How it Works
Watlow
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999
Operating Manual
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Watlow 999 Operating Manual

Series 998

Dual Channel, 1/8 DIN, Microprocessor-Based
Temperature/Process Controller
0600-0010-000 Rev G
February 2000 Supersedes: W998-XUMN Rev F
$10.00
Made in the U.S.A.
User’s Manual
Watlow Controls
1241 Bundy Boulevard, P.O. Box 5580, Winona, Minnesota USA55987-5580
Phone: (507) 454-5300, Fax: (507) 452-4507 http://www.watlow.com
User Levels:
• New User........................... go to Introduction
• Experienced User................... go to page 4.1
• Expert User............................. go to page 4.1
Installers:
• Set-up..................................... go to page 1.1
• Installation & Wiring ................go to page 2.1
CUS
CTI
TOTAL
CUS
TOMER
SATISFACTI
3 Year Warranty
ON
ISO 9001
Registered Company
Winona, Minnesota USA
Using the Manual
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.

Safety Information

We use note, caution and warning symbols throughout this book to draw your attention to important operational and safety information.A bold text “NOTE” marks a short message in the margin to alert you to an important detail.
A bold text “CAUTION” safety alert appears with information that is important for protecting your equipment and performance. Be especially careful to read and follow all cautions that apply to your application.
A bold text “WARNING” safety alert appears with information that is important for protecting you, others and equipment from damage. Pay very close attention to all warnings that apply to your application.
The safety alert symbol, ç, (an exclamation point in a triangle) precedes a general CAUTION or WARNING statement.

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, 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 Feedback

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)

Table of Contents

Introduction Starting Out with the Watlow Series 998
i The Series 998 ii Display Loop ii Operation Menus iii Setup Menus iii Factory Menus
Chapter 1 Hardware Setup
1.1 DIP Switch Locations and Functions
1.2 Input Type DIP Switches
1.3 External Power Supply DIP Switches
1.4 Setting the Lockout DIP Switch
Chapter 2 Installation and Wiring
2.1 Panel Cutout and Dimensions
2.2 Installing the Series 998
2.4 Wiring the Series 998
2.4 Power Wiring
2.4 Sensor Installation Guidelines
2.5 Event Input 1 Wiring
2.5 Wiring 0-20mA and 4-20mA Process Inputs
2.6 Wiring Example
2.7 Wiring Notes
2.8 Channel A Input Wiring
2.9 Channel B Input Wiring
2.10 Channel A Output Wiring
2.11 Channel B Output Wiring
2.12 Output 3 Wiring
2.13 Output 4 Wiring
Chapter 5 The Operation Menus
5.1 Navigating the Operation Menus
5.2 The System Menu
5.3 The Set Point Menu
5.3 System Prompts
5.8 PID A Menu
5.13 PID B Menu
Chapter 6 The Factory Menus
6.1 Navigating the Factory Menus
6.2 Panel Lockout Menu
6.8 Diagnostics Menu
6.14 Calibration Menu
Chapter 7 Tuning, Manual Operation, Alarms and Error Codes
7.1 Auto-tuning (Heat and/or Cool)
7.2 Manual Tuning
7.3 Manual and Automatic Operation
7.4 Changing the Output 3 Alarm Jumper
7.4 Using Alarms
7.6 Error Code E1 and E2 Messages
7.7 Error Code Actions
Chapter 8 Applications
8.1 Burst Fired, Zero Cross Output
8.2 Retransmit
8.3 Dead Band
8.3 Transmitter Power Supply
Chapter 3 Keys and Displays
3.1 Keys and Displays
3.2 Display Key and Loop
Chapter 4 The Setup Menus
4.1 Navigating the Setup Menus
4.2 Input Menu
4.16 Output Menu
4.32 Global Menu
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
WATLOW Series 998 User’s ManualTable of Contents
Notes
Table of ContentsWATLOW Series 998 User’s Manual
WATLOW Series 998 User’s Manual i

Introduction

Starting Out With the Watlow Series 998
Figure i ­The Series 998.
TL
W
W
A
PROCESS
1A 2A 1B 2B
CH A CH B
DISPLAY
SERIES 998
MODE
AUTO
MAN
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)
Channel A Input
(Input 1)
Channel B Input
(Input 2)
Event Input
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
Introduction
Introduction
ii WATLOW Series 998 User’s Manual
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.

Display Loop

Operation Menus

[`998]
[SP2A]
Set Point 2A
[`998]
[`SyS]
µ
[SP2b]
[OPEr]
[Ei1S] [Ot3S] [Ot4S] [A3LO] [A3HI] [A4LO] [A4HI] [`AUt]
Set Point 2B
System Menu
Operation Menus Event Input 1 Status Output 3 Status
Output 4 Status Alarm 3 Low Alarm 3 High Alarm 4 Low Alarm 4 High Auto-tune
µ
Channel A
Process
[`75]
[100]
Channel A
Set Point
[PiDA]
[Oper [PB1A] [rE1A] [It1A] [rA1A] [dE1A] [Ct1A] [Pb2A] [rE2A] [It2A] [rA2A] [dE2A] [Ct2A] [db`A]
Channel B
Process
∂
[`80]
[125]
Channel B
Set Point
∂
>
PID A Menu
Operation Menus Output 1 Proportional Band A
Output 1 Reset A Output 1 Integral A Output 1 Rate A Output 1 Derivative A Output 1 Cycle Time A Output 2 Proportional Band A Output 2 Reset A Output 2 Integral A Output 2 Rate A Output 2 Derivative A Output 2 Cycle Time A Dead Band A
Channel A
Process
[`75]
[`80]
Channel B
Process
>>
∂
∂
µ
[```]
[`°F]
Process
Units
[PiDb]
[OPEr]
[Pb1b] [rE1b] [It1b] [RA1b] [dE1b] [Ct1b] [Pb2b] [rE2b] [It2b] [rA2b] [dE2b] [Ct2b] [db`b]
PID B Menu
Operation Menus Output 1 Proportional Band B
Output 1 Reset B Output 1 Integral B Output 1 Rate B Output 1 Derivative B Output 1 Cycle Time B Output 2 Proportional Band B Output 2 Reset B Output 2 Integral B Output 2 Rate B Output 2 Derivative B Output 2 Cycle Time B Dead Band B
Introduction
WATLOW Series 998 User’s Manual iii
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
∂.

Setup Menus

[InPt]
[`SEt]
µ µ
[`In1] [dEC1] [`rL1] [`rH1] [CAL1] [rtd1] [Ftr1] [`In2] [dEC2] [`rL2] [`rH2] [CAL2] [rtd2] [Ftr2] [Lin2] [`Alt]
Input Menu
Setup Menus Input 1
Decimal 1 Range Low 1 Range High 1 Calibration Offset 1 RTD Calibration Curve 1 Input 1 Software Filter Input 2 Decimal 2 Range Low 2 Range High 2 Calibration Offset 2 RTD Calibration Curve 2 Input 2 Software Filter Input 2 Linearization Altitude
>
[OtPt]
[`SEt]
[Ot1A] [HY1A] [Ot2A] [HY2A] [PrcA] [Ot1b] [HY1b] [Ot2b] [HY2b] [Prcb] [`Ot3] [`Al3] [HYS3] [LAt3] [SIL3] [`Ot4] [`AL4] [HYS4] [LAt4] [SIL4] [Aout] [Prc3] [`ArL] [`ArH] [ACAL]
>
Output Menu
Setup Menus Output 1A
Hysteresis 1A Output 2A Hysteresis 2A Process A Output 1B Hysteresis 1B Output 2B Hysteresis 2B Process B Output 3 Alarm 3 Hysteresis 3 Latching 3 Silencing 3 Output 4 Alarm 4 Hysteresis 4 Latching 4 Silencing 4 Analog Output Process 3 Retransmit Low Limit Retransmit High Limit Retransmit Calibration Offset
>
[gLbl]
[`Set]
µ µ
[`C_F] [FAIL] [`err] [`Ei1] [Anun] [AtSP] [rP`A] [rt`A] [rP`b] [rt`b]
Global Menu
Setup Menus Celsius-Fahrenheit
Failure Mode Error Latching Event Input 1 Annunciator Auto-tune Set Point Ramping Channel A Ramp Rate Channel A Ramping Channel B Ramp Rate Channel B
>
[COM]
Communications Menu
[`SEt]
Setup Menus
[bAUd]
Baud Rate
[dAtA]
Data Bits and Parity
[Prot]
Protocol Type
[Addr]
Address
[IntF]
Interface Type

Factory Menus

[PLOC]
[Fcty]
µ
[`LOC] [`SYS] [PidA] [Pidb] [InPt] [OtPt] [gLbL] [COM] [diAg] [`CAL]
Panel Lockout Menu
Factory Menus User Lockout
System Menu Lockout PID A Menu Lockout PID B Menu Lockout Input Menu Lockout Output Menu Lockout Global Menu Lockout Communications Menu Lockout Diagnostics Menu Lockout Calibration Menu Lockout
>
[diAg]
[Fcty
µ µ
[dAtE] [SOFt] [Sn--] [AMb] [`gnd] [`rEF] [cnt1] [cnt2] [itY1] [ity2] [OtY1] [OtY2] [OtY3] [OtY4] [dISP] [tout]
Diagnostics Menu
Factory Menus Factory Ship Date
Software Revision Serial Number Ambient Temperature Ground A/D Count Ambient A/D Count Input 1 A/D Count Input 2 A/D Count Input 1 Module Input 2 Module Output 1 Module Output 2 Module Output 3 Module Output 4 Module Test Displays Test Outputs
>
[`CAL]
>
[Fcty]
[A`50] [A`00] [``tc] [a`OH] [A`20] [A`15] [A380] [A10U] [A`OU] [A20A] [A`4A] [A`Ou] [A100] [b`50] [b`00] [b`OH] [b`20] [b`15]
Calibration Menu Factory Menus
[b380] [b10U]
µ
[b`OU] [b`4A] [b`Ou] [b100] [1`4`] [1`20] [1`10] [110`] [2`4`] [2`20] [2`0`] [2`10] [3`LO] [3`HI] [`rSt] [`dFL]
Restore Factory Values Default Prompts
iv WATLOW Series 998 User’s Manual
Notes
Introduction

Chapter 1 Hardware Setup

DIP Switch Locations and Functions
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.
Figure 1.1 - Press the release tabs to remove the con­troller chassis.
Release
Tabs
A
W
PROCESS
1A 2A 1B 2B
CH A CH B
SERIES 998
W
TL
DISPLAY
AUTO
MAN
MODE
Release
Tabs
W
A
TL
W
PROCESS
1A 2A 1B 2B
Release
Tabs
CH A CH B
DSPY
MODE
AUTO
MAN
SERIES 998
Hardware Setup, Chapter 1
Release
Tabs
WATLOW Series 998 User’s Manual 1.1
DIP Switches
˜
NOTE: The input 2 DIP switch is mounted upside down.
˜
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
Input 1 (Channel A) Input 2 (Channel B)
(99__-2___-____) (99__-_2__-____)
NOTE: Only controllers with the indicated model numbers have these DIP switches.
Figure 1.2 ­Input DIP switches.
RTD
thermocouple: R, S or B
thermocouple: J, K, T, N, E, C, D, Pt2
0-20 or 4-20mA; 0-5, 1-5 or 0-10V
123
O N
↑
123
O N
↑
123
O N
↑
123
O N
↑
↑
N O
123
↑
N O
123
↑
N O
123
↑
N O
123
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.
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.
(99
DIP Switches
Lockout DIP
Output 3
Option Board and Dip
Control Chassis
Top View (996 & 998)
Left-side View (997 & 999)
Output 3 Output 4
__-____-T___) (99__-____-_T__)
ON
OFF
ONOFF
ONOFF
Output 4
Option Board and Dip
Figure 1.3 ­External signal con­ditioner power sup­ply DIPs.
12
O N
↑
12
O N
↑
12
O N
↑
20V ± 5% @ 30mA
12V ± 5% @ 30mA
5V ± 5% @ 30mA
12
O N
↑
12
O N
↑
12
O N
↑
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.
Lockout DIP
Control Chassis
Top View (996 & 998)
Left-side View (997 & 999)
ON
OFF
Figure 1.4 ­Lockout DIP switch.
12
O N
no hardware lockout or
↑
(Switch 1 has no effect.)
12
O N
lockout Setup and Factory menus or
↑
(Switch 1 has no effect.)
Input
Panel
Lockout
Output Global
Diagnostics Calibration
Commu­nications
12
O N
↑
12
O N
↑
1.4 WATLOW Series 998 User’s Manual
Hardware Setup, Chapter 1
TLTL
W
W
A
PROCESS
1A 2A 1B 2B
CH A
CH B
DISPLAY
SERIES 998
MODE
AUTO
MAN
4.03"
(102mm)
2.18"
(55mm)
TL
W
W
A
PROCESS
CH A CH B
MODE
SERIES 998
DSPY
AUTO
MAN
1A 2A 1B 2B
4.03"
(102mm)
2.18"
(55mm)

Chapter 2 Installation and Wiring

NOTE: A minimum of 1.66” (42.2mm) spacing between panel cutouts is recom­mended.
Figure 2.1a ­Series 998 Panel Cutout Dimensions.
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)
NOTE: Adjustable mount­ing brackets can also be side mount­ed.
Figure 2.1b ­Series 998 Dimensions.
Installation and Wiring, Chapter 2
0.68"
(17 mm)
Panel
4.06"
(103 mm)
Adjustable
Mounting Bracket
WATLOW Series 998 User’s Manual 2.1

Installing

Panel
Adjustable
Mounting Bracket
Bezel
External Gasket
Mounting Collar
Release Tabs
Top and Bottom (996 or 998) or Side (997 or 999) View
Mounting Slots
Side (996 or 998) or Top and Bottom (997 or 999) View
˜
Installing the Series 998
Installing and mounting requires access to the back of the panel.
NOTE: Removing the con­troller chassis from its case makes mounting easier.
Figure 2.2 ­Side and top view.
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.
2.2 WATLOW Series 998 User’s Manual
Installation and Wiring, Chapter 2
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.
Installing
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 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 diffi-
cult 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

Wiring

Fuse
22
21
Earth Ground
11
L2L1
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.
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
100 to 240VÅÅ(ac) nominal, (85 to 264 actual)
Vertical Package 99 8 Horizontal Package 99 9
24 to 28 V‡‡(ac/dc) nominal, (20 to 30 actual)
_ - _ _ _ _ - _ _ _ _ _ - _ _ _ _ - _ _ _ _
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.
Vertical Package 99 6
_ - _ _ _ _ - _ _ _ _
Horizontal Package 99 7 _ - _ _ _ _ - _ _ _ _
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
24
23
+24VÎ (dc)
10KΩ
4.99KΩ
OPTO ISOLATOR
750Ω
.01µf
4.99KΩ
Internal Circuitry
Wiring
23 24
23 24
+
-
Event Input 1
Standard on all units
14 - 36VÎ (dc) Event Input 1 off (open) 0 - 3VÎ (dc) Event Input 1 on (closed)
OR
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 cus-
tomer 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
Figure 2.5 ­Process wiring example.
Installation and Wiring, Chapter 2
4-20mA dc
Transmitter
R
Internal
Resistor
7Ω
1/8 Watt
+
—
x
100 to 400
ohms
—
+
+
24VÎ (dc)
Power Supply
—
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.
WATLOW Series 998 User’s Manual 2.5

Wiring Example

➥
Series 146 Limit Control 146E-1601-3000
High­Temperature Light
High-Limit Mechanical Control
Fuse
Mercury
Relay
Humidify
Dehumidify
Earthground
Fuse
L1 L2
L1 L2
12 13 14 15 16 17 18 19 20
8 9
10
21 22 11
Coil
123456789
10 11 12 131415 16 17
CNONC
Reset
L2
L2
L1
L2
L1
L2
Heater
Cooling Fan
Wet Bulb
RTD Sensor
Dry Temp
RTD Sensor
Limit Sensor
Environmental
Chamber
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.
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.

Wiring Notes

L1 L2
earth ground
11
21 22
power
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.
Installation and Wiring, Chapter 2
WATLOW Series 998 User’s Manual 2.7
9
10
+
-
9
10
8
S2
S1
S3
9
10
8
S2
S1
10
9-+
V
DC
O N
↑
123
O N
↑
123
O N
↑
123
O N
↑
123
O N
↑
123

Channel A Input Wiring

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.
Figure 2.8a
— Thermocouple
Thermocouple only 99 _ _ - 1
_ _ _ - _ _ _ _
Universal signal conditioner 99 _ _ - 2 _ _ _ - _ _ _ _
Figure 2.8b
— RTD, 2- or 3-wire
Universal signal conditioner 99 _ _ - 2
_ _ _ - _ _ _ _
Dip Switch Setting
Jumper 9 to 10 for 2-wire RTD
J, K, T, N, C, E, Pt2, D Dip Switch Setting
R, S, B Dip Switch Setting
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 2.8c
— 0-5VÎÎ, 1-5VÎÎor 0-10VÎÎ(dc) Process
Universal signal conditioner 99 _ _ - 2 _ _ _ - _ _ _ _
Input impedance: 10KΩ
Figure 2.8d
— 0-20mA or 4-20mA Process
Universal signal conditioner 99 _ _ - 2 _ _ _ - _ _ _ _
Input impedance: 7Ω
Dip Switch Setting
Dip Switch Setting
mA
-
8
10
+
2.8 WATLOW Series 998 User’s Manual
Installation and Wiring, Chapter 2

Channel B Input Wiring

19 20
+
-
19
20
18
S2
S1
19
20
18S2S1
S3
20
18
-
+
mA
20
19-+
V
DC
O N
↑
123
O N
↑
123
O N
↑
123
O N
↑
123
O N
↑
123
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.
Figure 2.9a — Thermocouple
Thermocouple only 99 _ _ - _ 1 _ _ - _ _ _ _
J, K, T, N, C, E, Pt2, D
Universal signal conditioner
Dip Switch Setting
99 _ _ - _ 2 _ _ - _ _ _ _
R, S, B Dip Switch Setting
Figure 2.9b
— RTD, 2- or 3-wire
99 _ _ - _ 2 _ _ - _ _ _ _
Dip Switch Setting
Jumper 19 to 20
for 2-wire
RTD
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 2.9c
99 _ _ - _ 2
— 0-5VÎÎ, 1-5VÎÎ, 0-10VÎÎ(dc) Process
_ _ - _ _ _ _
Input impedance: 10KΩ
Dip Switch Setting
Figure 2.9d — 0-20mA or 4-20mA Process
99 _ _ - _ 2 _ _ - _ _ _ _
Input impedance: 7Ω
Dip Switch Setting
Installation and Wiring, Chapter 2
WATLOW Series 998 User’s Manual 2.9

Channel A Output Wiring

14
-
+
12
14
-
+
13
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
Figure 2.10b
_ - _ _ _ _
— Dual Switched DC
99 _ _ - _ _ C _ - _ _ _ _
12
NO
13
COM
14
NO
12
+
-
13
14
23.5 to 30.6VÎ (dc)
+ VÎ
Internal Circuitry
External
External
External Load 1A
Load
Fuse
Load
1500
1500
1A L2
L1 L2 2A
+
External
-
Load 2A
12
Ω
13
Ω
14
Figure 2.10c
— 0-20mA and 4-20mA Process
Load impedance: 800Ω max.
99 _ _ - _ _ F
Figure 2.10d
_ - _ _ _ _
— 0-5VÎÎ, 1-5VÎÎand 0-10VÎÎ(dc) Process
Load impedance: 500Ω min.
99 _ _ - _ _ F
_ - _ _ _ _
2.10 WATLOW Series 998 User’s Manual
Installation and Wiring, Chapter 2

Channel B Output Wiring

15
+
-
17
16
+
-
17
External
Load
COM
L1
L2
Fuse
NO
15 16
17
NO
External
Load
L2
1B
2B
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
99 _ _ - _ _ _ K
Figure 2.11b
99 _ _ - _ _ _ C
Figure 2.11c
- _ _ _ _
— Dual Switched DC
- _ _ _ _
— 0-20mA and 4-20mA Process
Load impedance: 800Ω max.
99 _ _ - _ _ _ F
- _ _ _ _
15 16 17
+
Load
1b
-
23.5 to 30.6VÎ (dc)
+ VÎ
Internal Circuitry
1500
1500
+
Load
2b
-
15
Ω
16
Ω
17
Installation and Wiring, Chapter 2
Figure 2.11d
— 0-5VÎÎ, 1-5VÎÎand 0-10VÎÎ(dc) Process
Load impedance: 500Ω min.
99 _ _ - _ _ _ F
- _ _ _ _
WATLOW Series 998 User’s Manual 2.11

Output 3 Wiring

External
Load
COM
L1
L2
Fuse
NO Form A
1 2
NC Form B
or
1 2
External
Load
-
+ VÎ
Internal Circuitry
1 2
790Ω
19 to 32VÎ (dc)
+
1 2
+
-
1 2
+
-
+V
-V
Transmitter 4-20mA out
Input
1 or 2
+
-
Figure 2.12a — AC Outputs
• Solid-state Relay with
Contact Suppression
0.5 Amps Off-state impedance: 20KΩ min.
99 _ _ - _ _ _ _ - B
• Electromechanical Relay without
Contact Suppression
Form A or B, 5 Amps Off-state impedance: 31MΩ
99 _ _ - _ _ _ _ - J _ _ _
Figure 2.12b
Minimum load resistance: 500Ω
99 _ _ - _ _ _ _ - C
_ _ _
Form A or B Alarm Jumper Settings (Top View)
— Switched DC
_ _ _
• Solid-state Relay without
Contact Suppression
0.5 Amps Off-state impedance: 31MΩ
99 _ _ - _ _ _ _ - K _ _ _
Form B
Form A
Figure 2.12c
0-20mA, 4-20mA
Load impedance: 600Ω max.
99 _ _ - _ _ _ _ - M _ _ _
0-5VÎÎ, 1-5VÎÎor 0-10VÎÎ(dc)
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.
Load impedance: 500Ω min.
99 _ _ - _ _ _ _ - N
Figure 2.12d — External Transmitter Power Supply
99 _ _ - _ _ _ _ - T _ _ _ See Chapter 1 for DIP switch location and set-
tings.
2.12 WATLOW Series 998 User’s Manual
— Process Retransmit
_ _ _
Installation and Wiring, Chapter 2

Output 4 Wiring

External
Load
COM
L1
L2
Fuse
NO
5 6
NC
(7 for D & E outputs only)
7
5
External
Load
6
+
+ VÎ
Internal Circuitry
5 6 7
790
19 to 32VÎ (dc)
7
-
COM
Ω
5
6
+
-
+V
-V
Transmitter 4-20mA out
Input
1 or 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
_ _
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.
Installation and Wiring, Chapter 2
Figure 2.13b
— Switched DC, Open Collector
Minimum load resistance: 500Ω
99 _ _ - _ _ _ _ - _ C _ _
Figure 2.13c
— External Transmitter Power Supply
99 _ _ - _ _ _ _ - _ T _ _ See Chapter 1 for DIP switch location and settings.
For data communications wiring refer to How to Use Data Communications with the Watlow Series 988 Family Controls.
WATLOW Series 998 User’s Manual 2.13
Notes
2.14 WATLOW Series 998 User’s Manual
Installation and Wiring, Chapter 2

Chapter 3 Keys and Displays

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
1A 2A 1B 2B
CH A CH B
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
SERIES 998
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 >
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.
A
TL
W
PROCESS
DISPLAY
Lower Display
Indicates the channel A or channel B set point, or channel B process value, menu prompts, or alarm codes. Red or green, 0.3” (8mm) high,
W
seven-segment, four-digit LED display.
1A, 2A, 1B, 2B Indicator Lights
These lights indicate when out­put 1A, 2A, 1B or 2B is active.
Display Key ∂
The Display key is used to select which channel A and/or B parameter to displayed. On initial power-up the upper dis­play shows the channel A
AUTO
MAN
MODE
process value and the lower display shows the channel A set point value and the CH A light is on. One press of the Display key lights CH B and the upper display shows the channel B process value and the lower display shows the channel B set point value. A second press of the key lights both CH A and CH B, and the upper display shows the channel A process value and the lower display shows the channel B process value. See the next page for
more information on the Display Loop.
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.
Keys and Displays, Chapter 3
Figure 3.1 ­Series 998 Keys and Displays.
WATLOW Series 998 User’s Manual 3.1

Display Loop

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
Process
[`75]
[100]
Channel A
Set Point
∂
Channel B
Process
[`80]
[125]
Channel B
Set Point
∂
Channel A
Process
[`75]
[`80]
Channel B
Process
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
∂
∂
[```]
[`°F]
Process
Units
3.2 WATLOW Series 998 User’s Manual
Keys and Displays, Chapter 3
TL
W
W
A
PROCESS
1A 2A 1B 2B
CH A CH B
DISPLAY
SERIES 998
MODE
AUTO
MAN
TL
W
W
A
PROCESS
DISPLAY
MODE
1A 2A 1B 2B
CH A CH B
SERIES 998
AUTO
MAN

Chapter 4 The Setup Menus

Navigating the Setup Menus
To reach the Setup Menus, begin in the Display Loop and press both the Up-arrow > 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
NOTE: Press the Display key ∂ to return to the Display Loop from any point in any menu.
Menu appears only on units equipped with the data communications option (99__-____-_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 Up-arrow or Down-arrow key to select the next menu, or use the Mode key to 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 Up-arrow or Down-arrow key to change the prompt setting.
Refer to the Appendix for model number options. For additional informa­tion about communications and the communications prompts, refer to the supplemental manual Data Communications with the Watlow Series 988
Family of Controllers.
❶ 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.
[Inpt]
[`SEt]
[Otpt]
[`SEt]
[GLbl]
[`SEt]
[COM]
[`SEt]
Input Output Global Communications Menu Menu Menu Menu p. 4.2 p. 4.16 p. 4.32 p. 4.38
❷ Press the Up-arrow key > to select one of the
Setup menus.
Figure 4.1 ­Navigating the Setup menus.
Setup Menus, Chapter 4
WATLOW Series 998 User’s Manual 4.1
Setup-Input
TLTL
W
W
A
PROCESS
DISPLAY
MODE
1A 2A 1B 2B
CH A CH B
SERIES 998
AUTO
MAN

Reaching the Input Menu

❸ Select the Input Menu, then
press the Mode key µ to step through the prompts.
>>
>
[```)]
[DEC1]
❹ Press the Up-arrow key > or
the Down-arrow key < to select one of the prompt values.
[``)0]
[DEC1]
[`)00]
[DEC1]
[)000]
[DEC1]
>
→ [InPt] Input Menu
[`SEt] Setup Menus
µ
?
↓
[`In1] Input 1 (page 4.5)
µ
↓ ?
[dEC1] *Decimal 1
µ
↓ ?
[`rL1] Range Low 1
µ
↓ ?
[`rH1] Range High 1
µ
↓ ?
[CAL1] Calibration Offset 1
µ
↓ ?
[rtd1] *RTD Calibration Curve 1
µ
↓ ?
[Ftr1] Input 1 Software Filter
µ
↓ ?
[`In2] *Input 2 (page 4.10)
µ
↓ ?
[deC2] *Decimal 2
µ
↓ ?
[`rL2] *Range Low 2
µ
↓ ?
[`rH2] *Range High 2
µ
↓ ?
[CAL2] *Calibration Offset 2
µ
↓ ?
[rtd2] *RTD Calibration Curve 2
µ
↓ ?
[Ftr2] *Input 2 Software Filter
µ
↓ ?
[Lin2] *Input 2 Linearization
µ
↓ ?
←µ [`Alt] *Altitude
Enter your settings, from the controller’s upper display.
Figure 4.2 ­The Input Menu.
4.2 WATLOW Series 998 User’s Manual
*Prompts may not appear, depending on controller configuration.
Setup Menus, Chapter 4
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