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Watlow Electric Weather Radio 987 User's Manual

1. Id 5P idle set point 5 3 8 8 In 1 input 1 4 3 4 4 cA 1A rate output 1 PID A 5 12 Ine input 2 4 9 cA 16 rate output 1 PID B 5 12 InPE Input Menu 4 2 ACA rate output 2 PID A 5 15 In PE input lockout 6 5 rA b rate output 2 PID B 5 15 Int F interface type 4 47 c At E ramp rate 4 43 1 1A integral output 1 PID A 5 11 cRAE ratio 4 36 TE Tb integral output 1 PID B 5 11 rE 1A reset output 1 Pid A 5 11 IE CA integral output 2 PID A 5 14 r E 1b reset output 1 PID B 5 11 1E b integral output 2 PID 5 14 r E2A reset output 2 PID A 5 14 E Y l input 1 module type 6 r Eb reset output 2 PID B 5 14 E Y2 input 2 module type 6 r EU reverse action 4 37 c H 1 range high 1 4 5 4 6 o K L r He range high 2 4 11 4 12 8 11 rt range low 1 4 5 4 6 RE latching 4 36 rte range low 2 4 11 4 12 8 11 a latching 2 4 24 root square root extraction 8 14 8 15 LAE 3 latching 3 4 27 r P ramping function 4 43 8 17 LAE Y latching 4 4 30 r P remote set point 4 10 8 8 8 19 L n 1 input 1 linearization 4 8 8 14 8 15 r St restore 6 14 L me input 2 linearization 4 15 8 14 rtd RTD calibration curve 1 4 7 r de RTD calibration curve 2 4 1
2. Setup Input on oo ct Default Range High 2 con _ 3e 1S 80 8 816 98__ 1__ ___or tinued from previ 98222 ous page K H 308 2500 200 1371 E 328 758 200 399 n 3 e eF ie Q 4380 328 L14 1G 289 _ 799 W5 38 42060 G 2eF 16 NOTE W3 These values do not d 32 4200 l 0 3 16 affect the low or the high set point limit Pte 38 2543 0 1395 for process alarms high impedance 0 56 9990 9989 EE r 32 3200 0 17660 98__ 2 _ ___only 5 32 3288 0 1760 NOTE C b C 32 3300 C 0 0815 When high imped ance 0 50Jis rtd 328 14 72 208 808 selected for input 1 the range high for rtd 989 9999 733 153 27 both and can be extended to 9999 4 20 999 9999 units The range low when is selected G 20 999 9999 units can be extended to 999 0 6 49999999 units l 5 9991 9999 units 0 10 9991 9999 units 0 56 999 9999 units 0100 999 19999 units slidewire St id _100 1288 ohms current 0 8 amps potentiometer CPOE 0 1200 ohms 4 12 WATLOW Series 988 User s Manual Setup Menus Chapter 4 NOTE See Chapter 8 for more information on slidewire feed back NOTE See Chapter 8 for more information on slidewire feed back Setup Menus Chapter 4 Setup Input Learn Low Write the low end resistance of the slidewire potentiometer to the range low 2 parameter T
3. lf Default y y 98 1 no DIP J K T N E W5 W3 Pt2 0 50mV J H El n EJ C d Pte 8 50 thermocouple L tal L tal only 98 2 Input 1 DIP J K T N E W5 W3 Pt2 0 50mV J H El a EJ C d Pte 6 56 o aaa al thermocouple Input 1 DIP R S B C4 C_5 C8 thermocouple WATLOW Series 988 User s Manual 4 3 Setup Input MT la If Default y y Input 1 continued Input 1 DIP RTD RTD 0 1 gt from previous p page oA Crtd rbd RTD Input 1 DIP 4 20mA 0 20mA 0 5V 1 5V 0 10V dc aD Mm 0 20 0 5 CES 0 10 ee process Decimal 1 Select the decimal point location for process type input 1 data This prompt in conjunction with the Range Low and Range High prompts allows you to format and limit units of measure for process 1 e All prompts with units of measure related to input 1 will display in the selected decimal format e This affects propbands alarm set points process set points calibration offsets deadbands and ranges d amp C 1 This prompt appears only if you have set input 1 toa process input or to a thermocouple input set to 0 50mV Default d 0 000 JEC JEC JEC 4 4 WATLOW Series 988 User s Manual Setup Menus Chapter 4 NOTE These values do not affect the low or the high set point limit for process alarms NOTE When high imped ance is selected for input 1 the range high for both and can be ex
4. gEC O decimal 2 4 11 L OC front panel lockout 6 3 8 8 dFL default 6 14 L oP low power limit 4 41 d A9 Diagnostics Menu 6 7 L ooP loop error detect 8 10 d 19 diagnostics lockout 6 6 L Gud alarm 3 trigger 4 26 S d FF differential 4 36 L e local remote 5 8 d r direct action 4 37 Ur nH learn high 4 13 8 23 SEE Setup Menu 4 1 d 15P test displays 6 11 Ur at learn low 4 13 8 23 5H 96 slidewire hysteresis 4 16 JUPL duplex 4 38 5 IL 2 silencing 2 4 24 M N S 11 3 silencing 3 4 27 E J 5 IL 9 silencing 4 4 30 Pod Modbus 4 46 SL d slidewire 8 23 E 1 1 A D underflow error 7 8 _mt A non latching 4 36 Sn serial number 6 8 Ee A D underflow error 7 8 moJ none 4 38 SGFE software revision 6 8 E I 2 sensor under range error 7 8 _mor normal 4 36 SP set point 2 5 3 E2 2 sensor under range error 7 8 SP2c set point 2 control 4 22 E 3 sensor over range error 7 8 O St PEt set point 8 17 E2 3 sensor over range error 7 8 St Pt crossover set point value 4 39 E 1 4 A D overflow error 7 8 OFF control outputs off 8 8 SE rE start 8 17 E2 Y A D overflow error 7 8 on on 8 4 8 19 595 system lockout 6 4 E 1 event input 1 4 40 UPE r Operation Menus 5 1 5 16 S495 System Menu 5 2 E 15 event input 1 status 5 4 ae a ae ES 1 9 E d event input 2 4 40 4 41 outpu E 125 event te e 5 4 Gece output 2 4 21 T
5. Output Types e Inont e 6S5r el 5s 1 UN e del let Yc eles e cL Ab e Proc e Ur EE Lic EE SPLY aa e 985 el 23d no output module A 0 5A solid state relay K 0 5A solid state relay with suppression B switched de open collector C form C relay E form C relay 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 EIA TIA 232 or EIA TIA 485 communications U Gey Gt Ye Gt Y3 GE YY These prompts always appear 10 WATLOW Series 988 User s Manual Factory Menus Chapter 6 d 9P Factory Menus Chapter 6 Factory Diagnostics 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 Y or Down arrow key to select from the upper display and press the mode key Q 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 y YES d 9P 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 Y or Down arrow key to select an output out I lout lout 3 or lout 4 The LED for that outp
6. o If is set to settings for H Y 6 4 will be in degrees per minute or units per minute e If the input referenced by is set to the range is affected as listed below H3YS 4 This prompt appears only on controllers equipped with output 4 hardware for a relay 98__ ____ B__ 98__ ___ D _ 98 _ E _or98 ___ K _ or switched de 98__ ___ _ C_ If Default J 4 EF Global Menu 8 T a C_F Input 1 or 2 Global Menu see note above CESA Global Menu amp ma si Input 1 or 2 Global Menu see note above units a process input HYS4 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 L amp 4 This prompt appears only on controllers equipped with output 4 hardware for a relay 98__ ____ B__ 98__ ____ J__or 98 K or switched de 98 __ ___ C and with set to or AL Yn Default a LAEY LAEY Setup Menus Chapter 4 setup Output 5 iE y 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 A YL 0 and one AGH I See Chapter 7 for S IL 4 This prompt appears only on controllers equipped with output 4 more information hardware for a relay 98__ ____ B__ 98__ ____ D__ on alarms 98_ _ __
7. Ces Input 2 continued on next page Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 9 Setup Input In c If Default Input 2 continued rom previous bs Ed 98 3 pays no DIP slidewire potentiometer no SL d POE resistance C Ing C Fang only 98 4 _ no DIP current current lL mo SL id transformer Ind LIne g only 98 5 no DIP event 2 L nol LE ld digital event ine _Ine only r 6 p Remote Set Point 4 10 Enable a remote set point signal This prompt appears only if the controller is equipped with input 2 hardware and if is not set to and if in the Global Menu is set to _ nor Default y c5P WATLOW Series 988 User s Manual Setup Menus Chapter 4 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 process type input 2 data This prompt in conjunction with the Range Low and Range High prompts allows you to format and limit units of measure for process 2 e All prompts with units of measure related to input 2 will display in the selected decimal format e This affects propbands alarm set points process set points calibration offsets deadbands and ranges dE 2 This prompt appears only if you have set input 2 toa process input or a thermocouple input set to mv Default 0000 JEC JEC JEC R
8. This manual provides the information you will need to install and operate a Series 988 controller If you need information about Series 988 configurations and model num bers refer to the Appendix of this manual or for more detailed informa tion to Optimizing Your Process System with the Series 988 Controller An Application Guide for the Watlow Series 988 Family If your Series 988 controller will be used for data communications you will also need our communications manual Data Communications with the Watlow Series 988 Family of Controllers green cover Series 988 controllers are calibrated in the factory but if you need to do periodic calibration you will need our calibration manual Calibrating Watlow Process Controllers blue cover This manual explains the five steps of setting up a Series 988 controller 1 Set and document all of the DIP switches if applicable Chapter 1 2 Mount the controller Chapter 2 3 Wire and document the controller wiring Chapter 2 4 Configure and document the controller software Chapters 3 6 5 Run test and adjust your application Update documentation Chapters 7 and 8 and the Appendix provide detailed advice definitions and specifications along with application examples to help you optimize the safety and performance of your application Use the Table of Contents and Index to find specific information Document Every Step The Series 988 provides powerful and complex features
9. A L Input impedance ZOMQ Y K T N C E D Pte R S B 0 50mV DIP Settings DIP Settings Figure 2 9b RTD 2 or 3 wire 100 Q Universal signal conditioner E ads is A E AS a for 2 wire ES BAR El DIP Switch Ml Setting E Figure 2 9c 0 5V 1 5V or 0 10V dc Process Universal signal conditioner gt DIP Switch Setting Input impedance 1OKQ o y a O mo CO D 20 Figure 2 94 0 20mA or 4 20mA Process Universal signal conditioner td T DIP Switch Input impedance 70 Setting WATLOW Series 988 User s Manual 2 9 Input 2 Wiring NOTE See Chapter 8 for information on slidewire feedback NOTE A process output cannot be installed on output 1 when using a current transformer input NOTE Successful installa tion requires five steps e Model number and software choice Appendix e DIP switch set tings Chapter 1 e Sensor match Chapter 2 and Appendix e Sensor installation Chapter 2 and e Wiring Chapter 2 2 10 WATLOW Series 988 User s Manual Figure 2 10a Slidewire Feedback or Potentiometer Input 98__ _3 CCW Wiper CW The current transformer must be purchased separately Watlow current transformer part number 16 0246 up to 50 amps Systems that use more than 50 Amps need an interstage transformer For example if you use a 300A current transformer part 16 0073 and
10. EIA TIA 485 or EIA TIA 232 serial com munications 98__ __ _ U_ or EIA TIA 485 or EIA TIA 422 serial communications 98__ ___ S _ The computer must have a compati ble serial port or an appropriate converter must be used Overview The serial communications feature allows the Series 988 family to receive commands from and transmit data to a master device usually a comput er Any function that can be performed via the front panel can also be accomplished using a serial communications port allowing you to operate the controller from a computer and to store process data on a computer L4 acts as the RX TX indicator on the front display panel of the 988 The Series 988 is available with a choice of serial hardware interfaces An EIA TIA 232 interface allows for one master computer and one con troller with a maximum network length of 50 feet 15 meters The EIA TIA 485 or EIA TIA 422 option equips the controller for a multi drop interface up to 32 total network devices with EIA TIA 485 and up to 10 total network devices with EIA TIA 422 Each controller will have its own unique address The total maximum network length is 4 000 feet 1 219 meters All interfaces are isolated To select between EIA TIA 485 or EIA TIA 422 enter the Setup Menus by holding the up arrow Y and down arrow keys simultaneously until setup appears in the bottom display Use the up arrow key to select the Communications Menu C Gf 9 At t
11. i z Le Silencing 2 i G amp 3 Output 3 f ALI Alarm 3 35d Alarm 3 Side DEL 393 Hysteresis 3 i AE Latching 3 i z I 3 Silencing 3 f GEH Output 4 Alarm 4 Sd Alarm 4 Side Ln JEJENES 34 Hysteresis 4 A po ra lt Latching 4 a UN pe lt Silencing 4 A Analog Output DEL read Process 3 a 3 po JJ g 3 F O FE 3 cH Retransmit High Limit 4 0 80 8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Enter your settings from the controller s upper display Output 1 p 4 19 Output 2 p 4 21 Output 3 p 4 25 Output 4 p 4 28 Output 3 retransmit p 4 31 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 and Decimal 2 parame ters in the Input Menu Setup Menus Chapter 4 setup Output Output Prompts When you are in the Setup menus the Series 988 displays the menu selection In Pt GE PE StL bL or CGF 9 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 YY and Down arrow K4 keys to change the value in the upper display The new value will not take ef
12. my Py 8 OJ I el 686 Fer Ftr Fer Fer L mo root Eon Can O Press the Up arrow key Y or the Down arrow key to select one of the prompt values Prompts may not appear depending on controller configuration Figure 4 2 The Input Menu 4 2 WATLOW Series 988 User s Manual B 8 8 8 0 0 08 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 IMPE Setup Prompt Enter your settings from the controller s Input 1 upper display I 3 Im J ELE EU SEU RUE C I Decimal 1 3 1 Range Low 1 cH Range High 1 Input 1 p 4 3 AL I Calibration Offset 1 RTD Calibration Curve 1 Fa Software Filter 1 po in Linearization 1 i ine Input 2 SP Remote Set Point JBL EC Decimal 2 i rie Range Low 2 ce Range High 2 Dal Input 2 p 4 9 po rat Learn Low a Learn High po 3 x ALE Calibration Offset 2 i 2 ny Q 2 RTD Calibration Curve 2 I tre Software Filter 2 l po ine Linearization 2 41 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 and Decimal 2 parame ters in the Input Menu A CAUTION Changing the value of changes most other prompts to the factory default values Document all set tings before chang ing sensor type
13. 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 default setting 90 to define the auto tuning process Once the auto tune sequence has begun the output 1 and output 2 pro portional band is set to O and the control goes into an on off mode of con trol at the set point percentage determined by the parameter The displayed set point remains unchanged Auto tuning at a set point of 200 F auto tune auto tune begins complete 200 set point 1807 2 o e Ne eae eye ae eee eas a process 90 of set point AE SP default setting Temperature 100 Time Tuning Manual Operation Alarms and Error Codes Chapter 7 WATLOW Series 988 User s Manual 7 1 AM 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 The typical life of a mechanical relay is 100 000 cycles Verify that the cycle time selected is appro priate for the output device type Failure to do so could result in damage to equipment and or property 7 2 WATLOW Series 988 User s Manual When the control finishes learning the system it resumes standard PID control using the PID values established by the auto tuning pro
14. tomer supplied switch or by a change in dc voltage See Chapter 2 for volt age and wiring information The list below outlines the functions that can be controlled with a digital event input e Idle set point d5 lets the operator select a second idle set point e Turn control outputs off inhibits the control outputs e Alarm reset resets alarms from a remote location e Switch PID sets selects between PID set A or B requires enhanced software 98_B _ e Remote set point switches to remote set points e Front panel lockout locks out the front panel Keys to prevent tampering e Control output action switches the control action of outputs 1 and 2 from heating to cooling or vice versa e Auto Manual operation switches to the manual mode of opera tion at the percent power selected with F A 11 Global Menu and disables the Auto Man key 8 8 WATLOW Series 988 User s Manual General Software Features Chapter 8 General Software WATLOW 388 output 1 temperature sensor sensor heater PIDAN UIII switch input 3 event input 1 Figure 8 9 Heater with digital event Sample Application A manufacturing engineer is building an application that needs to switch to an idle temperature at the end of a batch and maintain that tempera ture until the next batch is loaded with minimum operator interaction By connecting an external switch to the digital event input he can select eithe
15. 0 5A with RC suppression NO amp C Switched dc or open collector isolated D Electromechanical relay Form C 5A with RC suppression NO NC 4 C E Electromechanical relay Form C 5A without contact suppression NO NC amp C F Universal process 0 5V dc 1 5V dc 0 10V dc 0 20mA 4 20mA isolated Solid state relay Form A 0 5A without contact suppression NO amp C dc Y 30MA External signal conditioner power supply 5 12 or 20V ut 3 None Solid state relay Form A 0 5A with RC suppression NO amp C Switched dc isolated Electromechanical relay Form A or B 5A without contact suppression NO or NC Solid state relay Form A 0 5A without contact suppression NO amp C Retransmit 0 20mA 4 20mA Retransmit 0 5V dc 1 5V dc 0 10V dc External signal conditioner power supply 5 12 or 20V utput 4 None Solid state relay Form A 0 5A with RC suppression NO amp C Switched dc or open collector isolated Electromechanical relay Form C 5A with RC suppression NO NC amp C Electromechanical relay Form C 5A without contact suppression NO NC amp Solid state relay Form A 0 5A without contact suppression NO amp C EIA TIA 232 communications opto isolated EIA TIA 485 EIA TIA 422 communications opto isolated External signal conditioner power supply 5 12 or 20V dc 30mA EIA TIA 485 EIA TIA 232 communications opto isolated ut to
16. 1A A 2 Ho Olt 98 __ F Minimum load impedance 1KQ Figure 2 13e External Signal Conditioner Power Supply Loop powered 15 1 y Transmitter E y 4 20mA out Wolves Sscsetisou ee EN se 98 __ T Input 1or2 WATLOW Series 988 User s Manual 2 13 Output 3 Wiring NOTE Successful installa tion requires five steps e Model number and software choice Appendix e DIP switch set tings Chapter 1 e Sensor match Chapter 2 and Appendix e Sensor installation Chapter 2 and e Wiring Chapter 2 NOTE Switching inductive loads relay coils solenoids etc with the mechanical relay or solid state relay output options requires using an R C suppressor Watlow carries the R C suppressor Quencharc brand name which is a trademark of ITW Paktron Watlow Part No 0804 0147 0000 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 2 14 WATLOW Series 988 User s Manual Figure 2 14a AC Outputs Solid state Relay with Contact Suppression dba External or 98 B Lo ge NO Form A 0 5 amps minimum off state impedance 20KQ i Electromechanical Relay without Contact Suppression 98 J Form A or B E alarm jumper Form A or B 5 amps off state impedance 31MQ settings 98__ __ J__ only Solid state Relay
17. 2 15 4 1 4 44 date 6 3 dead band 5 16 8 6 8 7 sample application 8 7 decimal 1 4 4 decimal 2 4 11 decimal point location of 4 3 4 35 Declaration of Conformity A 12 default 6 14 A 2 derivative A 2 output 1 5 12 output 2 5 15 deviation alarm 7 6 device address 8 4 DEV LED set point deviation 3 1 Diagnostics Menu 6 7 6 12 lockout 6 6 digital event input options 8 8 8 9 digital event wiring input 1 2 11 input 2 2 10 dimensions 2 1 DIN A 2 DIP switch functions 1 1 1 4 DIP switch locations 1 1 1 4 A 6 WATLOW Series 988 User s Manual DIP switch setting input 1 2 lockout 1 4 output 1 3 display 6 11 Display Key 3 1 Display Loop 3 2 displays 3 1 documentation maintaining ii 6 9 Down arrow Key 3 1 droop A 2 dual in line package DIP switches 1 1 1 4 duty cycle A 2 E environmental chamber 8 7 error code messages 7 8 error code results 7 10 error codes clearing 7 10 error latching 4 36 event input 1 4 40 event input 1 Status 5 4 event input 1 wiring 2 11 event input 2 4 40 event input 2 status 5 4 event input 2 wiring 2 10 external signal conditioner power supply A 2 power supply DIPs 1 3 power supply wiring output 2 2 13 output 3 2 14 output 4 2 15 F Factory Menus 6 1 6 14 factory ship date 6 8 failure mode 4 35 Fahrenheit 4 35 feedback iii filter time constants 8 12 8 13 input 1 4 7 input 2 4 15 form A 7 5 A 2 form B 7 5 A 2 form C A 2 front panel 3 1 front panel lockout 6
18. Carefully docu ment each step of the setup and any subsequent changes This will make it much easier to change adjust and troubleshoot your application Make the configuration documentation available to engineers and techni cians on all shifts who may need to work with the Series 988 We provide space in this manual to record configurations You may prefer to photo copy the blank forms and keep them in a separate binder However you maintain your documentation be sure to replace all old copies of the doc umentation with updated versions whenever the controller configuration is changed ii WATLOW Series 988 User s Manual Introduction Introduction Introduction Notes Cautions and Warnings 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 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 A symbol an exclamation point in a triangle precedes a general CAUTION or WARNING st
19. Figure 8 7b Environmental chamber with dead band General Software cool y cooling action 75 2 77 set se v gt GPI dbf coolset aai no action deadband A AA A EEEE E E EEE primary A y set point heating action setpoint Environmental Chamber chiller temperature sensor heater DOI Sample Application An engineer for an environmental chamber manufacturer who is design ing the heating and cooling system for a new chamber wants to minimize the energy costs of operating the chamber She has chosen the Series 988 and will configure the heat and cool outputs with a positive dead band When the chamber temperature is near ambient the cooling and heating systems had a tendency to buck one another resulting in inefficient use of energy The engineer started with a dead band of five degrees but in the process of tuning the system for optimal control the setting was reduced to two degrees This made the chamber more energy efficient and reduced wear on the refrigeration system General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 7 General Software Digital Events Requirements A single digital event input is standard on all controls A second digital input is available as an option for input 2 98__ 5__ __ Overview The digital event input options on the Series 988 controller allow the oper ator to select one of several software functions with the close of a cus
20. Menus S R S a IMPE QEPE 9LbL Ora Input Output Global Communications Menu Menu Menu Menu p 4 2 p 418 p 434 p 4 44 O Press the Up arrow key Y to select one of the Setup Menus Press the Mode key ES to step through the prompts OF O a a 4 F To 8 q 19999 O Press the Up arrow key Y or the Down arrow key to select one of the prompt values Figure 4 34 Navigating the Global Menu 4 34 WATLOW Series 988 User s Manual Setup prompt Enter your settings A from the controller s Celsius Fahrenheit upper display Failure Mode Error Latching Control Type Cascade Action PID p 4 38 ee ee ee eH eH He ee ee ee ee ee He eH B ddr ihe ell led a ed Event Input p 4 40 Ramping p 4 43 D e a a a e a e a a a e ds a a al Prompts may not appear depending on controller configuration 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 and Decimal 2 parame ters in the Input Menu Setup Menus Chapter 4 setup Global Global Prompts When you are in the Setup menus the Series 988 displays the menu selection in Pt QEPE 9L bt or CGF 4 in the upper display and in the lower display The Up arrow YY or Down arrow key QQ selects another menu Press the Mode key ES to display the first prompt
21. an interstage transformer part 16 0176 the 300A current transformer provides a 5A signal to the interstage transformer In turn the trans former sends a 20mA maximum signal to the controller AC Load 0 to 5A AC L2 A 19 Load wire 0 to CT L sli 20 Single phase current sensing up to 300 amps L1 16 0176 Transformer 3 phase using 2 current transformers 3 phase current sensing up to 300 amps Installation and Wiring Chapter 2 NOTE Successful installa tion requires five steps e Model number and software choice Appendix e DIP switch set tings Chapter 1 e Sensor match Chapter 2 and Appendix e Sensor installation Chapter 2 and e Wiring Chapter 2 Event Input 1 Wiring Figure 2 11a Digital Event Input 1 Available on all units A MES open 14 36V dc Event Input 1 off closed 0 3V dc Event Input 1 on o oO 0 4 99KQ 01puf l l l 24V dc 7509 23 24 10KQ 4 99KQ Figure 2 10c Digital Event Input 2 98 _ 5 _ ____ open 0 3V dc Event Input 2 off closed 14 36V dc Event Input 2 on O o 5V VDC Internal Circuitry E A ia Installation and Wiring Chapter 2 WATLOW Series 988 Users Manual 2 11 Output 1 Wiring NOTE Successful installa tion requires five steps e Model number and software choice Appendix e DIP switch set tings Chapter
22. and the switching differential is determined by the H9 2 value Output Menu Decimal precision is determined by the or d amp C e setting Input Menu Pb2A This prompt appears only if Global Menu is not set to SC d and if Output Menu is set to or or if AL 90 Global Menu is set to dgUPl If Default y y 8 8l _ 256 9999 dFL Calibration Menu Global Menu 8 00k 2 5 9999 Input 1 or 2 PbeR PbeR Input Menu amp gl 19 9999 dFL PbeR Calibration Menu Global Menu 8 _ gol 1919999 Input 1 or 2 Input Menu 80 __30 1999 9 of span _ OFLU PbOR Pb2A Calibration Menu WATLOW Series 988 User s Manual 5 13 Operation PID A or B m Reset Output 2A or 2B red C Pd b Tune reset to eliminate the offset or droop between the set point and the actual process temperature for PID A output 2 When setto 0 reset is disabled This prompt appears only if Calibration Menu is set to and Ph 2A is set higher than _ 8 If Default y y 0000 19999 repeats min rE2R I000 C 00 1980 DM ELR cE2R opa enu H E C A Integral Output 2A or 2B H E Pd b Tune integral to eliminate the offset or droop between the set point and the actual process temperature for PID output 2 When set to _ J integral is disabled E 2A This prompt appears only if Calibration Menu is set to and Ph 2A is set higher than _ 8 NOTE The PID B
23. b4A NOTE InPt nput menu lockout Acnt Ambient A D count A20 a did The controller will OP Jour mena iockout TEE oro around wo coum as c oo C glbL Global menu lockout ent Input 1 A D count i ne E E CSa a not default back to COM Communications menu lockou cnt2 y Input 2 A D count i A10U 1 120 normal display p diAg Diagnostics menu lockout I ity1 Input 1 module y bene de i H CAL Calibration menu lockout a ity2 y Input 2 module i a while in the Factory oyi T Output 1 modue A20A Cao CD E 2 A4A 5 24 CI Menu All outputs Oye Uc CUS ee ae Output 3 module 1 are disabled while P aa ae aro C 20 5 3 Oty4 Output 4 module E In this menu disp Test displays E Bao A x 210 OPLP _ Open loop a boH E SHI OO 9 St Restore factory value b15 y dL Default prompts A 10 WATLOW Series 988 User s Manual Appendix Electromechanical relays warranted for 100 000 clo sures only Solid state switching devices recom mended for applications requiring fast cycle times or extended service life A Current Transformer input cannot be used in conjunc tion with a process output installed on output 1 Slo Blo is a registered trademark of Littelfuse Inc User documentation may be available in French German Spanish Italian and Dutch as well as English Check Watlow s web site www watlow
24. or when the control is in the Calibration or Setup menus Using Alarms Output 2 3 and 4 of the Series 988 can function as alarms This is accomplished with the Gte or prompt Output Menu If ALE or is selected the output is energized in the non alarm condition and de energizes the output in the alarm condition Selecting AL lan or reverses this action de energizing the output in a non alarm condition and energizing it in an alarm condition If the L2 L3 or L4 LED on the front panel is lit this indicates an alarm condition for output 2 3 or 4 respectively Once you ve configured the outputs as alarms enter the Output Menu again and select the _ AL 2 or prompt At these prompts you can select the type of alarm process deviation or rate Each may be independently set low and high Choose between process alarm input 1 process alarm input 2 deviation alarm input 1 deviation alarm input 2 or rate alarm referenced to input 1 Example can reference the input 1 process value against the Ael G and AeHu settings or can reference the input 2 process value against the AZL 0 and AEH settings A process alarm sets an absolute temperature range or process value range When the temperature or process leaves the range an alarm occurs A process alarm is not tied to the set point Example If your set point is 100 F and a process alarm high limit is set to 150 F and the low limit is set to 50 F t
25. such as a Watlow Gordon 5702 isolated transmitter RTD 100 Q input Each 1Q of lead wire resistance can cause a 2 C 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 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 WATLOW Series 988 User s Manual 2 5 Wiring Example 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 A WARNING Install high or low temperature limit control protection in systems where an over tempera ture fault condition could present a fire hazard or other haz ard Failure to install temperature limit control protec tion where a poten tial hazard exists could result in dam age to equipment property and injury to personnel A WARNING To avoid damage to property and equip ment and or injury of loss of life use National Electric Code NEC stan dard wiring prac
26. 1 e Sensor match Chapter 2 and Appendix e Sensor installation Chapter 2 and e Wiring Chapter 2 NOTE Switching inductive loads relay coils solenoids etc with the mechanical relay or solid state relay output options requires using an R C suppressor Watlow carries the R C suppressor Quencharc brand name which is a trademark of ITW Paktron Watlow Part No 0804 0147 0000 2 12 WATLOW Series 988 User s Manual Figure 2 12a AC Outputs Solid state Relay with Contact Suppression 98 _ __B_ 0 5 amps minimum off state impedance 20KQ Electromechanical Relay with Contact Suppression Suppression between NO and COM contacts only 98 _ D_ ____ Form C 5 amps minimum off state impedance 20KQ Electromechanical Relay without Contact Suppression 98 _ __E _ Form C 5 amps off state impedance 31MQ Solid state Relay without Contact Suppression 98 __ K 0 5 amps off state impedance 31MQ Figure 2 12b Switched DC Open Collector ee Op ya 49 16 32V ae ua Maximum voltage 42V dc 13 a Qa Maximum current 1A TE E __ Internal Circuitry ES Figure 2 12c 0 20mA and 4 20mA Process 98 Fo act Maximum load impedance 800Q Figure 2 12d 0 5V 1 5V and 0 10V dc Process 98__ __F_ ____ Elie miS O E Minimum load impedance 1KQ Installation and Wiring Chapter 2 NOTE Successful installa tion requires five st
27. 15 Output 4 Wiring Chapter 3 Front Panel and Display Loop 3 1 Keys and Displays 3 2 Display Loop Chapter 4 The Setup Menus 4 1 Navigating the Setup Menus 4 2 Input Menu 4 18 Output Menu 4 34 Global Menu 4 44 Communications Menu Chapter 5 The Operation Menus 5 1 Navigating the Operation Menus 5 2 System Menu 5 9 PIDA and PID B Menus Table of Contents Table of Contents Chapter 6 The Factory Menus 6 1 Navigating the Factory Menus 6 2 Panel Lockout Menu 6 7 Diagnostics Menu 6 13 Calibration Menu Chapter 7 Tuning Manual Operation Alarms and Error Codes 7 1 Auto tuning Heat and or Cool 7 2 Manual Tuning 7 4 Manual and Automatic Operation 7 5 Changing the Output 3 Alarm Jumper 7 6 Using Alarms 7 8 Error Code E1 and E2 Messages 7 9 Error Code Actions Chapter 8 General Software 8 2 Burst Fire 8 4 Communications 8 6 Dead Band 8 8 Digital Events 8 10 Heater Current 8 12 Input Filter 8 14 Input Linearization 8 16 Ramp to Set Point 8 18 Remote Set Point 8 20 Retransmit 8 22 Slidewire Feedback Appendix A 2 Glossary A 4 Specifications A 5 Warranty and Returns A 6 Index A 10 Menu Overview A 11 Model Number Ordering Information A 12 Declaration of Conformity WATLOW Series 988 User s Manual Figure Int 1 The Series 988 Controllers Introduction Introduction to the Watlow Series 988 Controllers Watlow s Series 988 controllers set a new standard in the c
28. 3 8 8 G gas fired furnace 8 23 Global Menu 4 34 4 43 lockout 6 5 Glossary A 2 A 3 ground loops 2 4 2 5 H heater with digital event 8 9 heater current 8 10 8 11 heat treat oven 8 21 high power limit 4 42 humidity chamber 8 13 hunt 4 16 8 22 8 23 hunting A 2 hysteresis A 2 hysteresis 1 4 20 hysteresis 2 4 22 hysteresis 3 4 26 hysteresis 4 4 29 Appendix I idle set point 5 3 8 8 input 1 4 3 4 8 input 1 wiring 2 8 0 5V dc process 2 8 0 10V dc process 2 8 0 20mA process 2 8 0 50mV high impedance 2 8 1 5V dc process 2 8 4 20mA process 2 8 RTD 2 or 3 wire 2 8 thermocouple 2 8 input 2 4 9 4 16 input 2 wiring 2 9 2 10 0 5V dc process 2 9 0 10V dc process 2 9 0 20mA process 2 9 0 50mV high impedance 2 9 1 5V dc process 2 9 4 20mA process 2 9 current transformer input 2 10 digital event input 2 2 10 potentiometer input 2 10 RTD 2 or 3 wire 2 9 slidewire feedback 2 10 thermocouple 2 9 input DIP switches 1 2 0 5V 1 2 0 10V 1 2 0 20mA 1 2 0 50mV 1 2 0 50mV high impedance 1 2 1 5 1 2 4 20mA 1 2 RTD 1 2 thermocouple 1 2 input filter 8 12 8 13 input linearization 8 14 8 15 Input Menu 4 2 4 17 lockout 6 5 input module 6 9 input ranges tables input 1 4 5 4 6 input 2 4 12 input to output isolation 2 4 2 13 2 15 installation 2 1 2 3 integral A 2 output 1 5 11 output 2 5 14 interface type 4 47 isolation 2 4 A 2 J JIS A 2 jumper
29. 3028 1470 200 799 W5 32 4200 0 23 16 W3 dj 30 4200 0 23 16 32 12643 8 13956 high impedance 8 950 999 999 573 573 WATLOW Series 988 User s Manual 4 5 Setup Input rc E eL rH fi rek rH rH f Range Low 1 and 3 2 3280 O 1760 98 _ 2 A Range High 1 only in l continued from previous page Ss 32 3200 0 1150 b 32 3388 0 418 16 rtd 328 1472 200 800 NOTE These values do not rtd 999 9999 733 53 27 affect the low or the high set point limit 4 20 999 9999 units for process alarms 8 22 999 9999 units 8 5 999 9999 units 1 5 999 9999 units 0 10 999 9999 units Calibration Offset 1 Offset the input 1 signal by a positive or negative value This allows you to compensate for lead resistance sensor errors or other factors CAL 1 This prompt always appears Default Q S PR D i ges 20m CLF OF amp rtd F Global Menu Input Menu Global Menu amp red C F Global Menu Input Menu a process input is selected 4 6 WATLOW Series 988 User s Manual r D po m A Ta Ta un dD D XD uy P ES m UN e e e ry ry r
30. 46 WATLOW Series 988 User s Manual Setup Menus Chapter 4 Setup Menus Chapter 4 Interface Type Select the interface type for Output 4 Option selects EIA TIA 485 selects EIA TIA 422 This prompt appears only on controllers equipped with communications hardware for EIA TIA 485 and EIA TIA 422 98 __ S Default 48S Yee Interface Type Select the interface type for Output 4 Option U selects EIA TIA 485 selects EIA TIA 232 This prompt appears only on controllers equipped with communications hardware for EIA TIA 485 and EJA TIA 232 98 _ U Default add 48S WATLOW Series 988 User s Manual 4 47 Chapter 5 The Operation Menus NOTE Press the Display key to return to the Display Loop from any point in any menu Figure 5 1 Navigating the Operation Menus Operation Menus Chapter 5 Navigating the Operation Menus To reach the Operation Menus begin in the Display Loop and press the Mode key QB Depending on the controller configuration either the Set Point 2 prompt P 2 the Idle Set Point prompt or the Operation Menu prompt will appear in the lower display The three Operation Menus are System 654656 PID A P d and PID B P db Use the Mode key B to step past the Set Point 2 prompt or the Idle Set Point prompt Id 5P if they appear see prompt information Upon reach ing the Operation Menu prompt use the Up arrow Y or Down arrow E key to sele
31. 6 Factory Diagnostics y Factory Prompt Enter your settings from the controller s EE Factory Ship Date Upper display UN a a C a nl Ti Mm LO FE Software Revision UN n Serial Number Ambient Temperature Ej Ambient A D count Ground A D count Input 1 A D count t Input 2 A D count Y 1 Input 1 Module Type Ue Input 2 Module Type 0 8 0 8 08 0 8 0 0 0 0 0 0 0 0 0 0 8 SUR U ROSE OU SURE ALELLA Output 1 Module Type Output 2 Module Type Output 3 Module Type t Output 4 Module Type T Test Display r out Test Outputs Open Loop Figure 6 7 The Diagnostics Menu WATLOW Series 988 User s Manual 6 7 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 52 The second two digits represent the year 94 96 etc dAt E This prompt always appears Software Revision Shows the controller s software revision code when set to YE 5 This letter should match the software revision code on the cover of the manual that came with your controller njand W988 XUMN Rev NOO SOFt 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 s
32. Alarm 2 High Select the high trigger value for the output 2 alarm ACH This prompt appears only if Output Menu is set to some thing other than _ no If Default y Js highest or ReLO value of value of ALE ACH I or sensor Output Menu Input Menu range det or dEdjor LB Ji 9999 ALO ALO CAL AZH I A 3 L N Alarm 3 Low Select the low trigger value for the output 3 alarm A 3JL Q This prompt appears only if AL 3 Output Menu is set to some thing other than no If Default 4 y lowest or value of value of sae ALJ ALJ sensor or _eLe AJLO Output Menu range Input Menu dE I or dEejor 8 ALI ALI AJLO Output Menu Operation Menus Chapter 5 WATLOW Series 988 User s Manual 5 5 Operation System pm 3H Alarm 3 High Select the high trigger value for the output 3 alarm AJH_ This prompt appears only if Output Menu is set to some thing other than no If Default y y highest or AJLO value of value of ALI ALI or sensor Output Menu Input Menu range dE or dEejor EB as ne 9999 ALI ALI CALI Alarm 4 Low pm yy l F Select the low trigger value for the output 4 alarm AYL O This prompt appears only if Output Menu is set to some thing other than no If Default 4 y lowest or value of value of Se CALA sensor or _rtd Output Menu range Input Menu or or 8 ALA CALY A4LO Output Menu 5 6 WATLOW Series 98
33. BL PG 9999 Pb 1A Pb IA 80 PS 9999 Inputtor2 P6 IA Pb IR cc 0 1 14 9999 Pb IR Pb IA 3 GO 14 19999 Inouttor2 Pb IA Pb IA PL 00 30 19999 ofspan ALSO Pb 1A Pb IA Calibration Menu Global Menu Operation Menus Chapter 5 Operation PID A or B E Reset Output 1A or 1B C H b Tune reset to eliminate the offset or droop between the set point and the actual process temperature for PID output 1 When setto Q reset is disabled This prompt appears only if Calibration Menu is set to and Pb 1A is not setto 8 If Default 000 0 993939 repeats min 000 C 80 1080 cE iA Global Menu EIA Integral Output 1A or 1B E H b Tune integral to eliminate the offset or droop between the set point and the actual process temperature for PID output 1 When set to f integral is disabled IE 1A This prompt appears only if Calibration Menu is set to and Pb A is not setto Q NOTE a The PID B Menu appears only on 9999 min repeat controllers with enhanced software 98 B __ _ssi s Operation Menus Chapter 5 WATLOW Series 988 User s Manual 5 11 Operation PID A or B cHAlA cH lb NOTE The PID B Menu appears only on controllers with enhanced software Rate Output 1A or 1B Adjust the rate to eliminate overshoot on startup or after the set point changes The rate setting
34. Cycle Time Output 1B appear depending on controller configuration EB gt ja ES gt paa ES gt pa ES gt pa vone gt pa ene gt Ea C gt WATLOW Series 988 User s Manual 5 9 Operation PID A or B PID A or PID B Prompts NOTE Decimal points may not always be in the position specified below depending on the the settings in the Decimal 1 and Decimal 2 parame ters in the Input Menu NOTE The PID B Menu appears only on controllers with enhanced software to P de 5 10 WATLOW Series 988 User s Manual After you step past the Set Point 2 prompt and the Idle Set Point prompt g5P to the Operation menus the Series 988 displays the menu selection 545 or in the upper display and in the lower display The Up arrow Y or Down arrow key Kg 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 Y and Down arrow K4 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 QB Proportional Band Output 1A or 1B Select the proportional band for PID output 1 If setto Q it func tions as an on off control and the switching differential is determined by the value Output Menu The decimal precision is determined by Input Menu Pb IA This prompt always appears If Default y y 8
35. Menu Default appears only on a a 880 9999 repeats min leo 98 B __ IELA 5 14 WATLOW Series 988 User s Manual Operation Menus Chapter 5 NOTE The PID B Menu appears only on controllers with enhanced software Operation Menus Chapter 5 Operation PID A or B Rate Output 2 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 fjrateis disabled This prompt appears only if Calibration Menu is set to and Pb 2A is set higher than _ 0 Default 2 99 min Derivative Output 2A 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 Q derivative is disabled dE2A This prompt appears only if Calibration Menu is set to and Pb 2A is set higher than _ 8 Default y z min ECR ECR WATLOW Series 988 User s Manual 5 15 Operation PID A or B Cte Cycle Time Output 2A or 2B Select the time in seconds of a complete on off cycle C amp A This prompt appears only if Global Menu is not set to C fd and Pbe RA is set higher than ___ 8 If Default ap y mechanical si 19999 rel
36. O L3 L4 WATLOW a Y 4 NULO MAN O SERIES 989 0 68 17 mm WATLOW Series 988 User s Manual 2 18 55 mm Adjustable Panel A in WM y Mounting Bracket C JL Mi e a da a aa i M j C DF 8G p Ten ee 4 06 2 1 Installation NOTE Removing the con troller chassis from its case makes mounting easier Figure 2 2 Side and top view Installing the Series 988 Installing and mounting requires access to the back of the panel 1 Make a panel cutout using the panel cutout dimensions from the previ ous page 2 To remove the controller chassis from its case press in firmly on the two tabs on one side or the top of the bezel until they unsnap then unsnap 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 Side 986 or 988 or Top and Bottom 987 or 989 View Top and Bottom 986 or 988 or Side 987 or 989 View Adjustable wae Panel Mounting Bracket Mounting Slots 4 x External Gasket Mounting Collar 2 2 WATLOW Series 988 User s Manual Installation and Wiring C
37. The Communications Menu appears only on units equipped with the data communications option You will not see every prompt in any of these menus The unit s configuration and model number determine which prompts appear After stepping through each menu the Series 988 returns to the Setup Menu prompt SEEE Use the Up arrow Y and Down arrow keys to select the next menu or use the Mode key B to advance through the same menu again To move back wards through the menu hold the Mode key Q down and press the Up arrow key Y Use the Up arrow Y or Down arrow K 4 key to change the prompt setting Refer to the Appendix for model number options For information about communications and the communications prompts refer to the supple mental manual Data Communications with the Watlow Series 988 Family of Controllers Begin in the Display Loop and press the Up arrow Y9 and Down arrow 2 keys simultaneously to PENO DISPLAY OUT reach the Setup Menus 5 3 af Fa InPE QEPE 9LbL COPA Input Output Global Communications Menu Menu Menu Menu p42 p 418 p 434 p 4 44 Press the Up arrow key Y to select one of the Setup Menus WATLOW Series 988 User s Manual 4 1 Setup Input Reaching the Input Menu WATLOW MARE PROCESS o e O E DEV e DISPLAY OUT o AUTO MAN SERIES 988 Select the Input Menu then press the Mode key Q to step through the prompts ioe Og
38. by the corresponding LED on the front panel L2 L3 or L4 There may be an alarm message flashing in the lower display but if the prompt is set to Global Menu no alarm message is displayed When an alarm message is displayed it alter nately flashes with the current prompt at a one second interval in the lower display 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 will not appear and the appropriate L2 L3 or L4 LED and output will reflect a non alarm condition Silencing is active until the process has entered the safe region located between the low and high alarm settings Then devia tion outside this safe zone triggers an alarm If an alarm occurs at this point the output can be silenced by pressing the Auto Man key once but the controller still displays the alarm message Tuning Manual Operation Alarms and Error Codes Chapter 7 WATLOW Series 988 User s Manual 7 7 NOTE To view the error code press the Auto Man key once The upper dis play shows the error code for five seconds before returning to the display Figure 7 8 Error code display NOTE An alarm display will be masked by an error condition or when the control is in the Calibration or Setup menus 7 8 WATLOW Series 988 Error Code E1 and E2 Messages Four d
39. chamber makes the controller display jump two to three percent To remove this display dithering set the filter time constant for input 1 to two seconds This will smooth the dis play and provide a more realistic reading General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 13 General Software Input Linearization Requirements The square root extraction feature is standard on any Series 988 con troller with universal signal conditioner inputs The linearization prompt will appear if a process input is selected with the DIP switches see Chapter 1 Overview In many flow applications the output signal from a flow transmitter repre sents a squared value of the actual flow The square root must be extract ed from the signal to make it useful to the operator Many flow transmit ters offer this feature in the transmitter itself but this can add significant ly to the cost Using the square root extraction option in the Series 988 controller can save the operator money The feature is enabled simply by setting input 1 linearization or input 2 linearization to square root extraction root 8 14 WATLOW Series 988 User s Manual General Software Features Chapter 8 Figure 8 15a Graph of linearized signal Figure 8 15b Waste water treat ment with input lin earization General Software Features Chapter 8 General Software 10 linearized signal flow in gallons per 8 minute 6 4 2 0
40. com for availability Specify lan guage and quantity at time of order Appendix Model Number Ordering Information 1658 To order complete the code number to the right with the information below Series 988 a single channel temperature process controller 1 analog input 1 digital input 1 analog or digital input 4 outputs vows Supply amp Mounting 24 to 28V ac dc nominal vertical mounting 24 to 28V ac dc nominal horizontal mounting 100 to 240V ac dc nominal vertical mounting 100 to 240V ac dc nominal horizontal mounting gt 8 9 Software A B Standard Enhanced Includes cascade ratio duplex dual PID set Input 1 1 Thermocouple only Excluding Type B R and S 2 Universal signal conditioner Input 2 O None 1 Thermocouple only Excluding Type B R and S 2 Universal signal conditioner 3 Slidewire feedback 4 Current transformer 5 Digital contact event One digital event is standard on all units Output 1 B Solid state relay Form A 0 5A with RC suppression NO amp 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 F Universal process 0 5V dc 1 5V dc 0 10V dc 0 20mA 4 20mA isolated K Solid state relay Form A 0 5A without contact suppression NO C Output 2 A None B Solid state relay Form A
41. control See Chapter 8 for more information on the burst fire feature However if a mechanical contac tor or solenoid is switching power to the load a longer cycle time may be desirable to minimize 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 98_ _ 5 Rate Derivative Adjustment Increase or to 0 10 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 0 50 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 the approach to set point will be very sluggish Repeat as neces sary 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 Tuning Manual Operation Alarms and Error Codes Chapter 7 WATLOW Series 988 User s Manual 7 3 Auto Man NOTE When a se
42. in the lower display and its value in the upper display Use the Up arrow YY and Down arrow K43 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 QB Celsius Fahrenheit Select which temperature scale the controller will use This prompt appears only on controllers with either Input 1 or Input 2 set to something other than a process input Default 4 E F C_F Failure Mode Select the output level that the controller will maintain if an input fails e Bumpless transfer b PL 5 maintains the same output settings after an input failure FA iL This prompt always appears If Default I I uo bPLS 120 application FAIL FAIL FAIL a heat onl bP 5 8 100 application FA IL FAIL a bPLS 100 C0 application FAIL WATLOW Series 988 User s Manual 4 35 setup Global Error Latching Select whether errors will be latching or non latching e Non latching alarms turn off when there is no alarm condition e Latching alarms must be turned off manually This prompt always appears Default y ni A LAE Err Control Type Select a control method normal nor cascade 5 d ratio 1 AE or differential d FF This prompt appears only on controllers equipped with enhanced software 98_B ____ _ _ _ and input 2 hardware for a basic thermocou ple signal conditioner 98_ _ _1__ __ _ _ or a univ
43. ini or 0 50mV high impedance Figure 1 2 O Put te WIENER 0 20 or 4 20mA 0 5 1 5 or 0 10V e 1 2 WATLOW Series 988 User s Manual 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 Outputa gt outputs equipped with Option Board an external signal con Output 2 _ gt sji Option Board and DIP ditioner power supply Only controllers with model number 98_ _ _ ee ption Board an id SE T or98_ nal signal conditioner le hescr ower supply Top View 986 amp 988 P PPY Left side View 987 amp 989 Output 2 Output 3 Output 4 98__ __ Ear O lo 80 2 I 20V 5 30mA ie ihe be AL B 12V 5 30mA LA LA 5V 5 30MA BL E Output 4 Option Board and DIP 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 988 User s Manual 1 3 DIP Switches 4 The lockout DIP switch A 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 CAUTION The lockout DIP swit
44. location 7 5 junctions A 2 K keys 3 1 L L1 output 1 L2 output 2 L3 output 3 L4 output 4 latching 2 4 24 latching 3 4 27 latching 4 4 30 latching alarm 7 7 learn high range 4 13 learn low range 4 13 3 1 3 1 3 1 3 1 Appendix linearization A 2 linearization input 8 14 8 15 linearization 1 4 8 linearization 2 4 15 local remote 5 8 locating DIP switches 1 1 1 4 Lockout Panel Menu 6 2 6 6 lockout DIP switch 1 4 lockout level setting 6 2 6 6 loop error detect 8 10 lower display 3 1 low power limit 4 41 M maintaining documentation ii 6 9 manual operation 7 4 manual tuning 7 2 mechanical relay 7 2 menu lockout 6 2 6 6 Mode Key 3 1 8 23 Modbus 8 4 module types 6 9 6 10 mounting 2 1 2 3 muffle furnace 8 17 N National Electric Code NEC 2 4 2 6 2 7 NEMA 4X seal 2 3 A 2 non latching alarm 7 7 notes iii O on off control A 2 Operation Menus 5 1 5 16 operation parameters manual tuning 7 2 open loop 6 12 A 2 ordering information A 5 output A 2 output 1 4 19 output 1 wiring 2 12 0 5V dc process 2 12 0 10V dc process 2 12 0 20mA process 2 12 1 5V dc process 2 12 4 20mA process 2 12 ac outputs 2 12 switched dc open collector 2 12 output 2 4 21 output 2 wiring 2 13 0 5V dc process 2 13 0 10V dc process 2 13 0 20mA process 2 13 1 5V dc process 2 13 4 20mA process 2 13 ac outputs 2 13 external transmitter power supply 2 13 switche
45. longer exists i At 3 This prompt appears only on controllers equipped with output 3 NOTE hardware for a relay 98__ ____ B___ 98__ ____ J___or See real 7 for 98__ ___ _ K___ or switched de 988__ ___ C__ _ and with set more information t on alarms j ii Default J LAREI 5 IL J 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 A3t 0 and AJH I NOTE S IL 3 This prompt appears only on controllers equipped with output 3 See Chapter 7 for hardware for a relay 98__ ___ B___ 98__ ___ _ J___or sacl information 98 ___ K___ or switched de 98 _ C__ _ and with set on alarms to or AL Jal Default y 5 113 Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 27 setup Output Output 4 Select the alarm condition for output 4 de energizes output 4 in an alarm condition NOTE energizes output 4 in an alarm condition See Chapter 7 for E more information This prompt appears only on controllers equipped with output 4 on alarms hardware for a relay 98__ ____ _B_ 98__ ___ D__ 98 _ E _or98 _ HK _ or switched de 98__ ___ C_ A L y Alarm 4 Select the alarm type for alarm 4 e Pr I uses a process signal from input 1 el dE I uses a deviation from the input 1 signal e Pr 2 uses the process signal from input 2 This promp
46. measuring junction is an inte gral part of the sheath material No electrical isolation is provided isolated junction A form of thermocouple probe construction in which the measuring junction is fully enclosed in a protective sheath and electrically isolat ed from it Commonly called an ungrounded junction reference junction The junction in a thermo couple circuit held at a stable known temperature cold junction Standard reference temperature is 32 F 0 C thermocouple junction The point where the two dissimilar metal conductors join In a typical thermo couple circuit there is a measuring junction and a refer ence junction See reference junction ungrounded junction See isolated junction Appendix linearization square root The extraction of a linear signal from a nonlinear signal corresponding to the mea sured flow from a flow transmitter Also called square root extraction Modbus RTU Remote Terminal Unit NEMA 4X A NEMA specification for determining resis tance to moisture infiltration This rating certifies the con troller as washable and corrosion resistant on off A method of control that turns the output full on until set point is reached and then off until the process error exceeds the hysteresis open loop A control system with no sensory feedback output Control signal action in response to the differ ence between set point and process variable oversh
47. relay that uses only the normally closed NC and common contacts These contacts open when the relay coil is energized They close when power is removed from the coil form C A single pole 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 hunting Oscillation of process temperature between the set point and the process variable hysteresis A change in the process variable required to re energize the control or alarm output Sometimes called switching differential integral Control action that automatically eliminates offset or droop between set point and actual process tem perature See reset automatic isolation Electrical separation of sensor from high volt age circuitry Allows use of grounded or ungrounded sens ing element Joint Industrial Standards JIS A Japanese agency that establishes and maintains standards for equipment and components Also known as JISC Japanese Industrial Standards Committee its function is similar to Germany s Deutsche Industrial Norm DIN JIS Joint Industrial Standards junction The point where two dissimilar metal conduc tors join to form a thermocouple cold junction Connection point between ther mocouple metals and the electronic instrument See refer ence junction grounded junction Type of thermocouple probe in which the hot or
48. starting point for the ramp is the current process value If the ramp is initiated on start up the Series 988 looks at the process value upon power up and uses that value as the starting point for the ramp If a set point change initiates the ramp to set point function the controller looks at the process value when the change is made and uses that value as the starting point for the ramp If the set point is changed during a ramp the process value at the time of the change becomes the starting point for the new ramp 8 16 WATLOW Series 988 User s Manual General Software Features Chapter 8 General Software heaters III PU l Muffle Furnace output 1 limit PROCESS sens or sensor MITTITI INNI 00 TTTTTTTU UTE heaters SERIES 988 Figure 8 17 Muffle furnace with Sample Application ramp to set point An engineer needs to control the temperature of a muffle furnace The fur nace set point must be ramped up at a defined rate to prevent stressing the muffle and other system components By enabling the ramp to set point function in the Series 988 the engineer can control the rate at which the set point will rise Ramp to set point is enabled in the Global Menu using the Ramping Function prompt rP To ramp on start up only select start St r To ramp on start up and on any set point changes select set point St PE The ramp rate is in degrees per minute For further protectio
49. the Up arrow YY and Down arrow keys together and hold for three seconds The prompt will appear in the lower display Press and hold the Up arrow Y and Down arrow keys together again for three seconds until the 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 PL GC Diagnostics d A9 and Calibration CAL Upon reaching the Factory Menu prompt use the Up arrow Y or Down arrow E key to select a menu and the Mode key J to step through a menu 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 988 returns to the Factory Menu prompt Fct Y Use the Up arrow YY and Down arrow keys to select the next menu or use the Mode key 149 to advance through the same menu again To move backwards through the menu hold down the Mode key QB and press the Up arrow key Y Use the Up arrow Y or Down arrow K4 key to change the prompt setting O Press the Up arrow YY and Down arrow keys together and hold until the prompt appears in the lower display Press and hold again until the prompt appears in the lower display f y PO PLOC d A9 CAL Fet Y Fet YJ FetY Panel Diagnostics Calibration Lockout Menu Menu Menu p 6 7 p 6 13
50. the Up arrow Y and Down Setup Prompt arrow 2 keys simultaneously for Enter your settings from the controller s three seconds to reach the Setup Baud Rate upper display Menus dAER Data Bits and Parity Ss O OB y y y es Protocol Type InPt QEPE 9LbL COPA Address Input Output Global Communications Menu Menu Menu Menu p 42 p 418 p 434 p 4 44 aL ELE BLL uo 040 00 8 IMEF Interface Type Press the Up arrow key Y to select one of the Setup Menus Prompts may not appear depending on controller config uration Press the Mode key B to step through the prompts a OR NOTE 3 3 pa O The Communications Menu appears only on controllers 3000 1200 1800 equipped with communications bad baud hardware 98_ _ R 98 __ U _or98_ _ See Data Communications with 485 422 the Series 988 Family of Controllers for detailed informa tion on communications O Press the Up arrow key Y or the Down arrow key to select one of the prompt values Figure 4 44 Navigating the Communications Menu 4 44 WATLOW Series 988 User s Manual Setup Menus Chapter 4 Setup Menus Chapter 4 Communications Prompts When you are in the Setup menus the Series 988 displays the menu selection n Pt QEPE SL bL or CGF 9 in the upper display and in the lower display The Up arrow YY or Down arrow key selects another menu Press the Mode k
51. the controller set up as an on off controller Phe A 0 and with not setto nol This prompt does not appear on controllers equipped with output 2 process hardware Ine SL d or if in the Global menu d YPL If Default y y HY52 Global Menu amp is pi Input 1 or 2 HY52 Global Menu see note above ZEE HYS2 Global Menu amp n y Input 1 or 2 HY52 Global Menu see note above pi _999 Junits a process input HYS2 HY52 HYS Is selecte Set Point 2 Control Select a second set point enables a set point independent from the Set Point 1 value enables a set point at a deviation from the Set Point 1 value This prompt appears only if output 2 hardware is present and is equal to the output 1 setting Default y SPee SPee 4 22 WATLOW Series 988 User s Manual Setup Menus Chapter 4 setup Output e 2 Pud Alarm 2 Select the alarm type for alarm 2 Select the trigger points for the alarm with the Rel and A2H settings in the System Menu 646 uses the process signal from input 1 Changing the set point does not change the alarm response uses a deviation from the input 1 signal Changing the set point changes the alarm response NOTE pide pil ator el uses the process signal from input 2 This choice does not appear eee if the controller is not equipped with input 2 hardware or if is set to or _ 1d uses a deviation from the input 2 sign
52. without Contact Suppression a aa DA a A E 0 5 amps off state impedance 31MQ e Figure 2 14b Switched DC gt en ae 4910 30 gt ac 7900 Minimum load resistance 5000 2 y Internal Circuitry Figure 2 14c Process Retransmit 0 20mA 4 20mA Load impedance 6000 max 98 _ _ __ M__ _ 0 5V 1 5V 0 10V VDC Load impedance 5004 min 98 _ ____ N Figure 2 14d External Signal Conditioner Power Supply Loop powered 98__ T Eana abia E E Transmitter V 4 20mA out V 2 NOTE See Chapter 1 for power supply DIP switch information Installation and Wiring Chapter 2 NOTE Successful installa tion requires five steps e Model number and software choice Appendix e DIP switch set tings Chapter 1 e Sensor match Chapter 2 and Appendix e Sensor installation Chapter 2 and e Wiring Chapter 2 NOTE Switching inductive loads relay coils solenoids etc with the mechanical relay or solid state relay output options requires using an R C suppressor Watlow carries the R C suppressor Quencharc brand name which is a trademark of ITW Paktron Watlow Part No 0804 0147 0000 NOTE Input to output iso lation is defeated when the external transmitter power supply is used to power a signal con ditioner connected to input 1 or input 2 Installation and Wiring Chapter 2 Output 4 Wiring Figure 2 152 AC Ou
53. zone application see page 8 19 8 20 WATLOW Series 988 User s Manual General Software Features Chapter 8 General Software Heat treat Oven WATLOW input 1 EE output 1 temperature 2 ou sensor heaters ni Chart Recorder Figure 8 21 Heat treat oven with Sample Applications retransmit A Series 988 is being used to control the temperature of a heat treat oven The temperature of the process must be recorded on a chart recorder The oven temperature range stays between 600 and 900 F The chart recorder requires a 4 20mA signal In the Output Menu Gt PE set analog output to to tag the input 1 process value as the parameter to be retransmitted Set retransmit low limit to 600 to set the low range for the retransmit signal to 600 Set retransmit high limit to 900 to set the high range for the retransmit signal to 900 Set retransmit calibrate offset to O assuming there is no calibration offset required The retransmit output will be 4mA until the oven temperature is greater than 600 degrees F at which point the signal will increase with tempera ture to 20mA at 900 F and will not exceed 20mA General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 21 General Software NOTE Outputs must be compatible with the slidewire valve actu ators Slidewire Feedback Requirements A slidewire configuration uses at least two inputs and two control out puts Input 2 can only be select
54. 0 4 2 1995 Elektrostatische Entladung EN 61000 4 4 1995 Elektrische schnelle St Be ENV 50140 1994 Strahlungsimmunitat ENV 50141 1994 Leitungsimmunitat ENV 50204 1995 Mobiltelefon 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 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 fir Elektroger te zur Messung zur Steuerung und im Labor Teil 1 Allgemeine Richtlinien Declara que el producto siguiente Espanol Designaci n Series 986 987 988 989 N meros de modelo 9 8 6 7 8 9 Cualquier letra 1 2 012346 5 BCDEFoK ABCDEFKoT ABCJKM NoT ABCDEKRSOo T Cualquier combinaci n de dos letras Control categor a de instalaci n II grado de contaminaci n ambiental II 100 a 240 V Vca o 24 a 28V Vca Vcc 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 electromag
55. 0mV high impedance NOTE Successful installa tion requires five steps e Model number and software choice Appendix e DIP switch set tings Chapter 1 e Sensor match Chapter 2 and Appendix e Sensor installation Chapter 2 and e Wiring Chapter 2 Thermocouple only 98__ 1_ no DIP switches Universal signal conditioner NN J K T N C E D Pt2 R S Input impedance 20MQ 0 50mV DIP Settings DIP Settings B Figure 2 8b RTD 2 or 3 wire 100 Q Universal signal conditioner Jumper 98 2 9 to 10 EA NO AS for 2 wire old DIP Switch Setting Figure 2 8c 0 5V Universal signal conditioner 98 2 __ Input impedance 1OKQ DIP Switch Setting Figure 2 8d 0 20mA or 4 20mA Process Universal signal conditioner 98 2 __ Input impedance 7Q DIP Switch Setting 2 8 WATLOW Series 988 User s Manual O 00 ii O Installation and Wiring Chapter 2 NOTE Successful installa tion requires five steps e Model number and software choice Appendix e DIP switch set tings Chapter 1 e Sensor match Chapter 2 and Appendix e Sensor installation Chapter 2 and e Wiring Chapter 2 Installation and Wiring Chapter 2 Input 2 Wiring Figure 2 9a Thermocouple or 0 50mV high impedance Thermocouple only 98__ _1 __ no DIP switches Universal signal conditioner ee eae oh pE A L
56. 1 change with Up arrow YY or Down arrow g key Y 988 current input 2 reading Pr e input 2 process appears only if controller equipped with input 2 hardware NOTE aa 388 current input 1 reading If is selected 988 deviation from set point process 1 minus set point 1 DEV light on for Inde in the Input Menu the seal 8 current input 1 reading E E prompt will gt 00 _ 88 percent output OUT light on not appear C988 current input 1 reading gt C units selected units F or C Figure 3 2 The Display Loop 3 2 WATLOW Series 988 User s Manual Front Panel and Display Loop Chapter 3 Chapter 4 The Setup Menus NOTE When navigating through menus outputs will be dis abled NOTE Press the Display key to return to the Display Loop from any point in any menu Figure 4 1 Navigating the Setup Menus NOTE The lockout DIP switch hides the Setup Menus See Chapter 1 Setup Menus Chapter 4 Navigating the Setup Menus To reach the Setup Menus begin in the Display Loop and press both the Up arrow YY and Down arrow J4 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 inPt Output Gt Pt Global 9L bL and Communications GP 1 Use the Up arrow YY or Down arrow J4 key to select a menu and the Mode key QB to step through a menu
57. 200 or O to 2316 C D t c W3 o 32 to 4200F or O to 2316 C Pt 25 32 to 2543F or O to 1395 C 1 RTD JIS 328 to 1166 or 200 to 630 C 1 RTD DIN 328 to 14727 or 200 to 800 C 0 1 RTD JIS and DIN 99 9 to 999 9 F or 73 3 to 537 7 C 0 5V dc 999 to 9999 1 5V dc 999 to 9999 0 10V dc 999 to 9999 0 20mA 999 to 9999 4 20mA 999 to 9999 0 50mV dc 999 to 9999 Slidewire 100 to 12000 Current O to 50A Potentiometer 0 to 12000 Output Options e Solid state relay 0 5A 24V ac min 253V ac max opto isolated burst fire With or without contact suppression e Open collector Max voltage 42V dc max current 1A e Switched dc signal Min turn on voltage of 3V dc into min 500Q load max On voltage not greater than 32V dc into an infinite load isolated e Electromechanical relay Form C 5A 120 240V ac 6A 28V dc 1 8 hp 120V ac or 125VA 120V ac With or without contact sup pression Off state output impedance with RC sup pression is 20kQ A 4 WATLOW Series 988 User s Manual e Process 0 20mA 4 20mA into 800Q2 maximum 0 5V dc 1 5V dc or 0 10V dc into 1kQ mini mum reverse acting isolated e Electromechanical relay Form A B 5A 120 240V ac GA O 28V dc 1 8 hp 120V ac or 125VA 120V ac Without contact suppression e External transmitter power supply 5V 5 30mA 12V 5 O 30mA or 20V 5 30mA e EIA TIA 2
58. 32 communications or ElA TIA 485 EIA TIA 422 communications opto isolated 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 volt age Agency Approvals e UL C UL File 43684 e CE 89 336 EEC Electromagnetic Compatibility Directive EN 50081 2 1994 Emissions EN 50082 2 1995 Immunity e 73 23 EEC Low Voltage Directive EN 61010 1 1993 Safety e NEMA 4X Terminals e 6 compression universal head screws tighten to 5 inch pounds maximum accepts 20 14 gauge wire Line Voltage Power 100 to 240V ac 10 15 50 60HZ 5 24 to 28V ac dc 10 15 50 60Hz 5 16VA maximum Fused internally factory replaceable only Slo Blo type time lag 2A 250V for high voltage versions 5A 250V for low voltage versions e Non volatile memory retains data if power fails Operating Environment e 32 to 149 F 0 to 65 C 0 to 90 RH non condens ing Storage Temperature e 40 to 185 F 40 to 85 C Mechanical e 1 8 DIN panel mount NEMA 4X IP65 equivalent front panel e Overall width x height x depth horizontal 4 03 x 2 18 x 4 74 102mm x 55mm x 120mm vertical 2 18 x 4 03 x 4 74 55mm x 102mm x 120mm e Depth behind p
59. 4 Appendix WATLOW Series 988 User s Manual A 9 Menu Overview A y E y EA y A y A A Display Loop Press to exit Lower Display an y menu a nd Set point 1 Process input2 Inner Loop DEVLEDon OUTLEDon Process units Remote set point reac h th e D IS p ay set point or cascade only Ratio value Loop at any time Press QB to advance to the Operation Operation Menus menus Outputs are still active ldle set point A OPEr j Figure A 10 OPE _JOperation vy The Series 988 Map F A 7 SyS System y PIDA PIDA y PIDB PIDB p EdS Event input 1 status 4 Pb1A Output 1 proportional band A A Pbib Output 1 proportional band E E Ei2S Event input 2 status a rElA Output 1 reset A rElb Output 1 reset B E A2LO Alarm 2 low E ma Output 1 integral A e itib Output 1 integral B NOTE MODE y A2HI Alarm 2 high y CATA Output 1 rate A E Ab Output 1 rate B z T A3LO Alai 3 low dEIA Outpt 1 derivative A dEtb Output 1 derivative B This is a complete q ASHI Alarm 3 high EZD E ca Joutput 1 cycle time A CIB eu output 1 cycle time B listing of all Series SAR Alarm eee aoe Output 2 proportional band A eee Output 2 proportional band E 988 prompts A4HI Alarm 4 high E rE2A Output 2 reset A E2b Output 2 reset B Aut Auto tune It2A Output 2 integral A ela Output 2 integral B cd 2S L
60. 6 CFD Communications lockout 6 6 CEPT Communications Menu 4 44 8 4 CS AU cascade action 4 37 USC d cascade control 4 36 CE IA cycle time output 1 PID A 5 13 8 2 Ct 16 cycle time output 1 PID B 5 13 8 2 CEZA cycle time output 2 PID A 5 16 8 2 5 PA Cc 3 3 g Q Dd tr XD data bits amp parity 4 45 8 4 factory ship date 6 8 dead band 5 16 dead band PID A 5 16 8 6 dead band PID B 5 16 8 6 deviation alarm input 1 7 6 deviation alarm input 2 7 6 XD tr Q o Q o XD Q o Oo Q AN Q AN a a rm 5 derivative output 1 PID A 5 12 derivative output 1 PID B 5 12 derivative output 2 PID A 5 15 5 15 a rm o Q AN ye XD Q AN N o derivative output 2 PID B decimal 1 4 4 Qa rm mn Appendix Index prompts
61. 8 User s Manual Operation Menus Chapter 5 Operation System A Y H Alarm 4 High Select the high trigger value for the output 4 alarm AYH This prompt appears only if Output Menu is set to some thing other than no If Default 4 highest or A4LO value of value of CALY or _ cHe sensor Output Menu Input Menu range gE I or dECjor g sj ya 9999 ALY CALY CALY Output Menu fm i E Auto tune Initiate an auto tune appears only on controllers with enhanced software 98_B __ and with AL 30 Global Menu set to orlescd i tits This prompt always appears Default NOTE For more informa tion on auto tune P idf AUE see Chapter 7 Operation Menus Chapter 5 WATLOW Series 988 User s Manual 5 7 Operation System Local remote Select a local or remote set point With selected the controller displays the remote set point rather than the internal local set point and the set point cannot be changed with the Up arrow or Down arrow key This prompt appears only if Input Menu is setto Gal Default Lice e 5 8 WATLOW Series 988 User s Manual Operation Menus Chapter 5 Reaching the PID Menus Begin in the Display Loop and press the Mode key 1439 to reach the Set Point 2 prompt 5P2 the Idle Set Point prompt or the System Menu 595 System PIDA PID B Menu Menu Menu p 5 2 p 5 9 p 5 9 Use Mode key Q to step past the Set Point 2 prom
62. C Range low 2 i AL3 Val 3 Annunciator H2 Range high 2 i Alarm SA Press ey Or CI to LmL Learn range low ES J arate Alarm 2 S10s PRENE E e a HYS3 JH steresis 3 High power limit move between the De cai CAL2 Calibration offset 2 J BASHA Latching for alarm 3 Eric ano SBI poimi menus rtd2 RTD calibration curve y Sita Silence alarm 3 C Ramping function Fire Input 2 software filter Ot4 Output 4 Ramp rate Lin2 nput 2 linearization 1 AL4 Alarm 4 Press EJ to Hunt Slidewire dead band q A484 Alarm 4 side advance through a SWS Slidewire inner A a hysteresis a EAM Latching for alarm 4 menu SIL4 Silence alarm 4 k Aout nalo tput l I g outpu l Pre3 Process 3 Hold ES while i A rL Retransmit low limi I pressing D to ATE Retransml high lim ACAL Ret it cal offs move backwards adi a through the menus At the prompt press PY and g another Factory Menus e ats opace 3 seconds to enter the Factory menus Press Y or EZ to ce AR j a select prompt values i PLOC Panel Lockout E diAg Diagnostics y CAL Calibration ca i b380 LOC Front Panel lockout r dAtE y Factory ship date A50 5 atou r SyS System menu lockout SOFt Software revision Aoo 4 TE I n Pida PIDA menu lockout J Sn Serial number _ te C b20A MODE Pidb PIDB menu lockout a AMb Ambient temperatur AOH
63. Series 988 User s Manual Includes 986 987 988 and 989 1 8 DIN Microprocessor Based Temperature Process Controller User Levels e New US8T oooocccnoccccccccccccnnos go to Introduction e Experienced UsS er go to page 4 1 C 9 6 Installers SBlUPococccccccnccnccnnnonononanononanonos go to page 1 1 TOTAL e Wiri llation 2 1 iring amp Installation go to page CUSTOMER SATISFACTION 3 Year Warranty ISO 3001 Registered Company Winona Minnesota USA a LOW Watlow Controls 1241 Bundy Blvd P O Box 5580 Winona Minnesota USA 55987 5580 Phone 507 454 5300 Fax 507 452 4507 http www watlow com 0600 0009 0001 Rev W 10 00 March 1999 A Supersedes 0600 0009 0001 Rev V Made in the U S A ES Printed on Recycled Paper 10 Postconsumer Waste Introduction to the Watlow Series 988 Controllers li Using this Manual ii Document Every Step iii Notes Cautions and Warnings iii Technical Assistance iii We Value Your Feedback Chapter 1 Hardware Setup 1 1 Dip Switch Locations and Functions Chapter 2 Installation and Wiring 2 1 Panel Cutout and Dimensions 2 2 Installing the Series 988 2 4 Wiring the Series 988 2 4 Input to output Isolation 2 4 Power Wiring 2 5 Sensor Installation Guidelines 2 6 Wiring Example 2 8 Input 1 Wiring 2 9 Input 2 Wiring 2 11 Event Input 1 Wiring 2 12 Output 1 Wiring 2 13 Output 2 Wiring 2 14 Output 3 Wiring 2
64. U V W X Y Z Er 3 ambient temperature error 7 9 Ge 3 output 3 4 25 it out test outputs 6 11 Er 4 RAM identification error 7 9 GE output 4 4 28 Bes non volatile checksum error 7 9 Ge PE output lockout 6 5 Er 9 configuration error 7 9 Ge PE Output Menu 4 18 C Err error latching 4 36 Ct Y output 1 module type 6 10 Gt Ye output 2 module type 6 10 F Ot 43 output 3 module type 6 10 GE YY output 4 module type 6 10 failure mode 4 35 FE r 1 software filter 1 4 7 p Ft re software filter 2 4 15 FULL full 4 46 8 4 Pb IA proportional band output 1 PID A 5 10 Pb 16 proportional band output 1 PID B 5 10 G P bA proportional band output 2 PID A 5 13 Pb 2b proportional band output 2 PID B 5 13 Global Menu 4 34 P d switch PID sets 4 38 8 8 9L 51 global lockout 6 5 P de PID 2 crossover selection 4 38 P dA PID A Menu 5 3 H P db PID B Menu 5 3 P dAJ PID A lockout 6 4 H_ 9H alarm 3 trigger 4 26 P db PID B lockout 6 4 H P high power limit 4 42 Pt OC Panel Lockout Menu 6 1 6 6 Hunt hunt 4 16 8 22 8 23 Pr _ e input 2 process 3 2 8 10 HYS hysteresis 1 4 20 Pre process 1 4 20 H950 hysteresis 2 4 22 Prec process 2 4 21 HYS 3 hysteresis 3 4 26 Pr c J process 3 4 31 HY54 hysteresis 4 4 29 Proc crossover process value 4 39 P ot protocol type 4 46 8 4 R p
65. Verify the correct sensor type before making a change Failure to follow this guideline could result in damage to equipment or prop erty Document all settings before changing sensor type Input 1 continued on next page Setup Menus Chapter 4 Setup Input Input Prompts When you are in the Setup menus the Series 988 displays the menu selec tion InPE QEPE LLL Oor CGP in the upper display and in the lower display The Up arrow Y or Down arrow key Kg selects another menu Press the Mode key Q to display the prompt in the lower display and its value in the upper display Use the Up arrow YY or Down arrow K 4 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 QB Input 1 Select sensor type for input 1 This selection must match the sensor type connected to terminals 8 9 and 10 See 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 dF L E will flash in the upper display e Changes do not take effect automatically after five seconds you must press the Mode key Q to enter the sensor type change and advance to the next prompt This prompt always appears
66. _ E__or98__ ___ K _ orswitched de 98__ ___ C_ and with set to or AL Un Default y 5 14 Analog Output Select which value to retransmit as the output 3 signal e Prce retransmits the process 1 value e SEPE retransmits the set point NOTE e Pr ee retransmits the process 2 value This prompt appears only if the e controller is equipped with input 2 hardware and if is not set to on retransmit or Euel turns off retransmit function This prompt appears only on controllers equipped with retransmit hardware 98_ _ M___or98_ N Default Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 31 setup Output NOTE See Chapter 8 for more information on retransmit 4 32 WATLOW Series 988 User s Manual Process 3 Select the range for the retransmit signal at output 3 This prompt appears only on controllers equipped with retransmit hardware 98 __ M_ or98 _ N__ and with not set to no Default 4 4 20mA 0 20mA 0 5V 1 5V 0 10V dc 4 20 0 28 1 6 Q 18 Prc3 Prc3 Prc3 Prc3 Prc3 Retransmit Low Limit Select the low limit for the retransmit signal at output 3 e The default value is equal to or in the Input Menu depending on whether is set to or Prec e The decimal precision of is determined by JEL I Input Menu if is set to or St PE it is determined by JEC 2 if Aout is set to Pred This prompt appears only on controllers equipped with retransmit hardw
67. action linearization square root 8 14 8 15 A 2 storing data 8 4 8 5 switched dc open collector wiring output 1 2 12 output 2 2 13 output 3 2 14 output 4 2 15 switching sensitivity A 3 System Menu 5 1 5 8 lockout 6 4 T technical assistance iii 6 10 temperature limit control protection 2 6 terminal designation stickers 2 4 test chambers wih communications 8 5 test displays 6 11 test output 6 11 thermal system A 3 thermocouple 2 5 A 3 thermocouple break protection A 3 thermocouple wiring input 1 2 8 input 2 2 9 three mode control A 3 time constant filter input 1 4 7 input 2 4 15 time proportioning control A 3 tuning automatic 7 1 7 2 manual 7 2 7 4 settings 7 2 7 3 Tuning of Industrial Control Systems 7 1 U Up arrow Key 3 1 upper display 3 1 using manual ii iii V W warnings iii warranty A 5 waste water treatment 8 15 wiring 2 1 2 4 2 15 event input 1 2 11 event input 2 2 10 input 1 2 8 input 2 2 9 2 10 output 1 2 12 output 2 2 13 output 3 2 14 output 4 2 15 wiring example 2 6 wiring safety 2 4 2 6 2 7 X Y Z zero switching A 3 zone heating 8 19 A 8 WATLOW Series 988 User s Manual Prompt Index error 7 8 dl DO a L alarm 2 high 5 5 8 17 alarm 2 low 5 4 8 17 alarm 2 side 4 23 alarm 3 high 5 6 alarm 3 low 5 5 alarm 3 side 4 26 alarm 4 high 5 7 alarm 4 low 5 6 alarm 4 side 4 29 retransmit calibration off
68. al This prompt does not appear if the controller is not equipped with input 2 hardware or if is set to or Ee uses the rate of change at input 1 in degrees per minute This prompt appears only on controllers equipped with output 2 hardware and with set to or AL ln Default ALZ ALA ALO ALO ALE ALE A2Sd Alarm 2 Side Select what triggers alarm 2 e both triggers an alarm when the signal lt R2t G or AEH 1 e H 9H triggers an alarm when the signal gt AEH e L ol y triggers an alarm when the signal lt A2t J fi25 d This prompt appears only on controllers equipped with output 2 hardware and with set to or AL en Default L ASd ASd RASO Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 23 setup Output E At o Latching 2 Select whether alarm 2 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 L At 2 This prompt appears only on controllers equipped with output 2 NOTE hardware and with set to or AL en See Chapter 7 for more information Default on alarms Ay LALO LALO 6 fe e Silencing 2 Select silencing to inhibit alarm 2 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 Het 0J and AH This prompt appears only on controlle
69. anel 4 06 103mm e Weight less than or equal to 14 00z 0 40kg Sample Update Rates e 1 input 10Hz e 2 inputs 5Hz e Retransmit 1Hz e Remote set point 1Hz PID 10Hz Outputs 10Hz Display 2Hz Alarm Outputs 1 Hz Resolution e Inputs 16 bits e Outputs 12 bits 1 Electromechanical relays are warranted for 100 000 clo sures only Solid state switching devices are recom mended for applications requiring fast cycle times or extended service life 2 Not an ANSI symbol Appendix Total Satisfaction Warranty The Watlow Series 988 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 Mfg Co St Louis Missouri a manufacturer of industrial electric heating products since 1922 Watlow begins with a full set of specifications and completes an industrial product that is manufactured totally in house in t
70. ange Low 2 and Range High 2 Select the low and high limits for input 2 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 Jn 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 to 4 28 mA Set tol 188 Set tol 500 A 4mA input will display _ 180 A 12mA input will display 300 A 20mA input will display 50808 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 the controller is equipped with input 2 hardware and with Input 2 not set to or E 10 WATLOW Series 988 User s Manual 4 11
71. are 98 _ __ _ M_ or 98 _ N__ and with not setto no A rt A rt Setup Menus Chapter 4 Gy NOTE rc See Chapter 8 for more information on retransmit 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 in the Input Menu depending on whether is set to or Pred e The decimal precision of A AL is determined by dE I Input Menu if is set to or St PE it is determined by JEC 2 if Aout is set to Pre This prompt appears only on controllers equipped with retransmit hardware 98_ _ M__or988_ N and with not setto no iy 9999 AH AH Retransmit Calibration Offset Select an offset value for the retransmit signal at output 3 e The decimal precision of A AL is determined by gE I Input Menu if is set to or St PE it is determined by JEC 2 if Aout is set to Pred ACAL This prompt appears only on controllers equipped with retransmit hardware 98_ _ _M___or98 __ N__ andwith not set to no If Default 4 i CELF ACAL ACAL ACAL Global Menu aes ACAL ACAL ACAL Global Menu E l units a por apil ACAL ACAL ACAL is selecte WATLOW Series 988 User s Manual 4 33 setup Global Reaching the Global Menu Begin in the Display Loop and press the Up arrow Y and Down arrow 14 keys simultaneously for three seconds to reach the Setup
72. ashes in the upper display indicate a Series 988 error The control goes into the manual mode and maintains the percent output selected at the prompt Global Menu That value percent of out put is shown in the lower display E2 I A D underflow error The analog to digital A D converter of the input indicated by the first number is under range An open or reversed polarity sensor is the most likely cause Check the sensor Make sure the input prompt is set to the correct sensor E 2 Sensor under range error The sensor at the input indicated by the first number generated a value lower than that allowed for the range of the sensor or the analog to digital A D converter malfunctioned Make sure the setting for the input Input Menu matches the sensor type and that the sensor range falls within the range of the process being controlled ES 3 Sensor over range error The sensor at the input indicated by the first number generated a value higher than that allowed for the range of the sensor or the analog to digi tal A D converter malfunctioned Make sure the setting for the input Input Menu matches the sensor type and that the sensor range falls within the range of the process being controlled E2 4 A D overflow error The analog to digital A D converter at the input indicated by the first number is over range An open or reversed polarity sensor is the most like ly cause Check the sensor Make sure the in
73. atement The A symbol a lightning bolt in a triangle precedes an electric shock hazard CAUTION or WARNING safety 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 after checking all the steps you can get technical assistance by calling Watlow Controls at 507 454 5300 between 7 a m and 5 p m CST and asking for an applications engineer When you call have the following information on hand the controller s model number the 12 digit number is printed on the top of the stickers on each side of the controller s case and on the right hand or top circuit board your user s manual all configuration information and the Diagnostics Menu readings We Value Your Feedback Your comments and suggestions on this manual are welcome Please send them to Technical Writer Watlow Controls 1241 Bundy Blvd P O Box 5580 Winona MN 55987 5580 or call 507 454 5300 or fax 507 452 4507 The Series 988 User s Manual is copyrighted by Watlow Winona Inc O March 1999 with all rights reserved 1657 WATLOW Series 988 User s Manual 111 Chapter 1 Hardware Setup DIP Switch Locations and Functions The Watlow Series 988 has at least one and as many as six dual in line package DIP switches inside the controller depending on the model nu
74. ations hardware 98__ ___ _ R _ or98 _ S Default y FULL COP cera cora Diagnostics Menu Select the lockout level for the Diagnostics Menu Set the Diagnostics Menu lockout to no lockout non E read only or full lockout FULL This prompt always appears Default ol a 0 o 3 om and a JE d oa aj N JE d r o r Calibration Menu L zi L Select the lockout level for the Calibration Menu Set the Calibration Menu lockout to no lockout non E read only or full lockout FULL This prompt always appears Default nong lrERd L CAL CAL O 3 6 6 WATLOW Series 988 User s Manual Factory Menus Chapter 6 Reaching the Diagnostics Menu O Press the Up arrow Y and Down arrow 4 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 En PU PLOC ld 1 19 CAL Fcty Fct Fcty Panel Diagnostics Calibration Lockout Menu Menu Menu p 6 7 p 6 13 p 6 2 Use the Up arrow Y key to step from the Panel Lockout Menu PL QC to the Diagnostics Menu d A9 Press the Mode key B to step through the prompts So mol YES d ISP d ISP Sn A AD bout tovt O Press the Up arrow key Y or the Down arrow key to select one of the prompt values In the Diagnostics Menu only the values of d I9P and QPL P can be changed Factory Menus Chapter
75. ature will not function when the Series 988 has a process output for output 1 98_ _ F A Known cycle time is required to detect the current There is no cycle time associated with process outputs The maximum signal the input can accept from the current transformer secondary is 50mA So you must calculate the output range of the cur rent transformer before wiring the system General Software Features Chapter 8 Figure 8 11 Compression mold ing press using the heater current fea ture PROCESS DISPLAY General Software Compression Molding Press 10A SSR curren transformer O OOOO 10A heaters Q temperature sensor sensor Sample Application The Series 988 controls the lower platen of a compression molding press that contains five 10 ampere heaters A 50A 50mA current transformer is used to monitor heater current Set the Input 2 prompt to current Curr the Range Low 2 prompt to O and the Range High 2 prompt to 50 Find the range high 2 value with the following equation range high 2 _ maximum CT primary current load current x 50mA maximum output from CT secondary input The application uses a Watlow current transformer CT part 16 0233 which has a maximum input of 50 amperes which corresponds to a maxi mum output of 50mA range high 2 50Amps x 50mA 50mA Solving for rH2 gives you 50 This is the range high 2 setting General Software Featu
76. ave an open collector or solid state relay output controllers with option B C or K selected for output 1 98__ _ _ _ output 2 98_ _ _ _ output 3 98_ e ga ___ or output 4 98__ ____ _ e The time burst is appropriate for fast loads or very tight control It pro vides advantages only for PID control not for on off control e The short time bases used by burst fire makes it incompatible with the heater current feature 98 4 The heater current option requires a minimum of 300 milliseconds on time to get a reading e The Series 988 has built in zero cross detection circuitry eliminating the need for external firing circuitry to trigger SCR s The controller will not allow burst fire to be selected if its zero cross detection circuitry is not functioning e The feature is enabled by selecting burst fire at the cycle time prompt for the appropriate output in the PID Menu CE IA ICE Ib C amp A or CECI e Only the 988 and 989 can use the burst fire feature The low voltage units 986 and 987 cannot use burst firing Overview Variable time base burst firing from the Series 988 provides the most even distribution of power with the lowest level of noise generation RFI An SSR or SCR firing card translates a command signal into a burst of ac cycles The output is zero cross fired which always allows at least one full ac cycle to pass within the variable time base Burst firing is the pr
77. ay CEZA outputs open collector be St s ce 19999 or solid state CEA CEA relay outputs Dead Band Aor B db A Select the width of the zone between the action of the heating output and the 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 d amp C setting Input Menu This prompt appears only if Pb 2A is set higher than _ and NOTE The PID B Menu one output performs heating action and the other performs cooling action appears only on If Default controllers with al J enhanced software 98 B sel Oa OS O db A de A Global Menu db A db A Global Menu a process seb O Gate units input is selected deb A deb A db A 5 16 WATLOW Series 988 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 the Factory Menus To reach the Factory Menus begin in the Display Loop and press
78. bumpless transfer A smooth transition from auto closed loop to manual open loop operation The control output s does not change during the transfer 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 calibration offset An adjustment to eliminate the dif ference between the indicated value and the actual process value cascade Control algorithm in which the output of one control loop provides the set point for another loop The second loop in turn determines the control action 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 com pensate for the effective temperature at the cold junction current transformer A transformer designed for mea suring electrical current dead band The range through which a variation of the input produces no noticeable change in the output In the dead band specific conditions can be placed on control output actions Operators select the dead band It is usu ally above the heating proportional band and below the cooling proportional band default parameters The programmed ins
79. cess Changing the set point during an auto tune restarts the auto tune proce dure During auto tuning the process must cross the set point four times within an 80 minute time span for the Series 988 to successfully complete the auto tune If this does not happen within the 80 minute time limit the Series 988 chooses PID values based on the 80 minute tuning cycle per formed To start auto tuning 1 Press the Mode key Q to advance to the System Menu 95 Press the Mode key B to advance through the menu until the prompt appears in the lower display 2 Use the Up arrow O or Down arrow 2 key to select P dA or P db aa Only one PID set can be auto tuned at a time 3 Press the Display key EM While the control is in the tuning mode the lower display alternates every second between the normal informa tion and the prompt 4 When tuning is complete the displays return to their previous state and reverts to OFF The Series 988 installs the PID tuning parameters it has calculated and saves them in non volatile memory To abort auto tuning either reset the prompt to off press the Auto Man key twice or cycle power off and on In all cases aborting auto tune restores all values to their state before auto tuning began Manual Tuning For optimum control performance tune the Series 988 to your thermal system The tuning settings here are for a broad spectrum of applications your system may have somewhat different
80. ch 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 no hardware lockout Switch 1 has no effect lockout Setup and Factory menus Figure 1 4 Switch 1 has no effect Lockout DIP switch Input Output Gortirel Chassin Tap Where ima SAB Lettada Mew 07 amp HE A an an or E A A A or Commu Global Spk nications OR Panel Lockout 1 4 WATLOW Series 988 User s Manual gt gt Diagnostics Calibration ae Be F Hardware Setup Chapter 1 Chapter 2 Installation and Wiring NOTE Space panel cutouts at least 1 66 inches 42 2mm apart NOTE Adjustable mount ing brackets can be side mounted NOTE Holes can be cut in the panel using a Greenlee 1 8 DIN Hydraulic Kit 60068 punch 60069 die 60070 Figure 2 1 Series 988 and Series 989 dimensions and terminal number layout 984 3980 E A E L1 L2 L3 L4 DEV O OUT O ess G2 SERIES 988 DISPLAY AUTO MAN o 2 18 55 mm E 2 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 BOOM COM OO Installation and Wiring Chapter 2 4 03 102mm 4 03 102mm io a Li L2 DEV O OUT
81. ct a menu and the Mode key J to step through a menu 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 988 returns to the Operation Menu prompt OPEr Use the Up arrow YY and Down arrow 2 keys to select the next menu or use the Mode key QB to advance through the same menu again To move backwards through the menu hold the Mode key 3 down and press the Up arrow key Y Use the Up arrow Y or Down arrow K4 key to change the prompt setting Begin in the Display Loop and press the Mode key CB to reach the Set Point 2 prompt SP the Idle Set Point prompt or the Operation Menu OPE o Set Point 2 idSP Idle Set Point 20 Oe 595 P idf P idb OPEr OPEr System PIDA PID B Menu Menu Menu p 5 2 p 5 9 p 5 9 Use the Mode key 3 to step past the Set Point 2 prompt or the Idle Set Point prompt Id 5P if they appear see prompt information Upon reaching the Operation Menu prompt use the Up arrow Y9 key to select a menu WATLOW Series 988 User s Manual 5 1 Operation System Reaching the System Menu WATLOW as PROCESS Select the System Menu then press the Mode key Q to step through the prompts a A 999 998 997 0 MALO MALO A2LO O Press the Up arrow key YY to step through the prompt values The Down arrow key 4 backs throu
82. d 4 20 WATLOW Series 988 User s Manual Setup Menus Chapter 4 setup Output Output 2 Set the way that output 2 will respond to a difference between the set point and an input variable e Ale Alen HE de energizes output 2 in an alarm condition energizes output 2 in an alarm condition select reverse action so that output 2 responds when the input signal is less than the set point select direct action so that output 2 responds when the input signal is more than the set point This prompt appears only on controllers equipped with output 2 hardware not98 _ A __ and do not appear if out put 2 is a process output 98__ ___F ___J and do not appear if AL 90 in the Global Menu is set to JUPL Default y Ate Ote Cte Ote Process 2 Select the process range for output 2 This prompt appears only on controllers equipped with output 2 process hardware 98__ ___F ___ _ and with not set tol no Default y Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 21 HYS Hysteresis 2 Select the switching hysteresis for output 2 This determines the change in temperature or process units needed to turn the output from off to on o Jf is set to settings for HY 652 will be in degrees per minute or units per minute e If the input referenced by is set to the range is affected as listed below This prompt appears only on controllers equipped with output 2 hardware and with
83. d dc open collector 2 13 output 3 4 25 output 3 wiring 2 14 ac outputs 2 14 external transmitter power supply 2 14 process retransmit 2 14 switched dc open collector 2 14 output 4 4 28 output 4 wiring 2 15 ac outputs 2 15 external transmitter power supply 2 15 switched dc open collector 2 15 output configurations output 1 control 3 1 output 2 control or alarm 3 1 Index h r output 3 alarm or retransmit 3 1 output 4 alarm or communications 3 1 output DIP switches 1 3 Output Menu 4 18 4 33 lockout 6 5 output module types 6 10 output power supply output 2 2 13 output 3 2 14 output 4 2 15 overriding alarms 7 7 overshoot A 3 P P control A 3 panel back access 2 2 panel cutouts 2 1 2 2 Panel Lockout Menu 6 2 6 6 PD control A 3 PDR control A 3 PI control A 3 PID 2 crossover selection 4 38 PID control A 3 PID A Menu 5 9 5 16 PID B Menu 5 9 5 16 PID Menu lockout 6 4 PID parameters 7 1 PID sets switching 8 8 PLOC Menu 6 2 potentiometer wiring 2 10 power supply see external signal conditioner DIP switches 1 3 output 2 2 13 output 3 2 14 output 4 2 15 power wiring 2 4 process variable A 3 process 1 4 20 process 2 4 21 process 3 4 31 process alarm 7 6 process retransmit wiring 2 14 process value 8 16 proportional band A 3 output 1 5 10 output 2 5 13 proportional band adjustment 7 3 proportioning control A 3 protocol type 4 46 8 4 Q R ramping function 4 43 8 16 ramp rate 4 43 8 16 ram
84. e Factory menus the Series 988 displays the menu selection PL OEC d 1A9 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 Y and Down arrow 2 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 QB Front Panel Lockout Sets the Lockout level for the Front Panel This allows you to disable keys on the front of the controller O enables all keys I disables the Mode key QB g disables the Mode key Q and the Auto Man key 9a J disables the Mode key 1 3 and the Auto Man key and locks the set point value This prompt always appears Default 8 Loc LOC LOC LOC WATLOW Series 988 User s Manual 6 3 Factory Panel Lockout The prompts within the Panel Lockout Menu allow you to lockout an entire menu You can set the level of lockout to none non read only rERARd or lockout read and write FULL System Menu Select the lockout level for the System Menu Set the System Menu lockout to no lockout nonE read only or full lockout FUL L This prompt always appears Default mont EAd FULL L595 595 595 p iA PID A Menu Select the lockout level for the PID A Menu Set the PID A Menu lock out to no
85. e set points at the front panel with an event input from a remote computer using the communicatons feature or from an external switch using an event input General Software Features Chapter 8 General Software Figure 8 19 Zone heating with Sample Application remote set point An engineer has a machine with eight independent zones of heat He wants to change set points on all zones without having to adjust each con trol individually This can be achieved using a Series 988 with a 0 5V dc retransmit output as the master controller The seven remote 988s will use the 0 5V dc signal on input 2 as a remote set point When the set point is changed on the master controller the retransmit output changes the set points of the seven remote controllers By enabling the ramp to set point feature in the master controller all eight zones are ramped up to set point at a user defined rate on power up The retransmit output from the master Series 988 is set so that OV dc represents O F and 5V dc represents 800 F On the remote controllers set the input 2 DIP switch to the position for the 0 5 1 5 0 10V dc process input In the Input Menu under the Input 2 prompt Ind select 0 5 The Remote Set Point prompt should be set to ON and decimal 2 JE 2 set to O The range low 2 and the range high 2 parameters will establish the scaling for the remote set point input Range low 2 should be set to O and range high 2 should be se
86. ed as a slidewire input 98__ 3__ ____ Overview The Series 988 can control the position of a valve with a slidewire feed back position indicator The controller senses the resistance of the slidewire and compares it to the range low and range high settings to determine the valve position The controller compares this to the percent output and takes action to match the two by opening or closing the valve Set the hunt parameter to limit valve hunting The value is set for the percent of output 0 0 to 100 0 When the valve is within this dead band a change in output greater than half the hunt parameter is required to trigger action Output 1 responds to close commands and output 2 responds to open commands 8 22 WATLOW Series 988 User s Manual General Software Features Chapter 8 General Software Gas fired Furnace WanoW temperature 988 988 sensor 1 DEV T 00000000000000000 AAA gas valve cut off valve slidewire input Figure 8 23 Gas fired furnace Sample Application with slidewire feed A Series 988 controls the gas valve for a gas fired furnace to heat treat back large metal parts First the controller must be married to the slidewire feedback from the valve actuator To do this first set the Input 2 prompt to slidewire SL 1d Advance to the Learn Low Resistance prompt i cnt Close the valve manually to the minimum resistance reading from the slidewire Select in the upper d
87. eferred mode to control resistive loads The Series 988 detects when the ac sine wave of the load will cross the 0 volt point It uses this information to switch the load on or off only at a O volt point minimizing RFI The burst fire time base in the Series 988 varies from a maximum 1 66 second time base 1 percent output 1 cycle on 99 off down to a 33 3 mil lisecond time base 50 percent output 1 cycle on 1 off The graphs on the next page show how the time base varies with the percent output General Software Features Chapter 8 General Software 90 output 10 output 1 on 1 off 1 on 9 off coc IO coso ON I Figure 8 3a Sine waves of burst fire settings Semiconductor Oven input 1 388 output 1 temperature q88 E sensor heated platen Figure 8 3b Semiconductor oven with burst fire Sample Application A Series 988 controls a heated platen in a semiconductor oven Previously it used a power control requiring a 4 20mA signal to implement burst fire control We have replaced the power control with a Watlow Loyola QPAC with a QCD card that accepts a signal directly from an open collector out put of the Series 988 This gives smooth control at a lower overall system cost General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 3 General Software Communications Requirements Choose which interface your application will use EIA TIA 232 serial com munications 98 _ R _
88. eps e Model number and software choice Appendix e DIP switch set tings Chapter 1 e Sensor match Chapter 2 and Appendix e Sensor installation Chapter 2 and e Wiring Chapter 2 NOTE Switching inductive loads relay coils solenoids etc with the mechanical relay or solid state relay output options requires using an R C suppressor Watlow carries the R C suppressor Quencharc brand name which is a trademark of ITW Paktron Watlow Part No 0804 0147 0000 NOTE Input to output iso lation is defeated when the external signal conditioner power supply is used to power a transmitter connect ed to input 1 or input 2 Installation and Wiring Chapter 2 Output 2 Wiring Figure 2 13a AC Outputs Solid state Relay with Contact Suppression 98 _ _ ___B ____ 0 5 amps minimum off state impedance 20KQ Electromechanical Relay with Contact Suppression Suppression between NO and COM contacts only 98 _ __ _D ____ Form C 5 amps minimum off state impedance 20KQ Fuse Y ne ane E outputs only Electromechanical Relay without Contact Suppression 98 _ E ____ Form C 5 amps off state impedance 31MQ Solid state Relay without Contact Suppression 98 __ K 0 5 amps off state impedance 31MQ Figure 2 13b Switched DC Open Collector 19 to 32V dc a de pl AM EG Sl a Internal Circuitry 98 __ C Maximum voltage 42V dc Maximum current
89. er Wiring 100 to 240V ac dc nominal 85 to 264 actual m m N Vertical Package E ir AN Horizontal Package O 00 CO I I D a ee 22 111 3 K earth ground N 24 to 28 V amp ac dc nominal 20 to 30 actual El Jl Vertical Package 986_ ____ _ Horizontal Package 98 7 IM E A E mi Jii Installation and Wiring Chapter 2 AM CAUTION The Series 988 will not function with 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 NOTE Input to output iso lation is defeated when the external signal conditioner power supply is used to power a transmitter connect ed to input 1 or input 2 Installation and Wiring Chapter 2 Sensor Installation Guidelines Maintain isolation between input 1 and input 2 to prevent a ground loop A ground loop may cause incorrect readings dashes across the upper dis play or the display of error codes Thermocouple input Extension wire for thermocouples must be of the same alloy as the thermocouple itself 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
90. erial num ber The lower display shows the last four digits of the serial number 5618 This is what the controller with the serial number 0988345678 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 868 0 0 regardless of the settings of dEl IIdELO L dEFlJorL CLF APA5b This prompt always appears 6 8 WATLOW Series 988 User s Manual Factory Menus Chapter 6 Factory Diagnostics O Factory Use Only These prompts are used only at the factory These prompts always appear Inputs 1 and 2 Module Types 0 E g Displays which input module is installed in the controller Please doc ument this value before contacting the factory for technical assistance Input Types e nonE No input module e Ecg Thermocouple only module e Curr Current detect e SL d Slidewire module e UOFF Universal off e Ur Ed Universal rtd e UE ch Universal high gain thermocouple e UE cL Universal low gain thermocouple e yPA y Universal millivolts e UP rc Universal process e E 2 Event input 2 These prompts always appear Factory Menus Chapter 6 WATLOW Series 988 User s Manual 6 9 Factory Diagnostics O EJ EJ EJ 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
91. ers the heater current input measures 50 amps regardless of the percent output To view the heater current press the DISPLAY key and advance to the Process 2 prompt Pr 2 The upper display indicates the last valid cur rent reading The Input 2 prompt under the Input Menu can be set to current or loop error detect L ooP Current allows you to monitor heater current and set alarm set points based on high and low heater current values Alarms can only be configured as process alarms see Alarms in Chapter 7 Setting to loop error detect enables monitoring and alarm functions and also triggers an error and shuts off all outputs if current is present with output 1 off or when no current is present and output 1 power is more than zero There are limits associated with this feature e To obtain a reading the output on time must be a minimum of 0 3 seconds To calculate this multiply the percent output by the cycle time setting Example With 30 percent output and a 2 0 second cycle time the on time would be 0 30 x 2 0 0 6 seconds This would yield a valid reading If a valid reading is not possible the 988 will display the last valid reading e The heater current feature will not function with the cycle time on output 1 set to br St This does not apply to output 2 output 3 or output 4 This does not necessarily apply to the loop error detect feature If enabled any current detected with no output triggers an error e This fe
92. ersal signal conditioner 98 2 andwith set to GFF Default 4 36 WATLOW Series 988 User s Manual Setup Menus Chapter 4 setup Global C 6 A E Cascade Action Select the control action between the inner and outer loop of a cas cade system e Direct action makes the percent output from the outer loop directly proportional to the set point of the inner loop input 2 A 100 signal in the outer loop will set the inner loop to range high 2 Input Menu A 0 signal in the outer loop will set the inner loop to range low 2 Input Menu e Reverse action makes the percent output from the outer loop inversely proportional to the set point of the inner loop input 2 A 100 signal in the outer loop will set the inner loop to range low 2 Input Menu A 0 signal in the outer loop will set the inner loop to range high 2 Input Menu SAC This prompt appears only on controllers equipped with enhanced software 98_B ___ _ __ _ _ and with set to 50d Default y dair Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 37 ALIU P ide Algorithm Select the control algorithm selects one set of PID prompts selects proportional derivative control with manual reset in per cent power selects two complete sets of PID prompts This selection does not appear if is set toll SEd e JUPL selects duplex heating and cooling control This prompt does not appear unless output 1 is a process out
93. ey ES to display the first prompt in the lower display and its value in the upper display Use the Up arrow Y and Down arrow 2 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 WB Baud Rate Select the communications speed bAUd This prompt appears only on controllers equipped with communi cations hardware 98__ ____ R _ 98__ ____ U__or98__ ____ 253 Default Data Bits and Parity Select the communications format start bit 1 stop bit 1 e Setting to automatically sets JA Atol Bal dt A This prompt appears only on controllers equipped with communi cations hardware 98 _ R_ 98 U_ or98 Al Default y dAER dAER AdRERA WATLOW Series 988 User s Manual 4 45 Protocol Type Select the communications protocol e FULL selects ANSI X3 28 2 2 A 3 el on selects Xon Xoff e fF 990d selects Modbus This prompt appears only on controllers equipped with communi cations hardware 98 R _ 98 U__or98 __ E Default a FULL Prot Prot Prot 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 If Default y y 485 C Ol 34 IntF 422 8 9 IntF Prod C te i e47 IntF Addr 4
94. fect until after a five second delay or until you press the Mode key QB Output 1 Set the way that output 1 will respond to a difference between the set point and an input variable select reverse action so that output 1 responds when the input signal is less than the setpoint select direct action so that output 1 responds when the input signal is more than the setpoint This prompt always appears Default OE I DE WATLOW Series 988 User s Manual 4 19 setup Output Process 1 Select the process range for output 1 This prompt appears only on controllers equipped with output 1 process hardware 98__ _ _F ____ Default y 4 20mA 0 20mA 0 5V 1 5V 0 10V dc 4 20 1 6 8 10 Pre Pre Pre H y 6 Hysteresis 1 Select the switching hysteresis for output 1 This determines the change in temperature or process units needed to turn the output from full on to full off HYS 1 This prompt does not appear on controllers equipped with output 1 process hardware 98__ __F _ This prompt only appears with the controller set up as an on off controller Pb 1A 0 If Default J CESE HYS 1 H95 1 HYS 1 Global Menu amp T oF L E F int HYS HY S HY S Global Menu Input Menu ats HJ5 1 H951 H951 Global Menu amp ji L E F int HY S HY S HY S Global Menu Input Menu units x ve al E LC Un uy x ve Un a process input is selecte
95. gh the values Figure 5 2 The System Menu 5 2 WATLOW Series 988 User s Manual Enter your settings from the controller s upper display Set Points p 5 3 SP Set Point 2 ee Event Input p 5 4 Alarm 2 High Alarm 3 Low B 8 8 8 80 0 0 0 0 0 0 0 0 Alarm 3 High AYTO Alarm 4 Low Prompts may not appear depending on controller configuration Operation Menus Chapter 5 NOTE Decimal points may not always be in the position specified below depending on the the settings in the Decimal 1 and Decimal 2 parame ters in the Input Menu Operation Menus Chapter 5 Operation System System Prompts After you step past the Set Point 2 prompt and the Idle Set Point prompt g5P to the Operation menus the Series 988 displays the menu selection 545 or in the upper display and in the lower display The Up arrow Y or Down arrow key Kg 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 Y and Down arrow 2 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 QB Set Point 2 Select a second set point that will activate output 2 This allows you to boost the heating or cooling action of the output 1 device e The range and default settings depend on the n and settings Inpu
96. gh 5 2 alarm jumper changing 7 5 alarm low 5 2 alarm reset 8 8 alarms 7 5 7 7 alarms latching 7 7 alarms non latching 7 7 alarm silencing 7 7 algorithm 4 38 ambient temperature 6 3 analog output 4 31 annunciator 4 41 A 2 Auto Manual key 3 1 7 4 Auto Manual LED 3 1 7 4 auto manual operation 7 4 8 8 automatic operation 7 4 auto tune 5 7 auto tune set point 4 42 auto tuning 7 1 B baud rate 4 45 8 4 brackets 2 1 2 3 bumpless transfer 4 35 7 4 burst fire 8 1 8 3 A 2 C calibration curve RTD 2 4 14 calibration manual ii Calibration Menu 6 13 6 14 lockout 6 6 calibration offset A 2 calibration offset 1 4 6 calibration offset 2 4 14 calibration offset adjustment 7 3 cascade control A 2 cascade action 4 37 cautions iii Celsius 4 35 clearing error codes 7 10 closed loop A 2 cold junction A 2 communications 8 4 8 5 Communications Menu 4 44 4 48 8 4 lockout 6 6 compression molding press 8 11 consumer feedback iii controller chassis removing 1 1 7 5 controlling output action 8 8 control outputs off 8 8 control type 4 36 crossover process value 4 39 crossover set point value 4 39 current 8 10 current transformer 8 11 A 2 current transformer input 2 10 current transformer wiring 2 10 cycle time output 1 5 13 output 2 5 16 cycle time adjustment 7 3 D data bits amp parity 4 45 8 4 data communications ii 2 15 4 1 8 4 Data Communications with the Watlow Series 988 Family of Controllers ii
97. hapter 2 A CAUTION Follow the installa tion procedure exactly to guarantee a proper NEMA 4X seal Make sure the gasket between the panel and the rim of the case is not twisted and is seat ed properly Failure to do so could result in damage to equipment Installation the mounting collar over the back of the control 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 backward then down to secure it to the control case To guarantee a proper NEMA 4X seal Series 986 and 988 units vertical must have the mounting brackets located on either side of the unit When installing Series 987 and 989 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 Make sure the inside gasket is seated properly and not twisted Insert the controller chassis into its case and press the bezel until all four tabs snap To release the mounting brackets loosen the mounting bracket screws and push the brackets forward then pull it
98. haracteristics of industrial scientific and medical radio frequency equipment Class A EN 61000 3 2 1995 Limits for harmonic current emissions EN 61000 3 3 1995 Limitations of voltage fluctuations and flicker 73 23 EEC Low Voltage Directive 1993 Safety requirements for electrical equipment for measurement control and laboratory use Part 1 General requirements EN 61010 1 D clare que le produit suivant Francais D signation S rie 986 987 988 989 Num ro s de mod le s 98 6 7 8 ou 9 lettre quelconque 1 ou 2 0 1 2 3 4 ou 5 B C D E F ou K A B C D E F K ou T 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 c a c c 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 ENV 50140 1994 Insensibilit a nergie rayonn e ENV 50141 1994 Insensib
99. hat triggers alarm 3 e both triggers an alarm when the signal lt AJL O or gt A3H e H 9H triggers an alarm when the signal 2 AJH e i OL y triggers an alarm when the signal lt A31 6 This prompt appears only on controllers equipped with output 3 hardware for a relay 98__ ____ B___ 98__ ____ J___or 98 K __ orswitcheddc 98 _ C _ _ and with set to or AL In Default y LObLuy Hysteresis 3 Select the switching hysteresis for alarm 3 This determines the change in temperature or process units needed to turn the output from off to on o If is set to settings for HY6 3 will be in degrees per minute or units per minute e If the input referenced by is set to the range is affected as listed below HY5S 3 This prompt appears only on controllers equipped with output 3 hardware for a relay 98__ ____ B___ 98__ ____ J___or 98 ____ K___ orswitched dc 98__ ___ _ C___ If Default J y H953 H953 Global Menu a si w999 Input 1 or 2 H953 Global Menu see note above C F HY53 H953 Global Menu 8 wet as C_F Input 1 or 2 H953 Global Menu see note above L999 unts a process input HYS3 HY53 HY53 is selected 4 26 WATLOW Series 988 User s Manual Setup Menus Chapter 4 setup Output l AL 3 Latching 3 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
100. he U S A Watlow products include elec tric 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 sup plier to original equipment manufacturers These OEMs depend upon 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 e Name and phone number of person returning the material e 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 cred it for material A 20 percent restocking charge i
101. he control out put or outputs remain stable a bumpless or smooth transition The lower display changes from the set point to the output value e If FA Il is set from tol 100 the Series 988 switches to man ual operation at that percent power User s Manual Tuning Manual Operation Alarms and Error Codes Chapter 7 Figure 7 5 Alarm jumper location Alarms Changing the Output 3 Alarm Jumper If you have model number 98 __ __ J output 3 can be con figured as a Form A NO and common contact or Form B NC and com mon contact 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 chas sis 2 Set the jumper to the position you want See below for jumper location ar oo E NC NO Contacts Contacts Form B Form A Controller Chassis Top View 3 Return the controller chassis to the case Be sure you have it oriented correctly Press firmly but gently to seat the chassis If you select Form A the contact is open when power is removed from the control If you select Form B the contact closes when power is removed Tuning Manual Operation Alarms and Error Codes Chapter 7 WATLOW Series 988 User s Manual 7 5 Alarms NOTE An alarm display will be masked by an error condition
102. he high limit trips at 150 F and the low alarm at 50 F If you change the set point the process alarm lim its remain the same A deviation alarm alerts the operator when the process strays too far from the 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 a deviation alarm high limit is set to 7 F and the low limit is set to 5 F then 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 trip at 137 F and 125 F 7 6 WATLOW Series 988 User s Manual Tuning Manual Operation Alarms and Error Codes Chapter 7 Alarms A rate alarm alerts the operator when the process monitored by input 1 is increasing at a rate higher than the alarm high setting AZH I AJH 1 or AY YH I or decreasing at a rate lower than the alarm alarm low setting AeL0 A3L0 orlA4L0 The rate is sampled once a second 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 The alarm output is indicated
103. he interface prompt select between or 486 Other parameters that must be configured in the Communications Menu are the baud rate bAU d data bits and parity d AE A protocol Pr ot and device address Addr The protocol prompt must be set to full ANSI X3 28 2 2 A3 or RTU Modbus if multiple devices are used with the EIA TIA 485 or EIA TIA 422 interface If the full protocol or RTU Modbus is selected a device address must be selected at the address prompt For EIA TIA 232 full or on XON XOFF protocol may be selected 8 4 WATLOW Series 988 User s Manual General Software Features Chapter 8 General Software Test Test Test Test Test Chamber 1 Chamber2 Chamber3 Chamber4 Chamber 5 PROCESS WATLOW WATLOW WATLOW PROCESS e o o o ee o o e o o o L1 L2 L3 L4 Lola Li 12 L3 La Li 12 13 La Li 2 DEV e DEV e DEV e DEV e DEV e a OUT e oTe wout OUT e oTe 4 N AUTO AUTO AUTO AUTO AUTO MAN d MAN d MAN d MAN d MAN d SERIES 986 SERIES 988 SERIES 988 personal computer with EIA TIA 422 port Process Figure 8 5 Test chambers with Sample Application communications A test engineer uses Series 988s to control the temperatures of several automated test chambers His computer is linked to the controllers through its EIA TIA 422 serial communications port His computer pro gram monitors the temperatures of the chambers and initiates automatic test sequences when certain program parameters are met Af
104. his prompt appears only on controllers equipped with input 2 hardware and with Input 2 set to or POE Default y YES Learn High Write the high end resistance of the slidewire potentiometer to the range low 2 parameter This prompt appears only on controllers equipped with input 2 hardware and with Input 2 set to or POE Default YES po 3 gt X WATLOW Series 988 User s Manual 4 13 Setup Input E A A Pud Calibration Offset 2 Offset the input 2 signal by a positive or negative value This allows you to compensate for lead resistance sensor errors or other factors CAL 2 This prompt appears only if the controller is equipped with input 2 hardware and if is not set to or E e Minimum Default Max setting range If y y Global Menu 8 red vee Global Menu Input Menu Global Menu amp red 86 555 85 C F Global Menu Input Menu 0 999 units ry O po AY ry O po AY a process input is selected RTD Calibration Curve 2 Select the calibration curve for the RTD 2 input The RTD input uses either the European DIN 0 0038500 0 C or Japanese JIS 0 0039160 0Q C linearization standard This prompt appears only on controllers equipped with input 2 hardware and with set to or rtd Default a mt lio Y un 4 14 WATLOW Series 988 User s Manual Setup Menus Chapter 4 Fere L ing NOTE See Chapter 8 for more information on inp
105. hod by which the controller measures the flow of an uncontrolled variable and uses a proportion of it to control the flow of a second variable reference junction See junction reset Control action that automatically eliminates off set or droop between set point and actual process tem Appendix Glossary M Z perature Also see integral automatic reset The integral function of a PI or PID temperature controller that adjusts the process temperature to the set point after the system 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 pro portional band to compensate for droop no key reset A method for resetting the con troller s memory for instance after an EPROM change resistance temperature detector RTD A sensor that uses the resistance temperature characteristic to measure temperature There are two basic types of RTDs the wire RTD which is usually made of platinum and the thermis tor which is made of a semiconductor material The wire RTD is a positive te
106. ilit a l nergie par conduction ENV 50204 1995 T l phone cellulaire EN 50081 2 1994 Norme g n rique sur les emissions lectromagn tiques Partie 2 Environnement industriel EN 55011 1991 Limites et m thodes de mesure des caract ristiques d interf rences du mat riel radiofr quence industriel scientifique et m dical 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 EN 61010 1 1993 Exigences de s curit pour le mat riel lectrique de mesure commande et de laboratoire Partie 1 Exigences g n rales 1230 A 12 WATLOW Series 988 User s Manual Erkl rt daf das folgende Produkt Deutsch Beschreibung Serie 986 987 988 989 Modellnummer n 9 8 6 7 8 oder 9 beliebiger Buchstabe 1 oder 2 01234 oder 5 BC DEF oder K ABCDEFK oder T ABCJKMNoderT ABCDEKRS oder T 2 beliebige Buchstaben Klassifikation Regelsystem Installationskategorie II Emissionsgrad II Nennspannung 100 bis 240 V ac oder 24 bis 28 V ac dc Nennfrequenz 50 60 Hz Stromverbrauch Max 16 VA Erfullt die wichtigsten Normen der folgenden Anweisung en der Europ ischen Union unter Verwendung der untenstehenden einschlagigen Dokumente 89 336 EEC Elektromagnetische Ubereinstimmungsanweisung EN 50082 2 1995 EMC Rahmennorm fur Storsicherheit Teil 2 Industrielle Umwelt EN 6100
107. ion percent power temperature unit menu prompt name or alarm code L1 L2 L3 L4 These LED s indicate when output 1 2 3 or 4 are active Outputs can be configured as Oti Control Ot2 Control or Alarm Ot3 Alarm or Retransmit Ot4 Alarm or Communications flashes on transmit and receive Display Key Pressing this key enters the Display Loop Press the Display key at any time to return to this loop The next page has more information on the Display Loop Auto Man Key In Manual mode the lower display shows percent output Pressed once it clears any latched alarm If pressed again within five seconds it will toggle between Auto and Manual mode Auto Man LED Lit when the control is in Manual operation Press the Auto Man key twice to enter Automatic operation When blinking press the Auto Man key to toggle between Auto and Manual After five seconds without pressing the Auto Man key the LED stops blinking and returns to its previous state WATLOW Series 988 User s Manual 3 1 Display Loop Display Loop The Display Loop is the home state of the Series 988 controller Pressing the Display key returns the controller to the Display Loop from any prompt in any menu The controller automatically returns to the Display NOTE Loop from any menu when a minute passes without any keys being For information on pressed input 1 and input 2 ranges refer to Chapter 4 current input 1 reading set point
108. ion with both control outputs off e The alarm outputs are in their alarm state de energized with the LED lit e The lower display is blank e The upper display indicates the error code e All keys are inactive eWith ErS all Setup Menu prompts return to default values e The above conditions occur regardless of the value or the set tings in the Setup and Factory menus Cycle power to the control If the error is still present contact the factory 7 10 WATLOW Series 988 User s Manual Tuning Manual Operation Alarms and Error Codes Chapter 7 Chapter 8 General Software Burst Fire 8 2 Communications 8 4 Dead Band 8 6 Digital Events 8 8 Heater Current 8 10 Input Filter 8 12 Input Linearization 8 14 Ramp to Set Point 8 16 Remote Set Point 8 18 Retransmit 8 20 Slidewire Feedback 8 22 General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 1 General Software A CAUTION The burst fire fea ture only func tions with zero cross solid state devices It will not function correctly with random fire devices Verify that the output switching device is compatible before selecting burst fire Failure to follow this guideline could result in damage to equipment 8 2 WATLOW Series 988 User s Manual Burst Fire Requirements e This feature only works with zero cross solid state devices It will not function correctly with random fire devices e To enable burst fire the Series 988 must h
109. isplay and press the Mode key 3 to advance to the Learn High Resistance prompt L r n H Manually open the valve maximum slidewire resistance Select in the upper display and press the Mode key ES At this point both the high and low resistance values have been learned and stored in the range low 2 and range high 2 parameters You can also manually set the range low and range high values From the slidewire specifications determine the low and high resistance values and enter these at the Range Low and Range High prompts Once the control is operating adjust the hunt parameter to mini mize valve oscillations The hunt parameter sets up a dead band on both sides of the current valve position The desired valve position is then com pared to the actual position If the difference is greater than the one half of the hunt value the Series 988 repositions the valve to achieve the temper ature set point Once repositioning is complete the dead band is recalcu lated for the new valve position General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 23 Appendix Appendix Glossary Specifications Warranty and Returns Index Menu Overview Model Number Declaration of Conformity A 2 A 4 A 5 A 10 A 11 A 12 WATLOW Series 988 User s Manual A 1 Glossary A L annunciator A visual display that uses pilot lights to indicate the former or existing condition of several items in a system
110. it Select the high limit for the percent output For cooling direct acting enter a negative number This prompt always appears lf Default J J a heat cool o 100 application HP a heat only 189 application HP a cool only EP application CHIP H pm 6 p Auto tune Set Point Select the percentage at which the controller will auto tune the cur rent control set point At SP This prompt always appears Default z C150 AE SP AE SP AE SP 4 42 WATLOW Series 988 User s Manual Setup Menus Chapter 4 setup Global Ramping Function Select when the controller will ramp Ramping limits the speed at which an element can heat up Ramping is often used to protect parts that would crack or warp if they heat up too quickly e GFF sets the system to heat as quickly as possible e SE rt sets the system to ramp only at startup e SEPE sets the system to ramp at startup and whenever the set point changes This prompt appears only on controllers with Input Menu set to and with not set to and with Global Menu not set to orir Ae l Default r At Ramp Rate Select the ramping rate in degrees per minute This prompt appears only on controllers with set to or SEPEL Default y 90 9999 min CREE lr REE Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 43 Reaching the Communications Menu Begin in the Display Loop and gra press
111. lockout non read only or full lockout FUL L This prompt always appears Default nong irERd FULL P dA PID B Menu Select the lockout level for the PID B Menu Set the PID B Menu lock out to no lockout non E read only or full lockout FUL L This prompt appears only on controllers with enhanced software 98 B ___ _ ___ and with AL 90 Global Menu set to or Global Menu set toC SEd 6 4 WATLOW Series 988 User s Manual Factory Menus Chapter 6 UEPE LOL Factory Menus Chapter 6 Factory Panel Lockout Input Menu Select the lockout level for the Input Menu Set the Input Menu lock out to no lockout non E read only or full lockout FUL This prompt always appears Default Output Menu Select the lockout level for the Output Menu Set the Output Menu lockout to no lockout nonE read only or full lockout FUL L Gt PE This prompt always appears Default FULL DEPE QEPE QEPE Global Menu Select the lockout level for the Global Menu Set the Global Menu lock out to no lockout non E read only or full lockout FUL L 9t 51 This prompt always appears Default 4 9LbL WATLOW Series 988 User s Manual 6 5 Factory Panel Lockout E Op N Communications Menu Select the lockout level for the Communications Menu Set the Communications Menu lockout to no lockout nonE read only or full lockout FULL COP This prompt appears only on controllers equipped with Communic
112. mber 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 con trol 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 Release Tabs SERIES 988 Release Tabs Figure 1 1 Press the release tabs to remove the con troller chassis g DEV AUTO OUT O MAN O O L4 SERIES 989 L3 Release Tabs Hardware Setup Chapter 1 WATLOW Series 988 User s Manual 1 1 DIP Switches 1 Set the input DIP switches to match the Input 2 DIP sensors you are using in your application Input 1 DIP Only controllers with model number 98_ 2 __org8_ NOTE _2_ E tee es have an The Input 2 DIP input DIP switch eee switch is mounted upside down Input 1 Input 2 98 a n O e ei a NOTE Only controllers oh PEE with the indicated RTD 100 Q e m G model numbers have these DIP switches z thermocouple R S or B BOn dl DT Bee E thermocouple J K T N E C D Pt2
113. mperature coefficient sensor only while the thermistor can have either a negative or positive temperature coefficient retransmit output An analog output signal that may be scaled to represent the process value or set point value RTD See resistance temperature detector slidewire feedback A method of controlling the position of a valve It uses a potentiometer to vary resistance and indicate position of the valve switching sensitivity In on off control the tempera ture change necessary to change the output from full on to full off See hysteresis thermal system A regulated environment that consists 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 difference in temperature between the hot junction sensing junction and the leadwire connection to the instrument cold junc tion thermocouple break protection The ability of a con trol to detect a break in the thermocouple circuit and take a predetermined action three mode control Proportioning control with integral 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 p
114. n 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 ctricas r pidas ENV 50140 1994 Inmunidad radiada ENV 50141 1994 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 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 9 1996 Date of Issue General Manager Title of Authorized Representative LEO ba file oe Signature of Authorized Representative Appendix Watlow Series 988 User s Manual Watlow Controls 1241 Bundy Blvd P O Box 5580 Winona MN 55987 5580 Phone 507 454 5300 Fax 507 452 4507
115. n of the system output 2 3 or 4 can be configured as a rate alarm monitoring the rate of increase or decrease in the process variable on input 1 The Alarm Low and Alarm High prompts The 2 in these examples refers to output 2 establish the ramp down and ramp up rate set points respectively in degrees per minute General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 17 General Software NOTE Make sure all input and output impedances are compatible NOTE Input 1 and 2 are not isolated from each other 8 18 WvATLOW Series 988 User s Manual Remote Set Point Requirements Input 2 must be either a thermocouple 98__ 1__ _ _ _ or universal signal conditioner 98__ _2__ ____ To use a Series 988 as a master controller choose one of the retransmit options for output 3 of the master 98__ ____ M__ _ for 0 20mA or 4 20mA or 98 _ N__ _ for 0 5V de 1 5V or 0 10V Overview The remote set point feature allows the Series 988 to use a thermocouple RTD or process signal at input 2 to establish the set point This feature gives the Series 988 the ability to have its set point value manipulated by an external source A common application would use one ramping con troller with a set point retransmit output to ramp multiple controllers using the remote set point Or you could use an analog output from a PLC to send set point values to a Series 988 You may select between local and remot
116. nit from the set point OUT LED When lit the lower display shows the current percent output Up arrow Key Increases the value or changes the parameter in the upper display except for set point changes in ee Display Loop which occur in the lower display Hold the key down to increase the value rapidly New data takes effect in five seconds or when the Mode key or Display key is pressed Down arrow we Decreases the value or changes the parameter in the upper display except for set point changes in the Display Loop which occur in the lower display Hold the key down to decrease the value rapidly New data takes effect in five seconds or when the Mode key or Display key is pressed Up Down Keys Press simultaneously for three sec onds to go to the Setup Menu Continue to press both keys for another three seconds to go to the Factory Menu Access to the Setup and Factory menus can be dis abled with lockout DIP switch Figure 3 1 Series 988 Keys and Displays Front Panel and Display Loop Chapter 3 WATLOW 388 E E E E ee E E I DEV O OUT O fw Go SERIES 988 Mode Key va Enters new data and steps to the next prompt in the current menu DISPLAY lt a MAN o Mode Up arrow Keys Hold the Mode key then press the Up arrow key to move backwards through the cur rent menu Scrolling stops when you reach the top of the menu Lower Display Indicates the set point deviat
117. non linearized signal 4 20mA input signal output 1 transmitter Water Treatment Pond Sample Application A waste water process engineer needs to control the flow of a solution to be mixed with wastewater to treat it The transmitter provides a 4 20mA output without square root extraction The engineer used the Series 988 with a universal signal conditioner input and a 4 20mA process output to control the flow The input signal was linearized using the square root extraction feature of the 988 The above system has a flow range of O to 16 gallons per minute The range low and range high parameters for input 1 would be set to O and 16 respectively The input 1 linearization prompt L 1a 1 would then be set to square root extraction r got You can see from the above graph that without square root extraction to linearize the signal it would not be use ful for controlling the process WATLOW Series 988 User s Manual 8 15 General Software Ramp To Set Point Requirements This feature is standard on all units Overview Ramp to set point enables the Series 988 to ramp the set point at a user defined rate This allows the controller to start up a system or change between set points at a rate that will not stress the product or system components The ramp rate is defined in degrees per minute Ramp to set point can be initiated at start up only or at start up and also on any set point changes When a ramp is initiated the
118. nsor opens the con troller switches from automatic to manual operation 7 4 WATLOW Series 988 Manual and Automatic Operation To change from auto to manual operation press the Auto Man key twice Manual operation provides open loop control of the outputs from a range of 100 to 100 output The Series 988 allows a negative output value only when or Output Menu 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 Series 988 sets the power level to the setting of the parameter If is set to b PL S the controller retains the power level from the closed loop control When the Series 988 returns to closed loop control it restores the previ ous set point process value The Auto Man LED located on the Auto Man key A indicates whether the controller is in automatic or manual operation When the LED is lit the control is in manual operation When the LED is off it is in automatic operation When the LED flashes press the key again within five seconds to complete the change in operation e If is set to and the process has stabilized at a power level less than 75 5 for a two minute period prior to the sensor break then the Series 988 switches to manual operation at the last automatic power level If these conditions are not met the output goes to 0 power output disabled When transferring from automatic to manual operation t
119. ocal remote rA2A Output 2 rate A rA2b Output 2 rate B dE2A Output 2 derivative A dE2b Output 2 derivative B Not all prompts will i Ct2A Output 2 cycle time A A Ct2b Output 2 cycle time B appear on your con db A_ _ Dead band A dbb_ _ Dead band B trol They are dependent on your Press YY and for 3 seconds to enter configuration and Setup Menus Setup se the Setup menus Outputs are disabled model number a O Y p 1 F InPt Input y OtPt Output Global COM Communications r s E r bAUd pint Input 1 iJ Oti Output 1 Celcius_ Fahrenheit TAIA ae at dEC1 Decimal place 1 E Pret T 1 Failure mode ES aer l r ae parity z rL1 Range low 1 HYS1 Hysteresis 1 I ro rotocoi type T i t A A o2 Output 2 ProrArcning Addr Address o navigate H1 Range high 1 1 p Controltype inte 0 ntertace type CALI Calibration offset 1 esis Process 2 re Press to return T rtdi RTD calibration curve e Upa Hy steresis 2 Control algorithm to the Display Loop Ftrt Input 1 software filter we point 2 BD roe arah Lint Input 1 linearizati i arm from any location and E ue po j inearization A2Sd Alarm 2 side Crossover pepesa value to advance through MODE Pr UC Romo sai paint LAt2 Latching for alarm 2 O oe 1 vent input i SiL2 Silence alarm 2 the Display Loop 1 dEC2 Decimal place 2 E E j a Ot3 Output 3 vent input 2 L2 Jo
120. on Menu CAL A As PLOC gd A9 CAL FetY FetY Fcty Panel Diagnostics Calibration Lockout Menu Menu Menu p 6 7 p 6 13 p 6 2 Press the Mode key B to step through the prompts Ao cr St se O Press the Up arrow key Y or the Down arrow key to select one of the prompt values Refer to Calibrating Watlow Process Controls for information about the Calibration Menu A CAUTION Before attempting to calibrate make sure you have the proper equipment called for in each procedure The Series 988 is calibrat ed and tested before it leaves the factory Attempting to calibrate the controller with out the proper equipment could result in damage to property and or equipment Figure 6 13 The Calibration Menu Factory Menus Chapter 6 8 8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 iE CAL cty UN C3 of lol ile cs a aa js aaa Pe D lael lio ol il leal le ol lol ol lol mv lol ell o ml lol i ey ol el al tal el el fol tim lol ail n O Factory Calibration Diagnostics Prompt Enter your settings A from the controller s upper display A A DNA A DTA DTA DTA DA DTA DNA DA DTA DA DTA DA DTA ATA ATALA UN rr Restore aA asa ls ale SS a le FL Default WATLOW Series 988 User s Manual 6 13 Factory Calibration Restore Restores the original factory calibration values when set to YE59 This is a simple way to recove
121. ontroller indus try by packing an impressive array of features into an 1 8 DIN package No other controller offers the flexibility compact size and durability of the Series 988 It can control a wide variety of temperature and process appli cations with a broad range of input and output options that allow control of virtually any process variable The Series 988 is the only 1 8 DIN controller that can provide single unit cascade control of a process Its other features include heater current monitoring remote set point input ratio control and valve control through slidewire feedback The Series 988 also delivers expanded auto tuning capabilities increased alarm functionality and several unique control algo rithms When we refer to the Series 988 controller we refer also to the horizontal and low voltage versions of the Series 988 the 986 987 988 and 989 We recommend that you read all of this manual s introduction to familiarize yourself with the conventions and content of this manual and the steps to setting up a Series 988 controller Make sure you understand the Caution and Warning symbols we use in the book WATLOW Series 988 User s Manual i Introduction NOTE The 12 digit number is printed on the top of the stickers on each side of the controller s case and on the right hand or top circuit board NOTE The Menu Overview in the Appendix shows all the menus and prompts Using this Manual
122. oot The amount by which a process variable 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 manu al reset used in fast responding systems where the reset causes instabilities With PDR control an operator can enter a manual reset value that eliminates droop in the system PI control Proportioning control with integral automat ic reset action PID Proportional integral derivative A control mode with three functions proportional action dampens the sys tem response integral corrects for droop and derivative prevents overshoot and undershoot process variable The parameter that is controlled or measured Typical examples are temperature relative humidity pressure flow fluid level events etc The high process variable is the highest value of the process range expressed in engineering units The low process variable is the lowest value of the process range proportional band PB A range in which the propor tioning function of the control is active Expressed in units degrees or percent of span See PID proportional control A control using only the P pro portional value of PID control rate band A range in which the rate function of a con troller is active Expressed in multiples of the proportional band See PID ratio A met
123. p 6 2 Use the Up arrow key YY to select one of the Factory Menus WATLOW Series 988 User s Manual 6 1 Factory Panel Lockout Reaching the Panel Lockout Menu PLOC PROCESS 0 E O O E DEV bispLay OUT e MAN E SERIES 988 Select the Panel Lockout Menu then press the Mode key 163 to step through the prompts i O O FULL lrEARd lnonE Nn ODO D f e l T EJ LOC LOE LOC LOC O Press the Up arrow key YY or the Down arrow key to select one of the prompt values Figure 6 2 The Panel Lockout Menu 6 2 WATLOW Series 988 User s Manual po C3 ry cy Factory Prompt ln Enter your settings from the controller s Front Panel Lockout upper display System Menu PID A Menu PID B Menu Input Menu Output Menu Global Menu Communications Menu Diagnostics Menu 0 0 0 0 0 0 0 0 0 0 EEE Calibration Menu Prompts may not appear depending on controller configuration Factory Menus Chapter 6 MA CAUTION Setting to 2jor 3 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 auto 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 th
124. p to set point 8 16 8 17 range high 1 4 5 4 6 range high 2 4 11 4 12 range low 1 4 5 4 6 range low 2 4 11 4 12 rate output 1 5 12 output 2 5 15 rate alarm 7 7 8 17 rate band A 3 rate derivative adjustment 7 3 ratio control A 3 reference junction A 2 relay mechanical 7 2 release tabs 1 1 2 2 2 3 7 5 remote set point 4 10 8 8 8 18 8 19 removing controller chassis 1 1 2 2 2 3 7 5 reset output 1 5 11 output 2 5 14 WATLOW Series 988 User s Manual A 7 Index r z reset integral adjustment 7 3 restore 6 14 retransmit 8 20 8 21 A 3 retransmit calibration offset 4 33 retransmit high limit 4 32 retransmit low limit 4 32 RTD A 3 RTD calibration curve 1 4 7 RTD calibration curve 2 4 14 RTD input 2 5 RTD wiring input 1 2 8 input 2 2 9 RTU Modbus 8 4 S safety practices 2 4 2 6 2 7 semiconductor oven 8 3 sensor installation 2 5 sensor type input 1 4 3 input 2 4 9 4 10 serial number 6 8 set point in tuning 7 2 7 3 set point ramp to 8 16 8 17 set point 1 3 2 set point 2 5 1 5 3 set point 2 control 4 22 setting DIP switches 1 1 1 4 input 1 2 lockout 1 4 output 1 3 Setup Menus 4 1 4 48 shipping claims A 5 silencing 2 4 24 silencing 3 4 27 silencing 4 4 30 silencing alarms 7 7 slidewire feedback 8 22 8 23 A 3 slidewire feedback wiring 2 10 slidewire hysteresis 4 16 software filter 1 4 7 software filter 2 4 15 software revision 6 8 specifications A 4 square root extr
125. pt and the Idle Set Point prompt Id SP if they appear see prompt informa tion Upon reaching the Operation Menu prompt use the Up arrow YY key to select a menu Press the Mode key B to step through the prompts CO Arye 280 801 20d A JE 1A O Press the Up arrow key YY to step through the prompt values The Down arrow key Ad backs through the values Figure 5 9 The PID Menus Operation Menus Chapter 5 Operation PID A or B Operation Prompt V Enter your settings from the controller s Proportional Band Output 1A upper display Reset Output 1A Integral Output 1A Output 1 p 5 10 Rate Output 1A Derivative Output 1A a 7 E 7 D M d T m o 5 5 5 5 5 4 0 0 0 0 0 0 0 0 0 0 0 0 5 Cycle Time Output 1A t D o mu D Proportional Band Output 2A Reset Output 2A 2 Im M ma Integral Output 2A id at D Output 2 p 5 13 Rate Output 2A 3 x3 ae ma Derivative Output 2A Ld LECH Cycle Time Output 2A a Dead Band A P Idb BPE Operation Prompt_____ Enter your settings voor C from the controller s ue Proportional Band Output 1B Upper display woos El gt Reset Output 1B pa Integral Output 1B daput Sa Output 1 p 5 ES E Rate Output 1B ES _ pa Derivative Output 1B Gt Prompts may not ED gt Cib
126. put AL 9G This prompt appears only on controllers equipped with enhanced software 98 _B Default ads P ide dUPL ALSO ALO AL 90 ALO PID 2 Crossover Selection Select which parameter determines the crossover from PID A to PID B process Pr oc set point St Pt or none no This prompt appears only on controllers with AL 9G set to P ide Default SEPE P de 4 38 WATLOW Series 988 User s Manual Setup Menus Chapter 4 setup Global Crossover Process Value Select the process value at which the control algorithm will crossover between PID A and PID B PID A is active below this value and PID B is active above this value e This value cannot be set lower than range low 1 or higher than range high 1 cH This prompt appears only on controllers with set to Proc Default d cil crHi Proc Proc 6 p Crossover Set Point Value Select the set point value at which the control algorithm will crossover between PID A and PID B PID A is active below this value and PID B is active above this value e This value cannot be set lower than range low 1 or higher than range high 1 cH St Pt This prompt appears only on controllers with set to SE PE Default uy SEPE Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 39 setup Global Event Input 1 4 40 Select the effect of closing the event input 1 switch e vg disables event input 1 e QC locks out the front panel ke
127. put Input Menu is set to the correct sensor type The analog to digital A D converter input voltage may be too high to con vert an A D signal User s Manual Tuning Manual Operation Alarms and Error Codes Chapter 7 Er 3 Ambient temperature error The ambient temperature of the Series 988 has dropped below 32 F 0 C or risen above 149 F 65 C Calibration errors can also cause this error code Try setting Calibration Menu to YE 5 Read about Factory Calibration in Chapter 6 Er 4 RAM verification error An internal RAM failure has occurred Contact the factory Er 5 Non volatile checksum error An EEPROM checksum error was detected Turn the power off then back on again If this does not clear the error contact the factory GPL P Open loop detect This error is not available while in the on off mode It is only active when GPL Plis set to Diagnostics Menu Er 9 Configuration error An incorrect module has been installed in the control Contact the factory Error Code Actions All of the above error codes except Er 4 and will result in these conditions e If is set to Global Menu and the control was in automatic 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 Series 988 switches to manual opera tion at the last automatic powe
128. r from a mistake made while calibrating the controller This prompt always appears Default y YES cSt e SE d F L Default 6 14 Set the operating parameter defaults to domestic or international measures domestic 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 UN Su NUA Ea dFL WATLOW Series 988 User s Manual Factory Menus Chapter 6 Chapter 7 Tuning Manual Operation Alarms and Error Codes NOTE A useful reference on tuning is Tuning of Industrial Control Systems by Arman do B Corripio published by the Instrument Society of America NOTE Auto tune can be initiated if is setto onl Figure 7 1 Auto tuning example Auto tuning Heat and or Cool The Series 988 can automatically tune the PID parameters to fit the char acteristics of your particular thermal system Standard software units 98_A ___ _ __ _ _ have 1 set of PID parame ters Units with enhanced software 98 _ B _ __ _ and At 9G set to Global Menu have two sets of PID parameters PID A and PID B Only one PID set can be auto tuned at a time For information on tun ing a cascade system see Chapter 8 Before beginning the auto tune sequence make sure the parame
129. r level bumpless transfer If the con trol was in manual operation it remains there Press the Auto Man key once to see the error code The error code 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 dis play e If the control was operating with stable output values when the error occurred it continues to operate at those levels on a percent power basis e If output values were not stable or the percent output was greater than 75 the control outputs drop to 0 power off e If FA IL is not set to b5P 5 and the control was in automatic operation when the error occurred it goes into manual power operation The power level is determined by the FA prompt value _ 499 to percent Tuning Manual Operation Alarms and Error Codes Chapter 7 WATLOW Series 988 User s Manual 7 9 NOTE An alarm display will be masked by an error condition or when the control is in the Calibration or Setup menus To clear an error code o If is set to nt A the error code should clear once the prob lem is corrected o If is set to AE correct the problem and cycle power You can also clear the error by pressing both the Up arrow Y and Down arrow keys to enter the Setup Menu then press the Display key E Error codes 4 and will result in these conditions e The control is in automatic operat
130. r the operating temperature or the idle temperature with the flip of a switch The idle set point prompt is enabled by setting the Event Input 1 prompt E in the Global Menu to idle set point Id 5P The idle set point value is accessed by pressing the MODE key Q from anywhere in the display loop When the switch closes the lower display will indicate the idle set point and the controller will maintain this new set point General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 9 General Software NOTE To obtain a reading the output ON time must be a minimum of 0 3 seconds NOTE The heater current feature will not function with burst fire outputs NOTE The heater current feature will not function when the Series 988 has a process output for output 1 NOTE Current transformer up to 50A Part 16 0246 8 10 WATLOW Series 988 User s Manual Heater Current Requirements Choose the heater current option 98__ 4 _ _ _ _ for input 2 and an appropriate current transformer A current transformer must be ordered separately Output 1 cannot be used as a process output The heater current feature monitors only output 1 Overview The heater current feature measures and responds to heater current in a system This is an ideal method for detecting heater loss in applications with multiple heaters The current is measured when output 1 is on For instance if a system has five 10 amp heat
131. re to follow Setup Input Input 2 Select sensor type for input 2 This selection must match the sensor type connected to terminals 18 19 and 20 See Appendix for more infor mation about sensors e Changing the value of 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 dF Lt will flash in the upper display e Changes do not take effect automatically after five seconds you must press the Mode key Q to enter the sensor type change and advance to the next prompt This prompt and other Input 2 prompts appear only on controllers this guideline could equipped with input 2 hardware not 98__ 0 _ __ result in damage to equipment or prop erty Document all settings before If Default changing sensor i type 98 1 no DIP J K T N E W5 W3 Pt2 0 50mV Tea CJ CA C Ea CO ECO Ed CPES 0 50 thermocouple only NOTE 98 Es fl aglis selected put DIP J K T N E WS W3 Pt 0 50mV for _ inejnone of a the other input 2 7E _ mo J H EJ n El ll d Pte 8 50 prompte Will BOC appear _ thermocouple Input 2 DIP R S B wo Era ECO OS CA 1 2 3 thermocouple Input 2 DIP RTD RTD 0 19 no rtd Lrtd ele RTD Input 2 DIP 4 20mA 0 20mA 0 5V 1 5V 0 10V dc Ca G20 020 0063 CES 0 10
132. requirements NOTE This is a slow procedure that may take hours to obtain optimum values Tune heating outputs at a set point above the ambient process value Tune cooling outputs at a set point below the ambient process value If your controller is equipped with enhanced software 98 B __ _ _ the parameters may need to be tuned also Perform this procedure on both PID sets they are functionally identical The para meters within the procedure apply to both output 1 and 2 and PID A and B Tuning Manual Operation Alarms and Error Codes Chapter 7 1 Apply power to the Series 988 and enter a set point Begin with Pbjsetto ts rEjor ttjsettol G O _ Rjor _ dE set tol 80 0 set to 650 setto ___ 8 and set to OFF 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 issetto Q then r E and are inoperative and the Series 988 func tions as a simple on off control The prompt determines the switching differential value 3 Reset Integral Adjustment Gradually increase or until the upper display process value begins to oscillate or hunt Then slowly decrease or until the upper display stabilizes again near set point 4 Cycle Time Adjustment Set as required Faster cycle times sometimes achieve the best system
133. res Chapter 8 WATLOW Series 988 User s Manual 8 11 General Software NOTE Use this feature with caution because a large time constant could hide system upsets Input Filter Requirements This feature is standard on all Series 988 controllers Overview In certain applications the process being measured can be unstable which makes it difficult to control and also makes the constantly changing display difficult to read The Series 988 input filter can solve these prob lems by smoothing out just the display or the display and the input signal You can set a time constant in seconds for a low pass filter that will if you select a positive value affect the display only Select a negative value to fil ter the input signal itself 8 12 WATLOW Series 988 User s Manual General Software Features Chapter 8 General Software Display readings with input filter OFF Display readings with input filter ON RH RH time time Figure 8 13a Display readings with input filtering Humidity Chamber output 1 Process sensor humitidy transmitter M heater SERIES 988 Figure 8 13b Humidity chamber with input filtering Sample Application A Series 988 controls the humidity in an environmental chamber The rel ative humidity RH sensor provides a 4 20mA signal over a 0 100 RH range The sensor is very sensitive to changes caused by air flow in the chamber The turbulence in the
134. rocess temperature 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 WATLOW Series 988 User s Manual A 3 Specifications 1234 Control Mode e Dual input quad output optional retransmit of set point or process variable e Programmable direct and reverse acting control out puts e One step auto tuning Operator Interface e Local remote set point capability e Dual 4 digit LED displays upper 0 4 10mm lower 0 3 8mm e Mode Auto Man Display Up and Down keys Input e Contact input for software function select e Type J K T N C W5 5 D W3 gt E R S B Pt 25 thermocouple 1 or 0 1 RTD e 0 50mV dc 0 20mA 4 20mA 0 5V dc 1 5V dc 0 10V dc process e Slidewire digital event input or heater current options e Sensor break protection de energizes control output to protect system or selectable bumpless transfer to manual operation Latching or non latching e For C display or process units user selectable Sensor Ranges J t c 32 to 1500 F or 0 to 816 C K t c 328 to 2500 or 200 to 1371 C T t c 328 to 750 F or 200 to 399 C N t c 32 to 2372 or O to 1300 C R t c 32 to 3200F or O to 1760 C S t c 32 to 3200F or O to 1760 C B t c 1598 to 3300F or 870 to 1816 C E t c 328 to 1470F or 200 to 799 C C t c W5 32 to 4
135. rs equipped with output 2 hardware and with set to or AL ln Default 5 ile Sa 4 24 WATLOW Series 988 User s Manual Setup Menus Chapter 4 setup Output Output 3 Select the alarm condition for output 3 o de energizes output 3 in an alarm condition energizes output 3 in an alarm condition NOTE This prompt appears only on controllers equipped with output 3 See Chapter 7 for hardware for a relay 98__ ____ B___ 98__ ____ J___or more information 98__ ____ K___ or switched de 98__ ____ C___ on alarms Default A T 3 Alarm 3 Select the alarm type for alarm 3 e Pr uses the process signal from input 1 e dE I uses a deviation from the input 1 signal e Pr ej uses the process signal from input 2 This prompt does not appear if the controller is not equipped with input 2 hardware or if is set to or _E sel uses a deviation from the input 2 signal This prompt does not appear if the controller is not equipped with input 2 hardware or if is set to or E e uses the rate of change at input 1 in degrees per minute This prompt appears only on controllers equipped with output 3 hardware for a relay 98__ ____ B___ 98__ ____ J___or 98 KK or switched de 98 _ _ C____ and with set to or AL In Default dE ALI ALJ ALI ALJ Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 25 AJSd NOTE See Chapter 7 for more information on alarms Alarm 3 Side Select w
136. s applied for all returned stock controls and accessories 5 If the 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 signs of external damage it may have sustained enroute If there is apparent dam age either outside the box or to its contents make a claim with the shipper immediately Save the origi nal shipping carton and packing material WATLOW Series 988 User s Manual A 5 Index a h OUT LED 3 1 0 5V dc process wiring input 1 2 8 input 2 2 9 output 1 2 12 output 2 2 13 0 10V dc process wiring input 1 2 8 input 2 2 9 output 1 2 12 output 2 2 13 0 20mA process wiring input 1 2 8 input 2 2 9 output 1 2 12 output 2 2 13 0 50mV high impedance wiring input 1 2 8 input 2 2 9 1 5V dc process wiring input 1 2 8 input 2 2 9 output 1 2 12 output 2 2 13 4 20mA process wiring input 1 2 8 input 2 2 9 output 1 2 12 output 2 2 13 A access to panel back 2 2 ac output wiring output 1 2 12 output 2 2 13 output 3 2 14 output 4 2 15 address 4 46 alarm deviation 7 6 process 7 6 rate 7 7 alarm 2 4 23 alarm 2 high 5 5 alarm 2 low 5 4 alarm 2 side 4 23 alarm 3 4 25 alarm 3 high 5 6 alarm 3 low 5 5 alarm 3 side 4 26 alarm 4 4 28 alarm 4 high 5 7 alarm 4 low 5 6 alarm 4 side 4 29 alarm display masked 7 6 alarm hi
137. set 4 33 control output action 8 8 device address 4 46 alarm 2 4 23 alarm 2 reverse 7 6 XD a po C XD a UN Qa XD ly x xD Wy po c XD U UN Q ma lt x x po c XD lt UN Q D PA O po ma Mm tr 3 XD Qa Q 3 DO po a D po mu e XD po uy alarm 3 4 25 alarm 3 reverse 7 6 alarm 4 4 28 alarm 4 reverse 7 6 algorithm 4 38 alarm reset 8 8 ambient temperature 6 8 annunciator 4 41 analog output 4 31 retransmit high limit 4 32 retransmit low limit 4 32 auto tune set point 4 42 7 1 auto tune 5 7 7 2 ma po Wy 2 XD po lt xo po 2 po Lo c ma po 3 XD 3 3 o Anun Rout XD x XD 2 po D rr UN d XD cz tr Ud baud rate 4 45 oth alarm 3 trigger 4 26 Pt S bumpless transfer 4 35 r St burst fire 8 2 FO o Oo UN O 16 8 2 mn tr MW o cycle time output 2 PID B current 8 10 8 11 C F Celsius Fahrenheit 4 35 CAL calibration lockout 6 6 CAL Calibration Menu 6 13 CAL 1 calibration offset 1 4 6 CAL e calibration offset 2 4 14 Cnt control type 4 3
138. t Menu This prompt appears only if and Output Menu are both set to orl CL o LrHl Idle Set Point Select the set point to be activated by an event input This allows you to select a temperature that will be maintained when the application is idle e The range and default settings depend on the __ n 1 and settings Input Menu Id SP This prompt appears only if or Global Menu is set to Id 5P ri i Hl WATLOW Series 988 User s Manual 5 3 Operation System E 1S Event Input 1 Status Indicates whether the event input 1 circuit is open or closed read only This prompt appears only if Global Menu is set to some thing other than nol Default CLOS 115 E145 mM j e 6 Event Input 2 Status Indicates whether the event input 2 circuit is open or closed read only This prompt appears only on controllers equipped with a second digital event input 98__ 5__ ___ _ and with Global Menu set to something other than _ no Default CLOS E125 E125 e Pd Hl O Alarm 2 Low Select the low trigger value for the output 2 alarm AL O This prompt appears only if Output Menu is set to some thing other than _ no If Default y y lowest or Pre value of value of a Ate sensor or _rt d ROL O Output Menu range Input Menu or _dEd or 8 Ate ALO AOL O ALO Output Menu 5 4 WATLOW Series 988 User s Manual Operation Menus Chapter 5 Operation System AH
139. t does not appear if the controller is not equipped with input 2 hardware or if is set to or _ 1d uses a deviation from the input 2 signal This prompt does not appear if the controller is not equipped with input 2 hardware or if is set to or E2 e uses the rate of change at input 1 in degrees per minute This prompt appears only on controllers equipped with output 4 hardware for a relay 98__ ___ _ B _ 98_ _ ___ _ D__ 98 E _or98 K _ orswitcheddc 98 _ C Default J ALY ALY ALY ALY ALY ALY 4 28 WATLOW Series 988 User s Manual Setup Menus Chapter 4 NOTE See Chapter 7 for more information on alarms Setup Menus Chapter 4 setup Output Alarm 4 Side Select what triggers alarm 4 e both triggers an alarm when the signal lt A Yt 8 or AYH I e H 9H triggers an alarm when the signal gt AYH e i OL y triggers an alarm when the signal lt AYL GJ This prompt appears only on controllers equipped with output 4 hardware for a relay 98__ ____ B__ 98__ ___ D _ 98 E _or98 K _ orswitcheddc 98 _ C and with set to or AL Yn Default y WATLOW Series 988 User s Manual 4 29 HYSY NOTE See Chapter 7 for more information on alarms 4 30 WATLOW Series 988 User s Manual Hysteresis 4 Select the switching hysteresis for alarm 4 This determines the change in temperature or process units needed to turn the output from off to on
140. t to 800 To operate a specific zone ten degrees hotter than the others increase the range low 2 to 10 and the range high 2 to 810 With remote set point enabled and local selected under the Local remote prompt in the System Menu the set point is adjusted using the up arrow and down arrow keys Selecting remote under the Local remote prompt r disables the up arrow and down arrow keys allowing the set point value to be manipulated by the input 2 signal General Software Features Chapter 8 WATLOW Series 988 Users Manual 8 19 General Software Retransmit Requirements Output 3 is used for the retransmit option Choose either a milliamp 98_ 2 ___ M__ Joravoltage 98__ ____ N__ signal Select the output range in the Output Menu Overview The retransmit feature can be used to transmit an analog signal repre NOTE senting the value of either input process variable or the target set point Enhanced software variable The retransmit signal is factory configured as either a milliamp Is not required for 98 _ ___ M_ _ J oravoltage 98__ __ N__ signal In choosing this feature the type of retransmit signal the operator must take into account the input impedance of the device to be retransmitted to and the required sig nal type either voltage or milliamps Typically applications might use the retransmit option to record one of the variables with a chart recorder or to generate a set point for other controls in a multi
141. tended to 99939 The range low when Is selected can be extended to 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 input 1 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 In H 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 to 4 28 mA Set tof 100 Set to _ 500 A 4mA input will display _ 1080 A 12mA input will display 300 A 20mA input will display 5080 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 y y y Lei i Leal Crit Lead C 3e2 41580 0 8 16 98__ 1__ __or C rn Cet Cea Veli Lek 98 2 _ K 32 8 2508 200 49 73 328 __ 158 200 399 3e2 e3 ie 0 1300
142. ter complet ing a sequence the computer loads the next temperature to the controller The computer periodically interrogates each controller for its process tem perature set point and alarm status This information is stored on a disk to provide test verification data for the completed products General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 5 General Software A WARNING If the dead band is set to a negative value the heat and cool outputs can both be ON at the same time Dead Band Requirements The dead band feature is standard on any Series 988 controller with two control outputs The dead band prompts will appear if the control outputs are configured for heat cool or cool heat Overview The dead band prompts and db b located in the PID menus determine the amount of interaction between heat reverse acting and cool direct acting control outputs The dead band directly offsets the target set point of the cool control output With a positive dead band both control outputs will never be ON at the same time With the process in a positive dead band the output value is determined by adding the percent heat output to the percent cool output and only applying the result to the correct output cooling action if the sum is negative and heating action if it is positive 8 6 WATLOW Series 988 User s Manual General Software Features Chapter 8 Figure 8 7a Dead band graph input 1
143. tices to install and operate the Series 988 Failure to do so could result in such damage and or injury or death Figure 2 6 System wiring example 2 6 WATLOW Series 988 User s Manual L1 L2 earth ground high limit mechanical contactor c n oO mi l E N o N gt N ea E OOO bs 000 92A3 1DJ1 0000 limit control hh UIN ao heater 00000000 13 14 fis Th 988A 10CA AARR rear view optional normally open momentary switch process sensor limit sensor 120V ac Series 988 988A 10CA AARR temperature control 00 O SSR 240 10A DC1 solid state relay dc input 10 24 240V ac Series 92 92A3 1DJ1 0000 limit control QQOQO COO high temperature light Installation and Wiring Chapter 2 L1 A WARNING To avoid damage to property and equip ment and or injury of loss of life use National Electric Code NEC stan dard wiring prac tices to install and operate the Series 988 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 Wiring Notes L2 earth ground WATLOW Series 988 User s Manual 2 7 Input 1 Wiring Figure 2 8a Thermocouple or 0 5
144. tputs Solid state Relay with Contact Suppression 98 B 0 5 amps minimum off state impedance 20KQ os E Electromechanical Relay with Contact Suppression Suppression between NO and COM contacts only a External Lo Load NO COM 98 D src e e Ss e Form C 5 amps minimum off state impedance 20KQ 7 for D amp E outputs ony ME nm lel Electromechanical Relay without Contact Suppression EME 98 _E Form C 5 amps off state impedance 31MQ Solid state Relay without Contact Suppression 98 K 0 5 amps off state impedance 31MQ Figure 2 155 Switched DC Open Collector A Fs ot A A 910 380 de Maximum voltage 42V dc AR aS ae S Maximum current 1A Dy Q 22 Internal Circuitry ul Mil Mm E Figure 2 15c External Signal Conditioner Power Supply Loop powered NOTE See Chapter 1 for power supply DIP switch information Controllers with Output 4 R S or U For data communications wiring refer to Data Communications with the Watlow Series 988 Family of Controllers manual This manual can be downloaded from Watlow s website at www watlow com Product Techical Information Controls WATLOW Series 988 User s Manual 2 15 Chapter 3 Front Panel and Display Loop Keys and Displays Upper Display Indicates the actual process value prompt parameter value or error code DEV LED When lit the lower display shows the most recent deviation u
145. tructions that are permanently stored in the microprocessor software derivative The rate of change in a process variable Also known as rate See PID Deutsche Industrial Norm DIN A set of technical sci entific and dimensional standards developed in Germany Many DIN standards have worldwide recognition DIN See Deutsche Industrial Norm droop In proportional controllers the difference between set point and actual value after the system stabi lizes duty cycle The percentage of a cycle time in which the output is on external signal conditioner power supply A dc voltage source that powers external devices filter digital filter DF A filter that slows the response of a system when inputs change unrealistically or too fast Equivalent to a standard resistor capacitor A 2 WATLOW Series 988 User s Manual RC filter digital adaptive filter A filter that rejects high frequency input signal noise noise spikes heat cool output filter A filter that slows the change in the response of the heat or cool output The out put responds to a step change by going to approximately 2 3 its final value within the number of scans that are set form A A single pole single throw relay that uses only the normally open NO and common contacts These con tacts close when the relay coil is energized They open when power is removed from the coil form B A single pole single throw
146. u ud wt wt ue ll lc oil dc Y 30mA JCHMDAMVNOWDSO AZZAXCOWSO AA Display GG Green Green displays RR Red Red displays GR Green Red displays XX Custom overlays or default settings RG Red Green displays WATLOW Series 988 User s Manual A 1l Declaration of Conformity Series 986 987 988 989 96 WATLOW CONTROLS 1241 Bundy Boulevard Winona Minnesota 55987 USA Declares that the following product English Designation Series 986 987 988 989 Model Number s 9 8 6 7 8 or 9 Any letter 1 or 2 0 1 2 3 4 or 5 BCDEFork ABCDEFKorT ABCJKM Nor T ABC DEKR Sor T Any two letters Control Installation Category II Polution Degree II Rated Voltage 100 to 240V ac or 24 to 28V ac dc 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 Classification 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 ENV 50140 1994 Radiated immunity ENV 50141 1994 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 c
147. up and out Installation and Wiring Chapter 2 WATLOW Series 988 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 sensors 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 2 4 WATLOW Series 988 User s Manual Wiring the Series 988 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 988 uses optical isolation between the analog inputs and the controller outputs digital input This isolation provides a 500V ac bar rier to prevent ground loops when using grounded sensors and or periph eral 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 together This does not apply to Output 4 when configured as communications e The digital communications output 4 is separate from the above groups Pow
148. ure below illustrates the interaction between slidewire hysteresis 5H9Y56 and hunt Hunt SHYS5 This prompt appears only if the controller is equipped with slidewire hardware 98 Default __ 3 _ ____ and with Input 2 set to t id SHYS Slidewire Hysteresis slidewire position set point WATLOW Series 988 User s Manual 4 17 setup Output Reaching the Output Menu Begin in the Display Loop and press the Up arrow Y and Down arrow keys simultaneously for three seconds to reach the Setup Menus S5 O OB Ey Py aD LinPt DEPE 9tbt OPI Input Output Global Communications Menu Menu Menu Menu p 4 2 p 418 p 4 34 p 4 44 Press the Up arrow key Y to select one of the Setup Menus Press the Mode key WB to step through the prompts He CL Oe oO O EN y y l e 3 999 HYS O Press the Up arrow key Y or the Down arrow key to select one of the prompt values Prompts may not appear depending on controller configuration Figure 4 18 Navigating the Output Menu 4 18 WATLOW Series 988 User s Manual rr 0 rr SEE Setup Prompt JEN n t Output 1 y Process 1 SS ee Se ee ee ee Se Se i Gee Output 2 i ce Process 2 d 350 Hysteresis 2 Pec Set Point 2 Control EN ALO Alarm 2 25d Alarm 2 Side 8 8 0 0 0 0 0 80 0 0 j J Ate Latching 2 B VW
149. ut lineariza tion Setup Menus Chapter 4 Setup Input Software Filter 2 Select the filter time constant in seconds for input 2 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 Q to disable the filter This prompt appears only on controllers equipped with input 2 hardware and with not set to or E e Default Linearization 2 Select square root linearization for input 2 This prompt appears only if you have set Input 2 to a process input or to a thermocouple input set to mv Default root L ine L ine WATLOW Series 988 User s Manual 4 15 Setup Input dead Set the deadband as a percentage of output to keep the valve from hunting NOTE e The slidewire hysteresis 5H 45 setting provides additional control over a See Chapter 8 for valve more information on slidewire feed This prompt appears only if the controller is equipped with slidewire back hardware 98__ 3_ _ and with set to St id y 4 16 WATLOW Series 988 User s Manual Setup Menus Chapter 4 SHYS NOTE See Chapter 8 for more information on slidewire feed back Figure 4 17 Hunt and slidewire inner hysteresis Setup Menus Chapter 4 Setup Input Slidewire Hysteresis Set the inner hysteresis the point at which the valve output turns off e The fig
150. ut should light after a second or two indicating that the output has been successfully energized Do not press the mode key 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 y OFF lovt tout tout tout tout tout WATLOW Series 988 User s Manual 6 11 Factory Diagnostic O p 1 p Open Loop Checks the control loop consisting of the controller output power control heater and sensor With open loop enabled the controller moni tors the output power level and checks for a change in the process input value If the output power is at maximum for a period of time equal to the reset time and the process input has not changed by at least 5 F the controller will switch to manual mode at 0 output power and will be displayed in the lower display To clear this error enter the Setup Menu and press the display key EM To get back into auto mode press the Auto Man key G33 GPL P This prompt always appears Default y OFF GPL P 6 12 WATLOW Series 988 User s Manual Factory Menus Chapter 6 Reaching the Calibration Menu Begin in the Display Loop and press the Up arrow YY and Down arrow E key simultaneously for six seconds until the Setup Menu _ SEt then the Factory Menu appear Use the Up arrow key Y or Down arrow key to step through the Factory Menu to the Calibrati
151. will not influence the percent power if the process temperature is more than twice the proportional band from the set point When set to _ 9 rate is disabled This prompt appears only if Calibration Menu is set to and Pb IA is set higher than 8 Default s min CRAIR Derivative Output 1A or 1B 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 Q derivative is disabled dE 1A This prompt appears only if Calibration Menu is set to and Pb 1A is set higher than 0 Default e min dE TA 5 12 WATLOW Series 988 User s Manual Operation Menus Chapter 5 Pbef Pbdb NOTE The PID B Menu appears only on controllers with enhanced software Operation Menus Chapter 5 Operation PID A or B Cycle Time Output 1A or 1B Select the time in seconds of a complete on off cycle Ct 1A This prompt appears only if Input Menu is not set to a process Global Menu is not set to C 65 d and Pb A is set high er than 8 lf Default 4 J mechanical TA ee sec relay CETA CE iA outputs open collector ds 7 Sec or solid state Ct iA CEIA relay outputs Proportional Band Output 2A or 2B Select the proportional band for PID output 2 If setto fit func tions as an on off control
152. y ry ry m r m r m ry A qo A LO zu Baio d 29 LO hn Fo lp k w Elo bo units e Setup Menus Chapter 4 Setup Menus Chapter 4 Setup Input RTD 10042 Calibration Curve 1 Select the calibration curve for the RTD 1 input The RTD input uses either the European DIN 0 0038500 Q C or the Japanese JIS 0 0039 160 Q C linearization standard This prompt appears only if you have set to or rtd Default red red Software Filter 1 Select the filter time constant in seconds for input 1 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 Q to disable the filter This prompt always appears Default y Fitri Fer i Fer WATLOW Series 988 User s Manual 4 7 Setup Input 7 vA Linearization 1 Select square root linearization for input 1 This prompt appears only if you have set to a process input or to a thermocouple set to G 5 mvV NOTE See Chapter 8 for more information on input lineariza tion Default po Slee ee ahn 0 3100 rr 4 8 WATLOW Series 988 User s Manual Setup Menus Chapter 4 CAUTION Changing the value of changes most other prompts to the factory default values Document all set tings before chang ing sensor type Verify the correct sensor type before making a change Failu
153. ys e AL r jresets an alarm A 9 switches the controller to manual mode at the power level set at FA IL Global Menu and disables the Auto Man key e OFF turns all control outputs off de energize relays e P d switches from PID A to PID B e Acta selects the opposite control action for output 1 and 2 e e SP switches to a remote set point e Id SP switches to an idle or second set point This prompt always appears Default y CEN Ech LE EN Els LE CLE LE LEH E Je Event Input 2 Select the effect of closing the event input 2 switch The selections are the same as for event input 1 This prompt appears only on controllers equipped with hardware for a second event input 98__ 5 _ __ _ and with set to E 1d Default d E CE Ea Ea Ce CEA Cee Fe WATLOW Series 988 User s Manual Setup Menus Chapter 4 setup Global Annunciator Select whether alarm messages will flash in the lower display This prompt always appears Default i Anun l O pP Low Power Limit Select the low limit for the percent output For cooling direct acting enter a negative number This prompt always appears lf Default J a heat cool 190 application _toP a heat only B application LoP onl 180 eae ELSA Setup Menus Chapter 4 WATLOW Series 988 Users Manual 4 41 setup Global High Power Lim

Watlow Electric Weather Radio 987 User's Manual

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