Watlow 988 User Manual

1/8 DIN Microprocessor-Based Temperature/Process Controller

0600-0009-0001 Rev AA

April 2002 Supersedes: 0600-0009-0001 Rev Y

$10.00

Made in the U.S.A.

User’s Manual

Includes 986, 987, 988 and 989

User Levels:

• New User........................... go to Introduction

• Experienced User................... go to page 4.1

Installers:

• Set-up..................................... go to page 1.1

• Wiring & Installation................ go to page 2.1

1241 Bundy Boulevard., Winona, Minnesota USA

Phone: +1 (507) 454-5300, Fax: +1 (507) 452-4507 http://www.watlow.com

Series 988

English

TOTAL

3 Year Warranty

ISO 9001

Registered Company

Winona, Minnesota USA

WATLOW Series 988 User’s ManualTable of Contents

Ta ble of Contents

Introduction to the Watlow Series 988 Controllers

ii Using this Manual

ii Document Every Step iii Notes, Cautions and Warnings iii Technical Assistance iii We Value Your Feedback

Chapter 1 Hardware Setup

1.1 Dip Switch Locations and Functions

Chapter 2 Installation and Wiring

2.1 Panel Cutout and Dimensions

2.2 Installing the Series 988

2.4 Wiring the Series 988

2.4 Input-to-output Isolation

2.4 Power Wiring

2.5 Sensor Installation Guidelines

2.6 Wiring Example

2.8 Input 1 Wiring

2.9 Input 2 Wiring

2.11 Event Input 1 Wiring

2.12 Output 1 Wiring

2.13 Output 2 Wiring

2.14 Output 3 Wiring

2.15 Output 4 Wiring

Chapter 3 Front Panel and Display Loop

3.1 Keys and Displays

3.2 Display Loop

Chapter 4 The Setup Menus

4.1 Navigating the Setup Menus

4.2 Input Menu

4.18 Output Menu

4.34 Global Menu

4.44 Communications Menu

Chapter 5 The Operation Menus

5.1 Navigating the Operation Menus

5.2 System Menu

5.9 PID A and PID B Menus

Chapter 6 The Factory Menus

6.1 Navigating the Factory Menus

6.2 Panel Lockout Menu

6.7 Diagnostics Menu

6.13 Calibration Menu

Chapter 7 Tuning, Manual Operation, Alarms and Error Codes

7.1 Auto-tuning (Heat and/or Cool)

7.2 Manual Tuning

7.4 Manual and Automatic Operation

7.5 Changing the Output 3 Alarm Jumper

7.6 Using Alarms

7.8 Error Code E1 and E2 Messages

7.9 Error Code Actions

Chapter 8 General Software

8.2 Burst Fire

8.4 Communications

8.6 Dead Band

8.8 Digital Events

8.10 Heater Current

8.12 Input Filter

8.14 Input Linearization

8.16 Ramp to Set Point

8.18 Remote Set Point

8.20 Retransmit

8.22 Slidewire Feedback

Appendix

A.2 Glossary A.4 Specifications A.5 Warranty and Returns A.6 Index A.10 Menu Overview A.11 Model Number – Ordering Information A.12 Declaration of Conformity

WATLOW Series 988 User’s Manual i

Introduction

Introduction to the

Watlow Series 988 Controllers

Figure Int.1 The Series 988 Controllers.

Watlow’s Series 988 controllers set a new standard in the controller industry by packing an impressive array of features into an 1/8-DIN package. No other controller offers the flexibility, compact size and durability of the Series 988. It can control a wide variety of temperature and process applications, with a broad range of input and output options that allow control of virtually any process variable.

The Series 988 is the only 1/8 DIN controller that can provide single-unit cascade control of a process. Its other features include heater current monitoring, remote set point input, ratio control and valve control through slidewire feedback. The Series 988 also delivers expanded auto-tuning capabilities, increased alarm functionality and several unique control algorithms.

When we refer to the “Series 988” controller, we refer also to the horizontal and low-voltage versions of the Series 988: the 986, 987, 988 and 989. We recommend that you read all of this manual’s introduction to familiarize yourself with the conventions and content of this manual and the steps to setting up a Series 988 controller. Make sure you understand the “Caution” and “Warning” symbols we use in the book.

ii WATLOW Series 988 User’s Manual

Introduction

Using this Manual

This manual provides the information you will need to install and operate a Series 988 controller.

If you need information about Series 988 configurations and model numbers, refer to the Appendix of this manual or, for more detailed information, to Optimizing Your Process System with the Series 988 Controller: An

Application Guide for the Watlow Series 988 Family.

If your Series 988 controller will be used for data communications, you will also need our communications manual, Data Communications with the Watlow Series 988 Family of Controllers (green cover).

Series 988 controllers are calibrated in the factory, but if you need to do periodic calibration you will need our calibration manual, Calibrating Watlow Process Controllers, (blue cover).

This manual explains the five steps of setting up a Series 988 controller:

1. Set and document all of the DIP switches, if applicable: Chapter 1.

2. Mount the controller: Chapter 2.

3. Wire and document the controller wiring: Chapter 2.

4. Configure and document the controller software: Chapters 3-6.

5. Run, test and adjust your application. Update documentation.

Chapters 7 and 8 and the Appendix provide detailed advice, definitions and specifications along with application examples to help you optimize the safety and performance of your application. Use the Table of Contents and Index to find specific information.

Document Every Step

The Series 988 provides powerful and complex features. Carefully document each step of the setup and any subsequent changes. This will make it much easier to change, adjust and troubleshoot your application.

Make the configuration documentation available to engineers and technicians, on all shifts, who may need to work with the Series 988. We provide space in this manual to record configurations. You may prefer to photocopy the blank forms and keep them in a separate binder. However you maintain your documentation, be sure to replace all old copies of the documentation with updated versions whenever the controller configuration is changed.

˜

NOTE: The Menu Overview in the Appendix shows all the menus and prompts.

˜

NOTE: The 12-digit number is printed on the top of the stickers on each side of the controller’s case and on the righthand or top circuit board.

Introduction

WATLOW Series 988 User’s Manual iii

Introduction

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 ç symbol (an exclamation point in a triangle) precedes a general CAUTION or WARNING statement.

The Ó symbol (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 (507) 454-5300, between 7 a.m. and 7 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; all configuration information; and the Diagnostics Menu readings.

We Value Your Feedback

Your comments and suggestions on this manual are welcome. Please send them to, Technical Writer, Watlow Winona, 1241 Bundy Blvd., P.O. Box 5580, Winona, MN 55987-5580 or call (507) 454-5300 or fax (507) 452-

iv WATLOW Series 988 User’s Manual

Introduction

Notes

WATLOW Series 988 User’s Manual 1.1

Hardware Setup, Chapter 1

Chapter 1 Hardware Setup

DIP Switch Locations and Functions

The Watlow Series 988 has at least one and as many as six dual in-line package (DIP) switches inside the controller, depending on the model number. They allow users to configure the controller for a variety of input sensors, to provide power for external signal conditioners or to lockout front panel access to some functions.

To set any DIP switch:

• Remove the controller from the case by pressing firmly on the two release tabs on one side or the top of the bezel until they unsnap. Then firmly press the two release tabs on the opposite side or the bottom of the control until they unsnap. You will need to gently rock the bezel back and forth to release it from the chassis.

• Use the illustrations on the following pages to locate and set each DIP switch.

Figure 1.1 - Press the release tabs to remove the controller chassis.

Release

Tabs

A

W

PROCESS

L1 L2 L3 L4

DEV

% OUT

SERIES 988

W

TL

DISPLAY

AUTO

MAN

MODE

Release

Tabs

W

A

TL

W

PROCESS

L1 L2 L3 L4

Release

Tabs

DEV

% OUT

DSPY

MODE

AUTO

MAN

SERIES 989

Release

Tabs

1.2 WATLOW Series 988 User’s Manual

Hardware Setup, Chapter 1

DIP Switches

Figure 1.2 Input DIP switches.

Input 1 Input 2

(98 _ _-2_ _ _-_ _ _ _) (98 _ _-_2_ _-_ _ _ _)

RTD (100 Ω)

thermocouple: R, S or B

thermocouple: J, K, T, N, E, C, D, Pt2

or 0-50mV (high impedance)

0-20 or 4-20mA; 0-5, 1-5 or 0-10V

1. Set the input DIP switches to match the sensors you are using in your application. Only controllers with model number 98_ _2_ _ _-_ _ _ _ or 98_ __2_ _-_ _ _ _ have an input DIP switch.

˜

NOTE: The Input 2 DIP switch is mounted upside down.

˜

NOTE: Only controllers with the indicated model numbers have these DIP switches.

Input 2 DIP

Input 1 DIP

ON

Controller Chassis

Rear View

123

O N

↑

123

O N

↑

123

O N

↑

123

O N

↑

N O

123

↑

N O

123

↑

N O

123

↑

N O

123

DIP Switches

WATLOW Series 988 User’s Manual 1.3

Hardware Setup, Chapter 1

Output 2

Option Board and DIP

Output 4

Option Board and DIP

Contro ller Chassis

Top View (986 & 988)

Left-side V iew (987 & 989)

Output 3

Option Board and DIP

Output 1

Option Board

offon

on

off

Figure 1.3 External signal conditioner power supply DIPs.

Output 2 Output 3 Output 4

(98 _ _-_ _ _T-_ _ _ _) (98 _ _-_ _ _ _-T_ _ _) (98 _ _-_ _ _ _-_T_ _)

20V ± 5% @ 30mA

12V ± 5% @ 30mA

5V ± 5% @ 30mA

2. Set DIP switches for outputs equipped with an external signal conditioner power supply. Only controllers with model number 98_ _-_ _ _T-_ _ _ _, 98_ _-_ _ _ _-T_ _ _ or 98_ _-_ _ _ _-_T_ _ have an external signal conditioner power supply.

˜

NOTE: For other voltages or current settings contact the factory.

3. When the DIP switches are set, gently insert the controller chassis into the case and push it firmly into place until all four tabs snap into place.

˜

NOTE: Only controllers with the indicated model numbers have these DIP switches.

12

O N

↑

12

O N

↑

12

O N

↑

12

O N

↑

12

O N

↑

12

O N

↑

12

O N

↑

12

O N

↑

12

O N

↑

1.4 WATLOW Series 988 User’s Manual

Hardware Setup, Chapter 1

DIP Switches

Figure 1.4 Lockout DIP switch.

no hardware lockout or (Switch 1 has no effect.)

lockout Setup and Factory menus or (Switch 1 has no effect.)

4. The lockout DIP switch hides the Setup Menus (Input, Output, Global and Communications) and the Factory Menus (Panel Lockout, Diagnostics and Calibration). All units have a lockout DIP switch.

ç

CAUTION: The lockout DIP switch makes the Setup and Factory menus unavailable. Configure all the Setup and Factory menus before locking them out. Failure to do so could result in damage to equipment in the event of a setup error.

M

12

O N

↑

12

O N

↑

Input

[InPt]

[`SEt]

Panel

Lockout

[PLOC]

[Fcty]

Output Global

[OtPt]

[`SEt]

Diagnostics Calibration

[diAG]

[Fcty]

[GLbL]

[`SEt]

[`CAL]

[Fcty]

Communications

[CO

[`SEt]

12

O N

↑

12

O N

↑

WATLOW Series 988 User’s Manual 2.1

Installation and Wiring, Chapter 2

Chapter 2 Installation and Wiring

Figure 2.1 Series 988 and Series 989 dimensions and terminal number layout.

˜

NOTE: Adjustable mounting brackets can be side-mounted.

˜

NOTE: Space panel cutouts at least 1.66 inches (42.2mm) apart.

˜

NOTE: Holes can be cut in the panel using a Greenlee 1/8 DIN Hydraulic Kit #60068 (punch #60069, die #60070).

W

A

TL

W

PROCESS

L1 L2 L3 L4

DEV

% OUT

SERIES 988

2.18"

(55 mm)

DISPLAY

AUTO

MAN

MODE

4.03"

(102mm)

W

A

TL

W

PROCESS

L1 L2 L3 L4

4.03"

DEV

% OUT

DSPY

MODE

AUTO

MAN

2.18"

(55 mm)

SERIES 989

Panel Cutout

Maximum Panel

Thickness

0.38" (9.65mm)

3.62" + 0.03 -0.00 (92mm + 0.8)

1.77 + 0.02 -0.00 (45mm + 0.6)

1

21

2

3

4

5

6

7

8

9

231024

Panel

0.68"

(17 mm)

11

22

12

13

14

15

16

17

18

19

10

98 765432

23

24

19 18 17 16 15 14 13 12

20

4.06"

(103 mm)

Adjustable

Mounting Bracket

21

22

1

11

20

2.2 WATLOW Series 988 User’s Manual

Installation and Wiring, Chapter 2

Installation

Installing the Series 988

Installing and mounting requires access to the back of the panel.

1. Make a panel cutout using the panel cutout dimensions from the previous page.

2. To remove the controller chassis from its case, press in firmly on the two tabs on one side or the top of the bezel until they unsnap, then unsnap the two tabs on the opposite side or the bottom. Pull the chassis out of the case by gently rocking it.

3. Slide the case into the panel cutout. Check to see that the gasket is not twisted, and is seated within the case bezel flush with the panel. Slide

Panel

Adjustable

Mounting Bracket

Bezel

External Gasket

Mounting Collar

Release Tabs

Top and Bottom (986 or 988) or Side (987 or 989) View

Mounting Slots

Side (986 or 988) or Top and Bottom (987 or 989) View

˜

NOTE: Removing the controller chassis from its case makes mounting easier.

Figure 2.2 Side and top view.

WATLOW Series 988 User’s Manual 2.3

Installation and Wiring, Chapter 2

the mounting collar over the back of the control.

4. Loosen the mounting bracket screws enough to allow for the mounting collar and panel thickness. Place each mounting bracket into the mounting slots (head of the screw facing the back of the controller). Push each bracket backward then down to secure it to the control case. To guarantee a proper NEMA 4X seal, Series 986 and 988

units (vertical) must have the mounting brackets located on either side of the unit. When installing Series 987 and 989 units (horizontal) the brackets must be on the top and bottom of the unit.

5. Make sure the case is seated properly. Tighten the installation screws firmly against the mounting collar to secure the unit. To ensure a

NEMA 4X seal, there should be no space between the bezel and panel. Overtightening the screws will distort the case and make it diffi-

cult to remove or replace the controller.

6. Make sure the inside gasket is seated properly and not twisted. Insert the controller chassis into its case and press the bezel until all four tabs snap.

7. To release the mounting brackets, loosen the mounting bracket screws and push the brackets forward, then pull it up and out.

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.

Installation

2.4 WATLOW Series 988 User’s Manual

Installation and Wiring, Chapter 2

Wiring

Wiring the Series 988

Wiring options depend on the model number and DIP switch settings. Check the terminal designation stickers on either side of the controller and compare your model number to those shown here and with the model number breakdown on the inside back cover of this manual.

Input-to-output Isolation

The Series 988 uses optical isolation between the analog inputs and the controller outputs/digital input. This isolation provides a 500VÅ (ac) barrier to prevent ground loops when using grounded sensors and/or peripheral equipment.

Here is a breakdown of the isolation barriers:

• Analog inputs 1 and 2 are grouped together.

• Outputs 1 through 4 and the standard event input are grouped together. This does not apply to Output 4 when configured as communications.

• The digital communications output (4) is separate from the above groups.

Power Wiring

100 to 240V‡‡(ac/dc) nominal, (85 to 264 actual)

Vertical Package 98 8 _ - _ _ _ _ - _ _ _ _ Horizontal Package 98 9

_ - _ _ _ _ - _ _ _ _

24 to 28 V‡‡(ac/dc) nominal, (20 to 30 actual)

Vertical Package 98 6

_ - _ _ _ _ - _ _ _ _

Horizontal Package 98 7 _ - _ _ _ _ - _ _ _ _

Sensor Installation Guidelines

Maintain isolation between input 1 and input 2 to prevent a ground loop. A ground loop may cause incorrect readings, dashes across the upper display or the display of error codes.

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

Using grounded thermocouples for both input 1 and input 2 may create ground loop problems. To correct this problem, replace at least one of the grounded thermocouples with an ungrounded thermocouple. If the application requires grounded thermocouples, use an isolated transmitter, such as a Watlow Gordon 5702 isolated transmitter.

fuse

22

21

earth ground

11

L2L1

+

-

∫

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. Failure to do so could result in injury or death.

˜

NOTE: Input-to-output isolation is defeated when the external signal conditioner power supply is used to power a transmitter connected to input 1 or input 2.

Figure 2.4 Power wiring.

WATLOW Series 988 User’s Manual 2.5

Installation and Wiring, Chapter 2

Wiring

RTD (100 Ω) input: Each 1Ω of lead wire resistance can cause a +2°C error when using a two-wire RTD. A three-wire RTD sensor overcomes this problem. All three wires must have the same electrical resistance (i.e., same gauge, same length, multi-stranded or solid, same metal).

Process input: Isolation must be maintained between input 1 and input

2. If both input 1 and input 2 are used as process inputs, a separate power supply and transmitter must be used for each input. Output option T (external signal conditioner power supply) can be used to supply power for only one input.

Wiring 0-20 and 4-20mA Process Inputs

Certain “transmitters” used in process input applications are producing internal resistor failures in the Watlow Series 988 family of controllers. This is only apparent with the Series 988 family 1/8 DIN units with Process Inputs selected (0-20mA or 4-20mA dc only).

We are noticing that an external resistor is required to prevent a high in-rush current which burns out the Series 988 family controllers’ 7-ohm internal resistor. This high in-rush current occurs initially on “power-up.” If the transmitter turns full on for a split second during power-up, the available current weakens or damages the internal resistor.

Example: 20V / 7 ohms = 2,857mA (too much!).

The wiring diagram example below shows an application where a customer is using a 4-20mA dc transmitter and power supply to feed the input of a Series 988 controller. The Rx range (100 to 400 ohms) for the external resistor is recommended. We suggest starting with 250 ohms.

Example: Customer is using a 24VÎ (dc) power supply to power up the 4-20mA dc transmitter that inputs to the Series 988 terminals 8 (-) and 10 (+). To figure out what the internal Series 988’s handling current is for the 0-20mA or 420mA dc input to the Series 988 controllers, we need to apply Ohm’s Law: The square root of Watts divided by Resistance equals Current. Applying that formula to the example below produces the following: Square Root of (0.125 Watts / 7 ohms) = 134 mA dc (handling input current). This is the acceptable input current for the Series 988 universal input board.

Reminder, the input impedance of 7 ohms handles the majority of our customer applications; the external resistor (Rx) is only for certain transducers/transmitters that spike on power-up or power-down. Please make sure your customer’s transmitter / transducer fall within our Series 988 family (1/8 DIN) of controllers’ Process Input specification of 7 ohms input impedance.

ç

CAUTION: The Series 988 will not function with two grounded thermocouple inputs. Avoid using a grounded thermocouple for both input 1 and input 2. Failure to follow this guideline could result in damage to equipment.

NOTE: Input-to-output isolation is defeated when the external signal conditioner power supply is used to power a transmitter connected to input 1 or input 2.

988 Process

Input Control

Internal

Resistor

7Ω

1/8 Watt

+

—

R

x

100 to 400

ohms

4-20mA dc

Transmitter

—

+

24VÎ (dc)

Power Supply

—

2.6 WATLOW Series 988 User’s Manual

Installation and Wiring, Chapter 2

Wiring Example

Figure 2.6 System wiring example.

∫

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. Failure to do so could result in injury or death.

ç

WARNING: Install high or low temperature limit control protection in systems where an over temperature fault condition could present a fire hazard or other hazard. Failure to install temperature limit control protection where a potential hazard exists could result in damage to equipment, property and injury to personnel.

ç

WARNING: To avoid damage to property and equipment, and/or injury of loss of life, use National Electric Code (NEC) standard wiring practices to install and operate the Series

988. Failure to do so could result in such damage, and/or injury or death.

L1

120VÅ (ac)

L2

eart h ground

(+)

9

10

(-)

red

120VÅ (ac)

1

2

3

4

5

6

7

8

9

10

11

12

13

high- li mit

mechani cal

fuse

11

2221

(+)

12

(-)

13

988A-10C A-AAR R

rear view

L1

1

1 2

1

proc ess sens or li mit sensor

3

4

(+)

5

(-)

1 CR-1

8

11

17

coil

contactor

10+11

heater

Series 146

limit control

R

15

13 14

-

norm ally open

momentary s witch

1CR

16

SSR- 240-10A- DC1

out

12 43

in

21 22

9

10

910

12 13

(+)

14

(-)

15

dc i nput

SSR

heater

Series 988

988A-10CA-AARR

temperature control

12 13

67

in

3-32VÎ (dc)

(+)

out

24-240VÅ (ac)

12

13

14

10

11

4

146E-1601-3000

limit control

11

SSR-240-10A-DC1 solid-state relay, dc input

(-)

146E-1601-3000

3

5

18

high-temperature light

high- temper ature

light

optional

L2

2

WATLOW Series 988 User’s Manual 2.7

Installation and Wiring, Chapter 2

Wiring Notes

ç

WARNING: To avoid damage to property and equipment, and/or injury of loss of life, use National Electric Code (NEC) standard wiring practices to install and operate the Series

988. Failure to do so could result in such damage, and/or injury or death.

Figure 2.7 Wiring notes.

˜

NOTE: Sketch in your application on this page or a copy of it. See wiring examples in this chapter and in the Appendix.

L1 L2

earth ground

11

21 22

power

2.8 WATLOW Series 988 User’s Manual

Installation and Wiring, Chapter 2

Input 1 Wiring

Figure 2.8c —

0-5VÎÎ, 1-5VÎÎor 0-10VÎÎ(dc) Process

Universal signal conditioner

98 _ _ - 2 _ _ _ - _ _ _ _

Input impedance: 10KΩ

Figure 2.8a — Thermocouple or 0-50mV (high impedance)

Thermocouple only

98 _ _ - 1 _ _ _ - _ _ _ _ (no DIP switches)

Universal signal conditioner

98 _ _ - 2 _ _ _ - _ _ _ _

Input impedance: 20MΩ

Figure 2.8b — RTD (2- or 3-wire) (100 Ω)

Universal signal conditioner

98 _ _ - 2 _ _ _ - _ _ _ _

9

10

+

-

0-50mV

Figure 2.8d —

0-20mA or 4-20mA Process

Universal signal conditioner

98 _ _ - 2 _ _ _ - _ _ _ _

Input impedance: 7Ω

DIP Switch

Setting

R, S, B

DIP Settings

J, K, T, N, C, E, D, Pt2,

0-50mV DIP Settings

DIP Switch

Setting

DIP Switch

Setting

˜

NOTE: Successful installation requires five steps:

• Model number and software choice (Appendix);

• DIP switch settings (Chapter 1);

• Sensor match (Chapter 2 and Appendix);

• Sensor installation (Chapter 2); and

• Wiring (Chapter 2).

Jumper #9 to #10 for 2-wire

RTD

ç

CAUTION: An external resistor may be required for 0-20mA and 4-20mA process wiring to prevent a high inrush current which could burn out the controller’s 7-ohm resistor. See page

2.5 for recommendations.

123

O N

↑

123

O N

↑

+

9

-

10

123

O N

↑

S1

8

9

S2

10

8

S1

9

S2

10

S3

123

O N

↑

123

O N

↑

9-+

10

-

8

10

+

Figure 2.9d — 0-20mA or 4-20mA Process

Universal signal conditioner

98 _ _ - _ 2 _ _ - _ _ _ _

Input impedance: 7Ω

Figure 2.9c —

0-5VÎÎ, 1-5VÎÎor 0-10VÎÎ(dc) Process

Universal signal conditioner

98 _ _ - _ 2 _ _ - _ _ _ _

Input impedance: 10KΩ

Figure 2.9b —

RTD (2- or 3-wire) (100 Ω)

Universal signal conditioner

98 _ _ - _ 2 _ _ - _ _ _ _

WATLOW Series 988 User’s Manual 2.9

Installation and Wiring, Chapter 2

Input 2 Wiring

Figure 2.9a — Thermocouple or 0-50mV (high impedance)

Thermocouple only

98 _ _ - _ 1 _ _ - _ _ _ _ (no DIP switches)

Universal signal conditioner

98 _ _ - _ 2 _ _ - _ _ _ _

Input impedance: 20MΩ

Jumper

#19 to #20

for 2-wire

RTD

19

20

18

S2

S1

DIP Switch

Setting

R, S, B

DIP Settings

J, K, T, N, C, E, D, Pt2,

0-50mV DIP Settings

DIP Switch

Setting

DIP Switch

Setting

NOTE: Successful installation requires five steps:

• Model number and software choice (Appendix);

• DIP switch settings (Chapter 1);

• Sensor match (Chapter 2 and Appendix);

• Sensor installation (Chapter 2); and

• Wiring (Chapter 2).

ç

CAUTION: An external resistor may be required for 0-20mA and 4-20mA process wiring to prevent a high inrush current which could burn out the controller’s 7-ohm resistor. See page

2.5 for recommendations.

↑

N O

123

↑

N O

123

↑

N O

123

19 20

-

+

19 20

18S2S1

19

S3

20

+

-

0-50mV

↑

N O

123

↑

N O

123

19-+

20

18

20

-

+

Figure 2.10b — Current Transformer Input

98 _ _ - _ 4 _ _ - _ _ _ _

The current transformer must be purchased separately. Watlow current transformer part number is 16-0246 (up to 50 amps)..

Systems that use more than 50 Amps need an interstage transformer. For example, if you use a 300A current transformer, part #16-0073, and an interstage transformer, part #16-0176, the 300A current transformer provides a 5A signal to the interstage transformer. In turn, the transformer sends a 20mA maximum signal to the controller.

2.10 WATLOW Series 988 User’s Manual

Installation and Wiring, Chapter 2

Input 2 Wiring

20

19

L2

L1

CT

Load wire

Center leg not used

Figure 2.10a — Slidewire Feedback or Potentiometer Input

98 _ _ - _ 3 _ _ - _ _ _ _

19

20

18

CW

CCW

Wiper

NOTE: See Chapter 8 for information on slidewire feedback.

˜

NOTE: A process output cannot be installed on output 1 when using a current transformer input.

NOTE: Successful installation requires five steps:

• Model number and software choice (Appendix);

• DIP switch settings (Chapter 1);

• Sensor match (Chapter 2 and Appendix);

• Sensor installation (Chapter 2); and

• Wiring (Chapter 2).

Single-phase

Single-phase current sensing up to 300 amps

3-phase using 2 current transformers

3-phase current sensing up to 300 amps

AC Load

T1

Phase

T1

19 20

T3 T2

dot

T3

T2

Wh Bk

Bk Wh

CT

0 to 5A

AC

A

5A

Bk

16-0176

Transformer

Red

20mA

Red

0 to 20mA

19

20

19

20

WATLOW Series 988 User’s Manual 2.11

Installation and Wiring, Chapter 2

Figure 2.11b — Digital Event Input 2

98 _ _ - _ 5 _ _ - _ _ _ _

open 0-3VÎ (dc) Event Input 2 off closed 14-36VÎ (dc) Event Input 2 on

Figure 2.11a — Digital Event Input 1

Available on all units.

open 14-36VÎ (dc) Event Input 1 off closed 0-3VÎ (dc) Event Input 1 on

NOTE: Successful installation requires five steps:

• Model number and software choice (Appendix);

• DIP switch settings (Chapter 1);

• Sensor match (Chapter 2 and Appendix);

• Sensor installation (Chapter 2); and

• Wiring (Chapter 2).

Event Input 1 Wiring

+24VÎ (dc)

Internal Circuitry

+5VÎ (VDC)

Internal Circuitry

100Ω

4.7KΩ

1KΩ

.01µf

750Ω

18

19

20

4.99KΩ

10KΩ

OPTO ISOLATOR

23

4.99KΩ

24

.01µf

750Ω

18

20

23 24

+-

19

+

20

-

2.12 WATLOW Series 988 User’s Manual

Installation and Wiring, Chapter 2

Figure 12a —

AC Outputs

Solid-state Relay with Contact Suppression

98 _ _ - _ _ B _ - _ _ _ _

0.5 amps, minimum off-state impedance: 20KΩ

Electromechanical Relay with Contact Suppression

(Suppression between NO and COM contacts only)

98 _ _ - _ _ D _ - _ _ _ _

Form C, 5 amps, minimum off-state impedance: 20KΩ

Electromechanical Relay without Contact Suppression

98 _ _ - _ _ E _ - _ _ _ _

Form C, 5 amps off-state impedance: 31MΩ

Solid-state Relay without Contact Suppression

98 _ _ - _ _ K _ - _ _ _ _

0.5 amps, off-state impedance: 31MΩ

Output 1 Wiring

Figure 12b — Switched DC, Open Collector

98 _ _ - _ _ C _ - _ _ _ _

Maximum voltage: 42VÎÎ(dc) Maximum current: 1A

Figure 12d — 0-5V

ÎÎ

, 1-5VÎÎand 0-10VÎÎ(dc) Process

98 _ _ - _ _ F _ - _ _ _ _

Minimum load impedance: 1KΩ

Figure 12c — 0-20mA and 4-20mA Process

98 _ _ - _ _ F _ - _ _ _ _

Maximum load impedance: 800Ω

14

-

+

12

14

-

+

13

NOTE: Successful installation requires five steps:

• Model number and software choice (Appendix);

• DIP switch settings (Chapter 1);

• Sensor match (Chapter 2 and Appendix);

• Sensor installation (Chapter 2); and

• Wiring (Chapter 2).

NOTE: Switching inductive loads (relay coils, solenoids, etc.) with the mechanical relay 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 Paktron. Watlow Part No. 0804-0147-

0000.

19 to 32VÎ (dc)

+

790Ω

Internal Circuitry

12

13

14

External

Load

NO

12

13

COM

14

(#14 for D & E outputs only)

Fuse

NC

12

+

External

-

13

14

COM

L2

L1

Load

WATLOW Series 988 User’s Manual 2.13

Installation and Wiring, Chapter 2

Output 2 Wiring

Figure 13b — Switched DC, Open Collector

98 _ _ - _ _ _ C - _ _ _ _

Maximum voltage: 42VÎÎ(dc) Maximum current: 1A

Figure 13d — 0-5V

ÎÎ

, 1-5VÎÎand 0-10VÎÎ(dc) Process

98 _ _ - _ _ _ F - _ _ _ _

Minimum load impedance: 1KΩ

Figure 13c — 0-20mA and 4-20mA Process

98 _ _ - _ _ _ F - _ _ _ _

Maximum load impedance: 800Ω

15

+

-

17

16

+

-

17

Figure 13e — External Signal Conditioner Power Supply

98 _ _ - _ _ _ T - _ _ _ _

Figure 13a —

AC Outputs

Solid-state Relay with Contact Suppression

98 _ _ - _ _ _ B - _ _ _ _

0.5 amps, minimum off-state impedance: 20KΩ

Electromechanical Relay with Contact Suppression

(Suppression between NO and COM contacts only)

98 _ _ - _ _ _ D - _ _ _ _

Form C, 5 amps, minimum off-state impedance: 20KΩ

Electromechanical Relay without Contact Suppression

98 _ _ - _ _ _ E - _ _ _ _

Form C, 5 amps off-state impedance: 31MΩ

Solid-state Relay without Contact Suppression

98 _ _ - _ _ _ K - _ _ _ _

0.5 amps, off-state impedance: 31MΩ

NOTE: Successful installation requires five steps:

• Model number and software choice (Appendix);

• DIP switch settings (Chapter 1);

• Sensor match (Chapter 2 and Appendix);

• Sensor installation (Chapter 2); and

• Wiring (Chapter 2).

˜

NOTE: Input-to-output isolation is defeated when the external signal conditioner power supply is used to power a transmitter connected to input 1 or input 2.

NOTE: Switching inductive loads (relay coils, solenoids, etc.) with the mechanical relay 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 Paktron. Watlow Part No. 0804-0147-

0000.

Loop powered

19 to 32VÎ (dc)

+

790Ω

Internal Circuitry

15

16

17

External

Load

15

NO

COM

16

Fuse

NC

17

(#17 for D & E outputs only)

15

+

External

-

16

17

COM

L2

L1

Load

15

16

+

-

Input 1 or 2

1

Transmitter

+V

2

4-20mA out

-V

+

Figure 14c — Process Retransmit

0-20mA, 4-20mA, Load impedance: 600Ω max.

98 _ _ - _ _ _ _ - M _ _ _

0-5VÎÎ, 1-5VÎÎ, 0-10VÎÎ(VDC), Load impedance: 500Ω min.

98 _ _ - _ _ _ _ - N _ _ _

2.14 WATLOW Series 988 User’s Manual

Installation and Wiring, Chapter 2

NOTE: Input-to-output isolation is defeated when the external signal conditioner power supply is used to power a transmitter connected to input 1 or input 2.

NOTE: Successful installation requires five steps:

• Model number and software choice (Appendix);

• DIP switch settings (Chapter 1);

• Sensor match (Chapter 2 and Appendix);

• Sensor installation (Chapter 2); and

• Wiring (Chapter 2).

Figure 14d — External Signal Conditioner Power Supply

98 _ _ - _ _ _ _ - T _ _ _

Figure 14a —

AC Outputs

Solid-state Relay with Contact Suppression

98 _ _ - _ _ _ _ - B _ _ _

0.5 amps, minimum off-state impedance: 20KΩ

Electromechanical Relay without Contact Suppression

98 _ _ - _ _ _ _ - J _ _ _ _

Form A or B, 5 amps, off-state impedance: 31MΩ

Solid-state Relay without Contact Suppression

98 _ _ - _ _ _ _ - K _ _ _ _

0.5 amps, off-state impedance: 31MΩ

Figure 14b —

Switched DC

98 _ _ - _ _ _ _ - C _ _ _

Minimum load resistance: 500Ω

Form B

Form A

Form A or B alarm jumper settings (98______-J___ only)

˜

NOTE: See Chapter 1 for power supply DIP switch information.

Output 3 Wiring

NOTE: Switching inductive loads (relay coils, solenoids, etc.) with the mechanical relay 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 Paktron. Watlow Part No. 0804-0147-

0000.

Loop powered

19 to 32VÎ (dc)

1

790Ω

2

Internal Circuitry

NC Form B

External

L2

L1

Fuse

+

Load

NO Form A

COM

External

Load

or

-

+

-

1

2

-

1

2

1

+

2

-

Transmitter

4-20mA out

1

+

+V

2

-

-V

-

+

Input 1 or 2

WATLOW Series 988 User’s Manual 2.15

Installation and Wiring, Chapter 2

Figure 15b — Switched DC, Open Collector

98 _ _ - _ _ _ _ - _ C _ _

Maximum voltage: 42VÎÎ(dc) Maximum current: 1A

Figure 15a —

AC Outputs

Solid-state Relay with Contact Suppression

98 _ _ - _ _ _ _ - _ B _ _

0.5 amps, minimum off-state impedance: 20KΩ

Electromechanical Relay with Contact Suppression

(Suppression between NO and COM contacts only)

98 _ _ - _ _ _ _ - _ D _ _ _

Form C, 5 amps, minimum off-state impedance: 20KΩ

Electromechanical Relay without Contact Suppression

98 _ _ - _ _ _ _ - _ E _ _ _

Form C, 5 amps, off-state impedance: 31MΩ

Solid-state Relay without Contact Suppression

98 _ _ - _ _ _ _ - _ K _ _ _

0.5 amps, off-state impedance: 31MΩ

Output 4 Wiring

Figure 15c — External Signal Conditioner Power Supply

98 _ _ - _ _ _ _ - _ T _ _

5

6

+

-

+V

-V

Transmitter 4-20mA out

Input

1 or 2

+

-

Controllers with Output 4 (R, S, or U)

For data communications wiring refer to “Data Communications with the Watlow Series 988 Family of Controllers” manual. This manual can be downloaded from Watlow’s website at www.wat- low.com, Product Technical Information - Controls.

NOTE: Input-to-output isolation is defeated when the external transmitter power supply is used to power a signal conditioner connected to input 1 or input 2.

˜

NOTE: See Chapter 1 for power supply DIP switch information.

NOTE: Successful installation requires five steps:

• Model number and software choice (Appendix);

• DIP switch settings (Chapter 1);

• Sensor match (Chapter 2 and Appendix);

• Sensor installation (Chapter 2); and

• Wiring (Chapter 2).

NOTE: Switching inductive loads (relay coils, solenoids, etc.) with the mechanical relay 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 Paktron. Watlow Part No. 0804-0147-

0000.

Loop powered

External

L2

L1

Fuse

(#7 for D & E outputs only)

Load

NO

COM

NC

5

6

7

19 to 32VÎ (dc)

5

790Ω

6

7

Internal Circuitry

5

+

External

Load

COM

+

-

6

7

2.16 WATLOW Series 988 User’s Manual

Installation and Wiring, Chapter 2

Notes

WATLOW Series 988 User’s Manual 3.1

Front Panel and Display Loop, Chapter 3

Chapter 3 Front Panel and Display Loop

Upper Display

Indicates the actual process value, prompt parameter value or error code.

DEV LED

When lit, the lower display shows the most recent deviation unit from the set point.

% OUT LED

When lit, the lower display shows the current percent output.

Up-arrow Key

Increases the value or changes the parameter in the upper display (except for set point changes in the Display Loop, which occur in the lower display). Hold the key down to increase the value rapidly. New data takes effect in five seconds or when the Mode key or Display key is pressed.

Up + Down Keys

Press simultaneously for three seconds to go to the Setup Menu. Continue to press both keys for another three seconds to go to the Factory Menu. Access to the Setup and Factory menus can be disabled with lockout DIP switch.

Lower Display

Indicates the set point, deviation, percent power, temperature unit, menu prompt name or alarm code.

L1, L2, L3, L4

These LED’s indicate when output 1, 2, 3 or 4 are active. Outputs can be configured as: Ot1 Control Ot2 Control or Alarm Ot3 Alarm or Retransmit Ot4 Alarm or Communications

(flashes on transmit and

receive)

Display Key

Pressing this key enters the Display Loop. Press the Display key at any time to return to this loop. The next page has more information on the Display Loop.

Auto/Man Key

In Manual mode the lower display shows percent output. Pressed once, it clears any latched alarm. If pressed again within five seconds it will toggle between Auto and Manual mode.

Auto/Man LED

Lit when the control is in Manual operation. Press the Auto/Man key twice to enter Automatic operation. When blinking, press the Auto/Man key to toggle between Auto and Manual. After five seconds without pressing the Auto/Man key, the LED stops blinking and returns to its previous state.

Mode Key

Enters new data and steps to the next prompt in the current menu.

Mode + Up-arrow Keys

Hold the Mode key then press the Up-arrow key to move backwards through the current menu. Scrolling stops when you reach the top of the menu.

Figure 3.1 Series 988 Keys and Displays

Down-arrow Key

Decreases the value or changes the parameter in the upper display (except for set point changes in the Display Loop, which occur in the lower display). Hold the key down to decrease the value rapidly. New data takes effect in five seconds or when the Mode key or Display key is pressed.

Keys and Displays

W

TL

W

A

PROCESS

L1 L2 L3 L4

DEV

% OUT

DISPLAY

AUTO

MAN

MODE

SERIES 988

3.2 WATLOW Series 988 User’s Manual

Front Panel and Display Loop, Chapter 3

Display Loop

The Display Loop is the “home” state of the Series 988 controller. Pressing the Display key ∂ returns the controller to the Display Loop from any prompt in any menu. The controller automatically returns to the Display Loop from any menu when a minute passes without any keys being pressed.

Figure 3.2 The Display Loop

˜

NOTE: If [``no] is selected for [`In2], in the Input Menu, the [Pr`2] prompt will not appear.

˜

NOTE: For information on input 1 [`In1] and input 2 [`In2] ranges, refer to Chapter 4.

DISPLAY

DISPLAY DISPLAY

[`988]

current input 1 reading set point 1 (change with Up-arrow > or Down-arrow < key)

current input 2 reading

[Pr`2]

input 2 process (appears only if controller equipped with input 2 hardware)

current input 1 reading deviation from set point, process 1 minus set point 1 (DEV light on)

current input 1 reading

[`100]

percent output (%OUT light on)

current input 1 reading

[``°C]

units selected (units, °F or °C)

WATLOW Series 988 User’s Manual 4.1

Setup Menus, Chapter 4

Navigating the Setup Menus

To reach the Setup Menus, begin in the Display Loop and press both the Uparrow > and Down-arrow < keys for three seconds. The Setup Menu prompt [`SEt] will appear in the lower display, and the Input Menu prompt

[InPt] will appear in the upper display. The four Setup Menus are: Input [InPt]; Output [OtPt]; Global [GLbL]; and Communications [COM]. Use the

Up-arrow > or Down-arrow < key to select a menu and the Mode key µ to step through a menu. The Communications Menu appears only on units equipped with the data communications option.

You will not see every prompt in any of these menus. The unit’s configuration and model number determine which prompts appear. After stepping through each menu, the Series 988 returns to the Setup Menu prompt [`SEt]. Use the Up-arrow > and Down-arrow < keys to select the next menu, or use the Mode key µ to advance through the same menu again. To move backwards through the menu hold the Mode key µ down and press the Uparrow key >. Use the Up-arrow > or Down-arrow < key to change the prompt setting.

Refer to the Appendix for model number options. For information about communications and the communications prompts, refer to the supplemental manual Data Communications with the Watlow Series 988 Family of

Controllers.

Chapter 4 The Setup Menus

Figure 4.1 Navigating the Setup Menus.

❶ Begin in the Display Loop, and press the Up-arrow

> and Down-arrow < keys simultaneously to reach the Setup Menus.

❷ Press the Up-arrow key > to select one of the Setup Menus.

˜

NOTE: The lockout DIP switch hides the Setup Menus. See Chapter 1.

˜

NOTE: Press the Display key ∂ to return to the Display Loop from any point in any menu.

NOTE: When navigating through menus, outputs will be disabled.

W

PROCESS

L1 L2 L3 L4

DEV

% OUT

SERIES 988

PROCESS

L1 L2 L3 L4

DEV

% OUT

SERIES 988

W

TL

A

DISPLAY

AUTO

MAN

MODE

TL

W

A

[Inpt]

[`Set]

Input

Menu

p. 4.2

W

[OtPt] [gLbL] [COm]

[`Set] [`Set]

Output

Menu

p. 4.18

Global

Menu

p. 4.34

[`Set]

Communications Menu p. 4.44

DISPLAY

AUTO

MAN

MODE

4.2 WATLOW Series 988 User’s Manual

Setup Menus, Chapter 4

Figure 4.2 The Input Menu.

Setup-Input

❸ Select the Input Menu, then press the Mode key µ to step through the

prompts.

❹ Press the Up-arrow key > or the Down-arrow key < to select one of

the prompt values.

*Prompts may not appear, depending on controller configuration.

Reaching the Input Menu

W

TL

W

A

PROCESS

L1 L2 L3 L4

DEV

DISPLAY

% OUT

AUTO

MAN

MODE

SERIES 988

… …

[```0] [```1] [```2] [``60]

[Ftr1] [Ftr1] [Ftr1] [Ftr1]

[``no]

[Lin1]

[root]

[Lin1]

…

MODE

[Inpt]

[`Set]

[`In1]

[deC1]

[`rL1]

[`rH1]

[CAL1]

[rtd1]

[Ftr1]

[Lin1]

[`ln2]

[`rSp]

[deC2]

[`RL2]

[`RH2]

[LrnL]

[LrnH]

[CAL2]

[rtd2]

[Ftr2]

[Lin2]

[Hunt]

[SHYS]

Setup Prompt

Input 1

*Decimal 1

Range Low 1

Range High 1

Calibration Offset 1

*RTD Calibration Curve 1

Software Filter 1

*Linearization 1

*Input 2

*Remote Set Point

*Decimal 2

*Range Low 2

*Range High 2

*Learn Low

*Learn High

*Calibration Offset 2

*RTD Calibration Curve 2

*Software Filter 2

*Linearization 2

*Hunt

*Slidewire Hysteresis

Enter your settings, from the controller's upper display.

Input 1 (p. 4.3)

Input 2 (p. 4.9)

Slidewire (p. 4.16)

Watlow 988 User Manual [en, de, es]

Ta ble of Contents

Using this Manual

Document Every Step

Notes, Cautions and Warnings

Technical Assistance

We Value Your Feedback

Chapter 1 Hardware Setup

DIP Switch Locations and Functions

Chapter 2 Installation and Wiring

Installing the Series 988

Wiring the Series 988

Input-to-output Isolation

Power Wiring

Sensor Installation Guidelines

Wiring 0-20 and 4-20mA Process Inputs

Wiring Example

Wiring Notes

Input 1 Wiring

Input 2 Wiring

Event Input 1 Wiring

Output 1 Wiring

Output 2 Wiring

Output 3 Wiring

Output 4 Wiring

Chapter 3 Front Panel and Display Loop

Keys and Displays

Display Loop

Navigating the Setup Menus

Chapter 4 The Setup Menus

Reaching the Input Menu