Watlow Control Consoles Operating Manual

0600-0045-0000 Rev C

*0600-0045-0000*

March 2004 $5.00

User’s Manual

Control Console

1241 Bundy Boulevard, Winona, Minnesota USA

Phone: [phone], Fax: [phone] http://www.watlow.com

Registered Company

Winona, Minnesota USA

Safety Information

We use note, caution and warning symbols through­out this book to draw your attention to important
operational and safety information.

A "NOTE" marks a short message to alert you to an
important detail.

A "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"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.

The electrical hazard symbol, ∫ (a lightning bolt in
a triangle), precedes an electric shock hazard CAU­TION or WARNING safety statement.

Technical Assistance

If you encounter a problem with this product, review
your configuration information to verify that your
selections are consistent with your application:
inputs, outputs, alarms, limits, etc. If the problem
persists, you can get technical assistance from your
local Watlow representative (see back cover), by e­mailing your questions to
[e-mail] or by dialing +1 (507)
494-5656 between 7 a.m. and 5 p.m., Central
Standard Time (CST). Ask for an Applications
Engineer. Please have the following information
available when calling:

• Complete model number

• All controller configuration information

• User's Manual

• Wiring diagram.

Warranty

This product is warranted free from defects in mate­rial and workmanship for 36 months after delivery
to the first purchaser for use, providing that the
units have not been misapplied. Since Watlow has
no control over their use, and sometimes misuse, we
cannot guarantee against failure. Watlow's obliga­tions hereunder, at Watlow's option, are limited to
replacement, repair or refund of purchase price, and
parts that upon examination prove to be defective
within the warranty period specified. This warranty
does not apply to damage resulting from transporta­tion, alteration, misuse or abuse.

Return Material Authorization (RMA)

1. Call Watlow Customer Service, +1 (507) 454­5300, for a Return Material Authorization (RMA)
number before returning any item for repair. We
need this information:

• Ship to address

• Bill to address

• Contact name

• Phone number

• Method of return shipment

• Your P.O. number

• Detailed description of the problem

• Any special instructions

• Name and phone number of person returning
the product.

2. Prior approval and an RMA number, from the
Customer Service Department, is needed when
returning any unused product for credit. Make
sure the RMA number is on the outside of the
carton, and on all paperwork returned. Ship on a
Freight Prepaid basis.

3. After we receive your return, we will examine
the unit and try to verify the reason for the
return.

4. In cases of manufacturing defect, we will enter a
repair order, replacement order or issue credit
for material returned.

5. To return products that are not defective, goods
must be in new condition, in the original boxes
and they must be returned within 120 days of
receipt. A 20-percent restocking charge is applied
for all returned stock controls and accessories.

6. If the unit cannot be repaired, it will be returned
to you with a letter of explanation.

7. Watlow reserves the right to charge for no trou­ble found (NTF) returns.

The Control Console User's Manual is copyrighted
by Watlow Winona, Inc., copyright March 2004 with
all rights reserved.

Watlow Control Console ■ 1

Chapter 1: Product Overview

Features and Benefits . . . . . . . . . . . . . . . . . .2

Control Console Architecture . . . . . . . . . . . . .2

Power Requirements . . . . . . . . . . . . . . . . . . .2

Sensor Input . . . . . . . . . . . . . . . . . . . . . . . . . .2

Heater Output . . . . . . . . . . . . . . . . . . . . . . . . .3

Communications . . . . . . . . . . . . . . . . . . . . . . .3

Console Elements . . . . . . . . . . . . . . . . . . . . .3

Chapter 2: Installation & Wiring

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . .4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Appendix

Specifications . . . . . . . . . . . . . . . . . . . . . . . . .6

Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Output Power Switching . . . . . . . . . . . . . . . . .6

Power Requirements . . . . . . . . . . . . . . . . . . .6

Sensor Input . . . . . . . . . . . . . . . . . . . . . . . . . .6

Operating Environment . . . . . . . . . . . . . . . . . .6

Dimensions of Enclosure . . . . . . . . . . . . . . . .6

Accessory Parts . . . . . . . . . . . . . . . . . . . . . . .7

Ordering Information . . . . . . . . . . . . . . . . . . . .8

How to Reach Us . . . . . . . . . . . . . . . . . . . . .10

List of Figures

Figure 1 — Thermal system using a Control Console

with a limit . . . . . . . . . . . . . . . . . . . . . . . . . .3

Figure 2 — Rear view of console without the

communications option . . . . . . . . . . . . . . . .4

Figure 3 — Control Console without a limit . .5

Control Console: Table of Contents

T

2 ■ Control Console Watlow

Features and Benefits

• Fits easily into confined areas

• Easily transported

• Prewired output

• AMP Mate-'n'-Lok

® or twist-and-lock output con-

nector option on most configurations

• Miniature thermocouple connector

• Option of 1/32 or 1/16 DIN Series SD or Series 96
controllers.

• A 1/16 DIN size controller is not available in the
mini console.

• On-off rocker switch

• No external components required

• Quick installation and fast start up.

(Mate-'n'-lok

® is a registered trademark of AMP

Company.)

The Watlow Control Console offers a complete con­trol solution consisting of the temperature control(s),
thermocouple input(s), power-switching device(s) and
heater output(s), in a small package. Installation is
quick and easy; as few as three simple connections
and the console is ready for use in your application.
Each unit is supplied with a line cord, heater output
connector mates, thermocouple connector mates and
an on-off rocker switch. A solid-state relay is utilized
for fast, reliable switching of the load. The white,
powder-coated enclosure has vent openings on the
top and bottom for internal heat dissipation.

Control Console Architecture

This product comes in one, two or four zone configu­rations. The power cord, your choice of heater output
connector(s), the thermocouple input connector(s)
and communications connector (if applicable) are
mounted in the rear of the enclosure. All remaining
components are inside the enclosure.

The console comes with 1/16 or 1/32 DIN Series SD
or Series 96 controller(s). A solid-state relay serves
as the output power-switching device and is powered
through the line cord.

Power Requirements

MINI, SNGL and Light Duty DUAL Control
Consoles are fused at 10 amps total, 8 amp maxi­mum total load is recommended. The 120V Consoles
have a NEMA 5-15 plug. The 208/240V Consoles
have a NEMA 6-15 plug.

Heavy Duty DUAL Control Consoles are fused at 20
amps total. A 16 amp maximum total load is recom­mended. Each zone is individually fused at 10 amps
with 8 amps maximum load recommended.

The Heavy Duty DUAL contains a NEMA 5-20 plug.

Heavy Duty Controller/Limit Consoles are fused at
15 amps with 12 amps maximum load recommended.

Light Duty Controller/Limit Consoles are fused at 10
amps with 8 amps maximum load recommended.

QUAD consoles are fused at 20 amps total with 16
amps maximum load recommended. Each zone is
individually fused at 5 amps with 4 amps maximum
load recommended.

All models are available with 120V~ (ac) +10%/-15%

MINI, SNGL and Light Duty DUAL Consoles are
available with 208/240V~ (ac) +10%.

Sensor Input

The Consoles are ordered with a factory selectable
thermocouple (J, K or T) or 2-wire RTD.

The RTD option for the Series SD is only available
with a 100-ohm, platinum DIN curve.

The Series 96 has the option of JIS curve, which can
be selected by the user. Mating connectors are pro­vided with the sensor input(s).

Chapter One: Product Overview