Watlow Electric 980, 985 User Manual

Watlow
Controls, 1241 Bundy Blvd.,
Microprocessor-Based
Auto-tuning Control
(
User’s Manual)
P.O. 8ox
5580,
Winona, MN 55987-5580,
Phone:
507/454-5300,
Fax:
507/452-4507
W985-MA58-9307 February, 1993
Supersedes: W985-MA70-9043
$10.00
Made in the U.S.A.
0
Printed on
0
Recycled
Paper

How to Use the Manual

First..
Starting Out
Install/Wire
Front Panel Set Up
Tuning
Appendix
NOTE: Details of a *‘Note** appear here, in the narrow box on the outside of each page.
This manua/ will make
tion
is a good way to become familiar with the Series Chapter 1, Page Chapter Chapter 3, Page 22. Chapter 4, Page 24.
Chapter 5, Page 29.
Specifications, Page 34
Cali bration Glossary
Warranty
2,
Page
4.
6.
your
job
easier.
Reading it and applying the informa-
980/985.
An overview:
Notes
The user’s manual contains informational notes to alert you to important details. When you see a note icon, look for an explanation in the margin.
1 orJ3
Safety Information
This user‘s manual also has boldface safety information notes to protect both
LLL
CAUTION: Details of a “Caution” appear here, in the narrow box on the outside of each page.
you and your equipment. Please be attentive to them. Here are explanations:
The Caution symbol (exclamation point) in the wide text column alerts you to a “CAUTION,” a safety or functional hazard which could affect its performance. A full explanation is in the narrow column on the outside of the page.
0
WARNING: Details of a “Warning” appear here, in the narrow box on the outside of each page.
2
WATLOW Series 9801985 User’s Manual
The Warning symbol (lightning bolt) in the wide text column alerts you to a **WARNING,” a safety hazard which could affect you and explanation is in the narrow column on the outside of the page.
Your Feedback
Your comments or suggestions on this manual are welcome, please send them to: Technical Writer, Watlow Winona, Inc., 1241 Bundy Blvd., Winona, MN
55987, or phone and integral software are copyrighted by Watlow Winona, Inc., rights reserved.
T
A
0
507-454-5300.
The Watlow Series 9801985 User’s Manual
your eguipment
the equipment.
©
1988, with all
How to Use the Manual
or
A full
blrO293
Chapters
Figures, Table, Charts
page
Item
Chapter 1 4 Starting Out With The Watlow Series 4
General Description
Putting Your Control To Work
5
Overview of the Series
5
980/985
Menus
980/985
Chapter 2 6
How To Install And Wire The Series 6
System Planning 6
Sensor Installation Guidelines 6
Installation Guidelines For Preventing Noise
7
Noise
Checking For Ground Loops
9
9
Noise Suppression Devices Available..
10
Line Filtering Configurations For Controls
11
How To Install The Series
13
How To Wire The Series
21
System Wiring Example
980/985
980/985
980/985
Chapter 3
22
How To Use The Keys
22
Series
980/985
Displays & Load LED’s
Series
980/985
23
Keys
and
Displays
-
Chapter 4
24
How To Set Up The Series
24
Entering
25
Set Up Parameters
26
Set Up Menu
27
Operation Parameters
28
Operation Menu Chapter
29
How To Tune And Operate
29
Tuning - Manual
30
Tuning - Automatic
31
Manual and Automatic Operation
31
Using Alarms How To Deal With Error Codes
32 34
Appendix
34
Specifications
36
Model Number Information
37
Calibration Menu
38
Calibration Procedures
38
Glossary
41
42 42 43 43
Set Up Menu
5
Index Returns Shipping Claims Warranty Watlow Controls
980/985 -
-
page
4
Series
5
Overview of the Differential Mode Filter Wiring
10
Common Mode
10
Combination
10 12
Series Series
12
115 VAC Power
13
230 VAC Power
13
14
Thermocouple
14
Process Wiring Diagram RTD
15 15 16 16
l? 17 18 18
19
19 20 20 21 22
23
24 24 27 31 32 37 38
9
39
26
26
28
(2 wire) Wiring Diagram
RTD
(3 wire) Wiring Diagram Solid State Relay, Output 1 Wiring DC Output 1 (Open Collector) Wiring 6 Amp Relay, Output 1 Wiring O-lOVDC, 4-2OmA, O-2OmA, 0-5VDC, S.S. Relay, Output 2 Wiring DC Output, Output 2 Wiring 6A Mechanical Relay, Output 2 Wiring System Series
Series
Entering the Set Up Menu The Set Up Menu The Operation Menu
Alarm Display Examples
Error
Code Display Examples
The Calibration Menu
Calibration Parameters
Noise Suppression Device Ratings
RTD Settings
Set Up Menu
Input Ranges Operation Menu Prompts/Description
Item
980/985
Input & Output Overview
Series
980/985
Fifter Wiring
filter
Wiring
980/985
980/985
Panel Cutout Dimensions
Dimensions
Wiring Wiring
Wimg Diagram
Output 1 Wiring
Output 1 Wiring
Output 1 Wiring
Output 1 Wiring
Wiring
Example
980/985
Displays
980/985
Keys
Prompts/Description
Figure
1 2 3 4 5 6 7 8 9
10
11
12
13
14
15 16 17 18 19
20 21 22 23 24 25 26 27 28 29 31 32 33
34
Tables
1 2
Charts
1 2 3
How to Use
the
Manual
Chapter 1 Starting Out With The
Watlow Series 9801985,
Flgure 1 Series 980/985
and
-
Output
Overview
Input
A Microprocessor-Based
Dual Single Input Type J, K, T, N or
­Pt2
PID User Selectable
Control
Outputs-
or ON/OFF
Heat, Cool or Alarm
Output 1 or 2 Percent Power
Output Auto-tuning
1,
Heating
4
WATLOW Series
980/985
General Description
Welcome to the Watlow Series
cessor-based, matic/Manual capability with has closed loop control with sensory feedback, while the Manual mode has open loop control with user defined output power level. a Type J, K, T, N, or Platinel2 thermocouple,
primary output is Heating or Cooling, while the secondary output can be Heat, Cool or Alarm.
With the Series
Output 2. You may input a complete set of and select automatic tuning for Output 1 from the front panel. This includes proportional band, reset, rate and cycle tional band to zero, the Series 9801985 becomes a simple ON/OFF control with
a
3°F
or
Operator-friendly features include automatic LED indicators to aid in monitoring and set-up, as well as a calibration offset at the front panel. The Watlow Series
User’s Manual
980/985
1/8
DIN, auto-tuning temperature control, featuring the Auto-
980/985
1.7°C
switching differential,
automatically stores all information in a non-volatile memory.
you can select either
980/985,
bumpless
0.3°F
a dual output, single input, micropro-
transfer. In the Auto mode, the control
The
980/985
RTD,
or process input. The
PID
or ON/OFF for Output 1 or
PID
parameters for both outputs,
time.
By setting either output’s propor-
or
0.17°C
for 0.1 °
RTD.
Getting Started,
accepts
Chapter
1
Putting Your Control To Work
To put your Series
Read the User’s Manual. Plan your installation and wiring. Cut the panel mounting hole and install the control. Wire your Series Start the system and tune the Series Make final adjustments to the control parameters and record the data. That’s all there is to it.
Overview of the Series
Before getting into the details of installing and wiring the Series look at Figure 2, and at the three different menus. “Setup”, “Operation”, and “Calibration”. After you feel comfortable with the names and their functions, move on to installation and wiring.
Setup
980/985
980/985
to work, we suggest the following steps:
to the system.
980/985.
980/985
Configure the application. Establish levels of operator access, input type, units of measure, low and high range limits, and Output 2 configuration.
Menus
980/985’s
features to your
980/985,
take a
Figure 2 Overview
Series 980/985.
­ of the
Operation
Calibration
Enter the set point and the and alarm set points here. Parameters for
proportional band, reset, rate and cycle time for Outputs 1 and 2; alarm low and high; band: calibration offset and auto-tune are here also.
Supply various input signals to the
Series
calibration. Calibration procedures
should only be attempted with
proper equipment and by qualified
personnel.
980/985,
and it performs
PID
tuning values
dead-
auto-
Where To Go From Here
If your Series 980/985 is already installed and wired, go directly to “How to Use the Keys and Displays”, Chapter 3. If not, turn the page to Chapter 2, “How to Install and Wire the Series
980/985”,
and proceed from there.
Getting
Started,
Chapter 1
WATLOW
Series 980/985
User’s Manual
Chapter 2
How to Install and Wire the
Series 9801985
System Planning
This chapter tells you how to install the wiring information is right here. tested and "burned to install when you receive it.
But before you begin working, read through this chapter to gain an understand­ing of the entire installation. Consider sensor installation carefully. You’ll need
to look at the noise reduction guidelines before making your panel cutout.
in"
before leaving the factory, the Series
Because
Series 980/985.
Watlow
controls are thoroughly
All mounting and
980/985
is ready
Sensor Installation Guidelines
We suggest that you mount the sensor at a location in your process or system where it reads an average temperature. the material or space that you want to control.
be moderate. The sensor should be thermally insulated from the sensor mounting.
Put the sensor as near as possible to
Air flow past this sensor should
Installation Guidelines For Preventing Noise
For improved electrical noise immunity, install the Series
as possible from motors, relays, and other similar noise generators.
Do not run low power (sensor input) lines in the same bundle as AC power
lines. Grouping these lines in the same bundle can create electrical noise
interference which may result in error codes in the Series
980/985
980/985.
as far away
6
WATLOW
The Culprit
Most noise problems stem from wiring practices. They’re the major means of coupling noise from its sources to the control circuit The following information will tell you how to eliminate or decrease noise.
An Information Resource
An outstanding resource for information for wiring guidelines is the IEEE
Standard No.
New York, NY 10017.
Series 980/985 Users Manual
518-1982
and is available from IEEE, Inc. 345 East 47th Street,
Install
and
Wire,
Chapter 2
Noise Sources
Switches and relay contacts
operating
inductive loads such as
motor,
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
Physical separatlon and
planning the layout of the system. should be bundled together and physically kept separate from input signal lines (sensor lines). A 12 inch minimum separatlon is usually effective. Keep all switched output signal lines (high power level) separate from input signal lines (sensor lines). Cross other wiring at is unavoidable.
Another important practice is to look at the system layout and identify electri­cal noise sources such as solenoids, relay contacts, motors, etc., and where they are physically located. Then route the wire bundles and cables as far away as possible from devices close to a microprocessor control. Don’t have phase angle-fired devices in the same electrical enclosure or on the same power line with the control.
wire
routing must be given careful consideration in
For example, A.C. power supply lines
90°
angles whenever crossing lines
these noise
sources.
Don’t mount relays or switching
Shielded cables should be used for all low power signal
lines
to protect from
magnetic and electrostatic coupling of noise. Some simple pointers are:
• Whenever possible, low level signal
lines
should be run unbroken from
signal source to the control circuit.
• Connect the shield to the control circuit common at the control end only.
Never leave the shield unconnected at both ends. Never connect both shield ends to a common or ground.
• If the shield is broken at some termination point and then continued on, the
shield must be connected to maintain shield continuity.
• If the shield is used as a signal return, no electrostatic shieldlng should be
assumed. If this must be done, use a
triaxed
cable
(electrostatically
shielded coaxial cable).
Twisted pair wire should be used any time control circuit signals must travel over two feet or when they are bundled in parallel with other wires.
The size or gauge of wire should be selected by calculating the maximum circuit current and choosing the gauge meeting that requirement. Using
greatly larger wire sizes than required generally will increase the likelihood of
electrostatic (capacitance) coupling of noise.
Install
and Wire, Chapter 2
WATLOW Series
980/985 User's
Manual
7
• Ground loops must be eliminated in the entire control system. There are obvious loops which can be spotted by studying the"as-built" wiring diagram.
There are also the not-so-obvious ground loops that result from the technique of connecting internal circuit commons in the manufacturer's equipment. An example of this would be if a control circuit is designed to work with a grounded sensor input.
• Do not daisy chain A.C. power (or return) lines, or output signal (or return) lines to multiple
control
circuits. each input requiring A.C. power. Avoid paralleling L1 (power lead) and (return lead) to load power solenoids,
Use a direct line from the power source to
L2
If L1
contactors,
and control circuit
ts. (power lead) is used to switch a load, L2 (return lead) will have the same switched signal and could couple unwanted noise into a control circuit.
• Grounding the chassis of each piece of equipment in the system is very important. The simple practice of connecting each individuai chassis to the overall equipment chassis immediately adjacent to that piece, and then tie all
the major chassis ground wire) to ground at one single point will work best.
terminals
together with one lead (usually green
Don’t connect ground to
the control case if the control is mounted in grounded enclosure (prevent
ground loops).
• Do not confuse chassis grounds (safety ground) with control circuit commons or with AC. supply lines L2 (return or neutral line).
Each return system
wiring must be kept separate. Be absolutely sure chassis ground (safety) is
never used as a conductor to return circuit current
How To Eliminate Noise
• Use “snubbers”
such as relays, relay contacts, solenoids, motors, etc. A snubber is a simple filter device using a 0.1µ
100 ohm,
to
effectively
• The
For other
1/2
general
‘QUENCHARC”
PAKTRON
P.O. Box 5438
Lynchburg, VA 24502 Phone:
804-239-6941
• Metal Oxide Varistor
occur on the A.C. supply lines as a result of lightning strikes, switching large motors, etc. The MOV is available in several varieties and for 115 or 230 volt lines. The so repeatedly, deteriorates its ability to function.
• Watlow stocks several
("QUENCHARC™")
f,
600 volt, non-polarized capacitor in series with a
to filter out noise generated by devices
watt resistor. The device can be used on A.C. or D.C. circuits
dampen noise at its source.
purpose Watlow snubber, described above, is 0804-0147-0000.
sizes contact
(MOV)
can be used to limit voltage “spikes” that
device
dissipates the voltage “spikes” to ground and in doing
MOVs
have a limited life.
MOVs.
See Table 1.
8
WATLOW
Series
980/985
User's Manual
Install and
Wire,
Chapter 2
"Islatros" for the control Devices like the electric capabilities of the filter with power demands of the circuit.
and other similar power line filters are designed to
circuit
lslatrol
circuits to
and “buffer” the control circuit from
use media (electromagnetic filtering) other than
filter
out electrical noise. Take care in matching the power
A.C.
carry
the power
line noise.
Keep line
filters
as
close to the control as possible to minimize the area for interference pick up.
lslatrols
are available from:
Control Concepts Corporation 328 Water Street P.O. Box 1360 Blnghamton, NY Phone:
I
- 101 (1A,l20VAC) I ­I - 105 I - 115
(5A, 120VAC) I ­(15A, 120VAC)
The ultimate protection is an
“uninterruptable”
607/724-2464
202
207
the A.C. power line; when the line fluctuates, a battery powered verted circuit takes over, supplying power within
139O2-1360
(2.5A, 208/240VAC)
(7.5A, 208/240VAC)
power supply.
one-half
This 'senses'
to one cycle of the
6OHz
in-
A.C. line; very expensive.
How To Check For Ground Loops
To check for ground loops, disconnect the ground wire at the ground tion.
Measure the resistance from the wire to the point where it was
The ohmmeter should read a high ohm value.
If you have a low ohm value
across this gap, there is at least one ground loop present in your system. Or check for continuity; your reading should be "open”.
If you do find ity, you must now begin looking for the ground loops. Begin disconnecting grounds in the system one at a time, checking for continuity after each discon­nection. When continuity reads "open” you have eliminated the ground loop(s). Also, as you reconnect grounds, keep making the continuity test. to reconnect a ground loop.
termina-
connected.
continu-
It is possible
Noise Suppression Devices Available From Watlow
Watlow Controls stocks a few key noise suppression parts. You may order these by calling your local Watlow distributor.
Item
Common Mode Line
Differential
Metal Oxide
MOV
MOV
MOV
Install and Wire, Chapter 2
Mode Line Filter
Varistor
Filter
Electrical Ratlngs Part Number
25OV,
3 Amp 0804-0196-0000
Refer to the
15OV,
13OV,38
275V,
275V,
lslatrol
listing above.
80 Joule
Joule 0802-0304-0000
75 Joule
140 Joule
0802-0273-0000
802-0304-0000
0802-0266-0000
0802-0405-0000
WATLOW
Series
Table 1
­NoiseSuppressIon Device
Ratings
98O/985
User’s Manual
9
Figure
3
-
Differential Filter
Wiring
NOTE: Keep filters 12
inches or less
from the control.
Minimize
Mode
the line
distance where
nolse can be introduced to
control.
re-
Line Filtering Configurations For Controls
These three diagrams show you filter configurations for removing input power
noise. Choose the one best suited for your system.
For very dirty or applications - use a microcomputer-regulated power supply or Power Supply (U.P.S.)
Don’t fasten common mode line filters or filters with metal cases to metal that is at ground potential. This prevents ground loops and maintains filter effectiveness.
D.M.
Ll
.
Line Filter
critical
Uninterruptable
Control
Common Wiring
NOTE: To prevent ground loops do not fasten mode line filters cases to metal that is at ground tlal. reduce filter effec­tiveness.
Figure 5 Combination Differential/ Common Mode Filter
Wiring
Mode
2
Filter
common
filters
or
with metal
poten-
Doing so will
-
C.M. Line Filter
Control
I
Control
Ground
10 WATLOW
Series 980/985 User's Manual
Install and Wire, Chapter 2
How to Install the Series
980/985
Figures 6,7
and 8 provide the Series
980/985’s
panel cutout and dimensions. Do not, however, make your panel cutout until you are sure that you are placing the control in the best location. Read the noise guidelines at the beginning of this chapter before installing and wiring the Series
Figure
1.
Place
the panel cutout in the desired location.
6 shows you the
980/985.
panel cutout dimensions.
2.
To install,
carefully
insert the Series
980/985
into the panel cutout.
Push
the unit in until the bezel is seated securely against the panel.
3.
Included with your control are two adjustable mounting brackets; one for the
top and one for the bottom of the control case.
Installing the mounting
brackets requires access to the back side of the panel. On the top and bottom of the case are a series of slots running the length of
the case.
The first two shorter slots are for attaching the mounting brack-
ets. Figure 8 shows a side view with both mounting brackets.
4.
Loosen the mounting bracket screws with a Phillips screwdriver far enough
to allow for the panel thickness.
5.
Make sure that each bracket is placed in the first two slots from the front of the control, with the head of the screw facing the back of the control. to
Figure
8 for screw and bracket placement.
Refer
NOTE:
1
Removing the
Series 980/985 chassis from its case may make mounting easier.
6.
To attach, place the bracket into the slots (head of the screw facing the
back of the
case.
7.
Make sure the Series
control
and push backward, securing the brackets to the control
Do the same for the other side of the control.
980/985
case is seated properly. Tighten the
installa-
tion screws firmly against the panel to secure the unit in place.
8.
To remove the unit from its enclosure, loosen the captive screw at the
bottom of the
980/985’s
front panel with a Phillips screwdriver.
Pull the unit
from its case.
9.
To release the mounting brackets, push the brackets forward and pull out to
release them from the control case.
Install and Wire, Chapter
2
WATLOW
Series 980/985
User’s Manual
11
Panel Cutout
Max. Panel
Thickness
0.50
(12.7mm)
Figure 6 Series
-
980/985
Panel Cutout
Dimensions
3.82
+0.03 -
(92mm + 0.8)
T
I .89
(48.0 mm
~
0.00
Load Power
indicators
V
Figure 7 Series
-
980/985
Dimensions
Panel
_
Adjustuble
12
WATLOW Series 9801985 User’s Manual
‘Install and Wire, Chapter 2
How
to Wire the Series
980/985
The Series unit sticker on the control and compare your model number to those shown here and also the model number breakdown in the back of this manual.
Series while connections and terminal designations appear “outside” the line drawing. All outputs are referenced to a de-energized state. The final wiring figure is a
typical system example.
All wiring and fusing should conform to the National Electric Code and to any locally applicable codes as well
When you apply power without sensor inputs on the terminal strip, the Series 980/985 Press the AUTO/MANUAL key twice, and an ER 7 is displayed for one second. This error indicates an open sensor. Remove power to the control and connect the sensor properly, see Page 14.
980/985
980/985
will display “-
II
wiring is illustrated by model number option. Check the
internal circuits appear “inside“ the line drawing of the
II
.
”-in the Upper display, and a
-
Jumper #4 to #6 and Jumper #5 to #7 for 115
VAC operation
980/985,
"O"
in the Lower display.
L2
Earth
Ground
Figure 8 115 VAC Power Wiring
-
II 0
Install and Wire Chapter 2
0
Jumper #5 to #6 for 230 VAC operation
WATLOW
To National
Code (NEC) safety practices when wiring and connect­ing this unit to a
power source and to
electrical sensors or
peripheral devices.
Figure 9 230 VAC Power Wiring
Series
980/985 User’s Manual
0
avoid potential
electric
CAUTION:
shock, use
Electric
-
13
lnput Options
“1
Terminals 18 & 20
“, “2” & “3”,
Thermocouple Input
Figure 10
Input Options **2* & *3’, Thermo­couple Wiring
Diagram.
-
“1”,
Model # 98
II
– A - 1 _ _ - 0-0000
98_A-2 – – 98_A-3-
– –
0-0000
0-0000
II
I
1
NOTE:
You must use an isolated or ungrounded thermocouple if an external output device with a non-isolated circuit common is connected to the output.
Extenslon wire for thermocouples must be of the same alloy as the thermocouple
itself to limit errors.
These input connections are used in conjunction with your units sensor type. (Thermocouple and RTD only)
4-20mA
4-20mA
Flgure Input Options "3" Wlring
11
-
"2" &
Process Input
Diagram.
1
NOTE:
When using a 2OmA
process Input, the input impedance is 2 4 9 o h m s
4-
Input Options Terminals 15 -
Model
#98_A - 2 _ _ 0 - 0000
“2’ & “3”,
17
Process or Remote Set Point Input
98_A - 3 _ _ 0 - 0000
fl
0-5VDC 4-20mA INPUT
0 II
.
J3
When using a process input such
scale the display to match the measured range of the process signal. When using
a
0-5VDC
An example of this is: A pressure transducer operates over a range of 0 delivering a
the Series
Jumper Terminal 16 to Terminal 17 when using a input.
NOTE:
process input, the input impedance is 100K ohms.
4-20mA
980/985
4-20mA
output signal for this range. By setting rL= 0 and rH = 300,
is now displayed as a direct reading of pressure.
as
O-5VDC
16 17
0-5VDC, 4-20mA
or
4-2OmA,
INPUT
the rL and rH settings
-
300 PSI,
Input
Voltage
14
WATLOW
Series
980/985
User’s Manual
Install and Wire, Chapter 2
Input Options
“2” & "3"
Terminals 12 - 14
RTD - 2 Wire
ModeI#98
_A-2_
98_A-3_
II
II
Input Options Terminals 12 -
_0-0000
_0-0000
Jumper#l3to#l4
“2” & "3"
RTD - 3 Wire
14
Figure 12 Input Options "2" & “3”, Sensor
. . . . . .
-
RTD (2
Wiring.
wire)
Model#
98_
A-2_ _ 0-0000
98_A-3_
_0-0000
Figure 13 Input Options ‘*3”, Sensor Wiring.
.
.
.
.
.
.
-
J
NOTE:
Long lead lengths create electrical resistance. There will be input error for every That resistance, when added to the erroneous input to the instrument. To overcome this problem, use a three wire
RTD sensor, which compensates for lead length resistance. When extension wire is used for a three wire RTD, all three extension wires must have the same electrical resistance. (i.e. same gauge, copper stranded).
1ohm
of lead length resistance when using a two wire
resistance
of the
a
S
1° approximate
RTD
element, can result in
RTD.
­“2’ &
RTD (3 wire)
Install and Wire, Chapter 2
WATLOW Series
980/985 User's Manual
15
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