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Series 988 User`s Manual Watlow Controls

1. dJEC2 decimal 2 4 11 L OC front panel lockout 6 3 8 8 dFL default 6 14 L oP low power limit 4 41 d A9 Diagnostics Menu 6 7 L oo P loop error detect 8 10 RTD calibration curve 2 4 14 d 19 diagnostics lockout 6 6 L OL Jd alarm 3 trigger 4 26 d FF differential 4 36 9 7 i local remote 5 8 S d r direct action 4 37 Le nH learn high 4 13 8 23 d 1565P test displays 6 11 LraL learn low 4 13 8 23 SEEJ Setup Menu 4 1 dUPL duplex 4 38 GHYS slidewire hysteresis 4 16 M N S IL 2 silencing 2 4 24 E J S ILJ silencing 3 4 27 PAo d Modbus 4 46 silencing 4 4 30 E 1 T A D underflow error 7 8 aL A non latching 4 36 slidewire 8 23 E21 A D underflow error 7 8 ___no none 4 38 9 8 serial number 6 8 E I 2 sensor under range error 7 8 L_ nor normal 4 36 GOF E software revision 6 8 E2 2 sensor under range error 7 8 SP 1 set point 1 9 3 E I 3 sensor over range error 7 8 O SP 2 set point 2 5 3 Ee 3 sensor over range error 7 8 SP ec set point 2 control 4 22 E 1 4 A D overflow error 7 8 GFF control outputs off 8 8 CEPE set point 8 17 9 8 Ee 4 A D overflow error 7 8 onj on 8 4 8 19 St PE crossover set point value 4 39 E T event input 1 4 40 OPE r Operation Menus 5 1 5 16 Gt rt start 8 17 E 15 event input 1 status 5 4 UPL P open loop 6 12 7 9 595 system lockout 6 4 E d event inp
2. He CL OEI oO O o aT ee l H g 3J 999 Press the Up arrow key Y or the Down arrow key to select one of the prompt values Prompts may not appear depending on controller configuration Figure 4 18 Navigating the Output Menu 4 18 WATLOW Series 988 User s Manual Enter your settings mone from the controller s gt upper display O i ca Output 1 p 4 19 pa Process 1 ast p dat Hysteresist gx pa Output 2 co pea Pec Process 2 none pa 2 Hysteresis 2 3 Imone Output 2 p 4 21 gt Set Point 2 Control E 7 mone gt Alarm 2 pa T pa Alarm 2 Side gim pe e Latching 2 Saite Silencing2 L 3 Output 3 C Alarm 3 Output 3 p 4 25 Alarm 3 Side 3 Hysteresis 3 Ly 3 Latching 3 itz SilencingS L GEY Output 4 Alarm 4 i Output 4 p 4 28 Sd Alarm 4 Side 354 Hysteresis 4 A Latching 4 JEL 8 RUEL aE 5 iL 4 Silencing 4 L Analog Output Process 3 Output 3 retransmit Retransmit Low Limit p 4 31 Retransmit High Limit Fete aera elie a alaha ata Setup Menus Chapter 4 NOTE Decimal points may not always be in the position specified below depending on the the settings in the Decimal 1 and Decimal 2 parame ters in the Input Menu Setup Menus Chapter 4 setup Output Output Prompts When you are in the Setup menus the Series 988 displays the
3. 41 B y8 0 8 8 8 8 8 8 8 8 6 8 8 8 8 8 8 Soma a a A ic i ee i el Prompts may not appear depending on controller configuration Setup Menus Chapter 4 NOTE Decimal points may not always be in the position specified below depending on the the settings in the Decimal 1 and Decimal 2 parame ters in the Input Menu Setup Menus Chapter 4 setup Global Global Prompts When you are in the Setup menus the Series 988 displays the menu selection in PE QEPE 9L bt or CGF 4 in the upper display and in the lower display The Up arrow Y or Down arrow key selects another menu Press the Mode key to display the first prompt in the lower display and its value in the upper display Use the Up arrow Y and Down arrow g keys to change the value in the upper display The new value will not take effect until after a five second delay or until you press the Mode key QB Celsius Fahrenheit Select which temperature scale the controller will use This prompt appears only on controllers with either Input 1 or Input 2 set to something other than a process input Default E F C_F Failure Mode Select the output level that the controller will maintain if an input fails e Bumpless transfer b PL 5 maintains the same output settings after an input failure FA iL This prompt always appears If Default p 4 Keaicon bPLS C 100 O FA IL FAIL ace bP
4. Gnd These prompts always appear Inputs 1 and 2 Module Types Displays which input module is installed in the controller Please doc ument this value before contacting the factory for technical assistance Input Types non No input module t c Thermocouple only module Ce u Current detect e St 1d Slidewire module e OFF Universal off e U td Universal rtd e UE ch Universal high gain thermocouple e Ut cL Universal low gain thermocouple im Mm Cz C2 C Cz ro Universal millivolts Cz pe 3 Cc e UP re ce Universal process e amp 2 Event input 2 These prompts always appear Cz WATLOW Series 988 User s Manual 6 9 Factory Diagnostics 10 tJ eg eg WATLOW Series 988 User s Manual Outpu Display ts 1 2 3 and 4 Module Types the controller s output module Please document this value before contacting the factory for technical assistance Output Types e nonE e 55r I e 55 iS s d iri de FLES eicL Ab Proc eUrEt SHE RRA EL Es s al Ww at no output module A 0 5A solid state relay K 0 5A solid state relay with suppression B switched dc open collector C form C relay E form C relay with suppression D relay A B J process output F voltage retransmit N current retransmit M power supply T EIA TIA 232 communications R EIA TIA 485 or EIA TIA 422 communicat
5. dFL Factory Menus Chapter 6 6 14 WATLOW Series 988 User s Manual Chapter 7 Tuning Manual Operation Alarms and Error Codes NOTE A useful reference on tuning is Tuning of Industrial Control Systems by Arman do B Corripio pub lished by the Instrument Society of America NOTE Auto tune can be initiated if is setto oni NOTE For information about tuning a cas cade system see Chapter 9 NOTE Before attempting to auto tune a cascade system see Cascade Setup in Chapter 9 Figure 7 1 Auto tuning example Tuning Manual Operation Alarms and Error Codes Chapter 7 Auto tuning Heat and or Cool The Series 988 can automatically tune the PID parameters to fit the char acteristics of your particular thermal system A amp A __ have 1 set of PID parame ters Units with enhanced software 98_B _ ___ __ and set to Global Menu have two sets of PID parameters PID A and PID B Only one PID set can be auto tuned at a time For information on tun ing a cascade system see Chapter 8 Before beginning the auto tune sequence make sure the parame ter located in the Global Menu is at the proper setting This allows the user to select the tuning set point as a percentage of the current control set point See Chapter 4 for more information on this parameter The fig ure below uses the default setting 90 to define the auto tuning process Once the auto tune sequence has begun the
6. Open Loop Figure 6 7 The Diagnostics Menu WATLOW Series 988 User s Manual 6 7 Factory Diagnostics Factory Ship Date Shows the date that the final factory control test was performed The first two digits represent the week as numbered from to 2 The second two digits represent the year 94 95 etc dft EE This prompt always appears Software Revision Shows the controller s software revision code when set to Y 5 This letter should match the software revision code on the cover of the manual that came with your controller n and W988 XUMN Rev NOO SOF amp This prompt always appears Serial Number Shows the controller s serial number The first two letters in the upper display are to indicate that the controller is in serial number mode The right half of the upper display shows the first two digits of the serial num ber The lower display shows the last four digits of the serial number 5678 This is what the controller with the serial number 0988345678 would dis play This prompt always appears Ambient Temperature Shows the ambient temperature at the Input 1 terminals The temper ature is shown in F in the form Q00 0 regardless of the settings of OEE I IdECC dFijor CLF A 6b This prompt always appears 6 8 WATLOW Series 988 User s Manual Factory Menus Chapter 6 Factory Diagnostics Factory Use Only These prompts are used only at the factory
7. Ratio ndix Glossary Specifications Warranty and Returns Index Menu Overview Model Number Ordering Information Declaration of Conformity WATLOW Series 988 User s Manual Figure Int 1 The Series 988 Controllers Introduction Introduction to the Watlow Series 988 Controllers Watlow s Series 988 controllers set a new standard in the controller indus try by packing an impressive array of features into an 1 8 DIN package No other controller offers the flexibility compact size and durability of the Series 988 It can control a wide variety of temperature and process appli cations with a broad range of input and output options that allow control of virtually any process variable The Series 988 is the only 1 8 DIN controller that can provide single unit cascade control of a process Its other features include heater current monitoring remote set point input ratio control and valve control through slidewire feedback The Series 988 also delivers expanded auto tuning capabilities increased alarm functionality and several unique control algo rithms When we refer to the Series 988 controller we refer also to the horizontal and low voltage versions of the Series 988 the 986 987 988 and 989 We recommend that you read all of this manual s introduction to familiarize yourself with the conventions and content of this manual and the steps to setting up a Series 988 controller Make sure you understand
8. SERIES 988 NOTE Adjustable mount ing brackets can be side mounted i 1 Adjustabl Panel Cutout N a ey Mounino Se Maximum Panel C gt i NOTE Thickness il ay Co p Holes can be cut in 0 38 9 65mm i the panel using a Greenlee 1 8 DIN Aoo i Hydraulic Kit L 60068 punch 3 62 0 03 0 00 60069 die 60070 92mm 0 8 il L 4 J C E Figure 2 1 ar St Series 988 and d ian Series 989 ait 0 02 0 00 fae B 103 mm dimensions and Tomme 06 terminal number layout IOC MOM MOE Installation and Wiring Chapter 2 WATLOW Series 988 User s Manual 2 1 Installation Installing the Series 988 Installing and mounting requires access to the back of the panel 1 Make a panel cutout using the panel cutout dimensions from the previ ous page 2 To remove the controller chassis from its case press in firmly on the two tabs on one side or the top of the bezel until they unsnap then unsnap the two tabs on the opposite side or the bottom Pull the chassis out of the case by gently rocking it NOTE Removing the con 3 Slide the case into the panel cutout Check to see that the gasket is not troller chassis from twisted and is seated within the case bezel flush with the panel Slide its case makes mounting easier Figure 2 2 Side and top view 2 2 S
9. ard Failure to install temperature limit control protec tion where a poten tial hazard exists could result in dam age to equipment property and injury to personnel A WARNING To avoid damage to property and equip ment and or injury of loss of life use National Electric Code NEC stan dard wiring prac tices to install and operate the Series 988 Failure to do so could result in such damage and or injury or death Figure 2 6 System wiring example 2 6 WATLOW Series 988 User s Manual L1 L2 earth ground high limit mechanical contactor D oO 0 J Bi l E N O N N EERO OOO bs dSo00 92A3 1DJ1 0000 limit control h UIN heater OO000000 13 14 TE ath 988A 10CA AARR rear view optional normally open momentary switch process sensor limit Sensor 120V ac Series 988 988A 10CA AARR temperature control O SSR 240 10A DC1 solid state relay dc input 10 Series 92 92A3 1DJ1 0000 limit control OQ0O0OOO COO high temperature light Installation and Wiring Chapter 2 L1 A WARNING To avoid damage to property and equip ment and or injury of loss of life use National Electric Code NEC stan dard wiring prac tices to install and operate the Series 988 Failure to do so could result in such damage and or injury or death NOTE Sket
10. lE 1 Integral Output 1A or 1B H E H b Tune integral to eliminate the offset or droop between the set point and the actual process temperature for PID output 1 When set to _ integral is disabled IE 1A This prompt appears only if Calibration Menu is set to and Pb iAjisnotsetto Q NOTE The PID B Menu appears only on an min repeat controllers with enhanced software 98 B __ Operation Menus Chapter 5 WATLOW Series 988 User s Manual 5 11 Operation PID A or B cH IA cH lb NOTE The PID B Menu appears only on controllers with enhanced software Rate Output 1A or 1B Adjust the rate to eliminate overshoot on startup or after the set point changes The rate setting will not influence the percent power if the process temperature is more than twice the proportional band from the set point When set to Q rate is disabled This prompt appears only if Calibration Menu is set to and Pb 1A is set higher than 0 Default p z min icf if Derivative Output 1A or 1B Adjust the derivative to eliminate overshoot on startup or after the set point changes The derivative setting will not influence the percent power if the process temperature is more than twice the proportional band from the set point When set to Q derivative is disabled dE f This prompt appears only if df L Calibration Menu is set to and Ph 7A is set higher than 9 Default l ges min dE TA 5 12
11. s Manual Factory Menus Chapter 6 Reaching the Diagnostics Menu Press the Up arrow Y and Down arrow 62 keys together and hold until the prompt appears in the lower dis play Press and hold again until the prompt appears in the lower display 9 N9 O PLOC d AG CAL Fct FetY FetY Panel Diagnostics Calibration Lockout Menu Menu Menu p 6 7 p 6 13 p 6 2 Use the Up arrow Y key to step from the Panel Lockout Menu PL QC to the Diagnostics Menu d A9 Press the Mode key B to step through the prompts Fe nol YES d ISP Id ISP NAD Eout Eout Press the Up arrow key Y or the Down arrow key to select one of the prompt values In the Diagnostics Menu only the values of d 5P Eout and OPL P can be changed Factory Menus Chapter 6 Factory Diagnostics rr y Factory Prompt Enter your settings from the controller s Factory Ship Date Upper display GFE Software Revision 183l l s Un 3 Serial Number Ambient Temperature t Ambient A D count Ground A D count rr Input 1 A D count Ec Input 2 A D count 9 i Input 1 Module Type LC Input 2 Module Type B r DNATA DNA AA ANA DAANA DNA ANA DNA DA ATA DNA AEA DTL AAA Output 1 Module Type Output 2 Module Type LC Output 3 Module Type e E O EEEE ea Je Output 4 Module Type SP Test Display rr oul Test Outputs ro
12. tion and model number determine which prompts appear After stepping through each menu the Series 988 returns to the Factory Menu prompt Fct 9 Use the Up arrow Y and Down arrow keys to select the next menu or use the Mode key 3 to advance through the same menu again To move backwards through the menu hold down the Mode key 3 and press the Up arrow key Y Use the Up arrow Y or Down arrow g key to change the prompt setting Press the Up arrow Y and Down arrow Keys together and hold until the prompt appears in the lower display Press and hold again until the prompt appears in the lower display O Fa PLOC id 1A9 CAL Fct Panel Diagnostics Calibration Lockout Menu Menu Menu p 6 7 p 6 13 p 6 2 Use the Up arrow key 9 to select one of the Factory Menus WATLOW Series 988 User s Manual 6 1 Factory Panel Lockout Reaching the Panel Lockout Menu PI WATLOW PROCESS on on E e ee ec S i gt Badan DISPLAY OUT MAN o SERIES 988 Select the Panel Lockout Menu then press the Mode key B to step through the prompts 9 Aa FULL ERd lnonE vy vy vy iy y e l i EJ LOC LOC LOC LOC Press the Up arrow key or the Down arrow key to select one of the prompt values Figure 6 2 The Panel Lockout Menu 6 2 WATLOW Series 988 User s Manual ro C3 r Factory Prompt Fn N tr LC Enter your settings
13. 5 30mA 12V 5 30mA or 20V 5 30mA e EIA TIA 232 communications or ElA TIA 485 EIA TIA 422 communications opto isolated Accuracy e Calibration accuracy and sensor conformity 0 1 of span 1 LSD 77 F 5 F 25 C 3 C ambient and rated line voltage 10 e Accuracy span 1000 F 540 C minimum e Temperature stability 0 2 F F 0 1 C C change in ambient e Voltage stability 0 01 of span of rated line volt age Agency Approvals e UL C UL File 43684 e CE 89 336 EEC Electromagnetic Compatibility Directive EN 50081 2 1994 Emissions EN 50082 2 1995 Immunity e 73 23 EEC Low Voltage Directive EN 61010 1 1993 Safety e NEMA 4X Terminals e 6 compression universal head screws tighten to 5 inch pounds maximum accepts 20 14 gauge wire Line Voltage Power 100 to 240V ac 10 15 50 60HZ 5 24 to 28V ac dc 10 15 50 60HZ 5 16VA maximum Fused internally factory replaceable only Slo Blo type time lag 2A 250V for high voltage versions 5A 250V for low voltage versions e Non volatile memory retains data if power fails Operating Environment e 32 to 149 F 0 to 65 C 0 to 90 RH non condens ing Storage Temperature e 40 to 185 F 40 to 85 C Mechanical e 1 8 DIN panel mount NEMA 4X IP65 equivalent front panel e Overall width x height x depth horizontal 4 03 x 2 18 x 4 74 102mm x 55mm x 120mm vertical 2 1
14. 8 17 K 1 5V dc process 2 13 range high 1 4 5 4 6 4 20mA process 2 13 range high 2 4 11 4 12 keys 3 1 ac outputs 2 13 range low 1 4 5 4 6 external transmitter power supply 2 13 range low2 4 11 4 12 L switched dc open collector 2 13 rate output 3 4 25 output 1 5 12 L1 output 1 3 1 output 3 wiring 2 14 output 2 5 15 L2 output 2 3 1 ac outputs 2 14 rate alarm 7 7 L3 output 3 3 1 external transmitter power supply 2 14 rate band A 3 Appendix WATLOW Series 988 User s Manual A 7 Index r z rate derivative adjustment 7 3 ratio control 9 12 9 13 A 3 reference junction A 2 relay mechanical 7 2 release tabs 1 1 2 2 2 3 7 remote set point 4 10 8 8 8 18 8 19 removing controller chassis 1 L 2 2 3 7 5 reset output 1 5 11 output 2 5 14 reset integral adjustment 7 3 restore 6 14 retransmit 8 20 8 21 A 3 retransmit calibration offset 4 33 retransmit high limit 4 32 retransmit low limit 4 32 RID A 3 RTD calibration curve 1 4 7 RTD calibration curve 2 4 14 RTD input 2 5 RTD wiring input 1 2 8 input 2 2 9 RTU Modbus 8 4 S safety practices 2 4 2 6 2 7 semiconductor oven 8 3 sensor installation 2 5 sensor type input 1 4 3 input 2 4 9 4 10 serial number 6 8 set point in tuning 7 2 set point ramp to 8 16 set point 1 3 2 set point 2 5 1 5 3 set point 2 control 4 22 setting DIP switches 1 1 1 4 input 1 2 lockout 1 4 output 1 3 Setup Menus 4 1 4 4 shipping claims A 5 silencing
15. L _F HYS H 95 HYS 1 Global Menu amp L F L iai HYS HYS HYS 1 Global Menu Input Menu L F HYS 1 HYS HYS Global Menu amp om CLF l tal HYS 1 HYS HYS 1 Global Menu Input Menu el Ie units HYS HYS i a process input is selected 4 20 WATLOW Series 988 User s Manual Setup Menus Chapter 4 setup Output Output 2 Set the way that output 2 will respond to a difference between the set point and an input variable e AL e de energizes output 2 in an alarm condition Al 2a energizes output 2 in an alarm condition Ht select reverse action so that output 2 responds when the input signal is less than the set point select direct action so that output 2 responds when the input signal is more than the set point This prompt appears only on controllers equipped with output 2 hardware not98 _ _ __A __ and do not appear if out put 2 is a process output 98__ ___F ___ and do not appear if AL 90 in the Global Menu is set to d YPL Default AF ALA LOE Cte Cte OE Process 2 Select the process range for output 2 This prompt appears only on controllers equipped with output 2 process hardware 98__ ___F ___ _ and with not set tol no Default 1 4 20mA 0 20mA 0 5 V 1 5V 0 10V dc 4 20 8 20 G S 8 10 Prce Pree Pree Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 21 setup Output Hysteresis 2 Select the switching hysteresi
16. fe NY m 3 tr re rm c gt 3 2 rm c gt 3 2 rc Wn XD rc cascade action 4 37 cascade control 4 36 cycle time output 1 PIDA cycle time output 1 PID B cycle time output 2 PID A cycle time output 2 PID B current 8 10 8 11 rr in ry Qa 13 Ia 5 16 16 ry tr XD N m Are o ho ry tr aL mn 00 N m tr NY o 00 ho m c 9 9 g Q XD tr XD data bits amp parity 4 45 8 4 factory ship date 6 8 dead band 5 16 dead band PID A 5 16 dead band PID B 5 16 deviation alarm input 1 7 6 deviation alarm input 2 7 6 derivative output 1 PID A derivative output 1 PID B derivative output 2 PID A derivative output 2 PID B decimal 1 4 4 XD tr ON NN NN NN ON On On mn 00 6 Qa o XD Q o o QO m Q m a ae 5 1 T a M 5 a rm oc a m al mn on Sr SS es a AN MW eg z o m m Appendix Index prompts
17. from the controller s Front Panel Lockout upper display System Menu PID A Menu PID B Menu Input Menu Output Menu Global Menu Communications Menu Diagnostics Menu TEETE PSUR RRS SER Calibration Menu Prompts may not appear depending on controller configuration Factory Menus Chapter 6 AN CAUTION Setting to ejor J disables the Auto Man key and will force the controller into man ual mode if an open sensor occurs Verify that the con troller is operating in the desired mode auto or manual before setting the lockout level Failure to do so could result in dam age to equipment and or property Factory Menus Chapter 6 Factory Panel Lockout Panel Lockout Prompts When you are in the Factory menus the Series 988 displays the menu selection PL OC d A9 or AL in the upper display and in the lower display The Up arrow Y or Down arrow key selects another menu Press the Mode key Q to display the first prompt in the lower display and its value in the upper display Use the Up arrow Y and Down arrow 2 keys to change the value in the upper display The new value will not take effect until after a five second delay or until you press the Mode key QB Front Panel Lockout Sets the Lockout level for the Front Panel This allows you to disable keys on the front of the controller o 0 enables all keys I disables the Mode key QB disabl
18. likely cause Check the sensor Make sure the input prompt is set to the correct sensor E I 2 Ee 2 Sensor under range error The sensor at the input indicated by the first number generated a value lower than that allowed for the range of the sensor or the analog to digital A D converter malfunctioned Make sure the setting for the input Input Menu matches the sensor type and that the sensor range falls within the range of the process being controlled E 3 Ee 3 Sensor over range error The sensor at the input indicated by the first number generated a value higher than that allowed for the range of the sensor or the analog to digi tal A D converter malfunctioned Make sure the setting for the input Input Menu matches the sensor type and that the sensor range falls within the range of the process being controlled EC 4 A D overflow error The analog to digital A D converter at the input indicated by the first number is over range An open or reversed polarity sensor is the most like ly cause Check the sensor Make sure the input Input Menu is set to the correct sensor type The analog to digital A D converter input voltage may be too high to con vert an A D signal 7 8 WATLOW Series 988 User s Manual Tuning Manual Operation Alarms and Error Codes Chapter 7 Er 3 Ambient temperature error The ambient temperature of the Series 988 has dropped below 32 F 0 C or risen above 149 F 65
19. quence nominale 50 60 Hz Consommation d alimentation nominale 16 VA maximum Conforme aux exigences de la ou des directive s suivantes de l Union Europ enne figurant aux sections correspondantes des normes et documents associ s ci dessous 89 336 EEC Directive de compatibilit lectromagn tique EN 50082 2 1995 Norme g n rique d insensibilit lectromagn tique Partie 2 Environnement industriel EN 61000 4 2 1995 D charge lectrostatique EN 61000 4 4 1995 Courants lectriques transitoires rapides ENV 50140 1994 Insensibilit nergie rayonn e ENV 50141 1994 Insensibilit a nergie par conduction ENV 50204 1995 T l phone cellulaire EN 50081 2 1994 Norme g n rique sur les missions lectromagne tiques Partie 2 Environnement industriel EN 55011 1991 Limites et m thodes de mesure des caract ristiques d interf rences du mat riel radiofrequence industriel scientifique et m dical Classe A EN 61000 3 2 1995 Limites d mission d harmoniques EN 61000 3 3 1995 Limitations d carts de tension et de papillotement 73 23 EEC Directive li e aux basses tensions EN 61010 1 1993 Exigences de s curit pour le materiel lectrique de mesure commande et de laboratoire Partie 1 Exigences g n rales 1230 A 12 WATLOW Series 988 User s Manual Erklart daB das folgende Produkt Deutsch Beschreibung Serie 986 987 988 989 Modellnummer n 9 8 6 7 8 oder 9
20. 3 WATLOW PROCESS ee oe ee DEV OUT fw O SERIES 988 Mode Key Enters new data and steps to the next prompt in the current menu DISPLAY a MAN o Mode Up arrow Keys Hold the Mode key then press the Up arrow key to move backwards through the cur rent menu Scrolling stops when you reach the top of the menu Lower Display Indicates the set point deviation percent power temperature unit menu prompt name or alarm code L1 L2 L3 L4 These LED s indicate when output 1 2 3 or 4 are active Outputs can be configured as Oti Control Ot2 Control or Alarm Ot3 Alarm or Retransmit Ot4 Alarm or Communications flashes on transmit and receive Display Key Pressing this key enters the Display Loop Press the Display key at any time to return to this loop The next page has more information on the Display Loop Auto Man Key In Manual mode the lower display shows percent output Pressed once it clears any latched alarm If pressed again within five seconds it will toggle between Auto and Manual mode Auto Man LED Lit when the control is in Manual operation Press the Auto Man key twice to enter Automatic operation When blinking press the Auto Man key to toggle between Auto and Manual After five seconds without pressing the Auto Man key the LED stops blinking and returns to its previous state WATLOW Series 988 User s Manual 3 1 Display Loop Display Lo
21. 4 output DIP switches 1 3 0 10V dc process 2 8 Lockout Panel Menu 6 2 6 6 Output Menu 4 18 4 33 0 20mA process 2 8 lockout DIP switch 1 4 lockout 6 5 0 50mV high impedance 2 8 lockout level setting 6 2 6 6 output module types 6 10 1 5V dc process 2 8 loop error detect 8 10 output power supply 4 20mA process 2 8 lower display 3 1 output 2 2 13 RTD 2 or 3 wire 2 8 low power limit 4 41 output 3 2 14 thermocouple 2 8 lube oil tank 9 5 output 4 2 15 input 2 4 9 4 16 overriding alarms 7 7 input 2 wiring 2 9 2 10 M overshoot A 3 0 5V dc process 2 9 0 10V dc process 2 9 maintaining documentation ii 6 9 P 0 20mA process 2 9 manual operation 7 4 0 50mV high impedance 2 9 manual tuning 7 2 P control A 3 1 5V dc process 2 9 mechanical relay 7 2 panel back access 2 2 4 20mA process 2 9 are lockout 6 2 6 6 panel cutouts 2 1 2 2 current transformer input 2 10 mixing tank 9 13 Panel Lockout Menu 6 2 6 6 digital event input 2 2 10 Mode Key 3 1 8 23 PD control A 3 potentiometer input 2 10 Modbus 8 4 PDR control A 3 RTD 2 or 3 wire 2 9 model number ii iii A 11 PI control A 3 slidewire feedback 2 10 module types 6 9 6 10 PID 2 crossover selection 4 38 thermocouple 2 9 mounting 2 1 2 3 PID control A 3 input DIP switches 1 2 muffle furnace 8 17 PID A Menu 5 9 5 16 0 5V 1 2 PID B Menu 5 9 5 16 0 10V 1 2 N PID Menu lockout 6 4 0 20mA 1 2 PID parameters 7 1 9 8 0 50mV 12 National Electric Code NEC 2 4 2 6 2 7 PID
22. 5 Operation System System Prompts After you step past the Set Point 2 prompt and the Idle Set Point prompt dS P to the Operation menus the Series 988 displays the menu selection 545 or in the upper display and in the lower display The Up arrow Y or Down arrow key selects another menu Press the Mode key Q to display the first prompt in the lower display and its value in the upper display Use the Up arrow Y and Down arrow 2 keys to change the value in the upper display The new value will not take effect until after a five second delay or until you press the Mode key QB Set Point 2 Select a second set point that will activate output 2 This allows you to boost the heating or cooling action of the output 1 device e The range and default settings depend on the n _ t ijand settings Input Menu This prompt appears only if and Output Menu are both set to orf L Idle Set Point Select the set point to be activated by an event input This allows you to select a temperature that will be maintained when the application is idle e The range and default settings depend on the n I and settings Input Menu Id SP This prompt appears only if or E 2 Global Menu is set to Lid SP cl fl WATLOW Series 988 User s Manual 5 3 Operation System E j 1S Event Input 1 Status Indicates whether the event input 1 circuit is open or closed read only This prompt appears only if
23. 6 2 7 X Y Z zero switching A 3 zone heating 8 19 N S ma ei os A 8 WATLOW Series 988 User s Manual Prompt Index error 7 8 A alarm 2 high 5 17 alarm 2 low 8 17 alarm 2 side 4 23 alarm 3 high 5 6 alarm 3 low 5 5 alarm 3 side 4 alarm 4 high alarm 4 low 5 6 alarm 4 side 4 29 retransmit calibration offset 4 33 control output action 8 8 device address 4 46 alarm 2 4 23 IAL Cn alarm 2 reverse 7 Fi 4 26 5 7 alarm 3 4 25 o alarm 3 reverse 7 alarm 4 4 28 alarm 4 reverse 7 6 algorithm 4 38 9 8 alarm reset 8 8 ambient temperature 6 8 annunciator 4 41 analog output 4 31 retransmit high limit 4 32 retransmit low limit 4 32 auto tune set point 4 42 7 1 auto tune 5 7 7 2 baud rate 4 45 th alarm 3 trigger 4 26 L 5 bumpless transfer 4 35 r St burst fire 8 2 O BEE o Cc Wy Sr m j W Celsius Fahrenheit 4 35 calibration lockout 6 6 Calibration Menu 6 13 calibration offset 1 4 6 calibration offset 2 4 14 control type 4 36 Communications lockout 6 6 44 Communications Menu 4 4 ir XD re ry mm fe ir XD f gt m DI
24. 8 6 9 Cualquier letra 1 2 012346 5 BCDEFoK ABCDEFKoT ABCJKM NoT ABC DEKR S o T Cualquier combinaci n de dos letras Control categor a de instalaci n Il grado de contaminaci n ambiental II 100 a 240 V Vca 0 24 a 28V Vca Vcc 50 60 Hz Espa ol Clasificaci n Tensi n nominal Frecuencia nominal Consumo nominal de energ a 16 VA m ximo Cumple con los requisitos esenciales de las siguientes directivas de la Uni n Europea usando las secciones pertinentes de las reglas normalizadas y los documentos relacionados que se muestran 89 336 EEC Directiva de compatibilidad electromagn tica EN 50082 2 1995 Norma de inmunidad gen rica del EMC parte 2 Ambiente industrial EN 61000 4 2 1995 Descarga electrost tica EN 61000 4 4 1995 Perturbaciones transitorias el ctricas r pidas ENV 50140 1994 Inmunidad radiada ENV 50141 1994 Inmunidad conducida ENV 50204 1995 Tel fono port til EN 50081 2 1994 Norma de emisi n gen rica del EMC parte 2 Ambiente industrial EN 55011 1991 L mites y m todos de medici n de caracter sticas de perturbaciones de radio correspondientes a equipos de radiofrecuencia industriales cient ficos y m dicos Clase A EN 61000 3 2 1995 L mites para emisiones de corriente arm nica EN 61000 3 3 1995 Limitaciones de fluctuaciones del voltaje 73 23 EEC Directiva de baja tensi n 1993 Requerimientos de seguridad para equipos el ctricos de medici n control y uso en laborat
25. AIL OD Output Menu range Input Menu _ dE I or dEejor 0 ALI ALI AJLO Output Menu Operation Menus Chapter 5 WATLOW Series 988 User s Manual 5 5 Operation System fm 3 H Alarm 3 High Select the high trigger value for the output 3 alarm A 3H This prompt appears only if AL 3 Output Menu is set to some thing other than no If Default highest or Pre A390 value of value of ALI ALI or sensor Output Menu Input Menu range dE Nor C gE2jor AEE C 0 C399 9999 ALI ALI Alarm 4 Low pm UY l o Select the low trigger value for the output 4 alarm A4L0J This prompt appears only if Output Menu is set to some thing other than no If Default d d lowest Pr i orl Pre value of value of fAYH ALY sensor or ele Output Menu range Input Menu or d amp ejor i vo ALY L ALY AYE 5 6 WATLOW Series 988 User s Manual Operation Menus Chapter 5 Operation System Q Q H Alarm 4 High Select the high trigger value for the output 4 alarm AY4H This prompt appears only if Output Menu is set to some thing other than no If Default 4 highest or AYL GQ value of value of ALY or cHe sensor Output Menu Input Menu range gE I or d amp ejor L des 9999 ALY CALY CALY Output Menu pm U Auto tune Initiate an auto tune appears only on controllers with enhanced software 98_B _ __ and with
26. Global Menu is set to some thing other than no Default 4 cigs 115 Es i5 mM Pud 6 Event Input 2 Status Indicates whether the event input 2 circuit is open or closed read only This prompt appears only on controllers equipped with a second digital event input 98__ _5 _ ___ _ and with Global Menu set to something other than nol Default L GPEA CLOS E25 E25 pm Pud l o Alarm 2 Low Select the low trigger value for the output 2 alarm AL Q This prompt appears only if AL 2 Output Menu is set to some thing other than nol If Default 4 4 lowest or valueof value of AL ALe sensor or _rie ACL oD Output Menu range Input Menu or dE or 8 CALE ALO Output Menu 5 4 WATLOW Series 988 User s Manual Operation Menus Chapter 5 Operation System HEH Alarm 2 High Select the high trigger value for the output 2 alarm AH This prompt appears only if Output Menu is set to some thing other than no If Default d highest or FEL GO value of value of ALe ALe ACHI orl er He sensor Output Menu Input Menu range dE I or dEejor C 0 999 ee 9999 AL ALZ CAL ACH T pm 3 A o Alarm 3 Low Select the low trigger value for the output 3 alarm A 3JL 0JThis prompt appears only if Output Menu is set to some thing other than no If Default 1 1 lowest Pr i or valueof value of a ALJ ALJ sensor ori _rie
27. PID A or B E Reset Output 2A or 2B rEc A i C Pud 5 Tune reset to eliminate the offset or droop between the set point and the actual process temperature for PID A output 2 When setto Q0 reset is disabled This prompt appears only if Calibration Menu is set to and Pb 2A is set higher than _ Q If Default uf L 9999 repeats min 1000 C 00 G000 a l rE2A opa enu H t C pa Integral Output 2A or 2B H E Pud b Tune integral to eliminate the offset or droop between the set point and the actual process temperature for PID output 2 When set to _ YJ integral is disabled I 2A This prompt appears only if Calibration Menu is set to and Pb 2A is set higher than Qj NOTE The PID B Menu Default appears only on ae 989 99 repeats min 98_B 5 14 WATLOW Series 988 User s Manual Operation Menus Chapter 5 Operation PID A or B E E Rate Output 2 cACR i C pm Pud 5 Adjust the rate to eliminate overshoot on startup or after the set point changes The rate setting will not influence the percent power if the process temperature is more than twice the proportional band from the set point When set to _ 9 rate is disabled 82A This prompt appears only if Calibration Menu is set to USjand P62A is set higher than _ D Default q 8 99 min d pm Q Derivative Output 2A or 2B d Pud b Adjust the derivative to eliminate overshoot
28. auto tuned by setting AYE to P d While auto 9 4 tuning the outer loop will be controlled in an on off mode at a set point equal to x SP l Ina heating application make sure the set point is set at a value above ambient temperature In most cases the auto tuning feature will tune for acceptable control If not you must then manually tune the outer loop Before beginning manual tuning record the values of and generated by the auto tuning feature The auto tune for the outer loop will not generate a value for A 1A because rate derivative in the outer loop seems to cause instability in most systems Start manual tuning by setting to 000 Enter the desired process set point and let the system stabilize Once the system stabilizes observe the value of in the Display Menu If the value fluc tuates make the proportional band setting wider until the value stabilizes Make adjustment in 5 to 10 increments allowing time between adjustments for the system to stabilize Once has stabilized observe percent power in the display loop It should be stable 10 At this point the process temperature should also be stable but will exhibit droop stabilized below set point The droop can be eliminated with reset of integral Start with a setting of 0 01 allow 10 minutes for the process temperature to come up to set point If it has not increase the setting to 0 05 and wait another 10 minutes After this double the re
29. cycling of the heater Systems with long lag times between the energy source heater steam etc and the measured process value cannot be controlled accurately or efficiently with a single control loop because a lot of energy can build up before a response is detected This can cause the system to overshoot the set point which could damage the heater product or heat transfer medium such as a heat transfer fluid This graph illustrates a system with a long lag time Curve A represents a single control system with PID parameters that allow a maximum heat up rate Too much energy is introduced and the set point is over shot In most long lag time systems the process value may never settle out to an acceptable error Curve C represents a single control system tuned to minimize overshoot This results in unacceptable heat up rates with the final value taking hours to reach Curve B shows a cascade system that limits the energy Two controllers in one introduced into the sys tem allowing an opti mal heat up rate with minimal overshoot Figure 9 2a System heat up profiles using three different control methods time Figure 9 2b The cascade feature allows one Series This drawing shows two 988 controller to controllers configured internalize the func Outer loop Inner loop as a cascade system Controller Controller tions of two con The second controller trollers generates the internal set point The Ser
30. deviation alarm Low alarms are usually set at a negative deviation while high alarms area positive deviation Example If your set point is 100 F a deviation alarm high limit is set to 7 F and the low limit is set to 5 F then the high alarm trips at 107 F and the low alarm at 95 F If you change the set point to 130 F the alarms follow the set point and trip at 137 F and 125 F 7 6 WATLOW Series 988 User s Manual Tuning Manual Operation Alarms and Error Codes Chapter 7 Alarms A rate alarm alerts the operator when the process monitored by input 1 is increasing at a rate higher than the alarm high setting A2H I AZH J or AY4H I or decreasing at a rate lower than the alarm alarm low setting A2t G AZL GY or AYL GQ The rate is sampled once a second Alarms can be latching or non latching When the alarm condition is removed a non latching alarm automatically clears the alarm output and alarm message if one is present You must manually clear a latching alarm before it will disappear The alarm output is indicated by the corresponding LED on the front panel L2 L3 or L4 There may be an alarm message flashing in the lower display but if the prompt is set to Global Menu no alarm message is displayed When an alarm message is displayed it alter nately flashes with the current prompt at a one second interval in the lower display To clear a latching alarm first correct the condition then press
31. enabled the controller moni tors the output power level and checks for a change in the process input value If the output power is at maximum for a period of time equal to the reset time and the process input has not changed by at least 5 F the controller will switch to manual mode at 0 output power and will be displayed in the lower display To clear this error enter the Setup Menu and press the display key Q9 To get back into auto mode press the Auto Man key G3 GPL P This prompt always appears Default A C3 nN nN D r ze 6 12 WATLOW Series 988 User s Manual Factory Menus Chapter 6 Reaching the Calibration Menu Begin in the Display Loop and press the Up arrow Y and Down arrow key simultaneously for six seconds until the Setup Menu SEE then the Factory Menu appear Use the Up arrow key Y or Down arrow key to step through the Factory Menu to the Calibration Menu CAL 9 As PLOC d A9 CAL Fcty FetY FcetY Panel Diagnostics Calibration Lockout Menu Menu Menu p 6 7 p 6 13 p 6 2 Press the Mode key B to step through the prompts P cSt St Press the Up arrow key Y or the Down arrow key to select one of the prompt values Refer to Calibrating Watlow Process Controls for information about the Calibration Menu A CAUTION Before attempting to calibrate make sure you have the proper equipment called for in each pr
32. from the coil form B A single pole single throw relay that uses only the normally closed NC and common contacts These contacts open when the relay coil is energized They close when power is removed from the coil form C A single pole double throw relay that uses the normally open NO normally closed NC and common contacts The operator can choose to wire for a Form A or Form B contact hunting Oscillation of process temperature between the set point and the process variable hysteresis A change in the process variable required to re energize the control or alarm output Sometimes called switching differential integral Control action that automatically eliminates offset or droop between set point and actual process tem perature See reset automatic isolation Electrical separation of sensor from high volt age circuitry Allows use of grounded or ungrounded sens ing element Joint Industrial Standards JIS A Japanese agency that establishes and maintains standards for equipment and components Also known as JISC Japanese Industrial Standards Committee its function is similar to Germany s Deutsche Industrial Norm DIN JIS Joint Industrial Standards junction The point where two dissimilar metal conduc tors join to form a thermocouple cold junction Connection point between ther mocouple metals and the electronic instrument See refer ence junction grounded ju
33. is equipped with input 2 hardware and with Input 2 not set to or E ic WATLOW Series 988 User s Manual 4 11 setup Input an Default a Default Range Low 2 and rid re rid cHe Range High 2 con C 32 1500 _ _8 15 98__ 1__ ___or ous page K H 328 l2900 200 137 1 E 328 7158 gg0g _399 n 3 2 l2Z lg 0 1300 E 328 1470 200 _ 799 W5 32 4200 G 2F 16 NOTE W3 These values do not d C 32 4200 0 23 16 affect the low or the high set point limit PEt J2 2543 0 4995 for process alarms high impedance 0 58 9393 999 5 13 513 r 32 3208 0 4760 98 _ 2__ ___ only 5 3e 3282 0 4768 NOTE C b C 32 3300 C 0 7816 When high imped ance is 329 14 72 200 800 selected for input 1 me range lentes 995 8933 733 SF7T7 both and can be extended to 9999 999 99939 units The range low when is s
34. no DIP J K T N E W5 W3 Pt2 0 50mV C no J H E n E C d Pte 0 50 nemo aup only NOTE 2 i e a RSR EEA Doit ADiP J K T N E W5 W3 Pt 0 50mv for _ ng none of n the other input 2 mE C no J H E n E C d Pte 0 580 prompts will WEG appear thermocouple Input 2 DIP R S B Bore Cad Cr C_ 5 C6 1 2 3 thermocouple Input 2 DIP RTD RTD 0 19 L no cred l rtd eld RTD Input 2 DIP 4 20mA 0 20mA 0 5V 1 5V 0 10V dc p ono G 20 O 20 COs CS Go Ces Ine process Input 2 continued on next page Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 9 Ssetup Input ine Input 2 continued from previous page SP 4 10 WATLOW Series 988 User s Manual If Default 98 3 __ no DIP slidewire potentiometer l no SL d POE resistance Ing Ine only 98 4 no DIP current current no Sk id transformer lng Ing only 98__ 5 __ no DIP event 2 no LE digital event Line _ ing only Remote Set Point Enable a remote set point signal This prompt appears only if the controller is equipped with input 2 hardware and if is not set to and if in the Global Menu is set to nor Default L OFF SP Setup Menus Chapter 4 Range Low 2 and Range High 2 continued on next page Setup Menus Chapter 4 Ssetup Input Decimal 2 S
35. on startup or after the set point changes The derivative setting will not influence the percent power if the process temperature is more than twice the proportional band from the set point When set to Q derivative is disabled d 28 This prompt appears only if Calibration Menu is set to S I and Pb2Ajis set higher than _ Q Default NOTE 1 999 min The PID B Menu JEZA appears only on controllers with enhanced software Operation Menus Chapter 5 WATLOW Series 988 User s Manual 5 15 Operation PID A or B C 2 m Cycle Time Output 2A or 2B E E Pad b Select the time in seconds of a complete on off cycle C amp A This prompt appears only if Global Menu is not set to C fd and PbeAjis set higher than 9 If Default 1 1 mechanical SU 9999 relay outputs open collector oe a 9939 or solid state CLA relay outputs db m Dead Band A or B Select the width of the zone between the action of the heating output and the cooling output If you select a positive value the heat and cool outputs cannot be energized at the same time If you select a negative value both outputs can be energized at the same time e If a process input is selected the decimal precision will be determined by the dgE amp C I setting Input Menu This prompt appears only if PbeA is set higher than _ and NOTE one output performs heating action and the other performs cooling action The P
36. output 1 and output 2 pro portional band is set to O and the control goes into an on off mode of con trol at the set point percentage determined by the parameter The displayed set point remains unchanged Auto tuning at a set point of 200 F auto tune complete auto tune begins 200 set point 160 Nie eee Pe as Bue process Temperature 90 of set point RESP default setting 100 Time WATLOW Series 988 User s Manual 7 1 A CAUTION If a mechanical relay or contactor is switching power to the load a longer cycle time may be desirable to mini mize wear on the mechanical compo nents The typical life of a mechanical relay is 100 000 cycles Verify that the cycle time selected is appro priate for the output device type Failure to do so could result in damage to equipment and or property 7 2 WATLOW Series 988 User s Manual When the control finishes learning the system it resumes standard PID control using the PID values established by the auto tuning process Changing the set point during an auto tune restarts the auto tune proce dure During auto tuning the process must cross the set point four times within an 80 minute time span for the Series 988 to successfully complete the auto tune If this does not happen within the 80 minute time limit the Series 988 chooses PID values based on the 80 minute tuning cycle per formed To start auto tuning 1 Press
37. percent output 1 cycle on 1 off The graphs on the next page show how the time base varies with the percent output General Software Features Chapter 8 90 output 1 on 1 off Figure 8 3a Sine waves of burst fire settings input 1 Figure 8 3b Semiconductor oven with burst fire eves AEAN General Software 10 output 1 on 9 off Semiconductor Oven temperature sensor heated platen Sample Application A Series 988 controls a heated platen in a semiconductor oven Previously it used a power control requiring a 4 20mA signal to implement burst fire control We have replaced the power control with a Watlow Loyola QPAC with a QCD card that accepts a signal directly from an open collector out put of the Series 988 This gives smooth control at a lower overall system cost General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 3 General Software Communications Requirements Choose which interface your application will use EIA TIA 232 serial com munications 98__ ____ R _ EIA TIA 485 or EIA TIA 232 serial com munications 98__ __ _ _ _U__ or EIA TIA 485 or EIA TIA 422 serial communications 98__ ___ _ _S__ The computer must have a compati ble serial port or an appropriate converter must be used Overview The serial communications feature allows the Series 988 family to receive commands from and transmit data to a master device usually a comput er Any func
38. problem with the dual PID option Auto tuning PID A under normal atmospheric conditions then auto tuning PID B under vacuum conditions establishes PID values for two sets of system characteristics A pressure switch connected to the event input tells the controller when to switch between PID A and PID B eliminating the need to change PID values manually Enhanced Software Features Chapter 9 WATLOW Series 988 User s Manual 9 9 Enhanced Software Duplex Requirements The duplex control feature requires enhanced software and a process out put NOTE O Duplex applications KERVIN l require a special Certain systems require that a single process output control both heating valve and cooling outputs A Series 988 controller configured with enhanced software and a process output can function as two separate outputs With a 4 to 20mA output the heating output will operate from 12 to 20mA 0 to 100 percent and the cooling output will operate from 12 to 4mA 0 to 100 percent In some cases this type of output is required by the device that the 988 controls such as a three way valve that opens one way with a 12 to 20mA signal and opens the other way with a 4 to 12mA signal This feature reduces the overall system cost by using a single output to act as two outputs 9 10 WATLOW Series 988 User s Manual Enhanced Software Features Chapter 9 Enhanced Software Fluid Sample Container output 1 hot water temperature transmi
39. remove or replace the controller Make sure the inside gasket is seated properly and not twisted Insert the controller chassis into its case and press the bezel until all four tabs snap To release the mounting brackets loosen the mounting bracket screws and push the brackets forward then pull it up and out Installation and Wiring Chapter 2 WATLOW Series 988 User s Manual 2 3 A WARNING To avoid potential electric shock use National Electric Code NEC safety practices when wiring and connect ing this unit to a power source and to electrical sensors or peripheral devices Failure to do so could result in injury or death NOTE Input to output iso lation is defeated when the external signal conditioner power supply is used to power a transmitter con nected to input 1 or input 2 Figure 2 4 Power wiring 2 4 WATLOW Series 988 User s Manual Wiring the Series 988 Wiring options depend on the model number and DIP switch settings Check the terminal designation stickers on either side of the controller and compare your model number to those shown here and with the model number breakdown on the inside back cover of this manual Input to output Isolation The Series 988 uses optical isolation between the analog inputs and the controller outputs digital input This isolation provides a 500V ac bar rier to prevent ground loops when using grounded sensors and or periph eral equipment
40. the Auto Man key once Alarm silencing is available with all alarms This function overrides the alarm on initial power up On power up the alarm message will not appear and the appropriate L2 L3 or L4 LED and output will reflect a non alarm condition Silencing is active until the process has entered the safe region located between the low and high alarm settings Then devia tion outside this safe zone triggers an alarm If an alarm occurs at this point the output can be silenced by pressing the Auto Man key once but the controller still displays the alarm message Tuning Manual Operation Alarms and Error Codes Chapter 7 WATLOW Series 988 User s Manual 7 7 NOTE To view the error code press the Auto Man key once The upper dis play shows the error code for five seconds before returning to the J display Figure 7 8 Error code display NOTE An alarm display will be masked by an error condition or when the control is in the Calibration or Setup menus Error Code E1 and E2 Messages Four dashes in the upper display indicate a Series 988 error The control goes into the manual mode and maintains the percent output selected at the prompt Global Menu That value percent of out put is shown in the lower display El E2 1 A D underflow error The analog to digital A D converter of the input indicated by the first number is under range An open or reversed polarity sensor is the most
41. the Setup Menus WATLOW Series 988 User s Manual 4 1 Ssetup Input Reaching the Input Menu m WATLOW PROCESS E E E ee ec S DEV oispLay OUT cy MAN G2 Cc SERIES 988 Select the Input Menu then press the Mode key Q to step through the prompts eee og y vy 8 OJ I el 68 Fer i Ftr I Fer i Fieri _ no root Lan EL mh Press the Up arrow key Y or the Down arrow key to select one of the prompt values Prompts may not appear depending on controller configuration Figure 4 2 The Input Menu 4 2 WATLOW Series 988 User s Manual B rA DNA DNA DNA DEA DNA DYA DA DNA DYA DNA DA DYA DNA DNA DTA DTA DYA DTA DTA DTA A gt D tr SEE Setup Prompt Enter your settings from the controller s Input 1 upper display EC I Decimal 1 f gt I Range Low 1 HI Range High 1 Input 1 p 4 3 Li Calibration Offset 1 RTD Calibration Curve 1 E Software Filter 1 J EL EL EU SEU RUE rc 3 Linearization 1 i ine Input 2 SP Remote Set Point JBL ECE Decimal 2 i rie Range Low 2 rH Range High 2 Ja Input 2 p 4 9 f gt ral Learn Low r Learn High AL Calibration Offset 2 RTD Calibration Curve 2 JaUELEL tre Software Filter 2 i f gt ine Linearization 2 41 Setup Menus Chapter 4
42. the Mode key B to advance to the System Menu 595 Press the Mode key to advance through the menu until the AYE prompt appears in the lower display 2 Use the Up arrow Y or Down arrow 2 key to select or P idb Only one PID set can be auto tuned at a time 3 Press the Display key 9 While the control is in the tuning mode the lower display alternates every second between the normal informa tion and the prompt 4 When tuning is complete the displays return to their previous state and reverts to OFF The Series 988 installs the PID tuning parameters it has calculated and saves them in non volatile memory To abort auto tuning either reset the prompt to off press the Auto Man key twice or cycle power off and on In all cases aborting auto tune restores all values to their state before auto tuning began Manual Tuning For optimum control performance tune the Series 988 to your thermal system The tuning settings here are for a broad spectrum of applications your system may have somewhat different requirements NOTE This is a slow procedure that may take hours to obtain optimum values Tune heating outputs at a set point above the ambient process value Tune cooling outputs at a set point below the ambient process value __ the parameters may need to be tuned also Perform this procedure on both PID sets they are functionally identical The para meters within the procedure apply to both output 1 and 2 a
43. the Setup and Factory menus Cycle power to the control If the error is still present contact the factory 7 10 WATLOW Series 988 User s Manual Tuning Manual Operation Alarms and Error Codes Chapter 7 Chapter 8 General Software Burst Fire 8 2 Communications 8 4 Dead Band 8 6 Digital Events 8 8 Heater Current 8 10 Input Filter 8 12 Input Linearization 8 14 Ramp to Set Point 8 16 Remote Set Point 8 18 Retransmit 8 20 Slidewire Feedback 8 22 General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 1 General Software A CAUTION The burst fire fea ture only func tions with zero cross solid state devices It will not function correctly with random fire devices Verify that the output switching device is compatible before selecting burst fire Failure to follow this guideline could result in damage to equipment 8 2 WATLOW Series 988 User s Manual Burst Fire Requirements e This feature only works with zero cross solid state devices It will not function correctly with random fire devices e To enable burst fire the Series 988 must have an open collector or solid state relay output controllers with option B C or K selected for output 1 98__ _ _ _ output 2 98_ _ _ output 3 98_ e The time burst is appropriate for fast loads or very tight control It pro vides advantages only for PID control not for on off control e The short time bases used by
44. to 0 10 minute Then raise set point by 20 to 30 F or 11 to 17 C Observe the system s approach to the set point If the load process value overshoots the set point increase or to 0 50 minutes Raise the set point by 20 to 30 F or 11 to 17 C and watch the approach to the new set point If you increase or too much the approach to set point will be very sluggish Repeat as neces sary until the system rises to the new set point without overshooting or approaching the set point too slowly 6 Calibration Offset Adjustment You may want your system to control to a process value other than the value coming from the input sensor If so measure the difference between that process value perhaps at another point in the system and the process value showing in the upper display Then enter the offset value you want Calibration offset adds or subtracts degrees from the value of the input signal Tuning Manual Operation Alarms and Error Codes Chapter 7 WATLOW Series 988 User s Manual 7 3 Auto Man NOTE When a sensor opens the con troller switches from automatic to manual operation 7 4 WATLOW Series 988 User s Manual Manual and Automatic Operation To change from auto to manual operation press the Auto Man key twice Manual operation provides open loop control of the outputs from a range of 100 to 100 output The Series 988 allows a negative output value only when or Output Menu is set to cool A
45. 2 4 24 silencing 3 4 27 silencing 4 4 30 silencing alarms 7 7 slidewire feedback 8 22 8 23 A 3 slidewire feedback wiring 2 10 slidewire hysteresis 4 16 software filter 1 4 7 software filter 2 4 15 software revision 6 8 specifications A 4 square root extraction linearization square root 8 14 8 15 A 2 storing data 8 4 8 5 switched dc open collector wiring output 1 2 12 output 2 2 13 output 3 2 14 output 4 2 15 switching sensitivity A 3 system heat up profiles 9 2 System Menu 5 1 5 8 lockout 6 4 T technical assistance iii 6 10 e p Ol op a W lee temperature limit control protection 2 6 terminal designation stickers 2 4 test chambers wih communications 8 5 with dual PID sets 9 9 test displays 6 11 test output 6 11 thermal system A 3 thermocouple 2 5 A 3 thermocouple break protection A 3 thermocouple wiring input 1 2 8 input 2 2 9 three mode control A 3 time constant filter input 1 4 7 input 2 4 15 time proportioning control A 3 tuning automatic 7 1 7 2 manual 7 2 7 4 settings 7 2 7 3 Tuning of Industrial Control Systems 7 1 U Up arrow Key 3 1 upper display 3 1 using manual ii iii V W warnings iii warranty A 5 waste water treatment 8 15 water boiler 9 7 wiring 2 1 2 4 2 15 event input 1 2 11 event input 2 2 10 input 1 2 8 input 2 2 9 2 10 output 1 2 12 output 2 2 13 output 3 2 14 output 4 5 wiring example 2 6 wiring safety 2 4 2
46. 328 to 1470F or 200 to 799 C C t c W5 32 to 4200F or 0 to 2316 C D t c W3 o 32 to 4200F or 0 to 2316 C Pt 25 32 to 2543 F or 0 to 1395 C 1 RTD JIS 328 to 1166 F or 200 to 630 C 1 RTD DIN 328 to 1472 F or 200 to 800 C 0 1 RTD JIS and DIN 99 9 to 999 9 F or 73 3 to 537 7 C 0 5V dc 999 to 9999 1 5V dc 999 to 9999 0 10V dc 999 to 9999 0 20mA 999 to 9999 4 20mA 999 to 9999 0 50mV dc 999 to 9999 Slidewire 100 to 12000 Current 0 to 50A Potentiometer 0 to 12000 Output Options e Solid state relay 0 5A 24V ac min 253V ac max opto isolated burst fire With or without contact suppression e Open collector Max voltage 42V dc max current 1A e Switched dc signal Min turn on voltage of 3V dc into min 500Q load max On voltage not greater than 32V dc into an infinite load isolated e Electromechanical relay Form C 5A 120 240V ac 6A 28V dc 1 8 hp 120V ac or 125VA 120V ac With or without contact sup pression Off state output impedance with RC sup pression is 20kQ A 4 WATLOW Series 988 User s Manual e Process 0 20mA 4 20mA into 8002 maximum 0 5V dc 1 5V dc or 0 10V dc into 1kQ mini mum reverse acting isolated e Electromechanical relay Form A B 5A 120 240V ac 6A 28V dc 1 8 hp 120V ac or 125VA 120V ac Without contact suppression e External transmitter power supply 5V
47. 4 2 15 Ss P F Factory Menus 6 1 6 14 factory ship date 6 8 failure mode 4 35 Fahrenheit 4 35 feedback iii filter time constants 8 12 8 13 input 1 4 7 input 2 4 15 fluid sample container 9 11 form A 7 5 A 2 form B 7 5 A 2 form C A 2 front panel 3 1 front panel lockout 6 3 8 G gas fired furnace 8 23 Global Menu 4 34 4 43 9 8 lockout 6 5 Glossary A 2 A 3 ground loops 2 4 2 5 H heater with digital event 8 9 heater current 8 10 8 11 heat treat oven 8 21 high power limit 4 42 humidity chamber 8 13 hunt 4 16 8 22 8 2 hunting A 2 iS Appendix Index h r hysteresis A 2 L4 output 4 3 1 process retransmit 2 14 hysteresis 1 4 20 latching 2 4 24 switched dc open collector 2 14 hysteresis 2 4 22 latching 3 4 27 output 4 4 28 hysteresis 3 4 26 latching 4 4 30 output 4 wiring 2 15 hysteresis 4 4 29 latching alarm 7 7 ac outputs 2 15 learn high range 4 13 external transmitter power supply 2 15 I learn low range 4 13 switched dc open collector 2 15 linearization A 2 output configurations idle set point DSB linearization input 8 14 8 15 output 1 control 3 1 inner loop cascade 9 2 9 3 linearization 1 4 8 output 2 control or alarm 3 1 input 1 4 3 4 8 linearization 2 4 15 output 3 alarm or retransmit 3 1 input 1 wiring 2 8 local remote 5 8 output 4 alarm or communications 3 1 0 5V dc process 2 8 locating DIP switches 1 1 1
48. 42V dc 7 13 E Maximum current 1A a E Internal Circuitry Figure 2 12c 0 20mA and 4 20mA Process 98__ __EF_ __ To Maximum load impedance 8009 Figure 2 12d 0 5V 1 5V and 0 10V dc Process 98__ __F_ ____ a miS Minimum load impedance 1KQ e Installation and Wiring Chapter 2 NOTE Successful installa tion requires five steps e Model number and software choice Appendix e DIP switch set tings Chapter 1 e Sensor match Chapter 2 and Appendix e Sensor installation Chapter 2 and e Wiring Chapter 2 NOTE Switching inductive loads relay coils solenoids etc with the mechanical relay or solid state relay output options requires using an R C suppressor Watlow carries the R C suppressor Quencharc brand name which is a trademark of ITW Paktron Watlow Part No 0804 0147 0000 NOTE Input to output iso lation is defeated when the external signal conditioner power supply is used to power a transmitter connect ed to input 1 or input 2 Installation and Wiring Chapter 2 Output 2 Wiring Figure 2 13a AC Outputs Solid state Relay with Contact Suppression 98 _ ___B ____ 0 5 amps minimum off state impedance 20KQ Electromechanical Relay with Contact Suppression Suppression between NO and COM contacts only 98 __ _ D ____ Form C 5 amps minimum off state impedance 20KQ RR E AT Electromechanic
49. 6 cycle time adjustment 7 3 D data bits amp parity 4 45 8 4 data communications ii 2 15 4 1 8 4 Data Communications with the Watlow Series 988 Family of Controllers ii date 6 3 dead band 5 16 8 6 sample application decimal 1 4 4 decimal 2 4 11 decimal point location of 4 3 4 35 Declaration of Conformity A 12 default 6 14 A 2 derivative A 2 output 1 5 12 output 2 5 15 deviation alarm 7 6 device address 8 4 DEV LED set point deviation 3 1 Diagnostics Menu 6 7 6 12 lockout 6 6 differential control 9 6 9 7 digital event input options 8 8 8 9 digital event wiring input 1 2 11 input 2 2 10 dimensions 2 1 8 7 8 7 A 6 WATLOW Series 988 User s Manual DIN A 2 DIP switch functions 1 1 l DIP switch locations 1 1 1 DIP switch setting input 1 2 lockout 1 4 output 1 3 display 6 11 Display Key 3 1 Display Loop 3 2 displays 3 1 documentation maintaining ii 6 9 Down arrow Key 3 1 droop A 2 dual in line package DIP switches 1 1 1 4 dual PID sets 9 8 9 9 duty cycle A 2 duplex control 9 10 9 11 E environmental chamber 8 7 error code messages 7 8 error code results 7 10 error codes clearing 7 10 error latching 4 36 event input 1 4 40 event input 1 Status 5 4 event input 1 wiring 2 11 event input 2 4 40 event input 2 status 5 4 event input 2 wiring 2 10 external signal conditioner power supply A 2 power supply DIPs 1 3 power supply wiring output 2 2 13 output 3 2 14 output
50. 8 x 4 03 x 4 74 55mm x 102mm x 120mm e Depth behind panel 4 06 103mm Weight less than or equal to 14 00z 0 40kg Samplo Update Rates e 1 input 10Hz e 2 inputs 5Hz e Retransmit 1Hz e Remote set point 1Hz e PID 10Hz Outputs 10Hz Display 2Hz Alarm Outputs 1 Hz Resolution e Inputs 16 bits e Outputs 12 bits 1 Electromechanical relays are warranted for 100 000 clo sures only Solid state switching devices are recom mended for applications requiring fast cycle times or extended service life 2 Not an ANSI symbol Appendix Total Satisfaction Warranty The Watlow Series 988 is warranted to be free of defects in material and workmanship for 36 months after delivery to the first purchaser for use providing that the units have not been misapplied Since Watlow has no control over their use and some times misuse we cannot guarantee against failure Watlow s obligations hereunder at Watlow s option are limited to replacement repair or refund of pur chase price and parts which upon examination prove to be defective within the warranty period specified This warranty does not apply to damage resulting from transportation alteration misuse or abuse Watlow Controls Watlow Controls is a division of Watlow Electric Mfg Co St Louis Missouri a manufacturer of industrial electric heating products since 1922 Watlow begins with a full set of specifications and completes an i
51. 8 User s Manual Remote Set Point Requirements Input 2 must be either a thermocouple 98__ _1_ _ ___ _ or universal signal conditioner 98__ 2 _ _____ To use a Series 988 as a master controller choose one of the retransmit options for output 3 of the master 98__ ___ _ M____ for O 20mA or 4 20mA or 98 _ ___ N___ for 0 5V dc 1 5V or 0 10V Overview The remote set point feature allows the Series 988 to use a thermocouple RTD or process signal at input 2 to establish the set point This feature gives the Series 988 the ability to have its set point value manipulated by an external source A common application would use one ramping con troller with a set point retransmit output to ramp multiple controllers using the remote set point Or you could use an analog output from a PLC to send set point values to a Series 988 You may select between local and remote set points at the front panel with an event input from a remote computer using the communicatons feature or from an external switch using an event input General Software Features Chapter 8 General Software zone 1 zone 2 zone 4 zone 5 zone 6 zone 7 Master Remote Remote Remote Remote Remote E EER EER _ 388 i _ 988 wae et Goma cs es fia eS input 2 i input 2 Figure 8 19 Zone heating with Sample Application remote set point An engineer has a machine with eight independent zones of heat He wants to change set points on all zones wit
52. A tol Bal dt A This prompt appears only on controllers equipped with communi cations hardware 98___ ___ _ R 98_ ___ U__or98__ ____ 33 Default J dAtA dAtA dAtA WATLOW Series 988 User s Manual 4 45 Protocol Type Select the communications protocol e FULL selects ANSI X3 28 2 2 A 3 e on selects Xon Xoff F 99d selects Modbus This prompt appears only on controllers equipped with communi cations hardware 98__ ____ R__ 98__ ____ U__or98__ ___ _ _S__ Default i Address Select an address for the controller The computer will use this address when communicating with this controller This prompt appears only on controllers equipped with communica tions hardware for EIA TIA 485 and EIA TIA 422 If Default a J 48S 0l 31 Lint F Pod lC Bl Del esT IntF Add Addr 4 46 WATLOW Series 988 User s Manual Setup Menus Chapter 4 Interface Type Select the interface type for Output 4 Option S selects EIA TIA 485 selects EIA TIA 422 This prompt appears only on controllers equipped with communications hardware for EIA TIA 485 and EJA TIA 422 98 __ S Default 4 48S Yee Interface Type Select the interface type for Output 4 Option U selects EIA TIA 485 selects EIA TIA 232 This prompt appears only on controllers equipped with communications hardware for EIA TIA 485 and EJA TIA 232 98 _ __ _ U Default d REF Setup Menu
53. AL 90 Global Menu set to orfeScd i t s This prompt always appears Default NOTE For more informa tion on auto tune P d see Chapter 7 AUE Operation Menus Chapter 5 WATLOW Series 988 User s Manual 5 7 Operation System Local remote Select a local or remote set point With selected the controller displays the remote set point rather than the internal local set point and the set point cannot be changed with the Up arrow or Down arrow key L r This prompt appears only if Input Menu is set to Gal Default q Lar l r 5 8 WATLOW Series 988 User s Manual Operation Menus Chapter 5 Reaching the PID Menus Begin in the Display Loop and press the Mode key 83 to reach the Set Point 2 prompt _ P 2 the Idle Set Point prompt or the System Menu 595 o Set Point 2 idSP Idle Set Point C a a cy 5695 P idf P Idb OPEr OPEr System PIDA PID B Menu Menu Menu poz HSI Pog Use Mode key Q to step past the Set Point 2 prompt and the Idle Set Point prompt Id 5P if they appear see prompt informa tion Upon reaching the Operation Menu prompt use the Up arrow Y key to select a menu Press the Mode key B to step through the prompts a bP fs Te 000 00 i Q02 _999 JE TA dE 1A Press the Up arrow key Y to step through the prompt values The Down arrow key g backs through the values Figure 5 9 The PID
54. C Calibration errors can also cause this error code Try setting Calibration Menu to YE5 Read about Factory Calibration in Chapter 6 Er 4 RAM verification error An internal RAM failure has occurred Contact the factory Er 5 Non volatile checksum error An EEPROM checksum error was detected Turn the power off then back on again If this does not clear the error contact the factory GPL P Open loop detect This error is not available while in the on off mode It is only active when OPL P is set to Diagnostics Menu E 9 Configuration error An incorrect module has been installed in the control Contact the factory Error Code Actions All of the above error codes except Er 4 and will result in these conditions e If is set to Global Menu and the control was in automatic operation when the error occurred it goes into manual power operation If the output power is less than 75 5 power and there was a change in power lt 5 within the last two minutes the Series 988 switches to manual opera tion at the last automatic power level bumpless transfer If the con trol was in manual operation it remains there Press the Auto Man key once to see the error code The error code is shown in the upper display for five seconds and the lower display shows the power After five seconds the upper display reverts to the dis play e If the control was operating with stable outpu
55. D B based on a process value a set point value or the event input status e At PID 2 Crossover Selection Global Menu select what will cause the switch Crossover Process Value input 1 PIDs will switch based on the crossover process value Crossover Set Point 1 Value PIDs will switch at the crossover set point value PID A used below the crossover point and PID B above e no Crossover e At Event Input 1 or Event Input 2 select P d e PID A is used when the event input switch is open e PID B when the event input switch is closed Note One event input is standard on all units a second event input is an option 9 8 WATLOW Series 988 User s Manual Enhanced Software Features Chapter 9 Figure 9 9 Test chamber controlled with dual PID sets Enhanced Software Test Chamber output 1 output 2 temperature sensor sensor pressure heater TITTET Sample Application A test engineer needs to control the temperature in a test chamber that can be operated at normal atmosphere or under vacuum conditions If he tunes the controller for normal atmospheric conditions when he reaches the portion of his test that requires a vacuum he must stop the test and enter new PID parameters to maintain stable temperatures The system characteristics are so very different that one set of PIDs will not give satis factory results under both normal and vacuum conditions The Series 988 solves this
56. E Switching inductive loads relay coils solenoids etc with the mechanical relay or solid state relay output options requires using an R C suppressor Watlow carries the R C suppressor Quencharc brand name which is a trademark of ITW Paktron Watlow Part No 0804 0147 0000 NOTE Input to output iso lation is defeated when the external transmitter power supply is used to power a Signal con ditioner connected to input 1 or input 2 Installation and Wiring Chapter 2 Output 4 Wiring Figure 2 15a AC Outputs Solid state Relay with Contact Suppression 98 _ B 0 5 amps minimum off state impedance 20KQ I o_ n Electromechanical Relay with Contact Suppression Suppression between NO and COM contacts only External Load 8 S NO a COM 6 98 _ _ _ D___ a Fuse a i gt ra Form C 5 amps minimum off state impedance 20KQ 7 for D amp E outputs ony lm mn a Electromechanical Relay without Contact Suppression ana 98 _E Form C 5 amps off state impedance 31MQ Solid state Relay without Contact Suppression 98 _ K 0 5 amps off state impedance 31MQ Figure 2 155 Switched DC Open Collector Jo 5 pee Mee Piovi nna Maximum voltage 42V dc 6 3 Feed 8 site iS Maximum current 1A 7 Q e Internal Circuitry _ ny Mil a Ean Figure 2 15 c External Signal Conditioner Power Supply 98__ _T Loop powered NOTE See Chapter 1 f
57. Here is a breakdown of the isolation barriers e Analog inputs 1 and 2 are grouped together e Outputs 1 through 4 and the standard event input are grouped together This does not apply to Output 4 when configured as communications e The digital communications output 4 is separate from the above groups Power Wiring 100 to 240V amp ac dc nominal 85 to 264 actual m m N Vertical Package 90 o naaa Taa Horizontal Package CO 00 CO I I T D 22 11 Q K earth ground N 24 to 28 V amp ac dc nominal 20 to 30 actual l Vertical Package 986 _ ____ ___ Horizontal Package 987 E Fal 2 a qii Installation and Wiring Chapter 2 A CAUTION The Series 988 will not function with two grounded ther mocouple inputs Avoid using a grounded thermo couple for both input 1 and input 2 Failure to follow this guideline could result in damage to equipment NOTE Input to output iso lation is defeated when the external signal conditioner power supply is used to power a transmitter connect ed to input 1 or input 2 Installation and Wiring Chapter 2 Sensor Installation Guidelines Maintain isolation between input 1 and input 2 to prevent a ground loop A ground loop may cause incorrect readings dashes across the upper dis play or the display of error codes Thermocouple input Extension wire for thermocouples must be of the same
58. ID B Menu appears only on If controllers with i enhanced software db A db A Global Menu l db A db A Global Menu a process al O units input is selected db A idb A WATLOW Series 988 User s Manual Operation Menus Chapter 5 Chapter 6 The Factory Menus NOTE The Factory Menus will not appear if the hardware lockout DIP is set to on See Chapter 1 for more information NOTE The Factory Menus can only be entered when the setup prompt Is displayed NOTE Press the Display key to return to the Display Loop from any point in any menu Figure 6 1 Navigating the Factory Menus Factory Menus Chapter 6 Navigating the Factory Menus To reach the Factory Menus begin in the Display Loop and press the Up arrow Y and Down arrow keys together and hold for three seconds The prompt will appear in the lower display Press and hold the Up arrow Y and Down arrow keys together again for three seconds until the prompt appears in the lower display The Factory Menus will not appear if the hardware lockout DIP is set to on See Chapter 1 for more information on DIP switch settings The three Factory Menus are Panel Lockout PL QC Diagnostics dg A9 and Calibration CAL Upon reaching the Factory Menu prompt use the Up arrow Y or Down arrow key to select a menu and the Mode key W3 to step through a menu You will not see every prompt in any of these menus The unit s configura
59. LS Q Bpplieslion FATU o bPLS 700 C0 aE FAIL WATLOW Series 988 User s Manual 4 35 setup Global Error Latching Select whether errors will be latching or non latching e Non latching alarms turn off when there is no alarm condition e Latching alarms must be turned off manually This prompt always appears Default nla LAE Err Control Type Select a control method normal nor cascade d ratio At or differential d FF This prompt appears only on controllers equipped with enhanced software 98_B ____ ___ _ and input 2 hardware for a basic thermocou ple signal conditioner 98__ _l__ ___ _ or a universal signal conditioner 98 2 ___ and with set to GFF Default uF CSC cAt Cntl 4 36 WATLOW Series 988 User s Manual Setup Menus Chapter 4 setup Global L 6 m C Cascade Action Select the control action between the inner and outer loop of a cas cade system e Direct action makes the percent output from the outer loop directly proportional to the set point of the inner loop input 2 A 100 signal in the outer loop will set the inner loop to range high 2 Input Menu A 0 signal in the outer loop will set the inner loop to range low 2 et 2 Input Menu e Reverse action makes the percent output from the outer loop inversely proportional to the set point of the inner loop input 2 A 100 signal in the outer loop will set the inner loop to range l
60. Menus Operation Menus Chapter 5 Operation PID A or B Glo Operation Prompt __ Enter your settings from the controller s Proportional Band Output 1A upper display 6b 1A Reset Output 1A fe 18 Integral Output 1A Output 1 p 5 10 Rate Output 1A Derivative Output 1A TEIRRI i Cycle Time Output 1A E Proportional Band Output 2A Reset Output 2A Integral Output 2A Output 2 p 5 13 Rate Output 2A Derivative Output 2A Enter your settings from the controller s Prompts may not appear depending on controller configuration Integral Output 2B Output 2 p 5 13 Rate Output 2B Derivative Output 2B WATLOW Series 988 User s Manual 5 9 Operation PID A or B NOTE Decimal points may not always be in the position specified below depending on the the settings in the Decimal 1 and Decimal 2 parame ters in the Input Menu NOTE The PID B Menu appears only on controllers with enhanced software 98 B to P ide 5 10 WATLOW Series 988 User s Manual PID A or PID B Prompts After you step past the Set Point 2 prompt and the Idle Set Point prompt Id 9P to the Operation menus the Series 988 displays the menu selection 545 or in the upper display and in the lower display The Up arrow Y or Down arrow key selects another menu Press the Mode key Q to display the first p
61. NOTE Decimal points may not always be in the position specified below depending on the the settings in the Decimal 1 and Decimal 2 parame ters in the Input Menu A CAUTION Changing the value of changes most other prompts to the factory default values Document all set tings before chang ing sensor type Verify the correct sensor type before making a change Failure to follow this guideline could result in damage to equipment or prop erty Document all settings before changing sensor type Ind Input 1 continued on next page Setup Menus Chapter 4 setup Input Input Prompts When you are in the Setup menus the Series 988 displays the menu selec tion inPt QEPE 9L bl or CGF 4 in the upper display and in the lower display The Up arrow Y or Down arrow key selects another menu Press the Mode key Q to display the prompt in the lower display and its value in the upper display Use the Up arrow Y or Down arrow 4g key to change the value in the upper display The new value will not take effect until after a five second delay or until you press the Mode key QB Input 1 Select sensor type for input 1 This selection must match the sensor type connected to terminals 8 9 and 10 See Appendix for more information about sensors e Changing the value of changes all other prompts to the factory default values except the Communications and Lockout menus the prompt in the Glo
62. NOTE The heater current feature will not function with burst fire outputs NOTE The heater current feature will not function when the Series 988 has a process output for output 1 8 10 WATLOW Series 988 User s Manual Heater Current Requirements Choose the heater current option 98__ _4 _ __ _ _ for input 2 and an appropriate current transformer A current transformer must be ordered separately Output 1 cannot be used as a process output The heater current feature monitors only output 1 Overview The heater current feature measures and responds to heater current in a system This is an ideal method for detecting heater loss in applications with multiple heaters The current is measured when output 1 is on For instance if a system has five 10 amp heaters the heater current input measures 50 amps regardless of the percent output To view the heater current press the DISPLAY key and advance to the Process 2 prompt Pr 2 The upper display indicates the last valid cur rent reading The Input 2 prompt under the Input Menu can be set to current or loop error detect L 909 P Current allows you to monitor heater current and set alarm set points based on high and low heater current values Alarms can only be configured as process alarms see Alarms in Chapter 7 Setting to loop error detect enables monitoring and alarm functions and also triggers an error and shuts off all outputs if current is present with out
63. O 5 Wn 0 remote set point 4 10 8 8 8 19 restore 6 14 RTD calibration curve 1 4 7 input 1 linearization 4 8 8 14 8 15 a Wn rr LAE Y latching 4 4 3 i input 2 linearization 4 15 8 14 Ae Q Appendix WATLOW Series 988 User s Manual A 9 Menu Overview Figure A 10 The Series 988 Map NOTE This is a complete listing of all Series 988 prompts Not all prompts will appear on your con trol They are dependent on your configuration and model number To navigate Press to return to the Display Loop from any location and to advance through the Display Loop Press Y or 2 to move between the menus Press H to advance through a menu Hold QB while pressing Y to move backwards through the menus Press Y or 2 to select prompt values NOTE The controller will not default back to normal display while in the Factory Menu All outputs are disabled while in this menu MODE Display Loop Press to exit ES ee a E Lower Display an y menu a nd Setpoint 1 Process input2 Inner Loop DEVLEDon OUTLEDon Process units Remote set point reac h th e D IS pl ay set point or cascade only Ratio value Loop at any time Operation Menus System om Pma PbiA rE1A rA1A dE1A CtiA Output 1 res
64. OW Series 988 User s Manual Figure 2 10a Slidewire Feedback or Potentiometer Input cS 98 __ _3s ii gs CCW Qe Wiper 20 CW Figure 2 10b Current Transformer Input 98__ _4 The current transformer must be pur chased separately See Appendix for Watlow current transformer part numbers Systems that use more than 50 Amps need an interstage transformer For example if you use a 300A current transformer part 16 0073 and an interstage transformer part 16 0176 the 300A current transformer provides a 5A signal to the interstage transformer In turn the transformer sends a 20mA maximum signal to the controller 3 phase using 2 current transformers Figure 2 10c Digital Event Input 2 98__ _5 open 0 3V dc Event Input 2 off closed 14 36V dc Event Input 2 on pH a ee ee eS oe VDC i i Internal Circuitry i 100Q lt 4 7KQ i ii Otpt 1KQ 750Q 18 i LSc2 Seco Se SSeS ee eee Se ee eee See ee ee ee eee ee ee eee Installation and Wiring Chapter 2 NOTE Successful installa tion requires five steps e Model number and software choice Appendix e DIP switch set tings Chapter 1 e Sensor match Chapter 2 and Appendix e Sensor installation Chapter 2 and e Wiring Chapter 2 Event Input 1 Wiring Figure 2 11a Digital Event Input 1 Available on all units a on
65. Series 988 User s Manual Includes 986 987 988 and 989 a MET Loe ooo ya or 1 8 DIN Microprocessor Based Temperature Process Controller User Levels e New USE cccceeeeeeeees go to Introduction C 9 6 e Experienced Usev 5 go to page 4 1 Installers SOt UP cc ceccccseeeeesseeeeeeeeeeees page 1 1 a amp Installation aa ae 2 1 OAL CUSTOMER SATISFACTION 3YearWananty ISO 9001 Registered Company Winona Minnesota USA a LOW Watlow Controls 1241 Bundy Blvd P O Box 5580 Winona MN USA 55987 5580 Phone 507 454 5300 Fax 507 452 4507 0600 0009 0001 Rev V 10 00 December 1997 M ade in the U S A W988 XUMN Rev U00 Supersedes W988 XU me H Printed on Recycled Paper 10 Postconsumer Waste Series 988 User s Manual Includes 986 987 988 and 989 The Series 988 User s Manual is copyrighted by Watlow Winona Inc 1997 with all rights reserved 1233 Introduction to the Watlow Series 988 Controllers ii Using this Manual ii Document Every Step ji Notes Cautions and Warnings Technical Assistance We Value Your Feedback Chapter 1 Hardware Setup 1 1 Dip Switch Locations and Functions Chapter 2 Installation and Wiring 2 1 Panel Cutout and Dimensions 2 2 Installing the Series 988 2 4 Wiring the Series 988 2 4 Input to output Isolation 2 4 Power Wiring 2 5 Sensor Installation Guidelines 2 6 Wiring Exam
66. The decimal precision of A AL is determined by dE I Input Menu if is set to or St Pt it is determined by dEC 2 if Aout is set to Pred AOAL This prompt appears only on controllers equipped with retransmit hardware 98 _ __ _ M_ __or98 ___ N___ andwith not set to _ no If Default 4 CF Global Menu tk Global Menu sad Ul units a a a h IS selecte WATLOW Series 988 User s Manual 4 33 setup Global Reaching the Global Menu Begin in the Display Loop and press the Up arrow Y and Down arrow 2 Keys simultaneously for three seconds to reach the Setup Menus af Aa Stibt Cara InPt Gt Pt Input Output Global Communications Menu Menu Menu Menu p 4 2 p 418 p 4 34 p 4 44 Press the Up arrow key Y to select one of the Setup Menus Press the Mode key QB to step through the prompts Pye OF O SON a a ae D l 0 i e 9999 Press the Up arrow key Y or the Down arrow key to select one of the prompt values Figure 4 34 Navigating the Global Menu 4 34 WATLOW Series 988 User s Manual LoL paa Enter your settings C from the controller s C F Celsius Fahrenheit upper display i i A IL Failure Mode r Error Latching JEL ir ntL Control Type i SAC Cascade Action PID 2 Crossover Selection PID p 4 38 Crossover Process Value l
67. WATLOW Series 988 User s Manual Operation Menus Chapter 5 Pbeb NOTE The PID B Menu appears only on controllers with enhanced software Operation Menus Chapter 5 Operation PID A or B Cycle Time Output 1A or 1B Select the time in seconds of a complete on off cycle Ct 1A This prompt appears only if Input Menu is not set toa process Global Menu is not set to d and Pb 1A is set high er than Q0 If Default p 4 mechanical s 199 99 min relay CEIA outputs open collector br 5t Q Ia 19999 min or solid state CEIA CE IA relay outputs Proportional Band Output 2A or 2B Select the proportional band for PID output 2 If set to 0Q Jit func tions as an on off control and the switching differential is determined by the H9 2 value Output Menu Decimal precision is determined by the or d amp C 2 setting Input Menu Pb2A This prompt appears only if C nt Ll Global Menu is not set to CSCd and if Output Menu is set to or or if AL 90 Global Menu is set to dUPl If Default p 4 amp 0 __25 19999 dFi Calibration Menu Global Menu amp _OG al 2S 9999 Input 1 or 2 PbOR Input Menu amp 8 L_14 19999 dFi Pb2 A Calibration Menu Global Menu amp g __ 49 9999 Input 1 or 2 Input Menu 00 3 8 9999 of span dFi Pb2A Calibration Menu WATLOW Series 988 User s Manual 5 13 Operation
68. al Relay without Contact Suppression 98__ __E ____ Form C 5 amps off state impedance 31MQ Solid state Relay without Contact Suppression 98 _ ___K ____ 0 5 amps off state impedance 31MQ Figure 2 13b Switched DC Open Collector woo EM 98 F C P 19 to 32V dc TEV 15 iil ae i 17 Internal Circuitry Maximum voltage 42V dc Maximum current 1A External Load Figure 2 13c 0 20mA and 4 20mA Process JO F Maximum load impedance 800Q 93 lt F Minimum load impedance 1KQ Figure 2 13e External Signal Conditioner Power Supply Loop powered 1 V Transmitter 2 y 4 20mA out be 4 154 Ca 9S T i i Input lore WATLOW Series 988 User s Manual 2 13 Output 3 Wiring NOTE Successful installa tion requires five steps e Model number and software choice Appendix e DIP switch set tings Chapter 1 e Sensor match Chapter 2 and Appendix e Sensor installation Chapter 2 and e Wiring Chapter 2 NOTE Switching inductive loads relay coils solenoids etc with the mechanical relay or solid state relay output options requires using an R C suppressor Watlow carries the R C suppressor Quencharc brand name which is a trademark of ITW Paktron Watlow Part No 0804 0147 0000 NOTE Input to output iso lation is defeated when the external signal condit
69. alloy as the thermocouple itself to limit errors Using grounded thermocouples for both input 1 and input 2 may create ground loop problems To correct this problem replace at least one of the grounded thermocouples with an ungrounded thermocouple If the appli cation requires grounded thermocouples use an isolated transmitter such as a Watlow Gordon 5702 isolated transmitter RTD 100 Q input Each 1Q of lead wire resistance can cause a 2 C error when using a two wire RTD A three wire RTD sensor overcomes this problem All three wires must have the same electrical resistance i e same gauge same length multi stranded or solid same metal Process input Isolation must be maintained between input 1 and input 2 If both input 1 and input 2 are used as process inputs a separate power supply and transmitter must be used for each input Output option T external signal conditioner power supply can be used to supply power for only one input WATLOW Series 988 User s Manual 2 5 Wiring Example A WARNING To avoid potential electric shock use National Electric Code NEC safety practices when wiring and connect ing this unit to a power source and to electrical sen sors or peripheral devices Failure to do so could result in injury or death A WARNING Install high or low temperature limit control protection in systems where an over tempera ture fault condition could present a fire hazard or other haz
70. ally careful to read and follow all cautions that apply to your application A bold text WARNING safety alert appears with information that is important for protecting you others and equipment from damage Pay very close attention to all warnings that apply to your application The A symbol an exclamation point in a triangle precedes a general CAUTION or WARNING statement The A symbol a lightning bolt in a triangle precedes an electric shock hazard CAUTION or WARNING safety statement Technical Assistance If you encounter a problem with your Watlow controller review all of your configuration information for each step of the setup to verify that your selections are consistent with your applications If the problem persists after checking all the steps you can get technical assistance by calling Watlow Controls at 507 454 5300 between 7 a m and 5 p m CST and asking for an applications engineer When you call have the following information on hand the controller s model number the 12 digit number is printed on the top of the stickers on each side of the controller s case and on the right hand or top circuit board your user s manual all configuration information and the Diagnostics Menu readings We Value Your Feedback Your comments and suggestions on this manual are welcome Please send them to Technical Writer Watlow Controls 1241 Bundy Blvd P O Box 5580 Winona MN 55987 5580 or call 507 454 5300
71. bal Menu and the prompt in the Calibration Menu If you change the value the default warning dF L E will flash in the upper display e Changes do not take effect automatically after five seconds you must press the Mode key Q to enter the sensor type change and advance to the next prompt This prompt always appears If Default L 98 1 no DIP J K T N E W5 w3 Pt2 0 50mV J H El n E C d Pte 0 50 mary ouple only 98 _ 2 __ Input 1 DIP J K T N E W5 w3 Pt2 0 50mV Do oeM J H E n E C d Pte 0 50 of 2 ES cen Gel Cel Gel Cel Cet Cel Cel Cl thermocouple Input 1 DIP R S B c S b ot 2 3 thermocouple WATLOW Series 988 User s Manual 4 3 Setup Input ToT Default Input 1 continued from previous Input 1 DIP RTD RTD 0 1 EEN a e o 1 2 3 r t d r Ed page a al T RTD Input 1 DIP 4 20mA 0 20mA 0 5V 1 5V 0 10V dc oz 2 M0 20 CO 5 Ci 5 O 70 eee process Decimal 1 Select the decimal point location for process type input 1 data This prompt in conjunction with the Range Low and Range High prompts allows you to format and limit units of measure for process 1 e All prompts with units of measure related to input 1 will display in the selected decimal format e This affects propbands alarm set points process set points calibration offsets deadbands and
72. beliebiger Buchstabe 1 oder 2 01234 oder 5 BC DEF oder K ABCDEFK oder T ABCJUKMNoderT ABCDEKRS oder T 2 beliebige Buchstaben Klassifikation Regelsystem Installationskategorie II Emissionsgrad II Nennspannung 100 bis 240 V ac oder 24 bis 28 V ac dc Nennfrequenz 50 60 Hz Stromverbrauch Max 16 VA Erfullt die wichtigsten Normen der folgenden Anweisung en der Europ ischen Union unter Verwendung der untenstehenden einschlagigen Dokumente 89 336 EEC Elektromagnetische Ubereinstimmungsanweisung EN 50082 2 1995 EMC Rahmennorm f r Storsicherheit Teil 2 Industrielle Umwelt EN 61000 4 2 1995 Elektrostatische Entladung EN 61000 4 4 1995 Elektrische schnelle St6Be ENV 50140 1994 Strahlungsimmunitat ENV 50141 1994 Leitungsimmunitat ENV 50204 1995 Mobiltelefon EN 50081 2 1994 EMC Rahmennorm fir Emissionen Teil 2 Industrielle Umwelt EN 55011 1991 Beschr nkungen und Methoden der Messung von Funkst6 rungsmerkmalen industrieller wissenschaftlicher und medizinischer Hochfrequenzgerate Klasse A EN 61000 3 2 1995 Grenzen der Oberwellenstromemissionen EN 61000 3 3 1995 Grenzen der Spannungsschwankungen und Flimmern 72 23 EEC Niederspannungsrichtlinie zu entsprechen EN 61010 1 1993 Sicherheitsrichtlinien fur Elektrogerate zur Messung zur Steuerung und im Labor Teil 1 Allgemeine Richtlinien Declara que el producto siguiente Designaci n Series 986 987 988 989 N meros de modelo 9 8 6 7
73. burst fire makes it incompatible with the heater current feature 98 4 The heater current option requires a minimum of 300 milliseconds on time to get a reading e The Series 988 has built in zero cross detection circuitry eliminating the need for external firing circuitry to trigger SCR s The controller will not allow burst fire to be selected if its zero cross detection circuitry is not functioning e The feature is enabled by selecting burst fire at the cycle time prompt for the appropriate output in the PID Menu CE IA ICE Ib C amp A or CECI e Only the 988 and 989 can use the burst fire feature The low voltage units 986 and 987 cannot use burst firing Overview Variable time base burst firing from the Series 988 provides the most even distribution of power with the lowest level of noise generation RFI An SSR or SCR firing card translates a command signal into a burst of ac cycles The output is zero cross fired which always allows at least one full ac cycle to pass within the variable time base Burst firing is the preferred mode to control resistive loads The Series 988 detects when the ac sine wave of the load will cross the 0 volt point It uses this information to switch the load on or off only at a O volt point minimizing RFI The burst fire time base in the Series 988 varies from a maximum 1 66 second time base 1 percent output 1 cycle on 99 off down to a 33 3 mil lisecond time base 50
74. ch in your application on this page or a copy of it See wiring exam ples in this chapter and in the Appen dix Figure 2 7 Wiring notes Installation and Wiring Chapter 2 Wiring Notes earth ground WATLOW Series 988 User s Manual L2 2 7 Input 1 Wiring NOTE Successful installa tion requires five steps e Model number and software choice Appendix e DIP switch set tings Chapter 1 e Sensor match Chapter 2 and Appendix e Sensor installation Chapter 2 and e Wiring Chapter 2 2 8 WATLOW Series 988 User s Manual Figure 2 8a Thermocouple or 0 50mV high impedance Thermocouple only 98 l _ ____ Universal signal conditioner a J K T N C E D Pt2 R S B Input impedance 20MQ 0 50mV DIP Settings DIP Settings 4 9 0 50mV no DIP switches Slo Le co CW oO Figure 2 86 RTD 2 or 3 wire 100 Q Universal signal conditioner Jumper 98 2 9 to 10 SSeS SS for 2 wire ele DIP Switch Setting Figure 2 8c 0 5V Universal signal conditioner 98 2 __ Input impedance 10KQ DIP Switch Setting Figure 2 8d 0 20mA or 4 20mA Process 0 Universal signal conditioner 98 2 __ Input impedance 7Q CO DIP Switch Setting i i O Installation and Wiring Chapter 2 NOTE Successful installa tion requires five steps e Model number and software ch
75. cred it for material A 20 percent restocking charge is applied for all returned stock controls and accessories 5 If the unit is unrepairable it will be returned to you with a letter of explanation Repair costs will not exceed 50 percent of the original cost Shipping Claims When you receive your Watlow control examine the package for any signs of external damage it may have sustained enroute If there is apparent dam age either outside the box or to its contents make a claim with the shipper immediately Save the origi nal shipping carton and packing material WATLOW Series 988 User s Manual A 5 Index a h OUT LED 3 1 0 5V dc process wiring input 1 2 8 input 2 2 9 output 1 2 12 output 2 2 13 0 10V dc process wiring input 1 2 8 input 2 2 9 output 1 2 12 output 2 2 13 0 20mA process wiring input 1 2 8 input 2 2 9 output 1 2 12 output 2 2 13 0 50mV high impedance wiring input 1 2 8 input 2 2 9 1 5V dc process wiring input 1 2 8 input 2 2 9 output 1 2 12 output 2 2 13 4 20mA process wiring input 1 2 8 input 2 2 9 A access to panel back 2 2 ac output wiring output 1 2 12 output 2 2 13 output 3 2 14 output 4 2 15 address 4 46 alarm deviation process rate 7 7 alarm 2 4 23 alarm 2 high 5 5 alarm 2 low 5 4 alarm 2 side 4 2 alarm 3 4 25 alarm 3 high alarm 3 low 5 5 alarm 3 side 4 2 alarm 4 4 28 alarm 4 high 5 7 alarm 4 low 5 6 alarm 4 side 4 29 alarm dis
76. ctively The input 1 linearization prompt would then be set to square root extraction oot You can see from the above graph that without square root extraction to linearize the signal it would not be use ful for controlling the process General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 15 General Software Ramp To Set Point Requirements This feature is standard on all units Overview Ramp to set point enables the Series 988 to ramp the set point at a user defined rate This allows the controller to start up a system or change between set points at a rate that will not stress the product or system components The ramp rate is defined in degrees per minute Ramp to set point can be initiated at start up only or at start up and also on any set point changes When a ramp is initiated the starting point for the ramp is the current process value If the ramp is initiated on start up the Series 988 looks at the process value upon power up and uses that value as the starting point for the ramp If a set point change initiates the ramp to set point function the controller looks at the process value when the change is made and uses that value as the starting point for the ramp If the set point is changed during a ramp the process value at the time of the change becomes the starting point for the new ramp 8 16 WATLOW Series 988 User s Manual General Software Features Chapter 8 General Software heat
77. d as a percentage of output to keep the valve from hunting e The slidewire hysteresis 5H 5 setting provides additional control over a valve This prompt appears only if the controller is equipped with slidewire hardware 98_ _ 3 _ and with set to SL d J G3 __ 48 00O Hunk Hunk Hunt 4 16 WATLOW Series 988 User s Manual Setup Menus Chapter 4 SHYS NOTE See Chapter 8 for more information on slidewire feed back Figure 4 17 Hunt and slidewire inner hysteresis Setup Menus Chapter 4 Ssetup Input Slidewire Hysteresis Set the inner hysteresis the point at which the valve output turns off e The figure below illustrates the interaction between slidewire hysteresis SHYS and hunt Hunt SHYS5 This prompt appears only if the controller is equipped with slidewire hardware 98 Default __ _3 _ ___ _ and with Input 2 set to Si id SHYS Slidewire Hysteresis slidewire position set point WATLOW Series 988 User s Manual 4 17 setup Output Reaching the Output Menu Begin in the Display Loop and press the Up arrow Y and Down arrow keys simultaneously for three seconds to reach the Setup Menus as Ya DEPE JLbL corn Input Output Global Communications Menu Menu Menu Menu p 4 2 p 418 p 4 34 p 4 44 Press the Up arrow key Y to select one of the Setup Menus Press the Mode key WB to step through the prompts
78. dicates the desired difference between input 1 and input 2 The set point that input 1 will use is determined by the equa tion internal set point input 2 differential set point The lower display shows the differential set point which can be adjusted with the increment up arrow and decrement down arrow keys Please note that while in the differential control mode the internal set point for input 1 cannot be viewed and must be calculated with the equa tion 9 6 WATLOW Series 988 User s Manual Enhanced Software Features Chapter 9 Enhanced Software Water Boiler input 1 988 output 1 PROCESS outside temperature Sensor QD temperature sensor limit sensor input 2 DISPLAY heating element OTT Figure 9 7 Water boiler with differen Sample Application tial control The most common application using differential control is to maintain water temperature in a boiler at a differential to the outside air tempera ture A thermocouple at input 2 senses the outside air temperature and adjusts the internal set point to maintain the boiler water temperature 120 degrees higher Substituting values we have boiler temperature outside temperature 120 In this application the system uses two type J thermocouples one to sense boiler water temperature input 1 and one to sense the outside air temperature input 2 To configure the controller first enable i
79. e open 14 36V dc Event Input 1 off PH A closed 0 3V dc Event Input 1 on 4 99KQ O1pf have dc 7509 10KQ 4 99KQ p o Internal Circuitry Installation and Wiring Chapter 2 WATLOW Series 988 User s Manual 2 11 Output 1 Wiring Figure 2 12a AC Outputs NOTE Successful installa tion requires five steps e Model number and software choice Appendix DIP switch set tings Chapter 1 e Sensor match Chapter 2 and Appendix e Sensor installation Chapter 2 and e Wiring Chapter 2 NOTE Switching inductive loads relay coils solenoids etc with the mechanical relay or solid state relay output options requires using an R C suppressor Watlow carries the R C suppressor Quencharc brand name which is a trademark of ITW Paktron Watlow Part No 0804 0147 0000 2 12 WATLOW Series 988 User s Manual Solid state Relay with Contact Suppression 98 _ __ B_ ____ 0 5 amps minimum off state impedance 20KQ Electromechanical Relay with Contact Suppression Suppression between NO and COM contacts only 98 __ D_ ____ Form C 5 amps minimum off state impedance 20KQ Electromechanical Relay without Contact Suppression 98 _ __E_ ____ Form C 5 amps off state impedance 31MQ Solid state Relay without Contact Suppression 98__ K 0 5 amps off state impedance 31MQ Figure 2 12b Switched DC Open Collector Ors ee et 49 16 38 gt aj Zz Maximum voltage
80. e output signal from a flow transmitter repre sents a squared value of the actual flow The square root must be extract ed from the signal to make it useful to the operator Many flow transmit ters offer this feature in the transmitter itself but this can add significant ly to the cost Using the square root extraction option in the Series 988 controller can save the operator money The feature is enabled simply by setting input 1 linearization or input 2 linearization to square root extraction root 8 14 WATLOW Series 988 User s Manual General Software Features Chapter 8 Figure 8 15a Graph of linearized signal Figure 8 15b Waste water treat ment with input lin earization General Software linearized signal flow in gallons per 8 minute 6 4 2 0 non linearized signal 4 20mA input signal output 1 transmitter Water Treatment Pond Sample Application A waste water process engineer needs to control the flow of a solution to be mixed with wastewater to treat it The transmitter provides a 4 20mA output without square root extraction The engineer used the Series 988 with a universal signal conditioner input and a 4 20mA process output to control the flow The input signal was linearized using the square root extraction feature of the 988 The above system has a flow range of O to 16 gallons per minute The range low and range high parameters for input 1 would be set to O and 16 respe
81. eS a e cs The Communications Menu 9600 Geg 4800 appears only on controllers equipped with communications r Rua bAUd bAUd hardware 98__ RO See Data Communications with 485 422 the Series 988 Family of Controllers for detailed informa tion on communications Press the Up arrow key Y or the Down arrow key to select one of the prompt values Figure 4 44 Navigating the Communications Menu 4 44 WATLOW Series 988 User s Manual Setup Menus Chapter 4 bHUd Setup Menus Chapter 4 Communications Prompts When you are in the Setup menus the Series 988 displays the menu selection n Pt QEPE 9LbL or CGF 49 in the upper display and in the lower display The Up arrow Y or Down arrow key selects another menu Press the Mode key Q3 to display the first prompt in the lower display and its value in the upper display Use the Up arrow Y and Down arrow 2 Keys to change the value in the upper display The new value will not take effect until after a five second delay or until you press the Mode key WB Baud Rate Select the communications speed bAUd This prompt appears only on controllers equipped with communi cations hardware 98__ ___ _ R__ 98__ ___ _ U__or98__ ___ _ _S__ Default L 9600 C408 4800 bAUd bAU d bAU d Data Bits and Parity Select the communications format start bit 1 stop bit 1 e Setting Pr ot to automatically sets JA
82. ead band When the chamber temperature is near ambient the cooling and heating systems had a tendency to buck one another resulting in inefficient use of energy The engineer started with a dead band of five degrees but in the process of tuning the system for optimal control the setting was reduced to two degrees This made the chamber more energy efficient and reduced wear on the refrigeration system General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 7 General Software Digital Events Requirements A single digital event input is standard on all controls A second digital input is available as an option for input 2 98__ _5__ ___J Overview The digital event input options on the Series 988 controller allow the oper ator to select one of several software functions with the close of a cus tomer supplied switch or by a change in dc voltage See Chapter 2 for volt age and wiring information The list below outlines the functions that can be controlled with a digital event input e Idle set point i d 5P lets the operator select a second idle set point e Turn control outputs off inhibits the control outputs e Alarm reset resets alarms from a remote location e Switch PID sets selects between PID set A or B requires enhanced software 98_B _ e Remote set point switches to remote set points e Front panel lockout locks out the front panel keys to prevent tampering e Control output ac
83. ee Global Menu Input Menu Global Menu amp l rtd T e Global Menu Input Menu LG GG units a process input CALE CALE is selected RTD Calibration Curve 2 Select the calibration curve for the RTD 2 input The RTD input uses either the European DIN 0 0038500 Q C or Japanese JIS 0 0039 1602 Q C linearization standard This prompt appears only on controllers equipped with input 2 hardware and with set to or rtd Default q J 15 rtd WATLOW Series 988 User s Manual Setup Menus Chapter 4 Fire L ine NOTE See Chapter 8 for more information on input lineariza tion Setup Menus Chapter 4 Ssetup Input Software Filter 2 Select the filter time constant in seconds for input 2 This smooths a rapidly changing input signal for display or control purposes e Select a positive value to filter only the display e Select a negative value to filter the input signal e Set the value to _ _ Q to disable the filter This prompt appears only on controllers equipped with input 2 hardware and with not set to or E Default Ftre Fer Linearization 2 Select square root linearization for input 2 This prompt appears only if you have set Input 2 toa process input or to a thermocouple input set to mV Default d L ing L ing WATLOW Series 988 User s Manual 4 15 setup Input NOTE See Chapter 8 for more information on slidewire feed back Hunt Set the deadban
84. elect the decimal point location for process type input 2 data This prompt in conjunction with the Range Low and Range High prompts allows you to format and limit units of measure for process 2 e All prompts with units of measure related to input 2 will display in the selected decimal format e This affects propbands alarm set points process set points calibration offsets deadbands and ranges d amp C 2 This prompt appears only if you have set input 2 toa process input or a thermocouple input set to mv Default 28008 JECO JdELO JEC Range Low 2 and Range High 2 Select the low and high limits for input 2 These prompts limit the adjustment range for the set points The default values are the same as the limits of the sensor you selected by setting the input 2 DIP switch and selecting a value for Input 2 Jn e Process inputs are scaled by these values Range high is the value dis played when the maximum process signal is present at the input Range low is the value displayed when the minimum process signal is present at the input Example Set to 2 0 mA Set eLejto 100 Set to _ 500 A 4mA input will display A 12mA input will display 300 A 20mA input will display 99 e The low and high values of each sensor type are listed on the specifica tions page of the Appendix e Choose between Fahrenheit and Celsius at the prompt in the Global Menu These prompts appear only if the controller
85. elected 0 28 999 3999 units can be extended to 399 O S 993 199995 units 1 5 999 19999 units 0 I0 995 j9999 units 0 58 995 8999 units 0400 9994 9995 units slidewire SL id C 780 1280 ohms current GJ 58 amps potentiometer PO 0 1200 ohms 4 12 WATLOW Series 988 User s Manual Setup Menus Chapter 4 NOTE See Chapter 8 for more information on slidewire feed back NOTE See Chapter 8 for more information on slidewire feed back Setup Menus Chapter 4 setup Input Learn Low Write the low end resistance of the slidewire potentiometer to the range low 2 parameter This prompt appears only on controllers equipped with input 2 hardware and with Input 2 set to or POEL Default 4 YES Learn High Write the high end resistance of the slidewire potentiometer to the range low 2 parameter This prompt appears only on controllers equipped with input 2 hardware and with Input 2 set to or POEL Default p YES Lr nH Lr nH WATLOW Series 988 User s Manual 4 13 Setup Input a pm A Pud Calibration Offset 2 Offset the input 2 signal by a positive or negative value This allows you to compensate for lead resistance sensor errors or other factors CAL 2 This prompt appears only if the controller is equipped with input 2 hardware and if is not set to orf E2 If Minimum Default Max setting range 4 Global Menu amp rid n s
86. enu a Ohe _38 _999 _F Input 1 or 2 Global Menu see note above 555 C F HY53 H953 Global Menu a 283 __2g _555 Input 1 or 2 H953 Global Menu see note above gir 999 unts a process input HYS3 HYS3 HYS3 is selected 4 26 WATLOW Series 988 User s Manual Setup Menus Chapter 4 setup Output AL 3 Latching 3 Select whether alarm 3 will be latching or non latching A latching alarm must be turned off manually A non latching alarm turns off when an alarm condition no longer exists i At 3 This prompt appears only on controllers equipped with output 3 NOTE hardware for a relay 98__ ___ B__ _ 98_ _ __ _ _ J___or See Chapter 7 for 98__ ___ _ K___ or switched de 98__ ____ C__ _ and with set more information to or AL Jal on alarms Default AP LAE 5 IL J Silencing 3 Select silencing to inhibit alarm 3 on startup and to allow the opera tor to reset the alarm output not the visual display e Silencing disables the alarm until the signal is between A 3t Q and AJH I NOTE S it 3 This prompt appears only on controllers equipped with output 3 See Chapter 7 for hardware for a relay 98__ ___ B__ 98_ ____ J___or kiai information 98 __ _ K or switched de 98 __ ____ C___ and with set on alarms to or AL Jn Default 4 5 IL 3 Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 27 setup Output Output 4 Select the alarm condition for out
87. equipped with output 2 NOTE hardware and with set to or AL nl See Chapter 7 for more information Default on alarms J LAE LARE 6 fe Ce Silencing 2 Select silencing to inhibit alarm 2 on startup and to allow the opera tor to reset the alarm output not the visual display e Silencing disables the alarm until the signal is between Ae tL GQ and AH I This prompt appears only on controllers equipped with output 2 hardware and with set to or AL ln Default L Sie Sie 4 24 WATLOW Series 988 User s Manual Setup Menus Chapter 4 setup Output Output 3 Select the alarm condition for output 3 de energizes output 3 in an alarm condition energizes output 3 in an alarm condition NOTE This prompt appears only on controllers equipped with output 3 See Chapter 7 for hardware for a relay 98__ ___ _ B___ 98__ ___ _ J___ or more information 98_ __ K _ or switched dc 98_ a es _ C_ _ _ on alarms Default qo A 3 Alarm 3 Select the alarm type for alarm 3 e Pr uses the process signal from input 1 e dE I uses a deviation from the input 1 signal e Pe uses the process signal from input 2 This prompt does not appear if the controller is not equipped with input 2 hardware or if is set to or _E 1 uses a deviation from the input 2 signal This prompt does not appear if the controller is not equipped with input 2 hardware or if is set to or E2 e uses the rate of change at i
88. er ence between set point and process variable overshoot The amount by which a process variable exceeds the set point before it stabilizes P control Proportioning control PD control Proportioning control with derivative rate action PDR control Proportional derivative control with manu al reset used in fast responding systems where the reset causes instabilities With PDR control an operator can enter a manual reset value that eliminates droop in the system PI control Proportioning control with integral automat ic reset action PID Proportional integral derivative A control mode with three functions proportional action dampens the sys tem response integral corrects for droop and derivative prevents overshoot and undershoot process variable The parameter that is controlled or measured Typical examples are temperature relative humidity pressure flow fluid level events etc The high process variable is the highest value of the process range expressed in engineering units The low process variable is the lowest value of the process range proportional band PB A range in which the propor tioning function of the control is active Expressed in units degrees or percent of span See PID proportional control A control using only the P pro portional value of PID control rate band A range in which the rate function of a con troller is active Expressed in mult
89. er that will if you select a positive value affect the display only Select a negative value to fil ter the input signal itself 8 12 WATLOW Series 988 User s Manual General Software Features Chapter 8 General Software Display readings with input filter OFF Display readings with input filter ON RH RH time time Figure 8 13a Display readings with input filtering Humidity Chamber output 1 sensor PROCESS ma humitidy M heater transmitter SERIES 988 Figure 8 13b Humidity chamber with input filtering Sample Application A Series 988 controls the humidity in an environmental chamber The rel ative humidity RH sensor provides a 4 20mA signal over a 0 100 RH range The sensor is very sensitive to changes caused by air flow in the chamber The turbulence in the chamber makes the controller display jump two to three percent To remove this display dithering set the filter time constant for input 1 to two seconds This will smooth the dis play and provide a more realistic reading General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 13 General Software Input Linearization Requirements The square root extraction feature is standard on any Series 988 con troller with universal signal conditioner inputs The linearization prompt will appear if a process input is selected with the DIP switches see Chapter 1 Overview In many flow applications th
90. ers MUNTII TEE l Muffle Furnace limit papa output 1 o amp sensor PROCESS sensor DISPLAY MITTITI ININ 00 TTTTTTTT UTE heaters SERIES 988 Figure 8 17 Muffle furnace with Sample Application ramp to set point An engineer needs to control the temperature of a muffle furnace The fur nace set point must be ramped up at a defined rate to prevent stressing the muffle and other system components By enabling the ramp to set point function in the Series 988 the engineer can control the rate at which the set point will rise Ramp to set point is enabled in the Global Menu using the Ramping Function prompt rP To ramp on start up only select start 5t r To ramp on start up and on any set point changes select set point S Pt The ramp rate is in degrees per minute For further protection of the system output 2 3 or 4 can be configured as a rate alarm monitoring the rate of increase or decrease in the process variable on input 1 The Alarm Low AL 0 and Alarm High prompts The 2 in these examples refers to output 2 establish the ramp down and ramp up rate set points respectively in degrees per minute General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 17 General Software NOTE Make sure all input and output impedances are compatible NOTE Input 1 and 2 are not isolated from each other 8 18 WATLOW Series 98
91. es the Mode key Q and the Auto Man key 9A Jj disables the Mode key W and the Auto Man key and locks the set point value This prompt always appears Default d 8 tac LOC LOC LOC WATLOW Series 988 User s Manual 6 3 Factory Panel Lockout The prompts within the Panel Lockout Menu allow you to lockout an entire menu You can set the level of lockout to none pon read only e E Ad or lockout read and write FULL System Menu Select the lockout level for the System Menu Set the System Menu lockout to no lockout nonE read only r E Ad or full lockout FULL This prompt always appears Default J mont EAd FULL WN WN PID A Menu Select the lockout level for the PID A Menu Set the PID A Menu lock out to no lockout pgn read only or full lockout FUL L This prompt always appears Default i EAd FULL PidA PID B Menu Select the lockout level for the PID B Menu Set the PID B Menu lock out to no lockout nonE read only or full lockout FUL L This prompt appears only on controllers with enhanced software 98 B __ _ ___ _ and with Al 90 Global Menu set to or Global Menu set to 50 d 6 4 WATLOW Series 988 User s Manual Factory Menus Chapter 6 GEPE Gi be Factory Menus Chapter 6 Factory Panel Lockout Input Menu Select the lockout level for the Input Menu Set the Input Menu lock out to no lockout pgn read only or ful
92. et A Output 1 rate A rE2A t2A rA2A dE2A dbA Dead band A Output 2 reset A Output 2 rate A Output 1 proportional band A Output 1 integral A Output 1 derivative A dE1b Output 1 cycle time A Output 2 proportional band A Output 2 integral A Output 2 derivative A dE2b Output 2 cycle time A Press B to advance to the Operation menus Outputs are still active PIDE Pbib Output 1 proportional band B Output 1 reset B Output 1 integral B Output 1 rate B Output 1 derivative B rE2b t2b rA2b Output 1 cycle time B Output 2 proportional band B Output 2 reset B Output 2 integral B Output 2 rate B Output 2 derivative B Output 2 cycle time B dbb Dead band B Setup Menus Setup se 0 rS tt output Q As 5 Decimal place 1 Range low 1 I lt 2 rH1 Range high 1 Calibration offset 1 RTD calibration curve 1 Hysteresis 2 v JI Viz d 18 Input 1 software filter Control set point 2 Input 1 linearization Alarm 2 Input 2 A2Sd_ Alarm 2 side Remote set point Latching for alarm 2 Decimal place 2 Silence alarm 2 Range low 2 Output 3 Range high 2 Alarm 3 MODE Alarm 3 side Learn range low Learn range high HYS3 _ Hysteresis 3 Calibration offset 2 Latching for alarm 3 RTD calibration curve 2 SIL3 _ Silence alarm 3 Input 2 software filter Out
93. gher than range high 1 cH This prompt appears only on controllers with set to Proc Default 4 cil rH i Proc Proc 6 p Crossover Set Point Value Select the set point value at which the control algorithm will crossover between PID A and PID B PID A is active below this value and PID B is active above this value e This value cannot be set lower than range low 1 or higher than range high 1 cH S amp Pt This prompt appears only on controllers with set to SEPE Default 4 eL l CHI SEPE Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 39 Setup Global Event Input 1 4 40 Select the effect of closing the event input 1 switch e ng disables event input 1 e QC locks out the front panel keys e AL resets an alarm A 9 switches the controller to manual mode at the power level set at FA IL Global Menu and disables the Auto Man key e QF F turns all control outputs off de energize relays e P d switches from PID A to PID B e Acta selects the opposite control action for output 1 and 2 e 5P switches to a remote set point e Id SP switches to an idle or second set point This prompt always appears Default L E L amp E LEHN EHN CE CE LEN CE LEL E Z Event Input 2 Select the effect of closing the event input 2 switch The selections are the same as for event input 1 This prompt appears o
94. hen the signal lt AYU G f45 d This prompt appears only on controllers equipped with output 4 hardware for a relay 98__ ___ B _ 98__ ___ _ D__ 98 E _or98 ___ K_ _ orswitched dc 98 __ C_ and with set to or AL Yn Default p WATLOW Series 988 User s Manual 4 29 setup Output NOTE See Chapter 7 for more information on alarms 4 30 WATLOW Series 988 User s Manual Hysteresis 4 Select the switching hysteresis for alarm 4 This determines the change in temperature or process units needed to turn the output from off to on e If is set to settings for HY 5 4 will be in degrees per minute or units per minute e If the input referenced by is set to the range is affected as listed below HY54 This prompt appears only on controllers equipped with output 4 hardware for a relay 98__ ___ B _ 98__ ____ D__ 98 __ E _or98 ____ _K__ or switched de 98__ ___ _ C__ If Default d L _999 LCF Global Menu amp __38 a _999 C_F Input 1 or 2 Global Menu see note above s sal 09S L E Global Menu amp s eO ad 555 Input 1 or 2 Global Menu see note above sa 1 999 units a process input HYSY is selected Latching 4 Select whether alarm 4 will be latching or non latching A latching alarm must be turned off manually A non latching alarm turns off when an alarm condition no longer exists L At 4 This prompt appears only on contr
95. hout having to adjust each con trol individually This can be achieved using a Series 988 with a 0 5V dc retransmit output as the master controller The seven remote 988s will use the 0 5V dc signal on input 2 as a remote set point When the set point is changed on the master controller the retransmit output changes the set points of the seven remote controllers By enabling the ramp to set point feature in the master controller all eight zones are ramped up to set point at a user defined rate on power up The retransmit output from the master Series 988 is set so that OV dc represents O F and 5V dc represents 800 F On the remote controllers set the input 2 DIP switch to the position for the 0 5 1 5 0 10V dc process input In the Input Menu under the Input 2 prompt Ingl select 0 5 The Remote Set Point prompt should be set to ON and decimal 2 dE C 2 set to 0 The range low 2 and the range high 2 parameters will establish the scaling for the remote set point input Range low 2 should be set to O and range high 2 should be set to 800 To operate a specific zone ten degrees hotter than the others increase the range low 2 _ rL 2 to 10 and the range high 2 to 810 With remote set point enabled and local selected under the Local remote prompt in the System Menu the set point is adjusted using the up arrow and down arrow keys Selecting remote under the Local remote prompt r disables the up arrow and down arrow key
96. ide 986 or 988 or Top and Bottom 987 or 989 View Top and Bottom 986 or 988 u Panel ho Tipe ce or Side 987 or 989 View oo e Mounting Slots 4 x f External Gasket Mounting Collar WATLOW Series 988 User s Manual Installation and Wiring Chapter 2 A CAUTION Follow the installa tion procedure exactly to guarantee a proper NEMA 4X seal Make sure the gasket between the panel and the rim of the case is not twisted and is seat ed properly Failure to do so could result in damage to equipment Installation the mounting collar over the back of the control Loosen the mounting bracket screws enough to allow for the mounting collar and panel thickness Place each mounting bracket into the mounting slots head of the screw facing the back of the controller Push each bracket backward then down to secure it to the control case To guarantee a proper NEMA 4X seal Series 986 and 988 units vertical must have the mounting brackets located on either side of the unit When installing Series 987 and 989 units horizon tal the brackets must be on the top and bottom of the unit Make sure the case is seated properly Tighten the installation screws firmly against the mounting collar to secure the unit To ensure a NEMA 4X seal there should be no space between the bezel and panel Overtightening the screws will distort the case and make it diffi cult to
97. ies 988 effectively combines both controllers into a single package The primary controller measures the process in the outer or primary loop with input 1 and compares the value to the desired set point The differ 9 2 WATLOW Series 988 User s Manual Enhanced Software Features Chapter 9 Enhanced Software ence between the set point and the process temperature generates an internal percent output value for the second or inner loop controller This value cannot be seen by the operator This internal percent int output generates the internal set point for the secondary or inner loop The sec ondary loop uses this set point and the value of input 2 typically attached to the heater sheath to control the heat source temperature Algorithm The following formulas show how the primary control sends a set point based on input 2 range high and range low values to the secondary con trol The secondary control uses this set point SP int to generate a per cent output out to the heater 1 jnt PID Set A In1 SP 2 SPint H2 rL2 jpnt rL2 3 wout PID Set B In2 SPiptl The critical parameters are the range settings for input 2 of the inner loop controller The range high value rH2 is the maximum allowed set point for the secondary or inner loop The range low value rL2 is the mini mum allowed set point In a system controlling a heater this would be the maximum and minimum desired sheath tempera
98. ioner power supply is used to power a transmitter con nected to input 1 or input 2 Figure 2 14a AC Outputs Solid state Relay with Contact Suppression 98 _ _ ____ B 0 5 amps minimum off state impedance 2OKQ NC Form B External or L2 a tad NO Form A L1 COM Fuse Electromechanical Relay without Contact Suppression 98 ___ _ J Form A or B 5 amps off state impedance 31MQ Solid state Relay without Contact Suppression 98__ K 0 5 amps off state impedance 31MQ Form A or B alarm jumper settings 98_ J__ only Figure 2 14b Switched DC go C 7902 y Minimum load resistance 500Q 2 Internal Circuitry 19 to 32V dc External Load 6 Figure 2 14 c Process Retransmit 0 20mA 4 20mA Load impedance 6002 max 98 _ _ ____ M 0 5V 1 5V 0 10V VDC Load impedance 500 min 98__ ____ N Figure 2 14d External Signal Conditioner Power Supply JS _ T NOTE See Chapter 1 for power supply DIP switch information 2 14 WATLOW Series 988 User s Manual Loop powered Transmitter V 4 20mA out j m Installation and Wiring Chapter 2 NOTE Successful installa tion requires five steps e Model number and software choice Appendix e DIP switch set tings Chapter 1 e Sensor match Chapter 2 and Appendix e Sensor installation Chapter 2 and e Wiring Chapter 2 NOT
99. ions S EIA TIA 232 or EIA TIA 485 communications U OEY I Gt Ye Gt Y3 Gt YY These prompts always appear Factory Menus Chapter 6 d 9P Factory Menus Chapter 6 Factory Diagnostics Test Displays Runs a brief test of the controller s displays and LEDs To run the test scroll through the Diagnostics Menu until is shown in the lower display Use the Up arrow key Y or Down arrow key to select from the upper display and press the mode key QB The controller will run pattern tests blink all the LEDs on and off and end with the model number in both displays This prompt always appears Default a T d a UC wim a Test Outputs This prompt tests each output To run the test scroll through the Diagnostics Menu until is shown in the lower display Use the Up arrow key Y or Down arrow key to select an output out outed lout 3 or out 4 The LED for that output should light after a second or two indicating that the output has been successfully energized Do not press the mode key 3 to activate the test it starts automatically when anything other than is selected If any of the LEDs fail to light contact the factory This prompt always appears Default d out tout tout tout tovt WATLOW Series 988 User s Manual 6 11 Factory Diagnostic H pP l p Open Loop Checks the control loop consisting of the controller output power control heater and sensor With open loop
100. iples of the proportional band See PID ratio A method by which the controller measures the flow of an uncontrolled variable and uses a proportion of it to control the flow of a second variable reference junction See junction reset Control action that automatically eliminates off set or droop between set point and actual process tem Appendix Glossary M Z perature Also see integral automatic reset The integral function of a PI or PID temperature controller that adjusts the process temperature to the set point after the system stabilizes The inverse of integral automatic power reset A feature in latching limit controls that does not recognize power outage as a limit condition When power is restored the output is re energized automatically as long as the temperature is within limits manual reset 1 A feature on a limit control that requires human intervention to return the limit to normal operation after a limit condition has occurred 2 The adjustment of a proportional control to raise the pro portional band to compensate for droop no key reset A method for resetting the con troller s memory for instance after an EPROM change resistance temperature detector RTD A sensor that uses the resistance temperature characteristic to measure temperature There are two basic types of RTDs the wire RTD which is usually made of platinum and the thermis tor which is made
101. l Menu These prompts always appear Default Default Default Default 4 NS 4 Lei i Leal Lei i Lead C 3e2 41580 0 8 16 98 1 or C rn Crt Creat Cel cH I 98 2 _ K 328 2 500 200 137 1 328 750 200 399 al 3e le 3 te 0 1300 328 1470 200 799 W5 32 4200 Q 23 15 W3 l d 32 4200 0 23 16 32 2543 0 1395 high impedance 8 950 999 _999 543 9 13 WATLOW Series 988 User s Manual 4 5 setup Input l r L l ekl rH ekl rH rH i Range Low 1 and 3 2 3280 0J 1760 98_ 2 ee cae eee Range High 1 only in l continued from previous page 5 J2 J200 0 1160 b 32 3300 Q 418 16 rtd 328 1472 200 _888 NOTE These values do not rtd 999 9999 733 53 27 affect the low or the high set point limit 4 20 999 9999 units for process alarms 8 22 999 9999 units O S 999 9999 units l 5 999 9999 units 0 I0 999 9999 units Calibration Offset 1 Offset
102. l lockout FUL L This prompt always appears Default cr EAd FULL LinPt LinPE Output Menu Select the lockout level for the Output Menu Set the Output Menu lockout to no lockout pon read only or full lockout FUL L Gt Pt This prompt always appears Default FULL DEPE Global Menu Select the lockout level for the Global Menu Set the Global Menu lock out to no lockout non E read only or full lockout FUL L 9L 6t This prompt always appears Default FULL WATLOW Series 988 User s Manual 6 5 Factory Panel Lockout C op N Communications Menu Select the lockout level for the Communications Menu Set the Communications Menu lockout to no lockout nonE read only or full lockout FUL L c GF 9 This prompt appears only on controllers equipped with Communications hardware 98 __ R or 98 S__ Default ma A 2 9 M moO ry ae 2 IO rm f d e 3 r Diagnostics Menu Select the lockout level for the Diagnostics Menu Set the Diagnostics Menu lockout to no lockout nonE read only or full lockout FULL This prompt always appears Default Ap non rEAd FULL d1A9 d 1A9 d 189 Calibration Menu Select the lockout level for the Calibration Menu Set the Calibration Menu lockout to no lockout pon read only or full lockout FULL This prompt always appears Default 4 FULL CAL C CAL CAL 6 6 WATLOW Series 988 User
103. l to the difference between the set point and the actual process temperature zero cross Action that provides output switching only at or near the zero voltage crossing points of the ac sine wave See burst fire zero switching See zero cross WATLOW Series 988 User s Manual A 3 Specifications 1234 Control Mode e Dual input quad output optional retransmit of set point or process variable e Programmable direct and reverse acting control out puts e One step auto tuning Operator Interface e Local remote set point capability e Dual 4 digit LED displays upper 0 4 10mm lower 0 3 8mm e Mode Auto Man Display Up and Down keys Input e Contact input for software function select e Type J K T N C W5 5 D W3 E R S B Pt 25 thermocouple 1 or 0 1 RTD 0 50mV dc 0 20mA 4 20mA 0 5V dc 1 5V dc 0 10V dc process e Slidewire digital event input or heater current options e Sensor break protection de energizes control output to protect system or selectable bumpless transfer to manual operation Latching or non latching e or C display or process units user selectable Sensor Ranges J t c 32 to 1500 F or 0 to 816 K t c 328 to 2500 or 200 to 1371 C T t c 328 to 750 F or 200 to 399 C N t c 32 to 2372F or 0 to 1300 C R t c 32 to 3200F or O to 1760 C S t c 32 to 3200 F or 0 to 1760 C B t c 1598 to 3300F or 870 to 1816 C Etc
104. lected a device address must be selected at the address prompt For EIA TIA 232 full or on XON XOFF protocol may be selected 8 4 WATLOW Series 988 User s Manual General Software Features Chapter 8 General Software Test Test Test Test Test Chamber 1 Chamber2 Chamber3 Chamber4 Chamber 5 PROCESS DisPLay output 4 output 4 output 4 personal computer with EIA TIA 422 port Figure 8 5 Test chambers with Sample Application communications A test engineer uses Series 988s to control the temperatures of several automated test chambers His computer is linked to the controllers through its EIA TIA 422 serial communications port His computer pro gram monitors the temperatures of the chambers and initiates automatic test sequences when certain program parameters are met After complet ing a sequence the computer loads the next temperature to the controller The computer periodically interrogates each controller for its process tem perature set point and alarm status This information is stored on a disk to provide test verification data for the completed products General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 5 General Software A WARNING If the dead band is set to a negative value the heat and cool outputs can both be ON at the same time Dead Band Requirements The dead band feature is standard on any Series 988 controller with two control outputs The dead band
105. low flow ct of pigment transmitter transmitter eX uncontrolled flow of unmixed paint motorized valve Figure 9 13 Mixing tank with ratio con Sample Application trol Blue pigment must be added to paint at a ratio of one part per 100 to cre ate a mixed paint of the desired color The uncolored paint flows into the mixer in an uncontrolled stream that is set manually and sensed by input 2 A motorized valve controls the flow of pigment which is monitored by the flow sensor to input 1 The flow rate of the uncolored paint determines the set point for the motorized valve that controls the pigment flow If an operator needs to change the rate of flow for the uncolored paint the set point will shift accordingly to maintain the correct ratio in the mixing tank The application engineer set up this feature in software by choosing ratio as the control parameter in the Global Menu The set point value displayed was then a ratio value He entered 0 01 to maintain an input l input 2 ratio of 1 100 Enhanced Software Features Chapter 9 WATLOW Series 988 User s Manual 9 13 Appendix Appendix Glossary Specifications Warranty and Returns Index Menu Overview Model Number Declaration of Conformity gt No gt IN gt oO gt O gt gt gt N WATLOW Series 988 User s Manual A 1 Glossary A L annunciator A visual display that uses pilot lights to indicate the former o
106. menu selection fn Pt QEPE St bL or C GF in the upper display and in the lower display The Up arrow Y or Down arrow key selects another menu Press the Mode key Q to display the first prompt in the lower display and its value in the upper display Use the Up arrow Y and Down arrow 2 keys to change the value in the upper display The new value will not take effect until after a five second delay or until you press the Mode key QB Output 1 Set the way that output 1 will respond to a difference between the set point and an input variable select reverse action so that output 1 responds when the input signal is less than the setpoint select direct action so that output 1 responds when the input signal is more than the setpoint This prompt always appears Default 4 OE i WATLOW Series 988 User s Manual 4 19 setup Output Process 1 Select the process range for output 1 This prompt appears only on controllers equipped with output 1 process hardware 98__ _ _F Default H y 6 Hysteresis 1 Select the switching hysteresis for output 1 This determines the change in temperature or process units needed to turn the output from full on to full off HYS I This prompt does not appear on controllers equipped with output 1 process hardware 98__ __F_ This prompt only appears with the controller set up as an on off controller Pb IA __ 0 If Default J J
107. mit signal at output 3 This prompt appears only on controllers equipped with retransmit hardware 98 _ __ _ _ M_ or 98 ___ N___ andwith not set to no Default 1 4 20mA 0 20mA 0 5V 1 5V 0 10V dc 4 28 8 20 1 5 10 Prod Prc3 Prc3 PreJ Retransmit Low Limit Select the low limit for the retransmit signal at output 3 e The default value is equal to or in the Input Menu depending on whether is set to or Prec e The decimal precision of is determined by d amp C I Input Menu if is set to or St Pt it is determined by dEC 2 if Aout is set to Pred This prompt appears only on controllers equipped with retransmit hardware 98 _ __ _ _ M_ or 98 ___ N___ andwith not setto no A rL A reL Setup Menus Chapter 4 NOTE See Chapter 8 for more information on retransmit Setup Menus Chapter 4 setup Output Retransmit High Limit Select the high limit for the retransmit signal at output 3 e The default value is equal to or in the Input Menu depending on whether is set to or Prc e The decimal precision of A AL is determined by d amp C I Input Menu if is set to or St Pt it is determined by dEC 2 if Aout is set to Pre This prompt appears only on controllers equipped with retransmit hardware 98__ M __or98__ N__ _ and with not s 999 AH A cH Retransmit Calibration Offset Select an offset value for the retransmit signal at output 3 e
108. nction Type of thermocouple probe in which the hot or measuring junction is an inte gral part of the sheath material No electrical isolation is provided isolated junction A form of thermocouple probe construction in which the measuring junction is fully enclosed in a protective sheath and electrically isolat ed from it Commonly called an ungrounded junction reference junction The junction in a thermo couple circuit held at a stable known temperature cold junction Standard reference temperature is 32 F 0 C thermocouple junction The point where the two dissimilar metal conductors join In a typical thermo couple circuit there is a measuring junction and a refer ence junction See reference junction ungrounded junction See isolated junction Appendix linearization square root The extraction of a linear signal from a nonlinear signal corresponding to the mea sured flow from a flow transmitter Also called square root extraction Modbus RTU Remote Terminal Unit NEMA 4X A NEMA specification for determining resis tance to moisture infiltration This rating certifies the con troller as washable and corrosion resistant on off A method of control that turns the output full on until set point is reached and then off until the process error exceeds the hysteresis open loop A control system with no sensory feedback output Control signal action in response to the diff
109. nd PIDA and B If your controller is equipped with enhanced software 98_B Tuning Manual Operation Alarms and Error Codes Chapter 7 1 Apply power to the Series 988 and enter a set point Begin with Pbjsetto Isl jor t amp jsetto _G O _ rAjor dE set to 0288 set tol 59 setto _ and set to GFF 2 Proportional Band Adjustment Gradually increase until the upper display process value stabilizes at a constant value The process value will not be right on set point because the initial reset value is 0 00 repeats per minute If issetto Q then Jb and are inoperative and the Series 988 func tions as a simple on off control The HY5 prompt determines the switching differential value 3 Reset Integral Adjustment Gradually increase or until the upper display process value begins to oscillate or hunt Then slowly decrease or until the upper display stabilizes again near set point 4 Cycle Time Adjustment Set as required Faster cycle times sometimes achieve the best system control See Chapter 8 for more information on the burst fire feature However if a mechanical contac tor or solenoid is switching power to the load a longer cycle time may be desirable to minimize wear on the mechanical components Experiment until the cycle time is consistent with the quality of control you want will not appear on units with a process output 98_ _ 5 Rate Derivative Adjustment Increase or
110. ndustrial product that is manufactured totally in house in the U S A Watlow products include elec tric heaters sensors controls and switching devices The Winona operation has been designing solid state electronic control devices since 1962 and has earned the reputation as an excellent sup plier to original equipment manufacturers These OEMs depend upon Watlow Controls to provide compatibly engineered controls which they can incorporate into their products with confidence Watlow Controls resides in a 100 000 square foot marketing engineering and manufacturing facility in Winona Minnesota Appendix Warranty Returns Returns 1 Call Watlow Customer Service 507 454 5300 for a Return Material Authorization RMA num ber before returning any item for repair We need this information e Ship to address e Contact name e Phone number e Ship via e Your P O number e Symptoms and or special instructions e Name and phone number of person returning the material Bill to address 2 Prior approval and an RMA number from the Customer Service Department is needed when returning any unused product for credit Make sure the RMA number is on the outside of the carton and on all paperwork returned Ship on a Freight Prepaid basis 3 After we receive your return we will examine it and determine the cause for your action 4 In cases of manufacturing defect we will enter a repair order replacement order or issue
111. ng European Union Directive s using the relevant section s of the normalized standards and related documents shown 89 336 EEC Electromagnetic Compatibility Directive EN 50082 2 1995 EMC Generic immunity standard Part 2 Industrial environment EN 61000 4 2 1995 Electrostatic discharge EN 61000 4 4 1995 Electical fast transients ENV 50140 1994 Radiated immunity ENV 50141 1994 Conducted immunity ENV 50204 1995 Cellular phone EN 50081 2 1994 EMC Generic emission standard Part 2 Industrial environment EN 55011 1991 Limits and methods of measurement of radio disturbance characteristics of industrial scientific and medical radio frequency equipment Class A EN 61000 3 2 1995 Limits for harmonic current emissions EN 61000 3 3 1995 Limitations of voltage fluctuations and flicker 73 23 EEC Low Voltage Directive 1993 Safety requirements for electrical equipment for measurement control and laboratory use Part 1 General requirements English Classification EN 61010 1 D clare que le produit suivant Francais D signation S rie 986 987 988 989 Num ro s de mod le s 98 6 7 8 ou 9 lettre quelconque 1 ou 2 0 1 2 3 4 ou 5 B C D E F ou K A B C D E F K ou T A B C J K M N ou T A B C D E K R S ou T deux lettres quelconques Classification Commande installation cat gorie Il degr de pollution II Tension nominale 100 240 V ou 24 28 V c a c c Fr
112. nly on controllers equipped with hardware for a second event input 98__ _5__ ____ and with set to E ig Default q moll LOC Abe A F 9 GFF P id Acta td SP CE2 CE CE2 CE CE2 CE E2 CE2 WATLOW Series 988 User s Manual Setup Menus Chapter 4 Setup Global Annunciator Select whether alarm messages will flash in the lower display This prompt always appears Default OFF l o P Low Power Limit Select the low limit for the percent output For cooling direct acting enter a negative number This prompt always appears If Default t l a heat cool 00 application L LoP a heat only ___0 application LoP a cool only 100 HP application LoP Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 41 Setup Global High Power Limit Select the high limit for the percent output For cooling direct acting enter a negative number This prompt always appears If Default J J a heat cool 100 application HP a heat only ue g0 application HP ia 1 a cool only m application pm E 6 pP Auto tune Set Point Select the percentage at which the controller will auto tune the cur rent control set point At SP This prompt always appears Default U AE SP AE SP AE SP 4 42 WATLOW Series 988 User s Manual Setup Menus Chapter 4 setup Global Ramping Function Select when the co
113. nput 1 in degrees per minute This prompt appears only on controllers equipped with output 3 hardware for a relay 98__ ___ _ B___ 98_ _ ___ _ J___or 98 ___ K___ orswitcheddc 98 _ ____ C____ and with set to or AL gal Default l dE dE ALJ ALI ALJ ALJ Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 25 setup Output NOTE See Chapter 7 for more information on alarms Alarm 3 Side Select what triggers alarm 3 e both triggers an alarm when the signal lt AFL Q or AJH I e H _ 9H triggers an alarm when the signal gt AJH t Gud triggers an alarm when the signal lt AZL J 35d This prompt appears only on controllers equipped with output 3 hardware for a relay 98__ ___ _ B___ 98_ _ ___ _ J___ or 98 ___ K_ _ or switched dc 98 __ ___ _ C___ andwith set to or AL gal Default 1 iGbd Hysteresis 3 Select the switching hysteresis for alarm 3 This determines the change in temperature or process units needed to turn the output from off to on e If AL Jis set to r At E settings for HY5 3 will be in degrees per minute or units per minute e If the input referenced by is set to the range is affected as listed below HY5S3 This prompt appears only on controllers equipped with output 3 hardware for a relay 98__ ___ _ B___ 98_ _ ___ _ J___or 98 ____ K___ orswitched dc 98__ ___ _ C____ If Default 4 C_F HY953 HY953 HY953 Global M
114. nput 2 set to To enable the differential control algorithm set the control prompt in the Global Menu to differential d f F Press the DISPLAY key The lower display will read O indicating no differential between input 1 and input 2 Adjust the set point to 120 The internal set point for input 1 is now equal to the input 2 value plus 120 which will maintain the boiler water tem perature 120 degrees higher than the outside air temperature Enhanced Software Features Chapter 9 WATLOW Series 988 User s Manual 9 7 Enhanced Software Dual PID Sets Requirements The Series 988 controller needs the enhanced software option to use dual PID sets Overview Standard software units have a single set of PID parameters Units with enhanced software can use two independent sets of heat cool PID para meters PID A and PID B P db To enable dual PID enter the Global Menu and set the algorithm prompt to dual PID P d This second set of PID parameters enables the controller to switch between two sets of PIDs to compensate for changes in the system char acteristics This need can arise from a variety of circumstances such as significant set point changes controlling at 250 then controlling at 750 operating a furnace with half a load versus a full load of steel changing the speed of a conveyor through a curing oven or using different materials in an extruder Series 988 controllers can be configured to switch between PID A and PI
115. ntroller will ramp Ramping limits the speed at which an element can heat up Ramping is often used to protect parts that would crack or warp if they heat up too quickly e GFF sets the system to heat as quickly as possible e Str tj sets the system to ramp only at startup S amp PE sets the system to ramp at startup and whenever the set point changes This prompt appears only on controllers with Input Menu set to and with not set to and with Global Menu not set to orir Ae l Default 4 Gtr GtPe rP eP r P r Ait Ramp Rate Select the ramping rate in degrees per minute This prompt appears only on controllers with set to or SEPL Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 43 Reaching the Communications Menu Begin in the Display Loop and cora press the Up arrow Y and Down jn Setup Prompt Enter your settings arrow keys simultaneously for voor i from the controller s three seconds to reach the Setup pa Baud Rate upper display Menus mone C B AEA Data Bits and Parity D D Or o y Y ye gt Protocol Type laPt OtEPE 9tbt EOC O C gt T Input Output Global Communications ao C Menu Menu Menu Menu EN Interface Type p 4 2 p 418 p 4 34 p 4 44 Press the Up arrow key Y to select one of the Setup Menus Prompts may not appear depending on controller config uration Press the Mode key 3 to step through the prompts in NOTE
116. ocedure The Series 988 is calibrat ed and tested before it leaves the factory Attempting to calibrate the controller with out the proper equipment could result in damage to property and or equipment Figure 6 13 The Calibration Menu Factory Menus Chapter 6 A AEA DNA DA DNA A DNA DTA DTA DTA DTA DTA DA DNA ATAATA DA of lol ile ja gt 2 Py Bla Pe D aT lie in Sl lol lei fol lel ol tml aa tml ol de to Aal lol x ey ol e fal l DaD e fel tol al tol a lna c FetY l XD UN C3 Factory Calibration Diagnostics Prompt Enter your settings pna from the controller s upper display In rr Restore 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 ee SIS Sa lajal Jae is 8 elas nN i Default WATLOW Series 988 User s Manual 6 13 Factory Calibration JFL Restore Restores the original factory calibration values when set to _Y 5 This is a simple way to recover from a mistake made while calibrating the controller This prompt always appears Default 4 eSEE Default Set the operating parameter defaults to domestic or international measures e domestic sets the controller to F rate in minutes proportional band in degrees or units and reset in repeats per minute international sets the controller to C derivative in minutes proportional band in percent of span and integral in minutes per repeat This prompt always appears Default q US
117. of a semiconductor material The wire RTD is a positive temperature coefficient sensor only while the thermistor can have either a negative or positive temperature coefficient retransmit output An analog output signal that may be scaled to represent the process value or set point value RTD See resistance temperature detector slidewire feedback A method of controlling the position of a valve It uses a potentiometer to vary resistance and indicate position of the valve switching sensitivity In on off control the tempera ture change necessary to change the output from full on to full off See hysteresis thermal system A regulated environment that consists of a heat source heat transfer medium or load sensing device and a control instrument thermocouple t c A temperature sensing device made by joining two dissimilar metals This junction pro duces an electrical voltage in proportion to the difference in temperature between the hot junction sensing junction and the leadwire connection to the instrument cold junc tion thermocouple break protection The ability of a con trol to detect a break in the thermocouple circuit and take a predetermined action three mode control Proportioning control with integral reset and derivative rate Also see PID time proportioning control A method of controlling power by varying the on off duty cycle of an output This variance is proportiona
118. oice Appendix e DIP switch set tings Chapter 1 e Sensor match Chapter 2 and Appendix e Sensor installation Chapter 2 and e Wiring Chapter 2 Installation and Wiring Chapter 2 Input 2 Wiring Figure 2 9a Thermocouple or 0 50mV high impedance Thermocouple only 98 __ _ _1 1_ _ _ _ no DIP switches Universal signal conditioner ee jaja Bice 4 L Z L Input impedance 2OMQ _ K T N C E D Pt2 oe 0 50mV DIP Settings DIP Settings Figure 2 9 RTD 2 or 3 wire 100 Universal signal conditioner 98 _ _2__ DIP Switch Setting Figure 2 9c 0 5V 1 5V or 0 10V dc Process Universal signal conditioner f _ P o DIP Switch Setting 6 E Input impedance 10KQ 20 A 19 S Figure 2 9d 0 20mA or 4 20mA Process Universal signal conditioner 2 eke DIP Switch Input impedance 70 Setting WATLOW Series 988 User s Manual 2 9 Input 2 Wiring NOTE See Chapter 8 for information on slidewire feedback NOTE A process output cannot be installed on output 1 when using a current transformer input NOTE Successful installa tion requires five steps e Model number and software choice Appendix e DIP switch set tings Chapter 1 e Sensor match Chapter 2 and Appendix e Sensor installation Chapter 2 and e Wiring Chapter 2 2 10 WATL
119. ollers equipped with output 4 hardware for a relay 98__ _ __ B_ _ 98__ ___ _ J__or 98 ___ K or switched dc 98 __ ___ _ C__ and with set to or AL Ya Default 4 LAEY LAEY Setup Menus Chapter 4 setup Output x iE Q Silencing 4 Select silencing to inhibit alarm 4 on startup and to allow the opera tor to reset the alarm output not the visual display e Silencing disables the alarm until the signal is between A 4 Q and AYH I NOTE See Chapter 7 for S IL 4 This prompt appears only on controllers equipped with output 4 more information hardware for a relay 98__ ____ B_ _ 98__ ___ D__ on alarms 98 _ __ _ E__or98__ ___ _ K__ or switched de 98__ ___ _ C__ and with set to or AL Yn Default 4 Analog Output Select which value to retransmit as the output 3 signal e Prce i retransmits the process 1 value e GEP E retransmits the set point Mo e Pr c 2 retransmits the process 2 value This prompt appears only if the ei ict a se controller is equipped with input 2 hardware and if is not set to on retransmit or E2 turns off retransmit function This prompt appears only on controllers equipped with retransmit hardware 98__ M or 98_ N _ Default Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 31 setup Output NOTE See Chapter 8 for more information on retransmit 4 32 WATLOW Series 988 User s Manual Process 3 Select the range for the retrans
120. on alarm condition and energizing it in an alarm condition If the L2 L3 or L4 LED on the front panel is lit this indicates an alarm condition for output 2 3 or 4 respectively Once you ve configured the outputs as alarms enter the Output Menu again and select the AL 2 or prompt At these prompts you can select the type of alarm process deviation or rate Each may be independently set low and high Choose between process alarm input 1 process alarm input 2 dE l deviation alarm input 1 deviation alarm input 2 or rate alarm referenced to input 1 Example can reference the input 1 process value against the Ael G and AeH settings or can reference the input 2 process value against the A2 L 0 and AEH settings A process alarm sets an absolute temperature range or process value range When the temperature or process leaves the range an alarm occurs A process alarm is not tied to the set point Example If your set point is 100 F and a process alarm high limit is set to 150 F and the low limit is set to 50 F the high limit trips at 150 F and the low alarm at 50 F If you change the set point the process alarm lim its remain the same A deviation alarm alerts the operator when the process strays too far from the set point The operator can enter independent high and low alarm settings The reference for the deviation alarm is the set point Any change in set point causes a corresponding shift in the
121. onal band default parameters The programmed instructions that are permanently stored in the microprocessor software derivative The rate of change in a process variable Also known as rate See PID Deutsche Industrial Norm DIN A set of technical sci entific and dimensional standards developed in Germany Many DIN standards have worldwide recognition DIN See Deutsche Industrial Norm droop In proportional controllers the difference between set point and actual value after the system stabi lizes duty cycle The percentage of a cycle time in which the output is on external signal conditioner power supply A dc voltage source that powers external devices filter digital filter DF A filter that slows the response of a system when inputs change unrealistically or too fast Equivalent to a standard resistor capacitor A 2 WATLOW Series 988 User s Manual RC filter digital adaptive filter A filter that rejects high frequency input signal noise noise spikes heat cool output filter A filter that slows the change in the response of the heat or cool output The out put responds to a step change by going to approximately 2 3 its final value within the number of scans that are set form A A single pole single throw relay that uses only the normally open NO and common contacts These con tacts close when the relay coil is energized They open when power is removed
122. op The Display Loop is the home state of the Series 988 controller Pressing the Display key returns the controller to the Display Loop from any prompt in any menu The controller automatically returns to the Display NOTE Loop from any menu when a minute passes without any keys being For information on pressed input 1 and input 2 ranges refer to Chapter 4 current input 1 reading set point 1 change with Up arrow or Down arrow GQ key current input 2 reading input 2 process appears only if controller equipped with input 2 hardware NOTE If is selected for Iang in the Input Menu the 988 current input 1 reading deviation from set point process 1 minus set point 1 DEV light on 98 current input 1 reading prompt will percent output OUT light on not appear current input 1 reading units selected units F or C Figure 3 2 The Display Loop 3 2 WATLOW Series 988 User s Manual Front Panel and Display Loop Chapter 3 Chapter 4 The Setup Menus NOTE When navigating through menus outputs will be dis abled NOTE Press the Display key to return to the Display Loop from any point in any menu Figure 4 1 Navigating the Setup Menus NOTE The lockout DIP switch hides the Setup Menus See Chapter 1 Setup Menus Chapter 4 Navigating the Setup Menus To reach the Setup Menus begin in the Display Loop and press both the Up arrow Y and Down arrow g keys for th
123. or power supply DIP switch information For data communications wiring refer to Data Communications with the Watlow Series 988 Family of Controllers WATLOW Series 988 User s Manual 2 15 Chapter 3 Front Panel and Display Loop Keys and Displays Upper Display Indicates the actual process value prompt parameter value or error code DEV LED When lit the lower display shows the most recent deviation unit from the set point OUT LED When lit the lower display shows the current percent output Up arrow Key Increases the value or changes the parameter in the upper display except for set point changes in ee Display Loop which occur in the lower display Hold the key down to increase the value rapidly New data takes effect in five seconds or when the Mode key or Display key is pressed Down arrow key Decreases the value or changes the parameter in the upper display except for set point changes in the Display Loop which occur in the lower display Hold the key down to decrease the value rapidly New data takes effect in five seconds or when the Mode key or Display key is pressed Up Down Keys Press simultaneously for three sec onds to go to the Setup Menu Continue to press both keys for another three seconds to go to the Factory Menu Access to the Setup and Factory menus can be dis abled with lockout DIP switch Figure 3 1 Series 988 Keys and Displays Front Panel and Display Loop Chapter
124. or fax 507 452 4507 1233 WATLOW Series 988 User s Manual ili Chapter 1 Hardware Setup Figure 1 1 Press the release tabs to remove the con troller chassis Hardware Setup Chapter 1 DIP Switch Locations and Functions The Watlow Series 988 has at least one and as many as six dual in line package DIP switches inside the controller depending on the model number They allow users to configure the controller for a variety of input sensors to provide power for external signal conditioners or to lockout front panel access to some functions To set any DIP switch e Remove the controller from the case by pressing firmly on the two release tabs on one side or the top of the bezel until they unsnap Then firmly press the two release tabs on the opposite side or the bottom of the con trol until they unsnap You will need to gently rock the bezel back and forth to release it from the chassis e Use the illustrations on the following pages to locate and set each DIP switch WATLOW PROCESS 5888 Release E e he iy Release Tabs 2 Tabs OEV bispLaY OUT MAN SERIES 988 Release Tabs WATLOW ee PROCESS Hi Ea fw SERIES 989 Release Tabs WATLOW Series 988 User s Manual 1 1 D inane icealsss 1 Set the input DIP switches to match the sensors you are using in your application Input 1 DIP Only controllers with model number 98 __ In
125. orios Parte 1 Requerimientos generales EN 61010 1 Winona Minnesota USA Place of Issue Erwin D Lowell Name of Authorized Representative January 9 1996 Date of Issue General Manager Title of Authorized Representative Llp Ele Signature of Authorized Representative Appendix Watlow Series 988 User s Manual Watlow Controls 1241 Bundy Blvd P O Box 5580 Winona MN 55987 5580 Phone 507 454 5300 Fax 507 452 4507
126. ow 2 Input Menu A 0 signal in the outer loop will set the inner loop to range high 2 Input Menu SAC This prompt appears only on controllers equipped with enhanced software 98 B ___ _ ___ _ and with set to 50 d Default duc CASE CASE Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 37 setup Global P ide Algorithm Select the control algorithm selects one set of PID prompts selects proportional derivative control with manual reset in per cent power selects two complete sets of PID prompts This selection does not appear if is set to C d e d UPL selects duplex heating and cooling control This prompt does not appear unless output 1 is a process output AL 9G This prompt appears only on controllers equipped with enhanced software 98_B _ Default P ide dUPL AL90 AL90 AL90 ALSO PID 2 Crossover Selection Select which parameter determines the crossover from PID A to PID B process Pr oc set point St Pt or none no This prompt appears only on controllers with AL 9G set to P ide Default L GEPE P ide 4 38 WATLOW Series 988 User s Manual Setup Menus Chapter 4 setup Global Crossover Process Value Select the process value at which the control algorithm will crossover between PID A and PID B PID A is active below this value and PID B is active above this value e This value cannot be set lower than range low 1 or hi
127. play masked 7 6 alarm high 5 2 alarm jumper changing 7 5 alarm low 5 2 alarm reset 8 8 alarms 7 5 7 7 alarms latching 7 7 alarms non latching 7 7 alarm silencing 7 7 algorithm 4 38 9 3 ambient temperature 6 3 analog output 4 31 annunciator 4 41 A 2 Auto Manual key 3 1 a Auto Manual LED 3 1 7 4 auto manual operation 7 4 8 8 7 6 7 6 ie me gt N automatic operation 7A auto tune 5 7 auto tune set point 4 42 auto tuning 7 1 9 3 B baud rate 4 45 8 4 brackets 2 1 2 3 bumpless transfer 4 3 U1 LA burst fire 8 1 8 3 A 2 C calibration curve RTD 2 4 14 calibration manual ii Calibration Menu 6 13 6 14 lockout 6 6 calibration offset A 2 calibration offset 1 4 6 calibration offset 2 4 14 calibration offset adjustment 7 3 cascade control 9 2 9 5 A 2 auto tuning 9 3 manual tuning 9 4 cascade action 4 37 cautions iii Celsius 4 35 clearing error codes 7 10 closed loop A 2 cold junction A 2 communications 8 4 8 5 Communications Menu 4 44 4 48 8 4 lockout 6 6 compression molding press 8 11 consumer feedback iii controller chassis removing 1 1 7 5 controlling output action 8 8 control outputs off 8 8 control type 4 36 crossover process value 4 39 crossover set point value 4 39 current 8 10 current transformer 8 11 A 2 current transformer input 2 10 current transformer wiring 2 10 cycle time output 1 5 13 output 2 5 1
128. ple 2 8 Input 1 Wiring 2 Input 2 Wiring 2 11 Event Input 1 Wiring 12 Output 1 Wiring 2 13 Output 2 Wiring 2 14 Output 3 Wiring 2 15 Output 4 Wiring 3 1 Keys and Displays 3 2 Display Loop Chapter 4 The Setup Menus 4 1 Navigating the Setup Menus 4 2 Input Menu 4 18 Output Menu 4 34 Global Menu 4 44 Communications Menu Chapter 5 The Operation Menus 5 1 Navigating the Operation Menus 5 2 System Menu 5 9 PID A and PID B Menus Table of Contents Table of Contents Chapter 6 The Factory Menus 6 1 D D NINY 9 4 ee Navigating the Factory Menus Panel Lockout Menu Diagnostics Menu Calibration Menu Chapter 7 Tuning Manual Operation Alarms and Error Codes LL Le ie oo D ken 00 IO O1 N O Auto tuning Heat and or Cool Manual Tuning Manual and Automatic Operation Changing the Output 3 Alarm Jumper Using Alarms Error Code E1 and E2 Messages Error Code Actions Chapter 8 General Software 8 2 8 4 8 6 0 joo 00 O 00 NO O0 i D ee O O0 00 O0 NO O 00 NO NO Burst Fire Communications Dead Band Digital Events Heater Current Input Filter Input Linearization Ramp to Set Point Remote Set Point Retransmit Slidewire Feedback Chapter 9 Enhanced Software a2 9 6 O 00 9 1 J O M gt gt ppe 2 gt gt gt gt p gt gt gt gt Pp gt N Cascade Differential Dual PID Sets Duplex
129. press the Mode key sp to reach the Set Point 2 prompt 5 the Idle Set Point prompt Id 5P or the Operation Menu OPE er o Set Point 2 CdP Idle Set Point P o Oe 695 P IdA P Idb GPEr System PIDA PID B Menu Menu Menu poz Dal pag Use the Mode key 3 to step past the Set Point 2 prompt or the Idle Set Point prompt Id 5P if they appear see prompt information Upon reaching the Operation Menu prompt use the Up arrow Z3 key to select a menu WATLOW Series 988 User s Manual 5 1 Operation System Reaching the System Menu Select the System Menu then press the Mode key Q to step through the prompts pa 0 ele 999 gt mE AN __ 0 ALO RLO eto Press the Up arrow key Y to step through the prompt values The Down arrow key backs through the values Figure 5 2 The System Menu 5 2 WATLOW Series 988 User s Manual Enter your settings from the controller s upper display SP2 Set Point 2 Set Points p 5 3 ee REE Event Input 0 5 4 Alarm 2 High Alarm 3 Low B sB 8 8 8 8 8 8 8 8 BBB Alarms 0 5 4 Prompts may not appear depending on controller configuration Operation Menus Chapter 5 NOTE Decimal points may not always be in the position specified below depending on the the settings in the Decimal 1 and Decimal 2 parame ters in the Input Menu Operation Menus Chapter
130. prompts will appear if the control outputs are configured for heat cool or cool heat Overview The dead band prompts and db b located in the PID menus determine the amount of interaction between heat reverse acting and cool direct acting control outputs The dead band directly offsets the target set point of the cool control output With a positive dead band both control outputs will never be ON at the same time With the process in a positive dead band the output value is determined by adding the percent heat output to the percent cool output and only applying the result to the correct output cooling action if the sum is negative and heating action if it is positive 8 6 WATLOW Series 988 User s Manual General Software Features Chapter 8 Figure 8 7a Dead band graph input 1 Figure 8 7b Environmental chamber with dead band General Software cool cooling action 75 2 2 77 set go v gt SP 1 dbA coolset point no action deadband 75 beste Seek etree eee ee oe eee Ce eee eee Se eee ee SE primary A Rr set point heating action setpoint Environmental Chamber chiller temperature sensor Sample Application An engineer for an environmental chamber manufacturer who is design ing the heating and cooling system for a new chamber wants to minimize the energy costs of operating the chamber She has chosen the Series 988 and will configure the heat and cool outputs with a positive d
131. put 1 off or when no current is present and output 1 power is more than zero There are limits associated with this feature e To obtain a reading the output on time must be a minimum of 0 3 sec onds To calculate this multiply the percent output by the cycle time set ting Example With 30 percent output and a 2 0 second cycle time the on time would be 0 30 x 2 0 0 6 seconds This would yield a valid read ing If a valid reading is not possible the 988 will display the last valid reading e The heater current feature will not function with burst fire outputs Controllers with option B C or K selected for output 1 98 output 2 98_ _ _ _ output 3 or output 4 98__ _ _ _ _ _ __ This does not neces sarily apply to the loop error detect feature If enabled any current detect ed with no output triggers an error e This feature will not function when the Series 988 has a process output for output 1 98__ F A Known cycle time is required to detect the current There is no cycle time associated with process outputs The maximum signal the input can accept from the current transformer secondary is 50mA So you must calculate the output range of the cur rent transformer before wiring the system General Software Features Chapter 8 General Software Compression Molding Press PROCESS DISPLAY O OOOO 10A heaters temperature sensor sensor Figu
132. put 2 DIP 2 ___or98 amp _ 2 have an NOTE ie ae The Input 2 DIP input DIP switch saa ie lar switch is mounted upside down Input 1 Input 2 98 2 Fe e E NOTE Only controllers ot Zee with the indicated RTD 100 Q die G model numbers have these DIP switches or A a thermocouple R S or B ne gt SN BEE bet thermocouple J K T N E C D Pt2 Pr or 0 50mV high impedance Figure 1 2 AN PETE SWItENES 0 20 or 4 20mA 0 5 1 5 or 0 10V 1 2 WATLOW Series 988 User s Manual Hardware Setup Chapter 1 NOTE For other voltages or current settings contact the factory NOTE Only controllers with the indicated model numbers have these DIP switches Figure 1 3 External signal con ditioner power sup ply DIPs Hardware Setup Chapter 1 2 Set DIP switches for outputs equipped with an external signal con ditioner power supply Only controllers with model number 98_ _ _ ae a _ _T__ have an exter nal signal conditioner power supply 20V 5 30MA 12V 5 30mA 5V 5 30MA Output 1 3 Option Board Output 2 gt Option Board and DIP Output 3 3 Option Board and DIP gt z O Aj A gt z 0O Aj DIIRAN Controller Chassis Top View 986 amp 988 Left side View 987 amp 989 Output Option Board 4 and DIP 3 When the DIP switches are set gently insert the cont
133. put 4 de energizes output 4 in an alarm condition NOTE e energizes output 4 in an alarm condition See Chapter 7 for more information Q amp 4 This prompt appears only on controllers jen with output 4 on alarms hardware for a relay 98__ ___ B _ 98__ ____ D__ 98 _ _ E _or98 ____ K__ orswitched dc 98__ ___ C__ Default pm L uy Alarm 4 Select the alarm type for alarm 4 e Pr I uses a process signal from input 1 e d uses a deviation from the input 1 signal e Pe uses the process signal from input 2 This prompt does not appear if the controller is not equipped with input 2 hardware or if is set to or _E 1 uses a deviation from the input 2 signal This prompt does not appear if the controller is not equipped with input 2 hardware or if is set to or E2 e uses the rate of change at input 1 in degrees per minute ALY This prompt appears only on controllers ie with output 4 hardware for a relay 98__ ___ B _ 98__ ____ D__ 98 E _or98 ___ K_ _ orswitcheddc 98 __ C_ Default ALY ALY ALY ALY ALY ALY 4 28 WATLOW Series 988 User s Manual Setup Menus Chapter 4 NOTE See Chapter 7 for more information on alarms Setup Menus Chapter 4 setup Output Alarm 4 Side Select what triggers alarm 4 e bo th triggers an alarm when the signal lt A Yt G or AYH I e H 9H triggers an alarm when the signal AYH e QL Jd triggers an alarm w
134. put 4 Input 2 linearization Alarm 4 Slidewire dead band Alarm 4 side Slidewire inner Hysteresis 4 hysteresis Latching for alarm 4 gt ono cya ol l gt ElKIEIG D U _ Q oo Silence alarm 4 Analog output Process 3 Retransmit low limit gt gt Il Retransmit high limit _ Retransmit cal offset Press Y and for 3 seconds to enter the Setup menus Outputs are disabled Global Communications CE Baud rate CntL Proc StPt Ei1 i2 Celcius_ Fahrenheit Data bits and parity Failure mode Protocol type Error latching Controltype Cascade action Control algorithm PID 2 crossover selection Crossover process value Crossover set point value Event input 1 Event input 2 Annunciator Lowpower limit AtsP__ rAtE High power limit Auto tune set point Ramping function Ramp rate Factory Menus Foty Factory a E Panel Lockout Diagnostics Front Panel lockout dAtE Factory ship date System menu lockout SOFt_ Software revision PIDA menu lockout n Input menu lockout Output menu lockout MODE gn Serial number MODE PIDB menu lockout Ambient A D count Ground A D count Input 1 A D count Input 2 A D count Global menu lockout Communications menu lockout Diagnostics menu lockout Input 2 module Output 1 module Calibration menu lockou
135. r 98 __ ___ J___ output 3 can be con figured as a Form A NO and common contact or Form B NC and com mon contact alarm To change the alarm jumper 1 Remove the control from the case Release the two tabs on one side of the control then release the two tabs on the opposite side You may need to rock the bezel back and forth several times to release the chas SIS 2 Set the jumper to the position you want See below for jumper location NC Figure 7 5 Contacts e COTA Alarm jumper Form B i Form A location Fa sal tien eH Controller Chassis Top View 3 Return the controller chassis to the case Be sure you have it oriented correctly Press firmly but gently to seat the chassis If you select Form A the contact is open when power is removed from the control If you select Form B the contact closes when power is removed Tuning Manual Operation Alarms and Error Codes Chapter 7 WATLOW Series 988 User s Manual 7 5 Alarms NOTE An alarm display will be masked by an error condition or when the control is in the Calibration or Setup menus Using Alarms Output 2 3 and 4 of the Series 988 can function as alarms This is accomplished with the Gt2 or prompt Output Menu If AL or is selected the output is energized in the non alarm condition and de energizes the output in the alarm condition Selecting AL n or AL Yn reverses this action de energizing the output in a n
136. r existing condition of several items in a system bumpless transfer A smooth transition from auto closed loop to manual open loop operation The control output s does not change during the transfer burst fire A power control method that repeatedly turns on and off full ac cycles Also called zero cross fire it switches close to the zero voltage point of the ac sine wave Variable time base burst fire selectively holds or transits ac cycles to achieve the desired power level calibration offset An adjustment to eliminate the dif ference between the indicated value and the actual process value cascade Control algorithm in which the output of one control loop provides the set point for another loop The second loop in turn determines the control action closed loop A control system that uses a sensor to measure a process variable and makes decisions based on that feedback cold junction See junction cold cold junction compensation Electronic means to com pensate for the effective temperature at the cold junction current transformer A transformer designed for mea suring electrical current dead band The range through which a variation of the input produces no noticeable change in the output In the dead band specific conditions can be placed on control output actions Operators select the dead band It is usu ally above the heating proportional band and below the cooling proporti
137. ranges dE amp C 1 This prompt appears only if you have set input 1 toa process input or to a thermocouple input set to 0 50mV Default 4 0 000 JEC JEC 4 4 WATLOW Series 988 User s Manual Setup Menus Chapter 4 NOTE These values do not affect the low or the high set point limit for process alarms NOTE When high imped ance is selected for input 1 the range high for both and can be extended to 9999 The range low when Is selected can be extended to orl I rH Range Low 1 and Range High 1 continued on next page Setup Menus Chapter 4 setup Input Range Low 1 and Range High 1 Select the low and high limits for input 1 These prompts limit the adjustment range for the set points The default values are the same as the limits of the sensor you selected by setting the input 1 DIP switch and selecting a value for Input 1 nA I e Process inputs are scaled by these values Range high is the value dis played when the maximum process signal is present at the input Range low is the value displayed when the minimum process signal is present at the input Example Set to Y 2G mA Seti eL ijtol 100 Set to _ 500 A 4mA input will display A 12mA input will display 300 A 20mA input will display 99 e The low and high values of each sensor type are listed on the specifica tions page of the Appendix e Choose between Fahrenheit and Celsius at the prompt in the Globa
138. rature of a heat treat oven The temperature of the process must be recorded on a chart recorder The oven temperature range stays between 600 and 900 F The chart recorder requires a 4 20mA signal In the Output Menu Qt PE set analog output to Pr c l to tag the input 1 process value as the parameter to be retransmitted Set retransmit low limit to 600 to set the low range for the retransmit signal to 600 Set retransmit high limit Ar H to 900 to set the high range for the retransmit signal to 900 Set retransmit calibrate offset to O assuming there is no calibration offset required The retransmit output will be 4mA until the oven temperature is greater than 600 degrees F at which point the signal will increase with tempera ture to 20mA at 900 F and will not exceed 20mA General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 21 General Software NOTE Outputs must be compatible with the slidewire valve actu ators Slidewire Feedback Requirements A slidewire configuration uses at least two inputs and two control out puts Input 2 can only be selected as a slidewire input 98_ _ _3__ ____ Overview The Series 988 can control the position of a valve with a slidewire feed back position indicator The controller senses the resistance of the slidewire and compares it to the range low and range high settings to determine the valve position The controller compares this to the percent outpu
139. re 8 11 Compression mold Sample Application ing press using the The Series 988 controls the lower platen of a compression molding press heater current fea that contains five 10 ampere heaters A 50A 50mA current transformer is ture used to monitor heater current Set the Input 2 prompt to current Cur r the Range Low 2 prompt to O and the Range High 2 prompt to 50 Find the range high 2 value with the following equation range high 2 _ maximum CT primary current load current x 50mA maximum output from CT secondary input The application uses a Watlow current transformer CT part 16 0233 which has a maximum input of 50 amperes which corresponds to a maxi mum output of 50mA range high 2 50Amps x 50mA 50mA Solving for rH2 gives you 50 This is the range high 2 setting General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 11 General Software NOTE Use this feature with caution because a large time constant could hide system upsets Input Filter Requirements This feature is standard on all Series 988 controllers Overview In certain applications the process being measured can be unstable which makes it difficult to control and also makes the constantly changing display difficult to read The Series 988 input filter can solve these prob lems by smoothing out just the display or the display and the input signal You can set a time constant in seconds for a low pass filt
140. ree seconds The Setup Menu prompt will appear in the lower display and the Input Menu prompt will appear in the upper display The four Setup Menus are Input inPt Output Gt Pt Global 9L bL and Communications C 9 7 Use the Up arrow Y or Down arrow Key to select a menu and the Mode key Gg to step through a menu The Communications Menu appears only on units equipped with the data communications option You will not see every prompt in any of these menus The unit s configuration and model number determine which prompts appear After stepping through each menu the Series 988 returns to the Setup Menu prompt S amp t Use the Up arrow Y and Down arrow Keys to select the next menu or use the Mode key to advance through the same menu again To move back wards through the menu hold the Mode key 23 down and press the Up arrow key Y Use the Up arrow Y or Down arrow 2 key to change the prompt setting Refer to the Appendix for model number options For information about communications and the communications prompts refer to the supple mental manual Data Communications with the Watlow Series 988 Family of Controllers Begin in the Display Loop and press the Up arrow Z3 and Down arrow 4g keys simultaneously to reach the Setup Menus ag Aa EPE m LinP 8 Sibi COPD Input Output Global Communications Menu Menu Menu Menu p 4 2 p 418 p 434 p 4 44 Press the Up arrow key Y to select one of
141. roller chassis into the case and push it firmly into place until all four tabs snap into place WATLOW Series 988 User s Manual 1 3 DIP Switches A CAUTION The lockout DIP switch makes the Setup and Factory menus unavailable Configure all the Setup and Factory menus before lock ing them out Fail ure to do so could result in damage to equipment in the event of a setup error Figure 1 4 Lockout DIP switch 1 4 4 The lockout DIP switch hides the Setup Menus Input Output Global and Communications and the Factory Menus Panel Lockout Diagnostics and Calibration All units have a lockout DIP switch no hardware lockout Switch 1 has no effect gt Z O Control Chassis Top View 986 amp 988 Left side View 987 amp 989 A CA LI N T or or B Eie lockout Setup and Factory menus Switch 1 has no effect Commu nput Output Global acae Panel kokoni Diagnostics Calibration oe AX WATLOW Series 988 User s Manual Be Hardware Setup Chapter 1 Chapter 2 Installation and Wiring A WATLOW l 4 03 NOTE g BA ii 102mm Space panel PROCESS e cutouts at least 1 66 inches 42 2mm a J J J n WATLOW apart 4 03 p ee gag HEA DEV DISPLAY PROCESS 2 18 OUT 55 mm OUT MAN r ee ee g S ee E E Uh ge C210 2 18 55 mm SERIES 989
142. rompt in the lower display and its value in the upper display Use the Up arrow Y and Down arrow 2 keys to change the value in the upper display The new value will not take effect until after a five second delay or until you press the Mode key QB Proportional Band Output 1A or 1B Select the proportional band for PID output 1 If setto _ 9 it func tions as an on off control and the switching differential is determined by the HY 5 value Output Menu The decimal precision is determined by Input Menu Pb IA This prompt always appears lf oe l amp C OF O 25 19999 Pb iA Pb iA Calibration Menu Global Menu amp 80 __25 19999 Inputtor2 Ph 1A Pb IA Input Menu a Cf C__g _ 4 9999 PEIA Pb 1A Pb IA Calibration Menu Global Menu a G8 141 19999 Inouttor2 Pb IA Pb IA Input Menu amp Pade 00 38 9999 ofspan AL 9D Pb 1A Ph IA Ph 1A Calibration Menu Global Menu Operation Menus Chapter 5 Operation PID A or B E Reset Output 1A or 1B C H b Tune reset to eliminate the offset or droop between the set point and the actual process temperature for PID output 1 When setto Q reset is disabled This prompt appears only if Calibration Menu is set to and Pb 1A is not setto Q If Default q y 000 0 9999 repeats min 7 Pdr 4000 g0o 1000 Global Menu
143. s Chapter 4 WATLOW Series 988 User s Manual 4 47 Chapter 5 The Operation Menus NOTE Press the Display key to return to the Display Loop from any point in any menu Figure 5 1 Navigating the Operation Menus Operation Menus Chapter 5 Navigating the Operation Menus To reach the Operation Menus begin in the Display Loop and press the Mode key WB Depending on the controller configuration either the Set Point 2 prompt P 2 the Idle Set Point prompt or the Operation Menu prompt will appear in the lower display The three Operation Menus are System _ 545 PID A P d and PID B P db Use the Mode key B to step past the Set Point 2 prompt _ P 2 or the Idle Set Point prompt Id 5P if they appear see prompt information Upon reach ing the Operation Menu prompt use the Up arrow Y or Down arrow key to select a menu and the Mode key J to step through a menu You will not see every prompt in any of these menus The unit s configura tion and model number determine which prompts appear After stepping through each menu the Series 988 returns to the Operation Menu prompt GPE Use the Up arrow Y and Down arrow keys to select the next menu or use the Mode key 3 to advance through the same menu again To move backwards through the menu hold the Mode key 3 down and press the Up arrow key Y Use the Up arrow Y or Down arrow g key to change the prompt setting Begin in the Display Loop and
144. s allowing the set point value to be manipulated by the input 2 signal General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 19 General Software Retransmit Requirements Output 3 is used for the retransmit option Choose either a milliamp 98_ _ ____ M___ ora voltage 98__ ___ _ N____ signal Select the output range in the Output Menu Overview The retransmit feature can be used to transmit an analog signal repre NOTE senting the value of either input process variable or the target set point Enhanced software variable The retransmit signal is factory configured as either a milliamp is not required for 98__ ___ _ M___ ora voltage 98__ ____ N___ signal In choosing this feature the type of retransmit signal the operator must take into account the input impedance of the device to be retransmitted to and the required sig nal type either voltage or milliamps Typically applications might use the retransmit option to record one of the variables with a chart recorder or to generate a set point for other controls in a multi zone application see page 8 19 8 20 WATLOW Series 988 User s Manual General Software Features Chapter 8 General Software Heat treat Oven 1oOo PROCESS input 1 988 output 1 temperature 988 output 3 sensor heaters n Chart Recorder Figure 8 21 Heat treat oven with Sample Applications retransmit A Series 988 is being used to control the tempe
145. s for output 2 This determines the change in temperature or process units needed to turn the output from off to on elf AL elis set to At E settings for will be in degrees per minute or units per minute e If the input referenced by is set to the range is affected as listed below This prompt appears only on controllers equipped with output 2 hardware and with the controller set up as an on off controller 0 and with not set tol no This prompt does not appear on controllers equipped with output 2 process hardware ine SL d or if in the Global menu d YPL If Default L eK Wy HY52 Global Menu amp ia a Input 1 or 2 Global Menu see note above HYS2 Global Menu amp ee T Input 1 or 2 Global Menu see note above as C33 9 units a process input HYS HYS is selected Set Point 2 Control Select a second set point enables a set point independent from the Set Point 1 value enables a set point at a deviation from the Set Point 1 value This prompt appears only if output 2 hardware is present and is equal to the output 1 setting Default N SPee SPee 4 22 WATLOW Series 988 User s Manual Setup Menus Chapter 4 setup Output pm l Pad Alarm 2 Select the alarm type for alarm 2 Select the trigger points for the alarm with the A2 L G and A2H settings in the System Menu 595 uses the process signal from input 1 Changing the se
146. sal signal conditioner 3 Slidewire feedback 4 Current transformer 5 Digital contact event One digital event is standard on all units Output 1 B Solid state relay Form A 0 5A with RC suppression NO amp C C Switched dc or open collector isolated D Electromechanical relay Form C 5A with RC suppression E Electromechanical relay Form C 5A without contact suppression F Universal process 0 5V dc 1 5V dc 0 10V dc 0 20mA 4 20mA isolated K Solid state relay Form A 0 5A without contact suppression NO amp C Output 2 A None B Solid state relay Form A 0 5A with RC suppression NO amp C C Switched dc or open collector isolated D Electromechanical relay Form C 5A with RC suppression NO NC amp C E Electromechanical relay Form C 5A without contact suppression NO NC amp C F Universal process 0 5V dc 1 5V dc 0 10V dc 0 20mA 4 20mA isolated Solid state relay Form A 0 5A without contact suppression NO amp C External signal conditioner power supply 5 12 or 20V dc 30mA utput 3 None Solid state relay Form A 0 5A with RC suppression NO amp C Switched dc or open collector isolated Electromechanical relay Form A or B 5A without contact suppression NO or NC Solid state relay Form A 0 5A without contact suppression NO amp C Retransmit 0 20mA 4 20mA Retransmit 0 5V dc 1 5V dc 0 10V dc External signal condi
147. set setting until process value equals the set point If the process becomes unstable the reset value is too large Decrease the setting until the process stabilizes WATLOW Series 988 User s Manual Enhanced Software Features Chapter 9 Enhanced Software outer loop thermocouple input 1 988 output 1 PROCESS DISPLAY inner loop thermocouple limit sensor Lube Oil Tank Figure 9 5 Lube oil oo tank with cascade Sample Application control A Series 988 controller is used to heat lube oil to 125 F with a screw plug style heater To protect the oil from breaking down and maximize its life it is desirable to limit the maximum heater sheath temperature to 250 F The Series 988 is ordered with two thermocouple inputs Input 2 the inner loop in the cascade configuration measures the heater sheath Input 1 the outer loop measures the lube oil temperature before it leaves the tank The external set point is 125 By setting range high 2 to 250 the set point for the heater sheath will be limited thus extending the lube oil life Enhanced Software Features Chapter 9 WATLOW Series 988 User s Manual 9 5 Enhanced Software Differential Requirements Two inputs and the enhanced software option are required Overview Differential control allows the Series 988 to control one process at a differ ence to another process Input 2 acts as a remote set point input However the displayed set point in
148. set the range low and range high values From the slidewire specifications determine the low and high resistance values and enter these at the Range Low and Range High prompts Once the control is operating adjust the hunt parameter to mini mize valve oscillations The hunt parameter sets up a dead band on both sides of the current valve position The desired valve position is then com pared to the actual position If the difference is greater than the one half of the hunt value the Series 988 repositions the valve to achieve the temper ature set point Once repositioning is complete the dead band is recalcu lated for the new valve position General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 23 Chapter 9 Enhanced Software Cascade 9 2 Differential 9 6 Dual PID 9 8 Duplex 9 10 Ratio 9 12 Enhanced Software Features Chapter 9 WATLOW Series 988 User s Manual 9 1 Enhanced Software Cascade Requirements Cascade control requires enhanced software and two analog inputs input 1 to monitor the primary or outer loop and input 2 to monitor the sec ondary or inner loop At least one control output is required to control the process Overview Cascade control can handle a difficult process with minimal overshoot while reaching the set point quickly This minimizes damage to system components and allows for oversizing heaters for optimal heat up rates Heater life is also extended by reducing thermal
149. sets switching 8 8 0 50mV high impedance 1 2 NEMA 4X seal 2 3 A 2 PLOC Menu 6 2 1 5 12 non latching alarm 7 7 potentiometer wiring 2 10 4 20mA 1 2 notes iii power supply see external si conditioner RTD 1 2 DIP switches 1 3 thermocouple 1 2 O output 2 2 13 input filter 8 12 8 13 output 3 2 14 input linearization 8 14 8 15 on off control A 2 output 4 2 15 Input Menu 4 2 4 17 Operation Menus 5 1 5 16 power wiring 2 4 lockout 6 5 operation parameters manual tuning 7 2 process variable A 3 input module 6 9 open loop 6 12 A 2 process 1 4 20 input ranges tables ordering information A 5 process 2 4 21 input 1 4 5 4 6 outer loop cascade 9 2 9 3 process 3 4 31 input 2 4 12 output A 2 process alarm 7 6 input to output isolation 2 4 2 13 2 15 output 1 4 19 process retransmit wiring 2 14 installation 2 1 2 3 output 1 wiring 2 12 process value 8 16 integral A 2 0 5V dc process 2 12 proportional band A 3 output 1 5 11 0 10V de process 2 12 output 1 5 10 output 2 5 14 0 20mA process 2 12 output 2 5 13 interface type 4 47 1 5V de process 2 12 proportional band adjustment 7 3 isolation 2 4 A 2 4 20mA process 2 12 proportioning control A 3 ac outputs 2 12 protocol type 4 46 8 4 J switched dc open collector 2 12 output 2 4 21 Q R JIS A 2 output 2 wiring 2 13 9 jumper location 7 5 0 5V dc process 2 13 ramping function 4 43 8 16 junctions A 2 0 10V dc process 2 13 ramp rate 4 43 8 1 0 20mA process 2 13 ramp to set oa 8 16
150. t Output 2 module Output 3 module Output 4 module A 10 WATLOW Series 988 User s Manual Ambient temperature At the prompt press Y and Gg another 3 seconds to enter the Factory menus Calibration CAL Restore factory values Default prompts Appendix Electromechanical relays warranted for 100 000 clo sures only Solid state switching devices recom mended for applications requiring fast cycle times or extended service life 7A Current Transformer input cannot be used in conjunc tion with a process output installed on output 1 Slo Blo is a registered trademark of Littelfuse Inc Appendix Model Number Ordering Information 1237 To order complete the code number to the right with the information below 98 Series 988 a single channel temperature process controller 1 analog input 1 digital input 1 analog or digital input 4 outputs Power Supply amp Mounting 6 24to 28V amp ac dc nominal vertical mounting 7 24 to 28V amp ac dc nominal horizontal mounting 8 100 to 240V amp ac dc nominal vertical mounting 9 100 to 240V amp ac dc nominal horizontal mounting Software A Standard B Enhanced Includes cascade ratio duplex dual PID set Input 1 1 Thermocouple only Excluding Type B R and S 2 Universal signal conditioner Input 2 O None 1 Thermocouple only Excluding Type B R and S 2 Univer
151. t hunt 4 16 8 22 8 23 Pr input 2 process 3 2 8 10 9 4 HYS I hysteresis 1 4 20 Prec l process 1 4 20 HYS hysteresis 2 4 22 Pree process 2 4 21 HYS J hysteresis 3 4 26 Pr c J process 3 4 31 HYS4Y hysteresis 4 4 29 Pr oc crossover process value 4 39 9 8 Prot protocol type 4 46 8 4 Id SP idle set point 5 3 8 8 Q R In I input 1 4 3 4 4 AIA rate output 1 PID A 5 12 9 4 Ine input 2 4 9 cA ib rate output 1 PID B 512 In PE Input Menu 4 2 r AZA rate output 2 PID A 5 15 In PE input lockout 6 5 r Ab rate output 2 PID B 5 15 Int F interface type 4 47 c At EJ ramp rate 4 43 lE 1A integral output 1 PID A 5 11 r AE ratio 4 36 9 13 fe Tb integral output 1 PID B 5 11 r E IA reset output 1 Pid A 5 11 9 4 I 2A integral output 2 PID A 5 14 rE 6 reset output 1 PID B 5 11 lE b integral output 2 PID B 5 14 r EA reset output 2 PID A 5 14 LY input 1 module type 6 9 r Egb reset output 2 PID B 5 14 1E Ye input 2 module type 6 9 r EU reverse action 4 37 cH I range high 1 4 5 4 6 J K L r H range high 2 4 11 4 12 8 11 9 3 rL ij range low 1 4 5 4 6 LAE latching 4 36 rL range low 2 4 11 4 12 8 11 9 3 LAE latching 2 ren root square root extraction 8 14 8 15 LAE 3 latching 3 4 27 r P ramping function 4 43 8 17
152. t and takes action to match the two by opening or closing the valve Set the hunt parameter to limit valve hunting The value is set for the percent of output 0 0 to 100 0 When the valve is within this dead band a change in output greater than half the hunt parameter is required to trigger action Output 1 responds to close commands and output 2 responds to open commands 8 22 WATLOW Series 988 User s Manual General Software Features Chapter 8 General Software Gas fired Furnace temperature 9a rere sensor 00000000000000000 TTT TEE ELL gas valve cut off valve slidewire input Figure 8 23 Gas fired furnace Sample Application with slidewire feed A Series 988 controls the gas valve for a gas fired furnace to heat treat back large metal parts First the controller must be married to the slidewire feedback from the valve actuator To do this first set the Input 2 prompt to slidewire od Advance to the Learn Low Resistance prompt lL cnt Close the valve manually to the minimum resistance reading from the slidewire Select in the upper display and press the Mode key C9 to advance to the Learn High Resistance prompt L r n H Manually open the valve maximum slidewire resistance Select in the upper display and press the Mode key Q At this point both the high and low resistance values have been learned and stored in the range low 2 and range high 2 parameters You can also manually
153. t point does not change the alarm response uses a deviation from the input 1 signal Changing the set point changes the alarm response NOTE Bee sara ied uses the process signal from input 2 This choice does not appear a if the controller is not equipped with input 2 hardware or if is set l tol nojor E2 uses a deviation from the input 2 signal This prompt does not appear if the controller is not equipped with input 2 hardware or if is set to or Eg e uses the rate of change at input 1 in degrees per minute This prompt appears only on controllers equipped with output 2 hardware and with set to or AL ln Default Pe I l dEi Pre ALZ AL AL AL AL AL AiesSd Alarm 2 Side Select what triggers alarm 2 bo0 th triggers an alarm when the signal lt AL G or AEH I e H 9H triggers an alarm when the signal gt AEH I e i old triggers an alarm when the signal lt A2t J Af 25d This prompt appears only on controllers equipped with output 2 hardware and with QE set to ALe or Al en Default J ASd ASd A2Sd Setup Menus Chapter 4 WATLOW Series 988 User s Manual 4 23 setup Output AL pm Latching 2 Select whether alarm 2 will be latching or non latching A latching alarm must be turned off manually A non latching alarm turns off when an alarm condition no longer exists L At 2 This prompt appears only on controllers
154. t values when the error occurred it continues to operate at those levels on a percent power basis e If output values were not stable or the percent output was greater than 75 the control outputs drop to 0 power off e If FA ii is not set to 6 Pi 5 and the control was in automatic operation when the error occurred it goes into manual power operation The power level is determined by the FA IL prompt value 498 to percent Tuning Manual Operation Alarms and Error Codes Chapter 7 WATLOW Series 988 User s Manual 7 9 NOTE An alarm display will be masked by an error condition or when the control is in the Calibration or Setup menus To clear an error code e If is set to nL A the error code should clear once the prob lem is corrected e If is set to L At correct the problem and cycle power You can also clear the error by pressing both the Up arrow Y and Down arrow keys to enter the Setup Menu then press the Display key DISPLAY Error codes 4 and will result in these conditions e The control is in automatic operation with both control outputs off e The alarm outputs are in their alarm state de energized with the LED lit e The lower display is blank e The upper display indicates the error code e All keys are inactive e With Er 5 all Setup Menu prompts return to default values e The above conditions occur regardless of the value or the set tings in
155. the Caution and Warning symbols we use in the book WATLOW Series 988 User s Manual i Introduction NOTE The 12 digit number is printed on the top of the stickers on each side of the controller s case and on the right hand or top circuit board NOTE The Menu Overview in the Appendix shows all the menus and prompts Using this Manual This manual provides the information you will need to install and operate a Series 988 controller If you need information about Series 988 configurations and model num bers refer to the Appendix of this manual or for more detailed informa tion to Optimizing Your Process System with the Series 988 Controller An Application Guide for the Watlow Series 988 Family If your Series 988 controller will be used for data communications you will also need our communications manual Data Communications with the Watlow Series 988 Family of Controllers green cover Series 988 controllers are calibrated in the factory but if you need to do periodic calibration you will need our calibration manual Calibrating Watlow Process Controllers blue cover This manual explains the five steps of setting up a Series 988 controller 1 Set and document all of the DIP switches if applicable Chapter 1 2 Mount the controller Chapter 2 3 Wire and document the controller wiring Chapter 2 4 Configure and document the controller software Chapters 3 6 5 Run test and adj
156. the input 1 signal by a positive or negative value This allows you to compensate for lead resistance sensor errors or other factors CAL i This prompt always appears Default Qo x m A in Input Menu amp L rid Input Menu a a a O O O Oz loz oz o T Dey e mMm e ma e mMm Global Menu a process input is selected 4 6 WATLOW Series 988 User s Manual rs XD ro mq Ta m Ta DIAN mu mn mn min ie r r AA a a a Ta m r m Ta a a l a a m m r r r aa m HA m mu DINA DVA d DLO ma mwao m IO he to Sho units ry XD ro Setup Menus Chapter 4 Setup Menus Chapter 4 setup Input RTD 100Q Calibration Curve 1 Select the calibration curve for the RTD 1 input The RTD input uses either the European DIN 0 0038500 Q C or the Japanese JIS 0 0039 1602 Q C linearization standard This prompt appears only if you have set to or rtd Default 4 rtd Software Filter 1 Select the filter time constant in seconds for input 1 This smooths a rapidly changing input signal for display or control purposes e Select a positive value to filter only the display e Select a negative value to filter the input signal e Set the value to Q to disable the filter This prompt always appears Default 4 Fitri Feri Fer i WATLOW Series 988 User s Manual 4 7 setup Input l in Lineari
157. tion switches the control action of outputs 1 and 2 from heating to cooling or vice versa e Auto Manual operation switches to the manual mode of opera tion at the percent power selected with F A tl Global Menu and disables the Auto Man key 8 8 WATLOW Series 988 User s Manual General Software Features Chapter 8 General Software WATLOW mperatur EE temperature sensor sensor heater ULANTA UTA UT TTA UTA TTA U TUTE IIIT event input 1 Figure 8 9 Heater with digital event Sample Application A manufacturing engineer is building an application that needs to switch to an idle temperature at the end of a batch and maintain that tempera ture until the next batch is loaded with minimum operator interaction By connecting an external switch to the digital event input he can select either the operating temperature or the idle temperature with the flip of a switch The idle set point prompt is enabled by setting the Event Input 1 prompt I in the Global Menu to idle set point Id 5P The idle set point value is accessed by pressing the MODE key Q from anywhere in the display loop When the switch closes the lower display will indicate the idle set point and the controller will maintain this new set point General Software Features Chapter 8 WATLOW Series 988 User s Manual 8 9 General Software NOTE To obtain a reading the output ON time must be a minimum of 0 3 seconds
158. tion that can be performed via the front panel can also be accomplished using a serial communications port allowing you to operate the controller from a computer and to store process data on a computer L4 acts as the RX TX indicator on the front display panel of the 988 The Series 988 is available with a choice of serial hardware interfaces An EIA TIA 232 interface allows for one master computer and one con troller with a maximum network length of 50 feet 15 meters The EIJA TIA 485 or EIA TIA 422 option equips the controller for a multi drop interface up to 32 total network devices with EIA TIA 485 and up to 10 total network devices with EIA TIA 422 Each controller will have its own unique address The total maximum network length is 4 000 feet 1 219 meters All interfaces are isolated To select between EIJA TIA 485 or EJA TIA 422 enter the Setup Menus by holding the up arrow Y and down arrow keys simultaneously until setup appears in the bottom display Use the up arrow key to select the Communications Menu C Gf 9 At the interface prompt select between or 485 Other parameters that must be configured in the Communications Menu are the baud rate 6 AUd data bits and parity fA t A protocol Pr ot and device address Addr The protocol prompt must be set to full ANSI X3 28 2 2 A3 or RTU Modbus if multiple devices are used with the EJA TIA 485 or EIA TIA 422 interface If the full protocol or RTU Modbus is se
159. tioner power supply 5 12 or 20V dc 30mA utput 4 None Solid state relay Form A 0 5A with RC suppression NO amp C Switched dc or open collector isolated Electromechanical relay Form C 5A with RC suppression NO NC amp C Electromechanical relay Form C 5A without contact suppression NO NC amp Solid state relay Form A 0 5A without contact suppression NO amp C EIA TIA 232 communications opto isolated EIA TIA 485 EIA TIA 422 communications opto isolated External signal conditioner power supply 5 12 or 20V dc 30mA EIA TIA 485 EIA TIA 232 communications opto isolated lout tt tt bt brow t t bob tb bt wm uo CAMDAMVNOWDFSFO AZZXCOWFO AA Display GG Green Green displays RR Red Red displays GR Green Red displays XX Custom overlays or default settings RG Red Green displays WATLOW Series 988 User s Manual A 1l Declaration of Conformity Series 986 987 988 989 C 9G WATLOW CONTROLS 1241 Bundy Boulevard Winona Minnesota 55987 USA Declares that the following product Designation Series 986 987 988 989 Model Number s 9 8 6 7 8 or 9 Any letter 1 or 2 012340r5 BCDEFork ABCDEFKorT ABCJKM Nor T ABCDEKR Sor T Any two letters Control Installation Category II Polution Degree II Rated Voltage 100 to 240V ac or 24 to 28V ac dc Rated Frequency 50 60 Hz Rated Power Consumption 16VA maximum Meets the essential requirements of the followi
160. tter cold water Figure 9 11 Fluid sample container Sample Application with duplex control The system outlined above uses a three way valve for heating and cooling a fluid sample Coils surround the container holding the fluid When the temperature needs to be raised the signal to the valve will be between 12 and 20mA sending hot water through the coils When cooling is required the signal will be between 12 and 4mA sending cold water through the coils Enhanced Software Features Chapter 9 WATLOW Series 988 User s Manual 9 11 Enhanced Software Ratio Requirements Ratio control requires enhanced software Two analog inputs are required to monitor the process and at least one output adjusts the controlled part of the process Overview This feature allows the Series 988 to control one process as a ratio of another process This is especially useful in applications that mix two materials whether steam paint or food ingredients Input 2 of the controller measures the part of the process that is either uncontrolled or controlled by another device The part of the process con trolled by the 988 will be maintained at a level equal to the quantity mea sured at input 2 multiplied by the ratio term set by the user Input 1 mon itors the controlled part of the process 9 12 WATLOW Series 988 User s Manual Enhanced Software Features Chapter 9 Enhanced Software mixed paint sore Qora controlled flow f
161. tures of the heater Typically the range low term is set below the ambient temperature Otherwise the system could never fully cool down Setup When tuning a cascade system the inner loop must be tuned first In a heating system the inner loop is comprised of the output device and the input 2 sensor which usually measures the heater sheath temperature The output device controls a power switching device which in turn switches the heater The set point for the inner loop is generated by the outer loop and will have a range between range low 2 and range high 2 Hel Before tuning the inner loop you must make sure and are set properly Set the value of slightly lower than the ambient tem perature otherwise the system will never fully cool down Set to the maximum desired heat source temperature The inner loop can be auto tuned by setting to P _ db While auto tuning the inner loop will be controlled in an ON OFF mode at a set point equal to X eHe Once the inner loop PID B has completed auto tuning we can then auto tune the outer loop PID A The outer loop will generate the set point for the inner loop This is done by comparing the value of the input 1 sensor to the process set point performing the control algorithm by using the val ues of P df then generating a set point between rL ejand rH Enhanced Software Features Chapter 9 WATLOW Series 988 User s Manual 9 3 Enhanced Software The outer loop can be
162. ust your application Update documentation Chapters 7 and 8 and the Appendix provide detailed advice definitions and specifications along with application examples to help you optimize the safety and performance of your application Use the Table of Contents and Index to find specific information Document Every Step The Series 988 provides powerful and complex features Carefully docu ment each step of the setup and any subsequent changes This will make it much easier to change adjust and troubleshoot your application Make the configuration documentation available to engineers and techni cians on all shifts who may need to work with the Series 988 We provide space in this manual to record configurations You may prefer to photo copy the blank forms and keep them in a separate binder However you maintain your documentation be sure to replace all old copies of the doc umentation with updated versions whenever the controller configuration is changed ii WATLOW Series 988 User s Manual Introduction Introduction Introduction Notes Cautions and Warnings We use note caution and warning symbols throughout this book to draw your attention to important operational and safety information A bold text NOTE marks a short message in the margin to alert you to an important detail A bold text CAUTION safety alert appears with information that is important for protecting your equipment and performance Be especi
163. ut 2 4 40 4 41 GE i output 1 4 19 595 System Menu 5 2 E 25 event input 2 status 5 4 ao a a a Er 3J ambient temperature error 7 9 a z RAM identification error 7 9 OE4 output 4 4 28 T U V W X Y Z Er 5 non volatile checksum error 7 9 DEPE output lockout 6 5 test outputs 6 11 Er 9 configuration error 7 9 GE PE Output Menu 4 18 rr error latching 4 36 GE Y 1 output 1 module type 6 10 Ot Ye output 2 module type 6 10 Ot Y3 output 3 module type 6 10 Get YY output 4 module type 6 10 failure mode 4 ae software filter 1 1 47 software filter 2 4 15 ULL full 4 46 8 4 Pb 1A proportional band output 1 PID A 5 10 onal Pb 1 proportional band output 1 PID B 5 10 P bA proportional band output 2 PID A 5 13 Pbb proportional band output 2 PID B 5 13 Global Menu 4 34 P d switch PID sets 4 38 8 8 L global lockout 6 5 P d PID 2 crossover selection 4 38 9 8 P d A PID A Menu 5 3 9 8 P db PID B Menu 5 3 9 8 P d A PID A lockout 6 4 H 9H alarm 3 trigger 4 26 P db PID B lockout 6 4 H P high power limit 4 42 PLOC Panel Lockout Menu 6 1 6 6 Hun
164. utomatic operation provides closed loop on off or PID control When the operator transfers from a closed loop to an open loop the Series 988 sets the power level to the setting of the parameter If is set to 6 PL S the controller retains the power level from the closed loop control When the Series 988 returns to closed loop control it restores the previ ous set point process value The Auto Man LED located on the Auto Man key A indicates whether the controller is in automatic or manual operation When the LED is lit the control is in manual operation When the LED is off it is in automatic operation When the LED flashes press the key again within five seconds to complete the change in operation e If is set to and the process has stabilized at a power level less than 75 5 for a two minute period prior to the sensor break then the Series 988 switches to manual operation at the last automatic power level If these conditions are not met the output goes to 0 power output disabled When transferring from automatic to manual operation the control out put or outputs remain stable a bumpless or smooth transition The lower display changes from the set point to the output value e If FA it is set from tol 100 the Series 988 switches to man ual operation at that percent power Tuning Manual Operation Alarms and Error Codes Chapter 7 Alarms Changing the Output 3 Alarm Jumper If you have model numbe
165. zation 1 Select square root linearization for input 1 This prompt appears only if you have set to a process input or to a thermocouple set to 0 50mV NOTE See Chapter 8 for more information A on input lineariza tion L ini Lini 4 8 WATLOW Series 988 User s Manual Setup Menus Chapter 4 CAUTION Changing the value of changes most other prompts to the factory default values Document all set tings before chang ing sensor type Verify the correct sensor type before making a change Failure to follow setup Input Input 2 Select sensor type for input 2 This selection must match the sensor type connected to terminals 18 19 and 20 See Appendix for more infor mation about sensors e Changing the value of changes all other prompts to the facto ry default values except the Communications and Lockout menus the prompt in the Global Menu and the prompt in the Calibration Menu If you change the value the default warning dF Lt will flash in the upper display e Changes do not take effect automatically after five seconds you must press the Mode key Q to enter the sensor type change and advance to the next prompt This prompt and other Input 2 prompts appear only on controllers this guideline could equipped with input 2 hardware not 98__ _O__ ______ result in damage to equipment or prop erty Document all settings before If Default changing sensor I type 98 1

Series 988 User`s Manual Watlow Controls

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