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Microprocessor-Based
Auto-tuning Control
( User’s Manual)
Watlow Controls, 1241 Bundy Blvd., P.O. 8ox 5580, Winona, MN 55987-5580, Phone: 507/454-5300, Fax: 507/452-4507
$10.00
W985-MA58-9307
February, 1993
Made in the U.S.A.
Supersedes:
0 Printed on Recycled Paper
W985-MA70-9043
0
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How to Use the Manual This manua/ will make your job easier. Reading it and applying the informa- First.. An overview: tion is a good way to become familiar with the Series 980/985. Chapter 1, Page 4. Starting Out Chapter 2, Page 6. Install/Wire Chapter 3, Page 22. Front Panel Chapter 4, Page 24. Set Up Chapter 5, Page 29. Tuning Specifications, Page 34 Appendix Cali bration Glossary Warranty Notes The user’s manual contains informational notes to alert you to important details. When you see
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Figures, Table, Charts Chapters Figure Item Item page page 1 Input & Output Overview 4 Series 980/985 Chapter 1 2 5 Overview of the Series 980/985 4 Starting Out With The Watlow Series 980/985 3 Differential Mode Filter Wiring 10 4 General Description 4 10 Common Mode Fifter Wiring Putting Your Control To Work 5 5 10 Combination filter Wiring Overview of the Series 980/985 Menus 5 Panel Cutout Dimensions 6 12 Series 980/985 7 12 Series 980/985 Dimensions Chapter 2 8 13 115 VAC Power Wiring
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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 Auto- matic/Manual capability with
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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
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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 Because Watlow controls are thoroughly wiring information is right here. 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 a
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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. For example, A.C. power su
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• 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) Use a direct li
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"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. Keep line filters as close to the control as possible to minimize the area for interference pick up. lslatrols are availab
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Line Filtering Configurations For Controls These three diagrams show you filter configurations for removing input power For very dirty or critical noise. Choose the one best suited for your system. applications - use a microcomputer-regulated power supply or Uninterruptable Don’t fasten common mode line filters or filters with Power Supply (U.P.S.) metal cases to metal that is at ground potential. This prevents ground loops and maintains filter effectiveness. Figure 3 - Differential M
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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. Figure 6 shows you the 1. Place the panel cutout in the desired location. panel cutout dimensions. Push 2. To install, carefully insert the Series 980/985 into the pane
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Panel Cutout Max. Panel Thickness 0.50 (12.7mm) Figure 6 - Series 980/985 Panel Cutout ~ Dimensions 3.82 +0.03 - 0.00 (92mm + 0.8) Load Power indicators V T I .89 (48.0 mm Figure 7 - Series 980/985 Dimensions Panel _ Adjustuble ‘Install and Wire, Chapter 2 12 WATLOW Series 9801985 User’s Manual
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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“ the line drawing of the 980/985, 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 s
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lnput Options “ 1“, “2” & “3”, Thermocouple Input Terminals 18 & 20 Model # 98– A - 1 _ _ - 0-0000 98_A-2 – –0-0000 Figure 10 - Input Options “1”, 98_A-3- 0-0000 – – **2* & *3’, Thermo- couple Wiring Diagram. II II I 1 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. Extenslon wire for thermocouples must be of the same alloy as the thermocouple itself to limit errors. These input
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Input Options “2” & "3" RTD - 2 Wire Terminals 12 - 14 ModeI#98 _A-2_ _0-0000 98_A-3_ _0-0000 Figure 12 - Input Options "2" & “3”, RTD (2 wire) Sensor Wiring. Jumper#l3to#l4 . . II II . . . . Input Options “2” & "3 " RTD - 3 Wire Terminals 12 - 14 Model# 98_A-2_ _ 0-0000 Figure 13 - Input Options “2’ & 98_A-3_ _0-0000 ‘*3”, RTD (3 wire) Sensor Wiring. . . . . . . - J NOTE: Long lead lengths create electrical resistance. There will be a S 1° approximate input error for every 1ohm of lead length
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Output 1 Option “B”, Solid State Relay ModeI# 98_A-_ B _0-0000 Figure 14 - Solid State Relay, Output 1, Option “B” Wiring Diagram. Solid State Relay 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. This results in virtual absence of electri- cally generated noise, pIus output to input electrical isolation.
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Output 1 Option “D”, 6 Amp Mechanical Relay Model#98_A-_D _0-0000 Figure 16 - Mechanical 6 Amp mechanical Relay Relay, Output 1, Optlon “D” Wlrlng Diagram. 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” Contact of the relay. Off state impedance is 2 O K o h m minimum. Output 1 Option “E”, 0-I0 VDC Model# 98_A-_E _0-00
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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 - 0-20mA, Output 1, Option “G” Wiring Diagram. Process Output Proportional value determined by the control to balance the sensor input and set point. Th
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Output 1 Option “H”, O-5VDC Model# 98_A-_H _0-0000 Figure 20 - O-5VDC, Output 1, Option "H" Wiring Diagram. 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 Model# 98_A- B 0-0000 -- Figure 21 - S.S. Relay, Output 2, Option " B " Wiring Diagram. Solid State Relay Watlow’s solid state relays change state at zero volts, which is zero
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Output 2 Option “C", DC Output (Open Collector) Model# 98_A- C 0-0000 __ - . . Figure 22 - . DC Output (Open . Collector), output 2 . Option "C" Wiring . Diagram. . ’ 9 - 8 Heat, Cool + # or Alarm 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. The input specifications of the power switching device must match those listed for the SS switch output. The power switching
