Watlow Electric 980, 985 User Manual

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Watlow Electric 980, 985 User Manual

Chapters

 

Figures, Table, Charts

 

page

Item

page

Item

Figure

 

Chapter 1

4

Series 980/985 Input & Output Overview

1

4 Starting Out With The Watlow Series 980/985

5

Overview of the Series 980/985

2

4

General Description

10

Differential Mode Filter Wiring

3

5 Putting Your Control To Work

10

Common Mode Fifter Wiring

4

5

Overview of the Series 980/985 Menus

10

Combination filter Wiring

5

 

 

 

12

Series 980/985 Panel Cutout Dimensions 6

 

Chapter 2

12

Series 980/985 Dimensions

7

6

How To Install And Wire The Series 980/985

13

115 VAC Power Wiring

8

6

System

Planning

13

230 VAC Power Wiring

9

6

Sensor Installation Guidelines

14

Thermocouple Wimg Diagram

10

6 Installation Guidelines For Preventing Noise

14

Process Wiring Diagram

11

7

Noise

 

15

RTD (2 wire) Wiring Diagram

12

9 Checking For Ground Loops

15

RTD (3 wire) Wiring Diagram

13

9 Noise Suppression Devices Available..

16

Solid State Relay, Output 1 Wiring

14

10

Line Filtering Configurations For Controls

16

DC Output 1 (Open Collector) Wiring

15

11

How To Install The Series 980/985

l?

6 Amp Relay, Output 1 Wiring

16

13 How To Wire The Series980/985

17

O-lOVDC, Output 1 Wiring

17

21

System

Wiring Example

18

4-2OmA, Output 1 Wiring

18

 

 

 

18

O-2OmA, Output 1 Wiring

19

 

Chapter 3

19

0-5VDC, Output 1 Wiring

20

22 How To Use The Keysand Displays -

19

S.S. Relay, Output 2 Wiring

21

22

Series 980/985 Displays & Load LED’s

20

DC Output, Output 2 Wiring

22

23

Series 980/985 Keys

20

6A Mechanical Relay, Output 2 Wiring

23

 

 

 

21

System Wiring Example

24

 

Chapter 4

22

Series 980/985 Displays

25

24 How To Set Up The Series 980/985 -

23

Series 980/985 Keys

26

24

Entering Set Up Menu

24

Entering the Set Up Menu

27

25

Set Up Parameters

24

The Set Up Menu

28

26

Set Up Menu

27

The Operation Menu

29

27

Operation Parameters

31

Alarm Display Examples

31

28

Operation Menu

32

Error Code Display Examples

32

 

 

 

37

The Calibration Menu

33

 

Chapter 5

38

Calibration Parameters

34

29 How To Tune And Operate-

 

 

Tables

29

Tuning - Manual

 

 

30

Tuning - Automatic

9

Noise Suppression Device Ratings

1

31 Manual and Automatic Operation

39

RTD Settings

2

31

Using

Alarms

 

 

Charts

32 How To Deal With Error Codes

 

 

 

 

 

26

Set Up Menu Prompts/Description

1

34

Appendix

26

Input Ranges

2

34

Specifications

28

Operation Menu Prompts/Description

3

36Model Number Information

37Calibration Menu

38Calibration Procedures

38 Glossary

41Index

42Returns

42Shipping Claims

43Warranty

43 Watlow Controls

H o w to Use the M a n u a l

Chapter 1

Starting Out With The

Watlow Series 9801985,

A Microprocessor-Based Control

 

Dual Outputs-

Single Input -

PID or ON/OFF

Type J, K, T, N or Pt2

User Selectable

Flgure 1 -

Series 980/985 Input

and Output Overview

Heat, Cool or Alarm

Output 1 or 2

Percent Power

Output 1, Heating

Auto-tuning

General Description

Welcome to the Watlow Series 980/985, a dual output, single input, micropro- cessor-based, 1/8 DIN, auto-tuning temperature control, featuring the Automatic/Manual capability with bumpless transfer. In the Auto mode, the control has closed loop control with sensory feedback, while the Manual mode has open loop control with user defined output power level. The 980/985 accepts a Type J, K, T, N, or Platinel2 thermocouple, RTD, or process input. The primary output is Heating or Cooling, while the secondary output can be Heat, Cool or Alarm.

With the Series 980/985 you can select either PID or ON/OFF for Output 1 or Output 2. You may input a complete set of PID parameters for both outputs, and select automatic tuning for Output 1 from the front panel. This includes proportional band, reset, rate and cycle time. By setting either output’s proportional band to zero, the Series 9801985 becomes a simple ON/OFF control with a 3°F or 1.7°C switching differential, 0.3°F or 0.17°C for 0.1 ° RTD.

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 980/985 automatically stores all information in a non-volatile memory.

4 WATLOW Series 980/985 User’s Manual

Getting Started, Chapter1

Putting Your Control To Work

To put your Series 980/985 to work, we suggest the following steps:

Read the User’s Manual.

Plan your installation and wiring.

Cut the panel mounting hole and install the control. Wire your Series 980/985 to the system.

Start the system and tune the Series 980/985.

Make final adjustments to the control parameters and record the data. That’s all there is to it.

Overview of the Series 980/985 Menus

Before getting into the details of installing and wiring the Series 980/985, take a 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.

Configure the 980/985’s features to your application. Establish levels of operator

Setup access, input type, units of measure, low and high range limits, and Output 2 configuration.

Enter the set point and the PID tuning values

and alarm set points here. Parameters for Operation proportional band, reset, rate and cycle time for

Outputs 1 and 2; alarm low and high;deadband: calibration offset and auto-tune

are here also.

Supply various input signals to the Calibration Series 980/985, and it performs auto-

calibration. Calibration procedures should only be attempted with proper equipment and by qualified personnel.

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.

Figure 2 -

Overview of the

Series 980/985.

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 Series 980/985.Allmountingand wiring information is right here. Because Watlow controls are thoroughly tested and "burned in" before leaving the factory, the Series 980/985 is ready 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.

Sensor Installation Guidelines

We suggest that you mount the sensor at a location in your process or system where it reads an average temperature. Put the sensor as near as possible to the material or space that you want to control. Air flow past this sensor should be moderate. The sensor should be thermally insulated from the sensor mounting.

Installation Guidelines For Preventing Noise

For improved electrical noise immunity, install the Series 980/985 as far away 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.

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

StandardNo. 518-1982 and is available from IEEE, Inc. 345 East 47th Street,

New York, NY 10017.

6 WATLOW Series 980/985 Users Manual

Install and Wire, Chapter 2

Noise Sources

Switches and relay contacts operatinginductive 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 wire routing must be given careful consideration in planning the layout of the system. For example, A.C. power supply lines should be bundled together and physically kept separate from input signal lines(sensorlines).A12inchminimumseparatlonisusuallyeffective. Keep all switched output signal lines (high power level) separate from input signal lines (sensor lines). Cross other wiring at 90° angles whenever crossing lines 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 possiblefrom these noisesources. Don’t mount relays or switching 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.

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 maintainshieldcontinuity.

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

 

•Groundloops 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 groundedsensorinput.

• Do not daisy chain A.C. power (or return) lines, or output signal (or return) lines to multiple control circuits. Use a direct line from the power source to eachinputrequiring A.C.power.Avoidparalleling L1 (power lead) and L2 (return lead) to load power solenoids, contactors, and control circuits. If L1 (power lead) is used to switch a load, L2 (return lead) willhave 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 terminals together with one lead (usually green

wire) to ground at one single point will work best. 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” ("QUENCHARC™") to filter out noise generated by devices such as relays, relay contacts, solenoids, motors, etc. A snubber is a simple filter device using a 0.1µf, 600 volt, non-polarized capacitor in series with a 100 ohm, 1/2 watt resistor. The device can be used on A.C. or D.C. circuits to effectively dampen noise at its source.

The general purpose Watlow snubber, described above, is 0804-0147-0000.

For other ‘QUENCHARC” sizes contact

PAKTRON

P.O. Box 5438

Lynchburg, VA 24502

Phone: 804-239-6941

Metal Oxide Varistor (MOV) can be used to limit voltage “spikes” that 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 device dissipates the voltage “spikes” to ground and in doing so repeatedly, deteriorates its ability to function. MOVs have a limited life.

• Watlow stocks several MOVs. See Table 1.

8 WATLOW Series 980/985 User's Manual

Install and Wire, Chapter 2

"Islatros" and other similarpowerlinefiltersaredesignedto carrythe power for the control circuit and “buffer” the control circuit from A.C. line noise. Devices like the lslatrol use media (electromagnetic filtering) other than electric circuits to filter out electrical noise. Take care in matching the power capabilities of the filter with power demands of the circuit. Keep line filters as close to the control as possible to minimize the area for interference pick up.

lslatrols are availablefrom:

Control Concepts Corporation

 

328 Water Street

 

P.O. Box 1360

 

Blnghamton, NY 139O2-1360

 

Phone: 607/724-2464

I - 101 (1A,l20VAC)

I - 202 (2.5A, 208/240VAC)

I - 105

(5A, 120VAC)

I - 207 (7.5A, 208/240VAC)

I - 115

(15A, 120VAC)

 

The ultimate protection is an “uninterruptable” power supply. This 'senses' the A.C. power line; when the line fluctuates, a battery powered 6OHz inverted circuit takes over, supplying power within one-half to one cycle of the A.C. line; very expensive.

How To Check For Ground Loops

To check for ground loops, disconnect the ground wire at the ground termination. Measure the resistance from the wire to the point where it was connected. 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 continuity, 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. It is possible to reconnect a ground loop.

Noise Suppression Devices Available From Watlow

Watlow Controls stocks a few key noise suppression parts. You may order these by calling your localWatlowdistributor.

Item

Electrical Ratlngs

Part Number

 

 

 

Common Mode Line Filter

25OV, 3 Amp

0804-0196-0000

 

 

 

Differential Mode Line Filter

Refer to the lslatrol listing above.

Metal Oxide Varistor

15OV, 80 Joule

 

0802-0273-0000

MOV

13OV,38 Joule

0802-0304000- 0

MOV

275V, 75 Joule

0802-0266-0000

MOV

275V, 140 Joule

0802-0405-0000

 

 

 

Table 1 -

NoiseSuppressIon

Device Ratings

Install and Wire, Chapter 2

WATLOW Series 98O/985User’s Manual

9

Figure 3 -

Differential Mode

Filter

Wiring

NOTE: Keep filters 12 inches or less

from the control.

Minimize the line distance where

nolse can be reintroduced to control.

Common Mode Filter

Wiring

2

NOTE: To prevent

ground loops do not fasten common

mode line filters or filters with metal cases to metal that is at ground potentlal. Doing so will reduce filter effectiveness.

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 critical applicationsuse a microcomputer-regulatedpowersupplyor Uninterruptable PowerSupply(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.

Ll

.

D.M. Line Filter

 

 

 

Control

C.M. Line Filter

Control

I

Figure 5 -

 

 

 

 

Control

 

 

 

 

Combination

Ground

 

 

 

 

 

Differential/

 

 

 

 

 

 

 

 

 

 

Common Mode Filter

 

 

 

 

 

Wiring

 

 

 

 

 

10 WATLOW Series 980/985 User's Manual

Install and Wire, Chapter 2

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