Watlow 965 User Manual

Series 965

User's Manual

96

1/16 DIN

Microprocessor-Based

Auto-tuning Control

WatlowControls

TOTAL

CUSTOMER SATISFACTION

3YearWarranty

ISO 9001

Registered Company

Winona, Minnesota USA

Watlow Controls, 1241 Bundy Blvd., P.O. Box 5580, Winona, MN 55987-5580, Phone: [phone], Fax: [phone]

0600-0003-0000 Rev. C	$10.00
July 1998	Made in the U.S.A.
Supersedes: 0600-0003-0000 Rev. B	Printed on Recycled Paper

About This Manual

NOTE:

Details of a "Note" appear here, in the narrow box on the outside of each page.

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

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
ç	A Caution symbol (an exclamation point in a triangle) appears with information that is
	important to protect equipment and performance. Read and follow all cautions that apply
	to your application.

CAUTION: Details of a "Cau-

tion" appear here, in the narrow box on the outside of each page.

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 "Warn-

ing" appear here, in the narrow box on the outside of each page.

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, call for technical assistance: Watlow Controls at [phone], 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.

Warranty 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,MN55987-5580.Orcall(507)454-5300.Orfaxthemto(507)452-4507.(1459).

2

WATLOW Series 965 User's Manual

How to Use the Manual

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

7Wiring the Series 965

8Sensor Installation Guidelines

8 Input Wiring

10Output 1 Wiring

11Alarm Wiring

12System Wiring Example

Chapter 3

13 How To Use The Keys And Displays

13 Keys, Displays & LEDs

Chapter 4

14How To Set Up The Series 965

14Setting the Input Type DIP Switch

15Entering Setup Menu

16Setup Parameters

18Setup Menu Table

19Operation Parameters

20Operation Menu Table

Chapter 5

21How To Tune And Operate

21Auto-tuning

22Manual Tuning

23Manual and Automatic Operation

24Using Alarms

25Error Code Messages

Appendix 1

27 Noise Sources

27Decreasing Noise Sensitivity

28Eliminating Noise

Appendix 2

29Entering the Calibration Menu

30Restoring Factory Calibration

30Calibration Menu

Contents

31 Calibration Procedures

34 Glossary

36Index

37Warranty and Returns

38Specifications

39Model Number Information

40Declaration of Conformity

41Quick 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

WATLOW Series 965 User's Manual

3

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

Dual Control Output-

PID or on/off, User Selectable

Output 1 -

Heat or Cool

Output 2 -

Cool, Alarm

None

Output 1 or 2	Auto-tuning
Percent Power	for Heat &
	Cool PID
	Settings

General Description

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 WATLOW Series 965 User's Manual

Getting Started, Chapter 1

Chapter 2

Installation

Install and Wire the Series 965

1.77" to 1.79"

(44.96mm to 45.47mm)

Panel Cutout

NOTE:

Your Panel

1.77" to 1.79"

Thickness

Measurements

(44.96mm

between panel

0.06" to 0.38"

to 45.47mm)

cutouts are the

(1.5 to 9.7 mm)

minimum

recommended.

Figure 2 -

0.38"

Series 965

(9.65mm)

Multiple Panel

Minimum

Cutout Dimensions

0.85"

(20mm)

4.7"

Figure 3 -

Series 965

(119mm)

Dimensions

2.1"

4.1"

(53 mm)

(104mm)

		1.76"
		(45mm)
		NOTE: For rapid
		mounting, use
		Greenlee punch
		#60020 and die
	0.40"	#60021, or hand
		hydraulic unit, Kit
	(10mm)
		#7306. All available
	1.21"
	(31mm)	from Grainger.

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.

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

WATLOW Series 965 User's Manual 5

Installation

Figure 4 -	4A
Mounting, Case Side

View & Collar Cross

Section

4B

0 to 0.019 space						Panel
(0 to 0.483 mm)

Ridges
Bezel
Tabs
Mounting Collar
External Gasket
Teeth	Mounting Collar
	Cross Section
	(notice the offset teeth
	on each tab)

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.

Figure 5 -

Case Rear View and

NEMA 4X Seal

Example

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).

Make sure that the two corresponding 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.

6 WATLOW Series 965 User's Manual

Install and Wire, Chapter 2

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.

High Voltage

Model #

965A - 3

0 - 00

100 to 240 VÅ (ac), nominal

(85 to 264 actual)

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.

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

Low Voltage

Model #	965A - 3			1 - 00						Figure 7 -
	Ó									Low Voltage
					12-24V‡ (ac/dc)					Power Wiring
										Ó
										WARNING:
										If high voltage is
										applied to the low
										voltage unit,
										irreversible damage
										will occur.

Install and Wire, Chapter 2

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.

NOTE:

When an external device with a nonisolated circuit common is connected to the 4- 20mA or dc output, you must use an isolated or ungrounded thermocouple.

Figure 8 -

Thermocouple

Sensor Input Wiring

Thermocouple Input

Extension wire for thermocouples must be of the same alloy as the thermocouple itself to limit errors.

DIP Switch

Orientation

+ 3

T/C

- 5

ç

CAUTION:

Process input does not have sensor break protection. Outputs can remain full on.

0-5VÎ (dc) Process Input

ç

DIP Switch

Orientation

Figure 9 -		+						3
0-5V	Î
	(dc) Process
Sensor Input Wiring		V d c
					-			5

Input impedance: 10KΩ

8

WATLOW Series 965 User's Manual

Install and Wire, Chapter 2

RTD, 2- or 3-wire

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, copper stranded, same length).

DIP Switch

Orientation

	S1	2	S1	2
	S2	3	S2	3
	3-wire RTD		2-wire RTD
			Jumper
			Terminals
	S3	5	3 and 5.
			S3	5

4 - 20mA Process Input

ç

DIP Switch

Orientation

- 2

I d c

+ 5

Input impedance: 5Ω

Input Wiring

Figure 10 -

2- or 3-wire RTD Sensor Input Wiring

ç

CAUTION:

Process input does not have sensor break protection. Outputs can remain full on.

Figure 11 -

4-20mA Process

Sensor Input Wiring

Install and Wire, Chapter 2

WATLOW Series 965 User's Manual

9

Output 1 Wiring	Switched DC Output
	Model # 965A - 3 C	- 00	V+
			unregulated
				9
Figure 12 -			V—	10
Switched dc Output
Wiring
			Internal Circuitry

NOTE:		9	+
When an external				External
device with a non-		10	-	Load
isolated circuit
common is connected
to the 4-20mA or	Mechanical Relay Without Contact Suppression, Form C, 5 Amp
Switched dc output,
you must use an	Model # 965A - 3 D	- 00
isolated or un-
grounded thermo-
couple.
Figure 13 -
5 Amp Mechanical		8	N C
Relay Wiring				Fuse
		9	C O M	L 1

NOTE:		1 0	N O
			External
Switching inductive
		Customer Supplied	Load
loads (relay coils,
		Quencharc	L 2
solenoids, etc.) with
the mechanical
relay, switched dc or
solid-state relay	Process, 4-20mA
output options
requires using an	Model # 965A - 3 F	- 00
R.C. suppressor.
Watlow carries the
R.C suppressor
Quencharc brand			Maximum load
name, which is a
			resistance:
trademark of ITW
			800Ω
Pakron. Watlow Part
No. 0804-0147-0000.		9	+

	Figure 14 -		-	External
		10		Load
	4-20mA Process
	Wiring

Figure 15 -

0.5 Amp Solid-state

Relay Without

Contact Suppression

Wiring

Solid-state Relay Without Contact Suppression, 0.5 Amp

Model # 965A - 3 K

- 00

Custommer Supplied

	Quencharc
			L 2
			External
			Load
	8	S S 1
	1 0	S S 1	Fuse
			L 1

10

WATLOW Series 965 User's Manual

Install and Wire, Chapter 2

Output 2 Wiring

Switched DC Output

Model # 965A - 3 C - 00

6 +

7 -

External
Load
V+
unregulated
	6
V—	7
Internal Circuitry

Mechanical Relay Without Contact Suppression,

Form C, 5 Amp

Model # 965A - 3	D - 00
		Fuse
1 N C	6	C O M	L 1
	7	N O
		External
		Load
			L 2
		Customer Supplied
		Quencharc

Solid-state Relay Without Contact Suppression, 0.5 Amp

Model # 965A - 3	K - 00
1	SS2

	L1
Fuse
7	SS2
	External
	Load
	L2
	CustommerCustomer Supplied
	Quencharc

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.

NOTE:

Output is in open State in Alarm Condition.

Figure 18 -

0.5 Amp Solid-state Relay Without Contact Suppression Wiring

Install and Wire, Chapter 2

WATLOW Series 965 User's Manual

11

Wiring Example

Figure 19 -

System Wiring

Example

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.

çCAUTION:

Watlow mercury relay loads must have a unity power factor. For RESISTIVE LOADS ONLY.

L1

120VÅ (VAC)

L2

Earth Ground

Coil

Fuse
11	12	SSR-240-10A-DC1
			dc Input	Out
			SSR
				2
			1
3 (+)			4	3
				In
		9 +
5 (-)		10	-
Red 965A-3CA0-0000
Rear View

Process Sensor

	120VÅ (VAC)
	L1
	1
	1
	2
965A-3CA0-0000	3
1 Not Used	4

2S1, I-

3S2, TC+, V+

4Not Used

5	S3, TC-, V-, I+	5
			1
6	Not Used
7	Not Used
8	Not Used	6
			1
9	DC +1	7
10	DC -1	8
11	L1	9
12	L2	10
		11
		12
			1
		13

									High Temperature
									Light
High Limit
Mechanical
Controller
			92A3-1DJ1-0000
				Limit Control
Heater
							13	14
						10	11
						+	-
				Limit Sensor					Optional
								Normally Open
								Momentary Switch
										L2
3		11						12		2
4	(+)	3			Series 965
				965A-3CA0-0000
5	(-)
		5		Temperature control
				9		10
				6		7
					3-32VÎ (dc)		SSR-240-10A-DC1
				(+)	In	(-)
							DC Input Solid-state Relay
	1 CR-1
8			9		Out		10		Heater	2
				24-240VÅ		(ac)
11				1			2			2
			12	13
								Series 92
			13
				14			92A3-1DJ1-0000
		(+)	14					Limit Control
				10
		(-)	15	11			3
									16 1CR
										2
				4
17							5	18	R	2
							High Temperature
								Light

12

WATLOW Series 965 User's Manual

Install and Wire, Chapter 2

Keys/Displays

Chapter 3

How to Use the Keys and Displays

Figure 20 -

After one minute with no key activations, the control reverts to the process

Series 965 Keys

value in the upper display and the set point in the lower display.

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.

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.

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.

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.

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.

Keys & Displays, Chapter 3

WATLOW Series 965 User's Manual

13