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Series 998/999 - Zesta Engineering Ltd.

1. M A E SERIES 998 p Release Tabs WATLOW Series 998 User s Manual 1 1 DIP Switches NOTE The input 2 DIP switch is mounted upside down NOTE Only controllers with the indicated model numbers have these DIP switches Figure 1 2 Input DIP switches 1 Set the input DIP switches to match the sensors you are using in your application Only controllers with model number 99__ 22_ __ have input DIP switches RTD thermocouple R S or B thermocouple J K T N E C D 0 20 or 4 20mA 0 5 1 5 or 0 10V 1 2 WATLOW Series 998 User s Manual Input 2 DIP Channel B DIP Input 1 DIP Channel A DIP Controller Chassis Rear View Input 1 Channel A Input 2 Channel B 99 _ 2 _ A ai file Pt2 he gle 99 2 BE A PI 5 T D Hardware Setup Chapter 1 NOTE For other voltages or current settings contact the factory NOTE Only controllers with the indicated model numbers have these DIP switches Figure 1 3 External signal con ditioner power sup ply DIPs Hardware Setup Chapter 1 DIP Switches 2 Set DIP switches for outputs equipped with an external signal conditioner power supply Only controllers with model number gg T___or 99_ __ T_havean aien deus eae OFF external signal condi
2. If Default L CF Global Menu amp e e C_F La Global Menu Input Menu Global Menu amp e e C_F La Global Menu Input Menu a process input RETI HY2A is selected Process A m D Pech Select the process range for channel A This prompt appears only on controllers equipped with channel A process hardware 99_ _F __ Default L 4 20mA 0 20mA 0 5V 1 5V 0 10V de 0 10 Prec Prec Prec 4 20 WATLOW Series 998 User s Manual Setup Menus Chapter 4 HJ ib Setup Menus Chapter 4 Setup Output Output 1B Set the way that output 1B will respond to a difference between the set point and an input variable select reverse action so that output 1B responds when the input signal is less than the set point e select direct action so that output 1B responds when the input signal is more than the set point MARIA This prompt always appears Default 4 Snr gt ib Hysteresis 1B Select the switching hysteresis for output 1B This determines the change in temperature or process units needed to turn the output from full off to full on EERE This prompt does not appear if output 1 is a process output If Default a Global Menu amp EEE z EEN C_F Global Menu Input Menu Global Menu amp MF e e C_F Global Menu Input Menu a process input is selected WATLOW Series 998 User s Manual 4 21 Setup Output Gtceb HY Output 2B Set the way that output 2
3. O0 1A 2A 1B 2B Semiconductor Oven CHA CHB Heaters O00O SERIES 998 Temperature Tramsmitter WATLOW Series 998 User s Manual 8 1 Figure 8 2 Retransmit Example 8 2 WATLOW Series 998 Retransmit When output 3 is ordered as a process retransmit output channel A set point or process value input 1 or channel B set point or process value input 2 can be configured for retransmit For accurate readings when retransmitting to a chart recorder the retransmit can be scaled and offset separate from the input settings When model number 99 M _ _ _ is ordered a process range of 0 20mA or 4 20mA can be selected at the prompt in the Output Menu When model number 99 N __ _ is ordered a process range of 0 5V 1 5V or O 10V dc can be selected Here s an example The Series 998 is controlling the temperature of a heat treat oven The temperature of the process must be recorded on a chart recorder The oven s temperature operating range is from 600 to 900 F The chart recorder requires a 4 20mA signal To achieve this set the following prompts in the Output Menu Set to to identify the channel A process as the retransmit variable Set to to select 4 20mA as the output signal Set to WHN to set the retransmit signal low range at 600 F Set to WEH to set the retransmit signal high range at 900 F Setting to M assumes no calibration offse
4. D_ org9_ E or 99__ _K_ or switched de 99__ _C_ and with set to or GTA Default L Setup Menus Chapter 4 WATLOW Series 998 User s Manual 4 27 Setup Output EEE Hysteresis 4 Select the switching hysteresis for alarm 4 This determines the change in temperature or process units needed to turn the output from full off to full on e If the input referenced by is set to the range is affected as listed below PEER This prompt appears only on controllers equipped with output 4 hardware for a relay 99__ B_ org9_ D_ or 99_ E_ or 99__ _K_ or switched de 99__ _C_ and with set to or EETA If Default Vv J C_F Global Menu amp EN EED EEN EEE Global Menu Input Menu Global Menu amp z s a Global Menu Input Menu a process input PEEL EEG is selected Latching 4 Select whether alarm 4 will be latching or non latching A latching alarm must be turned off manually A non latching alarm turns off when an alarm condition no longer exists This prompt appears only on controllers equipped with output 4 hardware for a relay 99_ _ B_ or99_ D_ or99_ E_ or99_ __ K __ or switched de 99_ __ _C_ and with set to or GREE Default L 4 28 WATLOW Series 998 User s Manual Setup Menus Chapter 4 NOTE See Chapier 7 for more information on alarms Aout NOTE See Chapter 8 for more information on retransmit Setup Menus Chapter 4 Setup
5. ELZA set point 2B 5 3 System Menu 5 2 system menu lockout 6 4 T test outputs 6 12 WATLOW Series 998 User s Manual A 7 Specifications Specifications 1908 Control Mode e Dual input six output optional retransmit of set point or process variable e Programmable direct and reverse acting control outputs per chan nel e One step auto tuning Agency Approvals UL 873 c UL File 43684 NEMA 4X IP65 front panel 89 336 EEC Electromagnetic Compatibility Directive EN 55011 1991 Group 1 Class A Emissions EN 50082 2 1994 Immunity 73 23 EEC Low Voltage Directive EN 61010 1 1993 Safety Operator Interface e Dual four digit LED displays Upper 0 4 inch 10 mm Lower 0 3 inch 8 mm e Mode Auto Man Display Up and Down keys Accuracy e Calibration accuracy and sensor conformity 0 1 of span 1 LSD 77 F 5 F 25 C 3 C ambient and rated line voltage 10 e Accuracy span 1000 F 540 C minimum e Temperature stability 0 2 F F 0 1 C C change in ambient e Voltage stability 0 01 of span of rated line voltage Sensors Inputs e Contact input for software function select event input Thermocouple Types B C D E J K N R S T and Pt 2 RTD resolution in 1 or 0 1 RTD scales e Process variables 0 20mA 4 20mA 0 5V dc 1 5V dc and 0 10V dc Sensor break protection de energizes system for safety Latching or non latching e S
6. Global Menu is set to Range or Default none Hidden if input 1 and input 2 are process inputs 3 2 WATLOW Series 998 User s Manual Keys and Displays Chapter 3 Chapter 4 The Setup Menus NOTE Press the Display key to return to the Display Loop from any point in any menu NOTE The lockout DIP switch hides the Setup menus See Chapter 1 Figure 4 1 Navigating the Setup menus Setup Menus Chapter 4 Navigating the Setup Menus To reach the Setup Menus begin in the Display Loop and press both the Up arrow Y and Down arrow keys for three seconds The Setup Menu prompt will appear in the lower display and the Input Menu prompt will appear in the upper display The four Setup Menus are Input AZA Output MAAA Global ERR and Communications AHH Use the Up arrow 7Y or Down arrow key to select a menu and the Mode key QB to step through a menu The Communications Menu appears only on units equipped with the data communications option 99_ _ R or99_ __ S You will not see every prompt in any of these menus The unit s configura tion and model number determine which prompts appear After stepping through each menu the Series 998 returns to the Setup Menu prompt Use the Up arrow or Down arrow key to select the next menu or use the Mode key to advance through the same menu again To move backwards through the menu hold the Mode key down and press the Up arrow key Use the Up arrow or Down arrow key t
7. Input 2 DIP R S B no no ie Sid lng Ing Ing Ing thermocouple Input2 DIP RTD RTD 0 19 no oo e T TA oid S arr RTD Input 2 DIP 4 20mA 0 20mA 0 5V 1 5V 0 10V dc no 4 2080 20 MEEN EET lng Ing lng lng process Setup Menus Chapter 4 NOTE These values do not affect the low or the high set point limit for process alarms Range Low 2 and Range High 2 continued on next page Setup Menus Chapter 4 Setup Input Decimal 2 Select the decimal point location for channel B data This prompt in conjunction with the Range Low and Range High prompts allows you to format and limit units of measure for channel B e All prompts with units of measure related to channel B will display in the selected decimal format e This affects propbands alarm set points process set points calibration offsets deadbands and ranges FIARE This prompt appears only if is set to a process input Default 4 my A Range Low 2 and Range High 2 Select the low and high limits for channel B These prompts limit the adjustment range for the set points The default values are the same as the limits of the sensor you selected by setting the input 2 DIP switch and selecting a value for Input 2 BEZA e Process inputs are scaled by these values Range high is the value dis played when the maximum process signal is present at the input Range low is the value displayed when the minimum process signal is present at the input E
8. PLOC Fcty Panel Diagnostics Calibration Lockout Menu Menu Menu p 6 8 p 6 14 p 6 2 f PL oc Fcty eee 1A 2A 1B 2B CHA Press Y to select one of the Factory menus WATLOW Series 998 User s Manual 6 1 Factory Panel Lockout Reaching the Panel Lockout Menu rrr FetY e o o o 1A 2A 1B 2B CHA cHBe DISPLAY MAN 6 Select the Panel Lockout Menu HHA then press QB to step through the prompts H Press Y or GJ to select one of the prompt values Figure 6 2 The Panel Lockout Menu 6 2 WATLOW Series 998 User s Manual gt A gp GE o EF h cp ETO C cp GEE C cp GHEE HEC cp HIA C cp HA tE cp MA C o muna C cp EEE 4 fC m A Panel Lockout Menu Factory Menu Prompt Enter your settings __ from the controller s Boe upper display Front Panel Lockout System Menu Lockout PID A Menu Lockout PID B Menu Lockout Input Menu Lockout Output Menu Lockout Global Menu Lockout Communications Menu Lockout Diagnostics Menu Lockout Calibration Menu Lockout Prompt may not appear depending on controller configuration Factory Menus Chapter 6 AN CAUTION Setting to or disables the Auto Man key and will force the controller into man ual mode if an open sensor occurs Verify that the con troller is operating in the desired mode aut
9. Published by the Instrument Society of America ISA Member 48 00 list 60 00 approx phone 919 549 8411 Perform this procedure on both channels PID sets they are functionally identical The parameters within the procedure apply to both output 1A 2A 1b and 2b and PID A and PID B 1 Apply power to the Series 998 and enter a set point Begin with these PID parameters set to I or set to BHHNH or set to ita set to EY set to Sa HHA set to MFA 2 Proportional Band Adjustment Gradually increase until the upper display process value stabilizes at a constant value The process value will not be right on set point because the initial reset value is 0 00 repeats per minute If SZ is set to Hg then or Tuning Alarms and Error Codes Chapter 7 Auto Manual Operation and or are inoperative and the 998 functions as a sim ple on off control The hysterisis prompt determines the switching differential value 3 Reset Integral Adjustment Gradually increase or decrease until the upper display process value begins to oscillate or hunt Then slowly decrease or increase until the upper display stabilizes again near set point 4 Cycle Time Adjustment Set as required Faster cycle times sometimes achieve the best system control See Chapter 8 Burst Firing for more information However if a mechanical contactor or sole noid is switching power to the load a longer cycle time may be desirable to minim
10. The transmitter acts as a vari able resistor with respect to its input signal Transmitters are desirable when long lead or extension wires pro duce unacceptable signal degradation zero cross Action that provides output switching only at or near the zero voltage crossing points of the ac sine wave See burst fire zero switching See zero cross A 4 WATLOW Series 998 User s Manual Appendix 998 Index out LED 3 1 0 20MA or 4 20MA process 2 8 2 9 2 10 2 11 0 5V 1 5V 0 10V dc process 2 8 2 9 2 10 2 11 1A 2A 1B 2B indicator lights 3 1 A ac outputs 2 10 2 11 2 12 2 13 address of controller 4 40 alarm 3 4 24 alarm 3 high 5 5 alarm 3 low 5 5 alarm 4 4 27 alarm 4 high 5 6 alarm 4 low 5 6 alarm jumper 7 4 7 5 alarms 7 4 7 5 alarm silencing 7 5 altitude compensation 4 14 ambient temperature 6 9 analog output 4 29 annunciator 4 35 auto man key 3 1 auto manual operation 7 3 automatic operation 7 3 7 4 auto tune 5 7 auto tune set point 4 35 auto tuning 7 1 baud rate 4 39 burst fired zero cross output 8 1 C calibration menu 6 6 6 14 6 15 calibration offset 1 4 8 calibration offset 2 4 13 calibration offset adjustment 7 3 celsius fahrenheit 4 33 channel A indicator light 3 1 channel A input wiring 2 8 Channel A PID Menu 5 8 channel A process and set point 3 2 channel A output wiring 2 10 channel B input wiring 2 9 Channel B PID Menu 5 13 channel B process and s
11. and compensates to minimize overshoot and undershoot Derivative control is an instantaneous change of the control output in the same direction as the proportional error This is caused by a change in the process variable PV that decreases over the time of the derivative TD The TD is in units of seconds Deutsche Industrial Norm DIN A set of technical scientific and dimensional standards developed in Germany Many DIN standards have worldwide recogni tion DIN See Deutsche Industrial Norm droop In proportional controllers the difference between set point and actual value after the system sta bilizes A 2 WATLOW Series 998 User s Manual duty cycle The percentage of a cycle time in which the output is on external transmitter power supply A dc voltage source that powers external devices filter digital DF A filter that slows the response of a system when inputs change unre alistically or too fast Equivalent to a standard resistor capacitor RC filter form A A single pole single throw relay that uses only the normally open NO and common contacts These contacts close when the relay coil is energized They open when power is removed from the coil form B A single pole single throw relay that uses only the normally closed NC and com mon contacts These contacts open when the relay coil is energized They close when power is removed from the coil form C A single p
12. gt GREE PID A Menu C3 EFEM Pip B Menu pa Operation Menus lax Operation Menus Operation Menus CD Event Input 1 Status Output 1 Proportional Band A ENE Output 1 Proportional Band B Output 3 Status ED Output 1 Reset A mone Output 1 Reset B Ly Output 4 Status Output 1 Integral A Output 1 Integral B Alarm 3 Low 4 Output 1 Rate A 17 GEE Output 1 Rate B Alarm 3 High Output 1 Derivative A Output 1 Derivative B Alarm 4 Low Output 1 Cycle Time A Output 1 Cycle Time B Alarm 4 High Output 2 Proportional Band A Output 2 Proportional Band B UJ Auto tune Output 2 Reset A Output 2 Reset B Output 2 Integral A Output 2 Integral B Output 2 Rate A Output 2 Rate B Output 2 Derivative A Output 2 Derivative B Output 2 Cycle Time A Output 2 Cycle Time B U EES Dead Band A U EEA Dead Band B pie e WATLOW Series 998 User s Manual Introduction Introduction From the Setup menus press both the Up arrow and Down arrow keys F and amp 3 for three seconds to reach the Factory menus To return to the Display Loop from any point in any menu press the Display key z Setup Menus 2 CHEA Input Menu a GAJA Output Menu C3 EETA Global Menu O A Communications Menu N Setup Menus E73 Setup Menus MoDE Input 1 cs Output 1A Decimal 1 Hysteresis 1A Range Low 1 ay Output 2A Range High 1 Hysteresis 2A mE Calibration Offset 1 Process A RTD Calibration Curve 1 Output 1B Sa Input 1 Software Filter Hysteresis 1B Input 2 Output 2B Deci
13. 4 7 Setup Input r E l Default Default Default Default L L L L cH Range Low 1 and Range High 1 HEA EHTA EN EAN 99_ 2_ only continued from wou previous page EEA EEN E T NOTE EEEL FEEEE DHEE FERE These values do not EEEE CEEE units affect the low or the 0 20 EEEE BEEE units high set point limit for process alarms xn 1 ra units v in units a S units Calibration Offset 1 Offset the channel A signal by a positive or negative value This allows you to compensate for lead resistance sensor errors or other factors W This prompt always appears If Default Global Menu amp i GEE Global Menu Input Menu Global Menu amp i Global Menu Input Menu a process input is selected 4 8 WATLOW Series 998 User s Manual Setup Menus Chapter 4 Setup Input to RTD Calibration Curve 1 reco Select the calibration curve for the channel A RTD The RTD input uses either the European DIN 0 0038500 Q C or the Japanese JIS 0 003916Q Q C linearization standard This prompt appears only if you have set to or ride Default L Ld in J 1S Software Filter 1 Fer i Select the filter time constant in seconds for channel A This smooths a rapidly changing input signal for display or control purposes e Select a positive value to filter only the display e Select a negative value to filter the input signal e Set the value to SEF to di
14. A Gul MEEE Output 3 Module Output 4 Module Test Displays lb OG S Introduction co A T3 Restore Factory Values U 3A Default Prompts bute bute WATLOW Series 998 User s Manual i iv WATLOW Series 998 User s Manual Introduction Chapter 1 Hardware Setup DIP Switch Locations and Functions The Watlow Series 998 has at least one and as many as six dual in line package DIP switches inside the controller depending on the model number They allow users to configure the controller for a variety of input sensors to provide power for external signal conditioners or to lockout front panel access to some functions To set any DIP switch e Remove the controller from the case by pressing firmly on the two release tabs on one side or the top of the bezel until they unsnap Then firmly press the two release tabs on the opposite side or the bottom of the control until they unsnap You will need to gently rock the bezel back and forth to release it from the chassis e Use the illustrations on the following pages to locate and set each DIP switch Release Tabs Figure 1 1 Press the release tabs to remove the con troller chassis Hardware Setup Chapter 1 WATLOW 998 PROCESS 58888 E E E 1A 2A 1B 2B oe DISPLAY CHB cy AUTO SERIES 998 Release Tabs _ Release Tabs WATLOW D PROCESS ae Gl
15. Dual Solid state Relay without Contact Suppression 0 5 Amps Off state impedance 31MQ 99 K Figure 2 116 Dual Switched DC 99 C _ i 1B ah _ pee E Bend Load 28 1500 Q 16 1500 2 A E Internal Circuitry Figure 2 11 0 20mA and 4 20mA Process HT E 0 Load impedance 8002 max 99 E oz r Ey g J Pee Ee Figure 2 11d 0 5V 1 5V and 0 10V dc Process Load impedance 500Q min 99 E WATLOW Series 998 User s Manual 2 11 Output 3 Wiring Figure 2 12a AC Outputs e Solid state Relay without e Solid state Relay with O aa Tar Suppression Off state impedance 31MQ 5 Amps 99 y K Off state impedance 20KQ min 99 B e Electromechanical Relay without A ae Contact Suppression L2 fo o e Form A or B 5 Amps H a Off state impedance 31MQ 99 J Form A or B ia tyes woes Alarm J Setti i ale aa ettings a Figure 2 120 Switched DC Minimum load resistance 500Q 99 C Figure 2 12c Process Retransmit 0 20mA 4 20mA 2 Load impedance 6009 max m H 99 M 0 5V 1 5V or 0 10V dc NOTE Load impedance 5009 min a Input to output iso lation is defeated 99 J N when the external transmitter power Figure 2 124 External Transmitter Power Supply supply
16. EN 50081 2 1994 EMC Rahmennorm f r Emissionen Teil 2 Industrielle Umwelt EN 55011 1991 Beschr nkungen und Methoden der Messung von Funkst rungsmerkmalen industrieller wissenschaftlicher und medizinischer Hochfrequenzger te Gruppe 1 Klasse A EN 61000 3 2 1995 Grenzen der Oberwellenstromemissionen EN 61000 3 3 1995 Grenzen der Spannungsschwankungen und Flimmern 72 23 EEC Niederspannungsrichtlinie zu entsprechen EN 61010 1 1993 Sicherheitsrichtlinien f r Elektroger te zur Messung zur Steuerung und im Labor Teil 1 Allgemeine Richtlinien Declara que el producto siguiente Espa ol Designaci n Series 996 997 998 999 N meros de modelo 9 9 6 7 8 9 Cualquier letra 1 2 1 2 CE F o K C EFoK ABCUKMNoT ABCDEKR S o T Cualquier combinaci n de dos letras Control categoria de instalaci n Il grado de contaminaci n ambiental II 100 a 240 V o 24a 28V 50 60 Hz Clasificaci n Tensi n nominal Frecuencia nominal Consumo nominal de energ a 16 VA m ximo Cumple con los requisitos esenciales de las siguientes directivas de la Uni n Europea usando las secciones pertinentes de las reglas normalizadas y los documentos relacionados que se muestran 89 336 EEC Directiva de compatibilidad electromagn tica EN 50082 2 1995 Norma de inmunidad gen rica del EMC parte 2 Ambiente industrial EN 61000 4 2 1995 Descarga electrost tica EN 61000 4 4 1995 Perturbaciones transitorias el
17. Restore O CD Was Default Factory Menus Chapter 6 a Factory Menus Chapter 6 Factory Calibration Restore Restores the original factory calibration values This is a simple way to recover if you make a mistake calibrating the controller This prompt always appears Default L er E Default Set the operating parameter defaults to U S or international mea sures U S sets the controller to F rate in minutes proportional band in degrees or units and reset in repeats per minute international sets the controller to C derivative in minutes proportional band in percent of span and integral in minutes per repeat This prompt always appears Default L WATLOW Series 998 User s Manual 6 15 6 16 WATLOW Series 998 User s Manual Factory Menus Chapter 6 Chapter 7 Tuning Manual Operation Alarms and Error Codes Auto tuning Heat and or Cool The Series 998 can automatically tune the PID parameters for both channel A and channel B to fit the characteristics of your particular sys tem Only one channel s PID set can be auto tuned at a time Before beginning the auto tune sequence make sure the parame ter located in the Global Menu is at the proper setting This allows the user to select the tuning set point as a percentage of the current control set point See Chapter 4 for more information on this parameter The fig ure below uses the 90 default setting to define the auto tun
18. The manual is organized in setup order with chapters on wiring menus operation and applications If you under stand the concept of process temperature controls and feel comfortable skipping around through the manual use the black tabs at the top of each page to quickly scan the pages and find the topic needed The Menu Overview on the next page is a great place to start Also refer to Chapter 3 for information on the keys and displays The menu map is an overview of all menus and prompts and how to navi gate between them There are three main menu sets Setup menus W733 Operation menus HAJA and Factory menus A3 You can return to the Display Loop from anywhere by pressing the Display key DIP switch locations and settings are explained later in Chapter 1 WATLOW Series 998 User s Manual i Introduction Display Loop DISPLAY Channel A Channel B Channel A Ta Process Process Process OD a D an OD Channel A Channel B Channel B Process Set Point Set Point Process Units From the Display Loop press the Mode key 3 to reach the Operation menus To return to the Display Loop from any point in any menu press the Display key 39 From the Display Loop press both the Up arrow and Down arrow keys r and 3 for three seconds to reach the Setup menus Hold them down for another three seconds to reach the Factory menus Operation Menus Set Point 2A Set Point 2B Gm ka GEEA E EEH system Menu 3
19. altitude above sea level This prompt appears only if is set to SWE Default 4 a 2500 EFH fect 8 User s Manual Setup Menus Chapter 4 Setup Menus Chapter 4 WATLOW Series 998 User s Manual 4 15 gt Output Menu Setup Output A ww Setup Menus Enter your settings from the controller s neac nng the Output I upper display cp H Output 1A page 4 17 Begin in the Display Loop L and press the Up arrow Y and co EEJ Hysteresis 1A Down arrow 2 keys simulta neously for three seconds to reach the Setup Menus l go HEE Output 2A page 4 19 L mone PEHI Hysteresis 2A O O O 2 ye ey Cy ei SL bL MHAR cD Process A Input Output Global Communications l Menu Menu Menu Menu p 4 2 p 4 16 p 4 32 p 4 38 Cc MARA Output 1B k GS Press the Up arrow key 7Y to GREE Hysteresis 1B select one of the Setup Menus Sa a CD MAEA Output 2B Press the Mode key J to J step through the output co GEE Hysteresis 2B prompts l gt min Process B A co Output 4 page 4 27 l Cc Alarm 4 Cc Output 3 L cp GREE Hysteresis 4 ra 99 aaa i m y Mi a i ee cep MEE Latching 4 En Gs GS Gee ALG co EFFE Hysteresis 3 2 ray l fuone GAE Silencing 4 Press the Up arrow key 7Y or mone Latching 3 the Down arrow key GJ to J AE select one of the prompt values cp B Silencing3 gt Analog Output page 4 29 CD Process 3 CD HA Retransmit Low Limit Prom
20. appears with information that is important for protecting your equipment and performance Be especially careful to read and follow all cautions that apply to your application A bold text WARNING safety alert appears with information that is important for protecting you others and equipment from damage Pay very close attention to all warnings that apply to your application The safety alert symbol an exclamation point in a triangle precedes a general CAUTION or WARNING statement Technical Assistance If you encounter a problem with your Watlow controller review all of your configuration information for each step of the setup to verify that your selections are consistent with your applications If the problem persists an Application Engineer can discuss your applica tion with you Before calling please have the complete model number and user s manu al available You can get technical support by dialing 507 494 5656 7 a m to 7 p m Central Standard Time Your Feedback Your comments or suggestions on this manual are welcome please send them to Technical Writer Watlow Controls P O Box 5580 Winona MN 55987 5580 Phone 507 454 5300 Fax 507 452 4507 The Series 998 User s Manual is copyrighted by Watlow Winona Inc February 2000 with all rights reserved 1832 Table of Contents Introduction Starting Out with the Watlow Series 998 i The Series 998 ii Display Loop ii Operation Menus ii
21. equal to or in the Input Menu depending on whether is set to or EHAA This prompt appears only on controllers equipped with retransmit hardware 99__ M__ or 99__ N__ and with not set to er d Ra 4 30 WATLOW Series 998 User s Manual Setup Menus Chapter 4 Setup Menus Chapter 4 Setup Output Retransmit High Limit Select the high limit for the retransmit signal at output 3 e The default value is equal to or BEEFY in the Input Menu depending on whether is set to or GF This prompt appears only on controllers equipped with retransmit hardware 99__ M__ or 99__ N__ and with not set to ET Retransmit Calibration Offset Select an offset value for the retransmit signal at output 3 GIRI This prompt appears only on controllers equipped with retransmit hardware 99__ M_ or99_ N__ and with not set to nod If Default C_F Global Menu C_F Global Menu a process input ACAL is selected WATLOW Series 998 User s Manual 4 31 Setup Global Reaching the Global Menu gt EAA Global Menu A ww Setup Menus ___ Enter your settings ee T from the controller s Begin in the Display Loop and gt ae upper display press the Up arrow 9 and Down Celsius Fahrenheit page 4 33 arrow 2 keys simultaneously for three seconds to reach the Setup menus Failure Mode EZA Error Latchin E cs a oa ae y y i DEPE gl bL corn vl Event Input 1 Input Outpu
22. input LEPE REFE is selected WATLOW Series 998 User s Manual 4 25 Setup Output OLI Latching 3 LHES Select whether alarm 3 will be latching or non latching A latching alarm must be turned off manually A non latching alarm turns off when an alarm condition no longer exists NOTE MEE This prompt appears only on controllers equipped with output 3 See ohne 7 for hardware 99_ B_ or99_ C_ or99_ K__or99 _ E J__ and with Output Menu set to or HEF Default L LAE LAE 5 IL 3 Silencing 3 Select silencing to inhibit alarm 3 on startup and to allow the opera tor to reset the alarm output not the visual display e Silencing disables the alarm until the signal is between EN and AGH If ETRE This prompt appears only on controllers equipped with output 3 hardware not 99__ A__ and with Output Menu set to or GEES Default L nr 4 26 WATLOW Series 998 User s Manual Setup Menus Chapter 4 Setup Output L L Output 4 Set the alarm type for output 4 de energizes output 4 in an alarm condition energizes output 4 in an alarm condition This prompt appears only on controllers equipped with output 4 hardware for a relay 99__ B_ org9_ D_ or 99_ E or 99_ _K_ or switched dc 99_ C_ Default AL Un rr Alarm 4 Select the alarm channel and type for alarm 4 This prompt appears only on controllers equipped with output 4 hardware for a relay 99__ B_ or99_
23. one minute the display returns to displaying the channel A process and set point Display Loop Channel A Channel B Channel A Process Process Process 1 1 Channel A Channel B Channel B Process Set Point Set Point Process Units Display Loop Parameters Channel A Process and Set Point The channel A process value is shown in the upper display The set point is shown in the lower display it sets the operating set point for the channel A control outputs If channel A is in manual mode the set point is in percent output Range to in auto mode to Hy in manual mode heat cool GT to BH in manual mode heat only to GFA in manual mode cool only Default depends on input 1 range and type Channel B Process and Set Point The channel B process value is shown in the upper display The set point is shown in the lower display it sets the operating set point for the channel B control outputs If channel B is in manual mode the set point is in percent output Range to in auto mode to GH in manual mode heat cool GT to MH in manual mode heat only to FA in manual mode cool only Default depends on input 2 range and type Process A and Process B The channel A process value is displayed in the upper display with channel B process value displayed in the lower display Range depends on input types Default none Units Shows the units associated with the temperature value This para meter shows what the
24. only or full lockout EM This prompt always appears Default L FULL PID A Menu Lockout Select the lockout level for the PID A Menu Set the lockout to no lock out BREF read only or full lockout HNB This prompt always appears Default 4 P dA P dA P dA PID B Menu Lockout Select the lockout level for the PID B Menu Set the lockout to no lock out SREY read only or full lockout FA This prompt always appears Default 4 GET GET nN cE ic ic WATLOW Series 998 User s Manual Factory Menus Chapter 6 Factory Panel Lockout Input Menu Lockout Select the lockout level for the Input Menu Set the lockout to no lock out BREF read only or full lockout HMA This prompt always appears Default L FULL HH L p L Output Menu Lockout Select the lockout level for the Output Menu Set the lockout to no lockout PPPA read only or full lockout FM MAZA This prompt always appears Default l FULL o Global Menu Lockout GL bL Select the lockout level for the Global Menu Set the lockout to no lock out BREF read only or full lockout GM EJAY This prompt always appears Default l FULL Factory Menus Chapter 6 WATLOW Series 998 User s Manual 6 5 Factory Panel Lockout E gr n Communications Menu Lockout Q Select the lockout level for the Communications Menu Set the lock out to no lockout PPA read only or full lockout NA MH This prompt appears only if the controller is equipp
25. output 1B or 2B 5 16 reset integral adjustment 7 3 reset output 1A or 2A 5 10 reset output 1B or 2B 5 15 restore 6 15 retransmit 8 2 retransmit calibration offset 4 31 retransmit high limit 4 31 retransmit low limit 4 30 returns A 1 Rotronic humidity sensor 4 4 RTD 2 or 3 wire 2 8 2 9 RTD calibration curve 1 4 9 RTD calibration curve 2 4 13 RTD input 2 4 S safety information inside front cover sensor installation guidelines 2 4 serial number 6 9 set point 2A 5 3 set point 2B 5 3 Setup Menus iii 4 1 4 40 shipping claims A 1 silencing alarms 3 4 26 silencing alarms 4 4 29 specifications A 8 software filter 1 4 9 software filter 2 4 14 software revision 6 9 switched dc 2 12 2 13 System Menu 5 2 5 7 system menu lockout 6 4 T technical assistance inside front cover temperature relative humidity oper ation 4 3 temperature temperature operation 4 4 test displays 6 12 test outputs 6 12 thermocouple 2 8 2 9 thermocouple input 2 4 transmitter power supply 8 3 tuning 7 2 U units parameter 3 2 universal signal input switches 1 6 Up arrow key 3 1 upper display 3 1 V Vaisala humidity sensor 4 3 W warranty A 1 Watlow Controls A 1 wet bulb dry bulb 4 3 wiring 2 4 2 13 wiring example 2 6 wiring notes 2 7 A 6 WATLOW Series 998 User s Manual Appendix Prompt Index A alarm 3 high 5 5 alarm 3 low 5 5 alarm 4 high 5 6 alarm 4 low 5 6 retransmit calibration offse
26. signs of external damage it may have sustained enroute If there is apparent damage either outside the box or to its contents make a claim with the shipper immediately Save the original shipping carton and packing material WATLOW Series 998 User s Manual A 1 Glossary A J annunciator A visual display that uses pilot lights to indicate the former or existing condition of several items in a system burst fire A power control method that repeatedly turns on and off full ac cycles Also called zero cross fire it switches close to the zero voltage point of the ac sine wave Variable time base burst fire selectively holds or transits ac cycles to achieve the desired power level See zero cross calibration offset An adjustment to eliminate the dif ference between the indicated value and the actual process value closed loop A control system that uses a sensor to measure a process variable and makes decisions based on that feedback cold junction see junction cold cold junction compensation Electronic means to compensate for the effective temperature at the cold junction default parameters The programmed instructions that are permanently stored in the microprocessor soft ware derivative The rate of change in a process variable Also known as rate See PID derivative control D The last term in the PID con trol algorithm Action that anticipates the rate of change of the process
27. the 998 features unique to Watlow controls Some of this material is advanced and requires previous background or experience What we will cover in this chapter Standard Features e Burst fired zero cross output e Dead Band e Retransmit e Transmitter Power Supply Burst Fired Zero Cross Output The Series 998 can provide a variable time base zero cross output with superior controllability compared to a fixed time base time proportioning control This eliminates the need for additional hardware associated with power control devices When either output 1A or 1B is ordered as a switched dc option C or a solid state relay option K the 998 can operate as a burst fired control via the cycle time prompt s Here s an example The Series 998 is used to control a heated platen in a semiconductor oven In the past a control with a 4 20mA output was required to be used with a power control having burst fire control circuitry This result ed in additional system cost Now the power control is replaced with a Watlow QPAC with a QCD card or a Watlow dc input SSR This accepts a signal directly from an open collector output on the 998 providing smoother control at a lower overall system cost To achieve this set fj PID A Menu to RERA This sets the output 1 PID set A cycle time to burst fire Analog Input 1 WATLOW mN Control Output 1A x 9 g 8 Option C PROCESS y m DC Input SSR
28. the code number with the information below Model N um ber Series 998 99 D _ __ Power Supply amp Mounting L 6 24 to 28V ac dc nominal vertical mounting 7 24 to 28V ac dc nominal horizontal mounting 8 100 to 240VX ac dc nominal vertical mounting 9 100 to 240V ac dc nominal horizontal mounting Software D _ Dual channel hardware Channel A Input 1 Basic thermocouple signal conditioner excluding Type B R and S 2 Universal signal conditioner see range information Channel B Input 1 Basic thermocouple signal conditioner excluding Type B R and S 2 Universal signal conditioner see range information Channel A Output C Dualswitched de isolated E _ Dualelectromechanical relay Form A 2A without contact suppression F Single universal process 0 5V dc 1 5V dc 0 10V dc 0 20mA dc 4 20mA dc isolated K Dual solid state relay Form A 0 5A without contact suppression Channel B Output C Dualswitched de isolated E Dualelectromechanical relay Form A 2A without contact suppression F Single universal process 0 5V dc 1 5V dc 0 10V dc 0 20mA dc 4 20mA dc isolated K Dual solid state relay Form A 0 5A without contact suppression Output 3 A None B Solid state relay Form A 0 5A with RC suppression C Switched de isolated J Electromechanical relay Form A or B 5A
29. the output is a process output or GIET is not set higher than SEn If Default L L mechanical Ey min relay outputs open collector PET min or solid state CE E relay outputs d b b Dead Band B Select the width of the zone between the action of the channel B heating output and cooling output If you select a positive value the heat and cool outputs cannot be energized at the same time If you select a neg ative value both outputs can be energized at the same time e If a process input is selected the decimal precision will be determined by the RJJ setting Input Menu This prompt appears only if JIA and EFAA are set higher than QA and one channel B output performs heating action and the other performs cooling action If Default L Jb b Jb b Jb b Global Menu db b db b Jb b Global Menu a process E units input is selected EEA EmA odb b Operation Menus Chapter 5 WATLOW Series 998 User s Manual 5 17 5 18 WATLOW Series 998 User s Manual Operation Menus Chapter 5 Chapter 6 The Factory Menus NOTE The Factory Menus will not appear if the hardware lockout DIP is set to on See Chapter 1 for more information NOTE The Factory Menus can only be entered when the Setup prompt is displayed NOTE Press the Display key to return to the Display Loop from any point in any menu Figure 6 1 Navigating the Factory Menus Factory Menus Chapter 6 Navigating th
30. tioner power supply Lockout DIP lt Output 4 Option Board and Dip Control Chassis Top View 996 amp 998 Left side View 997 amp 999 Output 3 99 T 99 T_ 3zO ai AL 20V 5 30mA m n m n 12V 5 30mMA LA n ca LA n 5V 5 30mA 3 When the DIP switches are set gently insert the controller chassis into the case and push it firmly into place until all four tabs snap into place WATLOW Series 998 User s Manual 1 3 DIP Switches A CAUTION The lockout DIP switch makes the Setup and Factory menus unavailable Configure all the Setup and Factory menus before lock ing them out Failure to do so could result in dam age to equipment in the event of a setup error Figure 1 4 Lockout DIP switch 4 The lockout DIP switch hides the Setup Menus Input Output Global and Communications and the Factory Menus Panel Lockout Diagnostics and Calibration All units have a lockout DIP switch Lockout DIP All controllers leave the o j factory with both switches set to off Control Chassis Top View 996 amp 998 Left side View 997 amp 999 no hardware lockout Switch 1 has no effect or AL LA LA lockout Setup and Factory menus Switch 1 has no effect or Input Output Global Commu nications Uva EVA EWA UA ZA CAN WAN TA Panel a Lockout Diagnostics C
31. to limit errors Using grounded thermocouples for both input 1 and input 2 may create ground loop problems To correct this problem replace at least one of the grounded thermocouples with an ungrounded thermocouple If the appli cation requires grounded thermocouples use an isolated transmitter such as a Watlow Gordon 5702 isolated transmitter RTD input Each 1Q of lead wire resistance can cause a 2 F error when using a two wire RTD A three wire RTD sensor overcomes this problem All three wires must have the same electrical resistance i e same gauge same length multi stranded or solid same metal Maintain isolation between input 1 and input 2 to prevent a ground loop A ground loop may cause incorrect readings dashes across the upper display or the display of error codes Process input Isolation must be maintained between input 1 and input 2 If both input 1 and input 2 are used as process inputs a separate power supply and transmitter must be used for each input Output option T external signal conditioner power supply can be used to supply power for only one input Installation and Wiring Chapter 2 Figure 2 5 Process wiring example Event Input 1 Standard on all units i 14 36V dc Event Input 1 off open pope NA 0 3V dc Event Input 1 on closed ie oan eR TF asc a 24V d 7502 vi ii E 10KQ 4 99KQ ool SEA ia 23 nternal Circuitry db Wiring 0 20 an
32. value will not take effect until after a five second delay or until you press the Mode key Proportional Band Output 1B or 2B Select the proportional band for PID channel A outputs If set to HHE it functions as an on off control and the switching differential is determined by the REMIJA or FEE value Output Menu The decimal precision is determined by yagi Input Menu EEE This prompt always appears Calibration Menu Global the above amp 0 nu a E In a5 Calibration Menu Input Menu ER of span If Default L Pb ib Pb lb Calibration Menu Global Menu amp E a EEE Pb ib Pb lb Calibration Menu Global Menu the above a E A EEEE Pb lb Pb lb Calibration Menu Input Menu amp E GE a Pb ib Pb lb Pb ib Pb lb Pb lb Pb lb ai JFL Calibration Menu D S io 5 14 WATLOW Series 998 User s Manual Operation Menus Chapter 5 Operation PID B Reset Output 1B or 2B nm o Adjust the control action to eliminate the offset or droop between the set point and the actual process temperature for PID channel B out puts When set to SEA reset is disabled a M CoC This prompt appears only if Calibration Menu is set to and GJM is not set to BEE Default AAHH EEEE repeats min ie Ib Integral Output 1B or 2B Adjust the control action to eliminate the offset or droop between the H fa Pad b set point and the actual
33. values Figure 5 13 The PID B Menu Operation Menus Chapter 5 A gt cS i 68 8 8 80 6 S B8 9 8 B B B Operation PID B HEFTA Channel B PID Menu Operation Menus Enter your settings from the controller s upper display GENIA Proportional Band Output 1B page 5 14 Reset Output 1B ER Integral Output 1B Rate Output 1B FIJA Derivative Output 1B ET Cycle Time Output 1B GEEIA Proportional Band Output 2B page 5 14 Reset Output 2B PEI Integral Output 2B Rate Output 2B Prompts may not appear depending on controller configuration PTH Derivative Output 2B MEA Cycle Time Output 2B TENET ELEJA Dead Band B WATLOW Series 998 User s Manual 5 13 Operation PID B NOTE Decimal points may not always be in the position specified below depending on the the settings in the Decimal 1 parameter in the Input Menu a Ro mp ag IO Creo PID B Prompts After you step past the Set Point 2A prompt JA and the Set Point 2B prompt A to the Operation menus the Series 998 displays the menu selection ERE or in the upper display and HAJA in the lower display The Up arrow Y or Down arrow key J selects another menu Press the Mode key B to display the first prompt in the lower display and its value in the upper display Use the Up arrow and Down arrow keys to change the value in the upper display The new
34. when power is removed Using Alarms Output 3 and or 4 of the Series 998 can be selected as alarms This is accomplished in the Output Menu under the or B prompt If or is selected the output is energized in the non alarm condition and de energizes the output in the alarm condition Selecting or reverses this action the output is then de energized in the non alarm condition and energized in an alarm condition 7 4 WATLOW Series 998 User s Manual Tuning Alarms and Error Codes Chapter 7 NOTE An alarm display will be masked by an error condition or when the con trol is in the Calibration or Setup menus Alarms A flashing lower display indicates an alarm state Note If the parameter in the Global Menu is set to the lower display will not flash and there will be no indication of an alarm state on the front panel Once you ve configured the outputs as alarms enter the Output Menu again and select the and or prompt respectively These prompts select the type of alarm process or deviation Each may be inde pendently set low and high Choose between process input 1 MZAA process input 2 J deviation input 1 or deviation input 2 i Example can reference the channel A input 1 process value against the EJNN and QEPEN settings or can reference the input 2 process value against the JERI and GEER settings A process alarm sets an absolute temperature When the process exceeds that absolute temperature limit an alarm o
35. with suppression D relay A B J process output F voltage retransmit N current retransmit M power supply T EIA TIA 232 communications R EIA TIA 485 or EIA TIA 422 communications S MED HZA GUE UE These prompts always appear Factory Menus Chapter 6 WATLOW Series 998 User s Manual 6 11 Factory Diagnostics 6 12 Test Displays Runs a brief test of the controller s displays and LEDs To run the test scroll through the Diagnostics Menu until is shown in the lower display Use the Up arrow key 79 or Down arrow key to select from the upper display and press the mode key B The controller will run pattern tests blink all the LEDs on and off and end with the model number in both displays This prompt always appears Default 4 Test Outputs This prompt tests each output To run the test scroll through the Diagnostics Menu until is shown in the lower display Use the Up arrow key 79 or Down arrow key to select an output PAD HMA ERLE or WHA The LED for that output should light after a second or two indicating that the output has been successfully energized Do not press the mode key Q to activate the test it starts automatically when anything other than is selected If any of the LEDs fail to light contact the factory This prompt always appears Default tout tout tout tout tout WATLOW Series 998 User s Manual Factory Menus Chapter 6 Factory Menus C
36. without contact suppression K Solid state relay Form A 0 5A without contact suppression M Retransmit 0 20mA dc 4 20mA dc N Retransmit 0 5V dc 1 5V dc 0 10V dc T External signal conditioner power supply 5 12 or 20V dc 30mA Output 4 A None B Solid state relay Form A 0 5A with RC suppression C Switched dc or open collector isolated D _ Electromechanical relay Form C 5A with RC suppression E Electromechanical relay Form C 5A without contact suppression K Solid state relay Form A 0 5A without contact suppression R EIA TIA 232 communications opto isolated S EIA TIA 485 EIA TIA 422 communications opto isolated U EIA TIA 232 EIA TIA 485 communications opto isolated T External signal conditioner power supply 5 12 or 20V dc 30mA Display Color Upper Lower GG Green Green GR Green Red RG Red Green RR Red Red XX Custom overlays parameters or software NOTE User documentation may be available in French German Spanish Italian and Dutch as well as English Check Watlow s website www watlow com for availability Specify language at time of order Electromechanical relays warranted for 100 000 closures only Solid state switching devices recommended for applications requiring fast cycle times or extended service life 2 Not an ANSI symbol UL is a registered trademark of the Underwriters Laboratories Inc Slo Blo is a reg
37. 2 Software Filter Miers Input 2 Linearization 0 6 8 8 8 6 6 6 6 T Altitude Prompts may not appear depending on controller configuration Setup Menus Chapter 4 NOTE See Input 2 Linearization in this chap ter Setup Menus Chapter 4 Setup Input Temperature and Relative Humidity When the controller will be used to measure temperature and relative humidity channel A is designated as the temperature channel and chan nel B is the humidity channel Any sensor type may be used for either channel A or B This includes thermocouples RTDs or process inputs that have been properly scaled to represent a temperature Below are the three methods for measuring relative humidity with the Series 998 Wet Bulb Dry Bulb In this configuration a dry bulb connected to input 1 measures temperature on channel A A wet bulb input on input 2 in com bination with the dry bulb temperature senses relative humidity on chan nel B The Series 998 calculates the temperature difference between the two bulbs to determine percent relative humidity With a wet bulb dry bulb configuration the Input 2 Linearization prompt must be set to MAE The humidify and dehumidify outputs outputs 1B and 2B are disabled when the channel A temperature falls below 32 F 0 C or goes above 212 F 100 C The relative humidity process display in the Display Loop will display the error code for a low temperature error and if the temperature i
38. 98 Failure to do so could result in such dam age Limit Sensor 2 6 WATLOW Series 998 User s Manual Installation and Wiring Chapter 2 Wiring Notes L1 L2 earth ground WARNING To avoid damage to property and equip ment and or injury or loss of life use National Electric Code NEC stan dard wiring prac tices to install and operate the Series 998 Failure to do so could result in such damage and or injury or death NOTE Sketch in your application on this page or a copy of it See wiring exam ples in this chapter and in the Appen dix Figure 2 7 Wiring notes Installation and Wiring Chapter 2 WATLOW Series 998 User s Manual 2 7 Channel A Input Wiring NOTE Using a grounded thermocouple for both input 1 and input 2 can cause ground loop prob lems NOTE Model number 99 ft en has no input 1 DIP switch A CAUTION An external resistor is required for 0 20mA and 4 20mA process wiring to prevent a high in rush current which could burn out the controllers 7 ohm resistor See page 2 4 for recommen dations 2 8 WATLOW Series 998 User s Manual Figure 2 8a Thermocouple 1 3 Bee J K T N C E Pt2 D Dip Switch Setting zo Thermocouple only 99 1 Universal signal conditioner 99 2 Poe R S B Dip Switch Setting Figure 2 86 RTD 2 or 3 wire Universal signal conditioner 99 2 Dip Switch
39. B will respond to a difference between the set point and an input variable select reverse action so that output 2B responds when the input signal is less than the set point select direct action so that output 2B responds when the input signal is more than the set point MEFA This prompt appears only if channel B output is something other than a process output 99_ __F Default 4 Hysteresis 2B Select the switching hysteresis for output 2B This determines the change in temperature or process units needed to turn the output from full off to full on EEEIR This prompt does not appear if output 2 is a process output If Default 1 Global Menu amp MIY e EEN C_F Global Menu Input Menu Global Menu amp MIY e z C_F Global Menu Input Menu a process input HY2b HY2b is selected 4 22 WATLOW Series 998 User s Manual Setup Menus Chapter 4 NOTE See Chapier 7 for more information on alarms Setup Menus Chapter 4 Setup Output Process B Select the process range for output B This prompt appears only on controllers equipped with output B process hardware 99__ ___F Default l 4 20mA 0 20mA 0 5V 1 5V 0 10V dc Peceb Preeb Preceb Preeb Output 3 Set the alarm type for output 3 to de energize output during alarm condition to energize output during alarm condition This prompt appears only on controllers equipped with output 3 hardware for a relay 99__ B__
40. Chapter 8 Applications 8 1 Burst Fired Zero Cross Output 8 2 Retransmit 8 3 Dead Band 8 3 Transmitter Power Supply Appendix A 1 Warranty and Returns A 2 Glossary A 5 Index A 7 Prompt Index A 8 Specifications A 9 Ordering Information A 10 Declaration of Conformity WATLOW Series 998 User s Manual WATLOW Series 998 User s Manual Table of Contents Introduction Starting Out With the Watlow Series 998 Figure i The Series 998 Introduction WATLOW a Channel A Control Outputs 9 9 8 Output 1A and 2A Channel A Input p Input 1 PROCESS 8888 a Channel B Control Outputs Channel B Input gt ae oS T Output 1B and 2B Input 2 cHAe a Optional Outputs 3 and 4 Event Input j MAN amp alarms retransmit or F nooe gt Pc communications SERIES 998 Watlow s Series 998 process controller is capable of two independent channels of process control Each channel can be configured and tuned separately Each alarm option outputs 3 and 4 can be used to trigger an alarm based on either channel The retransmit option available on output 3 can be used to retransmit the process or set point value of either chan nel The digital communications option can be used to configure and monitor the controller with a personal computer from a remote location If you are unfamiliar with general controller operation it s a good idea to read through the entire manual
41. DIP switches user selectable options include 5 12 or 20V dc 30mA ratings which are UL listed Applications Chapter 8 WATLOW Series 998 User s Manual 8 3 8 4 WATLOW Series 998 999 User s Manual Applications Chapter 8 Warranty The Watlow Series 998 is warranted to be free of defects in material and workmanship for 36 months after delivery to the first purchaser for use providing that the units have not been misapplied Since Watlow has no control over their use and some times misuse we cannot guarantee against failure Watlow s obligations hereunder at Watlow s option are limited to replacement repair or refund of pur chase price and parts which upon examination prove to be defective within the warranty period specified This warranty does not apply to damage resulting from transportation alteration misuse or abuse Watlow Controls Watlow Controls is a division of Watlow Electric Manufacturing Company St Louis Missouri a man ufacturer of industrial electric heating products since 1922 Watlow begins with a full set of specifications and completes an industrial product that is manufac tured totally in house in the U S A Watlow products include electric heaters sensors controls and switching devices The Winona operation has been designing solid state electronic control devices since 1962 and has earned the reputation as an excellent supplier to original equipment manufacturers These OEMs depend u
42. Default L EEEE min repeat 5 10 WATLOW Series 998 User s Manual Operation Menus Chapter 5 mn OQ np n Operation Menus Chapter 5 3 D Operation PID A Rate Output 1A or 2A Adjust the rate to eliminate overshoot on startup or after the set point changes The rate setting will not influence the percent power if the process temperature is more than twice the proportional band from the set point When set to fq rate is disabled This prompt appears only if Calibration Menu is set to and HIA is set higher than Qa Default L SGT EEEE mir Derivative Output 1A or 2A Adjust the derivative to eliminate overshoot on startup or after the set point changes The derivative setting will not influence the percent power if the process temperature is more than twice the proportional band from the set point When set to Qf derivative is disabled FHI This prompt appears only if Calibration Menu is set to and HANIA is set higher than Qa Default SGT EEE mir WATLOW Series 998 User s Manual 5 11 Operation PID A CECA If mechanical relay outputs open collector or solid state relay outputs Q ar ma Dead Band A Cycle Time Output 1A or 2A Select the time in seconds of a complete on off cycle MAR This prompt does not appear if the output is a process output or EMT is not set higher than SEEN Default Select the width of the zone between
43. E Dip Switch Setting Figure 2 9d 0 20mA or 4 20mA Process 99 _2 _ _ o Input impedance 70 Tenu S SESE Dip Switch Setting ZO ao ca a WATLOW Series 998 User s Manual 2 9 Channel A Output Wiring Figure 2 10a AC Outputs Dual Electromechanical Relays without Contact Suppression Dual Form A 2 Amps Off state impedance 31MQ 99 2 E_ e Dual Solid state Relay without Contact Suppression Dual Form A 0 5 Amps Off state impedance 31MQ 99 z K_ Figure 2 100 Dual Switched DC 99 C_ External 1A Loads L2 ro External Load 2A 12 72 External External w 1 Load 1A H Load 2A o o 500 2 i 14 Internal Circuitry Figure 2 10c 0 20mA and 4 20mA Process Load impedance 8000 max 99 F_ EHEN 1 m cs S50 J ae Figure 2 10d 0 5V 1 5V and 0 10V dc Process Load impedance 500Q min 99 Es 2 10 WATLOW Series 998 User s Manual ng Spi m wo CI ii Installation and Wiring Chapter 2 Channel B Output Wiring Figure 2 11a AC Outputs Dual Electromechanical Relay without Contact Suppression Dual Form A 2 Amps Off state impedance 31MQ 99 E Installation and Wiring Chapter 2 e
44. Output Silencing 4 Select silencing to inhibit alarm 4 on startup and to allow the opera tor to reset the alarm output not the visual display e Silencing disables the alarm until the signal is between REJA and BELE GEE This prompt appears only on controllers equipped with output 4 hardware for a relay 99__ ___ _B_ or99_ __ _D_ or99_ __ _E_or99_ _K_ or switched de 99__ ___ _C__ and with set to or GEE Default L nn Analog Output Select which value to retransmit as the output 3 signal retransmits the channel A input value retransmits the set point for channel A retransmits the channel B input value This prompt appears only if is not set to SEEYA retransmits the set point for channel B EEA turns off the retransmit function This prompt appears only on controllers equipped with output 3 retransmit hardware 99__ M or 99__ N_ Default ap Pe AMS ARP SSP bn WATLOW Series 998 User s Manual 4 29 Setup Output Process 3 Select the range for the retransmit signal at output 3 This prompt appears only on controllers equipped with output 3 eee ay retransmit hardware 99_ M__ or 99__ N__ and with ee Chapter 8 for tett i more information on not set to Ry retransmit Default a 4 20mA 0 20mA 0 5V 1 5V 0 10V dc Pre3 IRRE IE IRE Retransmit Low Limit Select the low limit for the retransmit signal at output 3 e The default value is
45. Series 998 User s Manual Er 999 _ Aono j 999 g G Dual Channel 1 8 DIN Microprocessor Based Temperature Process Controller User Levels s New USBf occasie go to Introduction C e Experienced User go to page 4 1 Expert USer ccceecccceeeeeee go to page 4 1 Installers TOTAL s SEUD situer aieia go to page 1 1 i iri CUSTOMER Installation amp Wiring go to page 2 1 SATISFACTION 3YearWarranty ISO 9001 e Ie aE SS Registered Company Winona Minnesota USA A WATLOW Watlow Controls 1241 Bundy Boulevard P O Box 5580 Winona Minnesota USA 55987 5580 Phone 507 454 5300 Fax 507 452 4507 http www watlow com 0600 0010 000 Rev G 10 00 February 2000 Made in the U S A Supersedes W998 XUMN Rev F Printed on Recycled Paper 10 Postconsumer Waste NOTE Details of a Note appear here in the narrow box on the outside of each page 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 Using the Manual Safety Information We use note caution and warning symbols throughout this book to draw your attention to important operational and safety information A bold text NOTE marks a short message in the margin to alert you to an important detail A bold text CAUTION safety alert
46. Setting Jumper 9 to 10 for 2 wire RTD all Si 8 Seg s2 o AMI ES O Figure 2 8c 0 5V 1 5V or 0 10V dc Process Universal signal conditioner 99 2 Dip Switch Setting Input impedance 10KQ S 5 lo E Figure 2 8d 0 20mA or 4 20mA Process Universal signal conditioner 99 2 Input impedance 70 Dip Switch Seiting R CS i CHO EEE Installation and Wiring Chapter 2 NOTE Using a grounded thermocouple for both input 1 and input 2 can cause ground loop prob lems NOTE Model number 99 1_ __ has no In1 DIP switch AN CAUTION An external resistor is required for 0 20mA and 4 20mA process wiring to prevent a high in rush current which could burn out the controller s 7 ohm resistor See page 2 4 for recommen dations Installation and Wiring Chapter 2 Channel B Input Wiring Figure 2 91 Thermocouple E Thermocouple only jm ce 99 _ 4 E J K T N C E Pt2 D Universal signal conditioner Dip Switch Setting mi 99 Ke 2 ot 2 3 a ioe E R S B Dip Switch Setting Figure 2 9 RTD 2 or 3 wire E 99 P Roas A Jumper EE i 19 to 20 E for 2 wire El RTD o o ee E soo N Dip Switch Setting E s2_ K a ae Figure 2 9c 0 5V 1 5V 0 10V dc Process 99 _2 Input impedance 10KQ lt ols By S
47. The amount by which a process vari able exceeds the set point before it stabilizes P control Proportioning control PD control Proportioning control with derivative rate action PDR control Proportional derivative control with manual reset used in fast responding systems where the reset causes instabilities With PDR con trol an operator can enter a manual reset value that eliminates droop in the system PI control Proportioning control with integral auto reset action PID Proportional integral derivative A control mode with three functions proportional action dampens the system response integral corrects for droop and derivative prevents overshoot and undershoot proportional Output effort proportional to the error from set point For example if the proportional band is 20 and the process is 10 below set point the heat proportioned effort is 50 percent The lower the PB value the higher the gain proportional band PB A range in which the proportioning function of the control is active Expressed in units degrees or percent of span See PID Appendix Glossary N R proportional control A control using only the P proportional value of PID control range The area between two limits in which a quantity or value is measured It is usually described in terms of lower and upper limits rate Anticipatory action that is based on the rate of temperature change a
48. This prompt appears only on controllers equipped with communi cations hardware 99__ R_or99_ S_ Default EEN ED ETO Er GEN GMA Data Bits and Parity Select the communications format start bit 1 stop bit 1 7 data bits odd parity 7 data bits even parity 8 data bits no parity FGE This prompt appears only on controllers equipped with communi cations hardware 99_ R_ or 99_ S_ Default 1 mA ES EEA JAER dAER dAER Setup Menus Chapter 4 WATLOW Series 998 User s Manual 4 39 Setup Communications ma Q Q Protocol Type Select the communications protocol NA selects ANSI X3 28 2 2 A 3 BEEFY selects XON XOFF This prompt appears only on controllers equipped with communi cations hardware 99__ R_or99_ S_ Default 4 FULL On Address Select an address for the controller The computer will use this address when communicating with this controller This prompt appears only on controllers equipped with communica tions hardware for EIA TIA 485 and EIA TIA 422 99_ S_ If Default L Int F Interface Type Select the interface type selects EIA TIA 485 selects EIA TIA 422 This prompt appears only on controllers equipped with communi cations hardware for EIA TIA 485 and EIA TIA 422 99_ S_ Default a A 4 40 WATLOW Series 998 User s Manual Setup Menus Chapter 4 Chapter 5 The Operation Menus Navigating the Operation Menu
49. alibration uva Et EYA ZA FAN ZAN 1 4 WATLOW Series 998 User s Manual Hardware Setup Chapter 1 Chapter NOTE A minimum of 1 66 42 2mm spacing between panel cutouts is recom mended Figure 2 1a Series 998 Panel Cutout Dimensions NOTE Adjustable mount ing brackets can also be side mount ed Figure 2 1b Series 998 Dimensions 2 Installation and Wiring Panel Cutout Maximum Panel Thickness 0 38 9 65mm 3 62 0 03 0 00 92mm 0 8 1 77 0 02 0 00 45mm 0 6 2 18 55mm WATLOW PROCESS 8888 WATLOW DSPY ee 398 a 102mm 1A 2A 1B 2B PROCESS T pogo e cHpe manl cy TA A 8 Pr SERIES 998 MAN Py 7 i E i SERIES 998 102mm 218 m 55mm Adjustable P Ba i Mounting Bracket a 2 P i c q n q i SE oo ah p 7 0 68 a mja 4 06 17 mm 103 mm Installation and Wiring Chapter 2 WATLOW Series 998 User s Manual 2 1 Installing Installing the Series 998 Installing and mounting requires access to the back of the panel NOTE 1 Make a panel cutout Removing the con troller chassis from 2 To remove the controller chassis from its case press in firmly on the two its case makes tabs on one side or the top of the bezel until they unsnap then unsnap
50. ations with the Watlow Series 988 Family Controls Installation and Wiring Chapter 2 WATLOW Series 998 User s Manual 2 13 2 14 WATLOW Series 998 User s Manual Installation and Wiring Chapter 2 Chapter 3 Keys and Displays Upper Display S Indicates either actual process value for channel A or channel B the operating prompt values or error codes When powering up the display will be blank for Lower Display Indicates the channel A or channel B set point or channel B process value menu prompts or alarm codes Red or green 0 3 8mm high 3 seconds Red or green 0 4 seven segment four digit LED N 10mm high seven segment gt WATLOW i display four digit LED display 1A 2A 1B 2B Indicator CH A Indicator Light q q g Lights When lit if the CH B light is not PROCESS if These lights indicate when out on the channel A process value IN 7 put 1A 2A 1B or 2B is active is shown in the upper display Display Key and the channel A set point KA i value is shown in the lower dis r r r The Display key is used to play When both CH A and CH 1A 2A 1B 2B select which channel A and or B lights are on the upper dis CHA B parameter to displayed On play shows the channel A CHB DISPLAY initial power up the upper dis process value and the lower dis play shows the channel A plays shows the channel B AUTO process value and the lower process value p display shows the channel A
51. ber 5618 This is what the controller with the serial number 0998345678 would dis play This prompt always appears Ambient Temperature Shows the ambient temperature at the input 1 terminals The temper ature is shown in F in the form HHHH regardless of the settings of Pan ET EA o ER RIA This prompt always appears WATLOW Series 998 User s Manual 6 9 Factory Diagnostics Factory Use Only These prompts are used only at the factory Lad These prompts always appear Inputs 1 and 2 Module Types Display which input module is installed in the controller Please docu ment this value before contacting the factory for technical assistance Input Types no input module thermocouple only module universal off universal rtd universal high gain thermocouple universal low gain thermocouple universal millivolts universal process These prompts always appear 10 WATLOW Series 998 User s Manual Factory Menus Chapter 6 o Factory Diagnostics Outputs 1 2 3 and 4 Module Types Display the controller s output module Please document this value before contacting the factory for technical assistance amp fc rie Lefuc nof r Lc WW Output Types no output module A 0 5A solid state relay K 0 5A solid state relay with suppression B aa aa rc E a EEA switched de open collector C form C relay E form C relay
52. bilized at a power level less than 75 5 for a two minute period prior to sensor failure the channel switches to man ual operation at the last automatic power level If the conditions are not met the output goes to 0 power outputs disabled If GME parameter is set to a specific value 100 to 100 the chan nel switches to manual at the power selected by the ff parameter When transferring a channel from auto to manual operation the control output s remains stable bumpless When transferring from automatic to manual operation the output value appears in the lower display In the automatic operation the set point appears in the lower display Changing the Output 3 Alarm Jumper If you have model number 99__ ___ _ J___ output 3 can be config ured as a Form A NO and common con tact or Form B NC and common contact Top View alarm To change the alarm jumper 1 Remove the control from the case Release the two tabs on one side of the control then release the two tabs on the opposite side You may need to rock the bezel back and forth several times to release the chassis 2 Set the jumper to the position you want See below for jumper location 3 Return the control chassis to the case Be sure you have it oriented correctly Press firmly but gently to seat the chassis When you select Form A the contact is open when power is removed from the control When selecting Form B the contact is closed
53. cates whether the event input 1 circuit is energized HHA or de energized HJA This is a read only prompt This prompt appears only if Global Menu is set to some thing other than SEPTA CLOS 0p LI 5 Output 3 Status Indicates whether the output 3 circuit is energized EEHE or de energized fii This is a read only prompt WEY This prompt appears only in controllers with output 3 hardware not 99__ A CLOS MEF MEF E L u 5 Output 4 Status Indicates whether the output 4 circuit is energized EHH or de energized fri This is a read only prompt MACE This prompt appears only in controllers with output 4 hardware not 99_ A CLOUS 5 4 WATLOW Series 998 User s Manual Operation Menus Chapter 5 Alarm 3 Low 2 WW eo C3 Operation System Select the low trigger value for the output 3 alarm GEIN This prompt appears only if Output Menu is set to or EREI If L or Output Menu or Output Menu Alarm 3 High Default lowest valueof value of sa sensor or Sard range Input Menu Select the high trigger value for the output 3 alarm EEE This prompt appears only if Output Menu is set to or EREI If L or Output Menu KH o E Output Menu Operation Menus Chapter 5 Default highest value of Value of or sensor Input Menu range oE FEEF WATLOW Series 998 User s Manual 5 5 Operation System A u L E Alarm 4 Low Select the low t
54. ccurs A process alarm is independent from set point Example If your set point is 100 F and a process alarm is set at 150 F as the high alarm and 50 F as the low limit the high limit trips at 150 F and the low alarm at 50 F If you change the set point the process alarm limits remain the same A deviation alarm alerts the operator when the process strays too far from set point The operator can enter independent high and low alarm settings The reference for the deviation alarm is the set point Any change in set point causes a corresponding shift in the deviation alarm Low alarms are usually set at a negative deviation while high alarms are a positive deviation Example If your set point is 100 F and a deviation alarm is set at 7 F as the high limit and 5 F as the low limit the high alarm trips at 107 F and the low alarm at 95 F If you change the set point to 130 F the alarms follow the set point and trips at 137 F and 125 F Alarms can be latching or non latching When the alarm condition is removed a non latching alarm automatically clears the alarm output and alarm message if one is present You must manually clear a latching alarm before it will disappear There may be an alarm message flashing in the lower display but if the prompt is set to located in the Global Menu no alarm message is displayed When an alarm message is displayed it alternately flashes with the current prompt at a 1 second interval i
55. ctricas r pidas EN 61000 4 3 1996 Inmunidad radiada EN 61000 4 6 1996 Inmunidad conducida ENV 50204 1995 Tel fono port til EN 50081 2 1994 Norma de emisi n gen rica del EMC parte 2 Ambiente industrial EN 55011 1991 L mites y m todos de medici n de caracter sticas de perturbaciones de radio correspondientes a equipos de radiofrecuencia industriales cient ficos y m dicos Grupo 1 Clase A EN 61000 3 2 1995 L mites para emisiones de corriente arm nica EN 61000 3 3 1995 Limitaciones de fluctuaciones del voltaje 73 23 EEC Directiva de baja tensi n 1993 Requerimientos de seguridad para equipos el ctricos de medici n control y uso en laboratorios Parte 1 Requerimientos generales EN 61010 1 Winona Minnesota USA Place of Issue Erwin D Lowell Name of Authorized Representative January 24 1996 Date of Issue General Manager Title of Authorized Representative LO Eb Signature of Authorized Representative Appendix Appendix WATLOW Series 998 User s Manual A 11 Watlow Series 998 User s Manual Watlow Controls 1241 Bundy Boulevard P O Box 5580 Winona Minnesota USA 55987 5580 Phone 507 454 5300 Fax 507 452 4507 http www watlow com
56. d 4 20mA Process Inputs Certain transmitters used in process input applications are producing internal resistor failures in the Watlow Series 988 family of controllers This is only apparent with the Series 988 family 1 8 DIN units with Process Inputs selected 0 20mA or 4 20mA dc only We are noticing that an external resistor is required to prevent a high in rush current which burns out the Series 988 family controllers 7 ohm internal resistor This high in rush current occurs initially on power up If the transmitter turns full on for a split second during power up the available current weakens or damages the internal resistor Example 20V 7 ohms 2 857mA too much The wiring diagram example below shows an application where a cus tomer is using a 4 20mA dc transmitter and power supply to feed the input of a Series 988 controller The Rx range 100 to 400 ohms for the external resistor is recommended We suggest starting with 250 ohms Example Customer is using a 24VI dc power supply to power up the 4 20mA dc transmitter that inputs to the Series 988 terminals 8 and 10 To figure out what the internal Series 988 s handling current is for the 0 20mA or 4 20mA dc input to the Series 988 controllers we need to apply Ohm s Law The square root of Watts divided by Resistance equals Current Applying that formula to the example below produces the following Square Root of 0 125 Watts 7 ohms 134 mA dc
57. e Tune cooling out puts at a set point below the ambient process value 7 2 WATLOW Series 998 User s Manual Tuning A To start auto tuning 1 Press the Mode key J until the SEHA prompt appears in the lower display 2 Use the Up arrow or Down arrow key 79 to select or depending on which channel you want to tune Only one PID set can be auto tuned at a time 3 Press the Mode key While the control is in the tuning mode the lower display alternately displays the normal information and the prompt The time between alternations is one second 4 When tuning is complete the display return to their previous state and reverts to WHA The 998 installs appropriate PID tuning para meters and saves them in non volatile memory To abort auto tuning either reset the prompt to or cycle power off and on In all cases aborting auto tune restores all values to those previous to auto tuning Manual Tuning For optimum control performance tune both channels of the Series 998 to your thermal system The tuning settings here are for a broad spec trum of applications your system may have somewhat different require ments NOTE This is a slow procedure taking from minutes to hours to obtain optimum values If you are not familiar with tuning a thermal system we suggest you obtain and become familiar with the reference below before attempting to tune your system Tuning of Industrial Control Systems by Armando B Corripio
58. e Factory Menus To reach the Factory menus begin in the Display Loop and press the Up arrow Y and Down arrow keys together and hold for three seconds The Setup prompt will appear in the lower display Press and hold the Up arrow and Down arrow keys together again for three seconds until the Factory Menu prompt appears in the lower display The Factory menus will not appear if the hardware lockout DIP is set to on See Chapter 1 for more information on DIP switch settings The three Factory menus are Panel Lockout H H Diagnostics FRE and Calibration Wa Upon reaching press the Up arrow or Down arrow key to select a menu and the Mode key to step through a menu You will not see every prompt in any of these menus The controller s con figuration and model number determine which prompts appear After stepping through each menu the Series 998 returns to the Factory Menu prompt Use the Up arrow or Down arrow key to select the next menu or use the Mode key to advance through the same menu again To move backwards through the menu hold the Mode key down and press the Up arrow key Press the Up arrow or Down arrow key to change the prompt setting ZJ inPE PROCESS e e e e 1A 2A 1B 2B CHAS foispLay CHB am AUTO Hli 4J MAN H Press Y and together and hold until appears in the lower display Press and hold again until appears in the lower display CS 7 je
59. e in the upper display The new value will not take effect until after a five second delay or until you press the Mode key Proportional Band Output 1A or 2A Select the proportional band for PID channel A outputs If set to HHR it functions as an on off control and the switching differential is determined by the or value Output Menu The decimal precision is determined by Input Menu HIEI This prompt always appears If Default L L Pin i A GZD G Calibration Menu Global Menu amp E EDG EEE C_F A GZD G Calibration Menu Global Menu amp EE EED EEEE Pin i A GD G Input Menu 8 E Ga a C_F A GD G Calibration Menu Global Menu amp a GE FEES Pin i A GD G Input Menu EEn EIEN BEEE of span EnD GD G Calibration Menu WATLOW Series 998 User s Manual 5 9 Operation PID A Reset Output 1A or 2A Adjust the control action to eliminate the offset or droop between the set point and the actual process temperature for PID channel A out puts When set to fa reset is disabled This prompt appears only if Calibration Menu is set to and GEE is not set to Ey Default L EEEE repeats min Integral Output 1A or 2A Adjust the control action to eliminate the offset or droop between the set point and the actual process temperature for PID channel A out puts When set to SEE integral is disabled MAR This prompt appears only if Calibration Menu is set to and GEJ is not set to NFA
60. e wire RTD which is usually made of platinum and the thermistor which is made of a semiconductor material The wire RTD is a positive temperature coefficient sensor only while the ther mistor can have either a negative or positive tem perature coefficient WATLOW Series 998 User s Manual A 3 Glossary R Z RTD See resistance temperature detector thermal system A regulated environment that con sists of a heat source heat transfer medium or load sensing device and a control instrument thermocouple t c A temperature sensing device made by joining two dissimilar metals This junction pro duces an electrical voltage in proportion to the differ ence in temperature between the hot junction sensing junction and the lead wire connection to the instrument cold junction thermocouple break protection The ability of a control to detect a break in the thermocouple circuit and take a predetermined action three mode control Proportioning control with inte gral reset and derivative rate Also see PID time proportioning control A method of controlling power by varying the on off duty cycle of an output This variance is proportional to the difference between the set point and the actual process temperature transmitter A device that transmits temperature data from either a thermocouple or a resistance temperature detector RTD by way of a two wire loop The loop has an external power supply
61. ed with com munications hardware 99_ R or99_ S_ Default t nonE FULL Diagnostics Menu Lockout ma LO Select the lockout level for the Diagnostics Menu Set the lockout to no lockout PPPA read only or full lockout FM ERE This prompt always appears Default 4 CGE CELE CGE Calibration Menu 6 6 Select the lockout level for the Calibration Menu Set the lockout to no lockout PPPA read only or full lockout FM This prompt always appears Default none FULL WATLOW Series 998 User s Manual Factory Menus Chapter 6 Factory Menus Chapter 6 WATLOW Series 998 User s Manual 6 7 Factory Diagnostics Reaching the Diagnostics Menu Press the Up arrow 7Y and Down arrow keys together and hold until the prompt appears in the lower dis play Press and hold again until the prompt appears in the lower display Panel Diagnostics Calibration Lockout Menu Menu Menu p 6 8 p 6 14 p 6 2 Use the Up arrow Y key to step from the Panel Lockout Menu HNH to the Diagnostics Menu PEEN Press the Mode key to step through the prompts ra a B amp F tout Press the Up arrow key Y or the Down arrow key to select one of the prompt values NOTE In the Diagnostics Menu only the values of PREJZ and can be changed Figure 6 8 The Diagnostics Menu 6 8 WATLOW Series 998 User s Manual gt B om ni A gt cio bos a aa ata aa ata n
62. electable display of F C or process units Input Range Specified temperature ranges represent the controller s operational span Thermocouple Available with basic or universal signal conditioner Type C 32 to 4200 F 0 to 2316 C Type D 32 to 4200 F 0 to 2316 C Type E 328 to 1470 F 200 to 799 C Type J 32 to 1500 F 0 to 816 C Type K 328 to 2500 F 200 to 1371 C Type N 32 to 2372 F 0 to 1300 C Type T 328 to 750 F 200 to 399 C Pt 2 32 to 2543 F 0 to 1395 C Available with universal signal conditioner TypeB 1598 to 3300 F 870 to 1816 C Type R 32 to 3200 F 0 to 1760 C Type S 32 to 3200 F 0 to 1760 C A 8 WATLOW Series 998 User s Manual RTD Resolution DIN or JIS 1 DIN 328 to 1472 F 1 JIS 328 to 1166 F 0 1 DIN and JIS 99 9 to 999 9 F Process 999 to 9999 units for all 0 5V dc 1 5V dc 0 10V dc 0 20mA and 4 20mA Output Options e Dual solid state relay Form A 0 5A 24V ac min 253V ac max opto isolated burst fire switching Without contact suppres sion Off state output impedance 31MQ e Dual switched dc signal provides a minimum turn on voltage of 3V dc into a minimum 500Q load maximum on voltage not greater than 32V dc into an infinite load e Dual electromechanical relay Form A 2A 120 240V ac 2A 28V dc 1 8 hp 120V ac 125VA 120V ac Without contact suppression e Process 0 20mA 4 20mA
63. eration Menus Chapter 5 NOTE Decimal points may not always be in the position specified below depending on the Decimal 1 and Decimal 2 settings in the Input Menu SP 2b Operation Menus Chapter 5 Operation System System Prompts After you step past the Set Point 2A prompt E ge g and the Set Point 2B prompt A to the Operation menus the Series 998 displays the menu selection EEEE GEETA or in the upper display and HAJA in the lower display The Up arrow Y or Down arrow key J selects another menu Press the Mode key Q to display the first prompt in the lower display and its value in the upper display Use the Up arrow and Down arrow keys to change the value in the upper display The new value will not take effect until after a five second delay or until you press the Mode key Set Point 2A Set the operating set point for output 2A Allows output 2A to operate as a boost heat or a boost cool output The default setting depends on the setting Input Menu EZE This prompt appears only if and 36 Output Menu are both set to or to aa Set Point 2B Set the operating set point for output 2B Allows output 2B to operate as a boost heat or a boost cool output e The default setting depends on the setting Input Menu GEZIA This prompt appears only if and 7363 Output Menu are both set to or to aa WATLOW Series 998 User s Manual 5 3 Operation System Cc j 5 Event Input 1 Status Indi
64. et point 3 2 channel B output wiring 2 11 channel B indicator light 3 1 clearing error codes 7 8 Communications Menu 4 38 4 40 communications menu lockout 6 6 cycle time adjustment 7 3 cycle time output 1A or 2A 5 12 cycle time output 1B or 2B 5 17 Appendix D data bits and parity 4 39 dead band 8 3 dead band A 5 12 dead band B 5 17 decimal 1 4 6 decimal 2 4 11 Declaration of Conformity A 10 default 6 15 derivative output 1A or 2A 5 11 derivative output 1B or 2B 5 16 Diagnostics Menu 6 8 6 12 diagnostics menu lockout 6 6 DIP switch locations and functions 1 1 1 4 Display key 3 1 Display Loop ii 3 2 display loop parameters 3 2 display lower 3 1 display upper 3 1 Down arrow key 3 1 dual switched dc 2 10 2 11 2 12 2 13 E error code actions 7 7 7 8 error code E1 amp E2 messages 7 6 error latching 4 34 event input 1 2 4 4 34 event input 1 status 5 4 external transmitter power supply 2 12 2 13 F failure mode 4 33 Factory Menus iii 6 1 6 15 front panel lockout 6 3 factory ship date 6 9 factory use only prompts 6 10 G Global Menu 4 32 4 36 global menu lockout 6 5 H hardware setup 1 1 1 4 humidity sensors 4 3 4 4 hysteresis 1A 4 18 hysteresis 1B 4 21 hysteresis 2A 4 20 hysteresis 2B 4 22 hysteresis 3 4 25 hysteresis 4 4 28 Index l input 1 4 5 4 6 input 2 4 10 Input Menu 4 2 4 14 input menu lockout 6 5 input module types 6 10 input to ou
65. ffsets deadbands and ranges FIANE This prompt appears only if you have set Input 1 toa process input Default L EHD EEN Er HA 4 6 WATLOW Series 998 User s Manual Setup Menus Chapter 4 NOTE These values do not affect the low or the high set point limit for process alarms Range Low 1 and Range High 1 continued on next page Setup Menus Chapter 4 Setup Input Range Low 1 and Range High 1 Select the low and high limits for channel A These prompts limit the adjustment range for the set points The default values are the same as the limits of the sensor you selected by setting the input 1 DIP switch and selecting a value for Input 1 SH e Process inputs are scaled by these values Range high is the value dis played when the maximum process signal is present at the input Range low is the value displayed when the minimum process signal is present at the input Example Set SEAD to CHMA Set to BA Set to ta A 4mA input will display SEHN A 12mA input will display SEHH A 20mA input will display SETHH e The low and high values of each sensor type are listed on the specifica tions page of the Appendix e Choose between Fahrenheit and Celsius at the prompt in the Global Menu These prompts always appear Default Default Default Default L L L L m 1500 EEE EEG 99 1 or a E HI a THI 99 2 K DEFI ELHA ENN EEE w5 W3 BEA CEE EE HEED WATLOW Series 998 User s Manual
66. generated a value lower than that allowed for the range of the sensor or the A D circuitry malfunctioned Enter a valid input The A D value is below the range limits but within the A D con version limits Make sure input settings in the Input Menu match your sensor or EJE Sensor overrange error The input 1 or 2 sensor generated a value higher than that allowed for the range of the sensor or the A D circuitry malfunctioned Enter a valid input The A D value is above the range limits but within the A D con version limits Make sure input settings in the Input Menu match your sensor or GENEI A D overflow error The input 1 or 2 A D circuit is overrange An open or reversed polarity sensor is the most likely cause Check the sensor if the connection is good and functions properly call the factory The A D input voltage is too high to convert an A D signal Make sure input settings in the Input Menu match your sensor HEZE Ambient temperature error The ambient temperature of the Series 998 has dropped below 32 F 0 C or risen above 149 F 65 C A calibration error can also cause the error code Try a calibration restore to clear this alarm WSC RAM verification error An internal RAM failure has occurred Contact the factory Wi Non volatile checksum error Displayed when an EEPROM checksum error has been detected Turn the power off then back on again If the error has not cleared contact the fac tory WS C
67. handling input current This is the acceptable input current for the Series 988 universal input board 988 Process Input Control 4 20mA dc Transmitter B 24V dc 100 to 400 mi a Reminder the input impedance of 7 ohms handles the majority of our customer applications the external resistor Rx is only for certain trans ducers transmitters that spike on power up or power down Please make sure your customer s transmitter transducer fall within our Series 988 family 1 8 DIN of controllers Process Input specification of 7 ohms input impedance Installation and Wiring Chapter 2 WATLOW Series 998 User s Manual 2 5 Wiring Example Figure 2 6 System Wiring L1 L1 Examples L2 L2 XX High Temperature Light A WARNING To avoid potential electric shock use National Electric Code NEC safety practices when wiring and connect ing this unit to a power source and to electrical sensors or peripheral devices Failure to do so could result in injury or death High Limit Mechanical Control Environmental Chamber Cooling Wet Bulb Fan RTD Sensor 101112131415 16 17 Q000000 Dry Temp RTD Sensor p Reset Series 146 Limit Control 146E 1601 3000 Heater A CAUTION To avoid damage to property and equip ment use National Electric Code NEC standard wiring practices to install and operate the series 9
68. hapter 6 WATLOW Series 998 User s Manual 6 13 Factory Calibration Reaching the Calibration Menu Enter the Factory Menu again by pressing the Up arrow 7Y and Down arrow keys simulta neously for three seconds to enter the Setup Menu Ega and an additional three seconds to enter the Factory Menu HAEN cat FetY ome At the prompt A press Y or EJ to advance to the prompt Press QB to advance through the Calibration Menu The Calibration Menu begins with input 1 prompts and continues through to output 3 prompts Located at the end of the Calibration Menu are the Restore Factory Values and Default Parameters prompts See below Before continuing through the Calibration Menu refer to the proper calibration pro cedure for your controller NOTE This menu will con tinue looping through the para meters until you press the Display key to return to the Display loop Refer to Calibrating Figure 6 14 Watlow Process Controls The Calibration for information about the Menu Calibration Menu 6 14 WATLOW Series 998 User s Manual gt Calibration Menu Factory Menus A H 8 868 808 68 80 0 68 8 68 6 6 6 AEE EEEL I x My a Input 1 e E m E mute a el cp GE t a co mm t C o EAn t C o mB E o R es le co m t E co On a o OF a o D A o EM oe ae co m ae eee cp E
69. i Setup Menus iii Factory Menus Chapter 1 Hardware Setup 1 1 DIP Switch Locations and Functions 1 2 Input Type DIP Switches 1 3 External Power Supply DIP Switches 1 4 Setting the Lockout DIP Switch Chapter 2 Installation and Wiring 2 1 Panel Cutout and Dimensions 2 2 Installing the Series 998 2 4 Wiring the Series 998 2 4 Power Wiring 2 4 Sensor Installation Guidelines 2 5 Event Input 1 Wiring 2 5 Wiring 0 20mA and 4 20mA Process Inputs 2 6 Wiring Example 2 7 Wiring Notes 2 8 Channel A Input Wiring 2 9 Channel B Input Wiring 2 10 Channel A Output Wiring 2 11 Channel B Output Wiring 2 12 Output 3 Wiring 2 13 Output 4 Wiring Chapter 3 Keys and Displays 3 1 Keys and Displays 3 2 Display Key and Loop Chapter 4 The Setup Menus 4 1 Navigating the Setup Menus 4 2 Input Menu 4 16 Output Menu 4 32 Global Menu Table of Contents Chapter 5 The Operation Menus 5 1 Navigating the Operation Menus 5 2 The System Menu 5 3 The Set Point Menu 5 3 System Prompts 5 8 PID A Menu 5 13 PID B Menu Chapter 6 The Factory Menus 6 1 Navigating the Factory Menus 6 2 Panel Lockout Menu 6 8 Diagnostics Menu 6 14 Calibration Menu Chapter 7 Tuning Manual Operation Alarms and Error Codes 7 1 Auto tuning Heat and or Cool 7 2 Manual Tuning 7 3 Manual and Automatic Operation 7 4 Changing the Output 3 Alarm Jumper 7 4 Using Alarms 7 6 Error Code El and E2 Messages 7 7 Error Code Actions
70. ing process Once the auto tune sequence has begun the control outputs proportional band for the associated channel is set to 0 and that channel goes into an on off mode of control at the channel s set point percentage determined by the parameter The channel s displayed set point remains unchanged Note Any change in the set point while in auto tune restarts the auto tune procedure Auto tuning at a Set Point of 200 F Auto tune Auto tune Begins Complete 200 Set Point 808 Mein oo NG een A Process Set Point EEE Default Setting 100 Qa Figure 7 1 5 Auto tuning Example Time Once the control finishes learning the system it returns the channel to standard PID control with the PID values automatically set as a result of auto tuning Once auto tune has begun the process must cross the set point four times within 80 minutes for the 998 to successfully complete the auto tune If this does not happen within the time limit the Series 998 chooses PID values based on the 80 minute tuning cycle performed Tuning Alarms and Error Codes Chapter 7 WATLOW Series 998 User s Manual 7 1 A CAUTION If a mechanical relay or contactor is switching power to the load a longer cycle time may be desirable to mini mize wear on the mechanical compo nents Typical life of a mechanical relay is 100 000 cycles NOTE Tune heating out puts at a set point above the ambient process valu
71. into 800Q maximum 0 5V dc 1 5V dc or 0 10V dc into 1kQ minimum load isolated e Electromechanical relay Form A B 5A 120 240V ac 6A 28V dc 1 8 hp 120V ac 125VA 120V ac Without contact suppression e External transmitter power supply 5 12 or 20V dc 30mA EIA TIA 232 communications or EIA TIA 485 EIA TIA 422 commu nications opto isolated e Retransmit 0 20mA 4 20mA with 600Q max load impedance or 0 5V dc 1 5V dc and 0 10V dc with 500Q min load impedance Line Voltage Power e 100 240VX ac dc 10 15 50 60Hz 5 e 24 to 28V ac dc 10 15 50 60Hz 5 e Fused internally factory replaceable only Slo Blo type time lag 2A 250V for high voltage versions 5A 250V for low voltage versions e Power consumption 16VA maximum Non volatile memory retains data if power fails Operating Environment e 32 to 149 F 0 to 65 C 0 to 90 RH non condensing Storage Temperature e 40 to 185 F 40 to 85 C Terminals e 6 compression universal head screws accepts 20 14 gauge wire Controller Weight e 1 0 Ib 0 45 kg Shipping Weight e 3 01 Ibs 1 35 kg Sample Update Rates 2 inputs 5Hz Retransmit 1Hz PID 10Hz Control outputs 10Hz Alarm outputs 1Hz Display 2Hz Resolution e Inputs 16 bits 200 to 800 C 200 to 630 C 73 3 to 537 7 C Appendix Ordering Information 1083 To order complete
72. is used to power a transmitter connected to input 99 7 aL 1 or input 2 See Chapter 1 for DIP switch location and set tings 2 12 WATLOW Series 998 User s Manual Installation and Wiring Chapter 2 NOTE Input to output iso lation is defeated when the external transmitter power supply is used to power a transmitter connected to input 1 or input 2 Output 4 Wiring Figure 2 13a AC Outputs e Solid state Relay with e Electromechanical Relay with Contact Suppression Contact Suppression 0 5 Amps On NO and COM contacts only Off state impedance 20KQ min Form C 5 Amps Off state impedance 20KQ min 99 _B 99 _D e Solid state Relay without Contact Suppression e Electromechanical Relay with 0 5 Amps out Off state impedance 31MQ Contact Suppression Form C 5 Amps 99__ _K Off state impedance 31MQ 99 E External L2 aoad NO 5 COM 6 L1 Fuse NC 7 for D amp E outputs only lt j Wiel oo J ca oOo Figure 2 13b Switched DC Open Collector Minimum load resistance 500Q rrug to 32V dc 99 7 _C 5 H 7909 6 7 i__Internal Circuitry __ External S Load o4 lt 0 J ee _ 2 S S E E Figure 2 13c External Transmitter Power E 99__ _I See Chapter 1 for DIP switch location and settings Input 1or2 S For data communications wiring refer to How to Use Data Communic
73. istered trademark of Littelfuse Inc Appendix WATLOW Series 998 User s Manual A 9 Declaration of Conformity Series 996 997 998 999 WATLOWCONTROLS 1241 Bundy Boulevard Winona Minnesota 55987 USA CE Declares that the following product English Designation Series 996 997 998 999 Model Number s 9 9 6 7 8 or 9 Any letter 1 or 2 1 or 2 CEF or K CEFor K ABCJUKMNorT ABCDEK R S or T Any two letters Control Installation Category Il Polution Degree II Rated Voltage 100 to 240V or 24 to 28V Rated Frequency 50 60 Hz Rated Power Consumption 16VA maximum Meets the essential requirements of the following European Union Directive s using the relevant section s of the normalized standards and related documents shown 89 336 EEC Electromagnetic Compatibility Directive EN 50082 2 1995 EMC Generic immunity standard Part 2 Industrial environment EN 61000 4 2 1995 Electrostatic discharge EN 61000 4 4 1995 Electical fast transients EN 61000 4 3 1996 Radiated immunity EN 61000 4 6 1996 Conducted immunity ENV 50204 1995 Cellular phone EN 50081 2 1994 EMC Generic emission standard Part 2 Industrial environment EN 55011 1991 Limits and methods of measurement of radio disturbance characteristics of industrial scientific and medical radio frequency equipment Group 1 Class A EN 61000 3 2 1995 Limits for harmonic current emissions EN 61000 3 3 1995 Limitations of voltage fluctuation
74. ites et m thodes de mesure des caract ristiques d interf rences du mat riel radiofr quence industriel scientifique et m dical Groupe 1 Classe A EN 61000 3 2 1995 Limites d mission d harmoniques EN 61000 3 3 1995 Limitations d carts de tension et de papillotement 73 23 EEC Directive li e aux basses tensions 1993 Exigences de s curit pour le mat riel lectrique de mesure commande et de laboratoire Partie 1 Exigences g n rales A 10 WATLOW Series 998 User s Manual 1231 EN 61010 1 Erklart daB das folgende Produkt Deutsch Beschreibung Serie 996 997 998 999 Modellnummer n 9 9 6 7 8 oder 9 beliebiger Buchstabe 1 oder 2 1 oder 2 C E F oder K C E F oder K ABCJK M N oder T AB C D E K R S oder T 2 beliebige Buchstaben Klassifikation Regelsystem Installationskategorie Il Emissionsgrad Il Nennspannung 100 bis 240 V oder 24 bis 28 V Nennfrequenz 50 60 Hz Stromverbrauch Max 16 VA Erf llt die wichtigsten Normen der folgenden Anweisung en der Europ ischen Union unter Verwendung der untenstehenden einschl gigen Dokumente 89 336 EEC Elektromagnetische Ubereinstimmungsanweisung EN 50082 2 1995 EMC Rahmennorm f r St rsicherheit Teil 2 Industrielle Umwelt EN 61000 4 2 1995 Elektrostatische Entladung EN 61000 4 4 1995 Elektrische schnelle St e EN 61000 4 3 1996 Strahlungsimmunit t EN 61000 4 6 1996 Leitungsimmunit t ENV 50204 1995 Mobiltelefon
75. ize wear on the mechanical components Experiment until the cycle time is consistent with the quality of control you want will not appear on units with a process output option F 5 Rate Derivative Adjustment Increase or EIA to 1 00 minute Then raise set point by 20 to 30 F or 11 to 17 C Observe the system s approach to the set point If the load process value overshoots the set point increase or to 2 00 minutes Raise the set point by 20 to 30 F or 11 to 17 C and watch the approach to the new set point If you increase or too much approach to the set point is very sluggish Repeat as necessary until the system rises to the new set point without overshooting or approaching the set point too slowly 6 Calibration Offset Adjustment You may want your system to control to a process value other than the value coming from the input sensor If so measure the difference between that process value perhaps at another point in the system and the process value showing in the upper display Then enter the offset value you want Calibration Offset adds or subtracts degrees from the value of the input signal Manual and Automatic Operation To change from auto to manual first select the desired channel using the Display key Press the Display key until the desired CH A or CH B indicator light is lit Only one should be lit Then press the Auto Manual key twice Note Both channels can operate in the manual modes simultaneous
76. ly Manual operation provides open loop control of the outputs from a range of 100 to 100 output for heat cool operation 0 to 100 for heat only and 100 to 0 for cool only The 998 allows a negative output value only if HAIA GEEA or is set to cool Automatic operation provides closed loop on off or PID control When the operator transfers from a closed loop to an open loop the 998 sets the power level to the setting of the parameter If it is set to bumpless transfer then it retains the power level of the closed loop control When the 998 returns to closed loop control it restores the previous set point process value The Auto Manual light located at the key indicates auto or manual oper ation When it is on the channel indicated by the CH A or CH B light is Tuning Alarms and Error Codes Chapter 7 WATLOW Series 998 User s Manual 7 3 Alarms Figure 7 4 Alarms Jumper Location in manual operation Note It cannot be determined which channel is in the manual mode when both CH A and CH B lights are on When the Auto Manual light is off the channel is in automatic operation When the Auto Manual key is pressed once the Auto Manual light will flash Press the key again within five seconds to complete the change in operation When a sensor fails the channel associated with the failed sensor switch es from automatic to manual operation elf is set to EG and the bumpless transfer conditions are met process has sta
77. mal 2 Hysteresis 2B Range Low 2 Process B Range High 2 Output 3 T Calibration Offset 2 Alarm 3 RTD Calibration Curve 2 AFF Input 2 Software Filter MFT Input 2 Linearization REEE Hysteresis 3 M Latching 3 SYTHE Silencing 3 U Altitude Output 4 Alarm 4 REEE Hysteresis 4 EE Latching 4 SWIRL Silencing 4 Process 3 a Setup Menus C3 Celsius Fahrenheit EES amp Baud Rate Ay Error Latching Analog Output Setup Menus TM Failure Mode FLIT Data Bits and Parity Protocol Type Address Interface Type Event Input 1 GEA Annunciator Auto tune Set Point Ramping Channel A Ramp Rate Channel A Ramping Channel B LU Ramp Rate Channel B Retransmit Low Limit Retransmit High Limit 7H Retransmit Calibration Offset Factory Menus ee fj Panel Lockout Menu _ 3 gt ERGE Diagnostics Menu O A Calibration Menu _ Test Outputs AN Factory Menus N Factory Menus Factory Menus C3 User Lockout C3 3 Factory Ship Date C3 System Menu Lockout Software Revision A Og ET PID A Menu Lockout Ay Serial Number Ay mone GRETA PID B Menu Lockout Ambient Temperature Input Menu Lockout ELEZE Ground A D Count AY Output Menu Lockout Ambient A D Count b 0u Global Menu Lockout Input 1 A D Count b 100 Communications Menu Lockout Input 2 A D Count ERGE Diagnostics Menu Lockout Input 1 Module U Calibration Menu Lockout Input 2 Module MAEN Output 1 Module MEFA Output 2 Module
78. mounting easier the two tabs on the opposite side or the bottom Pull the chassis out of the case by gently rocking it 3 Slide the case into the panel cutout Check to see that the gasket is not twisted and is seated within the case bezel flush with the panel Slide the mounting collar over the back of the control Figure 2 2 Side and top view Side 996 or 998 or Top and Bottom 997 or 999 View Top and Bottom 996 or 998 Panel Adjustable n Pa Mounting Bracket or Side 997 or 999 View m 8 E E S E i BE e J Cc J ye J o M c ln Release Tabs s t m Sey f Sd A Bezel m o gt r Mounting Slots External Gasket Mounting Collar 2 2 WATLOW Series 998 User s Manual Installation and Wiring Chapter 2 A CAUTION Follow the installa tion procedure exactly to guaran tee a proper NEMA 4X seal Make sure the gasket between the panel and the rim of the case is not twisted and is seated properly Failure to do so could result in dam age to equipment Installation and Wiring Chapter 2 Installing Loosen the mounting bracket screws enough to allow for the mounting collar and panel thickness Place each mounting bracket into the mounting slots head of the screw facing the back of the controller Push each bracket backwa
79. mperature or process units needed to turn the output from full on to full off PEHI This prompt does not appear if output 1 is a process output OF aa os a a obal Menu C_F obal Menu G Js D fo 3 obal m a G obal Menu a process input is selected WATLOW Series 998 User s Manual Ex Ja Ex 5 DIN amp EEE a x x x x ED I 5 ED I 5 on En x x x F LC LC LC ey SA OS ze w an w Fa units Setup Menus Chapter 4 Setup Output n L a Output 2A Set the way that output 2A will respond to a difference between the set point and an input variable select reverse action so that output 2A responds when the input signal is less than the set point This prompt only appears if Iz is set to BERA select direct action so that output 2A responds when the input signal is more than the set point This prompt only appears if AF is set to BET MEEI This prompt appears only if channel A output is something other than a process output 99__ _ F Default 4 Erm EKO EM Setup Menus Chapter 4 WATLOW Series 998 User s Manual 4 19 Setup Output H uy ce A Hysteresis 2A Select the switching hysteresis for output 2A This determines the change in temperature or process units needed to turn the output from full off to full on PEHI This prompt does not appear if output 2 is a process output
80. n DI ha T a o z rr ir ir ir 2 2 3 We ce 2 ic D Cc ry LC Le Le LC rr m im 3 fa n in lus D Ey wy a a a N a io W 8 0 lt 0 8 8 8 8 08 0 0 08 8 8 8 60 6 Diagnostics Menu Factory Menu Prompt Enter your settings a from the controller s a Ship Date Upper display Software Revision Serial Number Ambient Temperature Ground A D Count Ambient A D count Input 1 A D count Input 2 A D count Input 1 Module Type Input 2 Module Type Output 1 Module Type Output 2 Module Type Output 3 Module Type Output 4 Module Type Test Displays Test Outputs Factory Menus Chapter 6 TEE APT Factory Menus Chapter 6 Factory Diagnostics Factory Ship Date Shows the date that the final factory control test was performed The first two digits represent the week as numbered from to BE The second two digits represent the year BER GEER ctc FGJ This prompt always appears Software Revision Shows the controller s software revision code This letter should match the software revision code on the cover of the manual that came with your controller SHEA and W998 XUMN Rev NO2 EY This prompt always appears Serial Number Shows the controller s serial number The first two letters in the upper display are to indicate that the controller is in serial number mode The right half of the upper display shows the first two digits of the serial num ber The lower display shows the last four digits of the serial num
81. n the lower dis play To clear a latching alarm first correct the condition then press the Auto Man key once Alarm silencing is available with all alarms This function overrides the alarm on initial power up On power up the alarm message is masked and the output reflects a non alarm condition The silencing is active until the process has entered the safe region located between the low and high alarm settings Any future deviation outside this safe region triggers an alarm If an alarm occurs at this point the output can be silenced by pressing the Auto Man key once but the alarm message is still displayed Tuning Alarms and Error Codes Chapter 7 WATLOW Series 998 User s Manual 7 5 NOTE An alarm display will be masked by an error condition or when the con trol is in the Calibration or Setup menus Error Code E1 and E2 Messages Four dashes HHHH in the upper display indicate a Series 998 error The associated channel goes to 0 output To view the error code press the Auto Man key once The upper display shows the error code for five sec onds before returning to the BE display or A D underflow error The input 1 or 2 A D circuit is underrange An open or reversed polarity sensor is the most likely cause Check the sensor if the connection is good and functions properly call the factory Make sure input settings in the Input Menu match your sensor or FJ Sensor underrange error The input 1 or 2 sensor
82. nd compensates to mini mize overshoot and undershoot See derivative rate band A range in which the rate function of a controller is active Expressed in multiples of the proportional band See PID reference junction see junction reference remote A controller that receives its set point signal from another device called the master remote set point A signal that indicates the set point for the process and is sent from another device reset Control action that automatically eliminates offset or droop between set point and actual process temperature Also see integral automatic reset The integral function of a Pl or PID temperature controller that adjusts the process temperature to the set point after the sys tem stabilizes The inverse of integral automatic power reset A feature in latching limit controls that does not recognize power outage as a limit condition When power is restored the output is re energized automatically as long as the temperature is within limits manual reset 1 A feature on a limit control that requires human intervention to return the limit to normal operation after a limit condition has occurred 2 The adjustment of a proportional control to raise the proportional band to compensate for droop resistance temperature detector RTD A sen sor that uses the resistance temperature character istic to measure temperature There are two basic types of RTDs th
83. nected to terminals 8 9 and 10 See the Appendix for more information about sensors e Changing the value of SHAN changes all other prompts to the facto ry default values except the Communications and Lockout menus the prompt in the Global Menu and the prompt in the Calibration Menu If you change the value the default warning will flash in the upper display e Changes do not take effect automatically after five seconds you must press the Mode key J to enter the sensor type change and advance to the next prompt This prompt always appears If Default L L 99 1 no DIP J K T N E w5 W3 Pt2 TEET a a thermocouple ifn l ED E ED ED Emn 6 Inf 99 2 Input 1 DIP J K T N E W5 W3 Pt2 gt a pn KOC mm r a a a ee thermocouple Input 1 DIP R S B WEN mm thermocouple WATLOW Series 998 User s Manual 4 5 Setup Input la If Default Input 1 continued t t from previous Input1 DIP RTD RTD 0 19 page BoU mm RTD Input 1 DIP 4 20mA 0 20mA 0 5V 1 5V 0 10V dc MEG CN Cia EN process Ta C Decimal 1 dtii Select the decimal point location for process type channel A data This prompt in conjunction with the Range Low and Range High prompts allows you to format and limit units of measure for channel A e All prompts with units of measure related to channel A will display in the selected decimal format e This affects propbands alarm set points process set points calibration o
84. o change the prompt setting Refer to the Appendix for model number options For additional informa tion about communications and the communications prompts refer to the supplemental manual Data Communications with the Watlow Series 988 Family of Controllers Begin in the Display Loop and press the Up arrow Z3 and Down arrow Q2 keys simultaneously to reach the Setup menus cA 9 Ae HAA ER ee Input Output Global Communications Menu Menu Menu Menu p 4 2 p 4 16 p 4 32 p 4 38 Press the Up arrow key Y to select one of the ee Setup menus WATLOW Series 998 User s Manual 4 1 Setup Input Reaching the Input Menu SEE eoeee 1A 2A 1B 2B CHA foispLay Select the Input Menu then press the Mode key QB to step through the prompts cA A amp A 99 0000 dECL ee Press the Up arrow key 7Y or the Down arrow key to select one of the prompt values Figure 4 2 The Input Menu 4 2 WATLOW Series 998 User s Manual 3 Input Menu Cc Setup Menus ___ Enter your settings eg from the controller s a upper display BEZE nput 1 page 4 5 Decimal 1 Range Low 1 Range High 1 WE Calibration Offset 1 RTD Calibration Curve 1 H 8 8 8 8 8 6 Input 1 Software Filter Input 2 page 4 10 Decimal 2 Range Low 2 Lange High 2 Ta Calibration Offset 2 RTD Calibration Curve 2 HFA Input
85. o or manual before setting the lockout level Failure to do so could result in dam age to equipment and or property Factory Menus Chapter 6 Factory Panel Lockout Panel Lockout Prompts When you are in the Factory menus the Series 998 displays the menu selection Gg or in the upper display and in the lower display The Up arrow Y or Down arrow key selects another menu Press the Mode key Q to display the first prompt in the lower display and its value in the upper display Use the Up arrow and Down arrow keys to change the value in the upper display The new value will not take effect until after a five second delay or until you press the Mode key The prompts within the Panel Lockout Menu allow you to lockout an entire menu You can set the level of lockout to none PPPA read only or lockout read and write RI Front Panel Lockout Set the lockout level for the front panel This allows you to disable keys on the front of the controller E enables all keys HE disables the Mode key QB disables the Mode key Q and the Auto Man key ga e disables the Mode key Q the Auto Man key A the Display key and locks the set point value This prompt always appears Default 1p O LOC LOC LOC WATLOW Series 998 User s Manual 6 3 Factory Panel Lockout 5 6 4 Q 5 3 oC System Menu Lockout Select the lockout level for the System Menu Set the lockout to no lockout RF read
86. ode is shown in the upper display for five seconds and the lower display shows the power After five seconds the upper display reverts to the display If the control was operating with stable output values when the error occurred it continues to operate at those levels on a power basis If output values were not stable or the percent output was greater than 75 the control outputs go to 0 power off If T is not set to FEA Global Menu and the control was in auto operation when the error occurred it goes into manual power operation The power level is determined by the BT value 100 to 100 See the table Tuning Alarms and Error Codes Chapter 7 WATLOW Series 998 User s Manual 7 7 To clear an error code elf is set to ANA the error code should clear once the problem is corrected elf is set to QAM correct the problem and cycle power You can also clear the error by pressing the Up arror or Down arrow keys Y to enter the Setup Menu then press the Display key J 7 8 WATLOW Series 998 User s Manual Tuning Alarms and Error Codes Chapter 7 Chapter 8 Applications A CAUTION Burst fired opera tion requires ac power supplied to the Series 998 Failure to supply ac power to the control results in no zero cross references and causes the Series 998 to default to a cycle time of one second Figure 8 1 Burst Fire Example Applications Chapter 8 This chapter details many of
87. ole double throw relay that uses the normally open NO normally closed NC and common contacts The operator can choose to wire for a form A or form B contact hysteresis A change in the process variable required to re energize the control or alarm out put Sometimes called switching differential integral Control action that automatically eliminates offset or droop between set point and actual process temperature See auto reset integral control I A form of temperature control The of PID See integral isolation Electrical separation of sensor from high voltage circuitry Allows use of grounded or ungrounded sensing element JIS See Joint Industrial Standards junction cold Connection point between thermocouple metals and the electronic instru ment See junction reference junction reference The junction in a ther Appendix mocouple circuit held at a stable known tempera ture cold junction Standard reference temperature is 32 F 0 C NEMA 4X A NEMA specification for determining resistance to moisture infiltration This rating certi fies the controller as washable and corrosion resis tant on off controller A temperature controller that operates in either full on or full off modes open loop A control system with no sensory feedback output Control signal action in response to the difference between set point and process variable overshoot
88. ompt appears only on controllers with and set to something other than a process input Default a CLF Failure Mode Select percent output or bumpless transfer when input fails This prompt affects both channels allows bumpless transfer AGEI This prompt always appears If Default Heat Cool ouput PEE Ein Heat ouput EE a ee Cool ouput E Zi WATLOW Series 998 User s Manual 4 33 Setup Global Error Latchin Err g Select whether input errors will be latching or non latching Non latching errors turn off when there is no error condition Latching errors must be turned off manually NOTE See Chapter 7 for This prompt always appears more information on errors Default L Event Input 1 Select the effect of closing the event input 1 switch BEET disables event input 1 locks out the front panel keys resets an alarm turns all control outputs off de energize relays This prompt always appears Default A ETA EES EIZ in 4 34 WATLOW Series 998 User s Manual Setup Menus Chapter 4 An wr NOTE Lower display alter nately flashes and lower display value when ramping is in process Setup Menus Chapter 4 Setup Global Annunciator Select whether alarm messages will flash in the lower display This prompt always appears Default ny Gn Auto tune Set Point Select the percentage at which the controller will auto tune the cur rent control
89. onfiguration error An incorrect module was installed in the control Contact the factory 7 6 WATLOW Series 998 User s Manual Tuning Alarms and Error Codes Chapter 7 Error Codes Error Code Actions Error codes EZE WZA or will result in these con ditions e The control is in Auto operation with both control outputs off e The alarm outputs are in their alarm state de energerzed with the indi cator light on e The lower display is blank e The upper display indicates the error code e All keys are inactive resets all Setup Menu prompts to their default values e The above conditions occur regardless of the value of FA or the presence of the Setup or Factory menus Cycle power to the control If the error is still present contact the factory Percent Output Level with FIA not set to AANG am o JENI set 1 to 100 FI setting HEI set 100 to 1 HEIN setting Error codes other than WFE MZZ or will result in these conditions If 7 is set to AMA Global Menu and the control was in auto operation when the error occurred it goes into manual power operation If the output power is less than 75 5 power and there was a change in power lt 5 within the last two minutes the 998 switches into manual operation at the last auto matic power level bumpless transfer If the control was in manual operation it remains there Press the Auto Man key once to see the error code The error c
90. or99__ J or 99_ K_ or switched de 99_ C_ Default ETE GE EE WATLOW Series 998 User s Manual 4 23 Setup Output NOTE See Chapier 7 for more information on alarms Alarm 3 Select the alarm channel and type for alarm 3 Select the trigger points for the alarm with the JE and GERM scttings in the System Menu ETA uses the process signal from channel A Changing the set point does not change the alarm response uses a deviation from the channel A signal Changing the set point changes the alarm response This prompt appears only on controllers equipped with output 3 alarm hardware 99__ B_ or99_ C_ or99_ K or gg J__ and with set to or REF Default 4 24 WATLOW Series 998 User s Manual Setup Menus Chapter 4 NOTE See Chapter 7 for more information on alarms Setup Menus Chapter 4 Setup Output Hysteresis 3 Select the switching hysteresis for alarm 3 This determines the change in temperature or process units needed to turn the output from full off to full on e If the input referenced by is set to the range is affected as listed below BEEE This prompt appears only on controllers equipped with output 3 hardware not 99__ A__ and with Output Menu set to or GEES If Default L C_F Global Menu amp a EEn C_F REFE Global Menu Input Menu Global Menu amp WIF ie C_F Global Menu Input Menu a process
91. output 2B 5 15 WER input 1 module type 6 10 input 2 module type 6 10 L latching 3 4 26 latching 4 4 28 linearization 2 4 14 GMa front panel lockout 6 3 O output 1A 4 17 output 1B 4 21 output 2A 4 19 output 2B 4 22 output 3 4 23 output 3 status 5 4 output 4 4 27 output 4 status 5 4 Output Menu 4 16 output menu lockout 6 5 GEZE output 1 module type 6 11 output 2 module type 6 11 output 3 module type 6 11 output 4 module type 6 11 P HIEI proportional band output 1A 5 9 Index GAHA proportional band output 1B 5 14 evga Proportional band output 2A 5 9 GIETA proportional band output 2B 5 14 ET Channel A PID Menu 5 8 GHEE PID A menu lockout 6 4 ET Channel B PID Menu 5 13 GEEA PID B menu lockout 6 4 Jam Panel Lockout Menu 6 2 process 3 4 30 process A 4 20 process B 4 23 protocol type 4 40 R rate output 1A 5 11 rate output 1B 5 16 rate output 2A 5 11 rate output 2B 5 16 reset output 1A 5 10 reset output 1B 5 15 reset output 2A 5 10 reset output 2B 5 15 range high 1 4 7 4 8 range high 2 4 11 4 12 range low 1 4 7 4 8 range low 2 4 11 4 12 ramping function for channel A 4 35 ramping function for channel B 4 36 ramp rate for channel A 4 36 ramp rate for channel B 4 36 RTD calibration curve 1 4 9 RTD calibration curve 2 4 13 restore 6 15 S silencing 3 4 26 silencing 4 4 29 serial number 6 9 software revision 6 9 EEE set point 2A 5 3
92. perature for channel A and input 2 senses temperature for channel B The alarm out puts can be configured to trigger from either input Also the retransmit option can be configured to retransmit either of the channel s process value or set point value 8 User s Manual Setup Menus Chapter 4 NOTE Decimal points may not always be in the position specified below depending on the the settings in the Decimal 1 parameter in the Input Menu A CAUTION Changing the value of changes most other prompts to the factory default values and clears all program steps Verify the correct sensor type before making a change Document all settings before changing sensor type Failure to fol low this guideline could result in dam age to equipment or property Input 1 continued on next page Setup Menus Chapter 4 Setup Input Input Prompts When you are in the Setup menus the Series 998 displays the menu selection 4 HIJA ERREYS or AHH in the upper display and in the lower display The Up arrow Y or Down arrow key selects another menu Press the Mode key QB to display the functions in the lower display and their value in the upper display Use the Up arrow or Down arrow key to change the value in the upper display The new value will not take effect until after a five second delay or until you press the Mode key Input 1 Select the sensor type for channel A This selection must match the sensor type con
93. pon Watlow Controls to provide compatibly engineered controls which they can incorporate into their products with confidence Watlow Controls resides in a 100 000 square foot marketing engineering and manufacturing facility in Winona Minnesota Appendix Warranty Returns Returns 1 Call Watlow Customer Service 507 454 5300 for a Return Material Authorization RMA num ber before returning any item for repair We need this information e Ship to address e Contact name e Phone number e Ship via e Your P O number e Symptoms and or special instructions Name and phone number of person returning the material Bill to address 2 Prior approval and an RMA number from the Customer Service Department is needed when returning any unused product for credit Make sure the RMA number is on the outside of the carton and on all paperwork returned Ship on a Freight Prepaid basis 3 After we receive your return we will examine it and determine the cause for your action 4 In cases of manufacturing defect we will enter a repair order replacement order or issue credit for material A 20 percent restocking charge is applied for all returned stock controls and acces sories 5 Ifthe unit is unrepairable it will be returned to you with a letter of explanation Repair costs will not exceed 50 percent of the original cost Shipping Claims When you receive your Watlow control examine the package for any
94. process temperature for PID channel B out puts When set to SERA integral is disabled EY This prompt appears only if Calibration Menu is set to GSW and GF is not set to SERN Default L ay EEEE min repeat Operation Menus Chapter 5 WATLOW Series 998 User s Manual 5 15 Operation PID B rA lb mt cnr seep i nm a nm 5 16 cb a mp ag WATLOW Series 998 User s Manual Rate Output 1B or 2B Adjust the rate to eliminate overshoot on startup or after the set point changes The rate setting will not influence the percent power if the process temperature is more than twice the proportional band from the set point When set to SEA rate is disabled This prompt appears only if Calibration Menu is set to and is set higher than SEEN Default L EH WEEE nin Derivative Output 1B or 2B Adjust the derivative to eliminate overshoot on startup or after the set point changes The derivative setting will not influence the percent power if the process temperature is more than twice the proportional band from the set point When set to fa derivative is disabled FINIA This prompt appears only if Calibration Menu is set to and PTA is set higher than SERN Default L ERED min Operation Menus Chapter 5 Operation PID B Cycle Time Output 1B or 2B ry n o Select the time in seconds of a complete on off cycle ry r NI oO MARG This prompt does not appear if
95. pts may not co Retransmit High Limit appear depending on controller configuration Figure 4 16 CD GG Retransmit Calibration Offset The Output Menu 4 16 WATLOW Series 998 User s Manual Setup Menus Chapter 4 NOTE Decimal points may not always be in the position specified below depending on the the setting of Decimal 1 in the Input Menu Setup Menus Chapter 4 Setup Output Output Prompts When you are in the Setup menus the Series 998 displays the menu selection EMA HAZA CHAA or MHH in the upper display and in the lower display The Up arrow Y or Down arrow 2 key selects another menu Press the Mode key Q to display the first prompt in the lower display and its value in the upper display Use the Up arrow or Down arrow key to change the value in the upper display The new value will not take effect until after a five second delay or until you press the Mode key Output 1A Set the way that output 1A will respond to a difference between the set point and an input variable select reverse action so that output 1A responds when the input signal is less than the set point select direct action so that output 1A responds when the input signal is more than the set point ME This prompt always appears Default L EKA EEMI EE WATLOW Series 998 User s Manual 4 17 Setup Output HY 4A Hysteresis 1A Select the switching hysteresis for output 1A This determines the change in te
96. rd then down to secure it to the control case To guarantee a proper NEMA 4X seal Series 996 and 998 units vertical must have the mounting brackets located on either side of the unit When installing Series 997 and 999 units horizon tal the brackets must be on the top and bottom of the unit Make sure the case is seated properly Tighten the installation screws firmly against the mounting collar to secure the unit To ensure a NEMA 4X seal there should be no space between the bezel and panel Overtightening the screws will distort the case and make it diffi cult to remove or replace the controller Insert the controller chassis into its case and press the bezel until all four tabs snap Make sure the inside gasket is seated properly and not twisted To release the mounting brackets loosen the mounting bracket screws and push the brackets forward then pull it up and out WATLOW Series 998 User s Manual 2 3 A WARNING To avoid potential electric shock use National Electric Code NEC safety practices when wiring and connect ing this unit to a power source and to electrical sen sors or peripheral devices Failure to do so could result in injury or death NOTE Input to output iso lation is defeated when the external signal conditioner power supply is used to power a transmitter con nected to input 1 or input 2 Figure 2 4 Power wiring A CAUTION The Series 998 will not function wi
97. rigger value for the output 4 alarm GEIE This prompt appears only if Output Menu is set to or ERE If L or Output Menu or Output Menu Alarm 4 High Default L lowest value of value of sensor or BAA range Input Menu Select the high trigger value for the output 4 alarm a AYLG GEEH This prompt appears only if Output Menu is set to or EIET If L or Output Menu or Output Menu 5 6 WATLOW Series 998 User s Manual Default L CTH value of or PEEP Input Menu Operation Menus Chapter 5 Operation System Oren Auto tune AUE Initiate an auto tune NOTE This prompt always appears For more informa tion on auto tune Default see Chapter 7 l Operation Menus Chapter 5 WATLOW Series 998 User s Manual 5 7 Operation PID A Reaching the PID Menus Begin in the Display Loop and press the Mode key to reach the Set Point 2A prompt RI the Set Point 2B prompt or the Operation Menu HAJA EEE Set Point 2A CS EEE 38 ae Set Point 2B es C3 es es Eine MWER GHEE System PIDA PIDB Menu Menu Menu p 5 2 p 5 8 p 5 13 Use the Mode key Q to step past the Set Point 2A prompt or the Set Point 2B prompt EYEE if they appear see prompt information Upon reaching the Operation Menu prompt HAA use the Up arrow key Y to select a menu Press the Mode key QQ to step through the prompts ee o E a CA aB rvs Press the Up ar
98. row key Y to step through the prompt values The Down arrow key GQ backs through the values Figure 5 8 The PID A Menu 5 8 WATLOW Series 998 User s Manual Acs H 8 8 0 8 4 T 8 8 8 8 8 8B B 4 EEFI Channel A PID Menu Operation Menus Enter your settings from the controllers upper display GENI Proportional Band Output 1A page 5 9 Reset Output 1A Ma integral Output 1A Rate Output 1A FINIA Derivative Output 1A M Cycle Time Output 1A GEIA Proportional Band Output 2A page 5 9 Reset Output 2A Pez Integral Output 2A Prompts may not appear depending on Rate Output 2A controller configuration FEZI Derivative Output 2A ME Cycle Time Output 2A Dead Band A Operation Menus Chapter 5 NOTE Decimal points may not always be in the position specified below depending on the Decimal 1 settings in the Input Menu oO o I D oC MM 3 Operation Menus Chapter 5 Operation PID A PID A Prompts After you step past the Set Point 2A prompt HZZ and the Set Point 2B prompt A to the Operation menus the Series 998 displays the menu selection EEEE GEETA or in the upper display and HAJA in the lower display The Up arrow Y or Down arrow key GJ selects another menu Press the Mode key Q to display the first prompt in the lower display and its value in the upper display Use the Up arrow and Down arrow keys to change the valu
99. s To reach the Operation Menus begin in the Display Loop and press the Mode key J Depending on the controller configuration either the Set Point 2A prompt K the Set Point 2B prompt or the Operation Menu prompt will appear in the lower display The three Operation Menus are System SEEE PID A BEETA and PID B GARFFI Use the Mode key QB to step past the Set Point 2A prompt or the Set Point 2B prompt A if they appear see prompt information Upon reaching NOTE Press the Display key to return to the Display Loop from any point in any menu the Operation Menu prompt use the Up arrow 79 or Down arrow key to select a menu and the Mode key QQ to step through a menu You will not see every prompt in any of these menus The controller s con figuration and model number determine which prompts appear After stepping through each menu the Series 998 returns to the Operation Menu prompt Use the Up arrow and Down arrow keys to select the next menu or use the Mode key to advance through the same menu again To move backwards through the menu hold the Mode key down and press the Up arrow key Use the Up arrow or Down arrow key to change the prompt setting 398 PROCESS 98 39 PEE E 1A 2A 1B 2B CHA CHBe DISPLAY AUTO MAN Dii OPE eee o 1A 2A 1B 2B CHAO oispLaY CHB i AUTO Hh MAN SEI Figure 5 1 Navigating the Operation Menus Opera
100. s above the range high Vaisala Model HMM 30C Solid state Relative Humidity Sensor With the Vaisala configuration channel A is used to measure temperature and channel B must be a process input with the Input 2 Linearization prompt set to SEHI The Series 998 provides temperature compensation for the Vaisala sensor The humidify and dehumidify outputs outputs 1B and 2B are disabled when the channel A temperature falls below 40 F 40 C or goes above 320 F 160 C The relative humidity process display in the Display Loop will display the error code for a low temperature error and if the temperature is above the range high WATLOW Series 998 User s Manual 4 3 Setup Input NOTE See Input 2 Linearization in this chap ter 4 4 WATLOW Series 99 Rotronic Model H260 Capacitive Relative Humidity Sensor With the Rotronic configuration channel A is used to measure temperature and channel B must be a process input with the Input 2 Linearization prompt set to REEF The Series 998 provides temperature compensation for the Rotronic sensor The humidify and dehumidify outputs outputs 1B and 2B are disabled when the channel A temperature falls below 5 F 20 C or goes above 320 F 160 C The relative humidity process display in the Display Loop will display the error code for a low temperature error and if the temperature is above the range high Temperature Temperature For temperature temperature operation input 1 senses tem
101. s and flicker 73 23 EEC Low Voltage Directive 1993 Safety requirements for electrical equipment for measurement control and laboratory use Part 1 General requirements Classification EN 61010 1 D clare que le produit suivant Fran ais D signation S rie 996 997 998 999 Num ro s de mod le s 99 6 7 8 ou 9 lettre quelconque 1 ou 2 1 ou 2 C E F ou K C E F ou K A B C J K M N ou T A B C D E K R S ou T deux lettres quelconques Classification Commande installation cat gorie Il degr de pollution II Tension nominale 100 240 V ou 24 28 V Fr quence nominale 50 60 Hz Consommation d alimentation nominale 16 VA maximum Conforme aux exigences de la ou des directive s suivantes de l Union Europ enne figurant aux sections correspondantes des normes et documents associ s ci dessous 89 336 EEC Directive de compatibilit lectromagn tique EN 50082 2 1995 Norme g n rique d insensibilit lectromagn tique Partie 2 Environnement industriel EN 61000 4 2 1995 D charge lectrostatique EN 61000 4 4 1995 Courants lectriques transitoires rapides EN 61000 4 3 1996 Insensibilit l nergie rayonn e EN 61000 4 6 1996 Insensibilit l nergie par conduction ENV 50204 1995 T l phone cellulaire EN 50081 2 1994 Norme g n rique sur les missions lectromagn tiques Partie 2 Environnement industriel EN 55011 1991 Lim
102. s only if is not set to EF If Default L Global Menu amp MIF N C_F Global Menu Input Menu C_F Global Menu amp MIF 2 EN EFE C_F Global Menu Input Menu a process input is selected RTD Calibration Curve 2 Select the calibration curve for the channel B RTD 2 input The RTD input uses either the European DIN 0 0038509 Q9 C or the Japanese JIS 0 0039162 Q C linearization standard This prompt appears only if you have set to or EIF Default l din MEE WATLOW Series 998 User s Manual 4 13 Setup Input Frere Lune 4 14 WATLOW Series 99 Software Filter 2 Select the filter time constant in seconds for channel B This smooths a rapidly changing input signal for display or control purposes e Select a positive value to filter only the display e Select a negative value to filter the input signal e Set the value to SEF to disable the filter This prompts appears only if is not set to FI Default y Fire Fitre Linearization 2 Set the type of relative humidity sensor being used e Select to provide temperature compensation when using the Vaisala HMM 30C humidity sensor Select BEEFN to provide temperature compensation when using the Rotronic H260 humidity sensor e Select when using a wet bulb dry bulb sensor This prompt appears only if is not set to SEPTA Default no Lind Line Lined Altitude Compensation Set barometric correction for
103. sable the filter This prompt always appears Default Fir I Fir I Setup Menus Chapter 4 WATLOW Series 998 User s Manual 4 9 Setup Input A CAUTION Changing the value of changes most other prompts to the factory default values Verify the correct sensor type before making a change Document all set tings before chang ing the input type Failure to follow this guideline could result in damage to equipment or prop erty NOTE If HEF is selected for none of the other input 2 prompts will appear 4 10 WATLOW Series 998 User s Manual Input 2 Select sensor type for channel B This selection must match the sensor type con nected to terminals 18 19 and 20 See the Appendix for more information about sensors e Changing the value of changes all other prompts to the factory default values except the Communications and Lockout menus the prompt in the Global Menu and the prompt in the Calibration Menu If you change the value the default warning will flash in the upper dis play e Changes do not take effect automatically after five seconds you must press the Mode key to enter the sensor type change and advance to the next prompt This prompt always appears If Default L L 99 1 _ no DIP J K T N E W5 W3 Pt2 no EEE n E EA GET thermocouple Ine Ing Ing Ing Ing 99 2 Input 2 DIP J K T N E w5 W3 Pt2 no gt aa pn ld no EE A Tne Tne thermocouple
104. set p point value and the CH A light CH B Indicator Light is on One press of the Display When lit if the CH A light is not key lights CH B and the upper on the channel B process value SERIES 998 display shows the channel B is shown in the upper display va process value and the lower value is shown in the lower dis play When both CH A and CH B lights are on the upper dis play shows the channel A process value and the lower dis play shows the channel B process value Up arrow Key Y Increases the value of the displayed prompt A light touch increases the value by one Holding the key down increases the value at a rapid rate New data does not take effect for five seconds or until the Mode or Display key is pressed Down arrow Key 3 and the channel B set point va Decreases the value of the displayed prompt A light touch decreases the value by one Holding the key down decreases the displayed value at a rapid rate New data does not take effect for five seconds or until the Mode J or Display key is pressed Up arrow Down arrow Keys Press simultaneously for three seconds to enter the Setup Menu Continue to press both keys for another three seconds to enter the Factory Menu Keys and Displays Chapter 3 display shows the channel B set point value A second press of the key lights both CH A and CH B and the upper display shows the channel A process value and the lo
105. set point EE This prompt always appears Ramping Function for Channel A Select when channel A will enter ramping mode Activates ramping on power up only Activates ramping on power up and any set point change This prompt always appears Default 4 SEPE WATLOW Series 998 User s Manual 4 35 Setup Global rt A NOTE Lower display alter nately flashes and lower display value when ramping is in process 4 36 WATLOW Series 99 Ramp Rate for Channel A Set the rate of heating for channel A This prompt appears when is set to or RHA Default L ar GT EEEE degrees minute Ramping Function for Channel B Select when channel B will enter ramping mode Activates ramping on power up only JJZ Activates ramping on power up and any set point change This prompt always appears Ramp Rate for Channel B Set the rate of heating for channel B This prompt appears when is set to or RAZA Default L ar TT EEEE cegrees minute 8 User s Manual Setup Menus Chapter 4 Setup Menus Chapter 4 WATLOW Series 998 User s Manual 4 37 Setup Communications Reaching the Communications Menu Begin in the Display Loop and press the Up arrow 9 and Down arrow GY keys simultaneously for three seconds to reach the Setup Menus es es es es Cie yO Oe HA EA Cara Input Output Global Communications Menu Menu Menu Menu p 4 2 p 4 16 p 4 32 p 4 38 Press the Up arrow key Y
106. t 4 31 address 4 40 alarm 3 4 24 alarm 4 4 27 altitide compensation 4 14 ambient temperature 6 9 GEPA annunciator 4 35 analog output 4 29 retransmit high limit 4 31 retransmit low limit 4 30 auto tune set point 4 35 auto tune 5 7 B MEHE baud rate 4 39 C celsius fahrenheit 4 33 calibration menu 6 6 6 14 calibration offset 1 4 8 calibration offset 2 4 13 Communications Menu 4 38 communications menu lock out 6 6 cycle time output 1A 5 12 cycle time output 1B 5 17 cycle time output 2A 5 12 cycle time output 2B 5 17 D data bits and parity 4 39 factory ship date 6 9 ERNE dead band A 5 12 ZAA dead band B 5 17 derivative output 1A 5 11 derivative output 1B 5 16 derivative output 2A 5 11 derivative output 2B 5 16 ZIE decimal 1 4 6 EIJE decimal 2 4 11 EZEIZA default 6 15 EME Diagnostics Menu 6 8 EGE diagnostics menu lockout 6 6 test displays 6 12 E m event input 1 4 34 GEEL event input 1 status 5 4 error latching 4 34 Appendix F Se failure mode 4 33 EHH software filter 1 4 9 software filter 2 4 14 G EMA Global Menu 4 32 EINAN global menu lockout 6 5 H hysteresis 1A 4 18 hysteresis 2A 4 20 hysteresis 1B 4 21 hysteresis 2B 4 22 hysteresis 3 4 25 hysteresis 4 4 28 GEM input 1 4 5 4 6 GET input 2 4 10 HTS Input Menu 4 2 input menu lockout 6 5 interface type 4 40 integral output 1A 5 10 integral output 1B 5 15 integral output 2A 5 10 integral
107. t Global Communications Menu Menu Menu Menu Annunciator p 4 2 p 4 16 p 4 32 p 4 38 Press the Up arrow key Y to EETA Auto tune Set Point page 4 35 select one of the Setup menus Ramping CHA Ramp rate CHA Press the Mode key Q to step through the prompts Ramping CH B 8 8 8 8 68 6 68 6 w Ramp rate CH B O M o Prompts may not appear depending on controller configuration Press the Up arrow key Y or the Down arrow key to select one of the prompt values Figure 4 32 The Global Menu 4 32 WATLOW Series 998 User s Manual Setup Menus Chapter 4 NOTE Decimal points may not always be in the position specified below depending on the Decimal 1 setting in the Input Menu C_F NOTE See Chapter 7 for more information on errors Setup Menus Chapter 4 Setup Global Global Prompts When you are in the Setup menus the Series 998 displays the menu selection MA3 HAA EPETA or a7 in the upper display and in the lower display The Up arrow Y or Down arrow key selects another menu Press the Mode key to display the first prompt in the lower display and its value in the upper display Use the Up arrow and Down arrow keys to change the value in the upper display The new value will not take effect until after a five second delay or until you press the Mode key Celsius Fahrenheit Select which temperature scale the controller will use This pr
108. t is required The retransmit output will be 4mA until the oven temperature reaches 600 F Once it is above 600 F the retransmit signal increases propor tionally to the temperature rise until it reaches 900 F The retransmit sig nal will not exceed 4mA or 20m lt A Analog SS Input 1 WATLOW a 9 9 8 Control PROCESS Output 1A Power n je eve Device e e e e 1A 2A 1B 2B CHA CHB DISPLAY AUTO MAN Heat Treat Oven Control G2 Output 3 Chart Recorder SERIES 998 4 20mA T Heater Temperature Tramsmitter User s Manual Applications Chapter 8 Misc Features Dead Band The dead band prompts and FISHES determine the amount of interaction between heat reverse acting and cool direct acting control outputs for channel A and B respectively Dead band directly offsets the cool control output set point With a positive dead band both control out puts will never be on at the same time With the process in the dead band while it is a positive dead band the output value is determined by adding the output value from each control output and applying the result to the appropriate output If the dead band value is negative the heat and cool outputs can be on at the same time Transmitter Power Supply When option T is ordered for output 3 or 4 the Series 998 can supply power to external signal conditioners transducers or transmitters Via internal
109. th two grounded ther mocouple inputs Avoid using a grounded thermo couple for both input 1 and input 2 Failure to follow this guideline could result in damage to equipment 2 4 WATLOW Series 998 User s Manual Wiring the Series 998 Wiring options depend on the model number and DIP switch settings Check the terminal designation stickers on either side of the controller and compare your model number to those shown here and with the model number breakdown on the inside back cover of this manual Input to output Isolation The Series 998 uses optical isolation between the analog inputs and the controller outputs digital input This isolation provides a 500VA ac bar rier to prevent ground loops when using grounded sensors and or peripheral equipment Here is a breakdown of the isolation barriers e Analog inputs 1 and 2 are grouped together e Outputs 1 through 4 and the standard event input are grouped togeth er This does not apply to Output 4 when configured as communications e The digital communications output 4 is separate from the above groups Power Wiring 100 to 240V ac nominal 85 to 264 actual Vertical Package 998 Horizontal Package 999 24 to 28 V ac dc nominal 20 to 30 actual Vertical Package 996 Horizontal Package 997_ Sensor installation Guidelines Thermocouple input Extension wire for thermocouples must be of the same alloy as the thermocouple itself
110. the action of the channel A heating output and cooling output If you select a positive value the heat and cool outputs cannot be energized at the same time If you select a negative value both outputs can be energized at the same time e If a process input is selected the decimal precision will be determined by the setting Input Menu EEE This prompt appears only if EJHA and GEG are set higher than QF and one channel A output performs heating action and the other performs cooling action If L Global Menu Global Menu a process input is selected ir a ln a LO ln a Wa ln Wa 5 12 WATLOW Series 998 User s Manual O D cr mE un Wn Wn units Operation Menus Chapter 5 Reaching the PID Menus Begin in the Display Loop and press the Mode key to reach the Set Point 2A prompt yey the Set Point 2B prompt or the Operation Menu MAJA Set Point 2A ca oe Set Point 2B O mone A oO Lem eo A GEE System PIDA PIDB Menu Menu Menu p 5 2 p 5 8 p 5 13 Use the Mode key to step past the Set Point 2A prompt or the Set Point 2B prompt EZA if they appear see prompt information Upon reaching the Operation Menu prompt HAJA use the Up arrow key Y to select a menu Press the Mode key 3 to step through the prompts o a woof wey Press the Up arrow key Y to step through the prompt values The Down arrow key GJ backs through the
111. tion Menus Chapter 5 Begin in the Display Loop and press the Mode key to reach the Set Point 2A prompt H the Set Point 2B prompt A or the Operation Menu MAJA PFE Set Point 2A S EE J Set Point 2B T a oy System PIDA PIDB Menu Menu Menu p 5 2 p 5 8 p 5 13 Use the Mode key to step past the Set Point 2A prompt or the Set Point 2B prompt if they appear see prompt information Upon reaching the Operation Menu prompt use the Up arrow key to select a menu WATLOW Series 998 User s Manual 5 1 Operation System Reaching the System Menu C 4 cp AA Set Point 2A vde mone GAJA Set Point 2B 4 L555 gt EEH System Menu OPE A Cc Operation Menus _ Enter your settings SARS from the controller s cine aa upper display ta ieee wall cD Event Input 1 Status page 5 4 J mone MAE Output 3 Status tE Select the System Menu then Cc Output 4 Status press the Mode key to step through the prompts Vv mone REIN Alarm 3 Low page 5 5 co GEEN Alarm 3 High wove GEIN Alarm 4 Low page 5 6 Vv x 0 se o en GEN GEER cD Alarm 4 High J o 6 Auto tune CEN MAE Prompts may not appear depending on controller configuration Press the Up arrow key to step through the prompt values The Down arrow key backs through the values Figure 5 2 The System Menu 5 2 WATLOW Series 998 User s Manual Op
112. to select one of the Setup Menus AD DISPLAY CHB Press the Mode key GB to step through the prompts FULLE onl Press the Up arrow key Y or the Down arrow key to select one of the prompt values Figure 4 38 The Communications Menu 4 38 WATLOW Series 998 User s Manual A gt Waga Communications Menu mone Setup Menus CD PEHE Baud Rate Vv cp HA Data Bits and Parity Vv CD Protocol Type Vv CD Address p Interface Type Prompts may not appear depending on controller configuration NOTE The Communications Menu appears only on controllers equipped with communications hardware 99__ R_or 99 S_ See Data Communications with the Series 988 Family of Controllers for detailed informa tion on communications Setup Menus Chapter 4 Setup Communications Communications Prompts When you are in the Setup menus the Series 998 displays the menu selection EAA GAZA or in the upper display and in the lower display The Up arrow or Down arrow key Q3 selects another menu Press the Mode key Q to display the first prompt in the lower display and its value in the upper display Use the Up arrow and Down arrow keys to change the value in the upper display The new value will not take effect until after a five second delay or until you press the Mode key Baud Rate Select the communications speed AZ
113. tput isolation 2 4 installation 2 1 2 3 integral output 1A or 2A 5 10 integral output 1B or 2B 5 15 interface type 4 40 L latching alarm 3 4 26 latching alarm 4 4 28 linearization 2 4 14 lower display 3 1 manual operation 7 3 7 4 manual tuning 7 2 7 3 menu maps ii iii Mode key 3 1 model number A 9 O Operation Menus ii 5 1 5 17 ordering information A 9 output 1A 4 17 output 1B 4 21 output 2A 4 19 output 2B 4 22 output 3 4 23 output 3 alarm jumper 7 4 7 5 output 3 status 5 4 output 3 wiring 2 12 output 4 4 27 output 4 status 5 4 output 4 wiring 2 13 Output Menu 4 16 4 31 output menu lockout 6 5 output module types 6 11 P Panel Lockout Menu 6 2 PID A menu lockout 6 4 PID A menus 5 8 5 12 PID B menu lockout 6 4 PID B menus 5 13 5 17 power wiring 2 4 process 3 4 30 process A 3 2 4 20 process B 3 2 4 23 process input 2 4 2 5 process retransmit 2 12 proportional band adjustment 7 2 WATLOW Series 998 User s Manual A 5 Index proportional band output 1A 5 9 proportional band output 1B 5 14 proportional band output 2A 5 9 proportional band output 2B 5 14 protocol type 4 40 R ramping function channel A 4 35 ramping function channel B 4 36 ramp rate channel A 4 36 ramp rate channel B 4 36 range high 1 4 7 4 8 range low 1 4 7 4 8 range high 2 4 11 4 12 range low 2 4 11 4 12 rate derivative adjustment 7 3 rate output 1A or 2A 5 11 rate
114. wer display shows the channel B process value See the next page for more information on the Display Loop Auto Man Key Used to switch from auto to manual control or vice versa Also used to reset alarms Mode Key 3 Steps the control through the menus New data is entered once the Mode key is pressed Mode Up arrow Key 23 O To move backwards through the menus hold down the Mode key then press the Up arrow key to scroll The Mode key must be pressed first and held before the Up arrow key will begin scrolling Scrolling is disabled once the keys are released or you reach the top of the menu Figure 3 1 Series 998 Keys and Displays WATLOW Series 998 User s Manual 3 1 Display Loop NOTE Lower display alter nately flashes and lower display value when ramping is in process Figure 3 2 The Display Loop Display Key and Loop On power up the Series 998 displays the channel A set point value in the lower display and the channel A process value in the upper display and the CH A channel A indicator light is on Press the Display key once to view the channel B set point and process values CH B will be lit Press the Display key once again and channel A process value is displayed in the upper display and channel B process value is displayed in the lower display At this point both CH A and CH B will be lit Press the Display key again to display units Any point in any menu if no key is pressed for
115. xample Set to REHMA Set to BN Set to BEN A 4mA input will display BEHN A 12mA input will display SEIN A 20mA input will display SEHN e The low and high values of each sensor type are listed on the specifica tions page of the Appendix e Choose between Fahrenheit and Celsius at the prompt in the Global Menu These prompts appear only if is not set to SEPTA WATLOW Series 998 User s Manual 4 11 only td o 1 r N aD e2 an e gt 5 gs D Th RSA M Hoe SRR o gt HES maoa ih moat mS a aSr unna in uua ASSR o a ee nS wee 7 2 2 e2 2 TS SSS 75 SS GMm 555 5 J am am ic ee a Z u ae go NM aD a wo UE E I UE E D ja Default J A 500 rH 2500 Le EF Le AER Bd 3G EE w Oa aa am a N Cag wu gt ma mu wa aa os ao o a ao w ea ea ee a Ww w u oe a CORRE aO ae es a on Ga a aa ae n EF CEFE HEA Default WS W3 a oF ee Pe Eu Ee CO Ci me m w a a N e v c av RO aw ao EE A 7 gt a n ESS BHT S g on EE aNSS ooa or 3 583 QEEG 5 Dy A 5259 Q IRRE igge ep Ul aes reece RES 8 ZES ES Setup Menus Chapter 4 WATLOW Series 998 User s Manual 4 12 CALE Setup Menus Chapter 4 Setup Input Calibration Offset 2 Offset the channel B signal by a positive or negative value This allows you to compensate for lead resistance sensor errors or other factors MEINE This prompt appear

Series 998/999 - Zesta Engineering Ltd.

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