Watlow 94 User Manual
Series 94
1/16 DIN Limit Controller
0600-0024-0000 Rev C Made in the U.S.A.
June 2002 $10.00
Supersedes 0600-0024-0000 Rev B
User’s Manual
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
CUSTOMER
SATISFACTION
FM
How to Use This Manual Watlow Series 94
Safety Information
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 safety alert symbol, ç, (an exclamation point in a triangle) precedes a
general CAUTION or WARNING statement.
The electrical hazard symbol, Ó, (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 +1 (507) 494-5656, 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; and all configuration information.
Your Feedback
Your comments or suggestions on this manual are welcome, please send them
to: Technical Writer, Watlow Winona, 1241 Bundy Boulevard, P.O. Box 5580,
Winona, MN 55987-5580, Phone: +1 (507) 454-5300, Fax: +1 (507) 452-4507.
The Series 94 User’s Manual is copyrighted by Watlow Winona, Inc., © June
2002, with all rights reserved. (2290)
NOTE:
Details of a “Note”
appear here in the
narrow margin on
the outside of each
page.
ç
CAUTION:
Details of a
“Caution” appear
here in the narrow
margin on the outside of each page.
Ó
WARNING:
Details of a
“Warning” appear
here in the narrow
margin on the left
side of each page.
Watlow Series 94 Table of Contents
Chapter 1: Overview ......................................................... 1.1
General Description ................................................ 1.1
Chapter 2: Install and Wire the Series 94 ..................... 2.1
Panel Cutout ............................................................2.1
Dimensions ..............................................................2.1
Installation Procedure ..............................................2.1
Wiring the Series 94 ................................................2.3
Sensor Installation Guidelines .................................2.4
Input Wiring .............................................................2.4
Output 1 Wiring ...................................................... 2.5
Output 2 Wiring ...................................................... 2.5
System Wiring Example .......................................... 2.7
Chapter 3: How to Use the Keys and Displays .............. 3.1
Keys, Displays & Indicator Lights ........................... 3.1
Chapter 4: How to Set Up the Series 94 ........................ 4.1
Setting the Input Type DIP Switch .......................... 4.1
Entering Setup Menu .............................................. 4.2
Setup Parameters ................................................... 4.3
Setup Menu Table ................................................... 4.5
Operation Parameters ............................................. 4.6
Operation Menu Table ............................................. 4.6
Chapter 5: Alarms and Errors ......................................... 5.1
Using Alarms .......................................................... 5.1
Error Code Messages ............................................. 5.2
Error Code Actions ................................................. 5.2
Appendix ........................................................................ A.1
Decreasing Noise Sensitivity ...................................A.1
Eliminating Noise .................................................... A.2
Calibration ................................................................A.3
Restoring Factory Calibration ................................. A.4
Calibration Menu .................................................... A.4
Calibration Procedures ........................................... A.5
Glossary ................................................................. A.7
Specifications ......................................................... A.9
Model Number Information .................................. A.10
Index .................................................................... A.11
Declaration of Conformity.......................................A.12
Quick Reference ................................................... A.13
Figures ...................................................... Page
Series 94 Input & Output Overview .................................1.1
Multiple Panel Cutout Dimensions .................................2.1a
Series 94 Dimensions ....................................................2.1b
Mounting Case Side View ............................................. 2.2a
Mounting Collar Cross Section .......................................2.2b
Case Rear View & NEMA 4X Seal Example ................... 2.2c
Power Wiring .................................................................. 2.3
Thermocouple Sensor Input Wiring .............................. 2.4a
2- or 3-wire RTD Sensor Input Wiring .......................... 2.4b
Output 1 Mechanical Relay Wiring ................................ 2.5a
Output 2 Mechanical Relay Wiring ................................ 2.5b
Output 2 Solid-state Relay w/o Suppression Wiring ......2.6a
Output 2 Switched DC Wiring ....................................... 2.6b
System Wiring Example .................................................. 2.7
Wiring Notes.....................................................................2.8
Series 94 Keys and Displays ........................................... 3.1
DIP Switch Location & Orientation ............................... 4.1a
Input DIP Switches.........................................................4.1b
Entering the Setup Menu .............................................. 4.2a
The Setup Menu ........................................................... 4.2b
The Operation Menu ....................................................... 4.6
Clearing an Alarm ........................................................... 5.1
Error Code Message ....................................................... 5.2
Entering the Calibration Menu ........................................ A.3
Calibration Menu ............................................................ A.4
Tables ...................................................... Page
Input Ranges ................................................................. 4.5a
Setup Menu Prompts/Description.................................. 4.5b
Operation Menu Prompts/Description ............................. 4.6
Quick Reference Sheet .........................................A.13-A.14
TC
Table of Contents
Watlow Series 94
Notes
Watlow Series 94 Overview ■ 1.1
Overview
General Description
Welcome to the Watlow Series 94, a 1/16 DIN microprocessor-based limit controller. The 94 has a single input that accepts a type B, J, K, T, N or S thermocouple or RTD input.
The Series 94 controller limits over-temperature conditions in thermal applications. The limit controller protects against high-temperature runaway conditions resulting from a shorted input sensor or a failed output device. A limit
controller is recommended in any application where thermal runaway could
affect operator safety, damage equipment or cause large product scrap costs.
The limit output is latching. An optional process alarm output can be configured as latching or non-latching, with high and low alarm set points.
Special 94 features include the optional NEMA 4X rating, dual four-digit displays in either red or green and optional low-voltage power supply.
Operator-friendly features include automatic LED indicators to aid in monitoring and setup, as well as a calibration offset at the front panel. The Watlow
Series 94 automatically stores all information in a non-volatile memory.
Single Input Type J, K, T, N, B or S
Thermocouple, or 1°
or 0.1° RTD
Output 1 - High/Low Limit
Output 2 - High/Low
Alarm or None
Overview of the Series 94
LIMIT 94
RESET
1
Figure 1.1 Series 94 Input and
Output Overview
Overview
1.2 ■ Overview Watlow Series 94
Notes
Panel Cutout
Your Panel
Thickness
0.06" to 0.38"
(1.5 to 9.7 mm)
1.77" to 1.79"
(44.96mm to 45.47mm)
1.77" to 1.79"
(44.96mm
to 45.47mm)
0.38"
(9.65mm)
Minimum
0.85"
(20mm)
LIMIT 94
2.1"
(53 mm)
2.1"
(53mm)
RESET
Watlow Series 94 Install and Wire ■ 2.1
Install and Wire
Figure 2.1a -
Series 94 Multiple
Panel Cutout
Dimensions.
Installation Procedure
Bold print denotes requirement for NEMA 4X seal. Follow this procedure to mount the Watlow Series 94 temperature control:
1. Make a panel cutout using the dimensions in Figure 1a.
2. If your controller model number begins with 94B
, make sure the
rounded side of the external case gasket is facing the panel surface. Check to see that the gasket is not twisted, and is seated within the
case bezel flush with the panel. Place the case in the cutout. Make sure
the gasket is between the panel cutout and the case bezel.
NOTE:
Measurements
between panel
cutouts are the minimum recommended.
Figure 2.1b-
Series 94
Dimensions.
0.40"
(10mm)
1.21"
(31mm)
4.1"
(104mm)
4.7"
(119mm)
1.76"
(45mm)
2
Install and Wire the Series 94
NOTE:
For rapid mounting,
use Greenlee 1/16
DIN punch, die, draw
stud, part number
60287.
3. While pressing the front of the case firmly against the panel, slide the
mounting collar over the back of the control. The tabs on the collar must line
up with the mounting ridges on the case for secure installation. See Figure 2
a. Slide the collar firmly against the back of the panel getting it as tight as
possible.
To ensure a tight seal, use your thumb to lock the tabs into place while pressing the case from side to side. Don’t be afraid to apply enough pressure to
install the control. The tabs on each side of the collar have teeth which latch
into the ridges. See Figure 2b. Each tooth is staggered at a different height,
so only one of the tabs on each side are ever locked into the ridges at any
time.
As depicted in Figure 2.2c, confirm that the tabs on one side of the collar correspond with those on the opposite side. Make sure the two corresponding
tabs are the only ones locked in the ridges at the same time.
If the corresponding tabs are not supporting the case at the same
time and the space between the panel and the case bezel is greater
than .019", you will will not have a NEMA 4X seal. This applies to
units with models designated 94B
. However, all units should be mounted
in this fashion to guarantee integrity of the mounting system.
2.2 ■ Install and Wire Watlow Series 94
Install and Wire
Figure 2.2a -
Mounting Case Side
View.
Figure 2.2b -
Mounting Collar
Cross Section with
offset teeth.
Figure 2.2c -
Case Rear View and
NEMA 4X Seal
Example.
0 to 0.019 space
(0 to 0.483 mm)
Bezel
Panel
External Gasket
Mounting Collar
Ridges
Teeth
Tabs
4. Insert the control chassis into its case and press the bezel to seat it. Make
sure the inside gasket is also seated properly and not twisted. The hardware
installation is complete. Proceed to the wiring section from here.
Removing the Series 94 Controller
When removing the mounting collar, we suggest using a thin tool such as a
putty knife or screwdriver to pry gently under each of the six tabs to disengage the teeth. Then rock the collar back and forth until it can be easily
pulled off the case.
NEMA 4X Seal Example.
Make sure that the two corresponding tabs
are locked in the ridges at the same time
.
ç
CAUTION: Follow the
installation 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 seated properly. Failure to do so
could result in damage to equipment.
Wiring the Series 94
The Series 94 wiring is illustrated by model number option. Check the unit
sticker on the controller and compare your model number to those shown here
and also the model number breakdown in the Appendix of this manual.
All outputs are referenced to a de-energized state. The final wiring figure is a
typical system example.
When you apply power without sensor inputs on the terminal strip, the Series
94 displays [`---] in the upper display, and [`Er7] in the lower display after
30 seconds on power-up. This error indicates an open sensor or A/D error. All
wiring and fusing must conform to the National Electric Code and to any locally
applicable codes as well.
Power Wiring
High Voltage
100 to 240Å (ac), nominal (85 to 264 actual) 94_ _-1_ _ 0 - 00_ _
Low Voltage
12-24V‡ (ac/dc) 94_ _- 1_ _ 1 - 00_ _
Figure 2.3 – Power wiring.
Watlow Series 94 Install and Wire ■ 2.3
Install and Wire
Ó
WARNING: To avoid
electric shock, use
National Electric
Code (NEC) safety
practices when
wiring and connecting this unit to a
power source and to
electrical sensors or
peripheral devices.
Failure to do so could
result in injury or
death.
NOTE:
Taking the unit out of
the case is not a normal operating condition and should only
be done by a qualified maintenance
installation technician. Power to the
case should be disconnected before
removing or
installing the controller into its case.
Ó
WARNING: The case
terminals may still
carry live voltage
when the unit is
removed.
Ó
WARNING:
Irreversible damage
will occur if high
voltage is applied to
the low voltage unit.
NOTE: Optional protective rear terminal
cover, 0822-0426-P001, is available.
Contact Watlow customer service or your
local Watlow sales representative.
LIMIT 94
RESET
L1 L2
11 12
Sensor Installation Guidelines
We suggest 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 you want to protect. Air flow past this sensor should be moderate.
The sensor should be thermally insulated from the sensor mounting.
See Chapter 4 for more information on DIP switch location and orientation.
Input Wiring
Figure 2.4a – Thermocouple
Extension wire for thermocouples must be of the same alloy as the thermocouple itself to limit errors.
DIP Switch orientation
Figure 2.4b – RTD (2- or 3-Wire) 100Ω Platinum
There could be a + 2°F input error for every 1Ω of lead length resistance
when using a 2-wire RTD. That resistance, when added to the RTD element
resistance, will result in erroneous input to the instrument. To overcome
this problem, use a 3-wire RTD sensor, which compensates for lead length
resistance. When extension wire is used for a 3-wire RTD, all wires must
have the same electrical resistance (i.e. same gauge, same length, multistranded or solid, same metal).
DIP Switch orientation
Install and Wire
2.4 ■ Install and Wire Watlow Series 94
Ó
WARNING: To avoid electric shock and damage to
property and equipment,
use National Electric
Code (NEC) safety practices when wiring and
connecting this unit to a
power source and to electrical sensors or peripheral devices. Failure to do
so could result in injury or
death.
NOTE:
When an external device
with a non-isolated circuit
common is connected to
the dc output, you must
use an isolated or ungrounded thermocouple.
+3
12
T/C
-5
O
N
↑
S1
3-wire RTD
2
3
S2
2-wire RTD
Jumper
Terminals
5
S3
3 and 5.
S1
2
3
S2
S3
5
12
O
N
↑
Watlow Series 94 Install and Wire ■ 2.5
Output 1 Wiring
Figure 2.5a – Mechanical Relay Without Contact Suppression
94_ _- 1D _ _- 00 _ _
Form C, 5 amps
Minimum load current:
100 mA at 5VÎ (dc)
Output 2 Wiring
Figure 2.5b – Mechanical Relay Without Contact Suppression
94_ _- 1D D _ - 00_ _
Form C, 5 Amp
Minimum load current:
100 mA at 5VÎ (dc)
Install and Wire
NOTE:
Successful installation requires four
steps:
• Choose the controller’s hardware
configuration and
model number
(Appendix);
• Choose a sensor
(Chapter Two and
Appendix);
• Install and wire the
controller (Chapter
Two);
• Configure the controller (Chapters
Three, Four and
Five).
NOTE 1:
Switching inductive
loads (relay coils,
solenoids, etc.) with
the mechanical relay,
switched dc or solidstate relay output
options requires use
of 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.
Ó
WARNING: To avoid
damage to property
and equipment,
and/or injury or loss
of life, use National
Electric Code (NEC)
standard wiring practices to install and
operate the Series
94. Failure to do so
could result in such
damage, and/or
injury or death.
N.O. contact opens in limit condition.
N.C. contact closes in limit condition.
N.O. contact opens in alarm condition.
N.C. contact closes in alarm condition.
Customer installed
Quencharc for inductive
loads only. See note 1.
NC 1
6 COM
7 NO
L1
L2
Customer installed
Quencharc for inductive
loads only. See note 1.
Figure 2.6a – Solid-state Relay Without Contact Suppression
94_ _- 1D K _- 00_ _
0.5 Amp (AC loads only)
Form A
Figure 2.6b – Switched DC
94_ _- 1D C _ - 00_ _
Install and Wire
2.6 ■ Install and Wire Watlow Series 94
NOTE:
Output is in de-energized
state in Alarm Condition.
NOTE 1:
Switching inductive loads
(relay coils, solenoids,
etc.) with the mechanical
relay, solid-state relay
output options requires
use of 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.
NOTE 2:
When an external device
with a non-isolated circuit
common is connected to
the dc output, you must
use an isolated or ungrounded thermocouple.
Ó
WARNING: To avoid damage to property and
equipment, and/or injury
or loss of life, use
National Electric Code
(NEC) standard wiring
practices to install and
operate the Series 94.
Failure to do so could
result in such damage,
and/or injury or death.
See note 2.
SS2
1
Fuse
7
SS2
Customer installed
Quencharc for inductive
loads only. See note 1.
External
L1
Load
L2
7 to 10VÎ(dc)
+
6
7
External
-
unregulated
Load
Internal Circuitry
100Ω
V—
6
7
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