Watlow Electric 160 User's Manual
Contents
1. Series 160 Relative Humidity Temperature Control System User s Manual w WAVLAT LOWY Watlow Controls 1241 Bundy Blvd Winona MN 55987 507 454 5300 Fax 507 452 4507 W160 MA10 9101 5 00 January 1991 Made in the U S A amp Printed on Recycled Paper General Description The Watlow Series 160 is an integrated relative humid ity temperature control system The control mode options include factory selected combinations of ON OFF time proportioning PI using manual reset and full PID Input for the Series 160 is a relative humidity temperature sensor Features include mechanical relay outputs remote setpot optional remote digital displays and various cable lengths to accommodate remote sensor location The Series 160 is also available as a RH Temperature signal conditioner only that can be interfaced to other Watlow controls Specifications Control Mode Humidity ON OFF e Hysteresis fixed 5 RH Proportional control Proportional band adjustable Typically 25 RH 5 e Cycle time fixed Typically 6 seconds 2 seconds PID Proportional with auto reset and rate integral and derivative Proportional band adjustable Typically 2 to 25 F 1 1 to 14 C Reset integral adjustable Typically 0 05 to 0 5 repeats per minute Rate derivative adjustable Typically 0 to 2 minutes per repeat Cycle time adjustable Typically 10 to 60 seconds PI using manual2. Actual Process The temperature or humidity process controlled in an application 2 Anti Reset Inhibits reset circuitry from Causing set point overshoot 3 Bulk Polymer Sensor Composite construction allowing water molecules to reach the humidity sensing element but keeps contaminants from attacking the element This is an impedance device requiring AC excitation 4 Cycle Time Time required to complete one cycle to energize and de energize the output 5 Dew Point or Frost Point The temperature at which condensation first occurs when a vapor is cooled 6 Droop The difference between set point and actual process variable 7 Duty Cycle Energized time divided by cycle time 8 Oscillation or Hunting Unstable operation occurring if the proportional band is too narrow or the system is upset by some outside source See Figure 15 on Page 12 9 Proportional Band When the actual process is within the proportional band usually specified in units degrees or RH the contro output will proportion the amount of power between 0 and 100 10 Rate Derivative Action that anticipates the rate of actual process temperature rise and automati cally widens the proportional band to prevent overshoot Returns the proportional band to the Static adjustment when the set point temperature is Stable within the static band boundaries pen E 11 Reset Integral Control action that eliminates offset or droo
3. Page 8 4 The A C input is not connected oris Check the A C input connections If not connected improperly present or proper see Page 6 5 Humidity setpot damaged Replace humidity setpot 6 RH sensor cable disconnected Reconnect sensor cable or replace 7 A faulty control Consult the factory Inaccurate temperature 1 Tariperatar sensor is Jamaga Replace sensor on control with calibration or readout interchangeable sensor 2 Sensor cable is opened or damaged Repair or replace 3 A faulty control Consult the factory 14 WATLOW Series 160 User s Manual The Watlow Series 160 is warranted to be free of defects in material and workmanship for 18 months after delivery to the first purchaser for use providing that the units have not been misapplied Since exposure to contaminants and or extreme environmental conditions may result in degradation the sensor is not warranted for performance beyond the time of delivery and installation Since Watlow has no control over their use and sometimes misuse we cannot guarantee against failure Watlow s obligations hereunder at Watlow s option are limited to replacement repair or refund of purchase price any 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 The following procedure applies for any products retur
4. L rf Indicator ON when limit trips High Limit Control Power 120 VAC Integral Setpot Q 140A 16XX 6000 High Limit Control i oo S Indicator ON when limit trips I TC Input OpenMomentary Switch op immersion Heater Limit Sensor Figure 13 Series 160 System Wiring Example 10 WATLOW Series 160 User s Manual F F 2 NOTE This is a typical tuning graph Depending on your PID settings your system may never respond like this Proportional Band Set point SS eT ee Se Se ee Actual Process Temperature Figure 14 PID Adjustment Graph for Temperature Tuning Procedure for Temperature PID Controls The setup procedure for most applications does not require the full Tuning Procedure for PID Controls if the following settings provide satisfactory control Initial Settings 1 Cycle time 10 seconds set full counter clockwise CCW 2 Proportional band 12 5 F 6 RH set to mid range 3 Rate 0 turn fully CCW 4 Reset 0 05 repeats minute turn fully CCW This is specific to the Series 160 Energize the system and allow the actual process temperature to stabilize After any PID adjustment is made the actual process temperature may become unstable Allow sufficient time for it to stabilize before making another adjust ment Proportional Band Adjustment Rotate the proportional band pot CCW 1 4 turn and observe system stability Repeat
5. See Page 7 and 8 3 For a dial scale assembly using mounting screws drill Mounting the Sensor Module 1 Drill two 0 15 4 mm diameter holes in the desired panel location DO NOT USE AS A TEMPLATE See Figure 2 2 Using two 6 32 screws mount the sensor module keeping the vent holes in line with the air flow Do not over tighten The maximum recommended torque is 8 0in Ibs 3 Connect the sensor module to the 160 with the input connector See Page 7 for location Before you begin your system design there are a few important factors to consider Accuracy and stability requirements The specified tolerance of all components in the humidity tempera ture system are interactive and inaccuracies of each component can add up Agency Regulations Some regulatory agencies have specific guidelines for sensor location and cleaning Verify any agency requirements before designing your system Air flow Proper air flow increases evaporation and response time This is only necessary in applications when rapid system response is critical Air flow speed cannot damage the sensor Cleaning The sensor cannot be cleaned Locate the sensor where it cannot be easily contaminated Con sider using a filter Dehumidification This is accomplished by using the normally closed N C contacts on the ON OFF humidity control or use the 160 signal conditioner with another Watlow control Contact the factory for more information on Watlow con
6. User s Manual D aE D000 000000 133 mm i seeeen eal cea BET 020 168 mm ax pr 0 35 gt a 5 mm aA 9 mm 1 87 48 mm Figure 1 Series 160 Dimensions 0 11 Dla 3 mm 4 mounting holes 2 NOTE A 3 ft 0 91 m standard length cable is shipped with the sensor gt CAUTION To prevent unnecessary force of each cable connection on the Series 160 a minimum of 3 0 76mm in length is needed as a strain relief for each end Figure 2 Sensor Module Dimensions Figure 3 Setpot Dimensions 3 36 85 mm 341 0 125 m 3 mm 43 mm 0 128 Dia 3 mm ASS 13 mm 19 mm E ENE q iz 44 mm Figure 4 Digital Display Dimensions amp Panel Cutout 2 ft 0 61 m i mey j minimum cable length 4 WATLOW Series 160 User s Manual installation Mounting the Series 160 Mounting Remote Setpot Assembly 1 Drill seven 0 19 5 mm diameter holes in the desired 1 panel location using the control as a template See Drill 2 25 60 mm diameter hole or use a 2 25 2 375 2 50 or 2 675 punch at desired remote setpot Figure 1 assembly location See Figure 3 2 Mount the Series 160 with seven 8 32 screws 2 Using the dial scale as a location template center and 3 Wire the control per Figure 5 or 6 on Page 6 mark all four mounting holes on the dial scale with a center punch 4 Connect the sensor load and line cord
7. 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 WATLOW Series 160 User s Manual 15
8. dity setpot assembly Temperature setpot assembly Accessories listed below are ordered separately Series 160 Relative Humidity Temperature Control 1 6 0 10410 0 Model options listed below Temperature Scale A Fahrenheit F B Celsius C Line Voltage ____________ 1 120 208 240VAC 2 24VAC Temperature Humidity Control Mode A Humidity and Temperature signal conditioners only B Humidity ON OFF Temperature PI with manual reset C Humidity Proportional Temperature PID Sensor Cable Length _ _ ________ _ 1 to 24 feet available 03 3ft 0 91m standard length 06 6ft 1 83m 09 9ft 2 74m 12 12ft 3 66m 15 15ft 4 57m 18 18ft 5 49m 21 21ft 6 40m 24 24ft 7 32m 10 RH sensor interchangeable Sensor Calibration 1 2 2 5 RH sensor not interchangeable Accessories Remote digital display 1 digit resolution D400 1002 0200 Push to read set point switch D400 0002 0200 Display process only J NOTE The Series 160 and required support electronics is purchased as a system To guarantee system conformance to the specified tolerance system components must not in any way be interchanged with those of other systems If you purchase replacements or accessories to your original 2 5 RH system 160X XXXX 2000 the system excluding cables must be returned to the factory and re calibrated as a single unit WATLOW Series 160
9. e temperature range Temperature range 35 to 170 F 1 7 to 77 C Ambient rejection lt 0 10 degree per degree rise in ambient Sensor lead resistance rejection No affect over range of allowable lead lengths Independent sensor cable lead length Terminals 1 4 quick connect terminals al Power 120 or 208 240VAC 10 15 User selectable 24VAC 10 15 Operating Environment Control range 32 to 140 F 0 to 60 C Relative Humidity 0 to 95 RH non condensing Exposing any RH sensor to contaminants and or continuous extreme environments may cause accuracy degradation The Watlow sensor while not totally immune exhibits superior performance as indicated in tests conducted Contact the factory for details Agency Recognition e UL197 873 pending e CSA 22 2 24 pending Dimensions Control Length 7 00 in 178 mm Width 5 25 in 133 mm e Height 1 87 in 48 mm Control Weight 1 10 Ib 0 50 kg e Sensor Weight 0 03 Ib 0 01 kg Setpot Assembly e Dial scale 3 in sq 76 mm e Pot depth behind 0 67 in 17mm Knob depth infront 0 68 in 17mm e Lead length 24 in 610 mm Weight 0 15 Ib 0 068 kg If you order a model with control option A you will receive Signal conditioner open board assembly Cased sensor module Sensor module cable Ordering Information In addition lf you order a model with control options B or C you will receive e Humi
10. eely Humidity sensitivity to temperature A stable tem perature is Critical to accurate humidity Example At 140 F 60 C and 60 humidity a 9 F 5 C shift in tem perature causes a 10 change in humidity WATLOW Series 160 User s Manual 5 Line Voltage WARNING To avoid potential electric shock use National Electric Code safety practices when wiring and connecting this unit to a power source and to electrical sensor modules or peripheral devices All wiring and fusing must conform to the National Electric Code and to any locally applicable codes also 300mA UL listed fuse L1 Not Used 24 or 120 VAC factory selectable Figure 5 24 or 120 VAC Power Wiring 160X 2X03 X000 or 160X 1X03 X000 300mA UL listed fuse Oe a wee 208 240VAC Figure 6 208 240VAC Power Wiring 160X 1X03 X000 6 WATLOW Series 160 User s Manual Er DODO 000000 Figure 7 Remote Setpot Wiring Auxiliary remote Auxiliary ramote digital display for digital display for Temperature Humidity DODDOVD 000000 A Figure 8 Input and Remote Display Connections WATLOW Series 160 User s Manual 7 Output Wiring cont Figure 9 Temperature Output 6 Amp Mechanical Relay Humidity Output L1 Figure 10 Humidity Output 6 Amp Mechanical Relay 8 WATLOW Series 160 User s Manual e Auxiliary Wiring J NOTE Signal conditioner o
11. it to the factory for calibration send only the open board assembly from units with the 2 5 sensors option Problem Probable Cause j Action Poor humidity or 1 Control parameters are Adjust the proportional band cycle time temperature control not adjusted properly reset amp rate per Tuning See Page 11 12 2 The sensor is not detecting Locate the sensor so it is measuring the appropriate process the actua process 3 Insufficient system air flow Circulate air through the chamber Inaccurate humidity or 1 Sensor characteristics have changed 1 Replace sensor on Fanta with inter temperature calibration changeable sensor option and readout 2 Return Series 160 to factory on idee bes with ep bisionangesns sensor 2 Humidity sensor damaged by Panty RH sensor and relocate in air duct environmental contamination with protective filter to minimize potential damage from environmental contamination Sensor cable is opened or damaged Repair or replace A faulty control Consult the factory Humidity load will 1 Humidity sensor damaged by Replace RH sensor and relocate sensor in air not energize or environmental contamination duct with protective filter to minimize poten de energize tial damage from environmental contamination 2 Open temperature sensor evince RH sensor 3 The load circuit is open Check the fuses circuit breakers load and wiring See Wiring on
12. ned to the factory bs You must call Watlow Customer Service 507 454 5300 for a Return Material Authorization RMA number before returning any item for repair We need this information Ship to address Bill to address Contact name Phone number Ship via P O number e Symptions and or special instructions Name and phone number of person returning the material We will not accept a return without an RMA number The RMA number must appear on the outside of the carton and on all paperwork Cartons without RMA numbers will be returned Ship on a freight prepaid basis You need prior approval and an RMA number from the Customer Service Department when you are returning an unused product for credit Also we must apply a 20 percent restocking charge for all returned stock controls and accessories After we receive your return we will examine it to determine the cause for your action In cases of manufacturing defect we will enter a repair order replacement order or issue credit for material If the unit is unrepairable we will return it to you with a letter of explanation Repair costs will not exceed 50 percent of the original cost Technical Assistance 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 damage either outside the box or to its contents make a claim with the
13. nly unit does not have relay outputs available Temperature Series 160 Oo ooo eaal Figure 11 Temperature Signal Conditioner Output Wiring 0 5VDC 35 to 170 F 1 7 to 77 C Humidity Series 160 oOo oe a gun Figure 12 Humidity Signal Conditioner Output Wiring 0 5VDC 30 to 95 WATLOW Series 160 User s Manual 9g System Wiring Example STOP WARNING install high or low temperature limit control protection in systems where an over or under humidity temperature fault condition could present a fire hazard or other hazard Failure to install temperature limit control protection where a potential hazard exists could result in damage to equipment and property and injury to personnel Temperature Humidity Display Display 160A 1C03 2000 Temperature RH Control ag Ground 7 Temperature Setpot L1 Li__C D D Humidity Setpot A CAUTION With Watlow mercury relays load must have a unity power factor For g NO F RESISTIVE LOADS ONLY a J NOTE RH and Temperature All fuses must be selected Sensor Module for proper protection in a nii given application i Process Temperature Limit Sensor Mercury Mercury Type J Thermocouple Relay and Relay and L2 dese for Heater for High Limit Temperature Relative Temperature Control Power integial Humidity Le 120 VAC Sopo Fuse L 140A 16XX 6000 High Limit Control
14. p between set point and actual process Can be automatic or manual operation 12 Relative Humidity RH Ratio of water vapor in the air to the quantity that would saturate the air at the existing temperature Expressed as a percent age 13 Switching Sensitivity or Differential The output will de energize when the actual process increases to set point plus half of the hysteresis The output will energize when the process decreases to the set point minus half of the hysteresis This action causes the process to average at set point This is specific to the Series 160 14 System A combination of electronic controls heaters sensors and switching devices that control a process 15 Thin Film RTD Sensor Screen printing a resis tive element on a substrate 16 Wet Bulb Dry Bulb Method determining relative humidity using a look up table together with a properly maintained wet sensor measuring minimum temperature of wetted bulb in air stream and a dry sensor measuring actual process temperature 17 0 or da Musical Notes are used to alert you to important details 18 The Stop Sign alerts you to a WARNING a safety hazard which could affect you and the equipment 19 The Deer Crossing Sign alerts you to a CAUTION a safety or functional hazard which could affect your equipment or its performance WATLOW Series 160 User s Manual 13 Troubleshooting Chart 2 NOTE When returning your un
15. reset Proportional band adjustable 2 to 25 F 1 1 to 14 C Manual reset adjustable 100 of proportional band e Cycle time adjustable Typically 10 to 60 seconds Signal Conditioner Only Linear signal output e Temperature 0 5VDC e Humidity 0 5VDC 35 to 170 F 1 7 to 77 C 30 to 95 RH Operator Interface Setpot Assemblies Temperature setpot with calibrated F C dial scale remote mounted Humidity setpot with calibrated RH dial scale remote mounted Display Assemblies Auxiliary humidity and temperature displays remote mounted LED load indicator lights Input Humidity bulk polymer sensor 30 to 95 RH Temperature thin film RTD sensor 35 to 170 F 1 7 to 77 C 2 WATLOW Series 160 User s Manual Output Humidity Electromechanical relay Form C 6A 115 230VAC 6A 28VDC 1 8 hp 115VAC 125VA 115VAC Temperature Electromechanical relay Form C 6A 115 230VAC 6A 28VDC 1 8 hp 115VAC 125VA 115VAC Accuracy 2 5 RH accuracy factory calibration standard non interchangeable sensor referenced at 77 F 25 C 10 RH accuracy factory calibration interchange able sensor referenced at 77 F 25 C Ambient rejection lt 0 17 RH F lt 0 30 RH C rise in ambient Sensor cable lead rejection No affect over range of allowable lead lengths Control Accuracy 2 7 F 1 5 C when the control is at 77 F 25 C the sensor is within th
16. shipper immediately Save the original shipping carton and the packing material lf you encounter a problem with your Watlow Control review all of your configuration information to verify that your selections are consistent with your application Input Output Displays Limits etc If the problem persists after checking the above you can get technical assistance by dialing 1 507 454 5300 An Application Engineer will discuss your problem with you Please have the following information available when calling Complete model number Bar Code Number located on sensor amp mother board All configuration information User s Manual Watlow Controls Watlow Controls is a division of Watlow Electric Manu facturing Company of St Louis Missouri Watlow is an established manufacturer of industrial electric heating products in business since 1922 Watlow boasts the ability to begin with a full set of specifications and to complete an industrial product that is manufactured totally in house in the U S A Products designed and manufactured by Watlow are electric heating elements sensors electronic temperature controls and power switching devices The Watlow Controls operation has been designing solid state electronic control devices since 1962 and has earned the reputation as an excellent supplier to original equipment manufacturers These OEMs depend upon Watlow Controls to provide compatibly engineered
17. t setting 2 Manual Offset Turn to mid range 3 Cycle Time Turn fully CCW fastest time Energize the system and allow the actual process humidity to stabilize When the system is stable the load will cycle at a constant rate 12 WATLOW Series 160 User s Manual power switching devices lengthen the cycle time to Proportional Band Adjustment Rotate the proportional band pot CCW a 1 4 turn observe system stability Repeat until the actual process humidity begins to hunt becomes unstable When hunting is observed rotate slowly CW in small increments until the system becomes stable Some systems may be stable enough to allow minimum proportional band setting fully CCW D Manual Offset In virtually all proportional control systems the actual process humidity may drop or rise to a point that is not the set point humidity This action takes place even though the actual process humidity has stabilized Adjust the offset pot slowly CW if the actual process humidity stabilizes below set point Adjust CCW if the actual process humidity stabilizes above set point If large changes in the set point are made readjustment of the manual reset may be required Cycle Time Set as required Best control is always achieved with faster cycle times However if a mechanical contactor or solenoid is used to switch power to the load slower cycle times may be desirable to minimize the wear on the mechanical components
18. times However if a mechanical contactor or solenoid is used to switch power to the load slower cycle times may be desirable to minimize the wear on the mechanical components WATLOW Series 160 User s Manual 11 Widen proportional band Control not within proportional band hunting result of wider prop band fs p NOTE This is a typical tuning graph Depending on your PID settings your system may never respond like this Humidity droop Reset back to set point manual reset or offset EA ee eee eee Full OFF eee aa hss 7 NF Pont FN ao ea Ba P ma Full ON Temperature Figure 15 PI Adjustment Graph For Humidity Tuning Procedure for Time Proportioning Controls Using Manual Reset PI for Humidity The setup procedure for most applications does not require the full Tuning Procedure for Time Proportion ing Controls using Manual Reset if the following settings provide satisfactory control 4 Proportional Band Mid range state power switching devices lf using mechanical 2 Cycle Time Counterclockwise CCW if using solid reduce mechanical wear by adjusting clockwise CW 3 Reset Set to mid range If actual process humid ity is below or above set point refer to manual offset adjustment following if the parameter values above do not provide satisfac tory control refer to the full tuning procedure below initial Settings 1 Proportional Band Turn fully CW wides
19. trols available Environmental contamination Exposing any RH sensor to contaminants and or continuous extreme environments may cause accuracy degradation The four 0 125 3 mm diameter clearance holes For self tapping screws tap drill sizes used are Tap drill size 43 0 089 dia for Screw thread size 42 0 093 dia Drill four 0 189 5 mm diameter holes in desired panel location See Figure 3 System Considerations Watlow sensor while not totally immune exhibits superior performance as indicated in tests conducted Take precautions to protect your sensor Response Time The response time for both humidity and temperature is almost instantaneous If a faster response time is needed add air flow to the application Humidity generation and temperature In a fast responding system steam can generate moisture Steam causes the ambient temperature to increase Consider a cooling system to counteract increased temperature Sensor retrofit All RH sensors degrade with time and environmental conditions This affects calibration accuracy and will be different for each system depend ing on its environment Prototype your application to determine the life expectancy of your sensor and start a periodic maintenance schedule Sensor location Locate the sensor so it cannot be physically damaged or exposed to contaminants A filter can be used to block the flow of contaminants yet allows air to move fr
20. until the actual process temperature begins to hunt becomes un Stable When hunting is observed rotate the pot CW in small increments until the temperature becomes Stable Some systems may be stable enough to allow minimum proportional band fully CCW Reduced Overshoot SS ss SSeS SS SSP TST TT EES SS nnn Rate Adjustment The rate pot controls overshoot as actual process temperature approaches set point temperature Rotate the rate pot 1 4 turn CW Change the set point tem perature 20 to 30 F C and observe the approach to set point lf the actual process temperature overshoots repeat the procedure until optimum approach to set point is achieved If the rate pot is advanced too far the system will be overdamped and approach to set point will be very sluggish Reset Adjustment Reset adjustment eliminates droop The reset adjust ment controls the time required to drive the error signal to zero A low setting 0 05 repeats minute requires long periods of time for the actual process temperature to reach set point If the reset time is set too fast 0 5 repeats minute the system may become unstable and oscillate about the set point temperature To adjust reset time rotate the reset pot 1 4 turn CW and observe stability Continue adjusting CW until the system becomes unstable Rotate CCW very slowly to regain stability Cycle Time Set as required Best control is always achieved with faster cycle
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