Watlow 922 User Manual
Series 922
User's Manual
Microprocessor-Based
Ramping Control
Watlow Controls
Watlow Controls, 1241 Bundy Blvd., P.O. Box 5580, Winona, MN 55987-5580, Phone: 507/454-5300, Fax: 507/452-4507
W922-XUMN Rev C00
April 1996
Supersedes:
W922-MA50-9246
Printed on Recycled Paper
$10.00
Made in the U.S.A.
Use The Manual
First…
This manual will make your job easier.
information is a good way to become familiar with the Series 922. Here's an
overview:
Reading it and applying the
Starting Out
Front Panel
Running a Program
Install/Wire
Tune
Programming
Alarms
Appendix
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 922 error codes and prompts, see Pages 87 - 89.
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 symbol (exclamation point in a triangle) precedes a general CAUTION or
WARNING statement.
The Symbol (a lighting bolt with an arrowhead in a triangle) precedes an
electric shock hazard CAUTION or WARNING safety statement.
Comments and Suggestions
Your comments or 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 phone 507/454-5300. The Watlow Series 922
User's Manual and integral software are copyrighted by Watlow Winona, Inc., ©
1988 with all rights reserved.
2
WATLOW Series 922 User's Manual
Table of Contents
Page Item
Contents
7 Starting out with the Watlow Series 922 - Chapter 1
7 "Read Me First"
8 Packing List
8 Put Your Control to Work —Three Steps
9 How to Open the 922
9 How to Set the DIP Switches
10 Changing the Position of a DIP Switch
11 Overview of the Three Operating Modes
12 How to Use the Keys and Displays - Chapter 2
12 Front Panel Information
13 Actual and Alphanumeric Display Area
13 Keyboard Area
14 Learning the Series 922 - Chapter 3
14 A Brief Overview
15 Enter Real Time
15 Before Entering Your Program
16 Programming File 1
17 Running Your Program
17 Editing Your Program
18 Adding an AUTOSTART Step Type
18 LINKing Files
19 The WAITFOR Step
20 Running Your Series 922
Starting Out
Front Panel
Sample Program
21 How to Install and Wire the Series 922 - Chapter 4
21 Sensor Installation Guidelines
22 Input Power Wiring
23 Definitions
23 The Dos and Don'ts of Clean Input Power
24 How to Check for Ground Loops
24 How to Eliminate Noise
24 Noise Suppression Devices Available from Watlow
24 Line Filtering Configurations For Controls
26 Installation Information
26 Installation Procedure
28 Series 922 Power Wiring
29 How to Wire the Series 922
29 Input Wiring
32 Output Wiring
33 Event Output Board
35 System Wiring Example
Contents
Install and Wire
WATLOW Series 922 User's Manual
3
Contents
Tuning
Programming
Alarms
Page Item
36 How to Tune the Series 922 - Chapter 5
36 Recommended Tuning Reference
36 Using a Chart Recorder
37 Tuning
38 How to Program the Series 922 - Chapter 6
38 Write Out Your Program
38 Select the Proper DIP Switch Settings
38 Event Input
38 Remote Hold Input
39 Event Outputs
39 Guaranteed Soak
40 The Four JUMPLOOP Types
41 JUMPLOOP Rules to Follow
42 Programming in General
42 SYSTEM Menu
45 SETUP Menu
57 PROGRAM Menu
63 How to Use the Series 922 Alarms - Chapter 7
63 Alarm Relay Configuration
63 Number of Alarms
64 Alarm Types
65 The Operating Band
65 Alarm Limits
66 Alarm Function, Latching or Non-Latching
67 Clearing an Alarm Message
67 An Alarm And The State Of The Alarm Relay
Appendix
Terminology
Quick Reference
4
WATLOW Series 922 User's Manual
68 Appendix
68 Specifications
70 Model Number Information
71 Thermocouple Field Calibration Procedure
73 RTD Field Calibration Procedure
75 Process Field Calibration Procedure
76 Glossary
83 Index
85 Warranty
85 Returning Merchandise
86 Shipping Claims
86 Watlow Controls
87 Series 922 Error Codes/Alarms
88 Series 922 Quick Reference
Contents
Figures
Page Item Figures
7 Series 922 Input and Output Overview Figure 1
9 How to Open the Series 922 Figure 2
10 DIP Switch Location and Orientation Figure 3
11 Overview of the Series 922 Figure 4
12 Series 922 Front Panel Information Figure 5
13 Actual and Alphanumeric Display Front Panel Information Figure 6
13 Keyboard Front Panel Information Figure 7
20 RUN Key Flow Diagram Figure 8
25 Differential Mode Filter Diagram Figure 9
25 Common Mode Filter Figure 10
25 Combination Differential- Common Mode Filter Diagram Figure 11
26 Series 922 Faceplate Dimensions Figure 12
27 Series 922 Dimensions (Side View) Figure 13
27 External Event/Alarm Board Dimensions (Side & End view) Figure 14
27 Series 922 Panel Cutout Dimensions Figure 15
28 Series 922 Power Wiring Diagram Figure 16
29 Input Option "1" & "6", Dual RTD, Wiring Diagram Figure 17
30 Input Option "2" & "7", RTD/Process, Wiring Diagram Figure 18
30 Input Option "3", T/C and Process, Wiring Diagram Figure 19
31 Input Option "4" Dual Process, Wiring Diagram Figure 20
31 Input Option "5", Dual T/C, Wiring Diagram Figure 21
32 Dual S.S. Relay Output, Option "BB", Wiring Diagram Figure 22
32 Solid State Switch, Option "CC", Wiring Diagram Figure 23
32 4-20mA/Solid State Output, Option "FB", Wiring Diagram Figure 24
33 External Event/Alarm Board Information Figure 25
33 External Board Control Power Figure 26
33 Ribbon Cable Connector to Series 922 Figure 27
34 Event Output Option "B" and "K" SSR Wiring Diagram Figure 28a
34 Event Output Option "C" Switched DC Wiring Diagram Figure 28b
35 Series 922 System Wiring Example Figure 29
39 Guaranteed Soak (GS) Example Figure 30
42 SYSTEM Key Flow Figure 31
45 SETUP Key Flow Figure 32
57 PROGRAM Key Flow Figure 33
64 Alarm Type for Alarm 1 is "Process" Alarm (ALTYP1 = P) Figure 34
64 Alarm Type for Alarm 1 is a "Deviation" Alarm (ALTYP1=D) Figure 35
65 Alarm Limits for alarms 1 and 2 with "Process" Type Alarm
(ALTYP1 = P, ALTYP2 = P) Figure 36
66 Alarm Limits for Alarms 1 and 2 with "Deviation" Type Alarm
(ALTYP = D, ALTYP = D) Figure 37
71 Reference Compensator-to-Series 922 Connector Diagram Figure 38
73 Decade Resistance Box-to-Series 922 Connection Diagram Figure 39
75 Voltage/Current Source to Series 922 Connection Diagram Figure 40
Contents
WATLOW Series 922 User's Manual
5
Contents
Tables
Page Item Table
10 DIP Switch Selection Table 1
16 Series 922 Ramp and Soak Program Table 2
17 Editing Your Program, Steps 4-7 Table 3
18 Adding the AUTOSTART Step Table 4
18 LINKing to Another File Table 5
19 The WAITFOR Step Table 6
24 Noise Suppression Device Ratings Table 7
43 SYSTEM Prompts and Description Table 8
46 SETUP Prompts and Description Table 9
58 PROGRAM Prompts and Description Table 10
74 RTD Parameter Settings Table 11
Chart
Page Item Chart
62 Master Step Chart Chart 1
6
WATLOW Series 922 User's Manual
Contents
Chapter 1
Starting out with the
Watlow Series 922,
A 2-Channel Ramping Control
Starting Out
Dual Inputs:
RTD, T/C or
Process Value
Event Input
Remote Hold Input
RS-422A or RS-423A (RS-232C Compatible)
Optional Computer Interface
Dual PID or ON/OFF
Outputs/Channel
8 Auxiliary
Outputs
or
2 Auxiliary
Outputs
"Read Me First."
Congratulations, you're about to become a fully-qualified user of the Watlow
Series 922! This versatile microprocessor-based ramping control is powerful,
yet simple to learn. A ramp progresses from one set point to another set point
over a period of time. In this chapter of the user's manual, you'll get an
overview of the 922 and its operation.
Figure 1 is a simplified view of the Series 922's capabilities. It is a 2-channel,
dual output per channel, microprocessor-based, 1/4 DIN-sized ramping
temperature control. The 922 accepts dual inputs, one per channel. This
includes Type J, K or T thermocouple, a 1° or 0.1° RTD input, or one of two
process inputs. You can order an external event output board with two or eight
auxiliary outputs. It has a full control temperature range, offset calibration, and
a front panel lockout feature.
Starting Out, Chapter 1
WATLOW Series 922 User's Manual
Figure 1 Series 922 Input and
Output Overview
7
Starting Out
The Series 922 is a dual channel PID controller. You may input individual sets of
PID parameters for each output. This includes rate, reset, proportional band and
cycle time. By setting the proportional band(s) to zero, the Series 922 becomes
a simple ON/OFF control, with a 3°F or 1.7°C switching differential.
Two of the Series 922's auxiliary outputs may be alarms or events. An event is
an ON/OFF auxiliary output relay signal. You can use events, based on time, to
trigger peripheral equipment or processes. Depending on your individual system
needs, you may order an external event board with two or eight outputs.
Operator-friendly features include automatic entry codes or "prompts" to aid in
setup. When there's a power outage, the Watlow Series 922 stores all information in a nonvolatile memory.
When you first apply power, the unit will "come up" with default values for set
points and control parameters. 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. 46-61.
Remove the Series 922 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 922 are two mounting brackets with integral
screws, and this manual.
Put Your Control to Work—Three Steps
Once your control is installed and wired, getting the Series 922 "up and running"
is a three-part process:
• First, match the control's "personality," to your system in what we call the
SETUP menu; that is input type, units of measure, range, calibration offset,
output action, alarm type, lockout.
• Second, tune the control, making final PID entries.
• Third, enter up to ten separate profiles in the PROGRAM menu.
8
WATLOW Series 922 User's Manual
Starting Out, Chapter 1
How to Open the 922
Before going further, open the Series 922 and pull the control chassis from its
case. Here's how:
The control chassis fastens to the case with a single screw located on the lower
front panel. See Figure 2. Turn the screw counterclockwise to loosen it. Three
or four strip connector plugs, in the rear of the control chassis, feed power and
signals through the back of the casing to the triple terminal strip. These plugs will
let go as you pull.
ç
When removing the Series 922 Control from its case, pull firmly but gently. When
returning the control to the case, be sure you have the top up to match the plugs
with the case. The 922 will not fit in to the case upside down. Always check to
see that it is oriented correctly. Press the unit in firmly, then turn the front panel
screw clockwise to secure it.
Place picture here.
Opening
ç
CAUTION:
The front panel
screw turns 90
only. Do not apply
excessive force or
turn the screw more
than 90°.
°
Place picture here.
How to Set the DIP Switches
The Watlow Series 922 has a set of Dual In-line Package (DIP) switches inside
the control on circuit board A007-1727. The locations of the board and switches
appear in Figure 3. The switches are clearly numbered from left to right. You
will use DIP Switches #1-4 and #6; #5 is not used. Table 1 on the next page
shows the DIP switch selections.
Figure 2 How to Open the
Series 922.
Starting Out, Chapter 1
WATLOW Series 922 User's Manual
9
DIP Switches
Figure 3 DIP Switch Location
and Orientation.
A007- 1727
Board
DIP
Switches
Control Chassis - Top View
Table 1 DIP Switch Selection.
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 userprogrammed
information is to be
cleared.
SPCLFUNC parameters define the
personality of your
Series 922. Such as
input type, units of
measure, range,
calibration offset,
output action, alarm
type, and lock out.
DIP Function Normal
SW# Operating
ON OFF Position
1 Cold Start Warm Start OFF
2 Display the factory selected Display all SPCLFUNC Choose
SPCLFUNC parameters parameters
3 Tenths of units displayed No decimal displayed Choose
4 0-5VDC/0-20mA input 1-5VDC/4-20mA input Choose
5 Not Used Not Used OFF
6 Factory Test/Calibrate Normal Operation OFF
DIP Switch #1 determines a warm or cold start. A "warm" start will save all
programmed information in the 922's memory backup. A "cold" start is a "clean"
startup condition; all user-programmed information is deleted. Your Series 922
leaves the factory programmed for a warm start. DIP Switch #2 selects whether
all SPCLFUNC parameters will be displayed or not. DIP Switch #3 determines
whether the decimal point will be displayed in tenths of units for 0-5V or 4-20mA
input and DIP Switch #4 is for 0-5VDC/0-20mA input or 1-5VDC/4-20mA input
selection. DIP Switch #5 is not used, and DIP Switch #6 is a factory test/calibrate switch.
Changing the Position of a Switch
Whenever you change the position of a DIP switch, follow this procedure:
1. Remove power from the Series 922. Turn the front panel screw 90° counterclockwise.
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.
10
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.
WATLOW Series 922 User's Manual
Starting Out, Chapter 1
Overview of the Three Operating Modes
Before getting into the details of the Series 922's keys and displays, take a look
at Figure 5 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.
Series 922: Three Mode Types
SYSTEM Mode
Generates a non-
Control
Outputs
Manually
Enter
Program
Steps & View
Program
SYSTEM
PROGRAM
ramping set point
for Channel 1 and 2
(fixed), and can
manipulate events,
clear alarms and
error codes.
PROGRAM Mode
Enter or view step type,
program loops,
wait for... conditions, set
points, auxiliary
(event) outputs ON/OFF,
and step duration.
922 Overview
Figure 4 Overview of the
Series 922
Operating
Modes
SETUP Mode
Set Up
Your
System
SETUP
Set up or change
operating parameters such as real
time, high/low
range, alarm types,
alarm points, PID
settings, RS-422
address.
Where To Go From Here…
You are now ready to continue to How to Use the Keys and Displays,
Chapter 2.
Starting Out, Chapter 1
WATLOW Series 922 User's Manual
11
Keys / Displays
Chapter 2
How to Use the Keys and Displays
This chapter will show you the Series 922 front panel, and the function of each
display, key and LED. Figures 6 and 7 explain the 922 front panel.
Front Panel Information
Use Figures 6 and 7 to assist you in learning the locations and functions of the
front panel components.
Use the following figures to learn the nature and function of the Series 922's keys
and displays.
Figure 5 Series 922 Front
Panel Information
Figure 6
Figure 7
Where To Go From Here
Once you have studied the keys and displays in this chapter, and have a good
idea of where everything is on the Series 922, 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 922 saves your program whenever
power is removed (warm start). With DIP Switch #1 ON, the 922 will clear its
memory of all programmed information whenever power is removed, substituting
default values (cold start).
12
WATLOW Series 922 User's Manual How to Use Keys and Displays, Chapter 2
Actual and Alphanumeric Display Area
ACTUAL Display
Shows the actual value
of the process variable
for Channel 1 in
four digits.
Keys / Displays
°F LED
Indicates the value in
the ACTUAL display is
temperature in degrees
Fahrenheit.
When both °C and °F
LEDs are OFF, the
922 is displaying
Process Variable
Units (PVUs).
°C LED
Indicates the value in
the ACTUAL display is
temperature in degrees
Celsius.
Keyboard Area
MODE Key
This key steps the
Series 922 in sequence
from prompt to prompt.
UP Key
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.
Alphanumeric Display
Shows entry prompts,
the parameter values in
alphanumerics and
Channel 2 ACTUAL
value.
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.
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 counterclockwise.
RUN/HOLD Key
Executes or holds a
program from any
Main menu.
ENTER Key
Enters selected (flashing) data into the microprocessor memory. This
will clear an error code,
or latched alarm indications when the ACTUAL
display value returns to
within the alarm limit.
Figure 6 Actual and Alphanumeric
Display
Front Panel
Information
Figure 7 Keyboard Front
Panel Information
Run/Hold LEDs
When the HOLD LED is
ON steady, the 922 is in
a HOLD condition.
When the HOLD LED
flashes, the unit is in a
WAITFOR step or has
exceeded the guaranteed soak deviation..
When the RUN LED is
ON the 922 is in the
RUN condition.
When the RUN LED is
flashing, the program is
being held by the remote
hold input.
How to Use Keys and Displays, Chapter 2 WATLOW Series 922 User's Manual
13
Sample Program
Chapter 3
Learning the Series 922 -
A Sample Program in Action
This chapter will guide you through an easy sample program for the Series
922. You can quickly grasp the necessary terms and concepts by entering
values and then observing this exercise.
If you feel that your knowledge of ramping controllers does not require a
sample program to learn the Series 922, skip this chapter.
A Brief Overview
WARNING:
Doing a cold
start will cause
all SETUP
parameters and
files to be lost.
DO NOT put DIP
switch #1 in the
one position
unless all user
programmed
information is to
be cleared.
This sample program teaches you the fundamentals of creating a ramping
profile, along with ways to expand that profile to its greatest versatility.
The program example starts with a simple ramp and soak profile. A "ramp"
progresses from one set point to another set point over a period of time.
Soaking controls the length of time the temperature holds at this level.
We then expand it to multiple ramp and soaks, add JUMPLOOP functions,
perform an AUTOSTART, LINK to another profile, and finally perform a
WAITFOR step.
This sample program only goes through the steps of programming
Channel 1 of the Series 922. The process for Channel 2 is the same.
Events 3 through 8 are not shown.
At this point make copies of your Master Step Chart on Page 62. It is a good
practice to keep track of your program as you go. It's also a good idea to sit
down and define exactly what you want your program to do.
Clear Memory, Set DIP Switches
If you haven't already cleared your Series 922's memory, do a "Cold Start."
Turn the power OFF, open the 922 and ensure that DIP Switch #1 is ON.
Apply power momentarily and reset DIP Switch #1 to OFF. The program
memory is now cleared. If you haven't done so already, attach your sensor as
described in Chapter 4.
14 WATLOW Series 922 User's Manual
Sample Program, Chapter 3
Enter Real Time
First, set the Series 922's "real time-of-day, 24-hour clock. Remember that
the MODE key is used to step through the menus. The UP/DOWN keys
are used to select parameters and values, and remain flashing until you
press the ENTER key.
1. Press the MODE key until the SETUP menu appears. Press the
ENTER key.
Sample Program
2. At ACCESS, select (0) with the UP/DOWN keys. Press ENTER. This
is the calibration (CALIB) menu.
3. Press the MODE key until HOUR appears in the alphanumeric display.
Note that hours are in a 24 hour format.
4. Use the UP/DOWN keys to place hours into the display. The display
flashes until you press ENTER.
5. Press MODE to continue to the MIN parameter. Enter the correct 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 ACCESS (0) prompt, which is the CALIB menu, you
see the Real Time (TI) displayed.
7. Continue to press MODE until you reach RETURN. Press ENTER to
return to SYSTEM.
Before Entering Your Program
Before we begin to program your Series 922, there are a few other initial
SETUP parameters to enter. If you haven't tried any programming since
your cold start, the C/F/U (Celcius/Fahrenheit/Units) and GS (Guaranteed
Soak) parameters are set to their appropriate values. Refer to the glossary
for a more detailed definition. If you have already tried stepping through the
parameters and entering values, it might be a good idea to go back and
double check to see that the values are correct.
NOTE: When either the
hours or minutes are
entered, internal
seconds are set to 0.
NOTE: DIP Switch #2
must be OFF to access
all SPCLFUNC parameters.
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.
2. Press MODE again until you see the C/F/U parameter. This parameter
defaults to F. Use the UP/DOWN keys to enter degrees F (Fahrenheit).
Press ENTER.
Sample Program, Chapter 3
WATLOW Series 922 User's Manual 15
Sample Program
Skip Step 3 if you do not have an external event board connected.
3. Continue through the menu with the MODE key until you see AUX1. Use the
UP/DOWN keys to enter AUX1 as an event (EV) and press ENTER. Do the
same for AUX2. Default is AL (Alarm).
4. Continue through the SPCLFUNC menu until you see GS (Guaranteed
Soak). Enter a value of (0); press ENTER. This parameter defaults to 0.
5. Press the MODE key to move to the RETURN parameter. Press ENTER to
return to SYSTEM.
Programming File 1
Our first step in programming is to make a short ramp and soak program. Step 1
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 programmed time. Step 4 is a STOP step which signals the end of a file.
1. From the SYSTEM menu, press MODE until you see the PROGRAM menu.
Press ENTER.
2. The Series 922 asks you for a FILE?. Your 922 should already say (1), but if
you have entered any values, it may be different. Make sure it says (1).
Press ENTER.
3. The display now shows STEP with a 1 flashing. Use the UP/DOWN keys to
select (1) then press ENTER if it is not already there.
4. Press the MODE key. Use the UP/DOWN keys to select the step type and
NOTE: EV1 and
EV2 will not
appear unless the
Event Output
board is connected, and AUX1
and 2 are events.
values. Press ENTER. Use Table 2 to enter the corresponding parameters
and values. The parameters appear from left to right on the table.
At the end of each menu, rather than press ENTER at the RETURN parameter to
get to SYSTEM, press MODE for the STEP prompt. The step number automatically increments and flashes. Press ENTER.
FILE? STEP STEP SP1 HOUR MIN SEC EV1 EV2
Table 2 Series 922
Ramp and Soak
Program
1 1 SETPOINT 75 0 0 1 OFF OFF
1 2 SETPOINT 100 0 0 25 ON OFF
1 3 SETPOINT 100 0 0 25 ON OFF
1 4 STOP
NOTE: Step 4 must
be entered as a step
even though it
defaults to a STOP
step.
Temp/°F
16 WATLOW Series 922 User's Manual
TYPE
125
100
75
50
25
Step 3
Step 2
Step 1
Initializes
Set Point.
0
0 5 10 15 20 25 30 35 40 45 50
Ramps from
75 to 100°F.
Time (seconds)
A soak step
holds set
point at 75°F.
Step 4
A stop step.
Sample Program, Chapter 3
Running Your Program
Sample Program
1. Return to SYSTEM using the ENTER key at the RETURN prompt. Press
the RUN/HOLD key.
2. The 922 asks what FILE? to run. Enter (1) if it is not already entered.
3. The 922 asks what step you would like to start on. Again, press (1) if it is
not already there, and press ENTER.
The 922 quickly shows the step type and jumps to Step 1; the RUN LED is lit.
After each step is completed, the next step the 922 performs appears.
You may step through the parameters to see what the step type is and what
the parameters are set at by pressing the MODE key. The Time Remaining is
also displayed at the end of the menu. Once the Time Remaining reaches
00:00:00, it shows what step the profile has progressed to.
Editing Your Program
Now 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
through 6 two more times. This is accomplished by programming a Jump
Step (JS) = 1 and Jump Count (JC) = 2. This means that once the 922 goes
through the program and reaches Step 6, it jumps back to Step 1 and
repeats the program two more times.
By this time you should understand the basic concept of the Series 922 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,
values and step types. Press ENTER and your information is entered.
1. Return to the PROGRAM menu.
2. Enter FILE? (1), Step (4). We are going to change this step type from a
STOP step to a SETPOINT step. This is 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.
FILE? STEP STEP SP1 HOUR MIN SEC EV1 EV2 JS JC
TYPE
1 4 SETPOINT 125 0 0 25 OFF ON - 1 5 SETPOINT 125 0 0 25 OFF ON - 1 6 JUMPLOOP - - - - - - 1 2
1 7 STOP
Step 6
Step 5
Soaks
Jumps to Step 1
and repeats
program twice.
(JC-2)
Temp/°F
125
Step 2
Ramps
100
75
Step 1
Initializes
50
Set Point.
25
0
0 10203040506070 8090100
Step 4
Ramps
Step 3
Soaks
Edit Program
Time (seconds)
Table 3 Editing Your
Program,
Steps 4 - 7
Sample Program, Chapter 3
WATLOW Series 922 User's Manual 17
Sample Program
.
Adding AUTOSTART and LINKing Files
The Series 922 gives you the capability to link files together. The LINK step
allows you to link the last step of a profile to the first step of another profile.
We are going to edit the program again by adding a LINK step at the end of the
profile. First, we must create another file. If you try to run your program with a
LINK that goes to a nonexisting file, you will receive ER2 0036. This error means
"no file found." Follow Table 5 to add a LINK and a new FILE to your program.
The 922 can also automatically start your program, or a step, on a specified day
and time. When you use an AUTOSTART in your program, it stops your program,
and waits for the day and time you entered under the AUTOSTART step type. The
Series 922 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. The days
accumulated increases by 1 every time the Real Time clock goes from 23:59 to
Table 5 LINKing to
Another File with
AUTOSTART.
FILE? STEP STEP TYPE SP1 DAY HOUR MIN SEC EV1 EV2 FILE?
1 8 LINK 5
5 1 AUTOSTART 0 current current + 5
5 2 SETPOINT 175 0 0 50 ON ON
5 3 SETPOINT 175 0 0 20 ON ON
5 4 SETPOINT 100 0 1 15 ON OFF
5 5 SETPOINT 100 0 0 10 ON OFF
5 6 SETPOINT 75 0 0 25 OFF OFF
5 7 STOP
00:00. If 0 is programmed for DAY, and the Real Time clock is greater than the
programmed AUTOSTART time, the AUTOSTART waits 6 days along with the
programmed time.
Run your program again beginning at FILE 1, STEP 8. Step through the menu to
see what step type you are on, and your time remaining. Watch to see what
happens at the end of File 1. The AUTOSTART waits for approximately 5 minutes
into the future before continuing with File 5.
175
Ramps to 175°F
150
125
Step 1
Autostart step.
Temp/°F
100
75
50
25
0
0:00 0:30 1:00 1:30 2:00 2:30
18 WATLOW Series 922 User's Manual
Step 2
Step 3
Soak step.
Profile #5
Step 4
Ramps to 100°F.
Minutes:Seconds
Step 6
Step 5
Soak step.
Ramps to 75°F.
Step 7
Stop step.
3:00
Sample Program, Chapter 3
Sample Program
The WAITFOR Step
The last step type we will work with is the WAITFOR step. This is a test step.
It compares a specified temperature with the process temperature, or a specified event state with the event input, before continuing the program. It can also
wait for a programmed time to elapse before continuing on with the program.
After the test is successful, the program continues with the next sequential
step. Events cannot be programmed in this step; they maintain their previous
state.
Return to PROGRAM and enter FILE? (5). Add a WAITFOR step to the end of
that file.
FILE STEP STEP W1 WHR WMN WE
TYPE
5 6 WAITFOR - - - 5 7 STOP
WHR, WMN, WE and W1 are unprogrammed. To program a WAITFOR time,
enter your values for WHR and WMN. The programmed WAITFOR time waits
until the specified amount of time has elapsed. WAITFOR time (WHR, WMN),
WE, and Channel 1 process variable (W1) can be programmed simultaneously.
Each of these Wait For conditions must be met before the program will continue. Once a WAITFOR condition is satisfied it latches, and does not have to
be performed again.
Run your program from FILE 5, STEP 1. If you do not want to go through the
entire program, you can START your program at any STEP in FILE 1 or 5.
When your program reaches FILE 5, STEP 6, the HOLD LED begins flashing.
This means your program is still running, but it is HOLDing, to WAITFOR the
ACTUAL temperature to equal the WAITFOR Channel 1 (W1). When they are
equal, the HOLD LED stops flashing. Your program continues to the last step,
a STOP step, and HOLDs again. In the HOLD mode the Series 922 controls
the process to the set points of the last SP step.
If you want to change a programmed step, return to the PROGRAM menu, and
enter the FILE and STEP number you want changed. Use the UP/DOWN keys
to select another step type and press ENTER.
Table 6 The WAITFOR Step
To clear all parameters under a step type of its programmed values, return to
that step type and press ENTER. All parameters return to their defaults.
Sample Program, Chapter 3
WATLOW Series 922 User's Manual 19
Sample Program
u
Running Your Series 922
To run your Series 922, you must be at one of the three main level operating
parameter menus, SYSTEM, PROGRAM, or SETUP. Press the RUN/HOLD key.
The Series 922 asks what file you want to run, and asks what step to begin with.
After entering the file and step number, your program begins, and the RUN LED is
lit. While in the RUN mode, you can only view the current file and step.
To stop a running program, press the RUN/HOLD key. To resume a previously
halted program press the RUN/HOLD key. When the FILE? parameter appears,
press the MODE key to advance to the next parameter. When START appears,
press the MODE key again. Next, the RESUME? parameter is now present. Press
ENTER.
RUN Menu
NOTE: Shaded
parameters may
not appear on
your control.
These parameters
are dependent on
how your control
is configured.
See Chapter 6 for
more information.
Figure 8 RUN Key Flow
Diagram
SYSTEM
( )
F ILE ?
( )
START
RESUME?
RETURN
To SYSTEM Men
[ ]
F ILE
[ ]
STEP
SETPOINT
[ ]
SE1
[ ]
SE2
[ ]
HOUR
[ ]
MIN
[ ]
SEC
00 : 00 : 00
[ ]
SP1
[ ]
SP2
[ ]
C2/RH
[ ]
EV1
[ ]
EV2
[ ]
EV3
[ ]
EV4
[ ]
EV5
[ ]
EV6
[ ]
EV7
[ ]
EV8
[ ]
EI
AT THE SYSTEM prompt, press to continue to PROGRAM mode.
E
Press to enter the PROGRAM parameter values, or
press to continue to SETUP.
M
One of the three step types will be displayed
depending on the type of step PROGRAMmed.
JUMPLOOP, STOP, and LINK step types are immediate, and will not be visible.
JUMPLOOP WAITFOR
[ ]
W1
[ ]
W2
[ ]
WHR
[ ]
WMN
[ ]
WE
00 : 00 : 00
M
E
DAY
HOUR
MIN
= MODE Key
= ENTER Key
M
AUTOSTART
[ ]
[ ]
[ ]
00 : 00 : 00
STOP LINK
F ILE
[ ]
= UP/DOWN Key
Where To Go From Here
Good job! You've just programmed and run the Series 922 sample program.
As soon as you feel comfortable with the Series 922 sample program, move on
to Installation and Wiring, Chapter 4. Or if you have already installed and wired
your system, go to the Master Step Chart in Chapter 5 and begin entering and
documenting your Series 922 program.
20 WATLOW Series 922 User's Manual
Sample Program, Chapter 3
Chapter 4
How to Install and Wire the Series 922
This chapter tells you how to install the Series 922. All mounting and wiring
information is right here. Because Watlow controls are thoroughly tested, and
"burned in" before leaving the factory, the Series 922 is ready to install when you
receive it.
But before you begin working or cutting holes in panels, read through this
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.
Miscellaneous Sensor Information
Temp - RH
Wet Bulb/Dry Bulb - In this 922 configuration, a dry bulb RTD measures tem-
perature on Channel 1. A wet bulb RTD, in combination with the dry bulb RTD,
senses relative humidity on Channel 2. The 922 calculates the temperature
difference between the two bulbs to determine per cent relative humidity.
Install/Wire
The humidity/dehumidify outputs (Outputs 3 & 4) are disabled when the Channel
1 temperature falls below 32°F/0°C, or goes above 212°F/160°C. The RH display
reads OFF, and the retransmit output is 0 (volts) if ANLG = C2. ANLG is located
in the Setup menu under Access (5).
Solid State - RH Sensor
Vaisala Model HMM 30C Relative Humidity Sensor - With the Vaisala configu-
ration, Channel 1 must be configured to measure temperature, and Channel 2
must be a process input configured for humidity with the Vaisala sensor. See
below for the TYP parameter description. This parameter is located in the Setup
menu, under Access (5). DIP switch #4 must be set to the ON position. The
humidity and dehumidify outputs (Outputs 3 & 4) are disabled when the Channel 1
temperature falls below -40°F/-40°C or goes above 320°F/160°C. The RH display
will read OFF and the retransmit output is 0 (volts) if ANLG = C2. ANLG is
located in the Setup menu under Access (5).
Temp - Temp
For Temp-Temp RTD operation, each dry bulb RTD or thermocouple senses
temperature for its channel.
RTDs
The RTDs for the Series 922 are customer-supplied items. They may be Gordon
Part #S001-0133-0000, which is a wire-wound RTD inside a sealed, 18% NickelSilver sheath, made for fast temperature response. The detector element is
platinum wire 100Ω at 0°C with a temperature coefficient of 0.003916Ω/Ω/°C. The
sheath is 0.1875 in. (4.7625mm)diameter, 2.75 in. (69.85mm) long. The three
wire leads are 48 in. (1219.2mm) long and teflon insulated.
NOTE: The dry bulb
and wet bulb sensor
should be mounted
in the same location.
However, do not
locate the wet bulb
ahead of the dry
bulb in the air
stream, this could
cause incorrect
relative humidity
readings.
How to Install and Wire, Chapter 4
WATLOW Series 922 User's Manual
21
Install/Wire
Contact Gordon at:
5710 Kenosha St., Box 500
Richmond, IL 60071
Phone: 815/678-2211
Excessive lead length in a two-wire RTD sensor can create indication errors. To
combat this, use a three wire sensor in long lead applications.
RTD - The Dry Bulb Installation
We suggest you mount the dry bulb RTD at a location in your process or
system where it reads an average temperature. Air flow past this sensor should
be moderate. The sensor should be thermally insulated from the sensor
mounting.
RTD - The Wet Bulb Installation
One way to prepare the RTD wet bulb sensor for reading relative humidity on
Channel 2 is to slip a cotton wick over the sensor sheath, Watlow Part # 08300111-0000 or an equivalent. Put one end of the wick in water. Some systems
use a small trough of water with a float valve to replenish the evaporating liquid.
Use distilled water to avoid mineral deposits on the wick that can change the
%RH reading. The wicking distance should be as short as practical. The
cotton wick must be free of any sizing and starch. The "float valve-trough"
systems should also remove the water when the ambient temperature goes
below freezing or above boiling.
To obtain valid %RH readings, air flow past the %RH sensor must be sufficient
to evaporate the maximum amount of water from the wick without drying it out.
Evaporation cools the sensor; the amount of cooling relates directly to the
relative humidity present.
Thermally insulate the wet bulb sensor from the sensor mounting. This prevents mounting surface heat from flowing into the sensor sheath and changing
the wet bulb temperature. (The result of such heat flow will be a humidity
reading higher than actual).
Thermocouple Installation Guidelines
Locate the thermocouples in your process or system where they read average
temperatures. Air flow past these sensors should be moderate. The sensors
must be thermally insulated from the sensor mounting. Both thermocouples
must be ungrounded to obtain correct readings.
Event Input and Remote Hold Input
22
These inputs accept a switch closure to digital common shown on Page 27.
WATLOW Series 922 User's Manual How to Install and Wire, Chapter 4
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. It is usually
a copper rod driven into the earth.
Safety Ground - A ground line run with electrical power wiring to protect personnel.
Computer Ground - A ground line for the ground connections to computers
or microprocessor-based systems. This line is isolated from safety ground.
Common Mode Line Filter - A device to filter noise signals present on both
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 Dos and Don'ts of Clean Input Power
Do keep line filters as close to the control as possible to minimize the area for
interference pick up.
Do use twisted pair wire and possibly shielded wire from line filters to the control
keep the line "clean."
Wiring Guide
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 minimum separation is
usually effective.
Do use common mode, differential mode or a combination of the two filters
wherever power may have electrical interferences.
Do cross other wiring at 90° angles whenever crossing lines is unavoidable.
Do have a computer ground line that is separate from all other ground lines. This
computer ground line should ideally 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 effectiveness.
How to Install and Wire, Chapter 4
WATLOW Series 922 User's Manual
23
Wiring Guide
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 connected.
The ohmmeter should read a high ohm value. If you have a low ohm value
across this gap, there is at least one ground loop present in your system.
Also, check for continuity; your reading should be "open". If you do find continuity, 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.
How To Eliminate Noise
• Use "snubbers" ("QUENCHARC™") to filter out noise generated by devices
such as relays, relay contacts, solenoids, motors, etc. A snubber is a simple
filter device using a 0.1µf, 600 volt, non-polarized capacitor in series with a
100Ω, 1/2 watt resistor. The device can be used on A.C. or D.C. circuits to
effectively dampen noise at its source.
• The general purpose Watlow snubber, described above, is 0804-0147-0000.
For other "QUENCHARC" sizes contact:
PAKTRON
P.O. Box 5439
Lynchburg, VA 24502
Phone: 804/239-6941
Table 7 Noise Suppression
Device Ratings
• A Metal Oxide Varistor (MOV) can be used to limit voltage "spikes" that occur
on the A.C. supply lines as a result of lightning strikes, switching large
motors, etc. The MOV is available in several varieties and for 115 or 230 volt
lines. The device dissipates the voltage "spikes" to ground and in doing so
repeatedly, deteriorates its ability to function. MOVs have a limited life.
• "Islatrols" and other similar power line filters are designed to carry the power
for the control circuit and "buffer" the control circuit from A.C. line noise.
Devices like the Islatrol use media (electromagnetic filtering) other than
electric circuits to filter out electrical noise. Take care in matching the power
capabilities of the filter with power demands of the circuit. Keep line filters as
close to the control as possible to minimize the area for interference pick up.
Noise Suppression Devices Available From Watlow
Watlow Winona stocks a few key noise suppression parts. You may order
these by calling your local Watlow distributor.
Item Electrical Ratings Part Number
Differential Mode Line Filter Refer to the Islatrol listing below.
Metal Oxide Varistor 150V, 80 Joule 0802-0273-0000
MOV 275V, 75 Joule 0802-0266-0000
24
WATLOW Series 922 User's Manual How to Install and Wire, Chapter 4
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. For very "dirty" or critical application -use microcomputer-regulated
power supply or Uninterruptable Power Supply (U.P.S.)
Wiring Guide
L1
L2
Ground
L1
L2
Ground
D.M. Line Filter
Line Load
C.M. Line Filter
Line Load
Shield
Shield
Control
Control
Figure 9 Differential Mode
Filter Diagram
NOTE
: Keep filters
12 inches or less
from the control.
Minimize the line
distance where
noise can be
reintroduced to
control.
Figure 10 Common Mode
Filter Diagram
L1
L2
Ground
How to Install and Wire, Chapter 4
C.M. Line
Filter
Line Load
MOV
D.M. Line
Filter
Line Load
Shield
NOTE: 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.
Control
WATLOW Series 922 User's Manual
Figure 11 Combination
Differential-Common
Mode Filter Diagram
25
Installation
CAUTION: The front
panel screw turns
90° only. Do not
apply excessive
force or turn the
screw more than
90°.
Installation Information
The Series 922 mounts in a panel cutout with two brackets. These brackets
hold the case against the front panel. The Series 922 behind-panel dimensions
are 3.56 in. (9.05mm) high by 3.56 in. (9.05mm) wide by 6.0 in. (15.24mm)
deep. Figure 12 shows the dimensions of the front panel bezel. The 922
weighs 2.75 lbs. (1.25Kg).
For unit dimensional and mounting information, including the location of mounting brackets and size of the front panel cutout, see Figures 13 through 15.
Your panel's thickness can be from 0.06 (1.5mm) to 0.25 in. (6.3mm).
Installation Procedure
Follow this procedure to mount the Watlow Series 922 Temperature Control:
1. Make a panel cutout per the dimensions in Figure 15.
2. Remove the 922 from its case by turning the front panel screw 90° counter
clockwise (CCW). Grip the bezel firmly and pull the control chassis out of
the case.
3. Place the case in the cutout you just made.
4. Attach the mounting brackets either to the top and bottom, or to both sides
of the unit.
Figure 12 Series 922 Faceplate
Dimensions
5. Tighten the mounting brackets securely against your panel.
6. Insert the control chassis into its case and press the bezel to seat it. Turn
the front panel screw 90° clockwise (CW) to lock the control in place. The
hardware installation is complete. Go on to the wiring section from here.
3.81 Sq.
(96.77mm)
3.81 Sq.
(96.77mm)
26
WATLOW Series 922 User's Manual How to Install and Wire, Chapter 4
0.92"
(23 mm)
Bezel
7.8"
(197 mm)
6.0"
(152 mm)
Install / Wire
DB9
Communications
Connector
0.25"
(6 mm)
4.0"
(102 mm)
3.5"
(89 mm)
Mounting Bracket
1.75"
(45 mm)
Alarm/Event Terminal Strip
8.0"
(203 mm)
7.5"
(191 mm)
3.0"
(76 mm)
1.3"
(33 mm)
3.56 "± 0.015"
(90 mm
± 0.381)
Event Output
Ribbon Connector
Figure 13 Series 922
Dimensions
(side view)
0.36"
(9 mm)
Figure 14 External Event/
Alarm Board
Dimensions
Power Terminal Strip
See Page 33 for power wiring.
Your Panel
Thickness:
0.06" to 0.25"
(1.524 to 6.35mm)
How to Install and Wire, Chapter 4
Series 922 Interface
Connection
3.62" to 3.65"
(92.00 to 92.79mm)
Panel
Cutout
3.63" x 3.63"
(92.08 x 92.08mm)
Nominal
Four 0.156' dia
(r4 mm) mounting holes
3.62" to 3.65"
(92.00 to 92.79mm)
Figure 15 Series 922
Panel Cutout
Dimensions
WATLOW Series 922 User's Manual
27
Wire Power
Series 922 Power Wiring
WARNING:
To avoid potential
electric shock, use
National Electric
Code safety practices when wiring &
connecting this unit
to a power source
and to electrical
sensors or peripheral devices.
Figure 16 Series 922 Power
Wiring Diagram.
WARNING:
To avoid electric
shock, connect the
chassis ground
terminal to "Earth
Ground."
NOTE:
For 115VAC,
jumper 17 to 19
and jumper 18 to 20
Chassis
17
GND
18
19
20
21
22
23
24
L1 (Hot)
L2 (Hot)
Earth
Ground
Chassis
Green
GND
Wire
GND
NOTE:
For 230VAC,
jumper 18 to 19
17
18
19
20
21
22
23
24
L1 (Hot)
L2 (Hot)
Earth
Ground
Green
GND
Wire
Remote Hold
External Event
Input
Connect AC power lines and jumper wires to the power supply terminal strip of
the Series 922. Study the strip connections carefully before beginning. Be
sure to use these jumpers on the power supply terminal strip. For 230VAC,
jumper 18 to 19. For 115VAC, jumper 17 to 19 and jumper 18 to 20.
Remote Hold
External Event
Input
CAUTION:
Remove the short
green ground
jumper on the back
of the 922 (T-21) if
your control is
mounted in a metal
panel connected to
safety (chassis)
ground. Removing
the jumper will
prevent ground
OR
loops
leave the short
green ground
jumper in place if
the Series 922 case
is not connected to
safety (chassis)
ground.
28
WATLOW Series 922 User's Manual How to Install and Wire, Chapter 4
All wiring and fusing must conform to the National Electric Code and to any
locally applicable codes also.
Before applying power, open the Series 922 and set DIP Switch #1 in the "ON"
position for a Cold Start. Replace the control chassis in the enclosure. Apply
power to the unit. (This clears all previously entered information from the 922;
it is a "clean" or "cold" start).
Now remove power again, open the unit, and set Switch #1 to OFF. (This
makes the next start a "warm" one, retaining all subsequently entered information in the processor's memory). Close the 922.
When applying power without sensor inputs on the Signal Conditioner terminal
strip, or if the control is not configured for the correct sensor input, the Series
922 alternately flashes from SYSTEM to ER1 00XX. This is an error code
indicating an open sensor. These are normal displays for a unit without sensors or improper configuration.
For more information on remote hold and external event input refer to page 38.
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