Instruction Manual for the Despatch/Watlow 1500 Control
Contents
1. Page 36 Despatch Watlow 1500 Control Instruction Manual Warm Cold Start Cont Table 10 DIP Switch Selection DIP Switch FUNCTION No ya NE ER Auxiliary Event Output 4 for both Ch 1 Auxiliary Event Output 4 for both Ch 1 and Ch 2 are alarm outputs and Ch 2 are event outputs Alarms are latching displayed until Alarms are non latching displayed only cleared manually as long as the alarm condition exists 3 RTD Unit Only The Ch 2 sensor is an RTD sensor The Ch 2 sensor is an RTD sensor Jumpers W151 and W153 on the signal Jumpers W151 and W153 on the signal conditioner board A007 1316 must be conditioner board A007 1316 must be installed installed T C Unit Only Not used Set in the ON position Dual PID per channel Single PID per channel Factory use only Must be in the ON position Cold start on power up Memory Warm start on power up Programmed cleared parameters set to default values are retained for all parameters values EC function after a cold start EF function after a cold start Changing the Position of a Switch Whenever you change the position of a DIP switch follow this procedure 1 Remove power from the 1500 Turn the front panel to loosen the controller from the case 2 Grip the front panel bezel and pull it straight out from the control case The control chassis will come out of the case as you pull the bezel 3 Set the DIP switch to the position you2. 30 f Holdfor30 min w Devices powered and cool fans Js33 scoi Repeat Devices powered on off cycle to step 33 PT dump to 47 for shutdown w o rapid depressurization Oooo Tooo oo o lankstecp o ooo O 35 36 37 38 42 as 44 45 45 E a a a eee 47 oo 60 oof0 05 Cool EV12 on Ramp down but maintain 60 RH 48 wa io2 Wait for liquid temperature of 1026C 49 oo 00 0010 1000 Openthe drain and ventto purge old water w1 40 t Waits for typical safe unloading temperature s51 oo o oo00 0000 00 00 o5 Note s in above sample indicate parameter is left blank Blank is not the same as zero Page 24 Despatch Watlow 1500 Control Instruction Manual Procedure for Programming HAST Profile 1 If power on check HALT LED If off press RUN HALT 2 Press RESTART 3 Press MODE until CHG PARA LED is lit 4 Press FCTN until FUNCTION display reads GA 5 Press UP arrow until DATA display stops at 2000 6 Press DOWN arrow until display reads 1995 press enter key 7 At Step 1 the display will read 01 SP if Step 1 is clear press enter S1 is displayed use arrow keys to 20 press enter S2 is displayed use arrow keys to 70 press enter E1 is displayed use arrow keys to 0000 press enter E2 is displayed use arrow keys to 0001 press enter HR is displayed use arrow keys to 00 press enter MN is displayed use a
3. LED should be on Page 6 Despatch Watlow 1500 Control Instruction Manual Manual Set Point Controller Cont 4 Enter the RH The humidity event must be off when outside of the range 4EC to 98EC Humidity beyond these extremes can result in equipment damage Ifa dry air system and an electronic humidity sensor are installed in lieu of a wet bulb sensor the optional dry air event may be outside the range of 4EC to 98EC NOTE In the DATA display the right most character for Event 11 is shown as 0001 a Press the FCTN key C2 is shown b Update the RH temperature by using the up down keys c Press enter when DATA display shows your desired set point 5 Change the auxiliary events a Press the FCTN key E1 is displayed b Turn the auxiliary event on or off 1 on 0 off Try varying set points and events and watch how each effects the output LEDs Despatch Watlow 1500 Control Instruction Manual Page 7 Guarded Access Programming The Guarded Access parameters control the process limits the three GA parameter loops are restricted to operators by special codes The Guarded Access codes prevent inexperienced or unauthorized operators from changing the parameters You must select one of the following GA 0000 To set CH 1 and CH 2 alarm limits GA 0001 To set CH 1 PID tune parameters GA 0002 To set CH 2 PID tune parameters GA 0006 To set set point scroll limits optional lockout and option recy
4. Control Instruction Manual Wait Steps Cont The Wait Step does not allow the linear ramping path to reach the new conditions as a Set Point Step does To optimize control reduce the overshoot and undershoot a Wait Step uses the PID Parameters to satisfy the wait condition In other words select the step type which best matches your needs Next Step The Next step NX step is used to select the program step After the final prompt in each of the step types SP JL or WT pressing ENTER advances the processor to NX At the same time the STEP display will advance by one Pressing ENTER again will bring up SP JL or WT if the next step has no programmed information If there is data in the subsequent step the processor will move to the first prompt in that submode If you want a different step from NX select the number of the step you want in the DATA display with the gt key and key then press ENTER Again the processor will move to one of the three step types if the step is blank or to the first prompt in the step type loop S1 JS or W1 Pressing FCTN at NX instead of ENTER will send the processor back to the initial prompt in the current step Recycle Option You may request that your program repeat indefinitely by selecting RC 1 in the GA 5 area of the CHG PARA mode With the Recycle option active you may expect to see continuous activity as the program sequence repeats However if your Step 1 is programmed a
5. display Alarm A1 is an indication of power loss 3 Clear the alarm by pressing the clear button on the Watlow 1500 4 The actual temperature and humidity will be shown in the ACTUAL display located at the top of the control Press the SEL key to toggle between temperature and humidity Temperature will be displayed on Channel 1 Humidity will be displayed on Channel 2 Despatch Watlow 1500 Control Instruction Manual NOTE Your control has already been configured at Despatch Use this manual as a guide to typical settings CAUTION Before making changes to your control consult with Despatch Industries Product Service at 1 800 473 7373 Page 3 Watlow 1500 Control The Watlow Series 1500 is a versatile microprocessor based control powerful yet simple to learn ERR RR KK 828832 QLS RRR p RLL LLLLLLS cooo Figure 1 illustrates the Watlow 1500 installed on the Series 16000 environmental chamber control panel Table 1 Watlow 1500 Displays Actual Shows the actual process conditions dry bulb temp if CH 1 LED is on RH if CH 2 is on Event Shows current status of all events Lowest significant event is left justified instead of right justified as when events are shown in data display Shows which step the programmer is currently pointed to Describes the function or type of data being displayed in the data display Data Shows current value for the function being viewed This di
6. in the DATA display OR Use the FCTN key to advance to the next prompt without entering a value b Press the ENTER key to enter the value in the DATA display as the new set point Page 16 Despatch Watlow 1500 Control Instruction Manual Creating Files Profiles Cont 6 Enter set points for the JL Jump Loop submode a Use the gt key and the key to enter the JS Jump Step parameter OR Use the FCTN key to advance to the next prompt without entering a value b Press the ENTER key c Use the gt key and the key to enter the JC Jump Count parameter OR Use the FCTN key to advance to the next prompt without entering a value d Press the ENTER key WT appears in the FUNCTION display Despatch Watlow 1500 Control Instruction Manual Page 17 Creating Files Profiles Cont 7 Enter the wait condition values for the WT Wait submode a Use the ENTER KEY W1 appears in the FUNCTION window indicating that a wait condition for the CH 1 set point can be entered b Use the gt key and the key to enter the wait condition OR Use the FCTN key to advance to the next prompt without entering a value c Press the ENTER key W2 appears requesting a wait for CH 2 set point d Repeat steps 3b and 3c for e WE Wait for Event e WH Wit for Real Hours e WM Wait for Real Minutes e WS Wait for Real Seconds Select actual time of day values for each Page 18 Despatch Watlow 1500 Control Ins
7. required for cooldown and shutdown Set Point Step The existing start conditions for each step depend upon the programmed step previously performed by the Watlow 1500 The desired end conditions for each step are also programmed During any set point step the Watlow 1500 follows a linear path between the existing start conditions and the desired end conditions When programming set points in the Watlow 1500 it is important to keep track of the ramping conditions at the start of a step and at the end of a step To clear a step 1 Place the controller in halt by pressing the RUN HALT key until RUN HALT LED is lit 2 Place the controller in the desired step to be cleared 3 Press the CLEAR pushbutton Despatch Watlow 1500 Control Instruction Manual Page 15 Creating Files Profiles See sections on SAMPLE HAST PROFILE and PROCEDURE FOR PROGRAMMING HAST PROFILE for LPB chambers 1 Press the MODE key to select the CHANGE DATA mode The FUNCTION display will indicate one of three submodes e SP Set Point e JL Jump Loop e WT Wait 2 Press the FCTN key until SP appears in the function display 3 Press the ENTER key S1 will appear in the FUNCTION display and 0000 will appear in the DATA display 4 Use the FCTN key to select the variable to edit See the example on Table 7 Channel 1 S1 5 Enter a set point for the channel selected in step 4 a Use the gt key and the key to change the value
8. to step 10 or other for different setpoint process pio 120 85 f o0 31 00 Change to85 RH condition 11 wz864 Waits for RH to reach near setpoint pi2 f 0000 f f oo 30 f Holdfor30 minutes o o 43 f oom f f o0 30 00 f Hold for 30 min w Devices powered and cool fans 44 gs12 scoi Repeat Device power offfon cycle to step 12 once 45 gsa7 scoi TS to 47 for ramp down w o rapid decompression e fJ J I J f f ae 20 130 f f 10 Ramp C1 to 130C 16C min first not RH 21 J e f f 05 Ram RH after temperature has been reached 22 fwzxea Waittornearsetconditions 23 f 0o00 oo f so Hold for 30 min w Devices not powered EV1 1 24 foon oo f s0 Hold for 30 min w Devices powered and cool fans 25 ss23 scor f f Repeat Devices powered on off cycle to step 23 26 ssa7 scot f Jump to 47 for shutdown w o rapid depressurization por Plank step o 30 140 20 Ramp temperature first to 1406C 16C min p31 35 J f 05 Begin RH ramp after temperature is reached 32 wxs4 J Wait for near setpoints RH condition 33 0o00 oo f 30 f Holdfor30 min w Devices not powered EV1 1 34 f oom oo f
9. 00 manual for more details Change Data Mode When the Watlow CHG DATA LED is lit the processor is in the change data mode While in this mode the programming steps can be entered into the processor There are three step types C Set Point SP C Jump Loop JL C Wait WT Halt Conditions The Watlow 1500 can HALT in three ways when the C processor encounters a Blank Step in the program C RUN HALT key is pressed while the program is running C remote hold input is shorted While in the HALT condition the Watlow 1500 actively maintains set points and event output conditions which existed at the time the processor was halted If you do not want the hot or humid conditions to be retained at the end of a programmed halt add a step just before the Blank Step End of Program to establish stand by set points near ambient with all Event Outputs OFF Page 14 Despatch Watlow 1500 Control Instruction Manual Blank Step Any unprogrammed step is first a Blank Step before information entered makes it a Set Point Jump Loop or Wait Step In normal programming only the last step in the program remains a Blank Step A Blank Step halts the processor If however the RECYCLE option was selected in the CHG PARA mode the program will return to Step 01 and repeat When programming a HAST chamber a Blank Step is not used A Jump Step is used to jump over blank steps to ensure the program will not stop until reaching steps 47 51
10. 009 press enter 15 At Step 9 the display will read 09 SP Press FCTN until JL appears press enter JS is displayed use arrow keys to 0010 press enter JC is displayed use arrow key to 0001 press enter Press FCTN until NX is displayed use arrow key to 0010 press enter Despatch Watlow 1500 Control Instruction Manual Page 27 Procedure for Programming HAST Profile Cont 16 At Step 10 the display will read 10 SP press enter S1 is displayed use arrow keys to 120 press enter S2 is displayed use arrow keys to 85 press enter E1 is displayed press FCTN E2 is displayed press FCTN HR is displayed press FCTN MN is displayed use arrow keys to 31 press enter SC is displayed use arrow keys to 00 press enter TIME is displayed NX is displayed use arrow keys to 0011 press enter 17 At Step 11 the display will read 11 SP press FCTN until WT appears press enter Press FCTN until W2 is displayed use arrow keys to 0084 press enter Press FCTN until NX is displayed use arrow keys to 0012 press enter 18 At Step 12 the display will read 12 SP press enter S1 is displayed press FCTN S2 is displayed press FCTN E1 is displayed press FCTN E2 is displayed press FCTN HR is displayed press FCTN MN is displayed use arrow keys to 30 press enter SC is displayed use arrow keys to 00 press enter TIME is displayed NX is displayed use arrow keys to 0013 press enter Page 28 Despatch Watlow 1500 Control In
11. 20 cece eee eee 13 Profile Mode 54 o3 aiicw oe ie Seige ree oes tee ote ee Ose ee SUSE 14 Change Data Mode nnaaa hoa eek cea ae cease hg ak Catia he alee aa 14 Halt Conditions iisen a tee ee Rhee ECAR EE EERE EEE EE EGE eee SESS se 14 Blank Step ciate ae ee eds ech a ge a ata ar 15 Set EONESleD t272060e7e tetdasaupes danse eee eater eee ee seats ee 15 Creating Files Profiles 3 4 65 64 ose augak ee eines ee Gee ihe Ok eek eee acd elk 16 Wait Steps tics ead decd aed wants Moenes poate Sake weit Genes ures Bee gag 20 NOM Step fxd hips bch beh de 2 Steet igh od a tah yh hs tog yd My a toa ey eyes 21 Recycle Option 25 04 amp 8 22 milirree ny See tin pels Sie tie Seley Se wie Sele See Se ee 21 Write Your Program lt s3 4222e80 sends ee dg eeed ieee eee does ee eak 22 WORKSHEETS siuerege tira Halt neous ear he E ee ae ale eee eae ea ee 23 Programming Work Sheet 23 oes Secpe Suet eee eased see ese eee wae cee 23 Sample HAST Profile for LPB Chambers 0202000 cee eeee 24 Procedure for Programming HAST Profile 05 25 HAST Chamber Programming Instructions and Definitions 31 Ecosphere Sample Program 0 0 cece eee eee 32 Ecosphere Sample Profile Worksheet 0000 cee eee eee 33 Cleaning a Program seee vie fic tie ee eee a e e ea a eee a e E 34 Tuning Programming Worksheet s co0c ceucoveteu sore ee oye ie bbe 35 Guarded ACCESS Chart oo aiig ct aanraai Bones Spree au
12. Cycle Time 0002 Ch 2 Calibration Adjust 0000 Pb Ch 2 Prop Band 0020 Ch 2 Reset 0006 Ch 2 Rate 0001 Rb Ch 2 Rate Band 0001 Ch 2 Cycle Time 0005 Cc Ch 1 Upper Set Point Limit Ch 1 Lower Set Point Limit Cir Ch 2 Upper Set Point Limit rc ee aie ee Ch 2 Lower Set Point Limit o0 T RH 0000 T T 0001 o D Address number RS 422 Keyboard Lock E al el el P db__ Ch 2 Dead Band 0001 ay LPB Series Guarded Access Chart Make a copy of this chart to document the Series 1500 Guarded Access for each program you use Program System Programmer Date GA Code Typical HASP Settings 0000 Ch 1 Upper Process Alarm Ch 1 Lower Process Alarm C2 a EEA aE De ed fed Ch 2 Upper Deviation Alarm CICICICIT Ch 2 Lower Deviation Alarm 0005 1 1 1 i 1 1 Ch 1 Cycle Time Ch 1 Dead Band a i Ch 2 Cycle Time Ch 2 Dead Band 2 2 2 2 2 Ch 1 Upper Set Point Limit N gt Ch 1 Lower Set Point Limit Ch 2 Upper Set Point Limit Ch 2 Lower Set Point Limit Ch 2 Calibration Adjust rc Recycle ON 1 OFF 0 T RH 0000 T T 0001 Address number RS 422 D i MIN 0006 Despatch Watlow 1500 Control Instruction Manual Page 13 Profile Mode This section of the manual provides details on programming the Watlow 1500 in the Change Data CHG DATA mode the Change Parameters CHG PARA mode and Guarded Access Refer to the Watlow 15
13. NX loop The i in Despatch Watlow 1500 Control Instruction Manual Page 19 Wait Steps The Wait WT submode allows the Watlow 1500 to wait for C Channel 1 and or Channel 2 actual process inputs C the real time of day not elapsed time as in set point steps You can wait for one or two of these conditions or all of them If you don t need one wait condition just press the FCTN key and the next Wait prompt will appear By doing this the particular wait function will remain blank and be ignored Table 8 Wait Steps Condition Displa Description W1 Channel 1 Actual Channel 2 Actual Wait for 1 wait for a closed switch condition Event 0 wait for an open switch condition at the Event input Enter 0 by pressing the ENTER key when the Data Display is blank or when a 0 is in the display Real Time When waiting for Time program all three units HR MN SC of Day If you program only 53 for minutes but enter nothing for Hours or Seconds the programmed time will be 53 minutes after midnight 00 53 00 If you press ENTER when WH WM or WS is shown you could end up waiting for midnight when you wanted wait for time ignored 2 A Wait Step maintains the same set points and event output conditions that existed at the end of the previous step To establish new set point values place a short 1 second step containing the conditions you wish to achieve immediately before the Wait Step Page 20 Despatch Watlow 1500
14. P N 260786 Rev 8 96 E 87 Instruction Manual for the Despatch Watlow 1500 Control SCS NA OOOO OCR 88o RO E RSG OOOO QOH PARA TME DATA a Arere Notice Users of this equipment must comply with operating procedures and training of operation personnel as required by the Occupational Safety and Health Act OSHA of 1970 Section 6 and relevant safety standards as well as other safety rules and regulations of state and local governments Refer to the relevant safety standards in OSHA and National Fire Protection Association NFPA section 86 of 1990 Caution Setup and maintenance of the equipment should be performed by qualified personnel who are experienced in handling all facets of this type of system Improper setup and operation of this equipment could cause an explosion that may result in equipment damage personal injury or possible death Dear Customer Thank you for choosing Despatch Industries We appreciate the opportunity to work with you and to meet your heat processing needs We believe that you have selected the finest equipment available in the heat processing industry At Despatch our service does not end after the purchase and delivery of our equipment For this reason we have created the Service Products Division within Despatch The Service Products Division features our Response Center for customer service The Response Center will direct and track your service cal
15. Press the gt key until DATA display shows 0006 4 Press ENTER key 5 Press the CLEAR key 6 Press the RESTART key Page 34 Despatch Watlow 1500 Control Instruction Manual Tuning Programming Worksheet Guarded Access Chart Make a copy of this chart to document the Series 1500 Guarded Access for each program you use Program System Programmer Date GA Code 0000 Dual Ch 1 Prop Band PID Ch 1 Reset O O a Ch 1 Rate Ch 1 Rate Band Ch 1 Cycle Time 0002 Ch 2 Dead Band Ch 2 Calibration Adjust Ch 2 Rate Ch 2 Rate Band Ch 2 Cycle Time Dual Ch 2 Prop Band PID Ch 2 Reset Ch 2 Lower Set Point Limit ee ee Recycle ON 1 OFF 0 T RH 0000 T T 0001 Address number RS 422 Keyboard Lock 0006 Ch 1 Upper Set Point Limit Ch 1 Lower Set Point Limit Ch 2 Upper Set Point Limit Despatch Watlow 1500 Control Instruction Manual Page 35 Warm Cold Start 1 A Warm start will save all programmed information in the memory 2 A Cold start is a Clean startup condition All MEMORY IS DELETED and the controller will return to default settings 3 Upon completion of Cold start return the control to Warm start otherwise the control will return to the default settings after each power loss 4 DIP Switch 6 determines a warm or cold start Your controller leaves the factory programmed for a warm start A007 1318 Board Figure 2 DIP Switch Location and Orientation
16. Watlow 1500 controller The microprocessor based controller is capable of measuring displaying and controlling temperature and humidity from a variety of inputs The controller is easy to use Control functions alarm settings and other parameters are easily entered through the front keypad Limited data can be protected from unauthorized changes with its guarded access mode security system Battery back up protects against data loss during AC power outages In this application the controller has been factory configured to control temperature and humidity conditions in your Despatch chamber Under normal conditions you should not have to reprogram this controller We have however included reprogramming instructions in this manual to help guide you through that process if it should become necessary Despatch Watlow 1500 Control Instruction Manual NOTE Your control has already been configured at Despatch Use this manual as a guide to typical settings CAUTION Before making changes to your control consult with Despatch Industries Product Service at 1 800 473 7373 Page 1 Page 2 Despatch Watlow 1500 Control Instruction Manual INSTRUCTIONS Operating To start the controller start the oven fans When you start the fans the following sequence will automatically take place 1 The controller will power up 2 The controller MNTR DATA LED will light up and the alarm indicator A1 will be flashing in the FUNCTION
17. becee Seprgce eubedee Spree cess 35 Warm COld Start ct otek tela oe Shee aes ee GE Rees ee GR Sara ee Ge eae Ak IAN 36 Changing the Position of a Switch 2 23 Se2 o353 aor asata ore eh yee 403 37 Despatch Watlow 1500 Control Instruction Manual Page iii List of Figures Figure 1 illustrates the Watlow 1500 installed on the Series 16000 environmental chamber control panel 245 0200 502258656 850s 54 2o0 82504 Se SSeS R ee sed 4 Figure 2 DIP Switch Location and Orientation 200 cece eee 36 List of Tables Table 1 Watlow 1500 Displays sce sare hi drinh earth Brand gt arte dhs dete arte dete hl dre 4 Table 2 Watlow 1500 KeyS 00 cece eee 5 Table 3 Watlow 1500 LEDS creii ind tented art estan ona ee nas mode ona seen nas R R nate a 5 Table 4 GA0001 and 0002 PID Tuning Parameters 00 200 eee aes 10 Mable 5 G A0000 AlanmnS cscs osc tedetuutuds teu sd Meee ud weet aed 10 Tale 6 Seting Options earet eaea os cepa Spa eae ope eae eae eae eee 11 Table 7 Set Point Step Programming Detail 00 0c eee eeeee 19 Table 8 Wait LDS cc cases epceee sep E Gate Saad sas Tandon Ganlg saya Gand sass Gad saya Tad A avg ng oso 20 Table 9 Despatch Sample Program 000 cece eee eee eee 32 Table 10 DIP Switch Selection a 0c0t4 detect dete eta deta eta tetas 37 Page iv Despatch Watlow 1500 Control Instruction Manual INTRODUCTION This INTRODUCTION section provides an overview of the
18. cle If GA 0001 and 0002 will not work try GA code 0005 for both channel parameters Use the following sequence to alter the GA prompts 1 Follow the steps for SETTING THE CLOCK 2 Select a GA code with the gt key and the key 3 Press ENTER The prompt appears in the DATA display 4 Press the FCTN key The next prompt in the loop appears in the DATA display Page 8 Despatch Watlow 1500 Control Instruction Manual Setting the Clock 1 Press the MODE key to select the Change Parameter CHG PARA mode The TIME LED will be ON The FUNCTION and DATA displays will show the real time of day 2 Press FCTN to produce the time prompt HR in the FUNCTION display 3 Enter the real time of day beginning with hours The CHG PARA programming prompts are listed below in the order they appear a Enter the real time of day 24 hour basis by selecting the hour with the gt key and the key b Press ENTER to enter the hour into the program The prompt MN will appear when you press ENTER c Select correct minutes and seconds After setting the real time the FUNCTION prompt should display a GA This is guarded access Despatch Watlow 1500 Control Instruction Manual Page 9 GA0001 and 0002 PID Tuning Prompts appear for CH 1 with Code 0001 and then repeat for CH 2 with Code 0002 Except for CA these parameters pertain directly to tuning your control to the system Table 4 GA0001 and 0002 PID Tuning Parameter
19. idity system has sufficient time to fill up with water S1 is changed to 40EC S2 E1 and E2 are left blank by pressing the FCTN key when those functions are displayed In a set point step blank data defaults to previous settings so S2 95 E1 0001 and E2 0000 Since Step 1 was the previous step by doing this if you wished to change S2 to 85 throughout the program you only have to change it on Step 1 The step duration is 30 minutes Since the previous set point was 25E the process set point will be ramped continu ously from 25E to 40E over the 30 minute span No change in set points S1 or S2 or events E1 or E2 Therefore control will act to hold 40EC and 95 for 30 minutes S1 is set back to 25EC It is ramped from 40EC over 30 minute period EA EE S1 is changed to 10EC This is ramped over a 1 second period so it is essentially a step change Note Event 1 1 is turned off To protect the equipment humidity control generally needs to be disabled when below freezing The control is set to wait for the CH 1 process to reach 8 All other waits are blank so they will be ignored Do not type zeros into wait functions that are to be ignored This is caused by pressing the ENTER key instead of the FCTN key when you scroll past the function you wish to ignore The above is the most typical problem encountered in a wait for step Another hold for 30 minutes This is a jump to Step 2 Steps 2 8 will be repeated 10 Set
20. l to ensure satisfaction Whenever you need service or replacement parts contact the Response Center at 1 800 473 7373 FAX 612 781 5353 Thank you for choosing Despatch Sincerely Despatch Industries Copyright October 24 2001 by Despatch Industries PREFACE This manual is your guide to the Watlow 1500 control It is organized to give you the information you need quickly and easily The INTRODUCTION section provides an overview of the control The THEORY OF OPERATION section details the function and operation of the control The INSTRUCTIONS section provides directions on unpacking installing operating and maintaining the control The APPENDIX section contains Special Instructions for operating the control instrument and a Troubleshooting Table An efficient way to learn about the control would be to read the manual while working with the control This will give you practical hands on experience with information in the manual and the control While reading this manual if a term or section of information is not fully understood look up that item in the appropriate section to familiarize yourself with that item Then go back and reread that section again Information skipped not understood or misunderstood could create the possibility of operating the equipment in an unsafe manner This can cause damage to the oven or personnel or reduce the efficiency of the equipment Despatch Watlow 1500 Control Inst
21. ow keys to 0010 press enter HR is displayed use arrow keys to 00 press enter MN is displayed use arrow keys to 00 press enter SC is displayed use arrow keys to 05 press enter TIME is displayed NX is displayed use arrow keys to 0006 press enter 12 At Step 6 the display will read 06 SP press FCTN until WT appears press enter Press FCTN until W4 is displayed use arrow keys to 099 5 press enter Press FCTN until NX is displayed use arrow keys to 0007 press enter Page 26 Despatch Watlow 1500 Control Instruction Manual Procedure for Programming HAST Profile Cont 13 At Step 7 the display will read 07 SP press enter S1 is displayed use arrow keys to 120 press enter S2 is displayed use arrow keys to 58 press enter E1 is displayed press FCTN E2 is displayed press FCTN HR is displayed press FCTN MN is displayed use arrow keys to 10 press enter SC is displayed use arrow keys to 00 press enter TIME is displayed NX is displayed use arrow keys to 0008 press enter 14 At Step 8 the display will read 08 SP press enter S1 is displayed use arrow keys to 120 press enter S2 is displayed use arrow keys to 59 press enter E1 is displayed press FCTN E2 is displayed use arrow keys to 0110 press enter HR is displayed use arrow keys to 00 press enter MN is displayed use arrow keys to 00 press enter SC is displayed use arrow keys to 01 press enter TIME is displayed NX is displayed use arrow keys to 0
22. ow keys to 0048 press enter Despatch Watlow 1500 Control Instruction Manual Page 29 Procedure for Programming HAST Profile Cont 23 At Step 48 the display will read 48 SP press FCTN until WT appears press enter Press FCTN until W4 is displayed use arrow keys to 0102 press enter Press FCTN until NX is displayed use arrow keys to 0049 press enter 24 At Step 49 the display will read 49 SP press enter S1 is displayed use arrow keys to 00 press enter S2 is displayed use arrow keys to 00 press enter E1 is displayed use arrow keys to 0010 press enter E2 is displayed use arrow keys to 1000 press enter HR is displayed press FCTN MN is displayed press FCTN SC is displayed use arrow keys to 01 press enter TIME is displayed NX is displayed use arrow keys to 0050 press enter 25 At Step 50 the display will read 50 SP press FCTN until WT appears press enter Press FCTN until W1 is displayed use arrow keys to 40 press enter Press FCTN until NX is displayed use arrow keys to 51 press enter 26 At Step 51 the display will read 51 SP press enter S1 is displayed use arrow keys to 00 press enter S2 is displayed use arrow keys to 00 press enter E1 is displayed use arrow keys to 0000 press enter E2 is displayed use arrow keys to 0000 press enter HR is displayed press FCTN MN is displayed press FCTN SC is displayed use arrow keys to 05 press enter TIME is displayed NX is displayed use arro
23. points are changed to 25EC and 60 a normal condition before program is ended Is a blank step SP when viewed in CHG DATA mode Program execution will end here Page 32 Despatch Watlow 1500 Control Instruction Manual Ecosphere Sample Profile Worksheet Program Name Date 5 A ON JU O Se ee lel came No S1 S2 4321 4321 HR MN SC Comments 1 25 95 oo01 0000 oo 10 00 Initialize systematambient 2 4o ooo 00 30 00 Rampto40EC in 30 minutes 3 f0 30 00 Holdfor30 minutes oo 4 3 J 00 f 30 00 Rampto25ECin30 minutes Ps f0 30 00 Hold25ECfor30 minutes po 10 f 0001 f oo oo 01 StepRampto 10 HumideventOFF 7 ewa o S S e S f Waittor eC _ ALL OTHER W S BLANK ps J 00 f 30 00 f Hold 10for30 minutes 9 sso2 scoi f f f ump tostep 2 Repeatonce 10 25 40 f 0007 f 00 f oo 01 f Return to ambient with low humidity pit spot SP Blank step End of program Ee le ee E E E d o Soo So S S S i NoE l i o Jf fd s indicate blanks which are not the same as 00 s To get blank in data display press the FCTN key instead of the pis fT ENTER key Despatch Watlow 1500 Control Instruction Manual Page 33 Clearing a Program To clear an entire program perform the following steps 1 Press MODE key until CHG PARA LED lights 2 Press FCTN key until GA shows in FUNCTION display 3
24. rrow keys to 00 press enter SC is displayed use arrow keys to 05 press enter TIME is displayed this displays the HR MN SC for what was just programmed NX is displayed use arrow keys to 0002 press enter 8 At Step 2 the display will read 02 SP press FCTN until WT appears if S1 is displayed press CLEAR and it will read SP press enter Press FCTN until W3 is displayed use arrow keys to 0001 press enter Press FCTN until NX is displayed use arrow keys to 0003 press enter Despatch Watlow 1500 Control Instruction Manual Page 25 Procedure for Programming HAST Profile Cont 9 At Step 3 the display will read 03 SP press enter S1 is displayed use arrow keys to 115 press enter S2 is displayed use arrow keys to 58 press enter E1 is displayed press FCTN E2 is displayed use arrow keys to 0010 press enter HR is displayed press FCTN MN is displayed use arrow keys to 40 press enter SC is displayed use arrow keys to 00 press enter TIME is displayed NX is displayed use arrow keys to 0004 press enter 10 At Step 4 the display will read 04 SP press enter Press FCTN until SC is displayed use arrow keys to 01 press enter TIME is displayed NX is displayed use arrow keys to 0005 press enter 11 At Step 5 the display will read 05 SP press enter S1 is displayed use arrow keys to 120 press enter S2 is displayed use arrow keys to 58 press enter E1 is displayed press FCTN E2 is displayed use arr
25. ruction Manual NOTE Read the entire INTRODUCTION and THEORY OF OPERATION before operating the control WARNING Failure to head warnings in this instruction manual and on the oven could result in death personal injury or property damage Page i Page ii Despatch Watlow 1500 Control Instruction Manual Table of Contents PREFACE sss ed by rev AVS Veco ee Meer E ae eae wine need i Tabl of Contents ei 2402456 oeer enDi Op n ERD Mer Soe he De e TEE e iii List of RICUIVC Soh reins co ders nteeno teens coe asta our to ater oh ns oo or Sha arta Us ghee Ae iv PISCE Tales ecerae Aa ene are rae ne ae aie ee ee a een ene Renee eee Seanad iv INTRODUCTION cesniccun aster ebar oor er er er err oer ae eels 1 INSTRUCTIONS ese host Sed Sead i be he te ce etn atte ae teh i Sale ae pte hte Sal de ate a tele ee arte Mak De 3 Op rating dem ee aaa a sre ep e arg A a A A aoe ass e 3 Watlow t500 Gontro 20 300 i aminn pinan cork Ea wed E Ban NENEA S 4 Manual Set Point Controller occ ere eres e oer ree noes eres eee eres ees 6 Guarded Access Programming oss 3e5 ees See hee See a See ee 8 Bening Ihe Clock 3 223th tee tothe eee bee eee hoes ee fot oe 9 GA0001 and 0002 PID Tuning 2 0 cose ee ee i ree re es wee ee ed 10 GAGO0O Alanis wis Bros ae oes eos Se Shae See ces 10 GA0006 Setting Options 2334503369 Yee eee OR ad Ad ne os 11 ECOSPHERE 16000 Series Guarded Access Chart 12 LPB Series Guarded Access Chart 00
26. s Band Reset ORs o O Rae ORT S O Rate Band Rate band defines where the rate function will occur The rate band will occur at one to seven times the proportional band With a 0 entry rate is always in effect Cycle Time CTP Dead Band The dead band defines an area on either side of set point where no switching action will occur Calibration CA Calibration offset enables you to offset the input value from Offset 10E to 10EC or EF GA0000 Alarms Prompts appear for CH 1 then repeat for CH 2 Refer to the Watlow User s Manual for details Table 5 GA0000 Alarms Upper Process Type Alarm If you do not want this alarm set to highest value Lower Process Type Alarm If you do not want this alarm set to lowest value Upper Deviation Type Ud If you do not want this alarm set to highest Alarm value Lower Deviation Type Le If you do not want this alarm set to lowest value Alarm Sequence repeats for Channel 2 and then leaves the guarded area returning to real time Page 10 Despatch Watlow 1500 Control Instruction Manual GA0006 Setting Options These parameters are high and low display and scroll limits and for some units two channel control type and device address Table 6 Setting Options Ce ee a Helon SetPoint Lime J e fn Front Panel Keyboard Enter Lockout C 1 to lock the entire front panel C Oto unlock it Recycle RC Select C 1 to activate the recycle option begin again at Step 1 af
27. s a Wait Step the processor will be waiting for a time or actual condition and no action will be taking place Despatch Watlow 1500 Control Instruction Manual Page 21 Write Your Program The number of steps in the program may be as many as 51 We suggest that you write it out on copies of the charts in this section This will enable you to program the Series 1500 quickly and without mistakes This Programming Chart will provide you with a back up copy of your entire program Page 22 Despatch Watlow 1500 Control Instruction Manual WORKSHEETS Programming Work Sheet Name Date 5 A ON JU O Eee ll came S1 S2 4321 4321 HR MN SC Comments Despatch Watlow 1500 Control Instruction Manual Page 23 Sample HAST Profile for LPB Chambers Name SAMPLE JEDEG PROGRAM Date A A ON JU O No S1 4321 4321 HR MN SC Comments ae E aa SESS 2 wao00t Checking for proper water level amp holds until satisfied 3 15 5a f ooo f 40 00 May be modified for special applications ie 85 85 a S J ot Not used reserved for special applications ie 85 85 5 12 58 oo1o 05 EV22 turs on fans and heaters 6 w4995 J Wai for near boiling condition 7 12 58 10 Purge airbyboilingfor10 minutes 8 120 59 f omo f 00 00 01 EV23 closes the vent solenoid 9 Jss10 scoi dump
28. splay is effected by the scroll up and down keys Page 4 Despatch Watlow 1500 Control Instruction Manual Watlow 1500 Control Cont Table 2 Watlow 1500 Keys Selects either channel 1 or channel 2 for the ACTUAL display Clears alarm codes from the FUNCTION display in the monitor data mode Clears the step in the STEP display in the change data mode when the unit is in the halt condition Clears all 51 programmed steps when the unit is in the halt condition and in the guarded access area of the change parameter mode Returns the controller to the initial program step only in the program halt condition RUN HALT Starts or stops the program The processor will resume a program where it was interrupted unless the RESTART key was pressed or the step number or set point data at the current step was changed during the halt condition MODE e Selects either the monitor data change data or change parameter mode The FUNCTION key steps through the prompts in each of the three modes ENTER Enters the selected data or next step operations in the change data and change parameter modes Increases and decreases the value in the DATA display A light touch changes the value by one Holding the key down causes the DATA display to increase rapidly Table 3 Watlow 1500 LEDs fT eD dL C C CDSCYiptiocn o s CSdY OLON CH 1 cH 2 F Indicates the value in the ACTUAL display is temperature in EF ec Indica
29. struction Manual Procedure for Programming HAST Profile Cont 19 At Step 13 the display will read 13 SP press enter S1 is displayed press FCTN S2 is displayed press FCTN E1 is displayed use arrow keys to 0011 press enter E2 is displayed press FCTN HR is displayed use arrow keys to 00 press enter MN is displayed use arrow keys to 30 press enter SC is displayed use arrow keys to 00 press enter TIME is displayed NX is displayed use arrow keys to 0014 press enter 20 At Step 14 the display will read 14 SP Press FCTN until JL appears press enter JS is displayed use arrow keys to 0012 press enter JC is displayed use arrow keys to 0001 press enter Press FCTN until NX is displayed use arrow keys to 0015 press enter 21 At Step 15 the display will read 15 SP Press FCTN until JL appears press enter JS is displayed use arrow keys to 0047 press enter JC is displayed use arrow keys to 0001 press enter Press FCTN until NX is displayed use arrow keys to 0047 press enter 22 At Step 47 the display will read 47 SP press enter S1 is displayed use arrow keys to 00 press enter S2 is displayed use arrow keys to 60 press enter E1 is displayed use arrow keys to 0010 press enter E2 is displayed press FCTN HR is displayed use arrow keys to 00 press enter MN is displayed use arrow keys to 00 press enter SC is displayed use arrow keys to 05 press enter TIME is displayed NX is displayed use arr
30. ter completing a profile C 0 to deactivate the recycle option Temp Temp 2 channel TT This prompt will not appear on thermocou temperature control ple units Select c 0000 for Temp RH control C 0001 or Temp Temp control RS 422 Address for the Ad This prompt appears only on units with data 1500 communications It applies only for an RS 422 interface Each device on the net work must have its own address Sequence then leaves the guarded area returning to real time Despatch Watlow 1500 Control Instruction Manual Page 11 ECOSPHERE 16000 Series Guarded Access Chart Make a copy of this chart to document the Series 1500 Guarded Access for each program you use Program System Programmer Date GA Code Typical ECOSPHERE Setting 0000 ci UP ChA Upper Process Aarm 10 i c _ LP__ Ch t Lower Process Alarm z SSCS c1 ua Ch 1 Upper Deviation Alarm se SSCS c ta Ch t Lower Deviation Alarm s SSS c2 UP Ch 2 Upper Process Alarm m SCS fe2__ LP__ Ch 2 Lower Process Alarm o sss c2 ua Ch 2 Upper Deviation Alarm w c2 ta Ch 2 Lower Deviation Alarm mo SS Pb Ch Prop Band o SSS S Ro Cht Rate Band oon CS Crt Dead Band oom Po Ch Prop Ba ooo Ro Cht Rate Band oono O Po Ch2Prop Baa owo Dual PID 0002 Dual PID 0006 Page 12 Despatch Watlow 1500 Control Instruction Manual Ch 2 Rate 0050 Rb Ch 2 Rate Band 0003 Ch 2 Reset 0010 Ch 2
31. tes the value in the ACTUAL display is temperature in EC RH PROG HALT Indicates that the processor is in the halt condition This may be caused by pressing the RUN HALT key or by a blank step in the program Flashing indicates that the processor is in remote hold condition MNTR Indicates the processor is in the monitor data mode While in this mode the DATA Watlow 1500 is used as a set point controller or a process profiler Indicates the processor is in the change data mode Indicates the processor is in the change parameter mode Indicates that the FUNCTION and DATA displays are showing time Despatch Watlow 1500 Control Instruction Manual Page 5 Manual Set Point Controller Use the following procedure to enter a dry bulb temperature RH or change auxiliary event status when the MNTR DATA LED is on 1 Press the RUN HALT key so the PROG HALT LED lights up Press the RESTART key Enter the dry bulb temperature a Press the FCTN key until C1 is signaled in the FUNCTION display b Update the dry bulb temperature by using up down arrow keys c Press enter when the desired set point is signaled in the data display Your set point is now in effect If the set point shown in the DATA display is higher than the value shown in the ACTUAL display for CH 1 then the heat LED near the Watlow 1500 should be on If the set point in the DATA display is lower than the value in the ACTUAL display for CH 1 then the cool
32. truction Manual Creating Files Profiles Cont Table 7 Set Point Step Programming Detail FUNCTION Step Display Programming Procedure Channel 1 1 Select the Channel 1 set point Set Point 2 Press ENTER or FCTN to leave blank Channel 2 1 Select the Channel 2 set point Set Point 2 Press ENTER or FCTN to leave blank Channel 1 E1 1 Selecta 1 or a 0 for each of the four available events Event 1 ON 0 OFF The DATA display shows the 1 or 0 Outputs entry for Events 4 through 1 from left to right 2 Press ENTER or FCTN to leave blank S1 S2 Channel 2 E2 1 Selecta 1 or a 0 for each of the four available events Event 1 ON 0 OFF The DATA display shows the 1 or 0 Outputs entry for Events 4 through 1 from left to right 2 Press ENTER NOTE If you ve set DIP Switch 1 ON then there are only three events available for each channel In that case each Event 4 is an alarm X Select hours Press ENTER The prompt MN will appear Select minutes press ENTER The prompt SC will appear Select seconds Press ENTER The step duration in hours minutes and seconds will appear in the FUNCTION and DATA displays The TIME LED will be ON Step H Duration Press FCTN to proceed to the next prompt NX Next Step N To display the next prompt in sequence press ENTER To display a different step 1 Enter that step number with the gt and keys 2 Press ENTER The Watlow 1500 will return to the SP JL WT
33. w keys to 0001 press enter 27 Press mode key to jump out of guarded access Page 30 Despatch Watlow 1500 Control Instruction Manual HAST Chamber Programming Instructions and Definitions C1 Channel 1 Temperature EC C2 Channel 2 Relative Humidity RH SP Set Points S1 Set Temperature S2 Set Relative Humidity E1 Event 1 4 3 2 1 L Power Devices 0 Off 1 On Cooling Fan 0 Off 1 On Nitrogen optional 0 Off 1 On Ramp Test Light 0 On 1 Off E2 Event 2 4 3 2 1 ee Autofill 0 Off 1 On Heaters 0 Off 1 On Vent Solenoid 0 Open 1 Closed Drain Solenoid 0 Closed 1 Open WT Wait Loop WE Wait Event 1 Wait for Temperature 2 Wait for Relative Humidity 3 Wait for Water Level 4 Wait for Water Temperature JL Jump Loop JS Jump to Step amp O l Number of Times to Perform Jump Z x lt Il Next Programming Step Despatch Watlow 1500 Control Instruction Manual Page 31 Ecosphere Sample Program The sample program on the following page is provided to demonstrate the function of the unit It is pre programmed in the factory and available for you to run upon installation of your chamber If the program has been cleared somehow you may wish to re enter it as programming practice Table 9 Despatch Sample Program Step Description Set points of 25EC and 95 RH entered for S1 and S2 Event 1 1 is on This enables the humidity control system This step is held for 10 minutes so that the hum
34. want 4 Return the control chassis to the case Be sure you have it oriented correctly It will not fit in upside down but check just the same Press firmly but gently to seat the chassis Despatch Watlow 1500 Control Instruction Manual Page 37
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