Watlow Micro-Based Autotuning Control SERIES... User manual

Microprocessor-Based

Auto-tuning Control

(

User’sManual)

Watlow

Controls, 1241 Bundy Blvd.,

P.O.

8ox

5580,

Winona,

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.

Printed on

Recycled

Paper

How to Use the Manual

First..

StartingOut

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.

LLL

CAUTION:

Details of a “Caution”

appear here, in the

narrow box on the

outside of each page.

WARNING:

Details of a “Warning”

appear here, in the

narrow box on the

outside of each page.

This

manua/

will

make

your

job

easier.

Reading it and applying the informa-

tion

is a good way to become familiar with the Series

980/985.

An overview:

Chapter 1, Page 4.

Chapter

Page

Chapter 3, Page 22.

Chapter 4, Page 24.

Chapter

Page 29.

Specifications, Page 34

Cali

bration

Glossary

Warranty

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.

orJ3

Safety Information

This user‘s manual also hasboldface safety information notes to protect both

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

your

eguipment

its performance. A full explanation is in the narrow column on the outside of

the page.

The Warning symbol (lightning bolt) 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.

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

507-454-5300.

The Watlow Series 9801985 User’s Manual

and integral software are copyrighted by Watlow Winona, Inc.,

1988, with all

rights reserved.

blrO293

WATLOW Series 9801985 User’s Manual

How to Use the Manual

Chapters

Figures, Table, Charts

page

Item

page

Item

4Starting Out With The Watlow Series

980/985

General Description

Putting Your Control To Work

Overview of the Series

980/985

Menus

Chapter 2

How To Install And Wire The Series

980/985

System Planning

Sensor Installation Guidelines

Installation Guidelines For Preventing Noise

Noise

Checking For Ground Loops

Noise Suppression Devices Available..

Line Filtering Configurations For Controls

How To Install The Series

980/985

How To Wire The Series

980/985

System Wiring Example

Chapter 3

How To Use The Keys

and

Displays

Series

980/985

Displays

Load LED’s

Series

980/985

Keys

Chapter 4

How To Set Up The Series

980/985

Entering

Set Up Menu

Set Up Parameters

Set Up Menu

Operation Parameters

Operation Menu

Chapter

How To Tune And Operate

Tuning

Manual

Tuning

Automatic

Manual and Automatic Operation

Using Alarms

How To Deal With Error Codes

Appendix

Specifications

Model Number Information

Calibration Menu

Calibration Procedures

Glossary

Index

Returns

Shipping Claims

Warranty

Watlow Controls

Chapter 1

Figure

Series

980/985

Input

Output Overview

Overview of the

Series

980/985

Differential Mode Filter Wiring

Common Mode

Fifter

Wiring

Combination

filter

Wiring

Series

980/985 Panel Cutout Dimensions

Series

980/985

Dimensions

115 VAC Power

Wiring

230 VAC Power

Wiring

Thermocouple

Wimg Diagram

Process Wiring Diagram

RTD

(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,

Output 1 Wiring

4-2OmA,

Output 1 Wiring

O-2OmA,

Output

Wiring

0-5VDC,

Output 1 Wiring

S.S. Relay, Output 2 Wiring

DC Output, Output 2 Wiring

6A Mechanical Relay, Output 2 Wiring

System

Wiring

Example

Series

980/985

Displays

Series

980/985

Keys

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

Prompts/Description

Input Ranges

Operation Menu Prompts/Description

Tables

Charts

How

Use

the

Manual

Chapter 1

Flgure

Series

980/985

Input

and

Output

Overview

Starting Out With The

Watlow Series 9801985,

A Microprocessor-Based

Control

SingleInput

Type

N or

Pt2

Dual

Outputs-

PID

or ON/OFF

User Selectable

Heat, Cool or Alarm

Output

or 2

Percent Power

Output

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 Auto-

matic/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

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 propor-

tional band to zero, the Series 9801985 becomes a simple ON/OFF control with

3°F

1.7°C

switching differential,

0.3°F

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.

WATLOW Series

980/985

User’sManual

GettingStarted,

Chapter

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.

Setup

Operation

Calibration

Configure the

980/985’s

features to your

application. Establish levels of operator

access, input type, units of measure, low and

high range limits, and Output 2 configuration.

Figure 2

Overview

of the

Series

980/985.

Enter the set point and the

PID

tuning values

and alarm set points here. Parameters for

proportional band, reset, rate and cycle time for

Outputs 1 and 2; alarm low and high;

dead-

band: calibration offset and auto-tune

are here also.

Supply various input signals to the

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.

Getting

Started,

Chapter 1

WATLOW

Series

980/985

User’s Manual

Chapter 2

How to Install and Wire the

Series 9801985

SystemPlanning

Thischaptertellsyouhowtoinstallthe

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 understand-

ing of the entire installation. Consider sensor installation carefully. You’ll need

to look at the noise reduction guidelines before making your panel cutout.

SensorInstallationGuidelines

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

Anoutstandingresource

for information for wiring guidelines is the IEEE

StandardNo.

518-1982

and is availablefrom IEEE, Inc.345 East 47thStreet,

New York, NY 10017.

WATLOW

Series

980/985

Users

Manual

Install

and

Wire,

Chapter 2

Noise Sources

Switchesandrelay contacts

operating

inductiveloadssuchas

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

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 electri-

cal 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

noise

sources.

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

• Groundloops mustbe eliminatedin the entirecontrolsystem. 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

(power lead)and

(return lead) to load power solenoids,

contactors,

and control circuit

ts.

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’tconnectgroundto

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

(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 0.1µ

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

effectively

dampennoiseatitssource.

• The

general

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

For other

‘QUENCHARC”

sizes contact

PAKTRON

P.O.Box5438

Lynchburg,VA24502

Phone:

804-239-6941

• Metal Oxide Varistor

(MOV)

can beused tolimit 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

havealimitedlife.

• Watlow stocks several

MOVs.

See Table 1.

WATLOW

Series

980/985

User's

Manual

Install and

Wire,

Chapter 2

"Islatros"

andother similarpowerlinefiltersaredesignedto

carry

thepower

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.

Keepline

filters

close to the control as possible to minimize the area for interference pick up.

lslatrols

are availablefrom:

ControlConcepts Corporation

328 Water Street

P.O.Box 1360

Blnghamton, NY

139O2-1360

Phone:

607/724-2464

101 (1A,l20VAC)

202

(2.5A,

208/240VAC)

105

(5A,

120VAC)

207

(7.5A,

208/240VAC)

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

in-

verted 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

termina-

tion.

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”.

Ifyoudofind

continu-

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 discon-

nection. 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 0802-0304-0000

802-0304-0000

MOV

275V,

75 Joule

0802-0266-0000

MOV

275V,

140 Joule

0802-0405-0000

Table

NoiseSuppressIon

Device

Ratings

Install and Wire, Chapter 2

WATLOW

Series

98O/985

User’sManual

Line Filtering Configurations For Controls

Figure

These three diagrams show you filter configurations for removing input power

noise. Choose the one best suited for your system.

Forverydirtyor

critical

applications

use a microcomputer-regulatedpowersupplyor

Uninterruptable

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.

Differential

Mode

Filter

Wiring

D.M.

Line Filter

NOTE: Keep filters

inches or less

from the control.

Minimize

the line

distance where

nolse can be

re-

introduced to

control.

Control

Common

Mode

Filter

Wiring

NOTE:

prevent

ground loops do not

fasten common

mode line

filters

with metal

cases to metal that

is at ground

poten-

tlal.

Doing so will

reduce filter effec-

tiveness.

Figure

Combination

Differential/

Common Mode Filter

Wiring

C.M. Line Filter

Control

Ground

Control

10 WATLOW

Series

980/985

User's

Manual

Install and Wire, Chapter 2

This manual suits for next models

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