Watlow 965 User Manual

Series 965
User's Manual
96
1/16 DIN
Microprocessor-Based
Auto-tuning Control
Watlow Controls
TOTAL
CUSTOMER
SA TISFACTION
3 Y ear W arranty
ISO 9001
Registered Company
Winona, Minnesota USA
0600-0003-0000 Rev. C July 1998
Supersedes: 0600-0003-0000 Rev. B
Printed on Recycled Paper
$10.00
Made in the U.S.A.
About This Manual
Starting Out

How to Use this Manual

We have designed this user's manual to be a helpful guide to your new Series 965. The headlines in the upper right and left corners indicate which tasks are explained on that page.

Notes and Safety Information

NOTE: Details of a "Note" appear here, in the narrow box on the outside of each page.
We use notes, cautions and warnings throughout this book to draw your attention to important information.
Notes are printed in bold in the margin to alert you to an important detail.
ç
A Caution symbol (an exclamation point in a triangle) appears with information that is
ç
CAUTION: Details of a "Cau­tion" appear here, in the narrow box on the outside of each page.
important to protect equipment and performance. Read and follow all cautions that apply to your application.
Ó
A Warning symbol (a lightning bolt in a diamond) appears with information that is important to protect people and equipment from damage. Pay very close attention to all warnings that apply to your application.
Ó
WARNING: Details of a "Warn­ing" appear here, in the narrow box on the outside of each page.

T echnical 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, call for technical assistance: Watlow Controls at (507) 454-5300, between 7:00 a.m. and 5:30 p.m. Central Standard Time. Ask for an applications engineer. When you call, have the following information ready:
• 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 top or right side of the circuit board);
• this user's manual;
• all configuration information;
• the Diagnostics Menu readings.

W arranty and Returns

For information about the warranty covering the Series 965, see page 37.

Comments and Suggestions

We welcome your comments and opinions about this user's manual and the Series 965. Send them to the Technical Editor, Watlow Controls, 1241 Bundy Blvd., P.O. Box 5580, Winona, MN 55987-5580. Or call (507) 454-5300. Or fax them to (507) 452-4507.
WATLOW Series 965 User's Manual2
(1459).
How to Use the Manual

Contents

Starting Out
Page Item
Chapter 1 4 Starting Out With The Watlow Series 965
4 General Description
Chapter 2 5 Install And Wire The Series 965
5 Panel Cutout 5 Dimensions 5 Installation Procedure 7 Wiring the Series 965 8 Sensor Installation Guidelines 8 Input Wiring 10 Output 1 Wiring 11 Alarm Wiring 12 System Wiring Example
Chapter 3 13 How To Use The Keys And Displays
13 Keys, Displays & LEDs
Chapter 4 14 How To Set Up The Series 965
14 Setting the Input Type DIP Switch 15 Entering Setup Menu 16 Setup Parameters 18 Setup Menu Table 19 Operation Parameters 20 Operation Menu Table
Chapter 5 21 How To Tune And Operate
21 Auto-tuning 22 Manual Tuning 23 Manual and Automatic Operation 24 Using Alarms 25 Error Code Messages
Appendix 1
27 Noise Sources 27 Decreasing Noise Sensitivity 28 Eliminating Noise
Appendix 2
29 Entering the Calibration Menu 30 Restoring Factory Calibration 30 Calibration Menu
31 Calibration Procedures 34 Glossary 36 Index 37 Warranty and Returns 38 Specifications 39 Model Number Information 40 Declaration of Conformity 41 Quick Reference
Figures & Tables Page Figure Item
4 Series 965 Input & Output Overview 1 5 Multiple Panel Cutout Dimensions 2 5 Series 965 Dimensions 3 6 Mounting, Case Side View & Collar 4 6 Case, Rear View & NEMA 4X Seal Example 5 7 High Voltage Power Wiring 6 7 Low Voltage Power Wiring 7 8 Thermocouple Sensor Input Wiring 8 8 0-5VÎ (dc) Process Sensor Input Wiring 9 9 2- or 3-wire RTD Sensor Input Wiring 10 9 4-20mA Process Sensor Input Wiring 11 10 Switched DC Output Wiring 12 10 5A Mechanical Relay Wiring 13 10 4-20mA Process Wiring 14 10 0.5A Solid-state Relay w/o Suppression Wiring 15 11 Switched DC Output Wiring 16 11 5A Mechanical Relay Wiring 17 11 0.5A Solid-state Relay w/o Suppression Wiring 18 12 System Wiring Example 19 13 Series 965 Keys and Displays 20 14 DIP Switch Location & Orientation 21 15 Entering the Setup Menu 22 15 The Setup Menu 23 19 The Operation Menu 24 21 Auto-tuning at a 200°F Set Point 25 24 Alarm Display Examples 26 29 Entering the Calibration Menu 27 30 Calibration Menu 28
Tables
18 Input Ranges 1 18 Setup Menu Prompts/Description 2 20 Operation Menu Prompts/Description 3
41 Quick Reference Sheet (Perforated)
How to Use the Manual
3WATLOW Series 965 User's Manual
Starting Out
Starting Out
Chapter 1 Starting Out With The Watlow Series 965,
A Microprocessor-Based Control
Single Input ­Type J, K, T, N or S Thermocouple,
RTD or Process
Figure 1 ­Series 965 Input and Output Overview
Output 1 or 2 Percent Power

General Description

Dual Control Output-
PID or on/off, User Selectable
Output 1 ­Heat or Cool
Output 2 ­Heat, Cool, Alarm or None
Auto-tuning for Heat & Cool PID Settings
Welcome to the Watlow Series 965, a 1/16 DIN microprocessor-based tempera­ture control. The 965 has a single input which accepts type J, K, T, N or S thermocouple, RTD or process input.
With dual output, the primary can be heating or cooling while the secondary can be a control output opposite the primary output (heat or cool), alarm or none. Both outputs can be selected as either PID or on/off. PID settings include proportional band, reset/integral, and rate/derivative. Setting the proportional band to zero makes the Series 965 a simple on/off control with switching differential selectable under the HSC parameter.
Special 965 features include the NEMA 4X rating, dual four digit displays in either red or green, optional low volt power supply, auto-tuning for both heat and cool outputs, ramp to set point for gradual warm-up of your thermal system, and automatic/manual capability with bumpless transfer.
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 965 automatically stores all information in a non-volatile memory.
4 Getting Started, Chapter 1
WATLOW Series 965 User's Manual

Chapter 2

(
)

Install and Wire the Series 965

1.77" to 1.79"
(44.96mm to 45.47mm)
Panel Cutout
NOTE: Measurements between panel cutouts are the minimum recommended.
0.85"
(20mm)
Your Panel
Thickness
0.06" to 0.38"
(1.5 to 9.7 mm)
1.77" to 1.79" (44.96mm
to 45.47mm)
0.38"
(9.65mm)
Minimum

Installation

Figure 2 ­Series 965 Multiple Panel Cutout Dimensions
4.7"
2.1"
(53 mm)
0.40"
(10mm)
1.21"
31mm
(119mm)
4.1"
(104mm)
Installation Procedure
Follow this procedure to mount the Watlow Series 965 temperature control:
1. Make a panel cutout per the dimensions in Figure 2.
2. Remove the 965 chassis from its case. Holding each side of the bezel, press in firmly on the side grips until the tabs release. Pull the chassis out of the case and set aside for later installation.
1.76"
(45mm)
Figure 3 ­Series 965 Dimensions
NOTE: For rapid mounting, use Greenlee punch #60020 and die #60021, or hand hydraulic unit, Kit #7306. All available from Grainger.
3. 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 you just made. Make sure the gasket is between the panel cutout and the case bezel. See Figure 4A.
Install and Wire, Chapter 2
5WATLOW Series 965 User's Manual
Installation
Figure 4 ­Mounting, Case Side View & Collar Cross Section
4A
0 to 0.019 space (0 to 0.483 mm)
Bezel
Panel
Ridges
Tabs
NOTE: 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. PRESS FIRMLY.
External Gasket
4B
Mounting Collar
Teeth
Mounting Collar
Cross Section
(notice the offset teeth
on each tab)
4. 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 4A again. Slide the collar firmly against the back of the panel getting it as tight as possible. Make sure you cannot move the case within the cutout; if you can you do not have a NEMA 4X seal.
Now let's make sure we have 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 4B. 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.
Looking at Figure 5, you see that the tabs on one side of the collar corre­spond with those on the opposite side. Make sure that the two correspond­ing tabs are the only ones locked in the ridges at the same time. If the matching tabs are not holding the case at the same time you will not have a NEMA 4X seal. You can make a visual check, or use your finger nail to pull out on each tab. Only one on each side is engaged, and they must be corresponding as in Figure 5. The space between the bezel and panel must be between 0 and 0.019" (0.48 mm).
Figure 5 ­Case Rear View and NEMA 4X Seal Example
WATLOW Series 965 User's Manual
Make sure that the two correspond-
ing tabs below are locked in the
ridges at the same time.
NEMA 4X Seal Example.
When removing the mounting collar, we suggest sliding a thin tool such as a putty knife or screwdriver under all three tabs on each side at once and pulling it back off the case.
5. 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.
Install and Wire, Chapter 26
How to Wire the Series 965
The Series 965 wiring is illustrated by model number option. Check the unit sticker on the control 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 965 displays [----] in the upper display, and a [```0] in the lower display, except for 0-5VÎ (dc) or 4-20mA process input units. Press the A/M key twice, and [ER`7] is displayed for one second. This error indicates an open sensor or A/D error. Remove power to the control and connect the sensor properly, see pages 8 and 9. All wiring and fusing must conform to the National Electric Code and to any locally applicable codes as well.

Power Wiring

Ó
WARNING: To avoid potential 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.
High V oltage
Model # 965A - 3 0 - 00 .
100 to 240 VÅ (ac),
nominal
(85 to 264 actual)
Low V oltage
Model # 965A - 3 1 - 00 .
Ó
12-24V‡ (ac/dc)
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.
Figure 6 ­High Voltage Power Wiring
Figure 7 ­Low Voltage Power Wiring
Install and Wire, Chapter 2
Ó
WARNING: If high voltage is applied to the low voltage unit, irreversible damage will occur.
WATLOW Series 965 User's Manual
7

Input Wiring

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 control. 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.
Thermocouple Input
NOTE: When an external device with a non­isolated circuit common is con­nected to the 4­20mA or dc output, you must use an isolated or un­grounded thermo­couple.
Figure 8 ­Thermocouple Sensor Input Wiring
ç
CAUTION: Process input does not have sensor break protection. Outputs can remain full on.
Extension wire for thermocouples must be of the same alloy as the thermo­couple itself to limit errors.
DIP Switch Orientation
+
3
T/C
-
5
0-5VÎ (dc) Process Input
ç
DIP Switch Orientation
Figure 9 ­0-5V
(dc) Process
Î
Sensor Input Wiring
WATLOW Series 965 User's Manual
8
+
V
dc
-35
Input impedance: 10K
Install and Wire, Chapter 2
RTD, 2- or 3-wire
There could be a + 2°F input error for every 1 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, copper stranded, same length).
DIP Switch Orientation
S1
3-wire RTD
S2
S3
2
3
2-wire RTD
Jumper
Terminals
5
3 and 5.
S1
S2
S3
2
3
5
Input Wiring
Figure 10 ­2- or 3-wire RTD Sensor Input Wiring
4 - 20mA Process Input
I
dc
Install and Wire, Chapter 2
-
2
+
5
Input impedance: 5
ç
ç
CAUTION: Process input does not have sensor
DIP Switch Orientation
WATLOW Series 965 User's Manual
break protection. Outputs can remain full on.
Figure 11 ­4-20mA Process Sensor Input Wiring
9

Output 1 Wiring

External
Load
109NO
COM
8 NC
Fuse
L1
L2
Customer Supplied
Quencharc
10
unregulated
V+
V—
9
Internal Circuitry
Figure 12 ­Switched dc Output Wiring
Switched DC Output
Model # 965A - 3
C - 00 .
NOTE: When an external device with a non­isolated circuit common is connected to the 4-20mA or Switched dc output, you must use an isolated or un­grounded thermo­couple.
Figure 13 ­5 Amp Mechanical Relay Wiring
NOTE: Switching inductive loads (relay coils, solenoids, etc.) with the mechanical relay, switched dc or solid-state relay output options requires using an R.C. suppressor. Watlow carries the R.C suppressor Quencharc brand name, which is a trademark of ITW Pakron. Watlow Part No. 0804-0147-0000.
Figure 14 ­4-20mA Process Wiring
+
9
External
-
10
Load
Mechanical Relay Without Contact Suppression, Form C, 5 Amp
Model # 965A - 3
D - 00 .
Process, 4-20mA
Model # 965A - 3
F - 00 .
+
9
-
10
Maximum load
resistance:
800
External
Load
Figure 15 -
0.5 Amp Solid-state Relay Without Contact Suppression Wiring
10
Solid-state Relay Without Contact Suppression, 0.5 Amp
Model # 965A - 3
WATLOW Series 965 User's Manual
K - 00 .
Custommer Supplied
Quencharc
8
10
SS1
SS1
L2
External
Load
Fuse
L1
Install and Wire, Chapter 2
Output 2 Wiring
7
unregulated
V+
V—
6
Internal Circuitry
Switched DC Output
Model # 965A - 3
C - 00 .
+
6
External
-
7
Load
Mechanical Relay Without Contact Suppression, Form C, 5 Amp
Model # 965A - 3 D - 00 .
1NC
6
7
Customer Supplied
COM
NO
Quencharc
Fuse
External
L1
Load
L2
Solid-state Relay Without Contact Suppression, 0.5 Amp
Model # 965A - 3
K - 00 .
NOTE: For more informa­tion on alarms see page 24.
Figure 16 ­Switched dc Output Wiring
Figure 17 ­5 Amp Mechanical Relay Wiring
NOTE: Switching inductive loads (relay coils, solenoids, etc.) with the mechanical relay, switched dc or solid-state relay output options requires using an RC suppressor. Watlow carries the RC suppressor Quencharc brand name, which is a trademark of ITW Pakron. Watlow Part No. 0804-0147-0000.
Install and Wire, Chapter 2
SS2
1
Fuse
L1
NOTE: Output is in open State in Alarm Condition.
7
SS2
External
Load
L2
Figure 18 -
0.5 Amp Solid-state Relay Without
Customer Supplied
Custommer Supplied
Quencharc
Quencharc
WATLOW Series 965 User's Manual
Contact Suppres­sion Wiring
11

Wiring Example

1
120VÅ (VAC)
L1
L2
2
3 5
4 5
1 2
1
2
(+)
(-)
3
11
18
12
13
14
15
2
1CR
16
High Temperature
Light
1
2 3
4
8
9 10 11
12
R
SSR-240-10A-DC1
DC Input Solid-state Relay
17
1
8
Heater
(+)
(-)
1 CR-1
910
2
910
67
11 12
5
6
7
Limit Control
Series 965
965A-3CA0-0000
Temperature control
Series 92
92A3-1DJ1-0000
13
4
3
5
11
12 13 14
10
(+)
(-)
3-32V
Î
(dc)
In
Out
24-240V
Å
(ac)
Figure 19 ­System Wiring Example
L1
120VÅ (VAC)
L2 Earth Ground
Fuse
ÓWARNING:
All wiring and fusing must conform to the National Electric Code NFPA70. Contact your local board for additional information. Failure to observe NEC safety guide­lines could result in injury to personnel or damage to property.
ç CAUTION:
Watlow mercury relay loads must have a unity power factor. For RESISTIVE LOADS ONLY.
High Temperature Light
Coil
High Limit
Mechanical
Controller
3 (+)
5 (-)
11 12
Red
965A-3CA0-0000
Rear View
SSR-240-10A-DC1
dc Input
SSR
9 +
10 -
Process Sensor
Out
2
1
3
4
Limit Control
In
Heater
13 14
11
10
-
+
92A3-1DJ1-0000
Limit Sensor
Optional
Normally Open
Momentary Switch
965A-3CA0-0000
1 Not Used 2 S1, I­3 S2, TC+, V+ 4 Not Used 5 S3, TC-, V-, I+ 6 Not Used 7 Not Used 8 Not Used 9 DC +1 10 DC -1 11 L1 12 L2
WATLOW Series 965 User's Manual
12
Install and Wire, Chapter 2
Chapter 3 How to Use the Keys and Displays
After one minute with no key activations, the control reverts to the process value in the upper display and the set point in the lower display.
Keys/Displays
Figure 20 ­Series 965 Keys and Displays
Upper Display
Red or green, 0.3" (8 mm) high, seven segment, four digit LED display, indicating either process, actual temperature, the operating parameter val­ues or an open sensor. When powering up, the Process display will be blank for five seconds. This display can be blank by setting [`dSP] to [`SEt]. See page 18.
Lower Display
Red or green, 0.3" (8 mm) high, seven-segment, four­digit LED display, indicating the set point, output value, parameters for data in the upper display, or error and alarm codes. This display can be blank by setting [`dSP] to [`Pro]. See page 18.
L1
When lit, this LED tells you when Out­put 1 is energized.
L2
When lit, this LED tells you when Output 2 is active. This output can be configured as a con­trol or alarm output.
MN
Lit when the control is in Manual op­eration. Press the A/M key twice to enter Automatic operation. When blinking, this indicates that pressing the A/M key toggles between Auto and Manual. After five seconds with­out pressing the A/M key, the LED stops blinking, and returns to its previ­ous state.
Mode Key
Steps the control through the Operating Menu; also, in the Auto mode, new data is self entering in five sec­onds.
Keys & Displays, Chapter 3 WATLOW Series 965 User's Manual
Up-arrow Key
Increases the value of the displayed parameter. A light touch increases the value by one. Holding the key down increases the value at a rapid rate. New data is self entering in five seconds.
Up-arrow/Down-arrow Keys
When pressed simultaneously for three seconds, the Setup Menu appears displaying the [`LOC] parameter. Continue to press the Up-arrow/Down-arrow keys, and the Calibration Menu appears.
Down-arrow Key
Decreases the value of the displayed parameter. A light touch decreases the value by one. Holding the key down decreases the displayed value at a rapid rate. New data is self entering in five sec­onds.
A/M Key
Pressed once, it clears any latched alarms and toggles between Auto and Manual mode. If pressed again within five seconds it will change from Auto to Manual or vice versa. While in Manual mode, percent power is in the lower dis­play.
13
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