Watlow Electric 96 User Manual

SERIES 96

Registered Company

Winona, Minnesota USA

ISO 9001ISO 9001

Plug and Play
Firmware and
Hardware

Features and Benefits

Burst fire

• Increase heater life/better temperature controllability

One input, one auxiliary input, four outputs

• Powerful flexibility at a competitive price

No dipswitches

• Easily configurable from the front panel

Multiple set points

• Flexible automatic control

Pluggable output modules

• Field expandable

Fast 10Hz sampling

• Improved control responsiveness

Programmable menus (Patent pending)

• Can be self-tailored for exact user needs

Open loop break protection

• Indication of thermal loop problem

NEMA 4X (IP65)

• Water and corrosion resistant front panel can be

washed down

16 programmable ramp and soak steps

• Profiles of dynamic production processes can be

programmed into the controller

Automatic tuning

• Easy one step tuning of PID control parameters

Watlow’s SERIES 96 is a powerful 1⁄16 DIN dual display
controller that offers many advanced functions. This new
controller can be tailored to perform hardware and software
needs with hardware modules that are pluggable and
exchangeable and software menus that may be user
programmed to fit exact application requirements.

With one universal input, a second auxiliary input and four
outputs the SERIES 96 can be programmed to perform:
temperature measurement, input event switching, remote
set point input, heating, boost heating, cooling, alarms,
digital communications, ramp and soak and retransmit.
These features make this controller ideally suited for
applications in markets such as plastics packaging,
semiconductor, food processing and lab equipment.

Set point ramping operations include two files with eight
steps in each. The files can be linked to create a 16-step
profile.

With fast 10Hz sampling, variable time base burst firing
outputs, NEMA 4X front panel and 0.1 percent calibration
accuracy this control can easily handle some of the
toughest application needs.

The SERIES 96 is manufactured by ISO 9001 registered
Watlow Controls and reliably backed by a three-year
warranty.

Your Authorized Watlow Distributor Is:

WIN-96-0307

1241 Bundy Boulevard, P.O. Box 5580
Winona, Minnesota 55987-5580 USA
Phone: [phone]
FAX: [phone]
Internet: www.watlow.com
E-mail: [e-mail]

© 2007 Watlow Electric Manufacturing Company Printed in the USA on Recycled Paper, 15% Postconsumer Waste

Specifications

Controller

• Microprocessor-based, user selectable control modes

• Heat and cool auto-tune for control outputs

• Universal input 1, auxiliary input 2, 4 outputs

• Control outputs user selectable as on-off, P, PI, PID

• Input sample period; Single input 10Hz (100 ms), dual
input 5Hz (200 ms) adjustable digital filter

• Display update; 2Hz (500 ms), adjustable digital filter

• Output update; burst, 0.1 to 999.9 seconds

• Input/Output/Communication isolation

• Displayed in °C, °F, or process units

Operator Interface

• Dual 4-digit LED displays: upper 10.2 mm (0.4 in.),
lower 6.2 mm (0.244 in.)

• Advance, Up Arrow, Down Arrow, Infinity tactile keys

Standard Conditions For Specifications

• Ambient temperature 25°C/77°F ±3°C, rated line
voltage, 50 to 60Hz, 0 to 90 percent RH
non-condensing, 15 minute warm-up

Universal Input 1

Thermocouple

• Type J, K, T, N, C (W5), E, Pt 2, D (W3), B, R, S
thermocouple types

• >20M

• Maximum 20

• 30µA open detection bias

RTD

• 2- or 3-wire platinum, 100Ω

• JIS and DIN curves

• Whole or tenth degree indication

• 150µA nominal RTD excitation current

Process

• Range selectable: 0-10VÎ(dc), 0-5VÎ(dc),

• Voltage input impedance 20k

• Current input impedance 100Ω

• Minimum current source resistance 1MΩ

• Input resolution 50,000 bits (approx.) at full scale

• mV input impedance 20M

Input 2

Event Input

• Contact or voltage

• 20K

• Voltage input: event high state 3 to 36V

• Resistance/contact input: event high state > 23k

Remote Set Point Input: mA or VDC Range Selectable

• Voltage input impedance 20kΩ

• Current input impedance 100Ω

Ω input impedance

Ω source resistance

Î(dc), 0-20mA, 4-20mA,

1-5V

Ω input impedance

event low state 0 to 2V

event low state 0 to 2k

Ω

Ω

Î(dc),

Î(dc)

Ω,

Ω

Output Types
Open Collector/Switched DC

• Open collector configuration:
Maximum voltage 42V
Maximum current 200mA
Maximum “on” resistance 1.1
Maximum offstate leakage current 100µA

• Switched dc configuration:
Switched dc supply voltage 22 to 28V
dc supply current limited to 30mA

Solid State Relay

• Optically isolated

• Zero cross switched

• Without contact suppression

• Minimum load current 0.5mA rms

• Maximum current 0.5A rms at 20 to 280V

• Maximum offstate leakage current 10µA rms

• For resistive loads only, must use RC suppression for
inductive loads

Electromechanical Relay

• Form C contact configuration

• Minimum load current 10mA @ 5V

• Rated resistive and inductive loads: 2A @ 250V

Î(dc) maximum

or 30V

• Electrical life 100,000 cycles at rated current

• For resistive loads only, must use RC suppression for
inductive loads

Process

• Range selectable: 0-20mA, 4-20mA, 0-5VÎ(dc),

Î(dc), 0-10VÎ(dc)

1-5V

• Reverse or direct acting

• 0 to 10V
resistance

• 0 to 20mA current output into 800
resistance

• Resolution:
dc ranges = 2.5mV nominal
mA ranges = 5µA nominal

• Calibration accuracy:
dc ranges = ±15mV
mA ranges = ±30µA

• Temperature stability 100ppm/°C

Retransmit

• Range selectable: 0-20mA, 4-20mA, 0-5VÎ(dc),
1-5V

• 0 to 10V
load resistance

• 0 to 20mA current output into an 800
resistance

• Resolution:
dc ranges = 2.5mV nominal
mA ranges = 5µA nominal

• Calibration accuracy:
dc ranges = ±15mV
mA ranges = ±30µA

• Temperature stability 100ppm/°C

Î(dc) voltage output into 1000Ω minimum load

Î(dc), 0-10VÎ(dc)

Î(dc) voltage output into a 1,000Ω minimum

Î(dc)

Ω

Î(dc)

Å(ac)

Î(dc)

Å(ac)

Ω maximum load

Ω maximum load

Communications

• EIA/TIA-485 or EIA/TIA-232

• Opto-isolated

TM

• Modbus

RTU protocol

• 1200, 2400, 4800, 9600, 19200 baud rates

• 32 maximum units can be connected (With additional
485 repeater hardware, up to 247 units may be
connected)

Accuracy

• Input ranges
Type J: 0 to 750°C or 32 to 1382°F
Type K: -200 to 1250°C or -328 to 2282°F
Type T: -200 to 350°C or -328 to 662°F
Type N: 0 to 1250°C or 32 to 2282°F
Type E: -200 to 900°C or -328 to 1470°F
Type C(W5): 0 to 2315°C or 32 to 4200°F
Type D(W3): 0 to 2315°C or 32 to 4200°F
Type Pt 2: 0 to 1393°C or 32 to 2540°F
Type R: 0 to 1450°C or 32 to 2642°F
Type S: 0 to 1450°C or 32 to 2642°F
Type B: 870 to 1700°C or 1598 to 3092°F
DIN: -200 to 800°C or -328 to 1472°F
JIS: -200 to 630°C or -328 to 1166°F
Process: -1999 to 9999 units

Thermocouple Inputs

• Calibration accuracy ±0.1 percent of span ±1°C at
standard conditions

Exceptions:
Type T; 0.12 percent of span for -200°C to -50°C,

Types R and S; 0.15 percent of span for 0°C to 100°C
Types B; 0.24 percent of span for 870°C to 1700°C

• Accuracy span: 540°C/1000°F minimum

• Temperature stability: ±0.1 degree per degree change
in ambient

RTD Inputs

• Calibration accuracy ±0.1 percent of span ±1°C at
standard conditions

• Accuracy span: 540°C/1000°F minimum

• Temperature stability: ±0.05 degree per degree change
in ambient

Process Inputs

• Voltage input ranges
Accuracy ±10mV ±1 LSD at standard conditions
Temperature stability ±100ppm/°C maximum

• Milliamp input ranges
Accuracy ±20µA ±1 LSD at standard conditions
Temperature stability ±100ppm/°C maximum

Agency Approvals

•UL®916 file number E185611, C-UL®, CE, NEMA 4X

Terminals

• Touch safe

• 22 to 12 AWG

Power

• 100-240Vı(ac/dc) +10 percent, -15 percent; 50/60Hz,
±5 percent

• 24-28V

ı(ac/dc) +10 percent, -15 percent; 50/60Hz,

±5 percent

• 7.0VA maximum power consumption

• Data retention upon power failure via nonvolatile
memory

Operating Environment

• 0 to 65°C, 32 to 149°F

• 0 to 90% RH, non-condensing

• Storage temperature: -40 to 85°C, -40 to 185°F

Dimensions

• Width 52 mm (2.05 in.)

• Height 52 mm (2.05 in.)

• Length 107 mm (4.2 in.)

• Depth behind panel surface 98.4 mm (3.875 in.)

• Approximate controller weight 0.2 kg (0.4 lbs)

Allowable Operating Ranges

Type J: 1.0 0 to 815°C or 32 to 1500°F

0.1 0.0 to 815.0°C or 32.0 to 999.9°F

Type K: 1.0 -270 to 1370°C or -454 to 2500°F

0.1 -199.9 to 999.9°C or -199.9 to 999.9°F

Type T: 1.0 -270 to 400°C or -454 to 750°F

0.1 -199.9 to 400.0°C or -199.9 to 750.0°F

Type N: 1.0 0 to 1300°C or 32 to 2372°F

0.1 0.0 to 999.9°C or 32.0 to 999.9°F

Type E: 1.0 -270 to 800°C or -454 to 1470°F

0.1 -199.9 to 800.0°C or -199.9 to 999.9°F

Type C: 1.0 0 to 2315°C or 32 to 4200°F

0.1 0.0 to 999.9°C or 32.0 to 999.9°F

Type D: 1.0 0 to 2315°C or 32 to 4200°F

0.1 0.0 to 999.9°C or 32.0 to 999.9°F

Type Pt 2: 1.0 0 to 1395°C or 32 to 2543°F

0.1 0.0 to 999.9°C or 32.0 to 999.9°F
Type R: 1.0 0 to 1760°C or 32 to 3200°F
Type S: 1.0 0 to 1760°C or 32 to 3200°F
Type B: 1.0 0 to 1816°C or 32 to 3300°F

DIN 1.0 -200 to 800°C or -328 to 1472°F

0.1 -199.9 to 800.0°C or -199.9 to 999.9°F
JIS 1.0 -200 to 630°C or -328 to 1166°F

0.1 -199.9 to 630.0°C or -199.9 to 999.9°F

Process -1999 to 9999 units

Functionality Matrix

Universal Remote 232/485

Input Set Point Control Alarm Retransmit Comm

Input 1

Input 2

Output 1

Output 2

Output 3

Output 4

Event &

ModbusTMis a trademark of AEG Schneider Automation.
UL®and C-UL®are registered trademarks of the Underwriter’s

Laboratories, Inc.

Note: These specifications are subject to change without prior notice.

Ordering Information

SERIES 96 9 6 - -

Microprocessor-based

1

⁄16 DIN with universal input 1.
Options include: software, power
supply, input 2, four outputs and
display color

Power Supply

A = 100-240Vı(ac/dc)
B = 24-28Vı(ac/dc)

Input 2

0 = None
1 = Event input & 0-5VÎ(dc)/ 4-20mA

(Remote set point input)

Output 1

C = Switched dc/open collector
D = Electromechanical relay, Form C,

2A, without RC suppression

F = Universal Process, range selectable:

0-20mA, 4-20mA, 0-5VÎ(dc),
1-5VÎ(dc), 0-10VÎ(dc)

K = 0.5A solid state relay without

RC suppression

Output 2

A = None
C = Switched dc output/open collector
D = Electromechanical relay, Form C,

2A, without RC suppression

F = Universal Process, range selectable:

0-20mA, 4-20mA, 0-5VÎ(dc),
1-5VÎ(dc), 0-10VÎ(dc)

K = 0.5A solid state relay without

RC suppression

Output 3

A = None
D = Electromechanical relay, Form C,

2A, without RC suppression

Output 4

A = None
D = Electromechanical relay, Form C,

2A, without RC suppression

M = Universal Retransmit, range selectable:0-20mA,

4-20mA, 0-5VÎ(dc), 1-5VÎ(dc), 0-10VÎ(dc)
R = EIA/TIA 232 Communications
U = EIA/TIA 485 Communications

Software/Preset Parameters

00 = Standard software (order with Standard Display/Overlay)
AA = Ramping software (order with Ramping Display/Overlay)
XX = Custom software
XX = Preset parameters

Standard Display/Overlay

Upper/Lower
RR = Red/Red display
RG = Red/Green display
GR = Green/Red display
GG = Green/Green display

Ramping Display/Overlay

Upper/Lower
BA = Red/Red display
BB = Red/Green display
BC = Green/Red display
BD = Green/Green display

2 3 4%

96

1

To be automatically connected to the nearest North American Technical and Sales Office call:

1-800-WATLOW2

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52.070 mm
(2.050 in.)

(9.322 mm)

0.367 in.

(107.747 mm)

4.242 in.
(98.425 mm)

3.875 in.

Customer's Front Panel

Panel Cutout

44.958 mm x 44.958 mm
(1.77 in. x 1.77 in.)

52.070 mm
(2.050 in.)

(59.182 mm)

2.330 in.