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Using This Retrofit Guide

1. Prompt Description Range Default Your Settings FILE Current system file to edit 1 10 1 STEP Select step number to view or edit Press MODE for step type prompt To change step type use the increment decrement key and press ENTER 1 99 1 SETPOINT Step Type SP1 Enter the temperature to achieve for the step s ending set point for Channel 1 according to the HOUR MIN SEC parameters R1L and R1H SP2 Enter the temperature to achieve for the step s ending set point for Channel 2 according to the HOUR MIN SEC parameters R2L and R2H Dependent on TYP parameter under SPCLFUNC HOUR Enter the hours programmed for this step 0 23 hours MIN Enter the minutes programmed for this step 0 59 minute SEC Enter the seconds programmed for this step 0 59 seconds EV1 Enter the Event Output 1 status Dependent on output amp AUX1 OFF or ON EV2 Enter the Event Output 2 status Dependent on output amp AUX2 OFF or ON EV3 Enter the Event Output 3 status Dependent on output board OFF or ON EV4 Enter the Event Output 4 status Dependent on output board OFF or ON EV5 Enter the Event Output 5 status Dependent on output board OFF or ON EV6 Enter the Event Output 6 status Dependent on output board OFF or ON EV7 Enter the Event Output 7 status Dependent on output board OFF or ON EV8 Enter the Event Output 8
2. These commands can accept an asterisk to indicate that they are not programmed 22 WATLOW Senes 922 How to Use Data Communications Commands AFL Command a SY This command asks the Series 922 for the fiie numbers of files that are pro grammed The syntax for the command not including protocol characters is lt Space gt AFL The command wiil return the following data in ASCII numbers Data 1 lt Space gt Data 2 lt Space gt Data 3 lt Space gt Data n Data 1 wiil always be 1 i e File 1 File 1 will always appear even with a cold started unit when that file is defaulted to a one step STOP step program Data 2 through Data n are the file numbers of the other programmed files TI Command f The T Command is used to set the Series 922 real time clock in hours minutes and seconds P The syntax for this command not including protocol characters is NOTE lt Space gt TI lt space gt lt Data 1 gt lt space gt lt Data 2 gt lt space gt lt Data 3 gt You may write to the Series 922 real time The arguments in ASCII numbers must always be prea Ex sT Data 1 Real time hours range 0 to 23 EASRA when the unit is in Data 2 Real time minutes range 0 to 59 the HOLD mode Data 3 Real time seconds range 0 to 59 The TI Command can oniy be used when the unit is in the HOLD mode 2 TI Command The TI command asks Series
3. Prompt Description Default ACCESS 1 PID To enter PID parameters use ACCESS 1 amp press ENTER Range Your Settings PB1H RS1H 0 900 F 0 500 C 0 500Units 0 00 5 00 repeats minute 45 F 25 C 25U 0 00 Enter the Channel 1 Proportional Band value Heating Enter the Channel 1 Reset value Heating Not displayed if PB1H 0 Enter the Channel 1 Rate value Heating Not displayed if PB1H 0 Enter the Channel 1 Cycle Time value Heating Not displayed if PB1H 0 Dependent on output amp OUT1 Enter the Channel 1 Rate Band value Heating Not displayed if PB1H 0 0 denotes rate is always functional Enter the Current Dead Band value for Channel 1 RT1H 0 00 5 00 minutes 0 00 CT1H 1 60 seconds 5 RB1H 0 7 times PB1H 0 DB1 36 to 36 F 20 to 20 C 0 20 to 20 Units 0 900 F 0 500 C 0 500Units 0 00 5 00 repeats minute PB1C RS1C 45 F 25 C 25U 0 00 Enter the Channel 1 Proportional Band value Cooling Enter the Channel 1 Reset value Cooling Not displayed if PB1C 0 Enter the Channel 1 Rate value Cooling Not displayed if PB1C 0 Enter the Channel 1 Cycle Time value Cooling Not displayed if PB1C 0 Dependent on output 8OUT1 Enter the Channel 1 Rate Band value Cooling Not displayed if PB1C 0 0 denotes rate is always functional Press the ENTER key to return to the SYSTEM prompt Press the MODE key to return to t
4. This command causes a Series 922 program to RESUME If the program is already RUNning an error will occur The syntax for this command not including protocol characters is lt Space gt RSUM lt Space gt 1 Check the RUN status with RUN 2 FST Command This command asks the number of steps programmed in the specified file The syntax for this command not including protocol characters is lt Space gt FST lt Space gt lt File gt This command will return the number of programmed steps in the specified file in a one or two character ASCII number How to Use Data Communications WATLOW Series 922 19 STP Command J eee The STP command is used to program a given step in a file Remember that total program space is 99 steps You can use the STP command only in the HOLD mode The syntax for this command not including protoco characters is lt Space gt STP lt Space gt lt File gt lt space gt lt Step gt lt space gt lt Step Type Bi Code gt lt space gt lt Data 4 gt lt space gt lt Data 5 gt lt space gt lt Data n gt ied Table 5 below shows how to interpret the syntax Note that each Data field is Serle eas step with an ASCII decimal number representing a specific value for each parameter the STP Command listed in the table The abbreviation W1 is Wait for Channel 1 ACTUAL tem only when the unit is perature in the HOLD mode A syntax example for a SETPOINT Step
5. Appendix WATLOW Series 922 User s Manual 71 T C Calibration Press the MODE key until DAS6 XXXX appears on the alphanumeric display Use the UP DOWN keys to adjust the alphanumeric display to match the reading on the DVM Once the two readings match press the ENTER key Press the MODE key until CH1Z XXXX appears on the alphanumeric display for Channel 1 CH2Z XXXX for Channel 2 Enter 0 00 millivolts from the millivolt source to the reference compensator or set the t c calibrator to 0 C 32 F Allow the Series 922 to stabilize for 10 seconds press the ENTER key Press the MODE key until parameter CH1G XXXX for Channel 1 CH2G XXXX for Channel 2 appears on the alphanumeric display Using the table below set the millivolt source to its appropriate setting from the millivolt source to the reference compensator If you are using the t c calibrator use the values in the table below Allow the Series 922 to stabilize for 10 seconds press ENTER Thermocouple Type Millivolt Source T C Calibrator Settin Settin J t c 42 283mV 1382 F 750 C K t c 50 633 mV 2282 F 1250 C T t c 17 816mV 662 F 350 C Remove power from the Series 922 Remove thermocouple wires from 6 and 8 for Channel 1 3 and 5 for Channel 2 Turn off the compensator Set DIP Switch 6 to the OFF position 72 WATLOW Series 922 User s Manual Appendix RTD Calibration RTD Field Calibration Procedure Equipment Required 100Q pre
6. 0 5v 4 20mA input Ls p Channel 1 Process 0 5V 4 20mA input CO N O OO A 0 N Input Option 5 Terminals 1 8 Model 922A 5 0 _ 000 Model 922A 8 0 _ 000 Model 922A 9 0 _ 000 j Retransmit Common _ Chart i E 3 4 Channel 2 5 6 T Channel 1 8 How to Install and Wire Chapter 4 Wire Input Figure 20 Input Option 4 Dual Process Wiring Diagram NOTE Jumper terminal 4 to 5 only when using 4 20mA input for Channel 2 NOTE Jumper Terminals 7 to 8 when using 4 20mA input for Channel 1 Figure 21 Input Option 5 8 or 9 Dual T C Wiring Diagram WARNING Use ungrounded sensor for proper operation WATLOW Series 922 User s Manual 31 Output Option BB Dual Solid State Rela Wire Output poo ean Model 922A BB _ _ 000 Figure 22 Dual S S Relay 2 2 2 2 2 G Output Option Output 1 BB Wiring ee eee Diagram Ghannelt 2 Seco Output 2 Output 3 Channel 2 eee eee Output 4 oe 2 Ei aeece L2 Neutral L1 Hot Output Option CC Solid State Switch Figure 23 Solid State Switch Model 922A _ CC _ _ 000 Option CC Wiring Diagram Output 1 Channel 1 NOTE If SPCLFUNC Output 2 parameters OUT 1 and or OUT2 are set to CL HT then Output 3 Outputs1 and or 3 Channel 2 will be the cooling output and A Outputs 2 and or Output 4 will be the heating outputs Output Option FB 4 20mA S
7. Figure 4 Overview of the Series 922 Operating Modes SYSTEM Mode Generates a non ramping set point for Channel 1 and 2 fixed and can manipulate events clear alarms and error codes PROGRAM Mode Enter or view step type program loops wait for conditions set points auxiliary event outputs ON OFF and step duration SETUP Mode Set up or change operating param eters such as real time high low range alarm types alarm points PID settings RS 422 address You are now ready to continue to How to Use the Keys and Displays Chapter 2 Starting Out Chapter 1 WATLOW Series 922 User s Manual 11 Keys Displays Chapter 2 How to Use the Keys and Displays This chapter will show you the Series 922 front panel and the function of each display key and LED Figures 6 and 7 explain the 922 front panel Front Panel Information Use Figures 6 and 7 to assist you in learning the locations and functions of the front panel components Use the following figures to learn the nature and function of the Series 922 s keys and displays Figure 5 Series 922 Front Panel Information Figure 6 Figure 7 e ea SERIES 22 Where To Go From Here Once you have studied the keys and displays in this chapter and have a good idea of where everything is on the Series 922 continue to Chapter 3 for the Sample Program If you skip the sample program do not forget to check the position of D
8. Retrofit does not have equivalent action as example no manual reset Retrofit controller does not have dual dial scale Hardware lockout is not available on retrofit Note 10 Retrofit controller does not have user selectable line voltage Note 11 Retrofit does not support remote set point or retransmit Check if pins 13 14 15 or 16 have termination If wires are on these pins select a different retrofit Note 12 Retrofit controller does not have user selectable control action Note 13 Solid state sensor required for humidity See http www vaisala com Note 14 Retrofit controller does not have user selectable control mode Note 15 Use auxiliary event board A0Q07 1732 F4B8 Note 16 Retrofit communications are different consult specifications Note 17 Verify retrofit input range matches application Series 922 922A 1BB0 A000 922A 1BB0 B000 922A 1BB0 C000 922A 1CC0 A000 922A 1CC0 BO00 922A 1CC0 C000 922A 1FB0 A000 922A 1FB0 B000 922A 1FB0 CO00 922A 2BB0 A000 922A 2BB0 B000 922A 2BB0 C000 922A 2CC0 A000 922A 2CC0 BO000 922A 2CC0 C000 922A 2FBO0 A000 922A 2FB0 B000 922A 2FB0 C000 922A 3BB0 A000 922A 3BB0 B000 922A 3BB0 C000 922A 3CC0 A000 922A 3CC0 B000 922A 3CC0 C000 922A 3FB0 A000 922A 3FB0 B000 922A 3FB0 C000 922A 4BB0 A000 922A 4BB0 B000 922A 4BB0 C000 922A 4CC0 A000 922A 4CC0 B000 922A 4CC0 C000 922A 4FBO0 A000 922A 4FB0 B000 922A 4FB0 CO000 922A 5BB0 A000 922A 5BB0 B000 922A 5BB0 C000 922A 5C
9. These limit points are themselves restricted by the controller s high and low range Operating Parameters RXH and RXL In other words you can t set an alarm limit beyond the range limits you enter into the microprocessor Figure 36 EEN T EEE E SENESE ENET E SENESE EEEE PEN ee ee E EE Alarm Limits for Pababa paleiepepepepeleie pegele ieieie pelele le ieee pelel i t Alarms 1 and 2 with Temp New SP Process Type e a a oa Alarm ALTYP1 P Ge EE are T a ALTYP2 P a E E teeter Tete a tiutan Tue NOTE Only Chan Actual nel 1 is shown here Time How To Use The Alarms Chapter 7 WATLOW Series 922 User s Manual 65 Alarms sD eee Denese dee sdeesneeetasstesnnaseseescesecseseesceescemaenmennens 1 a A1 H Temp e deren earned ec EEE ener eee op eeerei arte A Pe coe SR a eR New SP SP esari en en visas Mgatedes St eet AiL Figure 37 E E E A S E Alarm Limits for LELELELELELELLLELELELELELELE Alarms 1 and 2 with Actual Pacbubshebuhahuiahabohhnbahninnhebote Alarm ALTYP D OCC CCC Cr ETTET ALTYP D 0 C NOTE Only Chan nel 1 is shown here Alarm Function Latching or Non Latching Alarm function is either latching or non latching Latching is a means of saving indication of an alarm event for the operator to clear manually A latching alarm requires the operator to manually clear it with the ENTER key when ACTUAL returns to within the limits A non latching alarm clears itself automatically when ACTUAL returns to wi
10. UP Key Increases the value in the alphanumeric display A light touch increases the value by one digit Hold the key down to increase the displayed value at a rapid rate 90 Front Panel Screw Secures the control chassis in its case with a 1 4 turn clockwise or releases the chassis with a 1 4 turn counter clockwise ENTER Key Enters selected flash ing data into the micro processor memory This will clear an error code or latched alarm indica tions when the ACTUAL display value returns to within the alarm limit How to Use Keys and Displays Chapter 2 WATLOW Series 922 User s Manual Executes or holds a program from any Run Hold LEDS When the HOLD LED is ON steady the 922 is in a HOLD condition When the HOLD LED flashes the unit is in a WAITFOR step or has exceeded the guaran teed soak deviation When the RUN LED is ON the 922 is in the RUN condition When the RUN LED is flashing the program is being held by the remote hold input 13 Sample Program WARNING Doing a cold start will cause all SETUP parameters and files to be lost DO NOT put DIP switch 1 in the one position unless all user programmed information is to be cleared Chapter 3 Learning the Series 922 A Sample Program in Action This chapter will guide you through an easy sample program for the Series 922 You can quickly grasp the necessary terms and concepts by entering values and then observing
11. 1 5mm to 0 25 in 6 3mm Installation Procedure Follow this procedure to mount the Watlow Series 922 Temperature Control 1 Make a panel cutout per the dimensions in Figure 15 2 Remove the 922 from its case by turning the front panel screw 90 counter clockwise CCW Grip the bezel firmly and pull the control chassis out of the case 3 Place the case in the cutout you just made 4 Attach the mounting brackets either to the top and bottom or to both sides of the unit 5 Tighten the mounting brackets securely against your panel 6 Insert the control chassis into its case and press the bezel to seat it Turn the front panel screw 90 clockwise CW to lock the control in place The hardware installation is complete Go on to the wiring section from here 3 81 Sq _ ___ _ 96 77mm _ 3 81 Sq 96 77mm E Tn MODE A h d ENTER 1 A a S A a F a t F a S HO L D SERIES 922 GA 26 WATLOW Series 922 User s Manual How to Install and Wire Chapter 4 7 8 Install Wire h 197mm ________ DB9 Communications eed _ 6 0 23 mm 152 mm lt Connector gor 3 56 0 015 90 mm OMIM ay aaa _ n Ho Mounting Bracket Lat 75 Event Output 45 mm Ribbon Connector Figure 13 Series 922 Dimensions side view Alarm Event Terminal Strip 130 ai 33 mm 0 25 la 0 36 6 mm 9 mm Figure 14 External Event Alarm Board Dim
12. Dependent on AUX1 and ALTYP1 parameters Enter the Alarm 2 High value Displayed if AUX2 AL Dependent on AUX2 ALTYP2 and TYP parameters Enter the Alarm 2 Low value Displayed if AUX2 AL Dependent on AUX2 ALTYP2 and TYP parameters Press the ENTER key to return to the SYSTEM prompt Press the MODE key to return to the CALIB prompt Range Process Default Deviation Default Range Process Default Deviation Default amp High Slew Limit amp Low Slew Limit AXH 7 1382 F 750 C 999 F 555 C U AXL 7 32 F 0 C 999 F 555 C U 2282 F 1250 C 999 F 555 G U 328 F 200 G U___ 999 F 555 C U 662 F 350 C 999 F 555 C U 328 F 200 C 999 F 555 C U 100 555 0 999 1112 F 600 C 999 F 555 C U 328 F 200 C 999 F 555 C U 392 0 F 200 0 C 999 F 555 C U 99 9 F 99 9 C _ 999 F 555 C U 1985 F 1985 C 999 F 555 C U 117 F 117 C 999 F 555 C U 198 5 F 198 5 C 999 F 555 C U 11 7 F 11 7 C 999 F 555 C U 1985 F 1985 C 999 F 555 C U 285 F 285 C 999 F 555 C U 198 5 F 198 5 C 999 F 555 C U 28 5 F 28 5 C 999 F 555 C U See below A1L AL See below A2H See below A2L See below RETURN RH RTD Whole RTD Tenths 0 5 Whole 0 5 Tenths 4 20 Whole 4 20 Tenths RH RTD Whole RTD Tenths 0 5 Whole 0 5 Tenths 4 20 Whole 4 20 Tenths
13. Dual Sw dc Sw dc Dual Sw dc Sw dc 7 19 2004 Set Point Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Mounting 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN Retrofit F4DH KKKK 01RG F4DH KKKK 01RG F4DH KKKK 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH KKKK 01RG F4DH KKKK 01RG F4DH KKKK 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH KKKK 01RG F4DH KKKK 01RG F4DH KKKK 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH KKKK 01RG F4DH KKKK 01RG F4DH KKKK 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH KKKK 01
14. Example Fig 3 8 SPX 18 Space 8 Start Bits 5 Starting Communications in ANSI X3 28 Protocol 12 Start of Text STX 9 Stop Bits 5 Stopping Communications in ANSI X3 28 Protocol 13 STP 15 STP Command 20 STP Command Data 21 STP Command Data Response Table 6 21 STP Command Data Table 5 20 STRT 18 STRT Command 19 T That s All There is To It 24 TI 15 TI Command 23 TI 2 Command 23 Two Serial Hardware Interfaces and Two Software Protocols 3 TYP 15 W W1 22 W2 22 Watlow Controls 27 WHR 22 Wiring Data Communications 4 WMN 22 WRH 22 WRM 22 WRS 22 X XON XOFF Command Example Fig 4 10 XON XOFF Command Example Fig 5 11 XON XOFF Protocol for RS 423A 9 XON XOFF Protocol 3 How to Use Data Communications Watlow Controls Watlow Controls is a division of Watlow Electric Manufacturing 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 manufac tured by Watlow are electric heating elements sensors electronic temperature controls and power switching devices The Winona operation has been designing solid state electronic control devices since 1962 and has earned
15. How to Use Data Communications WATLOW Senes 922 3 Figure 1 RS 422 Interface Pin Designations Series 922 DB 9 Female with respect to the Series 922 A 1 CAUTION When referencing SIGNAL COMMON s to ground terminate at one point only at the host computer according to the host s hardware specifications A 2 CAUTION Do not connect or terminate a commu nication cable shield to any part of the control or its panel Reference all cable shields to a single ground point at the host computer ac cording to the host s hardware specifica tions Figure 2 RS 423 Interface Pin Designations Series 922 DB 9 Female with respect to the Series 922 WATLOW Series 922 RS 422A Interface Pinouts 4 922A XXXX C000 Commons A 1 4 REC SIGNAL COMMON not required Shields A gt 2 J NOTE The Electronic Industry Association EIA RS 422A standard recommends a maximum 4000 ft 1200mm total network distance RS 423A Interface Pinouts RS 232C Compatible 922A XXXX B000 RECEIVE Data In JUMPER PIN 3 TO PIN 4 lt SIGNAL COMMON Commons gt 1 Shields amp 2 TRANSMIT Data Out Jd NOTE The Electronic Industry Association EIA RS 423A standard recommends a maximum 50 foot total point to point distance Network Connections You can connect a data communication equipped Series 922 to any computer with an R
16. etc The MOV is available in several varieties and for 115 or 230 volt lines The device dissipates the voltage spikes to ground and in doing so repeatedly deteriorates its ability to function MOVs have a limited life Islatrols and other similar power line filters are designed to carry the power for the control circuit and buffer the control circuit from A C line noise Devices like the Islatrol use media electromagnetic filtering other than electric circuits to filter out electrical noise Take care in matching the power capabilities of the filter with power demands of the circuit Keep line filters as close to the control as possible to minimize the area for interference pick up Noise Suppression Devices Available From Watlow Watlow Winona stocks a few key noise suppression parts You may order these by calling your local Watlow distributor Item Electrical Ratings Part Number Differential Mode Line Filter Refer to the Islatrol listing below Metal Oxide Varistor 150V 80 Joule 0802 0273 0000 MOV 275V 75 Joule 0802 0266 0000 24 WATLOW Series 922 User s Manual How to Install and Wire Chapter 4 Wiring Guide Line Filtering Configurations for Controls These three diagrams show you filter configurations for removing input power noise Choose the one best suited for your system if you are unsure which one to use For very dirty or critical application use microcomputer regulated power su
17. reset proportional band and cycle time By setting the proportional band s to zero the Series 922 becomes a simple ON OFF control with a 3 F or 1 7 C switching differential Two of the Series 922 s auxiliary outputs may be alarms or events An event is an ON OFF auxiliary output relay signal You can use events based on time to trigger peripheral equipment or processes Depending on your individual system needs you may order an external event board with two or eight outputs Operator friendly features include automatic entry codes or prompts to aid in setup When there s a power outage the Watlow Series 922 stores all informa tion in a nonvolatile memory When you first apply power the unit will come up with default values for set points and control parameters These default values provide minimum operating information for the control until you program in the desired data The default values are listed in the Master Step Menus and Charts pp 46 61 Remove the Series 922 carefully from its shipping container Be sure to set this literature aside where it will not be discarded Packing List Included with your Watlow Series 922 are two mounting brackets with integral screws and this manual Put Your Control to Work Three Steps Once your control is installed and wired getting the Series 922 up and running is a three part process e First match the control s personality to your system in what we call the SETUP
18. starting out with the Watlow Series 922 A 2 Channel Ramping Control Dual PID or ON OFF Dual Inputs Outputs Channel RTD T C or Process Value Event Input Remote Hold Input E i E Ibo dey decy deip R 8 Auxiliary E gt Outputs RS 422A or RS 423A RS 232C Compatible Optional Computer Interface or 2 Auxiliary Outputs Read Me First Figure 1 AAAA Series 922 Input and l 7 Output Overview Congratulations you re about to become a fully qualified user of the Watlow Series 922 This versatile microprocessor based ramping control is powerful yet simple to learn A ramp progresses from one set point to another set point over a period of time In this chapter of the user s manual you ll get an overview of the 922 and its operation Figure 1 is a simplified view of the Series 922 s capabilities It is a 2 channel dual output per channel microprocessor based 1 4 DIN sized ramping temperature control The 922 accepts dual inputs one per channel This includes Type J K or T thermocouple a 1 or 0 1 RTD input or one of two process inputs You can order an external event output board with two or eight auxiliary outputs It has a full control temperature range offset calibration and a front panel lockout feature Starting Out Chapter 1 WATLOW Series 922 User s Manual 7 The Series 922 is a dual channel PID controller You may input individual sets of PID parameters for each output This includes rate
19. 0 C calibrated to JIS curve 3916 0 003916 Q Q C DIN curve 3850 0 003850 Q Q C Sensor break protection de energizes control outputs to protect system Ungrounded sensors required Operating ranges user selectable J t c 32 to 1382 F or O to 750 C K t c 328 to 2282 F or 200 to 1250 C T t c 328 to 662 F or 200 to 350 C 1 RTD 328 to 1112 F or 200 to 600 C 0 1 RTD 99 9 to 392 0 F or 99 9 to 200 0 C 0 5VDC 99 to 1800 units 4 20mA 99 to 1800 units RH 0 5VDC O to 100 RH Vaisala sensor Calibration offset or input signal 90 F 50 C 50 PVU s front panel adjustable 9 0 F 5 0 C for 0 1 C Units F C or process variable units are user selectable 68 WATLOW Series 922 User s Manual Appendix Output Control Per Channel Single or Dual BP e Solid state relay 0 5A 24VAC min 264 VAC max opto isolated zero Specifications cross switching e Solid state switch 20mA 20VDC max open collector switch to ground e 4 20mA into 6009 load maximum Output Input Auxiliary e External plug in module e Solid state relays 2 or 8 ea 0 5A 24VAC min 264 VAC max e Auxiliary supply 21 to 33VDC 25mA maximum e Switched DC signal provides a minimum turn on voltage of 3VDC ina minimum 500 load Maximum on voltage not greater than 32VDC into an infinite load Output Analog Retransmit e Device driven must have an input impedance gt 10kQ e Reference 0 Units 0 Vo
20. 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual Sw dc Sw dc Dual Sw dc Sw dc Dual Sw dc Sw dc Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 0 5A SSR Eight 0 5A SSR Dual Sw dc Eight Sw dc Dual 0 5A SSR Eight 0 5A SSR Note 3 Retrofit controller outputs are different Add external interposing mechanical or solid state relay if applicable Note 4 Retrofit controller has a programmable not fixed set point Lock set point using controller s lockout parameter Note 5 For DIN rail mounting or sub panel mounting purchase DIN rail adapter p n 0822 0586 P001 for 1 32 DIN or p n 0822 0586 P002 for 1 16 DIN Note 6 Add a quencharc suppressor Watlow p n 0804 0147 0000 for inductive loads Note 7 Retrofit does not have equivalent action as example no manual reset Note 8 Retrofit controller does not have dual dial scale Note 9 Hardware lockout is not available on retrofit Note 10 Retrofit controller does not have user selectable line voltage Note 11 Retrofit does not support remote set point or retransmit If wires are on these pins select a different retrofit Note 12 Retrofit controller does not have user selectable control action Note 13 Solid state sensor required for humidity See http www vaisala com Note 14 Retrofit controller does not have user selectable control mode Note 15 Use auxiliay event board A007 1732 F4B8
21. 73 F 23 C PROC AiL and A1H 73 4 F 23 0 C SP2 Monitor Enter CH 2 Fixed Set Point value TEMP R2L and R2H 73 F 23 C Dependent on TYP under SPCLFUNC PROC A2L and A2H 73 4 F 23 0 C C2 RH Displays CH 2 actual process variable Dependent on TYP under SPCLFUNC EV1 Monitor Enter the Event Output 1 status OFF or ON OFF Dependent on AUX1 EV amp output board EV2 Monitor Enter the Event Output 2 status OFF or ON OFF Dependent on AUX2 EV amp output board EV3 Monitor Enter the Event Output 3 status OFF or ON OFF Dependent on 8 event output board EV4 Monitor Enter the Event Output 4 status OFF or ON OFF Dependent on 8 event output board EV5 Monitor Enter the Event Output 5 status OFF or ON OFF Dependent on 8 event output board EV6 Monitor Enter the Event Output 6 status OFF or ON OFF Dependent on 8 event output board EV7 Monitor Enter the Event Output 7 status OFF or ON OFF Dependent on 8 event output board EV8 Monitor Enter the Event Output 8 status OFF or ON OFF Dependent on 8 event output board El Displays status of the external event input OPEN or CLOSE ER1 Displays Clears the most recent fatal error 0 18 ER2 Displays the most recent nonfatal error 0 40 CLR ALARM Displays the current alarm 1 High 1 Low 2 High 2 Low RETURN Press the ENTER key to return to the SYSTEM prompt Press the MODE key to return to the SP1 prompt Shaded p
22. 922 w SERIES 922 ra WAT LOW Watlow Controls 1241 Bundy Blvd Winona MN 55987 Phone 507 454 5300 Fax 507 452 4507 W922 SA20 8928 5 00 July 1989 Supersedes W922 SA10 8837 Page 3 gt AU ODOWOONNNGaaash item How to Use Data Communications with the 1 Watlow Series 922 Two Serial Hardware Interfaces and Two Software Protocols Communications Wiring RS 422A Interface Pinouts Rs 423A Interface Pinouts RS 232C Compatible Network Connections Connecting the Control and the Computer Communications Software Series 922 Communications Parameters ASCII and Series 922 Information 1 Series 922 General Message Syntax 2 Message Syntax 3 Data Rules Command List 4 Example Format 5 6 7 G N NOOO Tables XON XOFF Protocol for RS 423A How to Start and Stop Communicating with the Series 922 and XON XOFF XON XOFF Command Example XON XOFF Command Example ANSI X3 28 Protocol Device Address Starting Communications in ANSI X3 28 Protocol Stopping Communications in ANSI X3 28 Protocol ANSI X3 28 Command Example ANSI X3 28 Command Example 2 Command Command Other or Commands STRT Command HOLD Command RSUM Command F ST Command STP Command 2STP Command 2MTR Command 2 AFL Command TI Command 2TI Command CLRF Command NAKs and Error Codes That s All There Is To It Index Watlow Controls WATLOW Series 9
23. ACCESS 5 Select 1 or 2 DIAGNOS SPCLFUNC MAN1 C F U MAN2 TYP C2 RH OUT1 RETURN ACCESS 0 CALIB TI 00 00 D O NO JZ press to return to the first parameter G Op K ANL SCAL RBIH DBI PBIC RETURN RS1C To SYSTEM RTIC CAE RBiC tar Press to return to SYSTEM or COM BAUD _ x COM ID LOCK CLR FILE RETURN How To Program the Series 922 Chapter 6 WATLOW Series 922 User s Manual 45 Nr SETUP Menu SETUP Prompt Make photocopies keep Description ACCESS 0 CALIB To enter CALIB parameters use ACCESS 0 and ENTER original clean Range Table 9 SETUP Prompts and Description Default Your Settings TL XX XX Read only Displays the Real Time HH MM HOUR Enter the hours to display the system time of day clock 0 23 hours MIN Enter the minutes to display the system time of day clock 0 59 minutes CAL1 Enter the Calibration Offset value for Channel 1 90 to 90 F 50 to 50 C 9 0 to 9 0 F 5 0 to 5 0 C U CAL2 Enter the Calibration Offset value for Channel 2 Dependent on TYP parameter 90 to 90 F 50 to 50 C 9 0 to 9 0 F 5 0 to 5 0 C U A1H Enter the Alarm 1 High value Displayed if AUX1 AL Dependent on AUX1 and ALTYP1 parameters Enter the Alarm 1 Low value Displayed if AUX1
24. Band Heat 500 C 500 Units 500 RH Max IN range Set Range High Max IN range Set Range Low Set Reset Cool Set Reset Heat RBXC PBXH wo O O N n Min IN range RXL Min IN range 1 Resumes a holding program me of w SCAL 1mV per LSD 2mV per LSD 5mV per LSD 10mV per LSD sx AKL Enter fixed Set Poin STRT See Page 19 Start Program 18 WATLOW Series 922 How to Use Data Communications Other or Commands The following commands also require extra protocol characters with the syntax depending on the protocol you are using Add Start of Text and End of Text Characters to the syntax with ANSI X3 28 Protocol or the ending Carriage Return character to the syntax with XON XOFF Protocol The protocol charac ters are not shown in these commands but nonetheless must be used STRT Command This command causes a 922 program to start If the program is already RUN ning an error will occur The syntax for this command not including protocol characters is lt Space gt STRT lt Space gt lt File gt lt Space gt lt Step gt Check the RUN HOLD status with the RUN command HOLD Command This command causes a 922 program to HOLD If the program is already HOLDing an error will occur The syntax for this command not including protocol characters is lt Space gt HOLD lt Space gt 1 Check the HOLD status with RUN RSUM Command
25. CLSE Default Unprogrammed From RETURN you can go back to the SYSTEM prompt by pressing the ENTER key or return to FILE by pressing MODE One of six step types under the PROGRAM menu of the Series 922 that can be programmed to automatically start at a determined real time The AUTOSTART function is dependent on the three parameter settings below DAY HOUR and MIN If there is a loss of power to the Series 922 the real time clock is also lost and any programs dependent on time is incorrect Represents the number of days that the 922 waits until AUTOSTART takes place Each time 00 00 is achieved one day has gone by If left blank unprogrammed the day count is ignored for use as a daily event rather than weekly Range 0 to 6 days Default Unprogrammed Stands for the hour that the 922 waits for the time of day clock before AUTOSTART takes place Under the AUTOSTART step type Range 0 to 23 hours Default Unprogrammed This parameter represents the minutes that the 922 waits for on the time of day clock before AUTOSTART takes place Under the AUTOSTART step type Range 0 to 59 minutes Default Unprogrammed From RETURN you can go back to the SYSTEM prompt by pressing the ENTER key or return to FILE by pressing MODE One of six step types under the PROGRAM menu of the Series 922 that indicates the end of any file From RETURN you can go back to the SYSTEM prompt by pressing the ENTER key or return to FILE by pressing
26. Default 45 F 25 C 25 Units 4 5 F 2 8 C 2 5 Units 25 RH PB2C Reset integral cooling control action for Channel 2 that auto matically eliminates offset or droop between set point and actual process temperature in a proportional control Expressed in repeats per minute This parameter will not appear if PB2C is set to 0 or T or P Channel 1 only in the TYP parameter under the SPCLFUNC menu have been selected Range 0 00 to 5 00 repeats minute Default 0 00 RS2C The rate derivative cooling function for Channel 2 of the Series 922 The rate is determined by how fast the error being corrected is increasing Expressed in minutes This parameter will not appear if PB2C is set to 0 or if T or P Channel 1 only in the TYP param eter under the SPCLFUNC menu have been selected Range 0 00 to 5 00 minutes Default 0 00 RS2C 52 WATLOW Series 922 User s Manual How To Program the Series 922 Chapter 6 The cooling cycle time for Channel 2 expressed in seconds for a controller to complete one ON OFF cycle Time between successive turn ons This parameter will not appear if Your Series 922 has a 4 20ma output and OUT2 under the SPCLFUNC menu is set to CLHT PB2C is set to 0 or T or P Channel 1 only in the TYP parameter under the SPCLFUNC menu has been selected Range 1 to 60 seconds Default 5 A thermal control band for Channel 2 cooling that defines where the rate derivative function
27. MN STOP LINK SETPOINT To FILE Values HR MN SEC EV1 Events ON or OFF EV2 EV3 EV4 EV5 EV6 EV7 EV8 JUMPLOOP WAITFOR WHR WMN AUTOSTART DAY HR MN STOP LINK SETPOINT To FILE Values HR MN SEC EV1 Events ON or OFF EV2 EV3 EV4 EV5 EV6 EV7 EV8 JUMPLOOP WAITFOR WHR WMN AUTOSTART DAY HR MN STOP LINK Step Type SETPOINT To FILE Values HR MN SEC EV 1 Events ON or OFF EV2 EV3 EV4 EV5 EV6 EV7 EV8 JUMPLOOP WAITFOR WHR WMN AUTOSTART DAY HR MN STOP LINK To FILE WATLOW Series 922 User s Manual How To Program the Series 922 Chapter 6 Alarms Chapter 7 How To Use the Series 922 Alarms NOTE If your unit does not have an external output One of the most versatile features of the Watlow Series 922 is its capability for board or it s not alarms The alarms can be automatic signals for process error or temperature connected this related event type actions in your system section does not apply to your unit To use the alarms to their fullest extent you need to understand wha
28. Proper DIP Switch Settings Prior to programming and operating the Series 922 you must set the DIP Switches DIP Switch 1 sets a warm or cold start following power removal from the 922 With the DIP switch in the OFF position for a Warm Start the microprocessor uses previously programmed information as if power had not been removed A Cold Start starts clean or completely cleared of all user programmed information when the DIP switch is in the ON position All parameters are empty or set to the default limits DIP Switch 2 in the ON position displays only certain factory selected SPCLFUNC parameters Set the DIP Switch in the OFF position to display all parameters DIP Switch 3 selects tenths of units displayed for process inputs DIP Switch 4 is ON for 0 5VDC 0 20mA input amp OFF for 1 5VDC 4 20mA input DIP Switch 5 is not used Set it to the OFF position DIP Switch 6 is for factory test and calibration it must be OFF External Event Input The event input allows the Series 922 to be programmed to wait at that point in the profile until a change in status of the event input occurs It can be pro grammed to wait for a switch closure or opening at Terminals 22 and 24 via the WE wait for event step in the WAITFOR menu Remote Hold Input A contact closure across the remote hold input terminals 22 amp 24 causes the Series 922 to pause until the switch opens This is indicated by a flashing RUN LED While in this
29. Series 922 10 DIP Switch Location and Orientation 11 Overview of the Series 922 12 Series 922 Front Panel Information 13 Actual and Alphanumeric Display Front Panel Information 13 Keyboard Front Panel Information 20 RUN Key Flow Diagram 25 Differential Mode Filter Diagram 25 Common Mode Filter 25 Combination Differential Common Mode Filter Diagram 26 Series 922 Faceplate Dimensions 27 Series 922 Dimensions Side View 27 External Event Alarm Board Dimensions Side amp End view 27 Series 922 Panel Cutout Dimensions 28 Series 922 Power Wiring Diagram 29 Input Option 1 amp 6 Dual RTD Wiring Diagram 30 Input Option 2 amp 7 RTD Process Wiring Diagram 30 Input Option 3 T C and Process Wiring Diagram 31 Input Option 4 Dual Process Wiring Diagram 31 Input Option 5 Dual T C Wiring Diagram 32 Dual S S Relay Output Option BB Wiring Diagram 32 Solid State Switch Option CC Wiring Diagram 32 4 20mA Solid State Output Option FB Wiring Diagram 33 External Event Alarm Board Information 33 External Board Control Power 33 Ribbon Cable Connector to Series 922 34 Event Output Option B and K SSR Wiring Diagram 34 Event Output Option C Switched DC Wiring Diagram 35 Series 922 System Wiring Example 39 Guaranteed Soak GS Example 42 SYSTEM Key Flow 45 SETUP Key Flow 57 PROGRAM Key Flow 64 Alarm Type for Alarm 1 is Process Alarm ALTYP1 P 64 Alarm Type for Alarm 1 is a Deviatio
30. XOFF Command Example The general command syntax is the one you ve already seen Each command uses a Slightly different variation of it depending on the number of arguments required for a message The control must be in the HOLD mode to accept a change You want to change the Alarm 1 Low A1L value to 500 The Com mand will do the job The syntax with XON XOFF Protocol requires an ending Carriage Return lt CR gt Command Syntax with XON XOFF Protocol lt Space gt Data 1 lt space gt Data 2 lt CR gt With the Command Data 1 is the Series 922 parameter in this case Alarm 1 Low AiL Data 2 is the value you want to set for that parameter in this example 500 Enter in ASCII lt space gt A1L lt space gt 500 lt CR gt The hex string will be 3D2041314C203530300D lt Space gt A ASCII i Characters Space 5 0 HEX Value 3D 20 41 31 4C 20 35 30 30 OD Response from the Series 922 Sends a XOFF when a carriage retum is received and then an XON when the unit is done processing the command The complete list of Command data parameters and value limits is in Table 6 Pages 20 21 How to Use Data Communications XON XOFF XON XOFF 2 Command Example a eee You want to know the Alarm 1 Low A1L value The uses a variation of the message syntax shown just below This protocol requires an ending Carriage return character 2 Command syntax with
31. a STOP step which signals the end of a file 1 From the SYSTEM menu press MODE until you see the PROGRAM menu Press ENTER 2 The Series 922 asks you fora FILE Your 922 should already say 1 but if you have entered any values it may be different Make sure it says 1 Press ENTER 3 The display now shows STEP with a 1 flashing Use the UP DOWN keys to select 1 then press ENTER if it is not already there 4 Press the MODE key Use the UP DOWN keys to select the step type and NOTE EV1 and values Press ENTER Use Table 2 to enter the corresponding parameters EV2 will not and values The parameters appear from left to right on the table appear unless the valle At the end of each menu rather than press ENTER at the RETURN parameter to nected and AUX1 get to SYSTEM press MODE for the STEP prompt The step number automati and2 are events cally increments and flashes Press ENTER FILE STEP STEP SP1 HOUR MIN SEC EV 1 EV2 Table 2 TYPE Series 922 1 1 SETPOINT 75 0 0 1 OFF OFF ors 1 2 SETPOINT 100 0 0 25 ON OFF eee 3 SETPOINT 100 0 0 25 ON OFF 1 4 STOP NOTE Step 4 must be entered as a step 125 even though it defaults step Step 4 to a STOP 100 TE eee Step 2 A soak step Ramps from holds set 15 7 Temp F Step 1 75 to 100 F point at 75 F Initializes 50 Set Point 25 0 5 10 15 20 5 3 8 4 4 Time seconds WATLOW
32. accessories 3 After we receive your return we will enter a repair order replacement order or issue credit for material 4 In cases of manufacturing defect we will return it to you with a letter of explanation Repair costs will not exceed 50 percent of the original cost Appendix WATLOW Series 922 User s Manual 85 Shipping 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 shipper immediately Save the original shipping carton and the packing material Watlow Controls Watlow Controls is a division of Watlow Electric Manufacturing 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 Winona operation has been designing solid state electronic control devices since 1962 and has earned the reputation as an excellent supplier to Original equipment manufacturers These OEMs depend upon Watlow Controls to provide compatibly engineered controls which they can incorporate
33. an ER2 return to the ER2 parameter under the SYSTEM mode Press ENTER If the error persists refer to the Error Code list at the end of the manual to clear Range 0 40 Alarms 1 and 2 are considered nonfatal If you are in the RUN mode your program will continue to run ALMX XX appears and flashes alternately with the parameter you are presently on ENTER the CLR ALARM parameter to clear a latching alarm A non latching alarm clears itself once it falls within the alarm limits Range 1 High 1 Low 2 High 2 Low From any RETURN you can go back to SYSTEM prompt 44 WATLOW Series 922 User s Manual How To Program the Series 922 Chapter 6 SETUP Menu While in the HOLD mode press the MODE key until you see SETUP press ENTER These parameters are to setup the personality of your Series 922 Using the MODE to progress through the prompts use the UP DOWN keys to select parameters and values and press ENTER SETUP Menu Select each ACCESS number Follow that parameter sequence to enter values You must return to SYSTEM before you can continue to the next ACCESS number Graphics Key NOTE Shaded l parameters may not Figure 32 MODE Key appear on your SETUP Key Flow ENTER Key control These parameters are O UP DOWN Key dependent on how your control is configured See Pages 46 56 for At the SYSTEM prompt press to continue to SETUP cee information Press to enter the SETUP menu em ACCESS 3
34. and process Type T thermocouple and process Dual process Dual Type T thermocouple Dual RTD 0 1 RTD 0 1 and process Dual Type K thermocouple Dual Type J thermocouple Type K thermocouple and process Type J thermocouple and process Dual solid state relay Form A 0 5A with RC contact suppression Dual switched DC non isolated Process 4 20mA non isolated solid state relay Form A 0 5A with RC contact suppression None Isolated RS 423 232C compatible Isolated RS 422 Auxiliary event board Remote event alarm output board Cable Length 18 Event Output C2 C8 B2 B8 K2 K8 18 0 in 457 mm Other lengths contact factory 2 event outputs switched DC non isolated 8 event outputs switched DC non isolated 2 event outputs solid state relay Form A 0 5A with RC contact suppression 8 event outputs solid state relay Form A 0 5A with RC contact Suppression 2 event outputs solid state relay Form A 0 5A without RC contact suppression 8 event outputs solid state relay Form A 0 5A without RC contact suppression WATLOW Series 922 User s Manual Appendix T C Calibration Thermocouple Field Calibration Procedure Equipment Required e Type J K or T depending on model number Reference Compensator with reference junction at 0 C 32 F AND e Precision Millivolt Source OR e Type J K or T t
35. cooling expressed in degrees A proportional temperature band for Channel 1 or Channel 2 expressed in degrees within which a temperature controller proportioning function is active for heating Expressed in degrees Proportioning control A physical property whose value determines the response of an electronic control to given inputs Proportioning control with rate action Proportioning control with auto reset When ACCESS 1 is entered in the Series 922 the PID parameters will appear These parameters consist of Propor tional Integral auto reset and Derivative rate actions Proportioning control with auto reset and rate Thermal system element to be regulated such as time temperature relative humidity etc Displayed information which gives the operator programmer the programmed or intended process information i e intended set point intended alarm limit etc See Actual displayed data The span of temperature about the set point where time proportional control action takes place See Time proportioning control Represents a high limit to set point for Channel 1 or Channel 2 The default values are also the high limits of your input type Represents a low limit to set point for Channel 1 or Channel 2 The default values are also the low limits of your input type Anticipatory action that senses the rate of change of tempera ture and compensates to minimize overshoot Also deriva tive A therma
36. from the mean 0 C or 0 F A deviation type alarm is always a fixed degree distance positive or negative from Set Point SP If we change SP a process type alarm remains where it was originally set while a deviation type alarm will shift with SP the same number of degrees as its value The examples illustrate a plot of each alarm type Here we ve added a process alarm function to the basic graph Temp F y Process Alarm SP1 E A A A T E AT Fixed Distance from 0 Actual 0 C This graph shows a deviation alarm setting and how it shifts with a change in SP Deviation Alarm Fixed Degree digance from SP1 Temp ES E E SEE n EA New SP1 SP1 EEEE E E R Actual 0 C 64 WATLOW Series 922 User s Manual How To Use The Alarms Chapter 7 Alarms The Operating Band Now we need to set the alarm limits In doing so you ll define an operating band where you want system temperature or your controlled variable to be OK and alarm free By selecting an alarm type ALTYP and then the alarm limits AXL AXH you define the Operating Band The extreme limits of the Operating Band are defined by the 922 s high and low ranges RXL and RXH Alarm Limits You can set up alarm bands with the two available alarms Each of the two alarms has a high and a low limit point indicated by the L or H designation You specify in the Operating Data where you want A1L A1H A2L and A2H
37. ground loops disconnect the ground wire at the ground termina tion Measure the resistance from the wire to the point where it was connected The ohmmeter should read a high ohm value If you have a low ohm value across this gap there is at least one ground loop present in your system Table 7 Noise Suppression Device Ratings Also check for continuity your reading should be open If you do find conti nuity you must now begin looking for the ground loops Begin disconnecting grounds in the system one at a time checking for continuity after each discon nection When continuity reads open you have eliminated the ground loop s Also as you reconnect grounds keep making the continuity test Itis possible to reconnect a ground loop How To Eliminate Noise Use snubbers QUENCHARC to filter out noise generated by devices such as relays relay contacts solenoids motors etc A snubber is a simple filter device using a 0 1uf 600 volt non polarized capacitor in series with a 1009 1 2 watt resistor The device can be used on A C or D C circuits to effectively dampen noise at its source The general purpose Watlow snubber described above is 0804 0147 0000 For other QUENCHARC sizes contact PAKTRON P O Box 5439 Lynchburg VA 24502 Phone 804 239 6941 A Metal Oxide Varistor MOV can be used to limit voltage spikes that occur on the A C supply lines as a result of lightning strikes switching large motors
38. hex 02 and End of Text lt ETX gt hex 03 characters around the information you see above You ll learn how to do that in the pages ahead XON XOFF Protocol for RS 423A XON XOFF flow control Protocol allows a communicating device either a 922 or the host to suspend transmission of all messages from the other device and then to continue transmission when it s again ready The device that needs to suspend transmission sends the XOFF character hex 13 to stop the other device s transmitter and XON hex 11 to restart it Note that technically any character will restart the transmitter but only the XON character is not a part of any regular message that may be transferring Messages transmit according to the syntax described in the XON XOFF formats which follow for each command The XON XOFF Protocol requires a Carriage Return character hex OD at the end of every message How To Start and Stop Communicating with the Series 922 and XON XOFF Starting communication with XON XOFF Protocol is simple You just config ure your computer to agree with the Series 922 communication parameters and open its serial communication port in software Then begin to talk by transmitting a message to the Series 922 You stop communicating with XON XOFF Protocol simply by ceasing to send messages How to Use Data Communications WATLOW Series 922 9 XON XOFF Figure 5 XON XOFF Command Example 10 WATLOW Series 922 XON
39. information is entered 1 Return to the PROGRAM menu 2 Enter FILE 1 Step 4 We are going to change this step type from a STOP step to a SETPOINT step This is our second ramp Use Table 3 to enter values into the corresponding parameters 3 Once you have edited your program run it again and watch its progress FILE STEP STEP SP1 HOUR MIN SEC EV1 EV2 JS JC TYPE Table 3 1 4 SETPOINT 125 0 0 25 OFF ON Editing Your 1 5 SETPOINT 125 0 0 25 OFF ON Program 1 6 JUMPLOOP 1 2 Steps 4 7 1 7 STOP Step 6 Jumps to Step 1 and repeats program twice JC 2 125 Step 2 100 Step 3 Soaks 75 Temp F Step 1 Initializes 50 Set Point Edit Program O 10 20 30 40 50 60 70 80 90 100 Time seconds Sample Program Chapter 3 WATLOW Series 922 User s Manual 17 sample Program Adding AUTOSTART and LINKing Files The Series 922 gives you the capability to link files together The LINK step allows you to link the last step of a profile to the first step of another profile We are going to edit the program again by adding a LINK step at the end of the profile First we must create another file If you try to run your program with a LINK that goes to a nonexisting file you will receive ER2 0036 This error means no file found Follow Table 5 to add a LINK and a new FILE to your program The 922 can
40. into their products with confidence Watlow Controls resides in a 100 000 square foot marketing engineering and manufacturing facility in Winona Minnesota 86 WATLOW Series 922 User s Manual Appendix Series 922 Error Codes Alarms ER1 Error Codes and Actions 1 Internal RAM failure Contact factory 2 External RAM failure Contact factory 3 Bad battery error Contact factory 4 Channel 1 A D conversion error check sensor or contact factory 5 Channel 2 A D conversion error check sensor or contact factory 6 Ground A D conversion error contact factory 7 High reference A D conversion error contact factory 8 Channel 1 interpolation overrange Check specification for sensor input range 9 Channel 2 interpolation overrange Check specification for sensor input range 10 D A gain error Contact factory 11 Channel 1 zero error Contact factory 12 Channel 1 gain error Contact factory 14 Channel 2 zero error Contact factory 15 Channel 2 gain error Contact factory 18 Stack overflow error Contact factory NOTE If an error or alarm flashes on the display press the enter key to stop the flashing for 5 minutes To clear the alarm or error go to the system menu and press enter on the appropriate prompt Appendix ER2 Error Codes and Actions J 2 20 21 22 23 24 25 26 2 28 30 31 32 33 35 36 37 38 39 40 922 transmit buffer overflow Clear error retransm
41. lt STX gt lt space gt Data 1 lt space gt Data 2 lt ETX gt With the Command Data 1 is the Series 922 parameter in this case Alarm 1 Low A1L Data 2 is the value you want to set for that parameter in this example 500 Enter in ASCII lt STX gt lt space gt A1L lt space gt 500 lt optional carriage return gt lt ETX gt The hex string is 023D2041314C2035303003 lt STX gt Space gt A ASCII ti Figure 6 Character Space ANSI X3 28 5 0 Command Example HEX 02 3D 20 41 31 4C 20 35 30 30 03 Value Optional Carriage Return How to Use Data Communications WATLOW Series 922 13 ANSI X3 28 Figure 7 ANSI X3 28 Command Example 14 WATLOW Series 922 Response from the Series 922 lt ACK gt The hex response string is 06 You ll find the the complete list of Command arguments parameters and value limits in Table 4 Pages 17 18 ANSI X3 28 2 Command Example You need to know the Alarm 1 Low value A1L The uses a variation of the message syntax shown just below This syntax requires the protocol start of text and end of text characters 2 Command syntax with ANSI X3 28 Protocol lt STX gt lt space gt lt Data 1 gt lt ETX gt Enter in ASCII lt STX gt lt space gt lt A1L gt lt optional carriage return gt lt ETX gt The hex string will be 023F2041314C03 ls Optional Carriage aaa Return ASCII L Characters lt ETX gt H
42. menu The SYSTEM 24 hour time of day clock setting Adjustment to actual input temperature and to the temperature values the Series 922 uses for display and control Control of temperature about a set point by turning the output full ON below set point and full OFF above set point in heat mode Control system with no sensory feedback The 922 uses a closed loop Area around set point in the Series 922 where ACTUAL tempera ture is deemed safe or OK The band is defined under ACCESS 5 SPCLFUNC under the SETUP menu by Alarm Types ALTYP1 and ALTYP2 and under ACCESS 0 CALIB by Alarm High and Low Limits A1H A1L and A2H A2L WATLOW Series 922 User s Manual 79 Glossary O R fiat 80 Output Overshoot PB1C PB2C PB1H PB2H P control Parameter PD control PI control PID PID control Process Variable Programmed display data Proportional band Proportioning control R1H R2H R1L R2L Rate Rate Band RB1C RB2C WATLOW Series 922 User s Manual Select an output type Action in response to the difference between set point and process variable Action in response to difference between set point and process variable Condition whereby temperature exceeds set point due to initial power up or process changes A proportional temperature band for Channel 1 or Channel 2 expressed in degrees within which a temperature controller proportioning function is active for
43. menu that is input type units of measure range calibration offset output action alarm type lockout e Second tune the control making final PID entries e Third enter up to ten separate profiles in the PROGRAM menu 8 WATLOW Series 922 User s Manual Starting Out Chapter 1 How to Open the 922 Before going further open the Series 922 and pull the control chassis from its case Here s how The control chassis fastens to the case with a single screw located on the lower front panel See Figure 2 Turn the screw counterclockwise to loosen it Three or four strip connector plugs in the rear of the control chassis feed power and signals through the back of the casing to the triple terminal strip These plugs will let go as you pull N CAUTION When removing the Series 922 Control from its case pull firmly but gently When The front panel screw turns 90 returning the control to the case be sure you have the top up to match the plugs only Do not apply with the case The 922 will not fit in to the case upside down Always check to excessive force or see that it is oriented correctly Press the unit in firmly then turn the front panel turn the screw more screw clockwise to secure it than 90 a Figure 2 i How to Open the Series 922 How to Set the DIP Switches The Watlow Series 922 has a set of Dual In line Package DIP switches inside the control on circuit board A007 1727 The locations of the board and s
44. process temperature Percentage of load ON time relative to total cycle time ER1 Error 1 is considered a fatal error your system will shut down When the Series 922 shuts down all events will be turned off and your program will stop running When an error occurs ER1 00XX will alternately flash with the SYSTEM mode and ENTER the ER1 parameter This will clear your error unless it is a re occuring error and has not been resolved ER2 Error 2 is considered nonfatal If you are in the RUN mode your program will continue running unless it is a program error ER2 00XX appears and will flash alternately along with the parameter that you are presently on Clear an ER2 param eter under the SYSTEM mode If the error persists refer to the Error Code list on Page 90 to clear An event is an ON OFF auxiliary output relay signal You can use events based on time temperature or other process variables to trigger peripheral equipment or process These auxiliary outputs can be alarms or events EV1 and EV2 only appear when AUX1 and AUX2 EV respectively and when the two or eight output external event board is connected You can change the state of the events only in the HOLD mode Auxiliary outputs can be alarms or events These auxiliary outputs are events EV3 through EV8 only appear when the eight output external event board is connected Represents the current SYSTEM file of the Series 922 to be edited or reviewed Under the LI
45. set point without overshooting or approaching the set point too slowly Calibration Offset Adjustment You may want your system to control to a temperature other than the value coming from the input sensor If so measure the difference as much as 90 F or 50 C between that tem perature perhaps at another point in the system and the process value showing in the alphanumeric display Then enter the amount of CAL offset you want Calibration offset adds or subtracts degrees from the value of the input signal After you have tuned your Series 922 continue to Chapter 6 to learn how to Program your Series 922 for your system How To Tune and Run the Series 922 Chapter 5 WATLOW Series 922 User s Manual 37 a How To Program The Series 922 This chapter enables you to setup the Series 922 quickly and easily It explains why it s a good idea to write out your parameter values Chapter 6 also shows you flow diagrams of the programming process Write Out Your Program The Watlow Series 922 controls temperature for a specific heating and or cooling process Your setup parameter values when they re entered give the Series 922 orders for the work you want it to perform Since the amount of information in the setup is extensive we suggest that you write the value on a copy of the Master Step Chart on Page 62 This enables you to program the Series 922 quickly and without mistakes The chart makes a good record of your values Select the
46. status Dependent on output board OFF or ON RETURN Press the ENTER key to return to the SYSTEM prompt Press the MODE key to return to the FILE prompt JUMPLOOP Step Type JS Enter the step number the 922 will jump to 1 99 1 JC Enter the number of times the 922 will jump to the step indicated by JS 0 100 0 RETURN Press the ENTER key to return to the SYSTEM prompt Press the MODE key to return to the FILE prompt WAITFEOR Step Type WHR Enter the hours the 922 will wait relative to the beginning of the step 0 23 hours WMN Enter the minutes the 922 will wait relative to the beginning of the step 0 59 minutes WE Enter the state of the event input to wait for before continuing the program OPEN or CLSE W1 Enter a value to compare with the process variable of RiL R1H Channel 1 W2 Enter a value to compare with the process variable of R2L R2H Channel 2 Dependent on TYP parameter under SPCLFUNC RETURN Press the ENTER key to return to the SYSTEM prompt Press the MODE key to return to the FILE prompt AUTOSTART Step Type DAY Enter the number of days for the 922 to wait until AUTOSTART takes place 0 6days HOUR Enter the number of hours for the 922 to wait for the time of day clock before AUTOSTART takes place 0 23 hours MIN Enter the number of minutes for the 922 to wait for the time of day clock before AUTOSTART takes place 0 59 minutes RETURN Press the ENTER key to return to the SYSTE
47. the BAUD parameter ASCII and Series 922 Information nce The next page shows you ASCII and control key equivalent tables Following that you will find a detailed explanation of the Series 922 syntax and command structure for each of the two protocols How to Use Data Communications WATLOW Series 922 5 ASCII Char Table 1 ASCII Character Set Table 2 ASCII Control Characters Partial Set 6 WATLOW Series 922 ASCII Character Set Dec Hex Char Dec Hex Char Dec Hex Char Dec Hex Char 00 00 NUL 16 10 DLE 48 30 0 03 03 ETX 19 13 DC3 05 05 ENQ 21 15 NAK 37 2 53 35 5 o7 o7 BEL 23 17 EB 39 27 08 08 BS 24 18 CAN 40 28 56 38 8 09 09 HT 295 19 EM 41 29 of 39 9 10 OA LF 26 1A SUB 58 3A 11 OB VT 27 1B ESC 43 2B 59 3B 12 0C FF 28 1C FS l4 2C 13 0D CR 29 1D GS 45 2D 61 3D 14 0E SO 30 1E RS 46 2E 62 3E gt 15 OF SI 31 1F US 47 2F 63 3F RE GOA aed i TES EM SE A Dec Hex Char Dec Hex Char Dec Hex Char Dec Hex Char 64 40 80 50 P 96 60 112 70 p soa lang 67 43 C 83 53 S 99 63 c 115 73 s 68 44 D 116 74 t 69 45 E 85 55 U 117 75 70 46 F f 118 76 v 71 47 G 87 57 W 11977 w 72 48 H FEER 120 78 x 73 49 89 59 Y 105 69 i 121 79 74 4A J 90 5A Z 106 6A j 75 4B K 91 5B 107 6B k 123 7B 77 4D M 93 5D 109 6D m 125 7D 78 4E N 94 5E 110 6E n 126 7E HRe RH Ctrl F Acknowledge HAF REER STX CtriB Start of Text 02 ETX Ctrl C End of Text SEELA EO
48. the Channel 2 Reset value Cooling Not displayed if PB2C 0 Dependent on TYP parameter 0 00 5 00 repeats minute 0 00 RT2C Enter the Channel 2 Rate value Cooling Not displayed if PB2C 0 Dependent on TYP parameter 0 00 5 00 minutes 0 00 CT2C Enter the Channel 2 Cycle Time value Cooling Not displayed if PB2C 0 Dependent on output TYP amp OUT2 1 60 seconds 5 RB2C Enter the Channel 2 Rate Band value Cooling Not displayed if PB2C 0 Dependent on TYP parameter 0 denotes rate is always functional 0 7 times PB2C RETURN Prompt ACCESS 3 DIAGNOS To enter DIAGNOS parameter use ACCESS 3 and press ENTER Press the ENTER key to return to the SYSTEM prompt Press the MODE key to return to the PID prompt Description Range Default MAN1 Enter power output for Channel 1 100 to 100 MAN2 Enter power output for Channel 2 Dependent on TYP parameter 100 to 100 C2 RH Displays Channel 2 ACTUAL temperature humidity R2L to R2H RETURN NOTE Press the ENTER key to return to the SYSTEM prompt Press the MODE key to return to the DIAGNOS prompt Positive always refers to the heat output and Negative refers to the cool output How To Program the Series 922 Chapter 6 WATLOW Series 922 User s Manual 47 SETUP Menu NOTE Changing these parameter values will default other p
49. with an arrowhead in a triangle precedes an electric shock hazard CAUTION or WARNING safety statement Comments and Suggestions Your comments or 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 phone 507 454 5300 The Watlow Series 922 User s Manual and integral software are copyrighted by Watlow Winona Inc 1988 with all rights reserved Table of Contents Page O N N Contents Item Starting out with the Watlow Series 922 Chapter 1 Read Me First Packing List Put Your Control to Work Three Steps How to Open the 922 How to Set the DIP Switches Changing the Position of a DIP Switch Overview of the Three Operating Modes How to Use the Keys and Displays Chapter 2 Front Panel Information Actual and Alphanumeric Display Area Keyboard Area Learning the Series 922 Chapter 3 A Brief Overview Enter Real Time Before Entering Your Program Programming File 1 Running Your Program Editing Your Program Adding an AUTOSTART Step Type LINKing Files The WAITFOR Step Running Your Series 922 How to Install and Wire the Series 922 Chapter 4 Sensor Installation Guidelines Input Power Wiring Definitions The Dos and Don ts of Clean Input Power How to Check for Ground Loops How to Eliminate Noise Noise Suppression Devices Available from Watlow Line Filtering Configurations For Control
50. 0 VAC 115 230 VAC 115 230 VAC Input T t c T t c T t c T t c T t c T t c T t c T t c RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD Proc RTD Proc RTD Proc RTD Proc RTD Proc RTD Proc RTD Proc RTD Proc RTD Proc K t c K t c K t c K t c K t c K t c K t c K t c K t c K t c K t c K t c K t c K t c K t c K t c K t c K t c J t c J t c J t c J t c J t c J t c J t c J t c J t c J t c J t c J t c J t c J t c J t c J t c J t c J t c J t c Proc Control Mode Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Action Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable P
51. 2 will only appear when AUX2 EV and the external event board is connected to the Series 922 or EV2 will appear if T or P in the TYP parameter under the SPCLFUNC menu have been selected and an external event board is present Range OFF or ON Default Unprogrammed OFF Event OFF ON Event ON Represents the state the 6 event outputs are forced to when the How To Program the Series 922 Chapter 6 WATLOW Series 922 User s Manual 59 PROGRAM Menu SETPOINT step is executed These events only appear when the 8 output event board is connected to the Series 922 Range OFF or ON Default Unprogrammed OFF Event OFF ON Event ON mimi m lt ajA m N m 00 From RETURN you can go back to the SYSTEM prompt by pressing RETURN the ENTER key or return to FILE by pressing the MODE key One of six step types under the PROGRAM menu of the Series 922 that can be programmed as a step or file You can jump from one step to another within a file JUMPLOOP The Series 922 will jump loop to any step within your current file You cannot jump loop to another step in another file Range 1 to 99 Default 1 amp WY The number of times that the Series 922 jumps to the step that was specified by the JS step 0 Infinite number of jumps Range 0 to 100 Default 0 CH RETURN From RETURN you can go back to the SYSTEM prompt by pressing the ENTER key or return to FILE by pressing the MODE key One of si
52. 22 Figures item RS 422 Interface Pin Designations RS 423 Interface Pin Designations Series 922 General Message Syntax Example XON XOFF Command Example XON XOFF Command Example ANSI X3 28 Command Example ANSI X3 28 CommandExample item ASCII Character Set ASCII Control Characters Partial Set 2 Command Data and Responses Partial Set Command and Command Data STP Command Data 2STP Command Response Data 2MTR Command Response Data How to Use Data Communications How to Use Data Communications with the Watlow Series 922 This manual is a supplement to the Series 922 User s Manual It is for users with the data communications option use in conjunction with the Series 922 User s Manual This is expert user level material and requires previous experience with data communications Two Serial Hardware Interfaces and Two Software Protocols Depending on your units model number you may have one of two hardware interfaces 1 RS 422A for a multidrop or multiple device network up to ten devices total with 4000 network length limit Q22A XXX0 C000 or 2 RS 423A RS 232C compatible 922A XXX0 B000 for one on one com munication on a 50 network with a 922 and a host computer There are two protocols available to you both work with either interface But depending on the type of network you need you must use the correct combina tion of interface and protocol W
53. 22 How to 9 Fig 2 Output BB Wiring Dual SS Relay 32 Fig 22 Output CC Wiring SS Switch 32 Fig 23 Output FB Wiring 4 20mA SS Relay 32 Fig 24 Overview of the 922 Operating Modes 11 Fig 4 P Packing List 8 Power Wiring 28 Fig 16 Preventing Noise Installation Guidelines 23 Process Calibration 75 Process Variable Unit 4 20mA SS Relay 31 Fig 24 PROGRAM 57 Q Quick Reference 89 WATLOW Series 922 User s Manual 83 Index R Read Me First 7 Reference Compensator to Series 922 Connection Diagram 71 Fig 40 Returns 85 RTD Parameter Settings 74 Table 11 RTD Sensor Wiring Dual 29 Fig 17 RTD Process 30 Fig 18 Running Your Series 922 20 Fig 8 S Sample Program Chapter 3 14 Sensor Installation 21 29 Wiring 29 Series 922 Input and Output Overview 7 Fig 1 SETUP 45 Shipping Claims 86 Specifications 68 SS Relay Output Wiring 31 Fig 22 SS Switch Output Wiring 31 Fig 23 Steps To Put Your Control To Work 8 SYSTEM 42 System Wiring Example 35 Fig 29 T Table of Contents 3 Thermocouple Calibration 71 Thermocouple Sensor Wiring TC Process 30 Fig 19 Dual TC 31 Fig 21 Tuning 37 Reference 36 U V Vaisala sensor 21 W WAITFOR Step 19 Warranty 85 Watlow Controls 86 Where To Go From Here 11 12 20 Wiring Example 35 Fig 29 84 WATLOW Series 922 User s Manual Appendix Warranty Information The Watlow Series 922 is warrant
54. 25 in File 7 SP1 at 255 and SP2 at 50 for 1 hour 36 minutes 58 seconds with EV1 ON and EV2 through EV8 OFF would be l lt Space gt lt STP gt lt space gt lt 7 gt lt space gt lt 25 gt lt Space gt lt 1 gt lt space gt lt 255 gt lt Space gt lt 50 gt lt space gt lt 1 gt lt space gt lt 36 gt lt Space gt lt 58 gt lt space gt lt 1 gt lt Space gt lt 0 gt lt space gt lt 0 gt lt space gt lt 0 gt lt space gt lt 0 gt lt space gt lt 0 gt lt space gt lt 0 gt lt space gt lt 0 gt Table 5 STP Command r Data lt Non literal Description Step Type WAITFOR AUTOSTART STOP LINK lt Filet gt lt File gt Step cE a a ee ss ee Data6 Data 7 Data 8 Data 9 Data 10 Data 13 Data 14 Data 15 Data 16 These commands can accept an asterisk to indicate that they are not programmed 20 WATLOW Series 922 How to Use Data Communications 2 STP Command The STP command reads a given step in the Series 922 program space 99 Steps total Data returned from the unit that have a value of asterisk mean that the value is unprogrammed The syntax for this command is lt Space gt STP lt Space gt lt File gt lt Space gt lt Step gt The command will return the following information lt Step Type gt lt Space gt Data 2 lt Space gt Data 3 Data n Table 6 below shows how to interpret the response
55. 40 Series 922 Series 922 Terminal Strip Terminal Strip Channel 1 Channel 2 Voltage Current Source 2 Connect AC line voltage L1 to 17 L2 to 20 ground to 21 on the Series 922 terminal strip Jumper for correct line voltage See Chapter 4 How to Install and Wire 3 Set DIP Switch 6 ON Apply power to the 922 and allow it to warm up for 15 minutes The unit should be in the TEST mode 4 Connect DVM common to TP2 and DVM positive to TP1 on the A007 1728 or A007 1729 circuit board located on the top side behind the center chassis support This circuit board is dependent on your model number Your unit will have only one of these boards DVM should be set up for DC volts and in a range capable of displaying 6 3000 volts 5 Press the MODE key until DAS6 XXXX appears on the alphanumeric display Use the UP DOWN keys to adjust the alohanumeric display on the 922 to match the reading on the DVM Once the two readings match press the ENTER key 6 Press the MODE key until CH1Z XXXX appears on the alphanumeric display for Channel 1 CH2Z XXXX for Channel 2 ENTER OmA press ENTER Allow 10 seconds for stabilizing press the ENTER key 7 Press the MODE key until CH1G XXXX appears on the alphanumeric display for Channel 1 CH2G XXXX for Channel 2 Input 20mA press ENTER The unit is now calibrated for Channel 1 process inputs The process readings on the ACTUAL display should be at the R1H or R2H setting 8 Rem
56. 922 real time clock for its hours minutes and seconds The syntax for this command not including protocol characters is lt Space gt TI The command will return the following data lt Data 1 gt lt space gt lt Data 2 gt lt space gt lt Data 3 gt The arguments in ASCII numbers will always be Data 1 Real time hours range 0 to 23 Data 2 Real time minutes range 0 to 9 Data 3 Real time seconds range 0 to 59 How to Use Data Communications WATLOW Series 922 23 CLRF Command II EL The CLRF command clears a given file from 1 to 10 in the Series 922 program space 99 steps total This command can only be performed in the HOLD mode The syntax of the command not including protocol characters is lt Space gt CLRF lt Space gt lt File gt This command will not return an error message even though the file number may not exist NAKs and Error Codes i m When your message is not acknowledged NAK in RS 422A with ANSI X3 28 Protocol you may clear the ER2 code by reading it That is use the Command to query the ER2 parameter or scroll at the Series922 front panel in the SYSTEM menu to ER2 and press the ENTER key Then try the message again you may have made a syntax error See the error code listing in Table 3 Pages 15 16 With XON XOFF protocol and the RS 423A interface the 922 sends no feed back on commands Therefore you may want to query the status of ER 2 aft
57. BFB0 A000 922A BFB0 B000 922A BFB0 C000 Event Board A007 1732 18B2 A007 1732 18B8 A007 1732 18C2 A007 1732 18C8 A007 1732 18K2 A007 1732 18K8 Line Voltage 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC Input J t c Proc J t c Proc J t c Proc J t c Proc J t c Proc J t c Proc J t c Proc J t c Proc K t c Proc K t c Proc K t c Proc K t c Proc K t c Proc K t c Proc K t c Proc K t c Proc K t c Proc Control Mode Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Action Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Note 1 Retrofit controller requires a substitution of a 100 Ohm DIN RTD sensor Note 2 Mounting and dimensions of retrofit controller are different Verify that sufficient panel space and depth is available Series 922 Output Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual Sw dc Sw dc Dual Sw dc Sw dc Dual Sw dc Sw dc Dual 4
58. C0 A000 922A 5CC0 BO000 Watlow Controls Line Voltage 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC Input RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD RTD Proc RTD Proc RTD Proc RTD Proc RTD Proc RTD Proc RTD Proc RTD Proc RTD Proc T t c Proc T t c Proc T t c Proc T t c Proc T t c Proc T t c Proc T t c Proc T t c Proc T t c Proc Proc Proc Proc Proc Proc Proc Proc Proc Proc Proc Proc Proc Proc Proc Proc Proc Proc Proc T t c T t c T t c T t c T t c T t c T t c T t c T t c T t c Control Mode Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammab
59. Channel 2 ACTUAL temperature humidity Range R2L to R2H Default Unprogrammed From RETURN you can go back to the SYSTEM prompt by pressing the ENTER key or return to ACCESS 3 menu by pressing the MODE key In the SETUP menu ACCESS 5 must be selected to enter the SPCLFUNC parameters When ACCESS 5 is selected under the SETUP mode of the Series 922 the Special Function GPCLFUNC parameters appear Here you can select the degrees output type auxiliary and alarm types among others Accepts the sensor input and scales it to degrees Celsius Fahrenheit or Units of measure depending on the input type selected and the C F U selection made This prompt will not appear if DIP switch 2 is ON Changing this parameter defaults parameters SP1 A1L A1H and clears all files Range C F or U Default F How To Program the Series 922 Chapter 6 CT2C RB2C RETURN ACCESS 3 DIAGNOS MAN1 MAN2 C2 RH RETURN ACCESS 5 SPCLFUNC C F U WATLOW Series 922 User s Manual 53 SETUP Menu TYP OUT1 OUT2 54 WATLOW Series 922 User s Manual w C C Allows the operator to configure the unit to the type of actual process display to be shown This also affects the number of channels This parameter will not appear if DIP Switch 2 is ON Changing this parameter defaults all parameters and clears all files Range Dependent on input board type as follows T Temperat
60. DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN Retrofit F4DH CCCC 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH KKKK 01RG F4DH KKKK 01RG F4DH KKKK 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH KKKK 01RG F4DH KKKK 01RG F4DH KKKK 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH KKKK 01RG F4DH KKKK 01RG F4DH KKKK 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH KKKK 01RG F4DH KKKK 01RG F4DH KKKK 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH KKKK 01RG See Notes Below 16 6 6 16 6 16 6 6 16 6 16 16 16 6 6 16 6 16 6 16 6 16 16 16 6 16 6 16 6 16 6 16 16 16 6 16 6 16 6 16 6 16 16 16 6 16 6 16 Page 2 Series 922 922A ABB0 B000 922A ABB0 C000 922A ACC0 A000 922A ACC0 B000 922A ACC0 C000 922A AFB0 A000 922A AFB0 B000 922A AFB0 C000 922A BBB0 A000 922A BBB0 B000 922A BBB0 C000 922A BCC0 A000 922A BCC0 B000 922A BCC0 C000 922A
61. EX i Value 92 3F 20 4131 4C 03 First response from the Series 922 lt ACK gt The lt ACK gt hex response string is 06 Your computer s confirming response lt EOT gt The lt EOT gt response hex string is 04 Second response from the Series 922 lt STX gt lt current A1L value gt lt carriage return gt lt ETX gt The hex string is 023530302003 aia ASCII Characters li li igi am Valu 02 35 30 L Your computer s next response lt ACK gt or lt NAK gt if the message needs to be repeated The hex string is 06 or 15 Final response from the Series 922 lt EOT gt The hex string is 04 How to Use Data Communications Data 1 Respns information ACTUAL Actual process value Actual process value Comments Between R1L and RIH ACTUAL Between R2L and R2H Cleared when alarm is read ODAN A2L occurring AUX1 is an Alarm Output AUX1 is an Event Output AUX2 is an Alarm Output AUX2 is an Event Output All DIP Switches ON DIP Switch 1 OFF DIP Switch 1 2 OFF DIP Switch 1 3 OFF DIP Switch 1 4 OFF DIP Switch 1 5 OFF DIP Switch 1 6 OFF Closed external event status Open external event status Dual RTD RTD Process T C Process Dual Process Dual T C Dual RTD 0 1 0 1 RTD Process Q A m lt Cleared when key is read O c Heat Cool Cool Heat HOLD mode RUN mode T H T T T P T P P p Finds number of steps in a
62. H is set to 0 Range 0 00 to 5 00 minutes Default 0 00 RTIH Nr The Channel 1 heating cycle time usually expressed in seconds for a control ler to complete one ON OFF cycle Time between successive turn ons This parameter will not appear if Your Series 922 has a 4 20mA output and OUT1 under the SPCLFUNC menu is set to HTCL or PB1H is set to 0 Range 1 to 60 seconds Default 5 f CT1H A thermal control band for Channel 1 heating that defines where the rate derivative function begins This band is in multiples of the heat proportional band This parameter will not appear if PB1H is set to 0 Range 0 to 7 times the PB1H 0 denotes rate is always functional Default 0 RB1H 50 WATLOW Series 922 User s Manual How To Program the Series 922 Chapter 6 SETUP Menu The area for Channel 1 where no heating or cooling takes place ina heat cool proportional control Range 36 to 36 F 20 to 20 C 20 to 20 Units 3 6 F 2 0 to 2 0 C 2 0 to 2 0 Units U UJ Default 0 PBIC A temperature band expressed in degrees within which a temperature controller proportioning function is active for Channel 1 cooling Range 0 to 900 F 0 to 500 C 0 to 500 Units 0 0 to 90 0 F 0 0 to 50 0 C 0 0 to 50 0 Units Default 45 F 25 C 25 Units 4 5 F 2 5 C 2 5 Units RSC Reset integral cooling control action for Channel 1 that automatically eliminates offset or droop between s
63. IP Switch 1 before you begin programming your control after installation With DIP Switch 1 OFF the 922 saves your program whenever power is removed warm start With DIP Switch 1 ON the 922 will clear its memory of all programmed information whenever power is removed substituting default values cold start 12 WATLOW Series 922 User s Manual How to Use Keys and Displays Chapter 2 Actual and Alphanumeric Display Area Keys Displays F LED Indicates the value in the ACTUAL display is ACTUAL Display temperature in degrees Shows the actual value Fahrenheit of the process variable Peer ee we When both C and F for Channel 1 in oe en a i LEDs are OFF the four digits ee EE 922 iS displaying Units PVUs C LED g Indicates the value in i the ACTUAL display is C O temperature in degrees a Celsius Al h z Di Figure 6 S Prenn tari aes Actual and Alphanu Shows entry prompts meic the parameter values in Display alohanumerics and Front Panel Channel 2 ACTUAL information Keyboard Area vane DOWN Key Acts opposite the UP key Decreases the Figure 7 value in the alphanu Keyboard Front meric display A light Panel Information touch decreases the value by one digit Hold MODE Key the key down to de RUN HOLD Key crease the displayed value at a rapid rate This key steps the Series 922 in sequence from prompt to prompt Main menu rons RUN MODE a W Jor ENTER HOLD EATE 922 D
64. LAT alarm value is NLAT your alarms are non latching and will clear automatically when the ACTUAL display value returns to within the normal operating band If LAT LAT the alarms are latching and must be cleared Alarm conditions can be cleared by pressing the ENTER key while in the RUN mode or in the CLR ALARM parameter fe SYSTEM FILE FILE a RUN Menu k One of the three step types will be displayed depending on the type of step PROGRAMmed JUMPLOOP STOP and LINK step types are immediate and will not be visible F 88 WATLOW Series 922 User s Manual Appendix Series 922 Quick Reference SYSTEM PROGRAM SETUP Main Menu To SYSTEM Menu To PROGRAM Menu To SETUP Menu Ng SYSTEM Menu RETURN To SYSTEM A aa PROGRAM SETPOINT i a ep Re N J HOU To SYSTEM i I i S E a a xe gt x x x gt x x gt 5x ee x PROGRAM Menu STOP LINK RETURN FILE RETURN 2 WATLOW Series 922 User s Manual 89 90 WATLOW Series 922 User s Manual Appendix Appendix WATLOW Series 922 User s Manual 91 Watlow Series 922 User s Manual Watlow Controls 1241 Bundy Blvd P O Box 5580 Winona MN 55987 5580 Phone 507 454 5300 Fax 507 452 4507 How fo Use Daia Communications with the Watlow m9 A Srjes
65. M Key Flow 42 The next pages will show you each of the Series 922 menus and their prompts and values Each section SYSTEM SETUP and PROGRAM has a menu graphic with a table of values followed by prompt definitions Don t write in the tables and charts here but make copies to document your control Prompt definitions are also listed in the glossary Programming in General Programming the Series 922 is easy as 1 2 3 1 Use the MODE key to select the alphanumeric display prompt you want 2 Use the UP DOWN keys to select data or prompts in the alphanumeric display 3 Press ENTER SYSTEM Menu The SYSTEM mode has the capability to generate a non ramping set point and manipulate events You can also clear alarms and error codes from this menu Step through the SYSTEM menu using the key flow diagram and table below Graphics Key MODE Key ENTER Key UP DOWN Key SYSTEM Press to enter SYSTEM menu After selecting a value with the keys press Continue to the next parameter by pressing RETURN To SYSTEM WATLOW Series 922 User s Manual At any RETURN you can press to return to SYSTEM or press to return to the first parameter How To Program the Series 922 Chapter 6 Table 8 SYSTEM Prompts and SYSTE M Men u Description Make photocopies keep original clean SYSTEM Prompt Description Default Your Settings SP1 Monitor Enter CH 1 Fixed Set Point value TEMP RiL and RIH
66. M prompt Press the MODE key to return to the FILE prompt STOP Step Type STOP Press ENTER to display the last step of the program RETURN Press the ENTER key to return to the SYSTEM prompt Press the MODE key to return to the FILE prompt LINK Step Type FILE The current system file will always link to Step 1 in the file specified 1 10 1 RETURN Press the ENTER key to return to the SYSTEM prompt Press the MODE key to return to the FILE prompt WATLOW Series 922 User s Manual How To Program the Series 922 Chapter 6 PROGRAM Menu Shaded parameters may not appear on your control They are dependent on your control configuration One of three main level operating menus From the SETUP menu Program you can enter or view step type program loops wait for conditions set points auxiliary event outputs ON OFF and step duration FILE Represents the current SYSTEM file of the Series 922 to be edited or reviewed Range 1 to 10 files Default 1 Represents the current step of a file of the Series 922 to be edited or C reviewed Range 1 to 99 steps Default 1 m U One of six step types under the PROGRAM menu of the Series 922 SETPOINT Can be programmed as a file or a step to achieve or maintain a set point Represents the temperature that the system will try to achieve on Channel 1 in the amount of time given This will be done l
67. M prompt by pressing the ENTER key or return to ACCESS 0 menu by pressing the MODE key ACCESS 1 In the SETUP menu ACCESS 1 must be selected to enter the PID parameters When ACCESS 1 is entered under the SETUP menu of the Series 922 the PID parameters will appear These parameters consist of Proportional CH1 Integral auto reset and Derivative rate actions Choose between CH1 or CH2 Channel 1 Channel 2 If T or P have been entered in the TYP parameter under the SPCLFUNC menu Channel 2 will not appear Range CH1 CH2 Default CH1 A proportional temperature band expressed in degrees within which a temperature controller proportioning function is active for Channel 1 heating Expressed in degrees Range 0 to 900 F 0 to 500 C 0 to 500 Units 0 0 to 90 0 F 0 0 to 50 0 C 0 0 to 50 0 Units Default 45 F 25 C 25 Units 4 5 F 2 5 C 2 5 Units PB1H A reset integral heating control action for Channel 1 that automatically eliminates offset or droop between set point and actual process tempera ture in a proportional control Expressed by repeats per minute This parame ter will not appear if PB1H is set to 0 Range 0 00 to 5 00 repeats minute Default 0 00 RSH The rate derivative heating function for Channel 1 of the Series 922 The rate is determined by how fast the error being corrected is increasing Ex pressed in minutes This parameter will not appear if PB1
68. MODE One of six step types under the PROGRAM menu of the Series 922 that allows you to link one file to another Enter the number of the file that you want to link to from here Range 1 to 10 Default 1 From RETURN you can go back to the SYSTEM prompt by pressing the ENTER key or return to FILE by pressing MODE How To Program the Series 922 Chapter 6 WATLOW Series 922 User s Manual 61 VERIGI Rig Chart 1 Master Step chart 62 Step Type SETPOINT HR MN SEC Make photocopies keep original clean EV1 Events ON or OFF EV2 EV3 EV4 EV5 EV6 EV7 EV8 JUMPLOOP WAITFOR WHR WMN AUTOSTART DAY HR MN STOP LINK Step Type SETPOINT To FILE EV 1 Events ON or OFF EV2 EV3 EV4 EV5 EV6 EV7 EV8 JUMPLOOP WAITFOR WHR WMN AUTOSTART DAY HR MN STOP LINK Step Type SETPOINT To FILE EV 1 Events ON or OFF EV2 EV3 EV4 EV5 EV6 EV7 EV8 JUMPLOOP WAITFOR WHR WMN AUTOSTART DAY HR MN STOP LINK To FILE Values EV1 Events ON or OFF EV2 EV3 EV4 EV5 EV6 EV7 EV8 JUMPLOOP WAITFOR WHR WMN AUTOSTART DAY HR
69. NK parameter FILE stands for the file that you want to link to The Guaranteed Soak parameter guarantees that the actual temperature of Channel 1 is being controlled within a window around set point If exceeded the step time clock will stop until the actual temperature is within the soak window The HOUR parameter has three meanings depending upon which menu you are in PROGRAM menu The number of hours in combination with the MIN and SEC parameters that equal the total step time to achieve the temperature Under the AUTOSTART step type the hours that the 922 will wait for the time of day clock before AUTOSTART takes place SETUP menu Represents the SYSTEM 24 hour time of day clock Midnight 0 hours Appendix Hunting Hysterisis Input Integral Isolation JC JS JUMPLOOP LAT LINK LOCK MIN Offset ON OFF control Open loop Operating band Appendix Oscillation or fluctuation of process temperature between set point and process variable Glossary H O In ON OFF control the temperature change necessary to change the output from full ON to full OFF Process variable information being supplied to the instrument Control action that automatically eliminates offset or droop between set point and actual process temperature Also reset Electrical separation of sensor from high voltage circuitry Allows for application of grounded or ungrounded sensing ele
70. NTER key or return to SPCLFUNC by pressing the MODE key 56 WATLOW Series 922 User s Manual How To Program the Series 922 Chapter 6 PROGRAM Menu PROGRAM Menu From the Program menu you can create your files There can be up to ten profiles consisting of a total of 99 steps You can only choose one step type per step Graphics Key MODE REY NOTE Shaded ENTER Key parameters may not UP DOWN Key appear on your control These parameters are dependent on how your control is config ured See Pages 58 61 for more informa NOTE The Series 922 leaves the factory programmed for a warm start tion STOP steps will appear as a default until you program your 922 Figure 33 PROGRAM Key Flow Tele ie ot the SYSTEM prompt press to continue to PROGRAM mode Press to enter the PROGRAM menu Use the 3 to select one of the six step types Follow that menu for your STEP AUTOSTART STOP LINK FILE IN _3 i U NO RETURN z x 5 gt 5 gt gt gt gt gt RETURN RETURN HOUR S an h AN OO Oe IANN JOO RETURN Press to return to SYSTEM or press to return to the file prompt To SYSTEM How To Program the Series 922 Chapter 6 WATLOW Series 922 User s Manual 57 Table 10 PROGRAM Prompts and Description PROGRAM Menu Make photocopies keep original clean PROGRAM
71. Note 16 Retrofit communications are different consult specifications Note 17 Verify retrofit input range matches application Watlow Controls 7 19 2004 Set Point Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Mounting 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN 1 4 DIN Retrofit F4DH KKKK 01RG F4DH KKKK 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH KKKK 01RG F4DH KKKK 01RG F4DH KKKK 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH CCCC 01RG F4DH FKFK 01RG F4DH FKFK 01RG F4DH FKFK 01RG Open Bd Open Bd Open Bd Open Bd Open Bd Open Bd A007 1732 F4B2 A007 1732 F4B8 A007 1732 F4C2 A007 1732 F4C8 A007 1732 F4K2 A007 1732 F4K8 See Notes Below 6 16 6 16 16 16 6 6 16 6 16 6 6 16 6 16 16 16 6 6 16 6 16 Series 922 User s Manual 88 Ac TUAL pae PROGRAM n T pm an wen a W oll xcs L E T is i oe A N T J H a E SERIES 2 Microprocessor Based Ramping Control a LOW Watlow Controls Watlow Controls 1241 Bundy Blvd P O Box 5580 Winona MN 55987 5580 Phone 507 454 5300 Fax 507 452 4507 W922 XUMN Rev C00 10 00 April 1996 _ Made in the
72. Output AUX2 is an Event Output CALX 90 F 90 F Set Calibration offset 50 C 50 C 50 Units 50 Units 50 RH 50 RH Display F Display C Display Units PVUs CLRF Clears a designated file from memory Set Cycle Time Cool Set Cycle Time Heat DBX 36 F 36 F Set Dead Band 20 C 20 C 20 Units 20 Units 20 RH 20 RH EV1 Set EV1 OFF Set EV1 ON EV2 Set EV2 OFF Set EV2 ON EV3 0 1 Set EV1 OFF Set EV2 ON How to Use Data Communications Set altitude for humidity Commands J NOTE An X means that it applies to either Channel 1 or Channel 2 Table 4 Command and Command Data See Table 6 for more Com mand Data When the 922 RTD input Is 0 1 these parameters will have an_ mplled decimal point to the left of the least significant digit WATLOW Series 922 17 Data 2 Low Limit High Limit Code Function Set EV1 OFF Set EV2 ON Set EV1 OFF Set EV2 ON 1 Set EV1 OFF Set EV2 ON Set EV1 OFF Set EV2 ON 0 Set EV1 OFF 1 Set EV2 ON Set Guaranteed Soak Commands Data 1 Table 4 Continued When the 922 RTD input is 0 1 these parameters will have an Implied decimal point to the left of the least significant digit 18 F 10 C 10 Units 10 RH HOLD a Holds Program 1 Set Latched alarms 0 Set non latched alarms LOCK Lock front panel ia i PBXC 500 C 500 Units 500 RH 900 F Set Prop
73. RG F4DH KKKK 01RG F4DH KKKK 01RG F4DH CCCC 01RG F4DH CCCC 01RG See Notes Below 6 6 16 6 16 16 16 6 6 16 6 16 6 6 16 6 16 16 16 6 6 16 6 16 6 16 6 16 16 16 6 16 6 16 6 16 6 16 16 16 6 16 6 16 6 16 6 16 Page 1 Series 922 922A 5CC0 C000 922A 5FBO A000 922A 5FBO B000 922A 5FB0 C000 922A 6BB0 A000 922A 6BB0 B000 922A 6BB0 C000 922A 6CC0 A000 922A 6CC0 B000 922A 6CC0 C000 922A 6FBO A000 922A 6FBO B000 922A 6FB0 CO00 922A 7BB0 A000 922A 7BB0 B000 922A 7BB0 C000 922A 7CC0 A000 922A 7CC0 BO000 922A 7CC0 C000 922A 7FB0 A000 922A 7FB0 B000 922A 7FB0 C000 922A 8BB0 A000 922A 8BB0 B000 922A 8BB0 C000 922A 8CC0 A000 922A 8CC0 B000 922A 8CC0 C000 922A 8FBO0 A000 922A 8FBO0 B000 922A 8FB0 CO000 922A 9BB0 A000 922A 9BB0 B000 922A 9BB0 C000 922A 9CC0 A000 922A 9CC0 B000 922A 9CC0 C000 922A 9FBO0 A000 922A 9FBO B000 922A 9FB0 C000 922A ABBO0 A000 Watlow Controls Line Voltage 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 230 VAC 115 23
74. Represents the current SYSTEM file step of the Series 922 to be edited or reviewed One of six step types under the PROGRAM menu of the Series 922 that will indicate the end of any file WATLOW Series 922 User s Manual 81 Glossary S Z 82 SYSTEM Switching sensitivity Thermal System Thermocouple Thermocouple break protection Three mode control TI Time proportioning control Triac WAITFOR Warm start WE WHR WMN W1 W2 Zero switching WATLOW Series 922 User s Manual One of three main level operating parameters From the SYSTEM menu you can generate a non ramping set point fixed manipulate Events 1 through 8 clear error codes and latching alarms and monitor Channel 2 s actual temperature and the external input In ON OFF controls the temperature change necessary to change the output form full ON to full OFF 8 or F in the Series 922 A regulated environment consisting of a heat source heat transfer medium sensing device and a process variable control instrument Temperature sensing device that is constructed of two dissimi lar metals wherein a measurable predictable voltage is generated corresponding to temperature Fail safe operation that assures output shutdown upon an open thermocouple condition Proportioning control with reset and rate Represents the Real Time hours and minutes of the Series 922 s system Action which varies the amount
75. S 422A or RS 423A RS 232C compatible serial interface The serial interface is the key The IBM PC with an RS 232C serial output card for instance will talk to a single RS 423A equipped Series 922 Fora multiple 922 network with the same PC you ll need an RS 232 RS 422 converter to act as a bus or multiple connection point Watlow recommends the Burr Brown LDM 422 for that purpose The address is Burr Brown Inc 1141 West Grand Rd Suite 131 Tucson AZ 85705 Phone 602 624 2434 Fax 602 623 8965 How to Use Data Communications Connecting the Control and the Computer Remove power from both the Series 922 and your computer before connecting them together This prevents noise or static interference entering the data communication lines As soon as you connect the data communications line s you re ready to apply power to your system Communications Software lf you want to write your own communications software for the Series 922 or edit the program you will be able to do that with the information provided in this chapter Series 922 Communication Parameters seaman celine eter creme eee a To communicate with the Series 922 set your computer for these parameters Baud Rate 1200 2400 4800 9600 choose one Parity Odd Data Bits 7 Start Bits 1 Stop Bits 1 All the parameters listed above are factory selected except the Baud Rate parameter Baud Rate is found under the SPCLFUNC menu in
76. SP1 or SP2 Set Point temperature The user selectable scaling factors are 1 2 5 or 10mV per least significant digit If you don t have a chart recorder available you can still plot the time vs temperature system response Record the 922 s ACTUAL display readings on graph paper with an x y axis to accomplish the same thing WATLOW Series 922 User s Manual How To Tune and Run the Series 922 Chapter 5 For optimum control performance tune the 922 to the thermal system The tuning settings here are meant for a broad spectrum of applications your system may have somewhat different requirements Refer to the key flow charts diagrams and definitions on Pages 42 61 for prompt location and description Repeat this tuning procedure for both Channel 1 and 2 NOTE When tuning in the Heat mode use PID prompts followed by H When tuning in the Cool mode use PID prompts followed by C 1 Apply power to the Series 922 and enter a set point in the SYSTEM menu Next go into the SETUP mode and enter ACCESS 1 the SPCLFUNC Special Function parameter Using the MODE UP DOWN and ENTER keys set the Operating Parameters initially Proportional Band PB_H C 0 Reset RS_H C 0 00 Rate RT_H C 0 00 Cycle Time CT_H C 5 Under ACCESS 0 enter CAL_ 0 Allow actual process temperature to stabilize at or near Set Point SP The ACTUAL display will indicate when the load is stabilized near setpoint Proportional Ba
77. Series 922 User s Manual Sample Program Chapter 3 Running Your Program Sample Program 1 Return to SYSTEM using the ENTER key at the RETURN prompt Press the RUN HOLD key 2 The 922 asks what FILE to run Enter 1 if it is not already entered 3 The 922 asks what step you would like to start on Again press 1 if it is not already there and press ENTER The 922 quickly shows the step type and jumps to Step 1 the RUN LED is lit After each step is completed the next step the 922 performs appears You may step through the parameters to see what the step type is and what the parameters are set at by pressing the MODE key The Time Remaining is also displayed at the end of the menu Once the Time Remaining reaches 00 00 00 it shows what step the profile has progressed to Editing Your Program Now let s try editing the program by expanding it with another ramp and soak step and adding a jump loop We ll jump to Step 1 and repeat Steps 1 through 6 two more times This is accomplished by programming a Jump Step JS 1 and Jump Count JC 2 This means that once the 922 goes through the program and reaches Step 6 it jumps back to Step 1 and repeats the program two more times By this time you should understand the basic concept of the Series 922 and be able to get around on your own Remember that the MODE key takes you through the menus Use the UP DOWN keys to select parameters values and step types Press ENTER and your
78. T Ctri D End of Transmission 04 sa eee CR CtriM Carriage Return DC1 CtrlQ XON DC3 Ctri S XOFF 19 13 How to Use Data Communications Series 922 General Message Syntax As soon as you link the devices you ll be able to talk to the Series 922 using ASCII characters The Series 922 will respond to any parameter showing in the alphanumeric display plus some others The control will respond to either upper or lower case ASCII characters from your computer keyboard Both protocol interface combinations will respond to the general syntax providing the commands or queries are correctly transmitted However the ANSI X3 28 Protocol requires beginning and ending characters and the XON XOFF Protocol requires ending characters We ll look at those shortly Message Syntax Messages from your computer to the Series 922 must take this general form All commands do not require the full number of data fields Command lt Space gt Data 1 lt Space gt Data 2 lt Space gt Data 3 Data N Command is a character set to which the Series 922 will respond The brack ets lt gt enclose a non literal description Space is simply a delimiter an ASCII space character Hex 20 Data Fields are parameters and values specific to a command the number of possible data fields depends on the particular command you use Data 1 is here abbreviated Data 1 Data 2 is Data 2 and so on In the syntax explanations ahea
79. TYP See your TYP parameter setting R2H Enter the Range High value for Channel 2 Dependent on input selection Not displayed if DIP Switch 2 is ON Dependent on TYP See your TYP parameter setting AUX1 Enter the Auxiliary Output 1 AUX1 AL Alarm output AL AUX 1 EV Event output Not displayed if DIP Switch 2 is ON Dependent on event board AUX2 Enter the Auxiliary Output 2 AUX2 AL Alarm output AL AUX2 EV Event output Not displayed if DIP Switch 2 is ON Dependent on TYP amp event board ALTYP1 Enter Alarm Type 1 ALTYP1 P Process alarm P ALTYP1 D Deviation alarm Not displayed if DIP Switch 2 is ON Dependent on AUX1 amp event board ALTYP2 Enter Alarm Type 2 ALTYP2 P Process alarm P ALTYP2 D Deviation alarm Not displayed if DIP Switch 2 is ON Dependent on AUX2 TYP amp event board LAT Enter the Alarm function type LAT or NLAT NLAT Not displayed if DIP Switch 2 is ON RTD Enter input gain of RTD input channels for different curves JIS or DIN JIS Not displayed if DIP Switch 2 is ON Dependent on input ALT Set altitude in feet for humidity mode 0 2500 5000 0 Not displayed if DIP Switch 2 is ON Dependent on input GS Enter the Guaranteed Soak 0 50 C 0 ANLG Enter parameter the Analog retransmit signal represents C1 C2 SP1 SP2 Ct SCALE Enter millivolts to scale analog retransmit output 1 2 5 10 1 COM Select between XON XOFF or ANSI X3 28 protocol XON or STX STX Dependent on communications capability BAUD Select baud
80. U S A Supersedes W922 MA50 9246 les amp Printed on Recycled Paper Use The Manual First This manual will make your Job easier Reading it and applying the information is a good way to become familiar with the Series 922 Here s an overview Starting Out Introduction Chapter 1 Front Panel Keys and Displays Chapter 2 Running a Program Sample Program Chapter 3 Install Wire Installation and Wiring Chapter 4 Tune How to Tune Chapter 5 Programming How to Program Chapter 6 Alarms How to Use Alarms Chapter 7 Appendix Specifications Glossary Calibration Warranty Series 922 error codes and prompts see Pages 87 89 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 symbol exclamation point in a triangle precedes a general CAUTION or WARNING statement The symbol a lighting bolt
81. Using This Retrofit Guide This document is best viewed with Adobe Reader 6 0 To obtain the latest version of Adobe Reader visit http www adobe com Specification sheets on Watlow product may be obtained at http www watlow com literature specsheets User Manuals on Watlow product may be obtained at http www watlow com literature prodtechinfo Additional information on other Watlow products may be obtained by visiting http www watlow com To locate a controller search on the part number such as 965A 1CDO O0ORG Use the Help feature in Adobe Reader on how to search documents If there are multiple listings then the retrofit 1s conditional upon field use Select the appropriate selection The User s Manual is included at the bottom of this document when available Before selecting a replacement controller 1 Know the application e Temperature range e Sensor type e Is the sensor upgradable if required e Additional input requirements remote set points secondary sensor or events e Output required control alarm event e Is the power switching device upgradable e Operating voltage of controller e Mounting requirements panel space e Is asafety limit device required 2 Know the product e Inputs type and number of Control function direct cool or reverse heat Outputs switched DC SSR or mechanical relay Communication requirements Which control features are required cascade slidewire differentia
82. XH 17 D Data Bits 5 Data Link Escape DLE 13 Data Rules 7 DBX 17 Device Address 12 DIP 15 How to Use Data Communications index E El 15 End of Text ETX 9 ER1 16 ER2 16 EV1 18 EV2 18 EV3 18 EV4 18 EV5 18 EV6 18 EV7 18 EV8 18 Example Format 8 F Flow Control 9 FST 15 FST Command 19 G GS 18 H HOLD 18 HOLD Command 19 How to Start and Stop Communicating with the Series 922 and XON XOFF 9 How to Use Data Communications with the Watlow Series 922 3 j Identification Number 12 IN 15 Index 25 Interface Pinouts RS 422A Fig 1 4 RS 423A Fig 2 4 K KEY 15 L LAT 18 LOCK 18 WATLOW Series 922 25 Index M MDL 15 Message Syntax 7 MTR 15 MTR Command 22 MTR command Response Data Table 7 22 Multidrop 3 N NAKs and Error Codes 24 Network connections 4 O Other or Commands 19 OUTX 15 p Parity 5 PBXC 17 PBXH 17 Protocol RS 423A 9 ANSI X3 28 12 13 R RBXC 17 RBXH 17 RH 22 RM 22 RS 422A 3 4 RS 422A Interface Pinouts Fig 1 4 RS 423A 3 4 RS 423A Interface Pinouts RS 232C Compatible Fig 2 4 RSUM 18 RSUM Command 19 RSXC 17 RSXH 17 RTXC 17 RTXH 17 RUN 15 RXH 17 RXL 17 26 WATLOW Series 922 S SCAL 18 Series 922 Communication Parameters 5 Series 922 General Message Syntax 7 Series 922 General Message Syntax
83. XON XOFF Protocol lt space gt Data 1 lt CR gt Enter in ASCII lt space gt A1L lt CR gt The hex string will be 3F2041314C0D Space A 1 ASCII L Figure 5 Characters CR XON XOFF er id Command Example HEX Value 3F 20 41 31 4C OD The value of A1L will be between R1L Range Low and R1H Range High say 500 Response from the Series 922 lt XOFF gt lt XON gt lt current value of AiL gt lt CR gt The hex response string is 3530300D 5 ASCII 0 Characters 0 F ii Value 35 30 30 OD How to Use Data Communications WATLOW Series 922 11 ANSI X3 28 12 WATLOW Series 922 ANSI X3 28 Protocol The ANSI X3 28 Protocol provides high quality communications by requiring a response to every message With a multiple device or multidrop network this protocol prevents confusion among the separate devices Furthermore if noise occurs somewhere in the system no parameter will change because noise can t comply with the protocol By placing messages inside a protocol envelope the messages are protected In the examples to come you ll see how this works The ANSI X3 28 Protocol requires STX characters at the beginning of a message and ETX characters at the end Device Address tS If you are using the ANSI X3 28 Protocol you must have a device address identification number A Watlow RS 422A multidrop network can handle up to 10 devices with this protocol Set the addre
84. age wires Also keep all controller wiring separate from other nearby wiring Physical separation is extremely effective A 12 inch minimum separation is usually effective Do use common mode differential mode or a combination of the two filters wherever power may have electrical interferences Do cross other wiring at 90 angles whenever crossing lines is unavoidable Do have a computer ground line that is separate from all other ground lines This computer ground line should ideally terminate at the ground rod where the electrical service is grounded Don t connect computer ground to safety ground or any other ground points in the electrical system except at the ground rod Don t mount relays or switching devices close to a microprocessor control Don t run wires carrying line voltage with signal wires Sensor communications or other low power lines going to the control Don t use conduit for computer ground Don t have phase angle fired devices in the same electrical enclosure or on the same power line with the control Don t connect ground to the control case if the control is mounted in a grounded enclosure prevent ground loops Don t fasten common mode line filters or filters with metal cases to metal that is at ground potential This prevents ground loops and maintains filter effectiveness How to Install and Wire Chapter 4 WATLOW Series 922 User s Manual 23 Wiring Guide How to Check for Ground Loops To check for
85. ak step e Step 7 50 Stop step 25 0 00 0 30 1 00 1 30 2 00 2 30 3 00 Minutes Seconds WATLOW Series 922 User s Manual Sample Program Chapter 3 The WAITFOR Step Sample Program The last step type we will work with is the WAITFOR step This is a test step lt compares a specified temperature with the process temperature or a speci fied event state with the event input before continuing the program It can also wait for a programmed time to elapse before continuing on with the program After the test is successful the program continues with the next sequential step Events cannot be programmed in this step they maintain their previous State Return to PROGRAM and enter FILE 5 Add a WAITFOR step to the end of that file FILE STEP STEP W1 WHR WMN WE Table 6 TYPE The WAITFOR Step 5 6 WAITFOR 5 7 STOP WHR WMN WE and W1 are unprogrammed To program a WAITFOR time enter your values for WHR and WMN The programmed WAITFOR time waits until the specified amount of time has elapsed WAITFOR time WHR WMN WE and Channel 1 process variable W1 can be programmed simultaneously Each of these Wait For conditions must be met before the program will con tinue Once a WAITFOR condition is satisfied it latches and does not have to be performed again Run your program from FILE 5 STEP 1 If you do not want to go through the entire program you can START your program a
86. also automatically start your program or a step on a specified day and time When you use an AUTOSTART in your program it stops your program and waits for the day and time you entered under the AUTOSTART step type The Series 922 then executes the next sequential step AUTOSTART allows you to wait up to seven days in the future day 0 is always the current day The days accumulated increases by 1 every time the Real Time clock goes from 23 59 to 00 00 If 0 is programmed for DAY and the Real Time clock is greater than the Table 5 programmed AUTOSTART time the AUTOSTART waits 6 days along with the LINKing to Another File with programmed time AUTOSTART FILE STEP STEP TYPE SP1 DAY HOUR MIN SEC EV1 EV2 FILE 1 LINK 5 AUTOSTART 0 current current 5 SETPOINT 175 0 0 50 ON ON SETPOINT 175 SETPOINT 100 SETPOINT 100 SETPOINT 19 STOP O 1 15 ON OFF O 10 ON OFF O 25 OFF OFF O OIOJ O O1 O1 01 01 01 O1 01 NIO O1 amp Go PO O Run your program again beginning at FILE 1 STEP 8 Step through the menu to see what step type you are on and your time remaining Watch to see what happens at the end of File 1 The AUTOSTART waits for approximately 5 minutes into the future before continuing with File 5 Profile 5 175 Step 2 Ramps to 175 Step 4 Soak step 150 125 100 Autostart step Step 6 Temp F Step 5 Ramps to 75 F So
87. ameter selects a process or deviation alarm Process Range RiL to R1H R1L 10 to R1H 10 Process Default R1L R1L 10 Deviation Range R1H or 555 C 55 5 C 999 F U 99 9 F U to 0 Deviation Default Low end value A1L Represents the high process alarm or high deviation alarm for Output 2 of the Series 922 Displayed only when AUX2 AL and an external event board is connected ALTYP2 parameter selects a process or deviation alarm This parameter will not appear if TYP under the SPCLFUNC menu is set to T Temperature for Channel 1 only or P Process for Channel 1 only Process Range R2L to R2H R2L 10 to R2H 10 Process Default R2H R2H 10 Deviation Range 0 to 999 F 0 to 555 C Deviation Default 999 555 A2H How To Program the Series 922 Chapter 6 WATLOW Series 922 User s Manual 49 SETUP Menu The low process alarm or low deviation alarm for Output 2 of the Series 922 Displayed only when AUX2 AL and an external event board is present ALTYP2 parameter selects a process or deviation alarm This parameter will not appear if TYP under the SPCLFUNC menu is set to T Temperature for Channel 1 only or P Process for Channel 1 only Process Range R2L to R2H R2L 10 to R2H 10 Process Default R2L R2L 10 Deviation Range R2H or 555 C 55 5 C 999 F U 99 9 F U to 0 Deviation Default Low end value A2L RETURN From RETURN you can go back to the SYSTE
88. arameters and clear all files See Page 53 amp 54 for details Table 9 continued Make photocopies keep original clean Prompt Description Range Default Your Settings ACCESS 5 SPCLFUNC To enter SPCLFUNC parameter use ACCESS 5 and press ENTER C F U Enter the unit of measure code Celcius Fahrenheit Units C F U F Not displayed if DIP Switch 2 is ON TYP Enter actual process display to be shown Temperature Process Humidity Dual T C T Tord TT Dual RTD TTorTHorT TT Dual RTD 0 1 TTorTHorT TT 0 1 RTD Process TPorTVorT EP T C Process TPorTVorT TP RTD Process TPorTVorT TP Dual Process PPorPVorP PP Not displayed if DIP Switch 2 is ON OUT1 Enter the control output for Channel 1 Outputs 1 and 2 Heat PID Cool PID HTCL HTCL Cool PID Heat PID CLHT Not displayed if DIP Switch 2 is ON OUT2 Enter the control output for Channel 2 Outputs 3 and 4 Heat PID Cool PID HTCL HTCL Cool PID Heat PID CLHT Not displayed if DIP Switch 2 is ON Dependent on TYP RIL Enter the Range Low value for Channel 1 Dependent on input selection Not displayed is DIP Switch 2 is ON See your TYP parameter setting R1H Enter the Range High value for Channel 1 Dependent on input selection Not displayed if DIP Switch 2 is ON See your TYP parameter setting R2L Enter the Range Low value for Channel 2 Dependent on input selection Not displayed if DIP Switch 2 is ON Dependent on
89. arameters may not appear on your control They are dependent on your control configuration One of three main level operating menus From the SYSTEM menu you can generate a SYSTEM non ramp set point fixed manipulate Events 1 through 8 ON or OFF clear system errors and clear latching alarms Represents the current set point for Channel 1 SP1 Range R1L and R1H Default 73 F 23 C whole 73 4 F 23 0 C tenths Spo a Represents the current set point for Channel 2 SP2 will not appear if TYP under the SPCLFUNC menu is set up for T Temperature for Channel 1 only or for P Process for Channel 1 only Range R2L and R2H Default 73 F 23 C whole 73 4 F 23 0 C tenths C2 RH Represents the current value of the process variable from the sensor inputs for Channel 2 C2 will not appear if TYP under the SPCLFUNC menu is set up for T Tempera ture for Channel 1 only or P Process for Channel 1 only RH only appears if TYP TH TV orP V How To Program the Series 922 Chapter 6 WATLOW Series 922 User s Manual 43 SYSTEM Menu V m lt EV2 C oF i ER1 ER2 CLR ALARM RETURN This auxiliary output can be an alarm or event Events may be turned ON or OFF in the HOLD mode EV1 will only appear when AUX1 EV under the SPCLFUNC menu and when the external event output board is connected Range OFF or ON Default OFF This auxili
90. ary output can be an alarm or event Events may be changed ON or OFF in the HOLD mode EV2 will only appear when AUX2 EV under the SPCLFUNC menu and when the external event output board is connected or when TYP T or P and an external event board is connected Range OFF or ON Default OFF These auxiliary outputs are events Events may be turned ON or OFF in the HOLD mode EV3 through EV8 only appear when the 8 event output external board is connected Range OFF or ON Default OFF El monitors the status of the external event input OPEN will be displayed if the external event input is open or will display CLOSE if terminals 22 and 24 are tied together This is a switch input not voltage or current Range OPEN or CLOSE Default OPEN if nothing is connected to the input ER1 is considered a fatal error your system will shut down When the Series 922 shuts down all outputs will be turned off and the program will stop running When an error occurs ER1 00XX will alternately flash with the SYSTEM parameter To clear an error ENTER the SYSTEM mode and scroll to the ER1 parameter Press ENTER This clears the error unless it is a re occuring error and has not been resolved Some ER1 errors are self clearing Range 0 18 ER2 is considered nonfatal If you are in the RUN mode your program will continue running unless it is a program error ER2 OOXX appears and flashes alternately along with the parameter that you are on To clear
91. begins This band is in multiples of the cool proportional band This parameter will not appear if PB2C is set to 0 or T or P Channel 1 only in the TYP parameter under the SPCLFUNC menu has been selected Range 0 to 7 times the PB2C 0 denotes rate is always functional Default 0 From any RETURN you can go back to the SYSTEM prompt by pressing the ENTER key or return to PID by pressing the MODE key In the SETUP menu ACCESS 3 must be selected to enter the DIAGNOS parameters Here you can manually adjust percent power for Channel 1 and 2 When ACCESS 3 is selected under the SETUP mode of the Series 922 the DIAGNOS parameters appear The outputs will revert to open loop manual percent power control at the percent of power that they happen to be at before entering the DIAGNOS menu The control will revert back to a closed loop control when you leave the DIAGNOS menu Allows the operator to manually adjust the percent power output for Channel 1 If set to 100 the heat output for Channel 1 is full ON Range 100 to 100 Default power unit was at when DIAGNOS was entered Allows the operator to manually adjust the percent power output for Channel 2 This parameter will not appear if the TYP prompt has been set to T Tem perature for Channel 1 only or P Process for Channel 1 only If set to 100 the heat output for Channel 2 is full ON Range 100 to 100 Default power unit was at when DIAGNOS was entered
92. cision decade resistance box with 0 01 ohms resolution 4 1 2 digit digital voltmeter DVM Setup and Calibration NOTE Before calibration on an installed control make sure all data and parameters are documented 1 Connect the precision decade box to 6 7 and 8 of the Series 922 Figure 39 terminal strip for Channel 1 as shown on Figure 39 For Channel 2 connect Decade Resistance the precision decade box to 3 4 and 5 of the terminal strip Box to Series 922 Connection Diagram Connect AC line voltage L1 to 17 L2 to 20 ground to 21 Jumper for Series 922 Series 922 Terminal Strip Terminal Strip Channel 1 Channel 2 T 1 5 4 I 3 fi eats el Set DIP Switch 6 ON Apply power to the Series 922 and allow it to warm up for 15 minutes The unit should be in the TEST mode S S General Radio Model 1433 T correct line voltage see Chapter 4 How to Install and Wire Connect DVM common to TP2 and DVM positive to TP1 on the A007 1729 circuit board Located on the top side behind the center chassis support DVM should be set up for DC volts and in a range capable of displaying 6 300 volts Using the MODE key advance until the DAS6 XXXX parameter appears in the alphanumeric display Using the UP DOWN keys adjust the alpha numeric display to match the DVM display Press the ENTER key Press the MODE key until the CH1Z XXXX parameter for Channel 1 appears on the alphanumeric di
93. condition the 922 actively maintains the set point and event output conditions which exist 38 WATLOW Series 922 User s Manual How To Program the Series 922 Chapter 6 Event Outputs Events GS Another feature of the Series 922 is its capability for up to eight event outputs via an external event output board You have the option of ordering your 922 without events or adding an external board for two or eight outputs An event output is simply a pre programmed ON OFF event per program step The event may turn any number of peripheral devices ON or OFF to assist you in controlling your process system or environment For instance in an environmental chamber you might wish to circulate air at a given time in your program for one or more steps You may want to turn lights ON or OFF or signals lock out your humidifier or activate a video recorder EV1 and EV2 are not visible under the SYSTEM menu until you select AUX1 amp AUX2 as events in the SETUP menu and the two or eight event output board is connected Enter the SETUP menu and enter ACCESS 5 This is the SPCLFUNC Special Function parameter Press the MODE key until you reach the AUX1 parameter and press ENTER The default for AUX1 and AUX2 is AL Alarms Change the value to EV Events if it hasn t already been done If you return to the SYSTEM menu EV1 and EV2 are visible and can be turned ON or OFF from here EV1 and EV2 can also be viewed under the SETPOINT paramet
94. ct SP1 or SP2 C2 and SP2 will not appear if TYP parameter is T or P Control feature that inhibits automatic reset action outside of the proportional band Data entry points where a microprocessor based control prompts or asks the operator programmer for information input One of six step types under the PROGRAM menu of the Series 922 that can be programmed to automatically start at a certain time depending on the DAY HOUR and MIN parameter settings This parameter determines whether Auxiliary Output 1 will be an alarm or event output for the Series 922 This parameter determines whether Auxiliary Output 2 will be an alarm or event output for the Series 922 When AUX1 AL it represents the high process alarm or high deviation alarm for Alarm 1 This parameter represents the low process alarm or low deviation alarm for Alarm 1 of the Series 922 Displayed only when AUX1 AL Represents the high process alarm or high deviation alarm for alarm 2 of the Series 922 Displayed only when AUX2 AL The low process alarm or low deviation alarm for Alarm 2 of the Series 922 Displayed only when AUX2 AL Appendix BAUD CAL1 CAL2 CALIB C F U Closed Loop CLR FILE Cold Start COM COM ID CT1C CT2C CT1H CT2H Cycle time DAY DB1 DB2 Dead band Derivative Deviation Appendix Represents the baud rate 1200 2400 4800 9600 that serial Glossary B D communications wi
95. current switching capability 12 24 Supply voltage can be between 12 to 24 Volts 100 240 Supply voltage can be between 100 to 240 Volts 100 ohm DIN refers to 100 ohm platinum RTD that has a DIN curve 100 ohm JIS refers to 100 ohm platinum RTD that has a JIS curve 1 32 DIN Deutsche Industrial Norm standard for panel mounted controller hole size is cut to 1 78 w x 0 88 h 1 16 DIN Deutsche Industrial Norm standard for panel mounted controller hole size is cut to 1 78 w x 1 77 h 1 8V DIN Deutsche Industrial Norm standard for panel mounted controller hole size is cut to 1 78 w x 3 63 h 1 8H DIN Deutsche Industrial Norm standard for panel mounted controller hole size is cut to 3 63 w x 1 77 h 1 8S DIN Deutsche Industrial Norm standard for panel mounted controller hole size is cut to 2 68 w x 2 687h 14 DIN Deutsche Industrial Norm standard for panel mounted controller hole size is cut to 3 63 w x 3 63 h Action determines the direction of control Heat reverse acting or Cool direct acting Auto Reset the limit will automatically reset on a power cycle but requires manual reset on limit trip Cascade a control algorithm in which the output of one control loop provides a set point for another loop The second loop in turn determines the control action Ch Channel refers to an analog input There are single and dual channel controllers Control Mode the method
96. d we ll show you the specific arguments for each command It will speed the process though if you remember this general syntax Data Rules Data fields are parameters and values specific to particular commands These rules govern their use Specific data for each command is listed later in this chapter Data will be ASCII 0 through 9 unless otherwise noted Data can go up to four total characters including a minus sign Data can use leading zeros Up to 4 digits Data does not use decimal points therefore a number must have units equal to the least significance of the data value If for example a parameter s value is 1 and the least significant digit of the parameter is 0 1 the number sent as the data would be 10 That is to say the value is interpreted as 10 tenths Data sent to or returned from the unit to parameters that will accept it that has a value of asterisk means that the value is unprogrammed How to Use Data Communications WATLOW Series 922 7 Command List These commands represented by their respective ASCII characters will enable you to program the Series 922 from your computer keyboard More detailed descriptions of the commands are on the pages noted Finds the value of a specific parameter p 16 Sets a specific parameter to a specific value p 16 Example Format For your benefit we re presenting message response examples with syntax required for Series 922 communication In
97. defined for Event 2 AUX2 EV Event Output defined for Event 2 Default AL Determines whether the alarm type for Auxiliary Output 1 will be a process alarm or a deviation alarm for the Series 922 This parameter will not appear if The 2 or 8 event output board is not connected AUX1 EV or DIP Switch 2 is ON Range Alpha Display Alarm Type ALTYP1 P Process Alarm ALTYP1 D Deviation Alarm Default P Determines whether the alarm type for Auxiliary Output 2 will be a process alarm or deviation alarm This parameter will not appear if The external 2 event or 8 event output board is not connected if the TYP parameter has been set to T or P Channel 1 only or if DIP Switch 2 is ON Range Alpha Display Alarm Type ALTYP2 P Process Alarm ALTYP2 D Deviation Alarm Default P Selects alarms as latching or non latching Latching means the alarms remain active until you manually clear it This will not appear if DIP Switch 2 is ON Range LAT or NLAT Default NLAT Allows the operator to change the input gain of one or both of the RTD input channels for different curves This parameter will not appear if The input board type is Dual T C T C Process or Dual Process or DIP Switch 2 is ON Range JIS or DIN Default JIS The Altitude parameter represents the setting for altitude in feet above sea level for barometric correction when in the humidity mode This parameter only appears if the TYP parameter is set to T H This parameter
98. e Memory write not successful Number of steps stored is gt 99 No file found No step found No asterisk input allowed Infinite loop error File change error Cleared when ER2 is read 2 Command The Command finds the specific value of a Series 922 parameter Data 1 Tables 3 and 4 provide the complete list of parameters you may use plus responses You may use the Command in either the RUN or HOLD modes Data returned from the unit with a value of asterisk are unpro grammed parameters Command gt ooo The Command sets a specific Series 922 parameter Data 1 to a specific value Data 2 when the unit is in the HOLD mode Use Tables 3 and 4 to select parameters Data 1 in the lefthand column with low and high limit or code values Data 2 in the three center columns Use the table with either syntax How to Use Data Communications Data 2 LowLimit High Limit _ Code Function RXL value RXH value Set Alarm X High value iol Process 555 Deviation 999 C AXL RXL value RXH value Set Alarm X Low value Process 555 Deviation 999 E No alarms occurring A1H occurring AiL occurring A2H occurring A2L occurring ALT ANLG SP1 retransmit SP2 retransmit CH1 retransmit CH2 retransmit AT1 Set Alarm 1 to process Set Alarm 1 to deviation AT2 Set alarm 2 to process Set Alarm 2 to deviation AUX1 is an Alarm Output AUX1 is an Event Output AUX2 is an Alarm
99. e gt Data 5 Data n Table 7 below shows how to interpret the response syntax Note that each argument is an ASCII decimal number representing a specific value for each Parameter listed in the table A response would be lt 3 gt lt space gt lt 11 gt lt space gt lt 1 gt lt space gt lt 375 gt lt space gt lt 50 gt lt space gt lt 2 gt lt Space gt lt 30 gt lt space gt lt 0 gt lt space gt lt 1 gt lt Space gt lt 1 gt lt space gt lt 1 gt lt space gt lt 1 gt lt space gt lt 1 gt lt space gt lt 1 gt lt Space gt lt 1 gt lt space gt lt 1 gt This tells you that the current step is File 3 Step 11 a SETPOINT step the SP1 is 375 and SP2 is 50 Step Time is 2 30 00 EV1 through EV8 is ON Table 7 uses the following abbreviations W1 ACTUAL waitfor temperature for Channel 1 W2 ACTUAL waitfor temperature for Channel 2 WHR Wait for hours programmed WMN Wait for minutes programmed WRH Wait for remaining hours Table 7 WRM _ Wait for remaining minutes 2 MTR Command WRS Wait for remaining seconds Response Data ADA Autostart days accumulated lt gt Non literal RH Realtime hours Description RM Realtime minutes Step Type JUMPLOOP STOP lt File gt lt File gt Don i E 1 Data 5 Data 6 Data 7 Data lt WMN gt Data 9 lt WRH gt Data 10 Data 11 Data 13 Data 14 lt EV6 gt Data 15 Data 16 lt EV8 gt
100. e use ANSI X3 28 Protocol based on ANSI X3 28 1976 Subcategories 2 2 and A3 with the RS 422A interface to run a multiple device network We also use XON XOFF Protocol a simpler prototcol to run a two device network with an RS 423A interface XON XOFF Protocol requires no responses to messages like the ANSI X3 28 Protocol does XON XOFF will also work with the RS 422A interface but the network is limited to two devices Likewise ANSI X3 28 Protocol which provides a response to every message will work with the RS 423 interface But again you are limited to two devices lf you haven t already done so please read Introduction to Data Communica tions with WATLOW Controls shipped with your communications equipped Series 922 To select which protocol you are going to use go into the SPCLFUNC para meters under the SETUP menu ACCESS 5 Use the UP DOWN keys and advance to the COM parameter Select either XON for the XON XOFF communications protocol or STX for ANSI X3 28 2 2 A3 lf you are using ANSI X3 28 Protocol choose an address number for the control Communications Wiring To connect your Series 922 to a computer use the next page as a reference Your computer hardware manual will provide the serial port pin information Also refer to the noise prevention section in Chapter 2 of the Series 922 User s Manual In the often noisy environments of industrial locations it is important not to take noise isolation lightly
101. eads an average temperature Air flow past this sensor should be moderate The sensor should be thermally insulated from the sensor mounting RTD The Wet Bulb Installation One way to prepare the RTD wet bulb sensor for reading relative humidity on Channel 2 is to slip a cotton wick over the sensor sheath Watlow Part 0830 0111 0000 or an equivalent Put one end of the wick in water Some systems use a small trough of water with a float valve to replenish the evaporating liquid Use distilled water to avoid mineral deposits on the wick that can change the RH reading The wicking distance should be as short as practical The cotton wick must be free of any sizing and starch The float valve trough systems should also remove the water when the ambient temperature goes below freezing or above boiling To obtain valid RH readings air flow past the RH sensor must be sufficient to evaporate the maximum amount of water from the wick without drying it out Evaporation cools the sensor the amount of cooling relates directly to the relative humidity present Thermally insulate the wet bulb sensor from the sensor mounting This pre vents mounting surface heat from flowing into the sensor sheath and changing the wet bulb temperature The result of such heat flow will be a humidity reading higher than actual Thermocouple Installation Guidelines Locate the thermocouples in your process or system where they read average temperatures Air flo
102. ed to be free of defects in material and workmanship for 36 months after delivery to the first purchaser for use provid ing that the units have not been misapplied 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 alter ation misuse or abuse Returning Merchandise The following procedure applies for any products returned to the factory 1 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 e Ship to address e Bill 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 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 2 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
103. ensions p Terminal Stri Four 0 156 dia OWE LEM rip Series 922 Interface r4 mm mounting holes Connection See Page 33 for power wiring 3 62 to 3 65 92 00 to 92 79mm Your Panel Panel Thickness Cutout i i Figure 15 3 62 to 3 65 i n Series 922 0 06 to 0 25 92 08 x 92 08mm Binncuelone How to Install and Wire Chapter 4 WATLOW Series 922 User s Manual 27 Wire Power WARNING To avoid potential electric shock use National Electric Code safety prac tices when wiring connecting this unit to a power source and to electrical sensors or periph eral devices Green GND Wire Figure 16 Series 922 Power Wiring Diagram WARNING To avoid electric shock connect the chassis ground terminal to Earth Ground CAUTION Remove the short green ground jumper on the back of the 922 T 21 if your control is mounted in a metal panel connected to safety chassis ground Removing the jumper will prevent ground loops OR leave the short green ground jumper in place if the Series 922 case is not connected to safety chassis ground 28 g Chassis 17 GND WATLOW Series 922 User s Manual Series 922 Power Wiring NOTE NOTE For 115VAC For 230VAC jumper 17 to 19 jumper 18 to 19 and jumper 18 to 20 L1 Chassis L1 GND Green GND L2 Wire Le Earth Earth Ground Ground 22 22 23 Remote Hold 23 Remote Hold 24 External Event 4 External Event Input Input Connec
104. ep 2 SETPOINT Step 3 JUMPLOOP JS 02 JC 01 Step 4 JUMPLOOP JS 01 JC 01 Step 5 SETPOINT Step 6 JUMPLOOP JS 01 JC 01 Step 7 STOP The steps in sequence will be 1 2 3 2 3 4 1 2 3 2 3 4 5 6 1 2 3 2 3 4 1 2 3 2 3 4 5 6 7 Intertwined Loop An Intertwined loop can break across other loops Step 1 SETPOINT Step 2 SETPOINT Step 3 JUMPLOOP JS O1 JC 01 Step 4 JUMPLOOP JS 02 JC 01 Step 5 STOP The steps in sequence will be 1 2 3 1 2 3 4 2 3 1 2 3 4 5 Rules to Follow The one basic rule that you must follow is that you can only have a maximum of three consecutive jump loops coor 1 SETPOINT re Step 2 JUMPLOOP JS 01 JC 01 Step 3 JUMPLOOP JS 01 JC 01 Step 4 JUMPLOOP JS 01 JC 01 Step 5 JUMPLOOP JS 01 JC 01 Step 6 STOP Your program will run until it reaches Step 5 and flashes an ER2 0039 This is the infinite looping error and means you have too many consecutive loops Another rule to follow is you cannot JUMPLOOP to a step you are on You ll receive an ER2 0039 Clear the error in the ER2 parameter under the SYS TEM menu and retransmit your data Use simple loops in your program How To Program the Series 922 Chapter 6 WATLOW Series 922 User s Manual 41 SYSTEM Menu NOTE Shaded parameters may not appear on your control These parameters are dependent on how your control is configured See Pages 43 44 for more information Figure 31 SYSTE
105. er each command you send All communications related error codes are ER2 error codes that is they are not considered cause for a shutdown of the 922 unit itself There is always a communications error code generated when a lt NAK gt character is sent under the ANSI X3 28 With XON XOFF flow control error codes may be generated but there will be no standard indication of this fact That s All There Is To It T The best way to become really familiar with data communications is to use it Use this manual in conjunction with the Series 922 User s Manual and Intro duction to Data Communications with WATLOW Controls 24 WATLOW Series 922 How to Use Data Communications A Asterisk 7 20 21 22 ADA 22 AFL 15 AFL Command 23 ALM 15 ANLG 18 ANSI X3 28 Command Example Fig 6 13 ANSI X3 28 Command Example Fig 7 14 ANSI X3 28 Protocol 3 12 ASCIl and Series 922 Information 5 ASCII Character Set Table 1 6 ASCII Control Characters Partial Set Table 2 6 AT1 17 AT2 17 AUX1 15 AUX2 15 AXH 17 AXL 17 B Baud Rate 5 C Ci 15 C2 15 CALX 17 Carriage Return 9 CFU 17 CLRF 18 CLRF Command 24 Command 16 Command 16 Command Data amp Responses Partial Set for Table 4 15 Command Data and Table 4 17 Command List 8 Communications Software 5 Communications Wiring 3 Connecting the Control and the Computer 5 Contents 2 CTXC 17 CT
106. er in the PROGRAM menu EV3 through EV8 are not displayed unless you have the 8 event output board connected See the Model Number Information on Page 70 for ordering information If the events are programmed for one step and left unprogrammed for the next step the events maintain the last programmed status These event outputs are solid state relays rated at 0 5 amps up to 240VAC Guaranteed Soak The Series 922 Guaranteed Soak GS feature insures that the process tempera ture tracks a programmed ramp The Guaranteed Soak acts as a deviation alarm The program clock halts if the ACTUAL temperature exceeds the Guaranteed Soak value At this time the HOLD LED flashes The clock starts once the process variable is within the GS deviation value Programmed in degrees or process units GS is in the SETUP menu under ACCESS 5 Entering a value of 0 disables the Guaranteed Soak function The Guaranteed Soak function only applies to l Channel 1 Figure 30 is an example of the Guaranteed Soak function guest Guaranteed Soak GS Example Programmed Ramp NOTE If the program is put in the HOLD mode while holding for a guaranteed soak and restarted at another step the GS has to be met for the previous step before the program can continue Temperature Guaranteed Soak Window Around Set Point Time How To Program the Series 922 Chapter 6 WATLOW Series 922 User s Manual 39 Jumploops The Four JUMPLOOP Types The Ser
107. ered in the TYP parameter under the SPCLFUNC menu Channel 2 will not appear Range CH1 CH2 Default CH1 A proportional temperature band expressed in degrees within which a temperature controller proportioning function is active for Channel 2 heating Expressed in degrees This parameter will not appear if T or P Channel 1 only have been selected in the TYP parameter under the SPCLFUNC menu Range 0 to 900 F 0 to 500 C 0 to 500 Units 0 0 to90 0 F 0 0 to 50 0 C 0 0 to 50 0 Units 0 to 500 RH Default 45 F 25 C 25 Units 4 5 F 2 5 C 2 5 Units 25 RH PB2H How To Program the Series 922 Chapter 6 WATLOW Series 922 User s Manual 51 A reset integral heating control action for Channel 2 that automati cally eliminates offset or droop between point and actual process temperature in a proportional control Expressed by repeats per minute This parameter will not appear if PB2H is set to 0 or if T or P have been selected in TYP under the SPCLFUNC parameter Range 0 00 to 5 00 repeats minute Default 0 00 RS2H rr The rate derivative heating function for Channel 2 of the Series 922 The rate is determined by how fast the error being corrected is increasing Expressed in minutes This parameter will not appear if PB2H is set to 0 Range 0 00 to 5 00 minutes Default 0 00 RT2H The Channel 2 heating cycle time usually expressed in seconds for a controller to complete one ON OFF c
108. et point and actual process temperature in a proportional control Expressed in repeats per minute This parameter will not appear if PB1C is set to 0 Range 0 00 to 5 00 repeats minute Default 0 00 The rate derivative cooling function for Channel 1 of the Series 922 RTIC The rate is determined by how fast the error being corrected is increasing Expressed in minutes This parameter will not appear if PB1C is set to 0 Range 0 00 to 5 00 minutes Default 0 00 CTIC The cooling cycle time for Channel 1 expressed in seconds for a controller to complete one ON OFF cycle Time between successive turn ons This parameter will not appear if Your Series 922 has a 4 20mA output and OUT1 under the SPCLFUNC menu is set to CLHT or PB1C is set to 0 Range 1 to 60 seconds Default 5 RBIC A thermal control band for Channel 1 cooling that defines where the rate derivative function begins This band is in multiples of the cool proportional band This parameter will not appear if PB1C is set to 0 Range 0 to 7 times the PB1C 0 denotes rate is always functional Default 0 RETURN From RETURN you can go back to the SYSTEM prompt by pressing the ENTER key or return to PID by pressing the MODE key Under the PID menu Channel 2 can be selected These parameters consist of Proportional Integral auto reset and Derivative rate CH2 actions If T Temperature for Channeli only or P Process for Channel 1 only have been ent
109. file Finds data programmed in step 3 Ti i Page 20 MTR See Page 22 Monitors a RUN or HOLD step Mare tan HR MIN SEC Finds real time hours min sec MDL Model and Revision How to Use Data Communications Commands Table 3 2 Command Data and Responses Partial Set See Table 4 for more 2 Command Data WATLOW Series 922 15 Commands Table 3 Continued t NOTE You may write to a Series 922 parame ter with the Com mand only when the unit is in the HOLD mode 16 WATLOW Series 922 No error Internal RAM error External RAM error Bad battery error Ch 1 A D conversion error Ch 2 A D conversion error Ground A D conversion error High reference A D error Interpolation Overrange Ch 1 Interpolation Overrange Ch 2 D A gain error Channel 1 zero error Channel 1 gain error Channel 2 zero error Channel 2 gain error Stack overflow error Cleared when ER1 is read OOnNOnSWH O No error Transmit buffer overflow Receive buffer overflow Framing overrun error Parity error Talking out of tum Invalid reply error Command not found Parameter not found Incomplete command line Invalid character Number of chars overflow Input out of limit Read only command No Channel 2 available error Write allowed only Request to RUN invalid Request to HOLD invalid Command invalid RUN mode Self test mode not activ
110. for a warm start DIP Switch 2 selects whether all SPCLFUNC parameters will be displayed or not DIP Switch 3 determines whether the decimal point will be displayed in tenths of units for 0 5V or 4 20mA input and DIP Switch 4 is for 0O 5VDC 0 20mA input or 1 5VDC 4 20mA input selection DIP Switch 5 is not used and DIP Switch 6 is a factory test cali brate switch Changing the Position of a Switch Whenever you change the position of a DIP switch follow this procedure 1 Remove power from the Series 922 Turn the front panel screw 90 counter clockwise 2 Grip the front panel bezel and pull it straight out from the control case The control chassis will come out of the case as you pull the bezel 3 Set the DIP switch to the position you want 4 Return the control chassis to the case Be sure you have it oriented correctly It will not fit in upside down but check just the same Press firmly but gently to seat the chassis Starting Out Chapter 1 922 Overview Overview of the Three Operating Modes Before getting into the details of the Series 922 s keys and displays take a look at Figure 5 showing the three different modes After you feel comfortable with the names of the modes and their functions go ahead to learn the keys and displays Series 922 Three Mode Types Control Outputs SYSTEM Manually Enter Program Steps amp View Program PROGRAM Set Up Your System Where To Go From Here
111. formation bracketed by lt gt indicates a description rather than literal characters We show each ASCII character that you must transmit to the Series 922 including space between the charac ters A space is itself an ASCII character hex 20 For clarity we also represent each ASCII character as a hexadecimal pair The pairs are spread apart on the page for easy reading However electronic devices see the hex pairs all together in strings with no spaces in between For instance from the example just below you want to set the Alarm 1 Low AiL parameter to 500 Notice the syntax just below which uses the command lt Space gt A1L lt Space gt 500 Space j 1 Figure 3 ASCII L Series 922 Characters Space General Message Syntax Example 8 WATLOW Series 922 0 HEX Value 3D 20 41 31 4C 20 35 30 30 How to Use Data Communications XON XOFF To send the message on Page 8 Figure 4 you key the ASCII characters into your computer or write them into your program The computer in turn will send a string similar to the one at the bottom of the example 3D2041314C20353030 Notice that we haven t mentioned protocol here or any characters added to this syntax by a protocol With XON XOFF the message above can be transmitted with only an additional Carriage Return lt CR gt hex 0D character at the end However the ANSI X3 28 Protocol requires an envelope of Start of Text lt STX gt
112. fs Manual Reset the limit must be reset on a power cycle and requires manual reset on limit trip Multi RSP multiple remote set potentiometers were supported Each allowed the set point to be selected and adjusted Relay refers to an electromechanical relay Remote set point is adjusted using a remote potentiometer Panel the form factor of this controller is mounted through a hole cut in the panel PI Proportional and Integral a control mode with two functions proportional action dampens the systems response and integral corrects for droop PID Proportional Integral and Derivative a control mode with three functions proportional action dampens the systems response integral corrects for droop and derivative prevents overshoot and undershoot Potted the circuit board and electronics are encased in epoxy Proc Process input may accept 0 5 1 5 0 10 volts or 0 20 and 4 20 mA Profiling Controller will perform a sequence of programmed steps Programmable The feature is changeable in the field through jumpers and or parameter selection RTD Resistance Temperature Detector a sensor that is 100 ohms at 0 degrees C and made of platinum material SSR Solid State Relay these devices will switch AC voltage only and require a load to latch on Sw DC Switched DC a time proportioning DC output used to drive DC input solid state relays t c Thermocouple sensor device made by joining tw
113. gram Chapter 3 Sample Program Enter Real Time First set the Series 922 s real time of day 24 hour clock Remember that the MODE key is used to step through the menus The UP DOWN keys are used to select parameters and values and remain flashing until you press the ENTER key 1 Press the MODE key until the SETUP menu appears Press the ENTER key 2 At ACCESS select 0 with the UP DOWN keys Press ENTER This is the calibration CALIB menu 3 Press the MODE key until HOUR appears in the alphanumeric display Note that hours are in a 24 hour format 4 Use the UP DOWN keys to place hours into the display The display flashes until you press ENTER 5 Press MODE to continue to the MIN parameter Enter the correct value for minutes and press ENTER 6 Press the MODE key several times to return to the top of the ACCESS 0 menu At the ACCESS 0 prompt which is the CALIB menu you see the Real Time TI displayed 7 Continue to press MODE until you reach RETURN Press ENTER to return to SYSTEM Before Entering Your Program Before we begin to program your Series 922 there are a few other initial SETUP parameters to enter If you haven t tried any programming since your cold start the C F U Celcius Fahrenheit Units and GS Guaranteed Soak parameters are set to their appropriate values Refer to the glossary for a more detailed definition If you have already tried stepping through the parameters and entering va
114. he PID prompt RT1C 0 00 5 00 minutes 0 00 CT1C 1 60 seconds 5 RB1C 0 7 times PB1C 0 RETURN 46 WATLOW Series 922 User s Manual How To Program the Series 922 Chapter 6 Table 9 continued Prompt CH2 PB2H Description ACCESS 1 PID Continued To enter PID parameters use ACCESS 1 amp press ENTER Enter the Channel 2 Proportional Band value Heating Dependent on TYP parameter SETUP Menu Range 0 900 F 0 500 C 0 500Units Default 45 F 25 C 25U Your Settings RS2H Enter the Channel 2 Reset value Heating Not displayed if PB2H 0 Dependent on TYP parameter 0 00 5 00 repeats minute 0 00 RT2H Enter the Channel 2 Rate value Heating Not displayed if PB2H 0 Dependent on TYP parameter 0 00 5 00 minutes 0 00 CT2H Enter the Channel 2 Cycle Time value Heating Not displayed if PB2H 0 Dependent on output TYP amp OUT2 1 60 seconds 5 RB2H Enter the Channel 2 Rate Band value Heating Not displayed if PB2H 0 Dependent on TYP parameter 0 denotes rate is always functional 0 7 times PB2H DB2 Enter the Current Dead Band value for Channel 2 Dependent on TYP parameter 36 to 36 F 20 to 20 C 20 to 20 Units 0 PB2C Enter the Channel 2 Proportional Band value Cooling Dependent on TYP parameter 0 900 F 0 500 C 0 500U 45 F 25 C 25U RS2C Enter
115. hen is limit trips Is TA 140A 16XX 6000 L1 Say High Limit Control O Fuse iry A High Limit Mechanical Load T D 0 at Power O Contactor Bi ele L2 TC Input Heater Normally Open Momentary S Dry Temp Switch RTD Sensor Limit Sensor Oven Wet Bulb RTD Sensor WARNING With Watlow mercury relays load must have a unity power factor For RESIS TIVE LOADS ONLY How to Install and Wire Chapter 4 WATLOW Series 922 User s Manual 35 Chapter 5 How to Tune the Series 922 This chapter will explain tuning the 922 to the system it controls Recommended Tuning Reference There are a number of quality references on the art of tuning electronic controllers to the systems they control If you are not an instrument technician qualified to tune thermal systems we suggest that you obtain and become familiar with the reference below before attempting to tune your system Remember that the time you spend tuning your system is relative to the quality of control you need Tuning of Industrial Control Systems Armando B Corripio Published by the Instrument Society of America Using A Chart Recorder The tuning procedure will be greatly simplified if you use a chart recorder to assist in tuning the Series 922 Connect the chart recorder to the analog retransmit signal The analog retransmit signal provides a chart recorder output represented by C1 or C2 Actual process variable or
116. hermocouple calibrator e 4 1 2 digit Digital Voltmeter DVM Can be used with either configuration above Setup and Calibration kK NOTE Before calibration on an installed control make sure all data and parameters are documented 1 Connect the input side of the thermocouple reference compensator to 6 Positive and 8 Negative for Channel 1 3 Positive and 5 Negative for Channel 2 on the Series 922 terminal strip Short the output side of the compensator and turn on the compensator See Figure 38 If a t c calibrator is used connect to terminal 6 positive and 8 negative Series 922 Series 922 for Channel 1 3 positive and 5 negative for Channel 2 inthe 922 Terminal Strip Terminal Strip terminal strip Set the calibrator for the appropriate thermocouple Channel 1 Channel 2 Also set either 0 C or 32 F saan Omega Model PPPE Niles MCJ or T C Wires Reference Compen MCJ K or sator to Series 922 MCJ T Connection Diagram 2 Connect AC line voltage L1 to 17 L2 to 20 ground to 21 Jumper for correct line voltage See Chapter 4 How to Install and Wire 3 Set DIP Switch 6 to ON Apply power to the unit and allow it to warm up for 15 minutes The unit should be in the TEST mode 4 Connect DVM common to TP2 and DVM positive to TP1 on the A007 1728 circuit board located on the top side behind the center chassis support DVM should be set up for DC volts and in a range capable of displaying 6 3000 volts
117. ies 922 gives you the capability to perform four basic jumploop types in your programming The backward jump forward jump nested loops and intertwining loops These are only definitions of the four loops The Series 922 has very few rules concerning loops in your program Backward Jump The Backward jump is the most common jump A backward jump will force you to a step already performed The Jump Step JS must be less than the current step You cannot JUMPLOOP to the step that you are on Step 2 SETPOINT Step 3 SETPOINT Step 4 SETPOINT Step 5 JUMPLOOP JS 02 JC 01 Step 6 STOP The steps in sequence will be 2 3 4 5 2 3 4 5 6 Your Jump Count JC can be anything from 0 100 If you enter 0 this will be an infinite loop and will never progress to Step 6 Forward Jump The next loop type is a Forward jump By definition you can jump forward The Jump Step must be greater than this step Step 1 SETPOINT Step 2 SETPOINT Step 3 JUMPLOOP JS 05 JC 01 j Step 4 SETPOINT Step 5 STOP The steps in sequence will be 1 2 3 5 40 WATLOW Series 922 User s Manual How To Program the Series 922 Chapter 6 Nested Loop Jumploops A Nested loop is a jump loop within a loop You are forced to a step either forwards or backwards from your present location When nested loops are performed they cannot break across other loops Your JC can be from 0 100 with O being an infinite looping Step 1 SETPOINT ii St
118. inearly producing a ramp from a beginning set point to an end set point Range R1L to R1H Default Unprogrammed P Represents the temperature that the system will try to achieve on Channel 2 in the amount of time given This will be done linearly producing a ramp from a beginning set point to an end set point This parameter will not appear if the TYP prompt under the SPCLFUNC menu has been selected as T Temperature for Channel 1 only or P Process for Channel 1 only Range R2L to R2H Default Unprogrammed W 5 NO ep E The number of hours in combination with the MIN and SEC parameters that equal the total step time to achieve the temperature under the SETPOINT step type Range 0 to 23 hours Default Unprogrammed HOUR The number of minutes that equal total step time to achieve the MIN temperature of the Series 922 Under the SETPOINT step type Range 0 to 59 minutes Default Unprogrammed The number of seconds that equal total step time to achieve the SEC temperature of the Series 922 under the SETPOINT step type Range 0 to 59 seconds Default Unprogrammed 3 xr SNr Sr This auxiliary output can be an alarm or event EV1 will only appear eve O when AUX1 EV and the external event board is connected to the Series 922 Auxiliary outputs can be alarms or events Range OFF or ON Default Unprogrammed OFF Event OFF ON Event ON EV2 EV2 can be an alarm or event EV
119. ion C Switched DC AA CAUTION If AC load is connected to C option output damage may occur to event board and to 922 34 WATLOW Series 922 User s Manual Event Output Option B and K Solid State Relay 0 5A 24V VAC Min 253V VAC Max Model A007 1732 XXKX Without RC Suppression Minimum OFF state impedance 31M Model A007 1732 XXBX With RC Suppression Minimum OFF state impedance 20K Event Alarm Outputs ao Load Power Event Output Option C Switched DC Model A007 1732 XXCX How to Install and Wire Chapter 4 Wiring Example Single Phase 120VAC Application WARNING Install High or low temperature limit control protection in systems where an overtemperature or undertemperature 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 L2 Wet Bulb RTD amp Cooling Output internal to oven L1 N LT 120 VAC A Control L2 Power Figure 29 Series 922 System Wiring Example Earth Ground avo 290 Dry Temp RTD L1 Control Output L2 Dehumidifier L1 L1 Fuses L4 High Limit L1 Mercury Control Power Load 2 Relay for L2 120 VAC Power Control Integral Setpot Fuse 1 S Indicator ON w
120. isabled when the Channel 1 temperature falls below 40 F 40 C or goes above 320 F 160 C The RH display NOTE The dry bulb will read OFF and the retransmit output is 0 volts if ANLG C2 ANLG is and wee bulb S nsor located in the Setup menu under Access 5 should be mounted in the same location However do not Temp m Temp locate the wet bulb For Temp Temp RTD operation each dry bulb RTD or thermocouple senses ahead of the dry temperature for its channel bulb in the air p i stream this could cause incorrect relative humidity RTDs readings The RTDs for the Series 922 are customer supplied items They may be Gordon Part S001 0133 0000 which is a wire wound RTD inside a sealed 18 Nickel Silver sheath made for fast temperature response The detector element is platinum wire 100Q at 0 C with a temperature coefficient of 0 003916Q Q C The sheath is 0 1875 in 4 7625mm diameter 2 75 in 69 85mm long The three wire leads are 48 in 1219 2mm long and teflon insulated How to Install and Wire Chapter 4 WATLOW Series 922 User s Manual 21 Install Wire Contact Gordon at 5710 Kenosha St Box 500 Richmond IL 60071 Phone 815 678 2211 Excessive lead length in a two wire RTD sensor can create indication errors To combat this use a three wire sensor in long lead applications RTD The Dry Bulb Installation We suggest you mount the dry bulb RTD at a location in your process or system where it r
121. it 922 receiver buffer overflow Pro tocol or syntax violation retransmit Framing overrun error Check baud rate parity stop bits Parity error Check baud rate parity stop bits Talking out of turn STX protocol violation retransmit Invalid reply error Figure out com munications retransmit Command not found Check your program Parameter not found Check your program Incomplete command line Syntax error retransmit Invalid character Syntax error retransmit Number of characters overflow Numeric syntax error retransmit Input out of limit Transmitted value too large or small retransmit Read only command Cannot input a value for that parameter retransmit No Channel 2 available error Write only error A read was attempted on a parameter that can only be written to Request to run invalid Verify a run condition Request to hold invalid Verify a hold condition Command invalid in run mode Cannot enter values in run mode retransmit Self test mode not active Check to see that DIP switch 6 is ON Number of steps stored is gt or to 99 Enter steps only to 99 No file found Check your program retransmit No step found Check your program No asterisk input allowed Follow proper format for entering asterisks Infinite loop error Check the number of consecutive loops retransmit File change error An attempt to resume a changed file occurred Check your program WATLOW Se
122. l remote control other 3 Use your best judgment for selecting a replacement controller All applications require close examination of input output and the control mode needs to have the controller function properly 4 Safety Remember to make sure all redundant safety equipment is in place and working when retrofitting equipment If a system has been retrofitted without the proper safety equipment you could be liable if an accident occurs This is only a guide to replacement controllers If you have doubts please call 507 454 5300 and ask for technical support or email wintechsupport watlow com We re here to help The suggested replacement will differ in fit and form Please review the replacement controller specifications for suitability Carefully check the notes for additional information that may apply Your comments or suggestions on the Retrofit Guide are welcome Please send comments or corrections to Technical Writer Watlow Controls 1241 Bundy Boulevard P O Box 5580 Winona MN 55987 5580 phone 507 454 5300 fax 507 452 4507 This Retrofit Guide is copyrighted by Watlow Winona Inc February 2004 with all rights reserved 1455 Abbreviation amp Terminology as used in this document 0 5 0 5 amperes of current switching capability 2A 2 amperes of current switching capability 5A 5 amperes of current switching capability 10A 10 amperes of current switching capability 15A 15 amperes of
123. l control band that defines where the rate derivative function begins A Watlow rate band occurs centered on set point at one or more times the width of the proportional band The thermal control band for cooling in Channel 1 or Channel 2 that defines where the rate derivative function begins Appendix RB1H RB2H RS1C RS2C RS1H RS2H RT1C RT2C RT1H RT2H Reference junction Reset Reset windup inhibit RETURN RTD SE1 SE2 SEC Set point SETPOINT SP1 SP2 SPCLFUNC STEP STOP Appendix A thermal control band for heating in Channel 1 or Channel 2 that defines where the rate derivative function begins Glossary R T S Reset integral cooling control action for Channel 1 or Channel 2 that automatically eliminates offset or droop between set point and actual process temperature in a proportional control Expressed in repeats per minute A reset integral heating control action for Channel 1 or Channel 2 that automatically eliminates offset or droop between set point and actual process temperature in a proportional control Expressed in minutes The Rate derivative Cooling function for Channel 1 or Channel 2 that is determined by how fast the error being corrected is increasing Expressed in minutes The Rate derivative for the Heating function for Channel 1 and Channel 2 that is determined by how fast the error being corrected is increasing Expressed in minutes Sy
124. le Progammable Progammable Progammable Progammable Progammable Progammable Progammable Action Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Series 922 Output Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual Sw dc Sw dc Dual Sw dc Sw dc Dual Sw dc Sw dc Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual Sw dc Sw dc Dual Sw dc Sw dc Dual Sw dc Sw dc Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual Sw dc Sw dc Dual Sw dc Sw dc Dual Sw dc Sw dc Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual Sw dc Sw dc Dual Sw dc Sw dc Dual Sw dc Sw dc Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR
125. ll be running at This parameter will not appear under ACCESS 5 of the SPCLFUNC menu if your Series 922 does not have communications An offset of the process variable for Channel 1 or Channel 2 This number is added to the value that the system derives The final result is used for the set point as well as a front panel indication In the Series 922 when ACCESS 0 is entered under the SETUP menu the CALIB parameters appear These parameters setup the Real Time and the calibration offset of the process variable Accepts the sensor input and scales it to degrees Celsius Fahrenheit or Units of measure Control system that has a sensing device for process variable feedback Allows the operator to clear a file of the Series 922 A clean or completely cleared of user program information start up condition Factory settings Represents the selection of the protocol type for serial communi cations This selects XON XOFF protocol or ANSI X3 28 communication protocol under the ACCESS 5 SPCLFUNC menu This parameter will not appear if your Series 922 does not have communications Represents the device identification number as required for the ANSI X3 28 communications protocol for the Series 922 The Cooling Cycle Time for Channel 1 or Channel 2 usually expressed in seconds for a controller to complete one ON OFF cycle The time between successive turn ons The Heating Cycle Time for Channel 1 or Channel 2 usually e
126. lts e Scalable 1mV 2mV 5mV or 10mV per LSD e Maximum voltage Span 9 5 to 9 5 volts Accuracy e Calibration Accuracy and Sensor Conformity 0 15 of span 1 digit at 77 F 5 F 25 C 3 C ambient amp rated line voltage 10 e Accuracy Span 1000 F or 540 C minimum e Temperature Stability 0 18 F F 0 1 C C change in ambient e Voltage Stability 0 01 of span of rated line voltage Communications e Serial data communications e RS 422A or RS 423A RS 232C compatible e Most operator indication and controls e ANSI X3 28 protocol or XON XOFF protocol e Isolated e DB 9 Female connector Terminals e 6 compression type screw terminals Power e 115 230VAC 10 50 60Hz 5 e 18VA maximum e Data retention upon power failure via nonvolatile memory Operating Environment e 32 to 130 F 0 to 55 C e 0to 90 RH non condensing Dimensions e Height 3 8 in 96 52 mm e Width 3 8 in 96 52 mm e Overall depth 7 0 in 177 80 mm e Behind panel depth 6 0 in 152 50 mm with connector for communication and events 8 8 in 223 52 mm e Weight 2 8 Ib 1 27 kg Appendix WATLOW Series 922 User s Manual 69 70 922 A _ 10 0 0 0 Series 922 Dual channel microprocessor based dual input quad output ramping controller 99 steps 1 4 DIN Input WromNounRwn Output Per Channel BB CC FB Communications A B C Dual RTD 1 RTD 1
127. lues it might be a good idea to go back and double check to see that the values are correct 1 Press the MODE key until SETUP appears Press ENTER Once again you see the ACCESS parameter Use the UP DOWN keys to enter 5 and press ENTER this is the Special Function SPCLFUNC menu 2 Press MODE again until you see the C F U parameter This parameter defaults to F Use the UP DOWN keys to enter degrees F Fahrenheit Press ENTER Sample Program Chapter 3 NOTE When either the hours or minutes are entered internal seconds are set to 0 NOTE DIP Switch 2 must be OFF to access all SPCLFUNC parame ters WATLOW Series 922 User s Manual 15 16 Sample Program Skip Step 3 if you do not have an external event board connected 3 Continue through the menu with the MODE key until you see AUX1 Use the UP DOWN keys to enter AUX1 as an event EV and press ENTER Do the same for AUX2 Default is AL Alarm 4 Continue through the SPCLFUNC menu until you see GS Guaranteed Soak Enter a value of 0 press ENTER This parameter defaults to 0 5 Press the MODE key to move to the RETURN parameter Press ENTER to return to SYSTEM Programming File 1 Our first step in programming is to make a short ramp and soak program Step 1 initializes the set point to a known starting point for the ramp Step 2 is a short ramp Step 3 is a soak step which holds the programmed set point constant for the programmed time Step 4 is
128. ment The Jump Count parameter represents the number of times that the Series 922 will jump to a specified step The Jump Step parameter of the Series 922 will jump to any step within your current file You cannot Jump Step to another step in another file One of six step types under the PROGRAM menu of the Series 922 that can be programmed as a step or a file You can jump from one step to another within a file Latches your alarm outputs when the Series 922 has an alarm condition Remains active until you manually clear any alarms One of six step types under the PROGRAM menu of the Series 922 that allows you to link one file to another Allows for specific groups of parameters to be unaffected by the Up DOWN and ENTER keys preventing these parameters from being changed accidentally 0 No lock full access of all parameters 1 Prevents user from editing all parameters except the SYSTEM parameter group FILE and STEP 2 Prevents user from editing all parameters except ER1 ER2 ALRM in the SYSTEM menu the LOCK parameter the STEP and FILE parameter in the PROGRAM menu The MIN parameter has three meanings depending upon which parameter you are in PROGRAM menu The number of minutes that equal total step time to achieve the temperature of the Series 922 Under the AUTOSTART step type in the PROGRAM menu it represents the minutes that the 922 will wait for on the time of day clock before AUTOSTART takes place SETUP
129. mode you can only view the current file and step To stop a running program press the RUN HOLD key To resume a previously halted program press the RUN HOLD key When the FILE parameter appears press the MODE key to advance to the next parameter When START appears press the MODE key again Next the RESUME parameter is now present Press ENTER AT THE SYSTEM prompt press W to continue to PROGRAM mode Press to enter the PROGRAM parameter values or press MM to continue to SETUP SYSTEM FILE RESUME RETURN F ILE STEP One of the three step types will be displayed depending on the type of step PROGRAMmed JUMPLOOP STOP and LINK step types are immediate and will not be visible SETPOINT STOP LINK SEi1 FILE SE2 HOUR MODE Key ENTER Key UP DOWN Key Where To Go From Here Good job You ve just programmed and run the Series 922 sample program As soon as you feel comfortable with the Series 922 sample program move on to Installation and Wiring Chapter 4 Or if you have already installed and wired your system go to the Master Step Chart in Chapter 5 and begin entering and documenting your Series 922 program Sample Program Chapter 3 Chapter 4 Install Wire How to Install and Wire the Series 922 This chapter tells you how to install the Series 922 All mounting and wiring information is right here Because Watlow controls are thoroughly
130. n Alarm ALTYP1 D 65 Alarm Limits for alarms 1 and 2 with Process Type Alarm ALTYP1 P ALTYP2 P 66 Alarm Limits for Alarms 1 and 2 with Deviation Type Alarm ALTYP D ALTYP D 71 Reference Compensator to Series 922 Connector Diagram 73 Decade Resistance Box to Series 922 Connection Diagram 75 Voltage Current Source to Series 922 Connection Diagram Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28a Figure 28b Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 WATLOW Series 922 User s Manual 5 Tables Page Item 10 DIP Switch Selection 16 Series 922 Ramp and Soak Program 17 Editing Your Program Steps 4 7 18 Adding the AUTOSTART Step 18 LINKing to Another File 19 The WAITFOR Step 24 Noise Suppression Device Ratings 43 SYSTEM Prompts and Description 46 SETUP Prompts and Description 58 PROGRAM Prompts and Description 74 RTD Parameter Settings Chart Page Item 62 Master Step Chart 6 WATLOW Series 922 User s Manual Table Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Chart Chart 1 Contents Chapter
131. n Differential Filter 25 Fig 11 Common Mode Filter Wiring 25 Fig 10 D Decade Resistance Box to Series 922 Connection Diagram 73 Fig 41 Default Parameters 43 46 48 58 Differential Mode Filter Wiring 25 Fig 9 Dimensions External Event Alarm Board 27 Fig 14 Faceplate 26 Fig 12 Panel Cutout 27 Fig 15 Sideview 27 Fig 13 DIP Switch Location 10 Fig 3 Selection 10 Table 1 DIP Switches 10 38 How to Set 9 E Editing Your Program 17 Enter Operating Data And Operating Parameters Chapter 6 42 Error Codes 87 Event Inputs 28 33 38 44 Outputs 34 F Forward Jump 40 G Glossary 76 Ground Loops 24 Guaranteed Soak GS 39 H How To Install And Wire The Series 922 Chapter 4 21 Install the Series 922 26 Open the 922 9 Fig 2 Program the 922 Chapter 6 38 Appendix Index Set DIP Switches 9 Tune Chapter 5 36 Run 20 Use Alarms Chapter 7 63 Use the Keys and Displays Chapter 2 12 Wire The Series 922 29 Index 83 Input Options 29 Fig 17 21 Input Power Definitions 23 Intertwined Loop 41 Installation Procedure 26 J JUMPLOOP Types 40 Rules to Follow 41 K Keyboard Area 13 Fig 7 L Line Filtering Configuration 24 LINKing Files 18 M Master Step Chart 62 Chart 1 Microprocessor Are In a Way Like Trout 22 Model Number 70 Modes Overview 11 N Nested Loop 41 Noise Suppression Device Ratings 24 Table 7 O Open the 9
132. nal 5 to Terminal 4 Channel 1 Use Terminals 6 and 7 for RTD and jumper Terminal 8 to Terminal 7 WATLOW Series 922 User s Manual 29 Wire Input Figure 18 Input Options 2 amp 7 RTD Process Wiring Diagram NOTE For a two wire RTD Channel 1 Use Terminals 6 and 7 for RTD and jumper Terminal 8 to Terminal 7 NOTE Jumper terminal 4 to 5 only when using 4 20mA input Input Impedance 4 20mA 250 0 5V 100K Figure 19 Input Option 3 A or B T C and Process Wiring Diagram Input Options 2 amp 7 Terminals 1 8 Model 922A 2 0 000 amp Model 922A 7 Q _ 000 g Retransmit Common Recorder f Retransmit Output Optional Process 0 5V 4 20mA input NO Channel 2 o gt S1 Channel 1 RTD q x CO N O O A O Input Option 3 Terminals 1 8 Model 922A 3 0 000 Model 922A A 0 000 Model 922A B 0 000 g Retransmit Common Chart F E Retransmit Output Recorder bea h D Optional ska 4 q p Channel 2 5 J Process J i 7 g9 Channel 1 8 TIC 30 WATLOW Series 922 User s Manual How to Install and Wire Chapter 4 Input Option 4 Terminals 1 8 Model 922A 4 0 000 a Retransmit Common Chart Yr W Retransmit Output Optional Process 0 5V 4 20mA input g Channel 2 A ee Process 0 5V 4 20mA input Mm Process
133. nd Adjustment Gradually increase PB until the ACTUAL display temperature stabilizes to a constant value The temperature will not be right on set point because the initial reset value is 0 00 repeats per minute The ACTUAL temperature will stabilize below the desired setpoint When PB 0 RS RT and CT are inoperative and the 922 functions as a simple ON OFF control with a 3 F or 1 7 C switching differential Reset Adjustment Gradually increase RS until the ACTUAL display temperature begins to oscillate or hunt Then slowly decrease RS until the ACTUAL display stabilizes again near set point NOTE This is a slow procedure taking from minutes to hours to obtain optimum value Cycle Time Adjustment Set CT as required Optimum system control is always achieved with faster cycle times However if a mechanical contactor 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 Rate Adjustment Increase RT to 0 10 min Then raise SP by 20 to 30 F or 11 to 17 C Observe the system s approach to SP If the load temperature overshoots SP increase RT to 0 20 minutes Then raise SP by 20 to 30 F or 11 to 17 C and watch the approach to the new set point If RT is advanced too far approach to the set point will be very sluggish Repeat as necessary until the system rises to the new
134. nonymous with cold junction See Cold junction Control action that automatically eliminates offset or droop between set point and actual process temperature Also integral Synonymous with anti reset See Anti reset From any RETURN parameter you can go back to SYSTEM Resistance Temperature Detector Resistive sensing device displaying resistance versus temperature characteristics Displays positive temperature coefficient Only appear when in the RUN mode Represents the set endpoint of the current step for Channel 1 or Channel 2 that the Series 922 will try to achieve in the amount of time given This will be done linearly producing a ramp from a beginning set point to an end set point Seen only in the RUN mode The number of seconds that equal total step time to achieve the temperature of the Series 922 Intended value of the process variable One of six step types under the PROGRAM menu of the Series 922 Can be programmed as a file or a step to achieve or maintain a set point When in the PROGRAM menu this is the set point that the control will try to achieve by the end of the step When in the RUN mode it represents the current set point Its primary function is as the control point of the closed loop When ACCESS 5 is selected under the SETUP mode of the Series 922 the Special Function parameters appear Here you can select the input type degrees output type auxiliary and alarm types among others
135. o dissimilar metals whose standards is identified by a letter Temp Range the range over which the controller could have the set point adjustment Thermistor a sensor that changes resistance as the temperature changes Similar but not the same as an RTD Universal Input can be a thermocouple 100 ohm DIN RTD or process volts or milliamperes VAC Volts Alternating Current VAC DC Volts Alternating Current or Direct Current VDC Volts Direct Current VTB Sw DC Variable Time Base Switched Direct Current a time proportioning DC output where the cycle time is variable These notes are used to signify areas of concern in changing to a retrofit choice These notes are also printed at the end of the retrofit listing Note 1 Note 2 Note 3 Note 4 Note 5 Note 6 Note 7 Note 8 Note 9 Retrofit controller requires a substitution of a 100 Ohm RTD sensor for the thermistor Mounting and dimensions of retrofit controller are different Verify that sufficient panel space and depth is available Retrofit controller outputs are different Add external interposing mechanical or solid state relay 1f applicable Retrofit controller has a programmable not fixed set point Lock set point using controller s lockout parameter For DIN rail mounting or sub panel mounting purchase DIN rail adapter p n 0822 0586 P001 for 1 32 DIN or p n 0822 0586 PO002 for 1 16 DIN Add a suppressor Watlow p n 0804 0147 0000 for inductive loads
136. of ON and OFF time when close to the set point i e in the proportional band This variance is proportional to the difference between the set point and the actual process temperature In other words the amount of time the output relay is energized depends on the system temperature Solid state switching device One of six step types under the PROGRAM menu of the Series 922 that can be programmed to wait for a specific amount of time or a process value Start up condition where all program information is remem bered by the instrument s memory backup protection Represents the state that the Series 922 will wait for in the program for the remote event input to be present The hour that the system will wait for relative to when the step began This is not a measure of time of day Represents the minutes that the system will wait for relative to when the step began This is not a measure of time of day Temperature that the system will compare against the process variable of Channel 1 or Channel 2 and wait for before proceeding to the next step Action which provides output switching only at the zero voltage crossing points of the AC line Appendix A Accessories 70 Actual and Alphanumeric Display Area 13 Fig 6 Alarms Clearing 67 Function 66 Limits 65 Types 64 AUTOSTART Step Type 18 B Backward Jump 40 C Calibration 71 Chart Recorder 36 56 Clean Input Power The Do s and Don ts 23 Combinatio
137. olid State Model 922A _FBO _ 000 Figure 24 4 20mA Solid State HM 600 Max Max Output Option Output 1 4 20mA FB Wiring Ch 4 Diagram eee Output 3 Channel 2 32 WATLOW Series 922 User s Manual How to Install and Wire Chapter 4 Use the following figures to learn the connections and wiring of the External Event Alarm Board Refer to Page 27 for dimension and mounting information Eve nt Board Saure 2 i H i a im Lm E a Figure 28a amp 28b Figure 27 o EES o 2 za Control Power Control Power L2 Li GND L2 L1 GND Earth Ground Earth Ground L2B L2B L1B L1B L1A L1A L2A L2A N C N C 115 VAC 230 VAC An auxiliary power supply is available on the Series 922 event board to supply DC voltage needed to operate the Vaisala Model HMM 30C RH sensor or other transmitters or transducers The supply voltage varies from 21 to 33VDC with the maximum current output of 25mA External Event Board to Series 922 Connection Ribbon Cable Connection to Series 922 Figure 25 External Event Alarm Board Information Figure 26 External Board Control Power Wiring Figure 27 Ribbon Cable Connector to Series 922 How to Install and Wire Chapter 4 WATLOW Series 922 User s Manual 33 Event Board NOTE Check model number for appropriate diagram Figure 28 Event Option B and K Solid State Relay Figure 28a Event Opt
138. ove power from the Series 922 Remove wires from 6 and 8 for Channel 1 3 and 5 for Channel 2 Set DIP Switch 6 to the OFF position Appendix WATLOW Series 922 User s Manual 75 Glossary A B 76 Glossary This glossary includes general thermal system control terms ACCESS Actual Display data Alarm ALTYP1 ALTYP2 Analog retransmit Anti reset Automatic Prompts AUTOSTART AUX1 AUX2 A1H A1L A2H A2L WATLOW Series 922 User s Manual In the SETUP menu of the Series 922 an ACCESS number 0 1 3 5 must be selected to enter the personality of your Series 922 into the CALIB PID DIAGNOS and SPCLFUNC Any other number will return to SYSTEM Displayed information which gives the operator programmer real or actual data i e actual process temperature See Pro grammed display data A condition generated by the Series 922 indicating that the process has exceeded or fallen below the set or limit point Present only when AUX1 AL Determines whether the alarm type for Auxiliary Output 1 will be a process alarm or a deviation alarm for the Series 922 Present only when AUX2 AL Determines whether the alarm type for Auxiliary Output 2 will be a process alarm or deviation alarm Allows the operator to select which parameter the analog retransmit signal represents For a chart recorder output select Ci or C2 For a remote set point signal to slave controls sele
139. pply or Uninterruptable Power Supply U P S L1 D M Line Filter 74 Figure 9 Differential Mode L2 Line Load NAKA conte ia Ground NOTE Keep filters 12 inches or less from the control Minimize the line distance where noise can be reintroduced to control C M Line Filter M4 Figure 10 Line Load Common Mode Filter Diagram NOTE To prevent ground loops do not fasten common mode line filters or filters with metal cases to metal that is at ground poten tial Doing so will reduce filter effec tiveness C M Line D M Line Filter Filter Figure 11 Combination Line Load Line Load Differential Common Mode Filter Diagram How to Install and Wire Chapter 4 WATLOW Series 922 User s Manual 25 Installation Installation Information CAUTION The front panel screw turns 90 only Do not apply excessive force or turn the screw more than 90 Figure 12 Series 922 Faceplate Dimensions The Series 922 mounts in a panel cutout with two brackets These brackets hold the case against the front panel The Series 922 behind panel dimensions are 3 56 in 9 05mm high by 3 56 in 9 05mm wide by 6 0 in 15 24mm deep Figure 12 shows the dimensions of the front panel bezel The 922 weighs 2 75 lbs 1 25Kg For unit dimensional and mounting information including the location of mount ing brackets and size of the front panel cutout see Figures 13 through 15 Your panel s thickness can be from 0 06
140. rate for serial communications to run at 1200 2400 1200 Dependent on communications capability 4800 9600 COM ID Enter the Communications protocol Identification 0 9 0 Dependent on communications capability and COM STX LOCK Enter the Front panel Lock code 0 0 CLR FILE Press ENTER to display FILE Enter a file number to clear 1 10 1 RETURN Press the ENTER key to return to the SYSTEM prompt Press the MODE key to return to the SPCLFUNC prompt 48 WATLOW Series 922 User s Manual How To Program the Series 922 Chapter 6 Shaded parameters may not appear on your control They are dependent on your control configuration S ETU P M enu One of three main level operating menus From the SETUP menu you SETUP can set up or change system operating parameters such as real time high low range alarm types alarm points PID settings and communica tions You must select each ACCESS number to create the personality of your Series 922 0 ACCESS number 0 must be selected to enter the personality of your Series 922 into the CALIB parameters In the Series 922 when ACCESS 0 is entered under the SETUP menu the CALIB parameters appear These parameters setup the Real Time and the calibration offset of the process variable CALIB Represents the current Real Time hours and minutes of the Series 922 s System Midnight 0 hours and 0 minutes Read only parameter gt O O m op 09 TI 00 00 Represent
141. read the Safety Information in the narrow column on the outside of each page You will find internal circuits on the left in the following diagrams and external circuits on the right In addition input and output options are listed by model number Refer to the unit sticker on your control to be sure that you are wiring from the corresponding diagram We suggest that you read through the entire section before beginning your hookup Then proceed starting with the sensor inputs auxiliary outputs then control outputs data communications and finally power wiring It is very important to enter a system set point in the Series 922 before applying power to the load circuitry In all wiring diagrams internal circuits are on the left and external circuits are on the right Input Option 1 or 6 Terminals 1 8 NOTE Input impedance 1 Retransmit Common Chart must be 10K or greater 9 rw Retransmit Output Optional Channel 2 RTD Channel 1 How to Install and Wire Chapter 4 Wire Input WARNING To avoid electric shock make all connections on the back of this control before connecting power to the control Also disconnect power before opening the Series 922 Do not apply load power to the output circuits until you have entered a system set point Figure 17 Input Option 1 Dual RTD Wiring Diagram NOTE For a two wire RTD Channel 2 Use Terminals 3 and 4 for RTD and jumper Termi
142. ries 922 User s Manual 87 Series 922 Response to Error Codes ER1 Codes Shut Down Outputs The Series 922 will shut down its outputs whenever an ER1 code occurs An ER1 code usually represents a Series 922 malfunction Check These Items First Anytime you see an ER1 error code check for these four items first then follow the recommended action listed by the code a Low line voltage b Noisy environment noise event c Vibration d Temperature or moisture over specification ER2 Codes Do Not Shut Down Outputs ER2 error codes are data communication system related or file programming related Series 922 Alarm Messages ALM1__ Hl occurring ALM1__ LO occurring ALM2___ Hl occurring ALM2__ LO occurring Clearing an Error Code To clear an Error Code from the alphanumeric display first correct the problem then return to the SYSTEM menu Use the UP DOWN keys to reach the ER1 or ER2 parameter and press ENTER Press ENTER or transmit a 0 If the code returns or if the 922 replies to a data communicated 2 ER1 or ER2 query with the same code the problem still exists Refer to the Series 922 manual ER1 error codes can only be cleared when in the SYSTEM prompt and ER1 XX is flashing ER2 error codes can be cleared by returning to the SYSTEM menu or by pressing the ENTER key while in the RUN mode How to Clear an Alarm Code An alarm code will alternately flash with the parameter that you are presently on If the
143. rogammable Progammable Progammable Progammable Progammable Progammable Progammable Progammable Series 922 Output Dual Sw dc Sw dc Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual Sw dc Sw dc Dual Sw dc Sw dc Dual Sw dc Sw dc Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual Sw dc Sw dc Dual Sw dc Sw dc Dual Sw dc Sw dc Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual Sw dc Sw dc Dual Sw dc Sw dc Dual Sw dc Sw dc Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual 0 5A SSR 0 5A SSR Dual Sw dc Sw dc Dual Sw dc Sw dc Dual Sw dc Sw dc Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 4 20MA 0 5A SSR Dual 0 5A SSR 0 5A SSR 7 19 2004 Set Point Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Profiling Mounting 1 4
144. s Appendix Control Mode Microprocessor based user selectable modes Dual inputs dual control outputs per channel 8 event outputs 1 event input 1 remote hold input 99 step programmer with up to 10 profiles Control outputs User selectable as Heat Cool Cool Heat e Outputs independent or related via deadband for Heat Cool e ON OFF 3 F or 1 7 C switching hysteresis or 0 3 F or 0 17 C for 0 1 Units e PID parameters per channel Proportional band 0 to 500 C or 0 to 50 0 C for 0 1 Units Reset 0 00 to 5 00 repeats per minute Rate 0 00 to 5 00 minutes Rate band 0 to 7 times proportional band Cycle time 1 to 60 seconds e Deadband 36 F 20 C or Units 2 0 C for 0 1 Units Auxiliary outputs User selectable as e Events 1 amp 2 selectable as alarms for Channels 1 amp 2 e Process or deviation value per output e Alarms latching or non latching When non latching control will have 3 F 1 7 C switching hysteresis or 0 3 F 0 17 C for 0 1 Units e Separate high and low values per output Operator Interface Membrane front panel Four digit 1 2 LEDs displaying actual process input value LED indication of C F or process variable units MODE ENTER UP DOWN and RUN HOLD keys Eight character alohanumeric display of operating data Input Thermocouple RTD and electrical process input Automatic cold junction compensation for thermocouple RTD input 2 or 3 wire platinum 100 ohm
145. s Installation Information Installation Procedure Series 922 Power Wiring How to Wire the Series 922 Input Wiring Output Wiring Event Output Board System Wiring Example Starting Out Front Panel Sample Program Install and Wire WATLOW Series 922 User s Manual 3 Tuning Programming Alarms Appendix Terminology Quick Reference Page Item How to Tune the Series 922 Chapter 5 Recommended Tuning Reference Using a Chart Recorder Tuning How to Program the Series 922 Chapter 6 Write Out Your Program Select the Proper DIP Switch Settings Event Input Remote Hold Input Event Outputs Guaranteed Soak The Four JUMPLOOP Types JUMPLOOP Rules to Follow Programming in General SYSTEM Menu SETUP Menu PROGRAM Menu How to Use the Series 922 Alarms Chapter 7 Alarm Relay Configuration Number of Alarms Alarm Types The Operating Band Alarm Limits Alarm Function Latching or Non Latching Clearing an Alarm Message An Alarm And The State Of The Alarm Relay Appendix Specifications Model Number Information Thermocouple Field Calibration Procedure RTD Field Calibration Procedure Process Field Calibration Procedure Glossary Index Warranty Returning Merchandise Shipping Claims Watlow Controls Series 922 Error Codes Alarms Series 922 Quick Reference 4 WATLOW Series 922 User s Manual Contents Figures Page Item 7 Series 922 Input and Output Overview 9 How to Open the
146. s all files Represents the low limit to set points associated with Channel 2 Default values are also the low limits of the specific input type This parameter will not appear if the TYP parameter has been set to T or P Channel 1 only or DIP Switch 2 is ON Changing this parameter defaults parameters SP2 A2L A2H and clears all files Represents the high limit to set points associated with Channel 2 The default values are also the high limits of the specific input type This parameter will not appear if the TYP parameter has been set to T or P Channel 1 only or DIP Switch 2 is ON Changing this param eter defaults parameters SP2 A2L A2H and clears all files How To Program the Series 922 Chapter 6 This parameter determines whether Auxiliary Output 1 will be an alarm or event output for the Series 922 This parameter will not appear if the 2 event or 8 event output board is not connected or DIP Switch 2 is ON Range Alpha Display Auxiliary Output 1 s Function AUX1 AL Alarm Output defined for Event 1 AUX1 EV Event Output defined for Event 1 Default AL This parameter determines whether Auxiliary Output 2 will be an alarm or event output for the Series 922 This parameter will not appear if the external 2 event or 8 event output board is not connected the TYP parameter has been set to T or P Channel 1 only or DIP Switch 2 is ON Range Alpha Display Auxilary Output 2 s Function AUX2 AL Alarm Output
147. s selects XON XOFF protocol or ANSI X3 28 communica tion protocol This parameter will not appear if your Series 922 does not have communications Range XON or STX Default STX rr BAUD Represents the baud rate that serial communications will be running at This parameter will not appear if your Series 922 does not have communications Range 1200 2400 4800 9600 Default 1200 Represents the device identification number as required for the ANSI X3 28 communications protocol for the Series 922 This parameter will not appear if COM has been selected as XON or if your Series 922 does not have communications Range 0 to 9 Default 0 COM ID Allows for specific groups of parameters to be unaffected by the UP DOWN and ENTER keys preventing these parameters from being changed accidentally 0 No lock full access of all parameters 1 Prevents user from editing all parameters except the SYSTEM parameter group the LOCK parameter and the STEP and FILE parameter in the PROGRAM and pre run menus 2 Prevents user from editing all parameters except ER1 ER2 ALRM in the SYSTEM menu the LOCK parameter and the STEP and FILE parameter in the PROGRAM and pre run menus Range 0 to 2 Default 0 LOCK CLR FILE Allows the operator to clear a file of the Series 922 Press ENTER and choose the FILE that you want to clear Range 1 to 10 RETURN From RETURN you can go back to the SYSTEM prompt by pressing the E
148. s the SYSTEM 24 hour time of day clock for hours Range 0 to 23 hours Default 0 Nr HOUR The SYSTEM 24 hour time of day clock setting for minutes Range 0 to 59 minutes Default 0 CAL1 An offset of the process variable for Channel 1 This number is added to the value that the system derives The final result is used for the control point Range 50 to 50 units or C 5 0 to 5 0 for tenths or 90 to 90 F 9 0 to 9 0 for tenths Default 0 An offset of the process variable for Channel 2 This number is added to the value that the system derives The final result is used for the control point CAL2 will not appear if TYP under the SPCLFUNC menu is set up for T Temperature for Channel 1 only or for P Process for Channel 1 only Range 50 to 50 units or C 5 0 to 5 0 for tenths or 90 to 90 F 9 0 to 9 0 for tenths Default 0 CAL2 AIH When AUX1 AL and an external event board is connected the Series 922 will display this parameter representing the high process alarm or high deviation alarm for Output 1 ALTYP1 parameter selects a process or deviation alarm Process Range R1L to R1H R1L 10 to R1H 10 Process Default R1H R1H 10 Deviation Range 0 to 999 F 0 to 555 C Deviation Default 999 555 This parameter represents the low process alarm or low deviation alarm for Output 1 of the Series 922 Displayed only when AUX1 AL and an external event board is connected ALTYP1 par
149. splay CH2Z XXXX for Channel 2 Set the Appendix WATLOW Series 922 User s Manual 73 RTD Calibration Table 11 RTD Parameter Settings precision decade box to the correct RTD setting from Table 11 that corre sponds to the type of 922 unit you have Allow 10 seconds for settling press the ENTER key Press the MODE key until CH1G XXXX for Channel 1 appears on the alphanumeric display CH2G XXXX for Channel 2 Set the precision dec ade box to the correct RTD setting from Table 11 that corresponds tothe type of 922 unit you have Allow 10 seconds for settling and then press the ENTER key This unit is calibrated for JIS RTD on Channel 1 or 2 Remove power from the Series 922 Remove wires from 6 7 and 8 for Channel 1 Remove wires from 8 4 and 5 for Channel 2 Set DIP Switch 6 to the OFF position Parameters 0 1 RTD CH1Z or CH2Z 119 73 CH1G or CH2G 177 13 74 WATLOW Series 922 User s Manual Appendix Process Field Calibration Procedure Process Equipment Required e 4 1 2 digit digital voltmeter DVM e Precision voltage current source Setup and Calibration NOTE Before calibration on an installed control make sure all data and Figure 40 parameters are documented a a 1 Connect the voltage current source to 6 Positive and 8 Negative on the Source to Series 922 Series 922 terminal strip for Channel 1 4 Positive and 5 Negative for Connection Diagram Channel 2 See Figure
150. ss number with the Series 922 PROGRAM SPCLFUNC menu ACCESS 5 at the COM ID parameter Starting Communications in ANSI X3 28 Protocol Here s the syntax for starting communications with ANSI X3 28 Protocol The master device your computer must initiate the data link The example below uses the ASCII number 4 as a Series 922 device address Enter In ASCII using this syntax lt Address 4 gt lt ENQ gt ASCII 4 Characters a HEX Value 34 05 Response from the 922 lt Address 4 gt lt Acknowledge ACK gt ASCII 4 Characters lt ACK gt HEX Value __ ne 34 06 How to Use Data Communications ANSI X3 28 Stopping Communications in ANSI X3 28 Protocol The master device your computer must end communications with Device 4 by using Data Link Escape DLE and End of Transmission EOT characters Enter in ASCII lt DLE gt lt EOT gt ASCII Characters Tan HEX Value __ 10 04 Response from the 922 None ANSI X3 28 Command Example The Command sets a specific 922 parameter to a specific value The control must be in the HOLD mode to accept the change The general com mand syntax applies to all commands The definition and number of argu ments depends on the command itself See Table 4 Pages 17 18 In this example you want to change the Alarm 1 Low value to 500 Here the Command will do the job Command Syntax with ANSI X3 28 Protocol
151. syntax Note that each argument is an ASCII decimal number representing a specific value for each parameter listed in the table A response for a Step 8 in File 4 would be lt 1 gt lt space gt lt 235 gt lt space gt lt 50 gt lt space gt lt 1 gt lt space gt lt 20 gt lt space gt lt 15 gt lt Space gt lt 1 gt lt space gt lt 0 gt lt space gt lt 0 gt lt space gt lt 0 gt lt space gt lt 0 gt lt space gt lt 0 gt lt space gt lt 0 gt lt space gt lt 0 gt This tells you that Step 8 in File 4 is a SETPOINT step SP1 is 235 and SP2 is 50 Step Time is 1 20 15 EV1 is ON and EV2 through EV8 are OFF In Table 6 the abbreviation W1 is Wait for ACTUAL temperature on Table 6 Channel 1 STP Command Response Data lt gt Non literal Description Step Type Link File gt lt HOUR gt lt MIN gt These commands can accept an asterisk to indicate that they are not programmed How to Use Data Communications WATLOW Series 922 21 OMTR MTR Command The MTR command monitors the current RUNning or HOLDing step Data returned from the unit that have a value of asterisk mean that the value is unprogrammed The syntax for this command is lt Space gt MTR There are no arguments to the command The command will return the following data lt File gt lt Space gt lt Current Step gt lt Space gt lt Current Step Type gt lt Space gt Data 4 lt Spac
152. t AC power lines and jumper wires to the power supply terminal strip of the Series 922 Study the strip connections carefully before beginning Be sure to use these jumpers on the power supply terminal strip For 230VAC jumper 18 to 19 For 115VAC jumper 17 to 19 and jumper 18 to 20 All wiring and fusing must conform to the National Electric Code and to any locally applicable codes also Before applying power open the Series 922 and set DIP Switch 1 in the ON position for a Cold Start Replace the control chassis in the enclosure Apply power to the unit This clears all previously entered information from the 922 itis a clean or cold start Now remove power again open the unit and set Switch 1 to OFF This makes the next start a warm one retaining all subsequently entered informa tion in the processor s memory Close the 922 When applying power without sensor inputs on the Signal Conditioner terminal strip or if the control is not configured for the correct sensor input the Series 922 alternately flashes from SYSTEM to ER1 OOXX This is an error code indicating an open sensor These are normal displays for a unit without sen sors or improper configuration For more information on remote hold and external event input refer to page 38 How to Install and Wire Chapter 4 How to Wire the Series 922 This section has all the information you need to complete a good wiring job on the Series 922 and your system Please
153. t any STEP in FILE 1 or 5 When your program reaches FILE 5 STEP 6 the HOLD LED begins flashing This means your program is still running but it is HOLDing to WAITFOR the ACTUAL temperature to equal the WAITFOR Channel 1 W1 When they are equal the HOLD LED stops flashing Your program continues to the last step a STOP step and HOLDs again In the HOLD mode the Series 922 controls the process to the set points of the last SP step If you want to change a programmed step return to the PROGRAM menu and enter the FILE and STEP number you want changed Use the UP DOWN keys to select another step type and press ENTER To clear all parameters under a step type of its programmed values return to that step type and press ENTER All parameters return to their defaults Sample Program Chapter 3 WATLOW Series 922 User s Manual 19 Sample Program RUN Menu NOTE Shaded parameters may not appear on your control These parameters are dependent on how your control is configured See Chapter 6 for more information Figure 8 RUN Key Flow Diagram WATLOW Series 922 User s Manual Running Your Series 922 To run your Series 922 you must be at one of the three main level operating parameter menus SYSTEM PROGRAM or SETUP Press the RUN HOLD key The Series 922 asks what file you want to run and asks what step to begin with After entering the file and step number your program begins and the RUN LED is lit While in the RUN
154. t they are and what they will do Here s an overview of the different alarm parameters again Although you may already be aware of the alarms notice how these parameters interact Alarm Relay Configuration Series 922 alarm relays are configured to de energize when the ACTUAL value is beyond the alarm limits Normally open contacts are thus closed when tem peratures are OK That way alarm conditions exist if power is lost from the control Number Of Alarms There are two alarms in the Series 922 ALARM 1 and ALARM 2 These parame ters indicate an alarm condition or a de energized alarm relay with a flashing ALRMX XX in the alphanumeric display By retaining the indication of a previ ous alarm condition an operator absent from the control panel can be aware that an alarm occurred We ll look more closely at that in a few minutes Alarm 1 will only respond to Channel 1 and Alarm 2 only responds to Channel 2 How To Use The Alarms Chapter 7 WATLOW Series 922 User s Manual 63 Alarms Figure 34 Alarm Type for Alarm 1 is Process Alarm ALTYP1 P Figure 35 Alarm Type for Alarm 1 is a Devia tion Alarm ALTYP 1 D Alarm Types There are two Alarm Types for each alarm ALTYP1 and ALTYP2 are the prompts for Alarm 1 and Alarm 2 respectively The choices are Process alarm P or Deviation alarm D For review a process type alarm is one that is set at a fixed degree dis tance either positive or negative
155. tested and burned in before leaving the factory the Series 922 is ready to install when you receive it But before you begin working or cutting holes in panels read through this chapter to gain an understanding of the entire installation Consider sensor installation carefully You ll need to look at the noise reduction guidelines before making your panel cutout Miscellaneous Sensor Information Temp RH Wet Bulb Dry Bulb In this 922 configuration a dry bulb RTD measures tem perature on Channel 1 A wet bulb RTD in combination with the dry bulb RTD senses relative humidity on Channel 2 The 922 calculates the temperature difference between the two bulbs to determine per cent relative humidity The humidity dehumidify outputs Outputs 3 amp 4 are disabled when the Channel 1 temperature falls below 32 F 0 C or goes above 212 F 160 C The RH display reads OFF and the retransmit output is O volts if ANLG C2 ANLG is located in the Setup menu under Access 5 Solid State RH Sensor Vaisala Model HMM 30C Relative Humidity Sensor With the Vaisala configu ration Channel 1 must be configured to measure temperature and Channel 2 must be a process input configured for humidity with the Vaisala sensor See below for the TYP parameter description This parameter is located in the Setup menu under Access 5 DIP switch 4 must be set to the ON position The humidity and dehumidify outputs Outputs 3 amp 4 are d
156. that a controller uses to switch the outputs such as PID ON OFF and Manual Differential control algorithm in which the output is based on the difference of the inputs plus set point DIN Deutsche Industrial Norm a set of technical scientific and dimensional standards developed in Germany RTD sensors with the DIN curve change resistance at a rate of 0 00385 ohms ohms C DIN Rail standard DIN EN50022 mounting method for attaching devices onto a metal rail Fixed refers to a set point that is fixed at one value High Limit device will deactivate output on a temperature rise above set point Inductive Load any device that has a wire winding such as solenoids electromechanical relays or transformers Input refers to the sensor types that may be connected Integral the set point in integral on board to the controller JIS Joint Industrial Standards a set of technical scientific and dimensional standards developed in Japan RTD sensors with the JIS curve change resistance at a rate of 0 00396 ohms ohms C Line Voltage the voltage required powering the electronics of the controller Low Limit device will deactivate output on a temperature drop below set point 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 Brd the form factor of this controller is an open circuit board mounted on four standof
157. the reputation as an excellent supplier to original equipment manufacturers These OEMs depend upon Watlow Winona to provide compatibly engineered controls which they can incorporate into their products with confidence E Watlow Controls resides in a new 100 000 square foot marketing engineering and manufacturing facility in Winona Minnesota How to Use Data Communications WATLOW Series 922 27
158. thin the limits It s your choice Here again is the LAT information from the Operating Parameters LAT Defines Alarm Function NLAT Non latching Alarm relays are automatically energized when ACTUAL temperature returns to within the operating band as defined by ALTYP X AXL and AXH LAT Latching Requires the ENTER key to manually energize alarm relays after ACTUAL temperature returns to within the operating band as defined by ALTYP X AXL and AXH To clear an alarm in the RUN mode simply press ENTER To clear an alarm in the HOLD mode return to the SYSTEM prompt Press the MODE key until CLR ALRM is displayed and press ENTER 66 WATLOW Series 922 User s Manual How To Use The Alarms Chapter 7 Alarms Clearing An Alarm Message You can clear a latched alarm when the ACTUAL display value returns to within the operating band You do not need to clear indeed you cannot clear a non latching alarm A non latching alarm clears itself as soon as the AC TUAL display value returns to within the operating band There is a 3 F switching differential An Alarm And The State Of The Alarm Relay Simply stated a flashing alarm on the 922 alphanumeric display indicates the state of the alarm relay contacts A flashing alarm means that when an alarm condition is present ACTUAL beyond an alarm limit then the alarm relay is de energized How To Use The Alarms Chapter 7 WATLOW Series 922 User s Manual 67 Specification
159. this exercise If you feel that your knowledge of ramping controllers does not require a sample program to learn the Series 922 skip this chapter A Brief Overview This sample program teaches you the fundamentals of creating a ramping profile along with ways to expand that profile to its greatest versatility The program example starts with a simple ramp and soak profile A ramp progresses from one set point to another set point over a period of time Soaking controls the length of time the temperature holds at this level We then expand it to multiple ramp and soaks add JUMPLOOP functions perform an AUTOSTART LINK to another profile and finally perform a WAITFOR step This sample program only goes through the steps of programming Channel 1 of the Series 922 The process for Channel 2 is the same Events 3 through 8 are not shown At this point make copies of your Master Step Chart on Page 62 It is a good practice to keep track of your program as you go It s also a good idea to sit down and define exactly what you want your program to do Clear Memory Set DIP Switches If you haven t already cleared your Series 922 s memory do a Cold Start Turn the power OFF open the 922 and ensure that DIP Switch 1 is ON Apply power momentarily and reset DIP Switch 1 to OFF The program memory is now cleared If you haven t done so already attach your sensor as described in Chapter 4 14 WATLOW Series 922 User s Manual Sample Pro
160. ure H Humidity P Process V Vaisala RH sensor HMM 30C Dual T C TT T Dual RTD TT TH T Dual RTD 0 1 TT TH T 0 1 RTD Process TP TV T T C Process TP TV T RTD Process TP TV T Dual Process P P PV P Default The first column entry of the above board types Select an output type for Channel 1 Action in response to the differ ence between set point and process variable This parameter will not appear if DIP Switch 2 is ON Range Alpha Display Output 1 Output 2 OUT1HTCL Heat PID Cool PID OUT1CLHT Cool PID Heat PID Default HTCL Select an output type for Channel 2 Action in response to the differ ence between set point and process variable This parameter will not appear if the TYP parameter has been set to T Temperature for Channel 1 only or P Process for Channel 1 only under the TYP parameter or DIP Switch 2 is ON Range Alpha Display Output 3 Output 4 OUT2HTCL Heat PID Cool PID OUT2CLHT Cool PID Heat PID Default HTCL Represents a low limit to set point for Channel 1 The default values are also the low limits of your input type This prompt will not appear if DIP Switch 2 is ON Changing this parameter defaults parameters SP1 A1L A1H and clears all files Represents a high limit to set point for Channel 1 The default values are also the high limits of your input type This prompt will not appear if DIP Switch 2 is ON Changing this parameter defaults parameters SP1 A1L A1H and clear
161. w past these sensors should be moderate The sensors must be thermally insulated from the sensor mounting Both thermocouples must be ungrounded to obtain correct readings Event Input and Remote Hold Input These inputs accept a switch closure to digital common shown on Page 27 22 WATLOW Series 922 User s Manual How to Install and Wire Chapter 4 Definitions TTT CTU e l Ground Loop A condition created when two or more paths for electricity are created in a ground line or when one or more paths are created in a shield Earth Ground The starting point for safety and computer grounds It is usually a copper rod driven into the earth Safety Ground A ground line run with electrical power wiring to protect personnel Computer Ground A ground line for the ground connections to computers or microprocessor based systems This line is isolated from safety ground Common Mode Line Filter A device to filter noise signals present on both power line legs with respect to ground Differential Mode Line Filter A device to filter noise signals present between the two power lines themselves The Dos and Don ts of Clean Input Power Do keep line filters as close to the control as possible to minimize the area for interference pick up Do use twisted pair wire and possibly shielded wire from line filters to the control keep the line clean Do keep low power control wires physically separated as far as possible from line volt
162. will not appear if DIP Switch 2 is ON Range 0 2500 5000 Default 0 The Guaranteed Soak parameter guarantees the actual temperature for Channel 1 is being controlled within a window around set point while a profile is running If exceeded the step time clock stops until the actual temperature is within the soak window 0 Guaranteed Soak is not active gt 0 Guaranteed Soak Window active Only applies to Channel 1 Range 0 to 90 F 0 to 50 C 0 to 50 Units 0 to 9 0 F 0 to 5 0 C 0 to 5 0 Units Default 0 How To Program the Series 922 Chapter 6 SETUP Menu AUXI _ AUX2 ALTYP1 _ ALTYP2 _ LAT RTD GS WATLOW Series 922 User s Manual 55 SETUP Menu Allows the operator to select which parameter the analog retransmit ANLG signal represents For a chart recorder output select C1 or C2 Fora remote set point signal to slave controls select SP1 or SP2 C2 and SP2 will not appear if the TYP parameter is T or P See SCALE parameter below for further explanation C1 Channel 1 actual C2 Channel 2 actual SP1 Set point channel 1 SP2 Set point channel 2 Range C1 C2 SP1 SP2 Default C1 Allows the operator to scale the analog retransmit output for a certain number of millivolts per least significant digit of the value Reference 0 units 0 volts Range 1 2 5 10mV Default 1 SCALE COM Represents the selection of the protocol type for serial communi cations Thi
163. witches appear in Figure 3 The switches are clearly numbered from left to right You will use DIP Switches 1 4 and 6 5 is not used Table 1 on the next page shows the DIP switch selections Starting Out Chapter 1 WATLOW Series 922 User s Manual DIP Switches Figure 3 DIP Switch Location and Orientation Table 1 DIP Switch Selec tion WARNING Doing a cold start will cause all SETUP parameters and files to be lost DO NOT put DIP switch 1 in the ON position unless all user programmed information is to be cleared SPCLFUNC parame ters define the personality of your Series 922 Such as input type units of measure range calibration offset output action alarm type and lock out 10 WATLOW Series 922 User s Manual A007 1727 Board Control Chassis Top View Normal Operating Position Function ON OFF Cold Start Display the factory selected SPCLFUNC parameters Tenths of units displayed 0 5VDC 0 20mA input Not Used Factory Test Calibrate Warm Start OFF Display all SPCLFUNC Choose parameters No decimal displayed Choose 1 5VDC 4 20mA input Choose Not Used OFF Normal Operation OFF DIP Switch 1 determines a warm or cold start A warm start will save all programmed information in the 922 s memory backup A cold start is a clean startup condition all user programmed information is deleted Your Series 922 leaves the factory programmed
164. x step types under the PROGRAM menu of the Series 922 that can be programmed to wait for a specific amount of time a desired set point or both When either or both are used they must be true before the program continues WAITFOR Value the system compares against the process variable of Channel 1 and waits for before proceeding to the next step of the program Range R1L to R1H Default Unprogrammed b lt Value the system compares against the process variable of Channel 2 and waits for before proceeding to the next step of the program This parameter will not appear if T or P Channel 1 only in the TYP parameter under the SPCLFUNC menu have been selected Range R2L to R2H Default Unprogrammed i NO The hours the system will wait for relative to when the step began Weak Ud This is not a measure of time of day Range 0 to 23 hours Default Unprogrammed WMN _ Represents the minutes the system will wait for relative to when the step began This is not a measure of time of day Range 0to59 minutes Default Unprogrammed 60 WATLOW Series 922 User s Manual How To Program the Series 922 Chapter 6 WE Nr RETURN AUTOSTART DAY HOUR M Z a RETURN STOP RETURN LINK FILE RETURN PROGRAM Menu A wait for event input represented by a switch closure or opening at which the 922 continues the program This is not a voltage or current input Range OPEN or
165. xpressed in seconds for a controller to complete one ON OFF cycle Time between successive turn ons The time necessary to complete a full ON through OFF period in a time proportioning control system Represents the number of days that the 922 will wait until AUTOSTART takes place Each time 00 00 is achieved one day has gone by The Dead Band parameter for Channel 1 or Channel 2 represent ing the area where no heating or cooling takes place in a heat cool proportional control A temperature band between heating and cooling functions Anticipatory action that senses the rate of change of temperature and compensates to minimize overshoot and undershoot Also Rate The difference between the value of the controlled variable and the value at which it is being controlled WATLOW Series 922 User s Manual 77 Glossary Deas Default parameters 78 DIP Switch DIN Display capability Droop Duty cycle ER1 ER2 Events EV1 amp EV2 EV3 EV8 FILE GS HOUR WATLOW Series 922 User s Manual The parameters or programmed instructions which are perma nently stored in microprocessor software to provide a data base A Dual In line Package switch Deutsche Industrial Norms a widely recognized German standard for engineering units In a digital indicating instrument the entire span that can be indicated if fully utilized The difference in temperature between set point and stabilized
166. ycle Time between successive turn ons This parameter will not appear if Your Series 922 has a 4 20mA output and OUT2 under the SPCLFUNC menu is set to HTCL PB2H is set to 0 or you have selected T or P Channel 1 only in the TYP parameter under the SPCLFUNC menu Range 1 to 60 seconds Default 5 CH2H A thermal control band for channel 1 heating that defines where the rate derivative function begins This band is in multiples of the heat proportional band This parameter will not appear if PB2H is set to 0 or T or P Channel 1 only in the TYP parameter under the SPCLFUNC menu have been selected Range 0 to 7 times the PB2H 0 denotes rate is always functional Default 0 RB2H DB The area for Channel 2 where no heating or cooling takes place in a heat cool proportional control This parameter will not appear if T or P Channel 1 only have been selected in the TYP parameter under the SPCLFUNC menu Range 36 to 36 F 20 to 20 C 20 to 20 Units 3 6 to 3 6 F 2 0 to 2 0 C 2 0 to 2 0 Units 20 to 20 RH Default 0 A temperature band expressed in degrees within which a temperature controller proportioning function is active for Channel 2 cooling This parameter will not appear if T or P Channel 1 only have been selected in the TYP parameter under the SPCLFUNC menu Range 0 to 900 F 0 to 500 C 0 to 500 Units 0 0 to 90 0 F 0 0 to 50 0 C 0 to 50 0 Units 0 to 500 RH

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