 is ON, it indicates
Output 1 is energized.
When DIP switch #6 is
OFF, both °F and
LEDs
is displaying Process
Variable Units
°C
LED
When DIP switch #6 is
OFF, it indicates the value
in the ACTUAL display is
I
Alphanumeric Display
Shows entry prompts
and the parameter
values in alphanumerics.
temperature in degrees
Celsius. When DIP switch
#6
is ON, this LED indicates
Output 2 is energized.
°C
are OFF. The 920
(PVUs).
12
WATLOW Series 920
User's
Manual
How to Use Keys
and
Displays, Chapter
2
Keyboard Area
MODE Key
This key steps the
Series 920 in sequence
DOWN Key
Acts opposite the UP
key. Decreases the
value in the alphanumeric display. A light
touch decreases the
value by one digit. Hold
the key down to
decrease the displayed
value at a rapid rate.
Figure 7
Keyboard
Panel Information.
Front
RUN/HOLD Key
Executes or holds a
program from the
SYSTEM menu.
Run/Hold
When the HOLD LED is
ON steady, the 920 is in
a HOLD condition.
When the HOLD LED
flashes, the unit is
holding for a
Increases the value
in the alphanumeric
display. A light
touch increases the
value by one digit.
Hold the key down
to increase the
displayed value at
a rapid rate.
I
90°
Front Panel Screw
Secures the control
chassis in its case with
a
1/4
turn clockwise or
releases the chassis
with a
1/4
turn counter-
clockwise.
ENTER Key
Enters selected
(flashing) data into
the microprocessor
memory, or will mask
an error code or
latched alarm for
1
minute.
condition, or a guaranteed soak condition.
When the RUN LED is
ON the 920 is in the
RUN condition.
Where To Go From Here
Now that you have a good idea where everything is on the faceplate of the
Series 920, continue to Chapter 3 for the Sample Program. If you skip the
sample program, do not forget to check the position of DIP switch #1 before
you begin programming your control after installation. With DIP switch #1
OFF, the 920 saves your program whenever power is removed (warm start).
With DIP switch #1 ON, the 920 will clear its memory of all programmed
information whenever power is removed, substituting default values (cold
start).
How to Use Keys and Displays, Chapter
2
WATLOW Series 920 User’s Manual
LEDs
WAITFOR
13
Chapter
3
m
WARNING:
Doing a cold start
will cause all setup
parameters and files
to be lost. DO NOT
put DIP switch #1 in
the ON position
unless all
programmed
information is to be
cleared.
user-
Learning
the Series 920
-
A Sample Program in Action
This chapter
can quickly grasp the necessary terms and concepts by entering and
exercise.
If you feel that your
program to learn the Series 920, skip this chapter.
A Brief Overview
This sample program wilt teach you the fundamentals of creating a ramping profile,
along with ways to expand that profile to its greatest versatility.
The program example will start with a simple ramp and soak profile. A ramp progresses from one set point to another set point over a period of time, or ramp rate,
expressed in degrees/time. Soaking then controls the length of time the temperature
is held at this level.
We will, then expand it to
form an AUTOSTART, LINK to another profile, and finally perform a
At this point make copies of your Master Step Chart on Page 53.
to keep track of your program as you go.
exactly what you want your program to do.
will
guide you through an easy sample program for the Series 920. You
knowledge
multiple
observing
of profiling controllers does not require a sample
ramp and soaks, add
It is also a good idea to sit down and define
JUMPLOOP
functions, per-
It is a good practice
WAITFOR
this
step.
14
WATLOW
Enter Real Time of Day
First, set the Series 920s “real time-of-day,
key is used to progress through the menus. The UP/DOWN keys are used to select
parameters and values, and remain flashing until you press the ENTER key.
Press the MODE key until the SETUP menu appears. Press the ENTER key.
1.
2.
At ACCESS, enter (0) with the UP/DOWN keys; press ENTER. This is your
Series
calibration
3.
Press the MODE key until HOUR appears in the alphanumeric display and press
ENTER. Note that hours are in a 24 hour format.
920 User’s
Manual
(CALIB)
menu.
24-hour
clock.” Remember the MODE
Sample
Program, Chapter
3
2
4.
Use the UP/DOWN keys to place hours into the display. The display will flash
until you press ENTER.
5.
J
Press MODE to continue to the
rect value for minutes and press ENTER.
6.
Press the MODE key several times to return to the top of the ACCESS (0) menu.
At the top of the ACCESS (0), which is the
Time (Tl) displayed.
7.
Continue to press MODE until
SYSTEM.
Before Entering Your Program
Before we begin to program your Series
parameters to enter. Verify that DIP switch #7 is OFF. If you have not tried any
programming since your cold start, the C/F/U (Celsius/Fahrenheit/Units) and GS
(Guaranteed Soak) parameters are set to their appropriate values.
sary for a more detailed definition.
parameters and entering values, it might be a
to see that the values are correct.
1.
Press the MODE key until SETUP appears. Press ENTER. Once again you see
the ACCESS parameter. Use the UP/DOWN keys to enter (5) and press ENTER;
this is the Special Function (SPCLFUNC) menu.
MIN
parameter and press ENTER.
CALIB
menu, you
you
reach RETURN. Press ENTER to return to
Enter the cor-
will
see the Real
a
920,
there are a few other initial SETUP
Refer to the glos-
If you have already tried stepping through the
good
idea to go back and double check
J
NOTE:
When either the
hours or minutes are
entered,
seconds are set to 0.
J3
DIP switch #7 must
be OFF to access all
SPCLFUNC
ters.
internal
NOTE:
parame-
2.
Press MODE again until you see the C/F/U parameter. This parameter will defautt
to F. Use the UP/DOWN keys to enter degrees F (Fahrenheit). Press ENTER..
3.
Continue through the SPCLFUNC menu
Enter a value of (0); press ENTER. This parameter has a default of 0.
4.
Press the MODE key to move to the RETURN parameter. Press ENTER to return
to SYSTEM.
5.
Good job! You have completed the initial setup, and are ready to program the 920.
Programming. File
Our first step in programming will be to make a short ramp and soak program. Step
initializes the set point to a known starting point for the ramp, Step 2 is a short ramp,
Step 3 is a soak step, which holds the programmed set point constant for the pro-
grammed time.
1.
From the SYSTEM menu, press MODE until you see the PROGRAM menu.
Press ENTER.
2.
The Series 920 asks you for a FILE?. Your 920 should already say (I), but if you
have entered any values, it may be different. Make sure it says (1). Press ENTER.
Step 4 will be a STOP step which signals the end of a file.
1
until you see GS
(Guaranteed Soak).
1
3.
Press the MODE key and you are asked for a STEP. ENTER (1) if it is not already
there.
Sample Program, Chapter 3
WATLOW Series 920 User’s Manual
15
Press the MODE key. Use the UP/DOWN keys to select the step type and
4.
values.
Use Table 2 to enter the corresponding parameters and values. The parameters
5.
appear from
progress through the menus. After the step # is selected, use the UP/DOWN
keys to select a step type. Press ENTER. Use the UP/DOWN keys to select
parameters and values, they remain flashing until you press the ENTER key.
At the end of each menu, rather than pressing ENTER to go back to SYSTEM, press
MODE for the STEP prompt. The 920 automatically increments to the next step
number, with the step number flashing. Press ENTER.
left
to right on the table.
Remember that the MODE key is used to
Table 2
Series 920
Ramp and Soak
Program.
J
Step 4 must be
entered
even though it
defaults to a STOP
step.
-
NOTE:
as a step
125
Running Your Program
1.
Return to SYSTEM using the ENTER key at the RETURN prompt.
RUN/HOLD key.
Press
the
16
2.
The Series 920 now asks you what
not already entered.
Press the MODE
3.
Again, press (1) if it is not already there, and press ENTER.
The Series 920
LED is now lit. After each step is completed, the next step that the Series 920
performs will appear.
You may step through the parameters to see what the step-type is and what the
parameters are set at. The Time Remaining is also displayed at the end of the menu.
Once the Time Remaining reaches 00:00:00, it will show you what step it has progressed to. Refer to the Run menu on Page
WATLOW Series 920 User's Manual
quickly
FlLE?
you would like to run. Enter (1) if it is
key. The 920 asks you what step you would like to start on.
shows you the SP (Set Point) and jumps to Step 1. The
19.
Sample Program, Chapter 3
RUN
Editing Your Program
Let’s try editing the program by expanding it with another ramp and soak step and
adding a jump loop. We’ll jump to Step 1 and repeat Steps 1 - 6 two more times. This
is accomplished by programming a Jump Step (JS) = 1 and Jump Count (JC) = 2.
When your 920 goes through the program and reaches Step 6, it jumps back to Step
and repeats the program two more times.
By this time you should understand the basic concept of the Series 920 and be able to
get around on your own. Remember that the MODE key takes you through the menus.
Use the UP/DOWN keys to select parameters and values, and press ENTER.
1.
Return to the PROGRAM menu.
2.
Enter FILE?
step to a
(1),
Step (4). We are going to change this step type from a STOP
SETPOINT
step. This will be our second ramp. Use Table 3 to enter
values into the corresponding parameters.
3.
Once you have edited your program, run it again and watch its progress.
1
Table 3 Editing
Program,
Steps 4-7.
Your
1
Adding an AUTOSTART Step Type
The Series 920 can also automatically start your program, or a step, on a specified
day and time. When you use AUTOSTART, it stops your program, and waits for the
day and time you entered under the AUTOSTART step type. The Series 920 then
executes the next sequential step. AUTOSTART allows you to wait up to seven days
in the future; day 0 is always the current day.
1 every time the Real Time clock goes from 2359 to
DAY, and the Real Time clock is greater than the programmed AUTOSTART time,
the AUTOSTART waits 6 days along with the programmed time. If day is left blank,
the program begins each day at the real time programmed, regardless of the day.
Go to the PROGRAM menu.
Edit Step 7 from a STOP step to an AUTOSTART step.
Follow the table below for input values. This step will wait for approximately five
minutes in the future.
The
days accumulated increases by
0O:OO.
If 0 is programmed for
FILE
1
1
STEP#
7
8
STEP TYPE DAY
AUTOSTART 0
STOP
HOUR
Current Hours
MIN
Current Minutes +
5
Run this file starting at Step 7 and observe. The Series 920 will now wait until the
real time of day matches the programmed value.
Sample Program, Chapter 3
WATLOW Series 920 User’s Manual
Table 4
Adding the
AUTOSTART Step.
-
17
LlNKing
Files
Table 5
LlNKing
Another File.
-
to
The Series 920 enables you to link
files
together. The LINK step allows you to link the
last step of a profile to the first step of another profile.
Lets edit the program again by adding a LINK step at the end of the profile. But first,
lets create another file.
you’ll receive
ER2
If you run your program with a LINK going to a
non-existing
file,
0036, the “no file found“ error. Follow Table 5 to add a LINK and a
new FILE to your program.
FILE? STEP STEP SP HOUR
#
TYPE
1
5
5 2
5. 3
5 4
5
5
8
1
--_-
5
6
LINK .._
SETPOINT
SETPOINT
SETPOINT
SETPOINT
SETPOINT
STOP
_I75
175 0
100 0
100 0
75 0
----_
&___-._.
MIN
SEC
0
.
0
1
0
0
50..
20
15
10
25
EVl
EV2 FILE?
ON ON
ON ON
ON OFF
ON OFF
OFF OFF
_~
5
..~--
Run your program again beginning at FILE 1, STEP 8. Step through the menu to see
the step type you’re on, and time remaining. See what happens at the end of File
1.
Table 6
The
WAITFOR
18
Step.
WATLOW Series 920 User’s
The
WAITFOR
FILE STEP
The last step type we will work with is the
Step
5 6
5 7
#
STEP
NPE
WAITFOR
STOP
WPV
WHR
75
WAITFOR
step. This is a test step.
WMN
-
It compares a specified temperature with the process temperature, before continuing the
program.
It also waits for programmed time to elapse before continuing with the pro-
gram. After the test is successful, the program continues to the next sequential step.
Return to PROGRAM and enter FILE? (5). Add a
WHR and WMN are unprogrammed. To program a
for WHR and WMN. The programmed
WAITFOR
taneously. Once a
process variable (WPV), and time
WAITFOR
condition is satisfied, it won’t have to be performed again.
WAITFOR
WAITFOR
WAITFOR
step to the end of that file.
time, enter your values
time waits that time duration. Both
(WHR,WMN)
can be programmed simul-
Run your program from FILE 5, STEP 1. If you don’t want to go through the entire
program, START your program at any STEP in FILE 1 or 5. When the program reaches
FILE 5, STEP 6, the HOLD LED begins flashing. This means the program is still
running, but is
HOLDing,
Manual
to
WAITFOR
the ACTUAL temperature to equal the
Sample Proqram Chapter
3
WAITFOR
Your program then continues to the last step, a STOP step, and HOLD
To change a programmed step, return to the PROGRAM menu, and enter the FILE
and STEP number to change.
and press ENTER. Under a step type, to clear all parameters of the current values,
return to that step type and press ENTER. All parameters will return to
Process Variable
(WPV).
When equal, the HOLD LED stops flashing.
S
again.
Use the UP/DOWN keys to select another step type
their
defaults.
Running Your Series 920
To run the Series 920, you must be at one of the three main level operating parameter
menus, SYSTEM, PROGRAM, or SETUP. Press the RUN/HOLD key. The Series 920
asks you what file
the file and step number, the program begins and the RUN LED is lit. While in the
RUN mode, you can only view the current file and step.
you’d like
to run, and asks what step to begin with. After entering
To change your program, you must be in the HOLD mode. To
any time, press HOLD. When returning to your program, the Series 920 asks if
like to
been changed, generates an
the START prompt and begin the program again.
When in the PROGRAM menu, SP is programmed to the steps ending set point.
When in
the
RESUME? on the step you left off on. Trying to RESUME on a file that has
“ER2
0040”; this is a “Change File Error.” Advance to
the
RUN mode it shows the current set point. In the RUN mode, SE
steps ending set point. Refer to Pages 51 - 52 for definitions of other prompts.
At the SYSTEM prompt,
Press @ to enter the PROGRAM parameter values, or
press @ to continue to SETUP.
Graphics Key
@B
83
1 aa=
One of the three step types will be displayed
J
JUMPLOOP, STOP, and LINK step types are immediate, and will not be visible.
depending on the type of step
=
=
pressm
MODE Key
ENTER Key
UP/DOWN
stop your
program
at
you’d
shows
to continue to PROGRAM mode.
PROGFMMmed.
Figure 8
RUN Key Flow
Diagram.
1
Shaded parameters
may not
your control.
parameters are
dependent on how
your control is
configured. See
Chapter 6
information.
-
NOTE:
appear on
for
These
more
Sample Program, Chapter 3
WATLOW
Series 920 User’s
ManuaI
19
Chapter 4
How to Install and Wire the Series 920
This chapter tells you how to install the Series 920.
information is right here.
“burned in” before leaving the factory, the Series 920 is ready to install when you
receive it.
But before you begin working or cutting holes in
chapter to gain an understanding of the entire installation. Consider sensor
installation carefully. You’ll need to look at the noise reduction guidelines before
making your panel cutout.
Because
Watlow
controls are thoroughly tested, and
All
mounting and wiring
panels,
read through this
Sensor Installation Guidelines
We suggest that you mount the sensor at a location in your process or system
where it reads an average temperature. Put the sensor as near as Possible to
the material or space that you want to control. Air flow past this sensor should be
moderate. The sensor should be thermally insulated from the sensor mounting.
Excessive lead length
combat this, use a three wire sensor in long lead applications.
in a two-wire
RTD
sensor can create indication
errors.
To
Input Power Wiring
Microprocessors are in a way
like trout...
20
WATLOW Series
They require a clean environment to be successful and to prosper. A clean
environment means on one level an environment that is free of excessive dust,
moisture and other airborne pollutants. But primarily it means a “clean” source
of input power from which to base all its operations. What is “clean power”?
Clean power is simply a steady, noise-free line voltage source that
rating specifications of the hardware using it. Wiihout clean power to the
integrated circuitry, any microprocessor chip
Just as the water you get from a tap nowadays may not be
in some locales, so the line voltage coming into your facility may not be acceptable for your microprocessor devices. You may have to fitter or “clean” the
water or the power. In industrial environments, the potential for pollutants
increases, especially electrical noise due to high level power
occurring in one place.
The recommendations we are providing for you are ways to achieve a minimum
level of clean input power protection.
remove the potential for input power problems.
ures and still do not get results, please feel free to call us at the factory. We
are here to see that our control products work well and do the job they were
designed to do.
920 User’s Manual
In almost all cases these
isdoomed
If you’ve applied these meas-
to failure.
acceptable
HoHow w to Install and Wire, Chapter 4
How to Install and Wire, Chapter 4
meets
to drink
consumption
guidelines
the
Definitions
Ground Loop - A condition created when two or more paths for electricity are
created in a ground line, or when one or more paths are created in a shield.
Earth Ground - The starting point for safety and computer grounds.
a copper rod driven into the earth.
Safety Ground - A ground line run with electrical power wiring to protect personnel.
Computer Ground
or microprocessor-based systems. This line is isolated from safety ground.
Common Mode Line Filter - A
power
line legs with respect to ground.
Differential Mode Line Filter - A device to filter noise signals present
between the two power lines themselves.
The D
Do
interference pick up.
Do use twisted pair wire and possibly shielded wire from line filters to the control to
keep the line “clean”.
Do keep low power control wires physically separated as far as possible from line
voltage wires. Also keep all controller wiring separate from other nearby wiring.
Physical separation is extremely effective. A 12 inch
usually effective.
OS
and
keep line filters as close to the control as possible to minimize the area for
-
A ground line for the ground connections to computers
device
to filter noise signals present on both
Don’ts
of Clean Input Power
(304.8mm)
It is usually
minimum separation is
Do use common mode, differential mode or a combination of the two filters
wherever power may have electrical interferences.
Do cross other wiring at
Do have a computer ground line separate from all other ground lines. This computer
ground line should terminate at the ground rod where the electrical service is grounded.
Don’t connect computer ground to safety ground or any other ground points in
the electrical system, except at the ground rod.
Don’t
mount relays or switching devices close to a microprocessor control.
Don’t run wires carrying line voltage with signal wires (sensor, communications or
other low power lines) going to the control.
Don’t use conduit for computer ground.
Don’t
have phase angle-fired devices in the same electrical enclosure or on the
same power line with the control.
Don’t
connect ground to the control case if the control is mounted in a grounded
enclosure (prevent ground loops).
Don’t fasten common mode line filters or filters with metal cases to metal that is at
ground potential. This prevents ground loops and maintains filter
How to Install and Wire, Chapter 4
90°
angles whenever crossing lines is unavoidable.
effectiveness.
WATLOW Series
920 User's
Manual
21
How to Check for Ground Loops
To check for ground loops, disconnect the ground wire at the ground termination. Measure the resistance from the wire to the point where it was
The ohmmeter should read a high ohm value. If you have a low ohm value
across this gap, that means there is at least one ground loop present in your
system.
connected-
Table 7
Noise
Device Ratings.
-
Suppression
Also, check for continuity; your reading should be “open”.
If you do find conti-
nuity, you must now begin looking for the ground loops. Begin disconnecting
grounds in the system one at a time, checking for continuity after each disconnection. When continuity reads “open” you have eliminated the ground loop(s).
Also as you reconnect grounds, keep making the continuity test. It is possible
to reconnect a ground loop.
Noise Suppression Devices
Available from Watlow
Watlow Controls stocks a few key noise suppression parts. You may order
these by calling your local Watlow distributor.
Item
Common Mode Line Filter
Metal
Oxide
Varistor
MOV
I
MOV
MOV
Electrical
250V,
15OV,
130V,
I
275V,
275V,
Ratings
3 Amp
80
Joule
38 Joule
75 Joule
140 Joule
Part Number
0804-0196-0000
0802-0273-0000
1 0802-0304-0000 1
0802-0266-0000
0802-0405-0000
J
NOTE:
For
very
“dirty” or
critical
use micro-computer-regulated
power
Uninterruptable
Power Supply
(U.P.S.)
22
applications,
supply
of
WATLOW
Line Filtering Configurations For Controls
These three diagrams show you filter configurations for removing input power
noise. Choose the one best suited for your system if you are unsure which one
to use.
920 User's
j
Series Manual
Maual
Ll
L2
Ground
D.M. Line Filter
Keep filters
inches
12
(304.8mm)
or
less from the
control. Minimize
the line distance
J
1
where noise can be
w-introduced to the
control.
Control
Figure 9
Differential Mode
Filter Diagram.
-
Ll
L2
Ground
C.M.
Line
Line
C.M.Line Filter
Filter
Load
- 1
rL-___L:_k_-&~
D.M.
Line
Filter
Control
Control
Figure I0
-
Common Mode
Filter Diagram.
To
prevent
ground
loops, do not fasten
common mode line
filters or filters with
metal cases to metal
that is at ground
potential. Doing so
will reduce filter
effectiveness.
Figure 11
-
Combination
Differential-Common
Mode Filter Diagram.
WATLOW
Series
920 User’s
Manual 23
Installation Information
T
0
n
The front panel
screw turns
only. Do not apply
excessive force or
turn the screw more
than
CAUTION:
90°
90°.
The Series 920 mounts in a
hold
the case against
are 3.56 in.
deep.If your unit has a
Figure 12 shows the dimensions of the front
lbs. (1.25Kg).
For unit dimensional and mounting information, including the location of mounting brackets and size of the front
panel’s thickness can be from 0.06
(90.42mm)
panel
cutout with two brackets. These brackets
the
front
panel.
The Series 920 behind-panel dimensions
high by 3.56 in.
triac
output, add another 2.5 in
(90.42mm)
panel
cutout, see Figures 13 and 14. Your
(1.5mm)
wide by 6.0 in.
panel bezel.
to 0.25 in.
(152.4mm)
(63.5mm)
The 920 weighs 2.75
(6.3mm).
to the depth.
Installation Procedure
Follow
this procedure to mount the
1.
Make a
2.
Remove the 920 from its case by turning the front
clockwise
the case.
3.
Place the case in
4.
Attach the mounting brackets either to the top and bottom, or to both sides
of the unit.
5.
Tighten the mounting brackets securely against your panel.
panel
cutout per the dimensions in Figure 14.
(CCW).
Grip the bezel
the
cutout you just made.
Watlow
firmly
Series 920 Temperature Control:
panel
and
screw
pull
the control chassis out of
90°
counter-
Figure 12
Series 920 Faceplate
Dimensions.
-
6.
Insert the
the front
hardware installation is complete. Go on to the wiring section from here.
1~
control
panel
chassis into its case and press the bezel to seat it. Turn
screw
90°
clockwise (CW) to
3.81 Sq.
(96.77mm) ‘-1
lock
the control in place. The
1
3.81 Sq.
(96.77mm)
I
24
WATLOW
Series
920
User’s
Manual
How to
Install
and Wire, Chapter 4
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