Related Manuals for Watlow Micro-Based Autotuning Control SERIES 980/985
Summary of Contents for Watlow Micro-Based Autotuning Control SERIES 980/985
- Page 1 Microprocessor-Based Auto-tuning Control Watlow Controls, 1241 Bundy Blvd., 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 ( User’s Manual) 0 Printed on Recycled Paper $10.00 Made in the U.S.A.
-
Page 2: Safety Information
How to Use the Manual This manua/ will make First.. is a good way to become familiar with the Series 980/985. tion Chapter 1, Page Starting Out Chapter Install/Wire Chapter 3, Page 22. Front Panel Chapter 4, Page 24. Chapter 5, Page 29. Tuning Specifications, Page 34 Appendix... -
Page 3: Table Of Contents
Chapters Item page Chapter 1 Starting 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... -
Page 4: General Description
Chapter Starting Out With The Watlow Series 9801985, A Microprocessor-Based Control Single Input - Type J, K, T, N or Pt2 Flgure 1 - Series 980/985 Input Overview Output 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. -
Page 5: Where To Go From Here
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. -
Page 6: System Planning
Chapter 2 How to Install and Wire the Series 9801985 System Planning This chapter tells you how to install the Series 980/985. All mounting and 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. -
Page 7: Noise Sources
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 wire routing must be given careful consideration in planning the layout of the system. - Page 8 • 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.
-
Page 9: Noise Suppression Devices Available
"Islatros" and other similar power line filters are designed to carry the 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. -
Page 10: Line Filtering Configurations For Controls
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 applications - use Power Supply (U.P.S.) Don’t fasten common mode line filters or filters with metal cases to metal that is at ground potential. -
Page 11: How To Install The Series 980/985
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 980/985. -
Page 12: Series 980/985 Dimensions
Figure 6 - Series 980/985 Panel Cutout Dimensions Figure 7 - Series 980/985 Dimensions Panel 12 WATLOW Series 9801985 User’s Manual Panel Cutout Max. Panel Thickness 0.50 (12.7mm) 3.82 +0.03 - 0.00 (92mm + 0.8) Load Power indicators V I .89 (48.0 mm Adjustuble ‘Install and Wire, Chapter 2... -
Page 13: How To Wire The Series 980/985
How to Wire the Series 980/985 The Series 980/985 wiring is illustrated by model number option. Check the 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 980/985 internal circuits appear “inside“... - Page 14 lnput Options “1 “, “2” & “3”, Thermocouple Input Terminals 18 & 20 Model # 98 – A - 1 _ _ - 0-0000 Figure 10 - Input Options “1”, **2* & *3’, Thermo- couple Wiring Diagram. II II NOTE: You must use an isolated or ungrounded thermocouple if an external 4-20mA output device with a non-isolated circuit common is connected to the 4-20mA output.
- Page 15 Input Options “2” & " 3 " RTD - 2 Wire Terminals 12 - 14 ModeI#98 _ A - 2 _ _0-0000 98_A-3_ _0-0000 Jumper#l3to#l4 Input Options “2” & " 3 " RTD - 3 Wire Terminals 12 - 14 Model# 98_A-2_ _ 0-0000 98_A-3_ _0-0000 NOTE:...
- Page 16 Output ModeI# 98_A-_ B _0-0000 Figure 14 - Solid State Relay, Output 1, Option “B” Wiring Diagram. Solid State Relay Watlow's solid state relays change state at zero volts, which is *zero-cross switching.” They are also optically isolated, which means the output circuitry is energized by infrared light striking a photo-sensitive device.
- Page 17 Output 1 Option “D”, 6 Amp Mechanical Relay Model#98_A-_D _0-0000 Mechanical Relay Mechanical Relay The Electromechanical relay iS an electrical and mechanical d8vice with moving parts. When power is applied to the relay solenoid, Contact closure is Created through move- ment of the “Common”...
- Page 18 Output 1 Option “F", 4-20mA Model# 98_A-_F _0-0000 Figure 18 - 4-2OmA, Output 1, Option "F" Wiring Diagram. Process Output Proportional value determined by the control to balance the sensor input and set point. This value will fall between 4-20mA depending on your process output type. Output 1 Option “G”, O-20mA Model# 98_A-_G _0-0000 Figure 19 -...
- Page 19 Output 1 Option “H”, O-5VDC Model# 98_A-_H _0-0000 Process Output Proportional value determined by the control to balance the sensor input and set point. This value will fall between O-5VDC dependlng on your process output type. Output 2 Option “B”, Solid State Relay B 0-0000 Model# 98_A- Solid State Relay...
- Page 20 Output 2 Option “C", DC Output (Open Collector) Model# 98_A- Figure 22 - DC Output (Open Collector), output 2 Option "C" Wiring Diagram. Switched DC Watlow’s solid state switch is a low current DC output (open collector) used to switch an external power switching device such as a SSR or an electromechanical relay.
-
Page 21: System Wiring Example
WARNING: Install high or low temperature limit control protection in systems where an overtemperature fault condition could present a fire hazard or other hazard. Failure to install temperature limit control protection where a potential hazard exists could result in damage to equipment and property, and injury to personnel. CAUTION: Do not jumper load power from the control power terminals. -
Page 22: Lower Display
Chapter 3 How to Use the Keys and Displays Series 980/985 Displays and Load LED’s NOTE: The Upper display will always show the process value after 1 minute without key strokes. Figure 25 - Series 980/985 Displays LOAD 1 - When lit, this LED tells you when Output 1 is ener-... -
Page 23: Series 980/985 Keys
980/985 Series Keys UP/DOWN keys When pressed simultaneously for 3 sec- onds, the Setup Menu appears displaying the LOC parameter. From the LOC pa- rameter, press the UP/DOWN keys again and the Calibration Menu appears. Increases the value of the displayed parameter. -
Page 24: The Setup Menu
Chapter How To Setup The Series NOTE: While in the Setup Setting up the Series 980/985 is a simple process. First configure the 980/ menu, all outputs 985’s features to your application in the Setup Menu, and then enter values in are OFF. -
Page 25: Setup Parameters
Setup Parameters At the top of the menu, the Series 980/985 displays the user level of operation in the Upper display, and the LOC parameter in the Lower display. When pressing the MODE key, the value of the next parameter appears in the Upper display, and the parameter itself is in the Lower display. -
Page 26: Setup Menu
Latching: Selects whether the is an alarm. Latching alarms must be cleared before the alarm output will reset. Non-latching automatically resets the alarm output when the condition clears. The range is LAt or nLA, default is nLA. This only appears if the Ot2 = AL. Silencing: Selects alarms silencing (alarm inhibit). -
Page 27: Operation Parameters
1 g.f$fygj Operation Parameters Set Point 2: Sets the operating set point for Output 2 when control mode is Ht/ Ht or CL/CL. SP2 only appears when Ot1 and 0t2 are the same, and functions as an ON/OFF control. Proportional Band: Set the proportional bandwidth for each Output, adjustable °... -
Page 28: Operation Menu
Dead Band: Enter the Dead Band between the heating and cooling functions adjustable from ± 99°F/± 55°C. The default is 0°. Appears when Ot2 = CL. Alarm Low: Represents the low process alarm or low deviation alarm. Displayed only when 0t2 parameter is AL. Alarm High: Represents the high process alarm or high deviation alarm. -
Page 29: How To Tune And Operate
Chapter 5 How to Tune and Operate Tuning - Automatic Auto-tuning: The Series 9801985 gives you the capability to automatically tune the PlD parameters to fit the characteristics of your particular thermal system. The auto-tuning procedure operates on a thermal response value - slow, medium, or fast. -
Page 30: Tuning - Manual
Tuning - Manual For optimum control performance, tune the Series 985 to the thermal system The tuning settings here are meant for a broad spectrum of applications; your system may have somewhat different requirements. Manual and Automatic Operation To change from manual to auto operation, press the AUTO/MAN key twice. Manual operation provides direct (time proportioned % power) control of the outputs from -100% to 100%. -
Page 31: Using Alarms
Indication of Auto/Manual operation is the LED located on the AUTO/MAN key. When the LED is ON, the control is in the Manual operation, an alarm condition is present, and the output de-energizes. When the LED is OFF, the control is in AUTO operation and the alarm is energized. -
Page 32: How To Deal With Error Codes
How To Deal With Error Codes J’ Three dashes, “- - -", in the upper display indicate a Series 985 error. Press ~ twice- Read error • • Figure 32 - Error Code Display Examples NOTE: Electrical noise or a noise event, vibra- tion or excess environmental... - Page 33 Er 1, 2, 3 & 7 Errors - Control Outputs May Be ON If operator access is LOC 0 or . ..and the control was in AUTO operation when the error occurred, it will go into MANUAL (% power) operation. If the output power is less than 70%±5% change within the last two minutes, the 985 will switch into Manual operation at the last Automatic power level.
-
Page 34: Operator Interface
Appendix Control Mode • Operator Interface Input WATLOW Series 980/985 User’s Manual Single set point, non-ramping. Single input, dual outputs. Control outputs: User selectable as: Heat, Heat/Heat, Heat/Cool, Cool, Cool/Cool, Heat/Alarm, Cool/Alarm Outputs independent, or related via deadband for Heat/Cool. ON/OFF: 3°F or 1 .7°C switching hysteresis or 0.3°F or 0.l7°C for 0.10 Units PID parameters:... -
Page 35: Operating Environment
Primary Output (Heating or Cooling) Solid state relay, 0.5A @ 24VAC minimum, 253VAC maximum, opto- isolated, zero cross switching. Electromechanical relay, Form C, 6A @ 115/230VAC, 6A @ 28VDC, 1/8 hp. @ 115VAC 125VA @ 115VAC. Warranted to 100,000 cycles. Open collector, switched DC signal provides a minimum turn ON voltage of 3VDC into a minimum 500 ohm load, maximum ON voltage not greater than 32VDC into an infinite load. - Page 36 Series 980/985 Model Number Information The Series 980/985 Model Number, listed Control Series 980/985 = Dual output, microprocessor-based I/8 DIN Mounting = Horizontal = Vertical Input Type J thermocouple (3 digit only) Type J, K, T, N, PT 2 thermocouple; RTD 1°, 420mA, 0-5VDC (4 digit) Type J, K, T, N, PT 2 thermocouple;...
-
Page 37: Calibration Menu
Calibration Menu In the Calibration Menu, various input signals must be supplied in order for the control to go through its auto calibration. The calibration menu can only be entered from the LOC parameter in the Setup menu. Press the UP/DOWN keys simultaneously for 3 seconds (±... -
Page 38: Equipment Required
Figure 34 - The Calibration Menu. Thermocouple Field Calibration Procedure Equipment Required Type “J” Reference Compensator with reference junction at 320F/0°C, or Type “J” Thermocouple Calibrator set at 320F/0°C. Precision millivolt source, 0-50mV min. range, 0.01 mV resolution Setup And Calibration p NOTE Before calibration on an installed... -
Page 39: Rtd Settings
RTD Field Calibration Procedure Equipment Required 1K ohm precision decade resistance box with 0.01 ohms resolution. Setup And Calibration NOTE Before calibration on an installed control, make sure all data and parameters are documented. See Setup and Operation Charts, Pages 26 and 28. Connect the AC line voltage L1 to Terminal #4, L2 to Terminal #7, and Ground to Terminal #8. -
Page 40: Setup And Calibration
0 - 5 Volt Field Calibration Procedure Equipment Required Precision voltage source 0-5 volt minimum range with 0.001 volt resolution. Setup And Calibration NOTE NOTE: Not all parameters will appear. They are dependent on your unit type. Use only the steps that apply to your unit. - Page 41 4-20mA Input Field Calibration Procedure Equipment Required Precision current source 0-20mA minimum range with 0.01 mA resolution. Setup And Calibration 1 NOTE Before calibration on an installed control, make sure all data and parameters are documented. See Setup and Operation Charts, Pages 26 and 26.
- Page 42 0-20/4-20mA Output Field Calibration Procedure Equipment Required NOTE 470 ohm 1/2 watt 10% resistor. all parameters 4 - 1/2 digit Digital Multimeter. will appear. They are dependent on your unit type. Use Setup And Calibration only the steps that NOTE apply to your unit.
- Page 43 0-5/0-10 Volt Output Field Calibration Procedure Equipment Required 20K ohm, 1/4 watt, 10% resistor 1/2 digit Digital Multimeter. Setup And Calibration NOTE Before calibration on an installed control, make sure all data and parameters are documented. See Setup and Operation Charts, Pages 26 and 26.
- Page 44 Alarm: A condition, generated by a controller, indicating that the process has exceeded or fallen below the set or limit point. Anti-reset: Control feature that inhibits auto- matic reset action outside of the proportional band. Automatic prompts: Data entry points where a microprocessor-based control “prompts”...
- Page 45 PD control: Proportioning control with rate action. PI control: Proportioning control with auto-reset. PID control: Proportioning control with auto- reset and rate. Process varlable: Thermal system element to be regulated, such as time, temperature, relative humidity, etc. Programmed display data: Displayed informa- tion which gives the operator/programmer the “programmed”...
-
Page 46: Glossary
Appendix , 34 AUTO/MAN key, 23 Automatic Operation, 23,31 Auto-tuning, 30 Bumpless transfer, 31 Calibration, 38 Combination Differential Filter, 10, Fig. 5 Common Mode Fitter Wiring, 10, Fig 4 DCOutput 1, 16, Fig.16 DC Output 2,20, Fig. 20 Decrease Noise Sensitivity, How To, 7 Default Parameters, Installation, 26, Chart 1 Operation, 28, Chart 2... -
Page 47: Watlow Controls
Repair costs will not exceed 50 percent of the original cost. Watlow Controls Watlow Controls is a division of Watlow Electric Mfg. Co., St. Louis, MO, a manufacturer of industrial electric heating products, since 1922. Watlow begins with a full set of specifications and completes an industrial product that is manufactured totally in-house, in the U.S.A.
Need help?
Do you have a question about the Micro-Based Autotuning Control SERIES 980/985 and is the answer not in the manual?
Questions and answers