Watlow Electric 1500 User Manual

Series 1500

ACTUAL

ADJUST

Ramping and Profiling

Microprocessor-Based

Control

User's Manual

Watlow Controls, Inc: 1241 Bundy Blvd., Winona, MN 55987 507/454-5300, Fax: 507/452-4507

W150-MA30-9043 October, 1990

Supersedes: W150-MA20-8843

$10.00

Made in the U.S.A.

Use The Manual

How to Use the Manual

First...

Starting Out Sample Program

Install/Wire Programming

Appendix

Quick Reference

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

This manual will make your job easier.

way to become familiar with the Series 1500. Here's an overview. Introduction, Chapter 1, Page 4. A Sample Program in Action, Chapter 2, Page 16. Installation and Wiring, Chapter 3, page 26. Technical Reference, Chapter 4, Page 40. Calibration

Specification Ordering Information Technical Service Glossary Index Quick Reference on Back Cover

Reading it and applying the information is a good

Notes

This user's manual contains informational notes to alert you to important details. When you see a note or note icon, look for an explanation in the margin.

Safety Information

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

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

This user's manual also has boldface safety information notes to protect both you and your equipment. Please be attentive to them. Here are explanations.

∫

(The Stop Sign or Lightning Bolt Sign in the wide text column alerts you to a "WARNING," a safety hazard which could affect you and the equipment. A full explanation is in the narrow column on the outside of the page).

(The Deer Crossing Sign or Exclamation Point Sign in the wide text column alerts you to a "CAUTION," a safety or functional hazard which could affect your equipment or its performance. A full explanation is in the narrow column on the outside of the page).

Technical Assistance

If you encounter a problem with your Watlow control, review all of your configuration information to verify that your selections are consistent with your application...Inputs, Outputs, Alarms, Limits, etc. If the problem persists after checking the above, you can get technical assistance by dialing: 1-507-454-5300

An Application Engineer will discuss your problem with you. Please have the following information available when calling:

• Complete model number • Serial Number

• All configuration information • User's Manual The model and serial numbers can be found on the outside of the case.

Your Feedback

Your comments or suggestions on this manual are welcome, please send them to: Technical Writer, Watlow Controls, 1241 Bundy Blvd., Winona, MN 55987, phone 507/454-5300, fax 507/ 452-4507. The Watlow Series 1500 User's Manual and integral software are copyrighted by Watlow Winona, Inc., © 1985, 1986, 1987, 1988 with all rights reserved.

2 blf1090

WATLOW Series 1500 User's Manual

Page Item 4 Starting Out with the Series 1500 -Chapter 1

4 General Description 5 Opening the 1500 6 Setting the DIP Switches 7 Quick Wire 9 Overview of the 1500 Modes 10 Reading the Displays and Keys 12 Overview of the Software

16 Learning the Series 1500: A Sample Program

in Action - Chapter 2

16 ApplePie Sample Program 16 Sample Program Chart 17 Setting Event Outputs 17 Modes of Operation 18 Clear Memory, Set DIP Switches 19 Programming 22 Start Your Program 22 Halt Conditions 23 Ramping Conditions 23 Wait Step 24 Jump Loop Step 24 Recycle 25 Interactive Changing Set Points & Events

26 Install and Wire the Series 1500 - Chapter 3

26 Sensor Installation Guidelines 27 Event Input and Remote Hold Input 27 Noise 29 Input Power Wiring 32 Eliminating Noise 32 Opening the 1500 34 Installation Procedure 34 Electrical Connections and Wiring

40 Technical Reference - Chapter 4 40 How to Program

40 Select the Proper DIP Switch Settings

41 Programming CHG DATA

42 Halt Conditions 43 Set Point Step Programming 44 Jump Loop Step Programming 45 Wait Step Programming 45 Next Step Programming 46 Altering a Program

46 Programming CHG PARA

47 Guarded Access Programming

49 Alarms

49 Alarm Options 49 Event Alarm Output Option 49 Latching Option 49 Alarms 50 Upper/Lower Set Point Limits

51 Event Outputs

51 Event Input 51 Remote Hold Input 52 Analog Retransmit Outputs 53-56 RTD and T/C Guarded Access/Parameter Charts 57 Programming Chart

58 Tuning

58 Initial Settings 58 Simple ON/OFF Control

59 Run and Halt a Program

59 How to Run a Program 59 How to Halt a Program

Contents

59 Restarting a Program 59 Remote Hold Input

60 Data Communications

60 Communication Parameters 60 Protocol 60 Command Rules & Words 61 Syntax 73 Data Communication Error Codes 74 Troubleshooting

75 Field Calibration Procedure 80 Specifications 82 Model # Information 83 Technical Service

83 Warranty Information 83 Returning Merchandise 84 Shipping Claims 85 Glossary 89 Index 90 Quick Reference

Figures

4 Series 1500 Input and Output Overview 1 6 DIP Switch Location and Setting 2 7 Quick Wire AC Power Connection 3 8 Quick Wire Simulated Sensor Wiring 4 9 Overview of the Series 1500 Operating Modes 5 10 Series 1500 Front Panel Components 6 13 Monitor Data (MNTR DATA) Mode Overview 7 14 Change Data (CHG DATA) Mode Overview 8 15 Change Parameter (CHG PARA) Mode 9 31 Differential Mode Filter Diagram 10 31 Common Mode Filter Diagram 11 31 Differential Common Mode Filter Diag. 12 33 Unit and Panel Cutout Dimensions 13 35 Signal Conditioner Connections and Jumpers 14 36 Event Output, Remote Hold Input, Event Input

Conn. for Dual Solid State Relay Version 15

37 Event Output, Remote Hold Input, Event Input

Conn. for Dual Solid State Switch Version A 15

36 Power Supply Input, Temp & RH Output Conn.

for Dual Solid State Relay Version 16

37 Power Supply Input, temp & RH Output Conn.

for Dual Solid State Switch Version A 16 38 Power Supply Input, CH-1 & CH-2 Output Conn. 17 38 Wiring to Disable Channel 2 18 39 RS-422/423 Pin Designations and Jumpers 19 42 Change Data Mode Flow Diagram 20 46 Change Parameter Mode Flow Diagram 21

Tables

6 DIP Switch Position and Function Table 1 17 Sample Program Event Outputs Table 2 21 Sample Program Steps Table 3 31 Noise Suppression Device Ratings Table 4

Charts

17 Series 1500 Sample Program Chart Chart 1 53 RTD Guarded Access Chart Chart 2 54 T/C Guarded Access Chart Chart 3 55 RTD General Parameter Chart Chart 4 56 T/C General Parameter Chart Chart 5 57 Programming Chart Chart 6

WATLOW Series 1500 User's Manual 3

Starting Out

Chapter 1 Starting Out with the Watlow Series 1500

"Read Me First."

Congratulations, you're about to become a fully-qualified user of the Watlow Series 1500! It is a versatile microprocessor-based control; powerful, yet simple to learn. In this chapter of the user's manual, you'll get an overview of the 1500 and its software. You'll "light" the displays and get a feel for moving through the control functions.

Figure 1 is a simplified view of the 1500's capabilities. The control has dual inputs, one per channel, and dual control outputs for each channel. There is a choice of auxiliary (event) or alarm outputs, an event input and remote hold input. An "Event Output" in the Series 1500 is an ON/OFF solid state relay or solid state switch output for activating periphered equipment or processes. Models with optional communications may be connected to a computer via a serial communications interface.

Figure 1 Series 1500 Input and Output Overview

TEMP and %RH or TEMP See Pages 6, 8 & 35

Event Input See Pages 36 & 51

The Series 1500 will handle 51 separate control steps. Each step duration is variable from one second to 24 hours, 59 minutes, 59 seconds. The 1500 is a "profiling" control because it will control up to 51 consecutive steps with a single program; the resulting graph of all the steps makes a program "profile." The 1500 is a "ramping"

Dual Inputs See Pages 6, 35 & 82

Remote Hold Input See Pages 36 & 51

Dual Control Outputs/Channel See Pages 6 & 82

Heat/Cool See Page 36

Humidify/ De-Humidify or Heat/Cool See Page 36

8 Auxiliary (Event) Outputs, 4/Channel See Pages 36 & 51

RS-422A/RS-423A (RS-232C) Serial Communications Interface See Page 62

4 WATLOW Series 1500 User's Manual

3 Auxiliary (Event) Outputs/Channel and 1 Alarm Output/Channel See Pages 36, 49 & 51

Starting Out, Chapter 1

control because it will move from one process variable to another in a uniform manner.

Operator-friendly features include automatic "prompts," or entry codes, to assist you in programming and monitoring. The Series 1500 has other display codes to indicate a variety of alarm conditions about your process. The 1500 also has a "Jump Loop" option for repeating program steps or segments. A "Wait For" option makes this control responsive to particular process conditions, an external switch conditions or real times of day.

In addition, you can change the three-mode, PID control to a simple ON/OFF control by setting the proportional band parameter in each channel to zero.

When there's a power outage, the 1500 has memory protection provided by an internal Lithium battery and optional battery-backed clock.

The standard RTD version Series 1500 is factory-configured to operate in degrees Centigrade (°C) on Channel One and per cent relative humidity (%RH) on Channel Two. A software selection, the "Temp-Temp" option, is also available for the RTD unit. The Series 1500 Thermocouple version is strictly a "Temp-Temp" control. The 1500 has at least two switches you must set prior to entering your program. Information on how to set these switches follows in this chapter.

When you first apply power, the unit will "come up" with default values for set points, alarm points, control parameters, recycle, events and time. These default values provide minimum operating instructions until you enter your data. The default values are listed in Chapter 4, "Technical Reference."

Starting Out

Remove the Series 1500 carefully from its shipping container. Be sure to set this literature aside where it will not be discarded.

Packing List

Included with your Watlow Series 1500 RTD version are two 107Ω resistors, four jumper wires, two mounting brackets with integral screws, and this manual. The resistors and two jumpers will serve as pseudo-sensors at approximate room conditions while you learn the control. The other jumpers are for power connections.

How to Open the 1500

Before going further, open the Series 1500 and pull the control chassis from its case. Here's how:

The control chassis fastens to the case with a single screw located at the lower front panel. Turn the screw counterclockwise to loosen it. Three strip connector plugs, in the rear of the control chassis, feed power and signals through the back of the case to the triple terminal strip. These plugs will let go as you pull.

Pull firmly but gently to remove the Series 1500 from its case. The 1500 chassis will not fit into the case upside down. However, always check to see that it is oriented correctly before returning the chassis to the case. Press the unit in firmly, then turn the front panel screw clockwise to secure it. Do not overtighten the screw.

CAUTION: Before attempting to open a Series 1500 with data communications (RS-422/423 interface), remove the two screws and DB-15 male connector from the rear of the case.

WATLOW Series 1500 User's Manual 5

Starting Out

CAUTION: Power must be interrupted before a change in DIP Switch will take effect.

Figure 2 DIP Switch Location and Setting

How to Set the DIP Switches

The Watlow Series 1500 has a set of Dual In-Line Package (DIP) switches on circuit board, A007-1318. The location of the board and switches appear in Figure 2. The switches are clearly numbered; the "ON" direction is indicated by an arrow. Look at the DIP switches from the bottom of the control. You'll see them as they appear

below.

A007-1318 Board

DIP Switches

Table 1DIP Switch Position and Function

Control Chassis - Bottom View

Set the DIP switches according to Table 1 below. Make your initial choices now; you may always return to change them later. Set DIP Switch #6 ON for a "Cold Start."

Sw Position Function #1 ON Auxiliary (Event) Output #4 for both Ch-1 and Ch-2 are alarm outputs.

OFF Auxiliary (Event) Output #4 for both Ch-1 and Ch-2 are event outputs.

#2 ON Alarms are latching (displayed until cleared manually).

OFF Alarms are non-latching (displayed only as long as alarm condition exists).

RTD Unit Only #3 ON The Ch-2 sensor is an RTD sensor. Jumpers W151 and W153 on the Signal

Conditioner board (A007-1316) must be installed.

OFF The Ch-2 inputs is a 0-5V signal representing 0-100% RH. Jumpers W150

and W154 on the Signal Conditioner board (A007-1316) must be installed.

T/C Unit Only #3 ON Not Used. Set in the ON position.

#4 ON Dual PID per channel - #4 OFF Single PID per channel.

#5 ON Factory use only. Must be in the ON position.

#6 ON Cold Start on power-up. (Memory cleared, parameters set to default values.)* OFF Warm Start on power up. (Programmed values are retained for all parameters.)*

#7 ON °C function after a Cold Start.

OFF °F function after a Cold Start.

#8 OFF Not Used. Set in the Off position.

For further Warm and Cold Start information, see the Technical Reference, Chapter

6 WATLOW Series 1500 User's Manual

Starting Out, Chapter 1

Quick Wire

Starting Out

You may "power up " the Series 1500 with the following operational check-out. This procedure also prepares you for the Sample Program in Chapter 2. Or, you may skip this section and the sample program, and go directly to Chapter 3, Installation and Wiring.

∫

1. Put the 1500 chassis back in its case. Then place the unit on a bench and connect AC power lines and the jumper wires to the Power Supply terminal strip. Use Figure 3 below.

115VAC

CHASSIS GROUND

For 115VAC control operation, install a jumper wire from Terminal 32 to Terminal 35, and a separate jumper wire from Terminal 33 to Terminal 36. Bring line power in to Terminals 32 and 36. Connect the line ground wire to Terminal 34.

∫

WARNING: To avoid potential electric shock use National Electric Code safety practices when wiring and when connecting this unit to a power source and to electrical sensors or peripheral devices.

Figure 3 Quick Wire AC Power Connections

230VAC

CHASSIS GROUND

2. As soon as you apply power, the FUNCTION display will alternately flash "A1C1, A1-C1." Press the CLEAR key to clear the flashing A1. The display will then flash another A-code.

When you apply power without sensor inputs on the Signal Conditioner terminal strip, the Series 1500 will show a flashing "A-digit" in the FUNCTION display. The digit is an alarm code The ACTUAL display will show four steady dashes, "----," meaning "open sensor." These are normal displays for a unit without sensors.

Starting Out, Chapter 1

For 230VAC control operation, install a jumper wire from Terminal 33 to Terminal 35. Bring line power in to Terminals 32 and 36. Connect the ground wire to Terminal 34.

WATLOW Series 1500 User's Manual 7

ACTUAL Display

CLEAR Key

FUNCTION Display

Starting Out

3. If you did not set DIP Switch #6 in the "ON" position before, do that now: Disconnect power from the unit. Open the 1500, set DIP Switch #6 to ON for a Cold Start. Replace the control chassis in the enclosure. Reapply power to the unit. (This clears all previously entered information from the 1500; it is a "clean" or "cold" start).

4. Now remove power again, open the unit, and set Switch #6 to OFF. (This will make the next start a "warm" one, retaining all subsequently entered information in the processor's memory). Close the 1500.

5. Locate the Signal Conditioner terminal strip on the back of the Series 1500, it's on the far left as you look at the back of the unit. The resistors, or jumper wires for the T/C version, will simulate input sensors at room temperature for this procedure. Make the correct connections using Figure 4.

• For an RTD unit, connect a 107Ω resistor (provided) across Terminals 5 and 6, and another 107Ω resistor across Terminals 8 and 9. Also connect a jumper wire (provided) across Terminals 6 and 7, and another jumper wire across Terminals 9 and 10. See Figure 4.

• For a T/C unit, connect a jumper wire (provided) across Terminals 5 and 7, and another jumper wire across Terminals 8 and 10.

Figure 4 Quick Wire Simulated Sensor Wiring

RTD T/C

6. Apply power to the unit. With the CLEAR key, clear the "A1" alarm code and any other "A" code that appears after it. The ACTUAL display will be reading Channel 1 at simulated room temperature. Or the ACTUAL display will show Channel 2 at a simulated %RH or temperature reading. Use the CH.SELECT key to switch from one channel to the other.

If your Series 1500 responds this way, continue learning about the control. If your unit does not respond like this, call Watlow at 507/454-5300 and ask for an applications engineer.

8 WATLOW Series 1500 User's Manual

Starting Out, Chapter 1

Overview of the Three Operating Modes

Before getting into the details of the Series 1500's keys and displays, take a look at Figure 5, showing the three different modes. After you feel comfortable with the names of the modes and their functions, go ahead to learn the keys and displays.

Series 1500: Four Mode Types

Series 1500: Three Mode Types

Starting Out

See Your Program

Monitor Data Mode (MNTR DATA)

Examine current step information in a running program.

Set Up Program Steps

Change Data Mode (CHG DATA)

Set up or change step type, program loops, wait for… conditions, set points, auxiliary (event) outputs ON/OFF, and step duration.

Set a NonRamping Set Point

Monitor Data Mode (MNTR DATA)

Generate a

Set a non-ramping

non-ramping (fixed)

(fixed) set point and

set point and

manipulate event

outputs. At MNTR

DATA, halt the pro-

gram and press

RESTART. Select C1,

C2, E1 or E2.

Figure 5 Overview of the Series 1500 Operating Modes

Starting Out, Chapter 1

Set Up Your System

Change Parameter Mode (CHG PARA)

Set up or change system-wide parameters such as real time, high/low range, alarm types, alarm points, PID settings, RS-422 address.

WATLOW Series 1500 User's Manual 9

Starting Out

Figure 6 Series 1500 Front Panel Components

CH SEL key: CHANNEL

SELECT--Selects either Channel 1 or Channel 2 for the ACTUAL display.

How to Read the Displays and Use the Keys

Here's an understanding of the Series 1500 displays, keys and LEDs. Use Figure 6 to locate the keys, LEDs and displays described here. Try everything! You'll learn quickly how the 1500 works. The detailed overviews in the next section will further your knowledge.

CH-2 EVENT LEDs: Indicates the status of each Channel 2 Event

ACTUAL display: Shows the actual value of the variable in Channel 1 or Channel 2, in four digits.

Output with one of four LEDs visible only when the output is energized (ON). An Event Output in the Series 1500 is an ON/OFF solid state relay or switched DC output for activating periphered

equipment or processes.

CH-1, CH-2 LEDs: Indicates the channel in the ACTUAL display.

°F LED: When lit indicates the value

in the ACTUAL display is temperature in degrees Fahrenheit.

10 WATLOW Series 1500 User's Manual

% RH LED: When lit

indicates per cent relative humidity in the ACTUAL display.

°C LED: When lit, indicates tempera-

ture in degrees Celsius in the ACTUAL display.

CH-1 EVENT LEDs: Indicates the status of each Channel 1 Event Output with one of four LEDs visible only when the

output is energized (ON).

Starting Out, Chapter 1

Figure 6 (Con't) Series 1500 Front Panel Components

PROG END LED: PROGRAM END--

Indicates that the processor has reached the end of the program.

Starting Out

PROG HALT LED: PROGRAM HALT--When lit, indicates

that the processor is in the HALT condition. A RUN/HALT key press, or a "Blank Step" in the program causes a HALT. When flashing, indicates that the processor is in "Remote-Hold" condition. See RUN/HALT key.

CLEAR (erase) key: a. Clears alarm codes

from FUNCTION display in MONITOR DATA mode.

b. Clears the step in the STEP

display in CHANGE DATA mode when the unit is in the HALT condition.

c. Clears all 51 programmed steps

when the unit in the HALT condition, and in GUARDED ACCESS area of the CHANGE PARAMETER mode. (This prevents an operator from accidentally clearing an entire program. The GUARDED ACCESS data is not cleared).

STEP display: Indicates the current step number being programmed in the CHANGE DATA mode, or the current step being monitored in the MONITOR DATA mode.

RE-START key: Returns the controller to the initial program step only when the 1500 is in the PROGRAM HALT condition. See RUN/HALT key.

FUNCTION display: Shows the prompts used in the three modes. It also displays hours when TIME is selected in MONITOR DATA, CHANGE PARAMETER or CHANGE DATA modes. The FUNCTION display shows a flashing alarm code if one is activated.

RUN/HALT key: Starts or stops the program. The processor will resume a program where it was interrupted, unless the RESTART key was pressed, or the step number or set point data at the current step was changed during

the HALT condition.

DATA display: Indicates the entered data or monitored value in four digits.

CHG DATA LED: When lit indicates the processor is in the CHANGE DATA mode.

MNTR DATA LED: When lit, indicates the processor is in the MONITOR DATA mode.

MODE key: Selects either the MONITOR DATA, CHANGE DATA or CHANGE PARAMETER mode.

Starting Out, Chapter 1

FCTN key: The FUNCTION key steps through the prompts in each of the three modes.

ENTER key: Enters selected data or NEXT STEP operations in the CHANGE DATA and CHANGE PARAMETER modes.

CHG PARA LED: When lit indicates the processor is in the CHANGE PARAMETER mode.

TIME LED: When lit, indicates that the FUNCTION and DATA displays are showing time.

UP key: Increases the value in the DATA display. A light touch increases the value by one. Holding the key down causes the DATA display to increase rapidly.

WATLOW Series 1500 User's Manual 11

DOWN key: Acts opposite the UP key. Ramps the value in the DATA display downward. A light touch decreases the value by one. Holding the key down causes the DATA display to decrease rapidly.

Starting Out

Now that you have a good idea how the 1500's front panel works, look again at the operating modes. This time take a more detailed look.

Overview of the Mode Software

Again, the Series 1500 has three Operating Modes: Monitor Data, Change Data and Change Parameter. These modes change with the MODE key. They make up the basic software routines that run the Series 1500. Each mode has sub-routines and different prompts that appear in the FUNCTION display whenever you press the FCTN key.

Examine the three figures on the next pages, one for each of the modes. Understanding how these modes control the Series 1500 is the key to learning the control.

Figure 7 - Monitor Data (MNTR DATA) Mode Overview

Figure 8 - Change Data (CHG DATA) Mode Overview

Figure 9 - Change Parameter (CHG PARA) Mode Overview

12 WATLOW Series 1500 User's Manual

Starting Out, Chapter 1

Monitor Data Mode (MNTR DATA):

Starting Out

Monitoring a Halted Program

You may look at any step, but must be in the CHG DATA mode to change the step number.

You'll see:

• Step type.

• Ch-1 and Ch-2 set points.

• Auxiliary outputs programming.

• Step duration.

Monitoring a Running Program

You may look at the current step. You'll see:

Figure 7 Monitor Data (MNTR DATA) Mode Overview

• Ch-1 and Ch-2 current set points.

• Auxiliaries programmed ON or OFF.

• Time remaining.

Set a Non-Ramping Set Point

Set a non-rampong (fixed) set point and manipulate event outputs.

Starting Out, Chapter 1

WATLOW Series 1500 User's Manual 13

Starting Out

Figure 8 Change Data (CHG DATA) Mode Overview

Change Data Mode (CHG DATA):

Three Step Types for Entering Program Data

Set Point (SP):

a simple, regular profile step.

Set Point Step,

Program:

This Step# is an SP step.

Set Point for Ch-1.

Set Point for Ch-2.

Auxiliary (Event) Outputs, ON/OFF.

Step Duration.

Go to any next step.

Jump Loop (JL): Wait for…(WT):

a means for jumping to a step out of numerical sequence.

Jump Loop Step,

Program:

This Step# is a JL step.

Jump to Step# __.

a means to wait for a particular condition or time.

Wait for Step,

Program:

This Step# is a WT step.

Wait for this Ch-1 value to

Repeat that

occur, __. step, __ times (Jump Counts).

Wait for

this Ch-2

value to Go to any

occur, __. next step.

Wait for

Input Event

to achieve a

specified

conditon.

Wait for

this real

time, ___.

14 WATLOW Series 1500 User's Manual

Go to any

next step.

Starting Out, Chapter 1

Change Parameter Mode (CHG PARA)

Starting Out

For Entering System-Wide Parameters

Program Real Time

Then proceed to one of three "Guarded Access" areas – code-protected system setup parameters.

Program These Parameters:

Set Ch-1 & Ch-2 alarm type and high/low points.

Leave "Guarded Access."

Program These Parameters:

Set Recycle Option (program repeat).

Set up Ch-1 PID parameters and calibration offset.

Set up Ch-2 PID parameters and calibration offset.

Leave "Guarded Access."

Figure 9 Change Parameter (CHG PARA) Mode Overview

Program These Parameters:

Set up Ch-1 and Ch-2 high and low ranges.

Select Series 1500 Ch-1/Ch-2 Operation, TEMP-TEMP or TEMP-RH.

Set Recycle Option (program repeat).

Select RS-422 Address #.

Select keyboard lock status.

Leave "Guarded Access."

Where To Go From Here

You are now ready to go to the Sample Program, Chapter 2, or to Installation and Wiring, Chapter 3.

If you skip the sample program, do not forget to check the position of DIP Switch 6 before you begin programming your control after installation. With DIP Switch 6 OFF, the 1500 saves your program whenever power is removed (Warm Start). With DIP Switch 6 ON, the 1500 will clear its memory of all programmed information whenever power is removed,substituting default values (Cold Start).

Starting Out, Chapter 1

WATLOW Series 1500 User's Manual 15

Sample Program

Chapter 2 Learning the Series 1500 — A Sample Program

in Action

This chapter will guide you through an easy sample program for the Series 1500. You can quickly grasp the necessary terms and concepts by entering and observing this exercise.

If you feel that your knowledge of programmable controllers does not require a sample program to learn the Series 1500, feel free to skip this chapter. In the Technical Reference section (Chapter 4), you will find details on all material here.

IMPORTANT NOTE:

If you have a Series 1500 T/C version, or are using the RTD version for 2 channels of temperature control (TEMP-TEMP), then simply consider all sample program references to relative humidity as a second channel of temperature. Use the sample values as temperatures rather than relative humidities.

The Series 1500 Wonderful-Apple-Pie Sample Program

Let's assume that Great-Grandma handed down to you her secret recipe for wonderful apple pie. It's not that her ingredients are so different; but she took great care to control baking temperature and humidity, and to add topping ingredients at just the right times in the baking cycle. These really are fantastic apple pies, so you've bought an oven with a Series 1500 control, and you're starting an apple pie business.

Sample Program Chart

The chart here shows the baking process. Grandma's original recipe had Grandpa turn the oven on early in the morning. Grandpa would raise and lower the oven temperature at certain times, too. That is one of Grandma's secrets. With the Series 1500 you'll be able to make your oven "loop" between 275° and 110° three times before a pie is done.

If Great-Grandma was right, this process should turn out a really fine apple pie. Since your bakery will begin baking pies at the same time every morning, you'll want your Series 1500 to automatically start the process each day.

The chart below details the "wonderful-apple-pie" sample program for the Series

1500.

16 WATLOW Series 1500 User's Manual Sample Program, Chapter 2

Temp/

%RH

Step 1 Step 2

Step 3

Perform Steps 4-6 T

Step 4 Step 5

Sample Program

Chart 1 Series 1500 Sample Program Chart

(Wait)

Temp/

Step 1 Step 2

%RH

(Wait)

50%RH

Setting Event Outputs

90% RH

Step 3

90% RH

400°F

74% RH

Step 4 Step 5

74% RH

275°F

To make the pie process even more automated, you have your toppings — sugar, cinnamon and nutmeg—connected to solenoid dispensers controlled by the 1500's "Event Outputs." As you enter the sample program, you'll set the Event Outputs to trigger just when you want them to. You even have an Event Output to put your pies in and take them out of the oven at just the right times. You'll need to turn the Events ON as follows:

STEP CH #1 EVENTS CH #2 EVENTS

1 Wait 0 0 2 1, 2, 4 1, 2 32 3 4 3, 4 1, 4 51 2 6 1, 2, 4 2, 3, 4 8 3, 4 1, 3

Understanding the Modes of Operation

Sample Program, Chapter 2

WATLOW Series 1500 User's Manual 17

Table 2 Sample Program Event Outputs

Sample Program

Before you begin entering the program, notice three small lights (LEDs) on the bottom half of the 1500's front panel. They are labeled "MNTR DATA" (Monitor Data), "CHG DATA" (Change Data), and "CHG PARA" (Change Parameters). Press the MODE key to move through these three modes as you read about each one. Another LED, labeled "TIME" indicates when time is being displayed. "MNTR DATA": While a program is running, you'll want to observe what's happening. Some items can be observed in the "ACTUAL" display and in the nearby top half of the front panel: Actual Temperature or Relative Humidity, Events ON/OFF, etc. But you'll also want to know which step is being performed, and the amount of time remaining in the step.

You can monitor information in a running program by pressing the MODE key until the MNTR DATA LED is ON. Then press the FCTN key until you are observing the data you want. Right now you don't have a program entered, so no meaningful data is available. As soon as you enter the sample program, use this mode to watch things happen.

"CHG DATA": This is the mode where you'll enter program operating DATA (set points, time interval for each step and Event Outputs). In this mode, you can also change data or correct errors in the program. If you want to wait until a specific time before doing something or to set up program loops, you also enter that information in CHG DATA. With the CHG DATA LED on, pressing the FCTN key will move you through the functions you can program.

CAUTION: This sample program will activate some of the "Control Outputs" and "Event Outputs" on the Series 1500 terminal strips. To avoid any damage to your equipment while running the sample program, be sure all Event and Control Outputs are disconnected from the Series 1500 terminals. Or remove power from any external loads attached to the Series 1500.

"CHG PARA": Some Series 1500 information is more applicable to the overall

system than to just one specific program. This includes the "real time of day," system maximum/minimum alarm limits and "PID Parameters" which tune the overall system. This system-wide information is entered or changed in this mode.

Again – pressing the FCTN key selects functions while the CHG PARA LED is on. Many of these functions are protected from accidental change by a "Guarded Access" (GA) code before they can be viewed or altered. You'll learn the GA codes soon.

Before Y ou Begin…

Before you begin to enter your Sample Program, take this precaution:

Clear Memory, Set DIP Switches

To clear your Series 1500's memory, do a "Cold Start." Turn the power OFF, open the 1500 and ensure that DIP Switches 2, 3, 5 and 6 are ON and that DIP Switches 1,4,7 and 8 are OFF. If you haven't done so already, attach the provided 107Ω resistor and a jumper (or jumpers for a T/C version) to each sensor input as described in Chapter 1 under "Quick Wire." If you want to use your sensors, refer to Chapter 3, Figure 11 for wiring. Then turn the power ON and press the "CLEAR" key to clear the flashing alarm indication(s).

18 WATLOW Series 1500 User's Manual Sample Program, Chapter 2

Press the

ENTER key:

the display will flash, then it will change to “MN.”

Use the UP/DOWN keys

to place the correct value for minutes into the Data

Display; then press ENTER.

The display will show “SC” (seconds): again use the UP/DOWN keys to place

6. seconds into the display and then press ENTER.

Press the FCTN key several times

PARA

LED). You

should now see the correct real time on the display, with

until the TlME

LED is lit

(along with

the CHG

the seconds counting up.

Set the Recycle Option

Now, while still in the CHG that you want your program to automatically repeat each day until you decide to halt it. This “Recycle” condition is set within the “Guarded Access” (GA) section of the CHG PARA

mode. Do that now:

With

the CHG

Function Display. If you

around again.

Place

“0006,”

one of the Guarded Access codes, into the Data Display using

the UP/DOWN keys.

Press ENTER Display.

PARA mode,

PARA

LED ON, press

pass

until

the "RC,"

“RC,”

there is one more thing to enter. Remember

the

FCTN key until “GA” appears in the

GA, keep pressing

FCTN

until GA comes

(Recycle) prompt appears in the Function

Place a “0001” into the Data Display. Press ENTER.

Begin Entering Data

Now

that

you

have entered the real time and the Recycle option, go to the CHG

DATA mode to enter actual program data:

Press the MODE key until the CHG DATA LED is lit. The display will read “01

SP.”

Programming Step

Refer back to the sample program chart at the beginning of this section. that while you’d like to load your program and press the start button now, the first program step must hypothetically wait until early morning before it starts running. To program Step #1 as a Wait Step,” do this:

Press the FCTN key until "WT" appears in the Function Display.

Press the ENTER key,

2. Since you are waiting for a

3. FCTN

until

“WH”

W1”

(Wait for

specific

(Wait for Hours) appears.

Ch-1)

appears.

time, and not for input conditions, press

Remember,

Sample Program, Chapter 2

WATLOW Series

1500 Users

Manual

Sample Program

4. We suggest that you enter a time one hour from right now. Changing this time later is a simple matter. You go to the CHG DATA mode with "WH" displayed and then enter the new time. Select hours (0 to 23) and press

ENTER.

5. Also enter the "WM" (minutes) and "WS" (seconds). Select minutes, press ENTER. Wait a moment for the display to change, then select seconds and

press ENTER.

6. You have completed entering Step #1 as a "Wait Step." The display should

now read "01 NX 0002." This indicates that the 1500 is ready to move on to

program Step #2 unless you tell it otherwise.

Programming Step 2

1. Since you do indeed want to program Step #2 now, just press ENTER. The

display should read "02 SP", and you are ready to begin programming Step #2.

Refer again to the program chart. Note that the values you want to achieve are 400°, 90%RH. You want the 1500 to accomplish this in four minutes. You also want to have Ch-1 Events 1, 2 and 4 ON, and Ch-2 Events 1 and 2 ON during Step #2. We will now program all this data for Step #2:

1. Since the display reads "02 SP," and you do want to enter Set Point Data,

first press ENTER. The display changes to "S1" (Set Point for Ch-1).

2. Use the UP/DOWN keys to put "400.0" into the display. Some practice may be necessary to stop at the right value. Then press ENTER. The display

changes to "S2" (Set Point for Ch-2).

3. Place "090.0" into the display and press ENTER. The display changes to

"E1" (Events for Ch-1). The Data Display is blank right now.

4. In the Data Display,

the left.

display and press ENTER. The display will change to "E2" (Events for Ch-2).

5. Likewise, for Ch-2 Events #1 and 2 ON, ENTER the value "0011." The

6. Since Step #2 is only four minutes long, just press ENTER to enter "0000"

7. For Step #2 Minutes, ENTER "0004." The display changes to "SC."

8. For Step #2 Seconds, ENTER "0000." The display changes to "02 00

0400."

So, for Ch-1 Events #1, 2 and 4 ON, place "1011" into the

display changes to "HR" (The "hour" portion of the duration of Step #2).

hours. The display changes to "MN."

Event #1 is represented on the right and Event #4 is on

9. You have successfully programmed Step #2 as a "Set Point Step." The

display is indicating that Step #2 is programmed for a duration of 00 hours, 04 minutes, 00 seconds. Press either ENTER or FCTN; the display changes to "02 NX 0003."

10. Again since you do want to program Step #3 now, press ENTER. The

20 WATLOW Series 1500 User's Manual

display changes to "03 SP."

Sample Program, Chapter 2

Programming Steps 3 through 6

Now that you see how it’s done, enter the data for Set Point

be sure to stop and then return to these instructions when the display reaches SP.”

This is because you will be looping through Steps #4 through #6 three times.

Refer to the table below for

FCTN

STEP

Steps

#3,4,5

STEP#3

and

STEP

Steps

STEP#5

#3,4,5,

I Step#6

6. But,

“07

Programming Step 7, a Jump Loop Step

You now

performed when Step #6 is completed. “Set Point Step.” We want Step #7 to cause the 1500 to JUMP

times

a"JUMP LOOP

have Steps #1-6 programmed. When you run the program, Step

But, you do not want Step #7 to be a normal

back to

(for a

total

of 3 times through Steps

Step.”

With

the STEP and FUNCTION displays now reading “07 SP,” press the

FCTN key until “07 JL” comes up.

That’s why you’ll program Step #7 as

#4-6).

will be

Step #4 two

Table

Sample Program Steps

Press the ENTER key. The display changes to “JS” (Jump to Step

Enter the number of the step the program will jump to (“0004”).

ENTER. The display changes to “JC” (Jump Count).

Since you want to jump back to Step #4 two times (total of 3 times through

the loop), enter “0002.” Press ENTER. The display changes to “07 NX 0008.”

Press ENTER (you do want to program Step #8 now). The diiplay

changes to “08 SP.”

Programming Step 8

You’re ready to enter Step below (Stop with the display reading “08 NX 0009”):

S1 S2

El E2 HR MN SC 0000

Recall that you set the Recycle (RC) option to ON, so the program will repeat

indefinitely. You have now entered the entire program.

110.0

065.0

1100

0101

0000 0006

#8.

It’s a normal Set Point Step, enter the information

You’re almost ready to run it.

#).

Press

CAUTION: Notice

on the Sample Program Chart (at the beginning of this section) that the Series

1500

hoIds

the Step #8 set

points

and Step #8

Event Outputs ON as lt and waits through

Step #1 before beginning program over.

recycles

the

Sample Program, Chapter 2

WATLOW Series

1500 Users Manual

Almost Ready to Run

Remember that Step #1 was a “Wait Step.”

you won’t see

You may want ways to get back to Step #1 in 0009”; it is waiting for you to continue programming or monitoring. key to put “0001” in the Data display and press ENTER. The display will show “01 WI” (Step#l is a Wait Step). Now use the FCTN key to move through “SC;” enter a time real time1 0 minutes from now.

any action until the time you programmed into Step

to go

back and

adjust that time to a different value.

CHG

DATA mode. Your display is now reading “08 NX

Even though you press the “RUN” key,

#1.

There

are various

Use the DOWN “HR," “MN,”

and

Start Your Program!

The Wonderful Apple Pie

“RE-START’ “RUN/HALT’ key to start the program.

key

(upper

Sample Program

front panel) to set the program to Step

is all entered and ready. So press the

#1.

Then press the

Monitoring the Action

With the MNTR DATA LED lit, you can now use the FCTN key to check things out.

The control doesn’t seem to show much happening right now since Step #1 is a “Wait

Step.” Press the FCTN key.

programmed into Step programmed time.

In one display you’ll see the “WT” (Wait for) time you

#1. The

1500

watching for its real time to match that

CAUTION:

You

now

have a

basic

understandlng of how the

Series 1500

handles a control

program. Please

read and then continue

to the following

fine “Helpful Hints” sectlon will your the Series 1500 to the highest

level.

to refer

points.

The

raise

skills with

WATLOW

Now use the MODE You can watch as real time approaches your programmed time. When the times match, the step lights come ON to coincide with the Events you programmed for Step

the

program runs its course, you can use the

key to view the process. As you observe the varying data, the individual functions will become following information to gain an even more detailed understanding.

quite

number changes

clear.

Helpful Hints

Here are some Series 1500 fine points:

Halt Conditions

A Blank Step halts the Series 1500. A “Blank Step” is any step which is not programmed. An “SP” will appear in the Function Display when you select

a Blank Step with the MODE key. The Series 1500 can enter the HALT

Blank Step in a program, or you press the RUN/HALT key while a program

is running.

Series 1500 User’s Manual

key to

move to the

After you have

CHG PARA

02.

You will also see the Ch-1 and Ch-2 Event

observed

mode with the

MNTR DATA mode and the FCTN

the program for awhile, read the

condition

in two ways:

TlME

LED also ON.

#2.

It encounters a

Sample Program, Chapter

While in the HALT condition, the Series

Event Output conditions from the step it was in when it was halted, or from last

step before a

“Blank

Step” halted the control. made no change to the step data, the 1500 will complete the step from the time it stopped. If you

Thus, if your sample after performing Step

65%RH,

If you press the RUN/HALT key at

and with Ch-1 Events 3 and 4 ON and Ch-2 Events 1 and 3 ON.

with the oven at

change data, the step begins from beginning.

program

#8,

275°, 83.2%RH,

Event 2 ON.

However, you may not want the Step #8 conditions to be retained until tomorrow. Set Points of

You could add a step at the end of the program to establish

75°, 50%RH,

2. Ramping Conditions

When running any Set Point step, the Series 1500 notes what the existing starting conditions are and what the desired ending conditions are.

Then it follows a linear path between the two.

Although the desired ending conditions are specifically programmed into

each step, the beginning conditions depend on the step performed just previously. Know where you are going and where

1500

maintains the Set Points and

If you

restart

the control, having

did not have “Recycle” activated, it would halt

but would continue to hold the oven at 110°,

1-1/2

minutes into Step

and have

Ch-1

and with all Event

Event 1 ON and Ch-2

Cutputs

you've

OFF.

been.

#5,

it would Halt

Step #4 of your Sample Program is an example:

As the chart on page 17 shows, you expect to start Step #4 at ramp uniformly down to

time through Step

But when you “loop back-from Step

will be ramping upward from 11 O° to

this is not acceptable to you, you might want to jump loop back to Step

to reach a full

3. Wait Step

A Wait Step maintains the same Set Points that existed at the end of the previous step. With Step #1 as a Wait Step, this means that the 1500 will use the default values for Step #1 first run. values (11 O°, 65%RH, Ch. #1 Events 3 & 4 ON and

ON). If you were to halt the program during Step #3 and then “RESTART’ and run

it, Step #1 would retain the Step #3 values. Since this is not always desirable, you could place a short (1 second) step immediately before the Wait Step to establish different Set Point values.

275°.

This certainly is what happens on the first

#4.

400°

through Step #3 before you start Step

(75°, 50%RH,

However, when it recycles

from Step #6, it will retain the Step #8

#6,

your starting point is 11

275°.

ail events OFF) during its Ch. #2 Events

400°,

#4.

1 &

O°.

and

You

When waiting for

“53”

for Minutes, but enter nothing for Hours or Seconds, the programmed

time will be 53 minutes after midnight.

Sample Program, Chapter 2

"Time,”

program all three units (HR-MN-SC).

If you program

WATLOW

Series 1500 User's

Manual

In your sample program’s Wait Step, you used “Wait for time” because you

aren’t connected to a variable oven yet. could be as follows:

In Step

90%RH.

#2,

you have

Depending upon your system, this may either be impossible

to do, or you may reach the desired conditions much earlier than that.

This could

lf you reprogrammed Step #2 as a Wait Step, you could measure how

result

in bad apple pies.

long it takes to achieve the desired conditions, and then react immediately. Much better apple pies.

But, there is a choice to make here: The Wait Step does not follow the linear ramping path to reach the new conditions as a Set Point Step

does. A Wait Step uses the previous step’s Set Point. To optimize

control (reduce the overshoot and undershoot) a Wait Step uses the “PID

Parameters” to satisfy the wait condition. the step type which best matches your needs. (The are discussed in the Technical Reference Section that follows).

4. Jump Loop Step (JL)

In the sample program, you used this capability to jump from Step #6 back to Step #4 two times. Your “Jump Count” (JC) was set to

to 255 can be used in loops of this type.

A more common use of the Wait Step

allowed

exactly four minutes to reach

400°,

In other words, select

PID

parameters

“2.”

Any value from

If you program

“0”

into

“JC,”

the JUMP will occur infinitely. This set up a never-ending loop if the jump is backwards. Or you can set up a one-time “unconditional jump” if the jump is

forward.

If you use a forward

jump, the 0 choice makes no difference. The jump will be performed once.

But why would you ever want to simply jump forward and skip over some steps, you ask?

Suppose your overall program has various functional sections, not all of

which you want to do every time.

By ending each section with a Jump Step, you can easily alter the program to perform various sections in diierent sequences.

During programming work, you may want to develop and test a program in

sections. You can develop the separate sections with unprogrammed

Blank Steps between them, then unite the separate sections laterwith

Jump Steps.

As you learned earlier, jumping or looping into Steps from “different

directions” can sometimes cause unexpected results due to different starting conditions as you enter a new step. Watch for such possibilities.

5. Recycle

With

the Recycle option active, you might expect to see continuous activity as the

process

immediately start Step #1 after it completes Step

repeats the program sequence. This sample program will, in fact,

#8.

action

could

WATLOW

Series 1500

User's

Manual

Sample

Program, Chapter

However, remember that Step #1 is programmed as a "Wait Step," so it will wait until the same time tomorrow. Since you now know what a Wait Step does, you may want to reprogram Step #1 as a simple "Set Point" step so that you can view the Recycle action. If you do decide to reprogram Step #1, then read the following items.

• You cannot alter data or parameters while the program is running. The

1500 must be in the HALT condition.

• If you want to move to a different Step #, to see what is programmed there

and then modify that step, enter the CHG DATA mode. Then to reprogram it from the CHG DATA mode, go to the appropriate step as described above. Then press the CLEAR key. All programmed data (for this step only) will clear, and you can now reprogram it.

6. Interactive Changing of Set Points and Events

When in the halted condition, the Series 1500 actively maintains the current set points and Event Output status. At times, you may wish to change these conditions without actually entering and running a profile step. To do this, you must be in the "MONITOR DATA" mode, halted (PROG HALT LED ON) and "RESTART" key just pressed. Then use the function key to move to the desired prompt ("C1", "C2", "E1" or "E2"), use the INCREMENT/DECREMENT keys to move to the desired data, and press the ENTER key. The Series 1500 will quickly change to controlling at the new condition.

Sample Program

Where To Go From Here

As soon as you feel comfortable with the Series 1500 sample program, move on to Installation and Wiring, Chapter 3. Or if you have already installed and wired your system, go to the Programming Chart in Chapter 4 and begin entering and docu-

menting your Series 1500 program.

Sample Program, Chapter 2

WATLOW Series 1500 User's Manual 25

Installation-Wiring

Chapter 3 How to Install and Wire the 1500

This chapter tells you how to install and wire the Series 1500. There are also some suggestions for sensor installation.

guidelines before making your panel cutout.

Sensor Installation Guidelines

Temp-RH

In this 1500 configuration, a dry bulb RTD measures temperature on Channel 1. A wet bulb RTD, in combination with the dry bulb RTD, senses relative humidity on Channel 2. The 1500 calculates the temperature difference between the two bulbs to determine percent relative humidity.

Temp-Temp

For Temp-Temp RTD operation, each dry bulb RTD senses temperature for its channel.

Also, be sure to look at the noise reduction

RTDs

The RTDs for the Series 1500 are customer-supplied items. They may be Gordon Part #S001-0133-0000, which is a wire-wound RTD inside a sealed, 18% NickelSilver sheath, made for fast temperature response. The detector element is platinum wire 100Ω at 0°C with a temperature coefficient of 0.003916Ω/Ω/°C. The sheath is

0.1875 in. (5 mm) diameter, 2.75 in. (70 mm) long. The three wire leads are 48 in. (1219 mm) long and teflon insulated.

Contact Gordon at: 5710 Kenosha St., Box 500 Richmond, IL 60071 Phone: 815/678-2211

Excessive lead length in a two-wire RTD sensor can create indication errors. To combat this, use a three wire sensor in long lead applications.

RTD - The Dry Bulb Installation

We suggest you mount the dry bulb RTD at a location in your process or system where it reads an average temperature. Air flow past this sensor should be moderate. The sensor should be thermally insulated from the sensor mounting.

RTD - The Wet Bulb Installation

One way to prepare the RTD wet bulb sensor for reading relative humidity on Channel 2 is to slip a cotton wick over the sensor sheath, Watlow Part # 0830-0111-0000 or an equivalent. Put one end of the wick in water. Some systems use a small trough of water with a float valve to replenish the evaporating liquid.

26 WATLOW Series 1500 User's Manual

Installation - Wiring, Chapter 3

Installation-Wiring

Use distilled water to avoid mineral deposits on the wick that can change the %RH reading. The wicking distance should be as short as practical. The cotton wick must be free of any sizing and starch. The "float valve-trough" systems should also remove the water when the ambient temperature goes below freezing or above boiling.

To obtain valid %RH readings, air flow past the %RH sensor must be sufficient to evaporate the maximum amount of water from the wick without drying it out. Evaporation cools the sensor; the amount of cooling relates directly to the relative humidity present.

Thermally insulate the wet bulb sensor from the sensor mounting. This prevents mounting surface heat from flowing into the sensor sheath and changing the wet bulb temperature. (The result of such heat flow will be a humidity reading higher than actual.)

Thermocouple Installation Guidelines

Locate the thermocouples in your process or system where they read average temperatures. Air flow past these sensors should be moderate. The sensors must be thermally insulated from the sensor mounting. Both thermocouples must be un-

grounded to obtain correct readings.

Wiring Practices for Preventing Noise

Most noise problems stem from wiring practices, the major means of coupling noise from its sources to the control circuit.

An outstanding information resource for wiring guidelines is the IEEE Standard No. 518-1982 and is available from IEEE, Inc. 345 East 47th Street, New York, NY

10017.

Noise Sources

• Switches and relay contacts operating inductive loads such as motors, coils, solenoids, and relays, etc.

• Thyristors or other semiconductor devices which are not zero crossover-fired (randomly-fired or phase angle-fired devices).

• All welding machinery.

• Heavy current carrying conductors.

• Fluorescent and neon lights.

How to Decrease Noise Sensitivity

1. Our extensive noise testing has shown that the Series 1500 has a good level of noise immunity. In extremely noisy environments, however, the testing has shown that the most effective RFI techniques are:

a. An RFI filter (such as the Corcom 1ER1) in the power line mounted exter-

nal to the Series 1500 case. The RFI filter should be an RFI sealed type.

b. Shielded power cord with the shield terminated to the Series 1500 case

Installation - Wiring, Chapter 3

WATLOW Series 1500 User's Manual 27

+ 63 hidden pages

Watlow Electric 1500 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

How to Use the Manual

DIP Switches

Quick Wire