User’s Manual
Dual Channel, 1/8 DIN, Microprocessor-Based
Temperature/Process Controller
User Levels: |
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• New User........................... |
go to Introduction |
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• Experienced User................... |
go to page 4.1 |
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• Expert User............................. |
go to page 4.1 |
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Installers: |
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TOTAL |
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• Set-up |
go to page 1.1 |
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CUSTOMER |
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• Installation & Wiring |
go to page 2.1 |
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SATISFACTION |
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3YearWarranty |
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ISO 9001 |
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Registered Company |
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Winona, Minnesota USA |
Watlow Controls
1241 Bundy Boulevard, P.O. Box 5580, Winona, Minnesota USA 55987-5580 Phone: (507) 454-5300, Fax: (507) 452-4507 http://www.watlow.com
0600-0010-000 Rev G |
$10.00 |
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February 2000 |
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Made in the U.S.A. |
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Supersedes: W998-XUMN Rev F |
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NOTE:
Details of a “Note” appear here in the narrow box on the outside of each page.
CAUTION:
Details of a “Caution” appear here in the narrow box on the outside of each page.
WARNING:
Details of a “Warning” appear here in the narrow box on the outside of each page.
Using the Manual
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.
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, an Application Engineer can discuss your application with you.
Before calling, please have the complete model number and user’s manual available. You can get technical support by dialing 507/494-5656, 7 a.m. to 7 p.m. Central Standard Time.
Your comments or suggestions on this manual are welcome, please send them to: Technical Writer, Watlow Controls, P.O. Box 5580, Winona, MN 55987-5580, Phone: (507) 454-5300, Fax: (507) 452-4507. The Series 998 User’s Manual is copyrighted by Watlow Winona, Inc., © February 2000, with all rights reserved. (1832)
Introduction
Starting Out with the Watlow Series 998
iThe Series 998
iiDisplay Loop
iiOperation Menus
iiiSetup Menus
iii Factory Menus
Chapter 1
Hardware Setup
1.1DIP Switch Locations and Functions
1.2Input Type DIP Switches
1.3External Power Supply DIP Switches
1.4Setting the Lockout DIP Switch
Chapter 2
Installation and Wiring
2.1Panel Cutout and Dimensions
2.2Installing the Series 998
2.4Wiring the Series 998
2.4Power Wiring
2.4Sensor Installation Guidelines
2.5Event Input 1 Wiring
2.5Wiring 0-20mA and 4-20mA Process Inputs
2.6Wiring Example
2.7Wiring Notes
2.8Channel A Input Wiring
2.9Channel B Input Wiring
2.10Channel A Output Wiring
2.11Channel B Output Wiring
2.12Output 3 Wiring
2.13Output 4 Wiring
Chapter 3
Keys and Displays
3.1Keys and Displays
3.2Display Key and Loop
Chapter 4
The Setup Menus
4.1Navigating the Setup Menus
4.2Input Menu
4.16 Output Menu
4.32 Global Menu
Chapter 5
The Operation Menus
5.1Navigating the Operation Menus
5.2The System Menu
5.3The Set Point Menu
5.3System Prompts
5.8 PID A Menu
5.13 PID B Menu
Chapter 6
The Factory Menus
6.1Navigating the Factory Menus
6.2Panel Lockout Menu
6.8 Diagnostics Menu
6.14 Calibration Menu
Chapter 7
Tuning, Manual Operation, Alarms and
Error Codes
7.1Auto-tuning (Heat and/or Cool)
7.2Manual Tuning
7.3Manual and Automatic Operation
7.4Changing the Output 3 Alarm Jumper
7.4Using Alarms
7.6Error Code E1 and E2 Messages
7.7Error Code Actions
Chapter 8
Applications
8.1Burst Fired, Zero Cross Output
8.2Retransmit
8.3Dead Band
8.3Transmitter Power Supply
Appendix
A.1 |
Warranty and Returns |
A.2 |
Glossary |
A.5 |
Index |
A.7 |
Prompt Index |
A.8 |
Specifications |
A.9 |
Ordering Information |
A.10 |
Declaration of Conformity |
Table of Contents |
WATLOW Series 998 User’s Manual |
Notes
WATLOW Series 998 User’s Manual |
Table of Contents |
Starting Out With the Watlow Series 998
Figure i -
The Series 998.
Channel A Input
(Input 1)
Channel B Input
(Input 2)
Event Input
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WATL W |
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PROCESS |
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1A |
2A |
1B |
2B |
CH A |
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DISPLAY |
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CH B |
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AUTO |
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MAN |
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MODE |
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SERIES 998 |
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Channel A Control Outputs (Output 1A and 2A)
Channel B Control Outputs (Output 1B and 2B)
Optional Outputs 3 and 4 (alarms, retransmit or PC communications)
Watlow’s Series 998 process controller is capable of two independent channels of process control. Each channel can be configured and tuned separately. Each alarm option (outputs 3 and 4) can be used to trigger an alarm based on either channel. The retransmit option, available on output 3, can be used to retransmit the process or set point value of either channel. The digital communications option can be used to configure and monitor the controller with a personal computer from a remote location.
If you are unfamiliar with general controller operation, it’s a good idea to read through the entire manual. The manual is organized in setup order, with chapters on wiring, menus, operation and applications. If you understand the concept of process/temperature controls and feel comfortable skipping around through the manual, use the black tabs at the top of each page to quickly scan the pages and find the topic needed. The Menu Overview on the next page is a great place to start. Also, refer to Chapter 3 for information on the keys and displays.
The menu map is an overview of all menus and prompts and how to navigate between them. There are three main menu sets: Setup menus [`SEt]; Operation menus [OPEr]; and Factory menus [Fcty]. You can return to the Display Loop from anywhere by pressing the Display key. DIP switch locations and settings are explained later in Chapter 1.
Introduction |
WATLOW Series 998 User’s Manual |
i |
Introduction
Channel A |
Channel B |
Channel A |
∂ |
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Process |
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Process |
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Process |
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[`75] |
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[`80] |
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[`75] |
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[```] |
∂ |
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∂ |
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∂ |
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[100] |
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[125] |
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[`80] |
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[`°F] |
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Channel A |
Channel B |
Channel B |
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Process |
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Set Point |
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Set Point |
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Process |
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Units |
From the Display Loop, press the Mode key µ to reach the Operation menus.
To return to the Display Loop from any point in any menu, press the
Display key ∂.
From the Display Loop, press both the Up-arrow and Down-arrow keys > and < for three seconds to reach the Setup menus. Hold them down for another three seconds to reach the Factory menus.
[`998]
[SP2A] Set Point 2A
[`998]
[SP2b] Set Point 2B
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[`SyS]System Menu |
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> |
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[PiDA] PID A Menu |
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> |
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[PiDb] PID B Menu |
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[OPEr] Operation Menus |
[Oper Operation Menus |
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[OPEr] Operation Menus |
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[Ei1S] Event Input 1 Status |
[PB1A] Output 1 Proportional Band A |
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[Pb1b] Output 1 Proportional Band B |
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µ |
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[Ot3S] Output 3 Status |
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µ |
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[rE1A] Output 1 Reset A |
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µ |
[rE1b] Output 1 Reset B |
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[Ot4S] Output 4 Status |
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[It1A] Output 1 Integral A |
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[It1b] Output 1 Integral B |
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[A3LO] Alarm 3 |
Low |
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[rA1A] Output 1 Rate A |
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[RA1b] Output 1 Rate B |
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[A3HI] Alarm 3 |
High |
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[dE1A] Output 1 Derivative A |
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[dE1b] Output 1 Derivative B |
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[A4LO] Alarm 4 |
Low |
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[Ct1A] Output 1 Cycle Time A |
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[Ct1b] Output 1 Cycle Time B |
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[A4HI] Alarm 4 |
High |
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[Pb2A] Output 2 Proportional Band A |
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[Pb2b] Output 2 Proportional Band B |
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[`AUt] Auto-tune |
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[rE2A] Output 2 Reset A |
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[rE2b] Output 2 Reset B |
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[It2A] Output 2 |
Integral A |
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[It2b] Output 2 |
Integral B |
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[rA2A] Output 2 |
Rate A |
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[rA2b] Output 2 |
Rate B |
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[dE2A] Output 2 |
Derivative A |
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[dE2b] Output 2 |
Derivative B |
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[Ct2A] Output 2 |
Cycle Time A |
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[Ct2b] Output 2 |
Cycle Time B |
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[db`A] Dead Band A |
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[db`b] Dead Band B |
ii |
WATLOW Series 998 User’s Manual |
Introduction |
Introduction
From the Setup menus, press both the Up-arrow and Down-arrow keys > and < for three seconds to reach the Factory menus.
To return to the Display Loop from any point in any menu, press the Display key
∂.
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[InPt] Input Menu |
> |
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[`SEt] Setup Menus |
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µ |
[`In1] Input 1 |
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µ |
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[dEC1] Decimal 1 |
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[`rL1] Range Low 1 |
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[`rH1] Range High 1 |
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[CAL1] Calibration Offset 1 |
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[rtd1] RTD Calibration Curve 1 |
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[Ftr1] Input 1 Software Filter |
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[`In2] Input 2 |
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[dEC2] Decimal 2 |
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[`rL2] Range Low 2 |
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[`rH2] Range High 2 |
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[CAL2] Calibration Offset 2 |
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[rtd2] RTD Calibration Curve 2 |
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[Ftr2] Input 2 |
Software Filter |
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[Lin2] Input 2 |
Linearization |
[`Alt] Altitude
>
[OtPt]Output Menu >[gLbl]Global Menu >
[`SEt] Setup Menus |
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[`Set] Setup Menus |
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[Ot1A] Output 1A |
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µ |
[`C_F] Celsius-Fahrenheit |
µ |
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[HY1A] Hysteresis 1A |
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[FAIL] Failure Mode |
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[Ot2A] Output 2A |
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[`err] Error Latching |
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[HY2A] Hysteresis 2A |
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[`Ei1] Event Input 1 |
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[PrcA] Process A |
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[Anun] Annunciator |
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[Ot1b] Output 1B |
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[AtSP] Auto-tune Set Point |
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[HY1b] Hysteresis 1B |
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[rP`A] Ramping Channel A |
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[Ot2b] Output 2B |
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[rt`A] Ramp Rate Channel A |
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[HY2b] Hysteresis 2B |
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[rP`b] Ramping Channel B |
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[Prcb] Process B |
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[rt`b] Ramp Rate Channel B |
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[`Ot3] Output 3 |
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[`Al3] Alarm 3 |
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[HYS3] Hysteresis 3 |
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[LAt3] Latching 3 |
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[SIL3] Silencing 3 |
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[`Ot4] Output 4 |
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[`AL4] Alarm 4 |
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[HYS4] Hysteresis 4 |
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[LAt4] Latching 4 |
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[SIL4] Silencing 4 |
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[Aout] Analog Output |
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[Prc3] Process 3 |
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[`ArL] Retransmit Low Limit [`ArH] Retransmit High Limit [ACAL] Retransmit Calibration Offset
[COM] Communications Menu
[`SEt] Setup Menus
[bAUd] Baud Rate
[dAtA] Data Bits and Parity [Prot] Protocol Type [Addr] Address
[IntF] Interface Type
>
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[PLOC] Panel Lockout Menu |
> |
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[diAg] Diagnostics Menu |
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[`CAL] Calibration Menu |
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[Fcty] Factory Menus |
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[Fcty Factory Menus |
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[Fcty] Factory Menus |
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[`LOC] User Lockout |
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[dAtE] Factory Ship Date |
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[A`50] |
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[`SYS] System Menu Lockout |
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[SOFt] Software Revision |
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[A`00] |
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[b380] |
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[PidA] PID A Menu Lockout |
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[Sn--] Serial Number |
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[``tc] |
µ |
[b10U] |
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[Pidb] PID B Menu Lockout |
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[AMb] Ambient Temperature |
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[a`OH] |
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[b`OU] |
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[InPt] Input Menu Lockout |
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[`gnd] Ground A/D Count |
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[A`20] |
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[b`4A] |
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[OtPt] Output Menu Lockout |
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[`rEF] Ambient A/D Count |
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[A`15] |
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[b`Ou] |
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[gLbL] Global Menu Lockout |
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[cnt1] Input 1 A/D Count |
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[A380] |
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[b100] |
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[COM] Communications Menu Lockout |
[cnt2] Input 2 A/D Count |
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[A10U] |
[1`4`] |
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[diAg] Diagnostics Menu Lockout |
[itY1] Input 1 Module |
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[A`OU] |
[1`20] |
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[`CAL] Calibration Menu Lockout |
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[ity2] Input 2 Module |
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[A20A] |
[1`10] |
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[OtY1] Output 1 Module |
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[A`4A] |
[110`] |
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[OtY2] Output 2 Module |
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[A`Ou] |
[2`4`] |
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[OtY3] Output 3 Module |
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[A100] |
[2`20] |
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[OtY4] Output 4 Module |
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[b`50] |
[2`0`] |
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[dISP] Test Displays |
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[b`00] |
[2`10] |
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[tout] Test Outputs |
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[b`OH] |
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[3`LO] |
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[b`20] |
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[3`HI] |
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[b`15] |
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[`rSt] Restore Factory Values |
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[`dFL] Default Prompts |
Introduction |
WATLOW Series 998 User’s Manual |
iii |
Notes
iv |
WATLOW Series 998 User’s Manual |
Introduction |
DIP Switch Locations and Functions
Figure 1.1 - Press the release tabs to remove the controller chassis.
The Watlow Series 998 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.
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WATL W |
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PROCESS |
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Release |
1A |
2A |
1B |
2B |
Release |
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Tabs |
Tabs |
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CH A |
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DISPLAY |
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CH B |
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AUTO |
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MAN |
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MODE |
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SERIES 998 |
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Release
Tabs
WATLW
DSPY |
MODE |
PROCESS |
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CH A |
AUTO |
CH B |
MAN |
1A 2A 1B 2B |
SERIES 998 |
Release
Tabs
Hardware Setup, Chapter 1 |
WATLOW Series 998 User’s Manual |
1.1 |
DIP Switches
˜
NOTE:
The input 2 DIP switch is mounted upside down.
˜
NOTE:
Only controllers with the indicated model numbers have these DIP switches.
Figure 1.2 -
Input DIP switches.
1 - Set the input DIP switches to match the sensors you are using in your application. Only controllers with model number 99__- 22__-____ have input DIP switches.
Input 2 DIP
(Channel B)
DIP
Input 1 DIP
(Channel A)
DIP
ON |
ON |
Controller Chassis
Rear View
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Input 1 (Channel A) |
Input 2 (Channel B) |
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(99__-2___-____) |
(99__-_2__-____) |
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O 1 |
2 |
3 |
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N |
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O |
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RTD |
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2 |
1 |
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O |
1 |
2 |
3 |
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N |
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2 |
1 |
O |
thermocouple: R, S or B |
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O |
1 |
2 |
3 |
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N |
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2 |
1 |
O |
thermocouple: J, K, T, N, E, C, D, Pt2 |
↑ |
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O |
1 |
2 |
3 |
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↑ |
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N |
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3 |
2 |
1 |
O |
0-20 or 4-20mA; 0-5, 1-5 or 0-10V |
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1.2 |
WATLOW Series 998 User’s Manual |
Hardware Setup, Chapter 1 |
NOTE:
For other voltages or current settings contact the factory.
NOTE:
Only controllers with the indicated model numbers have these DIP switches.
Figure 1.3 - External signal conditioner power supply DIPs.
DIP Switches
2 - Set DIP switches for outputs equipped with an external signal conditioner power supply. Only controllers with model number 99__-____-T___ or 99__-____-_T__ have an external signal conditioner power supply.
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ON |
Lockout |
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DIP |
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OFF |
OFF |
ON |
Output 4 |
Option Board and Dip |
Output 3 |
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Option Board and Dip OFF |
ON |
Control Chassis
Top View (996 & 998)
Left-side View (997 & 999)
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Output 3 |
Output 4 |
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(99__-____-T___) |
(99__-____-_T__) |
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O 1 |
2 |
O 1 |
2 |
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N |
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20V ± 5% @ 30mA |
↑ |
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O 1 |
2 |
O 1 |
2 |
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N |
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12V ± 5% @ 30mA |
↑ |
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O 1 |
2 |
O 1 |
2 |
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5V ± 5% @ 30mA |
↑ |
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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.
Hardware Setup, Chapter 1 |
WATLOW Series 998 User’s Manual |
1.3 |
DIP Switches
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.
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.
All controllers leave the factory with both switches set to off.
ON
Lockout
DIP
OFF
Control Chassis
Top View (996 & 998)
Left-side View (997 & 999)
Figure 1.4 - Lockout DIP switch.
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O 1 |
2 |
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O 1 |
2 |
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N |
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N |
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no hardware lockout |
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or |
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(Switch 1 has no effect.) |
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O 1 |
2 |
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O 1 |
2 |
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lockout Setup and Factory menus |
↑ |
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or |
↑ |
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(Switch 1 has no effect.) |
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Input |
Output |
Global |
Commu- |
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nications |
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Panel |
Diagnostics |
Calibration |
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Lockout |
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1.4 |
WATLOW Series 998 User’s Manual |
Hardware Setup, Chapter 1 |
NOTE: |
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A minimum of 1.66” |
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(42.2mm) spacing |
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between panel |
Panel Cutout |
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cutouts is recom- |
Maximum Panel |
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mended. |
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Thickness |
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0.38" (9.65mm) |
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3.62" + 0.03 -0.00 (92mm + 0.8)
Figure 2.1a -
Series 998
Panel Cutout
Dimensions. 1.77 + 0.02 -0.00
(45mm + 0.6)
NOTE:
Adjustable mounting brackets can also be side mounted.
Figure 2.1b -
Series 998
Dimensions.
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WATL W |
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PROCESS |
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WATL W |
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DSPY |
MODE |
4.03" |
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2A |
1B |
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PROCESS |
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CH A |
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DISPLAY |
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AUTO |
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AUTO |
1A |
2A |
1B |
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SERIES 998 |
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MAN |
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MODE |
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4.03" |
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SERIES 998 |
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(102mm) |
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2.18" |
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(55mm) |
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Panel |
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Adjustable |
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Mounting Bracket |
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0.68" |
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4.06" |
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Installation and Wiring, Chapter 2 |
WATLOW Series 998 User’s Manual |
2.1 |
˜
NOTE:
Removing the controller chassis from its case makes mounting easier.
Installing the Series 998
Installing and mounting requires access to the back of the panel.
1.Make a panel cutout.
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 the mounting collar over the back of the control.
Figure 2.2 -
Side and top view.
Side (996 or 998) |
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or Top and Bottom (997 or 999) View |
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Panel |
Adjustable |
Top and Bottom (996 or 998) |
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or Side (997 or 999) View |
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Mounting Bracket |
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Release Tabs |
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Mounting Slots |
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Bezel |
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External Gasket |
Mounting Collar |
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2.2 |
WATLOW Series 998 User’s Manual |
Installation and Wiring, Chapter 2 |
Installing
4.Loosen the mounting bracket screws enough to allow for the mounting
çcollar and panel thickness. Place each mounting bracket into the
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.
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 996 and 998 units (vertical) must have the mounting brackets located on either side of the unit. When installing Series 997 and 999 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 difficult to remove or replace the controller.
6.Insert the controller chassis into its case and press the bezel until all four tabs snap. Make sure the inside gasket is seated properly and not twisted.
7.To release the mounting brackets, loosen the mounting bracket screws and push the brackets forward, then pull it up and out.
Installation and Wiring, Chapter 2 |
WATLOW Series 998 User’s Manual |
2.3 |
ç
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.
ç
CAUTION:
The Series 998 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.
Wiring the Series 998
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 998 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 |
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L1 |
L2 |
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100 to 240VÅ (ac) nominal, (85 to 264 actual) |
Fuse |
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22 |
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21 |
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11 |
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Vertical Package |
99 8 _ - _ _ _ _ - _ _ _ _ |
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Earth Ground |
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Horizontal Package |
99 9 _ - _ _ _ _ - _ _ _ _ |
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24 to 28 V‡ (ac/dc) nominal, (20 to 30 actual) |
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Vertical Package |
99 6 _ - _ _ _ _ - _ _ _ _ |
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Horizontal Package |
99 7 _ - _ _ _ _ - _ _ _ _ |
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Sensor Installation Guidelines
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.
RTD input: Each 1Ω of lead wire resistance can cause a +2°F 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).
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.
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.
2.4 |
WATLOW Series 998 User’s Manual |
Installation and Wiring, Chapter 2 |
Figure 2.5 - Process wiring example.
Event Input 1
Standard on all units
14 - 36VÎ (dc) Event Input 1 off (open) 0 - 3VÎ (dc) Event Input 1 on (closed)
23 |
24 |
OR 23 |
24 |
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+ |
- |
Wiring
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OPTO |
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ISOLATOR |
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4.99KΩ |
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.01µ f |
+24VÎ (dc) |
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750Ω |
10KΩ |
4.99KΩ |
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Internal Circuitry |
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23 |
24 |
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 4-20mA 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.
988 Process
Input Control
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4-20mA dc |
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Transmitter |
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Internal |
+ |
R x |
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Resistor |
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— + |
+ 24VÎ (dc) |
7Ω |
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100 to 400 |
Power Supply |
1/8 Watt |
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ohms |
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— |
— |
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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.
Installation and Wiring, Chapter 2 |
WATLOW Series 998 User’s Manual |
2.5 |
Figure 2.6 -
System Wiring
Examples.
ç
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
CAUTION:
To avoid damage to property and equipment, use National Electric Code (NEC) standard wiring practices to install and operate the series 998. Failure to do so could result in such damage.
L1 |
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L1 |
L2 |
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L2 |
Fuse |
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Mercury |
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High- |
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Relay |
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Temperature |
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Earthground |
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Fuse |
Light |
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21 22 |
11 |
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12 |
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13 |
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L1 |
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14 |
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15 |
Humidify |
L2 |
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16 |
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L1 |
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17 |
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8 |
Dehumidify |
L2 |
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18 |
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9 |
19 |
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Coil |
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10 |
20 |
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High-Limit |
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C NO NC |
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Mechanical |
1 |
2 |
3 |
4 |
5 |
6 |
7 |
8 |
9 |
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Control |
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Environmental |
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Chamber |
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Cooling |
Wet Bulb |
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Fan |
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RTD Sensor |
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L2 |
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10 11 12 13 14 15 16 17 |
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Dry Temp |
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RTD Sensor |
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Reset Series 146 |
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Heater |
Limit Control |
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146E-1601-3000 |
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Limit Sensor |
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2.6 |
WATLOW Series 998 User’s Manual |
Installation and Wiring, Chapter 2 |
ç
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 998. Failure to do so could result in such damage, and/or injury or death.
NOTE:
Sketch in your application on this page or a copy of it. See wiring examples in this chapter and in the Appendix.
Figure 2.7 -
Wiring notes.
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Wiring Notes |
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L1 |
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L2 |
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earth ground |
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21 |
11 |
22 |
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power |
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Installation and Wiring, Chapter 2 |
WATLOW Series 998 User’s Manual |
2.7 |
NOTE:
Using a grounded thermocouple for both input 1 and input 2 can cause ground loop problems.
NOTE:
Model number
99_ _-1 _ _ _-_ _ _ _
has no input 1 DIP switch.
ç
CAUTION:
An external resistor is 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 2.4. for recommendations.
Figure 2.8a — Thermocouple
Thermocouple only |
O 1 2 3 |
↑ |
|
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N |
99 _ _ - 1 _ _ _ - _ _ _ _
J, K, T, N, C, E, Pt2, D
Universal signal conditioner Dip Switch Setting
99 _ _ - 2 _ _ _ - _ _ _ _
O 1 2 3
N
↑
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R, S, B |
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+ |
9 |
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- |
10 |
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Dip Switch Setting |
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Figure 2.8b — RTD, 2- or 3-wire |
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Universal signal conditioner |
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99 _ _ - 2 _ _ _ - _ _ _ _ |
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O 1 2 3 |
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N |
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↑ |
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Dip Switch Setting |
S1 |
8 |
S1 |
8 |
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Jumper 9 to 10 |
S2 |
9 |
S2 |
9 |
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S3 |
10 |
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for 2-wire RTD |
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10 |
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Figure 2.8c — 0-5VÎ, 1-5VÎ or 0-10VÎ (dc) Process
Universal signal conditioner 99 _ _ - 2 _ _ _ - _ _ _ _
Input impedance: 10KΩ |
O 1 2 3 |
N |
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↑ |
Dip Switch Setting
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+ |
9 |
V DC |
- |
10 |
Figure 2.8d — 0-20mA or 4-20mA Process
Universal signal conditioner 99 _ _ - 2 _ _ _ - _ _ _ _
Input impedance: 7Ω
O 1 2 3 |
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- |
8 |
N |
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↑ |
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Dip Switch Setting |
mA |
+ |
10 |
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2.8 |
WATLOW Series 998 User’s Manual |
Installation and Wiring, Chapter 2 |
NOTE:
Using a grounded thermocouple for both input 1 and input 2 can cause ground loop problems.
NOTE:
Model number
99_ _-_ 1 _ _-_ _ _ _
has no In1 DIP switch.
ç
CAUTION:
An external resistor is 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 2.4. for recommendations.
|
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Channel B Input Wiring |
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Figure 2.9a — Thermocouple |
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Thermocouple only |
O 1 |
2 |
3 |
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N |
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99 _ _ - _ 1 _ _ - _ _ _ _ |
↑ |
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J, K, T, N, C, E, Pt2, D |
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Universal signal conditioner |
Dip Switch Setting |
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99 _ _ - _ 2 _ _ - _ _ _ _ |
O 1 |
2 |
3 |
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19 |
+ |
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20 |
- |
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Dip Switch Setting |
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Figure 2.9b — RTD, 2- or 3-wire |
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99 _ _ - _ 2 _ _ - _ _ _ _ |
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Jumper |
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19 to 20 |
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for 2-wire |
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RTD |
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O 1 2 3 |
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18 |
S1 |
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N |
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↑ |
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18 |
S1 |
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S2 |
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Dip Switch Setting |
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19 |
19 |
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S2 |
S3 |
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20 |
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20 |
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Figure 2.9c — 0-5VÎ , 1-5VÎ , 0-10VÎ (dc) Process
99 _ _ - _ 2 _ _ - _ _ _ _
Input impedance: 10KΩ
O 1 2 3 |
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N |
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↑ |
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19 |
+ |
V DC |
Dip Switch Setting |
20 |
- |
Figure 2.9d — 0-20mA or 4-20mA Process
99 _ _ - _ 2 _ _ - _ _ _ _
Input impedance: 7Ω
O 1 2 3 |
18 |
- |
N |
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↑ |
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mA |
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20 |
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+ |
Dip Switch Setting
Installation and Wiring, Chapter 2 |
WATLOW Series 998 User’s Manual |
2.9 |
Figure 2.10a — AC Outputs
•Dual Electromechanical Relays without Contact Suppression
Dual Form A, 2 Amps Off-state impedance: 31MΩ
99 _ _ - _ _ E _ - _ _ _ _
•Dual Solid-state Relay without Contact Suppression
Dual Form A, 0.5 Amps Off-state impedance: 31MΩ
99 _ _ - _ _ K _ - _ _ _ _
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External |
1A |
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12 |
NO |
Load |
L2 |
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13 COM |
Fuse |
L1 |
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14 |
NO |
L2 |
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External |
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Load |
2A |
Figure 2.10b — Dual Switched DC
99 _ _ - _ _ C _ - _ _ _ _
12 |
+ |
External |
+ |
External |
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13 |
- |
- |
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Load 1A |
Load 2A |
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14 |
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23.5 to 30.6VÎ (dc) |
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+ VÎ |
12 |
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1500 Ω |
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13 |
1500 |
Ω |
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14 |
Internal Circuitry |
Figure 2.10c — 0-20mA and 4-20mA Process
Load impedance: 800Ω max.
12
+
99 _ _ - _ _ F _ - _ _ _ _
14
-
Figure 2.10d — 0-5VÎ, 1-5VÎ and 0-10VÎ (dc) Process
Load impedance: 500Ω min.
99 _ _ - _ _ F _ - _ _ _ _
13
+
14
-
2.10 WATLOW Series 998 User’s Manual |
Installation and Wiring, Chapter 2 |
Figure 2.11a — AC Outputs
•Dual Electromechanical Relay without Contact Suppression
Dual Form A, 2 Amps Off-state impedance: 31MΩ
99 _ _ - _ _ _ E - _ _ _ _
•Dual Solid-state Relay without Contact Suppression
0.5 Amps
Off-state impedance: 31MΩ
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External |
1B |
15 |
NO |
Load |
L2 |
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16 |
COM |
Fuse |
L1 |
17 |
NO |
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L2 |
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External |
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2B |
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Load |
99 _ _ - _ _ _ K - _ _ _ _
Figure 2.11b — Dual Switched DC
99 _ _ - _ _ _ C - _ _ _ _
+ |
Load |
+ |
Load |
- |
1b |
- |
2b |
15 |
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16 |
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17 |
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23.5 to 30.6VÎ (dc) |
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+ VÎ |
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15 |
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1500 Ω |
16 |
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1500 Ω |
17 |
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Internal Circuitry
Figure 2.11c — 0-20mA and 4-20mA Process
Load impedance: 800Ω max.
99 _ _ - _ _ _ F - _ _ _ _
15 +
17 -
Figure 2.11d — 0-5VÎ, 1-5VÎ and 0-10VÎ (dc) Process
Load impedance: 500Ω min.
99 _ _ - _ _ _ F - _ _ _ _
16 +
17
-
Installation and Wiring, Chapter 2 |
WATLOW Series 998 User’s Manual 2.11 |
NOTE: Input-to-output isolation is defeated when the external transmitter power supply is used to power a transmitter connected to input 1 or input 2.
Figure 2.12a — AC Outputs |
• Solid-state Relay without |
|
• Solid-state Relay with |
Contact Suppression |
|
0.5 Amps |
||
Contact Suppression |
||
Off-state impedance: 31MΩ |
||
0.5 Amps |
||
99 _ _ - _ _ _ _ - K _ _ _ |
||
Off-state impedance: 20KΩ min. |
||
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||
99 _ _ - _ _ _ _ - B _ _ _ |
|
•Electromechanical Relay without
Contact Suppression
Form A or B, 5 Amps Off-state impedance: 31MΩ
99 _ _ - _ _ _ _ - J _ _ _
Form A or B
Alarm Jumper Settings (Top View)
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NC Form B |
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External |
or |
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L2 |
Load |
NO Form A |
1 |
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L1 |
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COM |
2 |
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Fuse
Form A
Figure 2.12b — Switched DC |
External |
+ |
1 |
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Minimum load resistance: 500Ω |
- |
2 |
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Load |
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99 _ _ - _ _ _ _ - C _ _ _ |
19 to 32VÎ (dc) |
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1 |
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+ VÎ |
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790Ω |
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2 |
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Internal Circuitry |
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Figure 2.12c — Process Retransmit
0-20mA, 4-20mA
Load impedance: 600Ω max.
99 _ _ - _ _ _ _ - M _ _ _
0-5VÎ, 1-5VÎ or 0-10VÎ (dc)
Load impedance: 500Ω min.
99 _ _ - _ _ _ _ - N _ _ _
+ -
1
2
Figure 2.12d — External Transmitter Power Supply
99 _ _ - _ _ _ _ - T _ _ _ |
Transmitter |
+V |
+ |
1 |
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- |
2 |
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4-20mA out |
-V |
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See Chapter 1 for DIP switch location and set- |
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tings. |
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-+ |
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Input |
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1 or 2 |
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2.12 WATLOW Series 998 User’s Manual |
Installation and Wiring, Chapter 2 |
Figure 2.13a — AC Outputs
•Solid-state Relay with
Contact Suppression
0.5 Amps
Off-state impedance: 20KΩ min.
99 _ _ - _ _ _ _ - _ B _ _
•Solid-state Relay without
Contact Suppression
0.5 Amps
Off-state impedance: 31MΩ
99 _ _ - _ _ _ _ - _ K _ _
•Electromechanical Relay with
Contact Suppression
(On NO and COM contacts only)
Form C, 5 Amps
Off-state impedance: 20KΩ min.
99 _ _ - _ _ _ _ - _ D _ _
•Electromechanical Relay without
Contact Suppression
Form C, 5 Amps
Off-state impedance: 31MΩ
99 _ _ - _ _ _ _ - _ E _ _
|
External |
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L2 |
Load |
NO |
5 |
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L1 |
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COM |
6 |
Fuse |
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NC |
7 |
(7 for D & E outputs only)
Figure 2.13b — Switched DC, Open Collector
Minimum load resistance: 500Ω 99 _ _ - _ _ _ _ - _ C _ _
19 to 32VÎ (dc) |
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+ VÎ |
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5 |
Ω |
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790 |
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6 |
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7 |
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Internal Circuitry |
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External |
+ |
5 |
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- |
6 |
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Load |
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COM 7
NOTE: Input-to-output isolation is defeated when the external transmitter power supply is used to power a transmitter connected to input 1 or input 2.
Figure 2.13c — External Transmitter Power Supply
99 _ _ - _ _ _ _ - _ T _ _
See Chapter 1 for DIP switch location and settings.
Transmitter |
+V |
+ |
5 |
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- |
6 |
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-V |
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4-20mA out |
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+ |
- |
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Input |
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1 or 2 |
|
For data communications wiring refer to How to Use
Data Communications with the Watlow Series 988 Family Controls.
Installation and Wiring, Chapter 2 |
WATLOW Series 998 User’s Manual 2.13 |
Notes
2.14 WATLOW Series 998 User’s Manual |
Installation and Wiring, Chapter 2 |
Upper Display
Indicates either actual process value for channel A or channel B, the operating prompt values, or error codes. When powering up, the display will be blank for 3 seconds. Red or green, 0.4” (10mm) high, seven-segment, four-digit LED display.
CH A Indicator Light
When lit, if the CH B light is not on, the channel A process value is shown in the upper display and the channel A set point value is shown in the lower display. When both CH A and CH B lights are on, the upper display shows the channel A process value and the lower displays shows the channel B process value.
CH B Indicator Light
When lit, if the CH A light is not on, the channel B process value is shown in the upper display and the channel B set point value is shown in the lower display. When both CH A and CH B lights are on, the upper display shows the channel A process value and the lower display shows the channel B process value.
Up-arrow Key >
|
Lower Display |
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|
Indicates the channel A or |
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|
channel B set point, or channel |
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B process value, menu |
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prompts, or alarm codes. Red |
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or green, 0.3” (8mm) high, |
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seven-segment, four-digit LED |
|
WATL W |
||
display. |
||
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||
|
1A, 2A, 1B, 2B Indicator |
|
|
Lights |
|
PROCESS |
These lights indicate when out- |
|
|
put 1A, 2A, 1B or 2B is active. |
|
|
Display Key ∂ |
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|
The Display key is used to |
|
1A 2A 1B 2B |
select which channel A and/or |
|
CH A |
B parameter to displayed. On |
|
DISPLAY |
initial power-up the upper dis- |
|
CH B |
play shows the channel A |
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||
AUTO |
process value and the lower |
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MAN |
display shows the channel A set |
|
point value and the CH A light |
||
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||
MODE |
is on. One press of the Display |
|
key lights CH B and the upper |
||
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||
SERIES 998 |
display shows the channel B |
|
process value and the lower |
||
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||
|
display shows the channel B |
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set point value. A second press |
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|
of the key lights both CH A and |
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CH B, and the upper display |
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shows the channel A process |
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value and the lower display |
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|
shows the channel B process |
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|
value. See the next page for |
|
more information on the Display Loop. |
Increases the value of the displayed prompt. A light touch increases the value by one. Holding the key down increases the value at a rapid rate. New data does not take effect for five seconds or until the Mode µ or Display ∂ key is pressed.
Down-arrow Key <
Decreases the value of the displayed prompt. A light touch decreases the value by one. Holding the key down decreases the displayed value at a rapid rate. New data does not take effect for five seconds or until the Mode µ or Display ∂ key is pressed.
Up-arrow + Down-arrow Keys
Press simultaneously for three seconds to enter the Setup Menu. Continue to press both keys for another three seconds to enter the Factory Menu.
Auto/Man Key å
Used to switch from auto to manual control or vice versa. Also used to reset alarms.
Mode Key µ
Steps the control through the menus. New data is entered once the Mode key is pressed.
Mode+Up-arrow Key µ + >
To move backwards through the menus, hold down the Mode key, then press the Up-arrow key to scroll. The Mode key must be pressed first and held before the Up-arrow key will begin scrolling. Scrolling is disabled once the keys are released or you reach the top of the menu.
Figure 3.1 -
Series 998 Keys and
Displays.
Keys and Displays, Chapter 3 |
WATLOW Series 998 User’s Manual |
3.1 |
NOTE:
Lower display alternately flashes [`rP`] and lower display value when ramping is in process.
Display Key and Loop
On power up, the Series 998 displays the channel A set point value in the lower display and the channel A process value in the upper display and the CH A (channel A) indicator light is on. Press the Display key once to view the channel B set point and process values (CH B will be lit). Press the Display key once again and channel A process value is displayed in the upper display and channel B process value is displayed in the lower display. At this point, both CH A and CH B will be lit. Press the Display key again to display units.
Any point in any menu, if no key is pressed for one minute the display returns to displaying the channel A process and set point.
Figure 3.2 -
The Display Loop.
Display Loop
Channel A |
Channel B |
Channel A |
∂ |
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Process |
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Process |
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Process |
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[`75] |
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[`80] |
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[`75] |
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[```] |
∂ |
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∂ |
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∂ |
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[100] |
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[125] |
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[`80] |
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[`°F] |
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Channel A |
Channel B |
Channel B |
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Process |
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Set Point |
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Set Point |
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Process |
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Units |
Display Loop Parameters
Channel A Process and Set Point: The channel A process value is shown in the upper display. The set point is shown in the lower display, it sets the operating set point for the channel A control outputs. If channel A is in manual mode the set point is in percent output.
Range: |
[`rL1] to [`rH1] in auto mode |
|
[-100] % to [`100] % in manual mode (heat/cool) |
|
[```0] % to [`100] % in manual mode (heat only) |
|
[-100] % to [```0] % in manual mode (cool only) |
Default: |
depends on input 1 range and type |
Channel B Process and Set Point: The channel B process value is shown in the upper display. The set point is shown in the lower display, it sets the operating set point for the channel B control outputs. If channel B is in manual mode the set point is in percent output.
Range: |
[`rL2] to [`rH2] in auto mode |
|
[-100] % to [`100] % in manual mode (heat/cool) |
|
[```0] % to [`100] % in manual mode (heat only) |
|
[-100] % to [```0] % in manual mode (cool only) |
Default: |
depends on input 2 range and type |
Process A and Process B: The channel A process value is displayed in the upper display with channel B process value displayed in the lower display.
Range: |
depends on input types |
Default: |
none |
Units: Shows the units associated with the temperature value. This parameter shows what the [`C-F] (Global Menu) is set to.
Range: |
[``°F] or [``°C] |
Default: |
none |
Hidden if: |
input 1 and input 2 are process inputs |
3.2 |
WATLOW Series 998 User’s Manual |
Keys and Displays, Chapter 3 |
NOTE:
Press the Display key ∂ to return to the Display Loop from any point in any menu.
Navigating the Setup Menus
To reach |
Setup Menus, begin in the Display Loop and press both the |
Up- |
> 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: [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 -____-_R__ or 99__-____-_S__).
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 998 returns to the Setup Menu prompt.
Use the |
arrow or Down-arrow key to select the next menu, or use the |
Mode |
advance through the same menu again. To move backwards |
through the menu hold the Mode key down and press the Up-arrow key.
Use the |
arrow or Down-arrow key to change the prompt setting. |
Refer to |
Appendix for model number options. For additional informa- |
tion |
communications and the communications prompts, refer to the |
supplemental manual Data Communications with the Watlow Series 988 Family Controllers.
TL W |
|
1B |
2B |
DISPLAY |
|
AUTO |
|
MAN |
|
MODE |
Begin in the Display Loop, and press the Up-arrow > and Down-arrow < keys simultaneously to reach the Setup menus.
NOTE:
The lockout DIP switch hides the Setup menus. See Chapter 1.
Navigating the Setup menus.
TL W |
|
1B |
2B |
DISPLAY |
|
AUTO |
|
MAN |
|
MODE |
|
SERIES 998 |
|
>> > >
[Inpt] [Otpt] [GLbl] [COM]
[`SEt] |
[`SEt] |
[`SEt] |
[`SEt] |
Input |
Output |
Global |
Communications |
Menu |
Menu |
Menu |
Menu |
p. 4.2 |
p. 4.16 |
p. 4.32 |
p. 4.38 |
Press the Up-arrow key > to select one of the Setup menus.
Setup Menus, Chapter 4 |
WATLOW Series 998 User’s Manual |
4.1 |
Setup-Input
Reaching the Input Menu |
→ |
[InPt] Input Menu |
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µ |
[`SEt] Setup Menus |
Enter your settings, |
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↓ |
? |
from the controller’s |
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upper display. |
µ[`In1] Input 1 (page 4.5)
|
WA |
↓ |
? |
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µ |
[dEC1] *Decimal 1 |
|
1A |
2A |
↓ |
? |
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µ |
[`rL1] Range Low 1 |
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CH B |
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CH A |
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↓ |
? |
|
SERIES 998 |
µ |
[`rH1] Range High 1 |
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↓ |
? |
µ[CAL1] Calibration Offset 1
Select the Input Menu, then |
↓ |
? |
press the Mode key µ to step |
µ |
[rtd1] *RTD Calibration Curve 1 |
through the prompts. |
↓ |
? |
µ[Ftr1] Input 1 Software Filter
↓ ?
µ[`In2] *Input 2 (page 4.10)
↓ ?
µ[deC2] *Decimal 2
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↓ |
? |
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[`rL2] *Range Low 2 |
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> |
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> |
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> |
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> |
µ |
||
[```)] [``)0] [`)00] [)000] |
↓ |
? |
||||||||
|
[`rH2] *Range High 2 |
|||||||||
[DEC1] |
[DEC1] |
[DEC1] |
[DEC1] |
µ |
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↓ |
? |
|
Press the Up-arrow key > or |
µ |
[CAL2] *Calibration Offset 2 |
||||||||
↓ |
? |
|||||||||
the Down-arrow key < to select |
||||||||||
|
[rtd2] *RTD Calibration Curve 2 |
|||||||||
one of the prompt values. |
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µ |
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↓ |
? |
µ[Ftr2] *Input 2 Software Filter
↓ ?
µ[Lin2] *Input 2 Linearization
↓?
←µ [`Alt] *Altitude
Figure 4.2 - |
*Prompts may not appear, depending |
The Input Menu. |
on controller configuration. |
4.2 |
WATLOW Series 998 User’s Manual |
Setup Menus, Chapter 4 |