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Watlow Electric 93 User's Manual

1. Output 2 A None C Switched dc output non isolated D Electromechanical relay Form C 5A without contact suppression Solid state relay Form A 0 5A without contact suppression A Il Line Voltage Power 0 100 to 240V ac nominal high voltage 1 12 to 24V amp ac dc low voltage Display Upper Lower RR Red Red RG Red Green GR Green Red GG Green Green 1 Electromechanical relays warranted for 100 000 closures only Solid state switching devices recom mended for applications requiring fast cycle times or extended service life 2To effect IP65 NEMA 4X rating requires a minimum mounting panel thickness of 1 5 mm 0 06 inch and surface finish not rougher than 812u mm 0 32p inch 3 Switching inductive loads relay coils etc requires using an RC suppressor Watlow Series 93 Appendix A 13 2s TD ro oa 2 lt Index A Advance key 3 1 Alarm High 4 7 Alarm Low 4 7 alarm silencing 5 5 alarms 5 4 automatic operation 5 3 autotuning 5 1 Autotune 4 7 B C calibration A 3 Calibration Menu A 4 Calibration Offset 4 7 Celsius F ahrenheit 4 3 dearing an alarm 5 4 Cyde Time 4 6 D default parameters Operation 4 6 4 7 Setup 4 3 4 5 Derivative 4 6 Deviation alarm 5 4 dimensions faceplate 2 1 panel cutout 2 1 side view 2 1 DIP Switches 4 1 Display 3 1 4 5 ODown arrow key 3 1 E entering the Setup Menu 4 2 error codes 5 5 5 6 F field
2. Dual four digit red or green displays Advance OUp arrow Down arrow and Infinity keys e User selectable screen display Accuracy e Calibration accuracy and sensor conformity 0 1 of span 1 C 25 C 3 C 77 F 5F ambient and rated line voltage e Accuracy span 540 C 1000 F minimum e Temperature stability 0 2 C C 0 2 F F rise in ambient maxi mum Sensors Inputs Thermocouple grounded or ungrounded sensors e RTD 2 or 3 wire platinum 100Q 0 C calibration to DIN curve 0 003850 Q C or JIS curve 0 00391 60 Q C user selectable Process 4 20mA 50 or 0 5V dc 10kQ input impedance Sensor break protection de energizes control output to protect system or selectable bumpless transfer to manual operation C or F or process units display user selectable Input Range Specified temperature ranges represent the controller s operation al span Thermocouple Type J 0 to 750 C 32 to 1382 F Type K 200 to 1250 C 328 to 2282 F Type N 0 to 1250 C 32 to 2282 F Type S 0 to 1450 C 32 to 2642 F Type T 200 to 350 328 to 662 F RTD Resolution DIN or JIS 1 200 to 700 C 328 to 1292 F 0 1 128 8 to 537 7 C 199 9 to 999 9 F Process 4 20mA 5Q or 999 to 9999 units 0 5V dc 10kQ or 999 to 9999 units Output 1 Heating or Cooling e Electromechanical relay Form C 5A 120 240V ac maxi mum without contact suppression rated
3. F 180 Units 0 AUE 0 to 3 0 Watlow Series 93 Setup 4 7 Notes 4 8 Setup Watlow Series 93 How to Tune and Operate the Series 93 NOTE Setthe HSC parameter under the Setup Menu to 2 C 3 F before auto tuning your con troller Figure 5 1 Autotuning at a Set Point of 200 F Autotuning Heat and or Cool The Series 93 can automatically tune the PID parameters to fit the characteristics of your particular thermal system The autotuning procedure operates on a thermal response value slow medium or fast Use the slow thermal response when your process does not need to reach the set point too rapidly or if it usually does not often exceed the set point A fast ther mal response produces a rapid temperature change over a short period of time Once the autotune sequence has begun the Output 1 heat proportional band is set to O and the control goes into an on off mode of control at 90 of the established set point The displayed set point remains unchanged Oncethe controller finishes learning the system it returns to a standard PID con trol with the PID values automatically set as a result of autotuning Autotune does not change cycle time parameters The controller can also be manually tuned See the next page for instructions on how to manually tune the controller Any change of the set point while in autotune re initiates the autotune procedure Autotune Autotune Begi
4. Messages Four dashes in the upper display indicate a Series 93 error The error code is visible in the lower display Sensor underrange error applies only to RTD units The sensor input generated a value lower than the allowable signal range or the analog to digital circuitry malfunctioned Enter a valid input Make sure the __ nr parameter Setup Menu and the DIP switch settings both match your sensor Configuration error The control ler s microprocessor is faulty call the factory Nonvolatile checksum error The nonvolatile memory checksum discovered a checksum error Unless a momentary power interruption occurred while the controller was storing data the nonvolatile memory is bad Call the factory Analog to digital underflow error The analog to digital circuit is underrange An open or reversed polarity sen sor is the most likely cause Check the sensor if the connection is good and functions properly call the factory The analog to digital underrange voltage is too low to convert an analog to digital signal Make sure the para meter Setup Menu matches your sensor and the DIP switches are set accordingly Analog to digital overflow error The analog to digital circuit is overrange An open or reversed polarity sensor is the most likely cause Check the sensor if the connection is good and the sensor functions properly call the factory The analog to digital overrange voltage is too high to con
5. Reference Compensator with reference junction at 0 C 32 F or Type J Thermocouple Calibrator set at 0 C 32 F Precision millivolt source 0 50mV min range 0 01mV resolution oe And Calibration 1 Connect the ac line voltage L1 and L2 to the proper terminals 2 Connect the millivolt source to Terminal 5 Negative and Terminal 3 Positive on the Series 93 terminal strip Use regular 20 24 gauge wire Make sure the DIP switch is set for thermocouple input See Chapter Four Apply power to the controller and allow it to warm up for 15 minutes After warm up put the controller in the Calibration Menu See Figure A 3 Select YES Press the Infinity key twice to enter the manual mode The controller is calibrating when indicator light is on Make sure the controller is in manual mode only when you are in the correct parameters At the 0 00 prompt enter 0 00mV from the millivolt source to the controller Allow at least 10 seconds to stabilize Press the Advance key At the 50 0 prompt enter 50 00mV from the millivolt source to the Series 93 Allow at least 10 seconds to stabilize Press the Advance key At the _ prompt disconnect the millivolt source and connect the reference com pensator or thermocouple calibrator to Terminal 5 Negative and Terminal 3 Positive on the Series 93 terminal strip If using a compensator turn on and short the input wires If using the J calibrator set it to simulate 0 C 32 F Al
6. Removing the Series 93 Controller When removing the mounting collar we suggest using a thin tool such as a putty knife or screwdriver to pry gently under each of the six tabs to disen gage the teeth Then rock the collar back and forth until it can be easily pulled off the case 2 2 Install and Wire Watlow Series 93 AN Wiring the Series 93 WARNING To avoid The Series 93 wiring is illustrated by model number option electric shock Hee Check the unit sticker on the controller and compare your model National Electric number to those shown here and also the model number break Code NEC safety down in the Appendix of this manual practices when wiring and connect ing this unit to a All outputs are referenced to a de energized state The final wiring figure is a typical system example power source and to When you apply power without sensor inputs on the terminal electrical sensors or strip the Series 93 displays in the upper display and peripheral devices _ G inthelower display except for 0 5V dc or 4 20mA Failure to do so could process input units Press the Infinity key twice and result in injury or is displayed for one second This error indicates an open sensor death or an analog to digital error All wiring and fusing must con form to the National Electric Code and to any locally applicable codes as well 5 NOTE Taking the unit out of Power W ri ng the case is not a nor ma
7. parameter values or an open sensor When powering up the Process display will be blank for five seconds To set to blank set _g5P to _5EE in the Setup Menu Lower Display Indicates the set point output value parameters for data in the upper display or error and alarm codes To set to blank set _ d5P to _ Prolin the Setup Menu Advance Key Press to step through the Operations Setup and Calibration Menus In the Auto mode new data is self entering in five seconds Up arrow and Down arrow Keys Increases or decreases the value of the displayed parameter e Press lightly to increase or decrease the value by one e Press and hold down to increase or decrease the displayed value at a rapid rate New data will self enter in five seconds or can be entered by pressing the Advance Key Output 1 Indicator Light Lit when Output 1 is energized Output 2 Indicator Light Lit when Output 2 is active This output can be configured as a control or alarm output Percent Power Indicator Light Lit the controller is in Manual operation Press the Infinity key twice to enter Automatic operation Blinking press the OInfinity key to toggle between Auto and Manual Returns to its previous state and stops blinking if the O Infinity key is not pressed within five seconds Infinity Key Press once to clear any latched alarms Also disables alarm output if silencing is enabled Press again within five second
8. 104 mm 4 1 in 45 mm 1 76 in 10mm 0 40 in 31mm 1 21 in Installation procedure Bold print denotes requirement for IP65 NEMA 4X seal Follow this procedure to mount the Watlow Series 93 temperature controller 1 Makea panel cutout using the dimensions in Figure 2 1a 2 If your controller model number begins with 93B make sure the rounded side of the external case gasket is facing the panel sur face Check to see that the gasket is not twisted and is seated within the case bezel flush with the panel Place the case in the cutout Make sure the gasket is between the panel cutout and the case bezel o TD S S uN i Watlow Series 93 Install and Wire 2 1 D a pat 2 o Figure 2 2a Mounting Case Side View Figure 2 2b Mounting Collar Cross Section with offset teeth A CAUTION Follow the installation procedure exactly to guarantee a proper IP65 NEMA 4X seal Make sure the gasket between the panel and the rim of the case is not twisted and is seated properly Failure to do so could result in damage to equip ment Figure 2 2c Case Rear View and IP65 NEMA 4X Seal Example 0 to 0 483 mm space 0 to 0 019 in Panel a Ridges Tabs Teeth 3 While pressing the front of the case firmly against the panel slide the mounting collar over the back of the controller The tabs on the
9. 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 D signation S rie 93 Num ro s de mod le s 93 A ou B A ou B 1 C D F ou K A C D ou K 0 ou 1 quatre lettres ou chiffres quelconques Commande installation cat gorie Il degr de Francais Classification pollution II Tension nominale 100a240V ou 24 Fr quence nominale 50 60 Hz Consommation d alimentation nominale 6 VA maximum Conforme aux exigences de la ou des directive s suivante s 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 3 2 1995 Limites de courant harmonique EN 61000 3 3 1995 Limites de fluctuation et de vacillement de la tension EN 61000 4 2 1995 D charge lectrostatique EN 61000 4 4 1995 Courants lectriques transitoires rapides EN 61000 4 3 1996 Insensibilit l nergie rayonn e EN 61000 4 6 1996 Insensibilit l nergie par conduction ENV 50204 1995 T l phone cellulaire EN 50081 2 1994 Norme g n rique sur les missions
10. 9 units Integral O off or 0 1 to 99 9 minutes per repeat Reset 0 off or 0 01 to 9 99 repeats per minute Rate derivative O off or 0 01 to 9 99 minutes Cycle time 0 1 to 999 9 seconds Output 2 User selectable as Control with action opposite that of Output 1 heating or cooling Process or deviation alarm with flashing alarm message e Process or deviation alarm without alarm message Alarm with separate high and low set points e Hysteresis 1 to 9999 or units switching differential Line Voltage Power e 100 240V ac 15 10 4 85 264V ac 50 60Hz 5 e 12 24V ac dc 10 15 10 26V ac dc 50 60Hz 5 e Fused internally factory replaceable only Slo Blo type time lag 1A 250V for high voltage versions 2A 250V for low voltage versions Maximum power consumption 12VA 100 to 240V 7VA 12 to 24V Data retention upon power failure via non volatile memory Operating Environment e 0 to 65 C 32 to 149 F e 0 to 90 RH non condensing Storage Temperature e 40 to 85 C 40 to 185 F Terminals e 6 compression universal head screw terminals accepts 20 14 gauge wire Controller Weight e 0 2kg 0 4 Ib Shipping Weight e 0 34 kg 0 75 Ib Dimensions e Compact 1 16 DIN size and IP652 NEMA 4X front panel make the Series 93 easy to apply and maintain in a wide variety of applications The unique mounting bezel gasket and collar make installation a snap Overall He
11. 93 1C_ 00 _ GR D f 7to OV do va 940 dl as Lg xterna 6 i i dl Y Internal Circuitry 2 8 Install and Wire Watlow Series 93 AA WARNING To avoid damage to property and equipment and or injury or loss of life use National Electric Code NEC standard wiring practices to install and operate the Series 93 Failure to do so could result in such damage and or injury or death Wiring Example L1 120V ac L2 Earth Ground High Limit Mechanical Controller DIN a mite 2 DA1C 1624 C000 4 93BB 1CA0 00RR Rear View Limit Sensor Process Sensor 94BB 1DA0 00RR Limit Controller 120 ac L1 L2 12 2 Series 93 93BB 1CA0 00RR 93BB 1CA0 00RR Temperature Controller 1 Not used 2 Si l 9 10 3 S2 TC V 4 Not used 2 1 5 3 TC V l 0 o DIN a mite 6 not used DA1C 1624 C000 7 not used O1 20 21 8 not used 3 4 9 D C 10 D C hi ene ee T 12 21 Series 94 94BB 1DA0 00RR Limit Controller AA 5 ei 10 9 i ry Ne Figure 2 9 System Wiring Example Watlow Series 93 Install and Wire 2 9 D D ts D DAMA Wiring Notes Sketch in your application on this page or a copy of it Seethe wiring example in this chapter WARNING To avoid elec tric shock and damage to property and equipment use National Electric Code NEC safe
12. 93 terminal strip Use regular 20 24 gauge wire Apply power to the controller and allow it to warm up for 15 minutes After warm up put the controller inthe _ AL menu See Figure A 3 Select YES Press the Advance key until the 4A0 prompt is displayed Press the OI nfinity key twice to enter the manual mode The controller is calibrating when the indicator light is on At the prompt the multimeter should read approximately 4mA Allow at least 10 seconds to stabilize Use the OUp arrow 9Down arrow keys reverse acting to adjust the reading on the multimeter for 3 85mA 0 10mA Press the Advance key Atthe 289 prompt the multimeter should read approximately 20mA Allow at least 10 seconds to stabilize The controller will leave the _ AL mode if one minute passes between key activations except for 4 20mA units Use the OU p ODown keys reverse acting to adjust the reading on the multimeter for 20 15mA 0 10mA To conclude the 4 20mA output calibration press the Infinity key twice then press the Advance key to reach the next prompt or to exit from the CAL menu Le D 2 2 lt Watlow Series 93 Appendix A 7 Notes gt Ke D D gt gt lt Watlow Series 93 A 8 Appendix Glossary A alarm A signal that indicates that the process has exceeded or fallen below the set or limit point For example an alarm may indicate that a process is t
13. The ramping set point is not shown Entering the Setup Menu or manual operation disables the outputs and ramp Once you exit either one the Series 93 controls to the last entered set point Range _SE Ua OFF Default OFF Rate Selects the ramping rate in degrees per hour Will not appear if __ P is set tol OFF Range 0 to 9999 Default 100 hr 4 4 Setup Watlow Series 93 Power Limiting The power limiting function in power for heat only Power Limiting will function if _ P Nissetto 0 Range Dependent on output type 0 to100 Default 100 d 5 P Display Selects which displays are active or viewable Five seconds after select ed the appropriate display goes blank Press Advance OU p arrow or Down arrow to override this feature and cause the current value to be displayed for 5 seconds Range _nor Normal displays Default Set Point lower display only Table 4 5a Process upper display only In T nsor Range Low nsor Range High Input Ranges put Type Sensor Range Lo Sensor Range Hig J 0 C 32 F 750 C
14. and compensates to minimize over shoot and undershoot See derivative reference junction See junction reset Control action that automatically eliminates offset or droop between set point and actual process tempera ture Also see integral reset automatic The integral function of a Pl or PID temperature controller that adjusts the process tempera ture to the set point after the system stabilizes The inverse of integral reset windup inhibit See anti reset resistance temperature detector RTD A sensor that uses the resistance temperature characteristic to mea sure temperature There are two basic types of RTDs the wire RTD which is usually made of platinum and the thermistor which is made of a semiconductor materi al The wire RTD is a positive temperature coefficient sensor only while the thermistor can have either a nega tive or positive temperature coefficient reverse action An output control action in which an increase in the process variable causes a decrease in the output Heating applications usually use reverse action RTD See resistance temperature detector S set point The desired value programmed into a con troller For example the temperature at which a system is to be maintained switching sensitivity In on off control the temperature change necessary to change the output from full on to full off See hysteresis T Y thermal system A regulated environment that consists of a heat sour
15. as the process tem perature is inside the parameter alarm limit If the alarm is non latching The alarm clears itself automatically as soon as the process temperature is inside the parameter alarm limit Auto tuning at a Se Autotune Begins Temperature 90 of Press once Clear a latched and corrected alarm 5 4 Tuning and Operating Watlow Series 93 Error Code NOTE An alarm display will be masked by an error condition or when the controller is in the Calibration or Setup Menus Figure 5 5 Error Code Message A CAUTION Electrical noise or a noise event vibration or excess environ mental moisture or temperature may cause Series 93 errors to occur If the cause of an error is not otherwise appar ent check for these Alarm Silencing is available with the deviation alarm and has two uses When is selected as on the operator must manually disable the alarm by pressing the O Infinity key once on initial power up in either the latching or non latching mode Alarm silencing disables the alarm output relay However the Output 2 indicator light also the lower display when issetto dEA shows an alarm condition until the process value is within the safe region of the deviation alarm band Once the process value crosses into the safe region both a latching or a non latching alarm is ready Any future deviation outside this safe band triggers an alarm
16. digital overrange voltage is too high to convert an analog to digital signal Make surethe ___ fm parameter Setup Menu matches your sensor and the DIP switches are set accord ingly Watlow Series 93 Appendix A 17 a TD rT 2 oa lt Parameter Value Range Factory Default Appears If Setup Menu A A OV PPS CLOC 0 4 C Ta y H E a ty DIP switch selectable ST rtd red 0 5 420 CEC 0 0 0 0 00 0 falis setto 0 5 or C420 C_F C or F Dependenton _dFL tn is set to J S Cred oC red ro C r ltol rh Input dependent C ch C chto rt Input dependent Loe 1 hejor CL hE Enter theSetupMenuby CASE e o pressing the OUp arrow and TA IS a ODown arrow keys simulta CPE A Process Alarm neously for three seconds The Pe Process with no alarm message lower display shows the LdEAl Bees at Loc Lock parameter and a Ras ion with no alarm message the upper display shows its CASA T to 5555 0 1 to 555 5 0 01 to 55 550 2 0 2 0 020 CMe elis not set tol Lon current level All keys are 1 to 9999 0 1 to 999 9 0 01 to 99 990F 3 0 3 0 03F or Cna inactive until you rele
17. examination prove to be defec tive within the warranty period specified This warranty does not apply to dam age resulting from transportation alteration misuse or abuse Returns e Call or fax Customer Service for a Return Material Authorization RMA number before returning a controller Put the RMA number on the shipping label and also on a description of the problem e 20 of net price restocking charge applies to all standard units returned to stock Watlow Series 93 User s Manual Watlow Controls 1241 Bundy Blvd P O Box 5580 Winona MN 55987 5580 Phone 507 454 5300 Fax 507 452 4507
18. for Output 2 when is an alarm Appears only if Ge ejisnotsetto Conjor no See the Operation Menu for _Pb 1 Range 1 to 5555 0 1 to 555 5 0 01 to 55 5 C 1 to 9999 0 1 to 999 9 0 01 to 99 99 F Default 2 0 2 0 02 C 3 0 3 0 03 F Latching Selects whether the alarm is latching or non latching Latching alarms must be cleared by pressing the Infinity key before the alarm output will reset Selecting non latching will automatically reset the alarm output when the condition clears Appears only if Ge isnotsetto Conjor no Range LAE or al Al Default Silencing Selects alarm silencing inhibit for the alarm Appears only when issetto dEA or _ dE For more information see Chapter 5 Range _Gnjor _OF Default OFF RTD Selects the RTD calibration curve for RTD inputs Will not appear unless _Injisset tol rt djor rtd y 15 is0 0039160 0 C d injis 0 0038509 2 C Range _d injor _ J 15 Default Ramping Choose _5 r and the set point ramps at the selected rate in hr from the process actual temperature to the set point when power is applied to the con troller start up It will not ramp with a set point change is the same as St r but ramps with a set point change It ramps from the previous set point to a new one at the selected ramp rate Select for no ramping action When ramp ing the lower display alternately flashes __ P The set point displayed is the desired end set point
19. industrial EN 61000 3 2 1995 L mites para corriente arm nica EN 61000 3 3 1995 Limitaciones de oscilaciones y fluctuaciones de voltaje EN 61000 4 2 1995 Descarga electrost tica EN 61000 4 4 1995 Perturbaciones transitorias el ctricas r pidas EN 61000 4 3 1996 Inmunidad radiada EN 61000 4 6 1996 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 para medici n de caracter sticas de perturbaciones de radio correspondientes a equipos de radiofrecuencia industriales cient ficos y m dicos Grupo 1 Clase A EN 61000 3 2 1995 L mites para emisiones de corriente arm nica EN 61000 3 3 1995 Limitaciones de fluctuaciones del voltaje 73 23 EEC Directiva de Baja Tensi n 1993 Requerimientos de seguridad para equipos el ctricos de medici n control y uso en laboratorios Parte 1 Requerimientos generales EN 61010 1 Winona Minnesota USA Place of Issue November 1997 Date of Issue Signature of Authorized Representative Erwin D Lowell Name of Authorized Representative General Manager Title of Authorized Representative Watlow Series 93 Appendix A 15 Appendix Notes gt Ke D D gt gt lt Watlow Series 93 A 16 Appendix Series 93 Quick Reference Keys and Displays Upper Display Indicates the process value actual temperature operating
20. is on Make sure the controller is in the manual mode only before changing the when you are in the correct parameters calibration equip ment 5 At the 4 00 parameter set the current source to 4 00mA Allow at least 10 seconds to stabilize Press the Advance key 6 At the 20 0 parameter set the current source to 20 00mA Allow at least 10 seconds to stabilize The controller leaves the _ CAL mode if 1 minute passes between key activa tions Press the Infinity key twice to exit the manual mode To conclude press the infinity key twice then press the Advance key to reach the next prompt or to exit from the CAL menu A 6 Appendix Watlow Series 93 4 20mA Output Field Calibration Procedure Equipment Required NOTE Before calibrating an installed controller make sure all data and parameters are documented See the Setup and Operation Tables in Chapter Four NOTE When the indica tor light is on the controller is auto matically calibrating Your sequence is VERY important Always move to the next parameter before changing the calibration equip ment 3000 1 2 watt 10 resistor 4 1 2 digit Digital Multimeter Setup And Calibration 1 Connect the ac line voltage L1 and L2 tothe proper terminals of the Series 93 See Chapter Two Set the multimeter to measure current Connect the multimeter in series with the 3004 resistor to Terminal 9 Positive and 10 Negative on the Series
21. lectromagn tiques Partie 2 Environnement industriel EN 55011 1991 Limites et m thodes de mesure des caract ristiques d interf rences du mat riel radiofr quence industriel scientifique et m dical Groupe 1 Classe A EN 61000 3 2 1995 Limites d mission d harmoniques EN 61000 3 3 1995 Limitations d carts de tension et de papillotement 73 23 EEC Directive li e aux basses tensions EN 61010 1 1993 Exigences de s curit pour le mat riel lectrique de mesure de commande et de laboratoire Partie 1 Exigences g n rales 1505 Erkl rt daB das folgende Produkt Beschreibung Serie 93 Modellnummer n 9 3 A oder B A oder B 1 C D F oder K AC D oder K 0 oder 1 4 beliebige Buchstaben oder Ziffern Regelsystem Installationskategorie Il Emissionsgrad Il Deutsch Klassifikation Nennspannung 100 bis 240 V oder 24 bis 28 V Nennfrequenz 50 60 Hz Nominaler Stromverbrauch Max 6 VA Erf llt die wichtigsten Normen der folgenden Anweisung en der Europ ischen Union unter Verwendung des wichtigsten Abschnitts bzw der wichtigsten Abschnitte der normalisierten Spezifikationen und der untenstehenden einschl gigen Dokumente 89 336 EEC Elektromagnetische Ubereinstimmungsanweisung EN 50082 2 1995 EMC Rahmennorm f r St rsicherheit Teil 2 Industrielle Umwelt EN 61000 3 2 1995 Grenzen der Oberwellenstromemission EN 61000 3 3 1995 Grenzen der Spannungsschwankungen und Flimmern EN 61000 4
22. lights Decreasing Noise Sensitivity Physical separation and wire routing must be given careful consideration in planning the system layout For example ac power supply lines should be bundled together and physically kept separate from input signal lines sensor lines A 305 mm 12 inch minimum separation is usually effec tive Keep all switched output signal lines high power level separate from input signal lines sensor lines Cross other wiring at 90 angles whenev er crossing lines is unavoidable Look at the system layout identify and locate electrical noise sources such as solenoids relay contacts motors etc Route the wire bundles and cables as far away as possible from these noise sources Don t mount relays or switching devices close to a microprocessor controller Don t have phase angle fired devices in the same electrical enclosure or on the same power line with the controller Shielded cables should be used for all low power signal lines to protect them from magnetic and electrostatic coupling of noise Some simple pointers are 0 Whenever possible run low level signal lines unbroken from signal source to the controller circuit Connect the shield to the controller circuit common at the controller end only Never leave the shield unconnected at both ends Never connect both shield ends to a common or ground Maintain shield continuity at daisy chain connection points by recon necting the broken shield A
23. mechanical relay or contac tor is switching power to the load a longer cycle time may be desirable to minimize wear on the mechanical components Typical life of a me chanical relay is 100 000 cycles To abort autotuning either reset the parameter to 0 press the Infinity key twice or cycle power off and on In all cases aborting autotune restores all values to those previous to autotuning Manual Tuning For optimum controller performance tune the Series 93 to your thermal sys tem The tuning settings here are for a broad spectrum of applications your system may have somewhat different requirements NOTE This is a slow procedure taking from minutes to hours to obtain optimum value 1 Apply power to the Series 93 and enter a set point Set Operation parame ters as follows Pbjto IC rE C__te tol gg _ Ay _ dEltol 000 _ Cejtol_ 50 CAL tol 0 AUtjtol 8 2 Proportional Band Adjustment Gradually increase _ P5 until the upper display temperature stabilizes to a constant value The process tem perature will not be right on set point because the initial reset value is 0 00 repeats per minute When PpjJissetto0 rE lEjand _ rA are inoperative and the Series 93 functions as a simple on off con troller The parameter determines the switching differential value 3 Reset l ntegral Adjustment Gradually increase __ E or decrease until the upper display temperature begins to oscillate or hunt Then slowly de
24. po At the top of the Setup Menu the Series 93 displays the user level of operation in the upper display and the _1 QC parameter in the lower display Press the 9 Advance key and the value of the next parameter appears in the upper display and the parameter appears in the lower display Lock Selects the level of operator lock out as defined below Range Oto 4 Default 0 8 All operating parameters may be viewed or changed Manual opera tion is permitted When in manual operation percent power is adjustable Bumpless transfer to manual mode will occur on sensor break These point process value and alarm settings are the only visible parameters set point is adjustable in this level Manual operation and auto tune are permitted When in manual operation percent power is adjustable Bumpless transfer to manual mode will occur on sensor break The set point process value and alarm settings are the only visible parameters set point is adjustable in this level Manual operation is permit ted When in manual operation percent power is adjustable Bumpless transfer to manual mode will occur on sensor break The set point and process value are the only visible parameters set point is adjustable in this level Manual operation is not permitted Bumpless transfer is defeated and outputs are disabled on sensor break The set point and process value are the only visible parameters set point is not adjustable in this level of l
25. production Nicole Smith production Trish J ohnson production Sarah Toraason human resources Second Row Steve Lubahn marketing Craig Dennis marketing Arlene Fox production Shawn Cady production Kim Page production Roger Ruehmann applications engineer Keith Ness engineer Standing Pam Obieglo customer planner Mark Wagner engineer Matt Cyert production Dan J ohnson agency coordinator Mary Koisti produc tion J oe Seifert shipping Penny Roraff production Lisa Voelker engi neering technician Cindy Panek production Dean McCluskey engineer J ohn Gabbert technical editor Tom Butler test engineer Sally Kotschevar purchasing ii Table of Contents Watlow Series 93 1 Overview of the Series 93 Figure 1 1 Series 93 Input and Output Overview Dual Control Output Single Input PID or on off User Selectable Type J K T Nor S Thermocouple Output 1 RTD or Process Heat or Cool Output 2 Heat Cool Alarm or None General Description Welcome to the Watlow Series 93 a 1 16 DIN microprocessor based tempera ture controller The 93 has a single input which accepts type K T N or S thermocouple RTD or process input With dual output the primary output can be heating or cooling while the secondary output can be a control output opposite the primary output heat or cool alarm or none Both outputs can be selected as either PID or on off PID settings include proportional ba
26. proportioning function is active for Output 1 or 2 When is set to O the unit functions as an on off control on Output 1 and 2 will not appear if Pb J is set to 0 or is not set tol Con The switching differential is determined by the parameter Range if is set to US Pb 1 0 to 555 C 0 to 999 F 0 to 999 Units 0 0 to 5 5 C 0 0 to 9 9 F 0 0 to 9 9 units P b 2 The same as except lower limit is 1 or 0 1 Defaults is set to 2 5 C 25 F is set to 25 Range if issetto 1 0 to 999 9 of span Defaults is set to 3 0 is set to 3 0 Reset Integral 1 and 2 An integral control action for Output 1 or 2 that auto matically eliminates offset or droop between set point and actual process tem perature E M_E 1 Will not appear if gt P amp is set to 0 JE Appears if is not set to 0 and issetto Con Either reset or integral will appear depending on howthe _gF L parameter is set in the Calibration Menu See the Appendix Range if issetto YS 0 to 9 99 repeats minute Default 0 00 Range if issetto 5 1 00 1 to 9 99 minutes per repeat Default 0 00 Rate Derivative 1 and 2 The rate derivative function for Output 1 or Output 2 Eliminates overshoot on startup or after the set point changes A M dE I Will not appear if Pb His set to 0 L_d amp 2 Appearsif Pb Iis not set to 0 and issetto Con Either rate or derivative appears depending on how is set in the Calibration Menu Rangeif dgFLj issetto gyS
27. 1382 F NOTE H 200 C 328 F 1250 C 2282 F t 200 C 328 F 350 C 662 F Document your Setup 0 C 32 F 1250 C 2282 F Menu parameters CS 0 C 32 F 1450 C 2642 F Do not mark any values rtd 1 200 C 328 F 700 C 1292 F s red 0 19 128 8C 199 9F 537 7 C 999 9 F N ee photocopies 420 4mA 999 units 20mA 9999 units rise ae 8 5 OV dc 999 units 5V dc 9999 units Setup Menu Prompts and Descriptions Parameter Value Range Factory Default Appears If LOC 0 to 4 0 In J H E a 5 J DIP switch selectable redil ctd 0 6 429 dEC 0 0 0 0 00 0 _Injis set tof G S5 or 420 C F Cor F Dependent on L tajissettol__ YH EJ al S _ red or cl rijto ch Input dependent ch rhjto Input dependent DE hRE ort CE HSC 1 to 55 0 1 to 5 5 0 01 to 0 55 C 2 0 2 0 02 C 1 to 99 0 1 to 9 9 0 01 to 0 99 3 0 3 0 03F te Con Control Con Pr A Process alarm Pr Process with no alarm message dEAR Deviation alarm dE Deviation with no alarm message no None HSA 1 to 5555 0 1 to 555 5 0 01 to 55 55 C 2 0 2 0 02 is not set to or 1 to 9999 0 1 to 999 9 0 01 to 99 99 F 3 0 3 0 03F LAE E REJor _ntA alfl Gt lis not set tol Conjor _ no Sit Onjor _0FF OFF GE Dis setto dEAjor _ dE red Jigjor _d im _Injis set to red or _c td cP SE Ramping on power up OFF On Ramping to set point at all times OFF None re 0 to 9999 100 hr is not set to PL 0 to 100 100 DE Nor _ Ot 2 is set to ht
28. 2 1995 Elektrostatische Entladung EN 61000 4 4 1995 Elektrische schnelle St Be EN 61000 4 3 1996 Strahlungsimmunit t EN 61000 4 6 1996 St rimmunit t ENV 50204 1995 Mobiltelefon EN 50081 2 1994 EMC Rahmennorm f r Emissionen Teil 2 Industrielle Umwelt EN 55011 1991 Beschr nkungen und Methoden der Messung von Funkst rungsmerkmalen industrieller wissenschaftlicher und medizinischer Hochfrequenzger te Gruppe 1 Klasse A EN 61000 3 2 1995 Grenzen der Oberwellenstromemissionen EN 61000 3 3 1995 Grenzen der Spannungsschwankungen und Flimmern 73 23 EEC Niederspannungsrichtlinie zu entsprechen EN 61010 1 1993 Sicherheitsrichtlinien f r Elektroger te zur Messung zur Steuerung und im Labor Teil 1 Allgemeine Richtlinien Declara que el producto siguiente Designaci n Serie 93 N meros de modelo 93 AoB AoB 1 CDFoK ACDoK 061 Cualquier combinaci n de cuatro n meros y letras Control categoria de instalaci n II grado de contaminaci n ambiental II 100a240V 024 Espafiol Clasificaci n Tensi n nominal Frecuencia nominal 50 60 Hz Consumo nominal de energ a 6 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
29. Auto to Manual or vice versa While in Manual mode percent power is in the lower display Watlow Series 93 Keys and Displays 3 1 Notes gt lt D v a Q a Tal D lt D 3 2 Keys and Displays Watlow Series 93 4 How to Set Up the Series 93 A WARNING Remove power from the controller before remov ing the chassis from the case or changing the DIP switches Removing the controller from the chas sis is not a normal oper ating condition and should only be done by a qualified technician Figure 4 1a DIP Switch Location and Orientation Figure 4 1b Input DIP Switches Setting up the Series 93 is a simple process First set the DIP switches to match your input type Refer to the orientation below for the Input value Next configure the Series 93 s features to your application in the Setup Menu then enter values in the Operating Menu Both tasks use the Advance key to move through the menus and the U p arrow Down arrow keys to select data Before entering information in the Setup Menu set the parameter If C 5 1 is selected C proportional band in of span derivative and inte gral are the defaults If U5 is selected F proportional band in degrees reset and rate are the defaults Changing the _ FL prompt will set parameters to their factory default Document all current parameter settings first See the calibration section in the Appendix to change this pa ramet
30. S Default 0 Operation Menu Operation Menu Prompts and Document your Series 93 Operation Parameters Descriptions Do not mark any values here make photocopies instead Operation Parameters Value Range Factory Default If issetto US 0 to 555 C 0 to 999 F 0 to 999 Units 2 5 C 0 to 55 5 C 0 to 99 9 F 0 to 99 9 Units 25 F 0 is control is set to switch differential If issetto S J 0 0 to 999 9 of span 3 rel 0 00 to 9 99 repeats minute 0 00 repeats minute 0 00 No Reset Won t appear if is set to 0 or is setto 5 1 tel 0 0 to 99 9 minutes repeat 0 00 No Integral 00 0 minutes repeat Won t appear if is set to 0 or is setto U5 cAI 0 00 to 9 99 minutes 0 00 minutes 0 00 No Rate Will not appear if is set to 0 or issetto 5 1 dEl 0 00 to 9 99 minutes 0 00 No Derivative 0 00 minutes Won t appearif Pb Iis set to 0 or is setto US CE 0 1 to 999 9 5 0 seconds Won t appear if Pb Iis setto 0 or _ 428 Pb Same as Pb I P amp 2 lower limit 1 0 1 0 01 rE Same range as r 1 tee Same range as IE I rho Same range as rA I dE Same range as dE I Cee Same range as CE J ALO Deviation 999 to 0 999 Process to Will not appear if is set to or Con CAH I Deviation 0 to 999 999 Process to Will not appear if is set to or Con CAL 100 C 180
31. Series 93 User s Manual 1 16 DIN Microprocessor Based Auto tuning Control User Levels e New User go to page 1 1 e Experienced User go to page 2 1 e Expert user go to page 2 1 Installers e Installation go to page 2 1 97 Wi ee coser o a aed go to page 2 3 ORL CUSIOMER SATISFACTION y ISO 9001 da A NS C1 Sel AR UAE E WS Registered Company Winona Minnesota USA Watlow Controls 1241 Bundy Blvd P O Box 5580 Winona Minnesota USA 55987 5580 Phone 507 454 5300 Fax 507 452 4507 http www watlow com 0600 0001 0000 Rev C Made in the U S A February 1999 10 Supersedes 0600 0001 0000 Rev B Recycled Paper At Least 10 Postconsumer Waste NOTE Details of a Note appear here in the narrow margin on the left side of each page A CAUTION Details of a Caution appear here in the narrow margin on the left side of each page AN WARNING Details of a Warning appear here in the narrow margin on the left side of each page Safety Information We use note caution and warning symbols throughout this book to draw your attention toimportant 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 im
32. Y External L O oad Watlow Series 93 Install and Wire 2 7 5j D a a pat 2 o NOTE Successful installation requires four steps Choose the controller s hardware configuration and model number Appendix e Choose a sensor Chapter Two and Appendix Install and wire the controller Chapter Two e Configure the con troller Chapters Three Four and Five NOTE Output is in open state in Alarm Condition NOTE Switching inductive loads relay coils solenoids etc with the mechanical relay switched dc or solid state relay output options requires use of 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 A WARNING To avoid dam age to property and equip ment and or injury or loss of life use National Electric Code NEC stan dard wiring practices to install and operate the Series 93 Failure to do so could result in such dam age and or injury or death Output 2 Wiring Figure 2 8a Mechanical Relay Without Contact Suppression 9 1 D_ 00 _ FormC 5A Minimum load current 100mA 5V dc E 5 s Customer supplied Quencharc Figure 2 8b Solid state Relay Without Contact Suppression 93 1 K_ 00__ 0 5A ac loads only 4 L1 Fuse ae i pm 7 L2 L2 Customer supplied Quencharc Figure 2 8c Switched DC
33. ase both CLAE CURE JO CALA CaLA OE dis not set tol Con keys You can reach the Lock oras parameter from anywhere LS it Om or OFF COFF C Ot 2 is set to JER or Use the Advance key to _ d move through the menus and Crkdl Cd 15 0r d in Cda is set to eE d or LF the GUESS ic perils TP USE e is set to Ramping on power up OFF arrow eys O sel ata ou on is setto Ramping to set point always will not see all parameters in DFF is set to None this menu depending on the FE 0 to 9999 100 hr Le PJ is not set to OFF controller s configuration and CPL 5 to 100 100 model number Cds nor normal Cher C SEE Set Point lower only Setup si Pr o Process upper only fn Input lema Operation Menu _F Celsius Fahrenheit r Range Low Parameter Value Range Factory Default c H Range High If is setto US C OE I Output 1 0 to 555 C 0 to 999 F 0 to 999 Units 25 H T ps Gontrol 0 to 55 5 C 0 to 99 9 F 0 to 99 9 Units 2 5 Je a pe de 0 is set to on off control is set to switch differential ysteresis Alarm a URE Latching f _dFL is set to S 1 S IL Silencing 0 0 to 999 9 of span 3 a AL El 0 00 to 9 99 repeats minute 0 00 repeats minute 7 Rate 9 0 00 No Reset Won t appear if is set to 0 PL Power Limiting or dFtlis settof 5 7 d5P Display TET 0 0 to 99 9 minutes rpt 0 00 No Integral 00 0 minutes repeat Parameter may not always appear Won t appearit Pb Tis set to 0 or issetto U5 cal 0 00 to 9 99 minut
34. atching alarm before it will disappear Errors Four dashes in the upper display indicate a Series 93 error The error codeis visible in the lower display Sensor underrange error applies only to RTD units The sensor input generated a value lower than the allowable signal range or the ana log to digital circuitry malfunctioned Enter a valid input Makesurethe _ nj parameter Setup Menu and the DIP switch settings both match your sensor Configuration error The controller s microprocessor is faulty call the factory Nonvolatile checksum error The nonvolatile memory checksum discovered a checksum error Unless a momentary power interruption occurred while the con troller was storing data the nonvolatile memory is faulty Call the factory Analog to digital underflow error The analog to digital circuit is underrange An open or reversed polarity sensor is the most likely cause Check the sensor if the connection is good and functions properly call the factory The ana log to digital underrange voltage is too low to convert an analog to digital signal Make sure the In parameter matches your sensor and the DIP switches are set accordingly Analog to digital overflow error The analog to digital circuit is overrange An open or reversed polarity sensor is the most likely cause Check the sensor if the connection is good and the sensor functions properly call the facto ry The analog to
35. c control aspects The operator sets output levels N NEMA 4X ANEMA specification for determining resis tance to moisture infiltration and corrosion resistance This rating certifies the controller as washable and corro sion resistant O offset process The difference in temperature between the set point and the actual process tempera ture Offset is the error in the process variable that is typ ical of proportional only control See also droop on off A method of control that turns the output full on until set point is reached and then off until the process error exceeds the hysteresis open loop A control system with no sensory feedback output Control signal action in response to the differ ence between set point and process variable overshoot The amount by which a process variable exceeds the set point before it stabilizes P Q P control Proportioning control parallel circuit A circuit configuration in which the same voltage is applied to all components with current divided among the components according to their respective resistances or impedances parameter A variable that is given a constant value for a specific application or process PD control Proportioning control with derivative rate action percent power control Open loop control with output power set at a particular level percent power limit Restriction of output power to a predetermined level Pl control Proportioning control with i
36. calibration A 5 A 7 G general description 1 1 Glossary A 9 H high voltage wiring 2 3 Hysteresis 4 4 l indicator lights 3 1 infinity key 3 1 Input wiring 2 4 DIP Switch 4 1 ranges 4 5 RTD 4 4 thermocouple 2 4 type 4 3 Integral 4 6 J K Keys 3 1 L ladder wiring diagram 2 9 Latching 4 4 5 4 Lock Parameter 4 3 low voltage wiring 2 3 Lower Display 3 1 M manual operation 5 3 manual tuning 5 2 mechanical relay 5 Amp Output 1 Wiring 2 6 Output 2 Wiring 2 8 Model Number A 13 mounting collar 2 2 mounting case 2 2 N Noise eliminating A 2 sources A 1 decreasing sensitivity A 1 O Operation Menu 4 6 4 7 Operation Parameters 4 6 Output 1 4 4 Output 2 4 4 Output Wiring 5A Mechanical Relay 2 6 2 8 4 20mA 2 7 switched dc 2 7 2 8 solid state relay 2 6 2 8 overview of the Series 93 1 1 P Percent Power Indicator Light 3 1 Power Limiting 4 5 power wiring 2 3 process alarm 5 4 process input 2 5 Proportional Band 4 6 Q Quick Reference Sheet A 17 A 18 R Ramping 4 4 Range High 4 4 Range Low 4 3 Rate 4 6 removing controller 2 2 Reset 4 6 restoring calibration A 4 returns back cover RTD Calibration A 5 RTD Sensor Wiring 2 4 S sensor installation 2 4 Set Point 4 6 Setup Menu 4 1 4 2 Setup Parameters 4 3 Silencing 4 4 Specifications A 12 T thermocouple calibration A 5 thermocouple sensor wiring 2 4 tuning 5 1 5 3 U Z OUp arrow key 3 1 Upper Display 3 1
37. ce 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 junc tion and the leadwire connection to the instrument cold junction thermocouple break protection The ability of a control to detect a break in the thermocouple circuit and take a predetermined action three mode control Proportioning control with integral reset and derivative rate Also see PID time proportioning control A method of controlling power by varying the on off duty cycle of an output This variance is proportional to the difference between the set point and the actual process temperature triac A solid state device that switches alternating cur rent Z 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 2s TD rT 2 oa lt Watlow Series 93 Appendix A 11 Specifications Specifications 1639 Control Mode e Microprocessor based user selectable control modes e Single input dual output e 2 5Hz Input Sampling Rate e 1Hz Display Update Rate Ramp to set point O to 9999 degrees or units per hour e Heat and cool autotune Operator Interface Sealed membrane front panel
38. ce key At the 255 prompt set the decade resistance box to 255 42 Allow at least 10 seconds to stabilize Press the Infinity key twice to exit the manual mode The controller will leave the _ CAL mode if one minute passes between key activations To condude the RTD calibration press the Infinity key twice then press the Advance key to reach the next prompt or to exit fromthe _ AL menu 2s TD T o oa lt Watlow Series 93 Appendix A 5 0 5 Volt Input Field Calibration Procedure Equipment Required e Precision dc voltage source 0 5 volt minimum range with 0 001 volt resolution Setup and Calibration 1 Connect the ac line voltage L 1 and L2 to the proper terminals on the Series 93 2 Connect the voltage current source to Terminal 3 and 5 on the Series 93 terminal strip Use regular 20 24 gauge wire Make sure the DIP switch is set for process input NOTE see Chapter Four Before calibrating an 3 Apply power to the controller and allow it to warm up for 15 minutes After warm up installed controller put the controller in the AL menu See Figure A 3 Select YES Press the make sure all data Advance key until 0 00 is displayed and parameters are 4 Press the OI nfinity key twice to enter the manual mode The controller is calibrating documented See the Setup and when the indicator light is on Make sure the controller is in the manual mode only Operon Tables in when you are in the correc
39. collar must line up with the mounting ridges on the case for secure installation See Figure 2 2a Slide the collar firmly against the back of the panel getting it as tight as possible Toensurea tight seal use your thumb to lock the tabs into place while press ing the case from side to side Don t be afraid to apply enough pressure to install the controller The tabs on each side of the collar have teeth which latch into the ridges See Figure 2 2b Each tooth is staggered at a different height so only one of the tabs on each side are ever locked into the ridges at any time Confirm that the tabs on one side of the collar correspond with those on the opposite side Make sure the two corresponding tabs are the only ones locked in the ridges at the same time If the corresponding tabs are not supporting the case at the same time and the space between the panel and the case bezel is greater than 019 inch you will will not have a IP65 NEMA 4X seal This applies to units with models designated 93B However all units should be mounted in this fashion to guarantee integrity of the mounting system IP65 NEMA 4X Seal Example Make sure that the two corresponding tabs are locked in the ridges at the same time 4 Insert the controller chassis into its case and press the bezel to seat it Make sure the inside gasket is also seated properly and not twisted The hardware installation is complete Proceed to the wiring section from here
40. crease or increase until the upper display sta bilizes again near the set point 4 Cycle Time Adjustment Set as required Faster cycle times sometimes achieve the best system control However if a mechanical contac tor or solenoid is switching power to the load a longer cycle time may be de sirable 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 5 Rate Derivative Adjustment ncrease _ rA _ dgEjto1 00 minute Then raise the set point by 11 to 17 C or 20 to 30 F Observe the system s approach to the set point If the load temperature overshoots the set point in crease l__rA __dEJto2 00 minutes Raise the set point by 11 to 17 C or 20 to 30 F and watch the approach to the new set point If you increase A __ dE too much the approach to the set point is very sluggish Repeat as necessary until the system rises tothe 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 temperature other than the value coming from the input sensor If so measure the difference between that temperature perhaps at another point in the system and the process value showing in the upper display Then enter the calibration offset value you want Calibration offset adds or sub tract
41. dSP normal AGE Set Point lower only Process upper only Watlow Series 93 Setup 4 5 NOTE The upper display will always return to the process value after 1 minute with out key strokes NOTE Shaded parameters may not appear depending on the controller s configu ration and model number oO O 0 UN AE TD QUAN Ai in MIMD mm im Fr rr ir AE Operation Menu Operation Menu 93 Control Set Point Pb 1 Proportional Band 1 rE 3 Reset 1 IE 1 Integral 1 cA Rate 1 dE l Derivative 1 CE 1 Cycle Time 1 AL 8 Alarm Low AH 1 Alarm High P62 Proportional Band 2 r Eg Reset 2 IE 2 Integral 2 r A Rate 2 dE 2 Derivative 2 CE 2 Cycle Time 2 CAL Calibration Offset AUE Autotune Parameter may not always appear Operation Parameters Set Point Sets the operating set point for Output 1 Represents the process value the system tries to achieve for Output 1 SP does not appear on the lower display The control set point value is displayed and can be incremented or decremented without pressing the Advance key The lower display may be blank if is set to _ Pro Ina ramping mode the lower display alternately flashes the desired end set point and eP Proportional Band 1 and 2 A proportional band expressed in degrees or of span within which a
42. e Infinity key once as soon as the process temperature is inside the _ HSA parameter alarm limit Ifthe alarm is non latching The alarm clears itself automatically as soon as the process temperature is inside the _ 5A parameter Press once to cleara latched and corrected alarm Flashing or in the lower display indicates an alarm when isset tol Pe A or _dEA Thelower display alternately shows information from the current parameter and the 160 jor alarm message at one second intervals The alarm output is de energized and the Output 2 indicator light is lit Alarm Silencingis available with the deviation alarm and has two uses When is set to on the operator must manually disable the alarm by pressing the Infinity key once on initial power up in either the latching or non latching mode Alarm silencing dis ables the alarm output relay However the Output 2 indicator light also the lower display when _ GE 2 is set to _ dE A shows an alarm condition until the process value is within the safe region of the deviation alarm band Once the process value crosses into the safe region both a latching or a non latching alarmis ready Any future deviation outside this safe band triggers an alarm Latching Both process and deviation alarms can be latching or non latching When the alarm condition is removed a non latch ing alarm automatically clears the alarm output You must manually clear a l
43. er Setting the Input Type DIP Switch The Series 93 input type can be user selectable at any time via a Dual In line Package DIP switch inside the control located on the left viewed from the bottom To set the DIP switch remove the control chassis from the case Holding each side of the bezel press in firmly on the side grips until the tabs release You may need to rock the bezel back and forth several times to release the chassis The locations of the board and switches appear in Figure 4 1 Refer to the input types below for DIP switch orientation The DIP switch configuration must match the sensor selected under the parameter in the Setup Menu Controller Chassis Bottom View Thermocouple RTD Process gt A S O 1 2 Oo 1 2 A lo lad st Input Types Watlow Series 93 Setup 4 1 Entering the Setup Menu Figure 4 2a Entering the Setup Menu Figure 4 2b The Setup Menu NOTE While in the Setup Menu all outputs are off The Operation Menu will appear as the default menu of the Series 93 The Setup Menu displays the parameters that configure the Series 93 s features to your application Enter the Setup Menu by pressing the OU p arrow and Down arrow keys si multaneously for 3 seconds The lower display shows the Lock parame ter and the upper display shows its current level All keys are inactive until you release both keys Y ou can reach the Lock parameter from a
44. es 0 00 minutes 0 00 No Rate Will not appear if is set to 0 Note or dFLlissetto 5 7 Do not enter any values here dEl 0 00 to 9 99 minutes 0 00 No Derivative 0 00 minutes make photocopies instead Won t appear if _Pb tis set to 0 or issetto _ US Cel 0 1 to 999 9 5 0 seconds Won t appear if Pb 1 0 or _4Y20l Pbe Same as Pb 7 _ P amp 2 lower limit 1 0 1 0 01 rEg Same range as _r E I Operation Menu 9 3 Control Set Point lte Same range as _JE 1 CPET Proportional Band 1 cA2 Same range as AT r E I Reset 1 TE 1 Integral 1 L dE e Same range as dE A I Rate 1 dE 1 Derivative 1 Cee Same range as ET CE 1 Cycle Time 1 L ALG ALO Alarm Low Deviation 999 to 0 999 CRH D Alarm High Process Pr to AD Ern oe Bande Will not appear if is setto nolor Con F TE 2 Integral 2 AHI cho Rate 2 g Deviation 0 to 999 999 ios Process Pr CALD to TAL Calibration Offset Will not appear if is set to or Con A Autotune CAL 100 C 180 F 180 Units 0 Parameter may not always appear RUE 0to3 A 1 Appendix Watlow Series 93 Watlow Controls Watlow Controls is a division of Watlow Electric Mfg Co St Louis Missouri a manufacturer of industrial electric heating products since 1922 Watlow begins with a full set of specifications and completes an industrial product that is manu factured totally in house in the U S A Watlow products include electric heaters sensors controls a
45. ight 55mm 2 1 inches Width 55 mm 2 1 inches Depth 120 mm 4 7 inches Bezel Height 55 mm 2 1 inches Width 55 mm 2 1 inches Depth 15mm 0 6 inches Chassis Height 45 mm 1 8 inches Width 45 mm 1 8 inches Depth 105 mm 4 1 inches Agency Approvals UL508 c UL CE IP65 NEMA 4X File 102269 CE 89 336 EEC EN 50082 2 EN 50081 2 73 23 EEC EN61010 1 1 Electromechanical relays warranted for 100 000 closures only Solid state switching devices recommended for applications requiring fast cycle times or extended service life 2 To effect IP65 NEMA 4X rating requires a minimum mounting panel thickness of 1 5 mm 0 06 inch and surface finish not rougher than 0 000812 mm 0 000032 inch 3 Switching inductive loads relay coils etc requires using an RC suppressor 4 Operating environment is 0 to 60 C for live voltage exceeding 240V A 12 Appendix Watlow Series 93 Series 93 Model Number Information Ordering Information 1068 93 1 00 Part Number Microprocessor based 1 16 DIN Single Input Dual Output Two Four Digit Displays IP65 NEMA 4X2 Option A Without IP65 NEMA 4X Rating B With IP65 NEMA 4X Rating CE Option A Without CE B WithCE Output 1 C Switched dc output non isolated D Electromechanical relay Form C 5A without contact suppression F Process 4 20mA dc non isolated K Solid state relay Form A 0 5A without contact suppression
46. k set to in the Setup Menu Advance Key Press to step through the Operations Setup and Calibration Menus In the Auto mode new data is self entering in five seconds Up arrow and Down arrow Keys Increases or decreases the value of the displayed parameter Press lightly to increase or decrease the value by one e Press and hold down to increase or decrease the displayed value at a rapid rate New data will self enter in five seconds or can be entered by pressing the Advance Key e Press both simultaneously for three seconds to enter the Setup Menu The parameter appears e Continue pressing both keys to enter the Calibration Menu Figure 3 1 Series 93 Keys and Displays Output 1 Indicator Light Lit when Output 1 is energized Output 2 Indicator Light Lit when Output 2 is active This output can be configured as a control or alarm output Percent Power Indicator Light e Lit the controller is in Manual operation Press the Infinity key twice to enter Automatic operation e Blinking press the Infinity key to toggle between Auto and Manual Returns to its previous state and stops blinking if the Infinity key is not pressed within five seconds ao ES oa ee m xo lt N y x Infinity Key e Press once to clear any latched alarms It also disables the deviation alarm output if silencing is enabled e Press again within five seconds to change from
47. l operating condi tion and should only be done by a quali High Voltage MIES maintenance 100 to 240 ac nominal 85 to 264 actual 93__ 1__0 00_ _ installation techni cian Power to the case should be dis Low Voltage connected before 12 to 24V ac dc 93__ 1__1 00__ removing or installing the con troller into its case WARNING The case terminals may still carry live voltage when the unit is removed A WARNING Irreversible damage will occur if high voltage is applied to Figure 2 3 Power Wiring the low voltage unit Watlow Series 93 Install and Wire 2 3 AX A Sensor Installation Guidelines WARNING To avoid elec tric shock and damage to We suggest you mount the sensor at a location in your process or system where it reads an average temperature Put the sensor as near as possible to the mate property and equipment use National Electric rial or space you want to control Air flow past this sensor should be moderate Code NEC safety prac The sensor should be thermally insulated from the sensor mounting tices when wiring and connecting this unit to a power source and to electrical sensors or peripheral devices Failure to do so could Input Wiring result in injury or death See Chapter 4 for more information on DIP switch location and orientation Figure 2 4a Thermocouple NOTE Extension wire for thermocouples must be of the same alloy as the thermo Whe
48. low 10 seconds for the controller to stabilize The controller will leave the _ CAL mode if one minute passes between key activations To conclude the thermocouple calibration press the Infinity key twice then press the Advance key to reach the next prompt or to exit from the L CAL menu RTD Field Calibration Procedure Equipment Required NOTE When the indica tor light is on the controller is auto matically calibrating Your sequence is VERY important Always move to the next parameter before changing the calibration equip ment 1KQ precision decade resistance box with 0 019 resolution Setup And Calibration 1 2 Connect the ac line voltage L1 and L2 to the proper terminals Connect the decade resistance box to Terminal 2 3 and 5 on the terminal strip Use regular 20 24 gauge wire of the same length and type Make sure the DIP switch is set for RTD input see Chapter Four Apply power to the controller and allow it to warm up for 15 minutes After warm up put the controller in the _ AL menu See Figure A 3 Select YES Press the Advance key until the 440 prompt is displayed Press the O Infinity key twice to enter the manual mode The controller is calibrating when the indicator light is on Make sure the controller is in manual mode only when you are in the correct parameters At the 440 prompt set the decade resistance box to 44 01 Allow at least 10 seconds to stabilize Press the OS Advan
49. m message displayed sets a process alarm with no alarm message displayed 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 set tings The reference for the deviation alarm is the set point Any change in set point causes a corresponding shift in the deviation alarm sets a deviation alarm with an alarm message displayed sets a deviation alarm with no alarm message displayed Example If your set point is 100 F and a deviation alarm is set at 7 F as the high limit and 5 F as the low limit 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 Latching Both process and deviation alarms can be latching or non latch ing When the alarm condition is removed a non latching alarm automati cally clears the alarm output You must manually clear a latching alarm before it will disappear Flashing _ Gjor H jin the lower display indicates an alarm when is set tol Pr A or dE A The lower display alternately shows information from the current parameter andthe _ Gjor _ H alarm message at one second intervals The alarm output is de energized and the Output 2 indicator light is lit To clear an alarm e First correct the alarm condition then If the alarm is latching Clear it manually press the Infinity key once as soon
50. n an external device couple itself to limit errors with a non isolated cir cuit common is connect 0 ed to the 4 20mA or dc g B output you must use an O EA 5j D n pat 2 o isolated or ungrounded ot 2 thermocouple h lad DIP Switch Orientation Thermocouple Figure 2 4b RTD 2 or 3 Wire 1000 Platinum There could be a 2 F input error for every 1Q of lead length resistance when using a 2 wire RTD That resistance when added to the RTD element resistance will result in erroneous input to the instrument To overcome this problem use a 3 wire RTD sensor which compensates for lead length resistance When extension wire is used for a 3 wire RTD all wires must have the same electrical resistance i e same gauge same length multi stranded or solid same metal O 3 wire RTD Fe AID Jumper w Terminals s3 5 3and5 Y 5 O 1 2 Ab lop DIP Switch Orientation 2 4 Install and Wire Watlow Series 93 NOTE Figure 2 5a 0 5V dc Process Successful installa tion requires four steps Choose the con troller s hardware configuration and ove model number og a Input impedance 10kQ A s O 1 2 au Appendix Volts de XT kd Choose a sensor 5 DIP Switch Orientation Chapter Two and 0 Appendix v Install and wire the controller Chapter a Two NE Figure 2 5b 4 20mA Process Configure the con Input impedance 5Q t
51. nd reset integral and rate derivative Setting the proportional band to zero makes the Series 93 a simple on off controller with switching differential selectable under the parameter Special 93 features include the optional NEMA 4X rating optional CE compliance dual four digit displays in either red or green optional low voltage power supply autotuning for both heat and cool outputs ramp to set point for gradual warm up of your thermal system and automatic manual capability with bumpless transfer Operator friendl y features include automatic LED indicators to aid in monitoring and setup as well as a calibration offset at the front panel The Watlow Series 93 automatically stores all information in a non volatile memory Watlow Series 93 Overview 1 1 Notes Q lt 2 D 1 2 Overview Watlow Series 93 Install and Wire the Series 93 NOTE For rapid mounting use Greenlee 1 16 DIN punch die draw stud part number 5073941 7 NOTE Measurements between panel cutouts are the mini mum recommended Figure 2 1a Series 93 Multiple Panel Cutout Dimensions Figure 2 1b Series 93 Dimensions 93 mm 44 96 mm to 45 47 mm 21in miles e 177t01 79in Panel Cutout Your Panel 53 mm Thickness 2 1 in to 45 47 mm 1 5 to 9 7 mm 1 77 to 1 79 in 0 06 to 0 38 in a 9 65 mm 0 38 in Minimum 20 mm 0 85 in gt 119 mm 4 7 in
52. nd switching devices The Winona operation has been design ing solid state electronic control devices since 1962 and has earned the reputa tion as an excellent supplier to original equipment manufacturers These OEMs depend upon Watlow Controls to provide compatibly engineered controls that 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 How to Reach Us Quality and Mission Statement Watlow Controls will be the world s best supplier of industrial temperature control products services and systems by exceeding our customers employees and shareholders expectations Contact Your Authorized Watlow Distributor is e or Phone 507 454 5300 e Fax 507 452 4507 e For technical support ask for an Applications Engineer e To place an order ask for Customer Service e To discuss a custom option ask for a Series 93 Product Manager Warranty The Watlow Series 93 is warranted to be free of defects in material and work manship 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 sometimes misuse we cannot guarantee against failure Watlow s obligations hereunder at Watlow s option are limited to replacement repair or refund of purchase price and parts which upon
53. ns Complete 200 Set Point O A AS AS GP RE Process Temperature Set Point 100 gt D a e o D 5 In order for the Series 93 to successfully complete the autotune the process must cross 90 of the set point four times within 80 minutes after the autotune has started If this does not happen within the 80 minute time limit the _ Pb remains at 0 and the controller functions in an on off mode Tostart autotuning 1 Press the 9 Advance key until the _ AYE prompt appears in the data display 2 Select a thermal response value using the QUp arrow G Down arrow keys 1 for a slow response 2 for an average response and 3 for a system that responds quickly A thermal response value of 2 satisfactorily tunes most thermal systems 3 Press the O Advance key While the controller is in the tuning mode the lower display alternately displays the normal information and the prompt _ AYE at one second intervals Watlow Series 93 Tuning and Operating 5 1 gt Lo pb gt o Y oO TS 1 E Ev A Lo NOTE Tune heating outputs at a set point above ambient temperature Tune cooling outputs at a set point below ambient temperature 4 When tuning is complete the displays return to their previous state and reverts to 0 The Series 93 installs appropriate PID tuning parameters and saves them in the non volatile memory If a
54. ntegral automatic reset action A 10 Appendix Watlow Series 93 PID Proportional integral derivative A control mode with three functions proportional action dampens the system response integral corrects for droop and deriva tive 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 programmed display data Displayed information that gives the operator the intended process information such as intended set point intended alarm limit etc corresponding to temperature prompt A symbol or message displayed by the con troller that requests input from the user proportional Output effort proportional to the error from set point For example if the proportional band is 20 and the process is 10 below set point the heat propor tioned effort is 50 percent The lower the PB value the higher the gain 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 R rate Anticipatory action that is based on the rate of tem perature change
55. nual is copyrighted by Watlow Winona Inc February 1999 with all rights reserved 1638 How to Use This Manual Watlow Series 93 TC Table of Contents Chapter 1 Overview eerren 1 1 General Description seses 1 1 Chapter 2 Install And Wire The Series 93 2 1 Panel Cuto t sosiaa nanet ea 2 1 Dimension Srni connectar 2 1 Installation Procedure c occinncinininnnnnnonccnoninnnnnnns 2 1 Wiring the Series 93 aseeseen 2 3 Power WI Oui mens ntss 2 3 Sensor Installation Guidelines 0 0 cee 2 4 Iput WITING acicate 2 4 Output DT WITING siirinsesi a dni aa rre 2 6 Output 2 Wiring ieai e 2 8 System Wiring Example sssr 2 9 Chapter 3 How To Use The Keys And Displays 3 1 Keys Displays and Indicator Lights 3 1 Chapter 4 How To Set Up The Series 93 4 1 Setting the Input Type DIP Switch 4 1 Entering Setup Menu ou eects 4 2 Setup Parameters c ceccceseeessseseeteeeeeseeeesesees 4 3 Setup Menu Table oo cceseeseeseteteeeteeeseseeeeteeesees 4 5 Operation Parameters s es 4 6 Operation Menu Table n se 4 7 Chapter 5 How To Tune And Operate 5 1 AUTOTUNINQ ori acc 5 1 Manual TURING ore 5 2 Manual and Automatic Operation 0 0 5 3 USING Ala MS 25m nine 5 4 Error Code Messages sneren 5 5 Error Code ACtions 0 ccceesceeeeeeteteeeteteteteeneeeees 5 6 Appendix A 1 Noise and Ins
56. nywhere Use the 6 Advance key to move through the menus and the QU p arrow and ODown arrow keys to select data Y ou will not see all parameters in this menu depending on the controller s configuration and model number After stepping through the menu it returns to the set point parameter under the Operation Menu If no keys are pressed for approximately 60 seconds the controller returns tothe default display Process over Set Point Setup Menu Lock Input Decimal Celsius Fahrenheit Range Low Range High Output 1 Hysteresis Control Output 2 Hysteresis Alarm Latching Silencing RTD Ramping Rate P Power Limiting d Display EJ a M Fr ry mn 5 x a 5 rr a 5 TD i a Parameter may not always appear 4 2 Setup Watlow Series 93 Setup Parameters NOTE Shaded parameters may not appear depending on the controller s configuration and model number NOTE Set the QC parameter value as the final step in programming the Series 93 controller to prevent locking yourself out of the Operation and Setup Menu during ini tial programming A CAUTION A process input does not have sensor break protection or bumpless transfer A CAUTION Changing sets all parameters to factory defaults Document all set tings before changing this parameter in ra Q M N ra a
57. o calibrate make sure you read through the procedures carefully and have the proper equipment called for in each procedure Make sure the DIP switches are in the proper position for the input type See Chapter Four Entering the Calibration Menu In the Calibration Menu various input signals must be supplied for the con troller to go through its auto calibration The Calibration Menu can only be entered from the Lock parameter in the Setup Menu Press the QUp arrow Down arrow keys simultaneously for 3 seconds 1 second The parameter appears in the lower display with no in the upper display Any inadvertent change in the displayed data when pressing the O p arrow Down arrow keys is ignored Calibration values won t be retained unless you are in the manual mode Press the OU p arrow or Down arrow key to change the upper display to Press GO Advance to enter the calibration se quence Upon entering the calibration menu the upper display window indicates CAL It continues to indicate with the exception of calibration of the 4 20mA output while the operator walks through the entire calibration parameter list While calibrating the 4 20mA output the upper display contains a numeric value to be slewed up or down until the output value is correct The controller uses the lower display to prompt the user as to what the input should be With the parameter select either __ 65 System International and the displayed paramete
58. ock out Manual operation is not per mitted Bumpless transfer is defeated and outputs are disabled on sensor break Input Selects the sensor input type The internal DIP switch must also match the fa parameter See DIP switch orientation and see input type temperature ranges in the following chart Range J H K E a 5 rtd rtd 0 5 420 Default J Decimal Selects the location of the decimal point for all process related data This parameter only appears if the parameter is set to 0 5 or 420 Make sure the internal DIP switch matches the parameter Range 0 0 0 0 00 Default 0 Celsius Fahrenheit Selects the units of temperature measurement for the control This parameter only appears if the parameter s set to a thermocouple or RTD input The default is dependent on the parame ter located in the Calibration Menu Refer tothe Appendix Range dor F If dFfLjissetto 6 N Default If dfblissetto U5 Default Range Low Selects the low limit of the set point Also used to scale the low end of the process input 0 0V dc and 4mA represent Range Low for a process input The process input is linearly scaled between and C eH See the model number and specification in the Appendix for range values or refer to the following table Range Sensor range low to Range High Default Low limit of sensor type for a thermocouple or RTD 500 for a process input Watlow Se
59. oo hot or too cold alarm deviation Warns that a process has exceeded or fallen below a certain range around the set point Alarms can be referenced at a fixed number of degrees plus or minus from set point alarm hysteresis A change in the process variable required to re energize the alarm output alarm silence A feature that disables the alarm relay output anti reset A control feature that inhibits automatic reset action outside the proportional band Also called anti reset windup anti reset windup The feature of a PID temperature controller that prevents the integral automatic reset cir cuit from functioning when the temperature is outside the proportional band This standard feature helps stabi lize a system Also called anti reset automatic prompts Data entry points where a micro processor based controller asks the operator to enter a control value bumpless transfer A smooth transition from auto closed loop to manual open loop operation The con trol output s does not change during the transfer C calibration offset An adjustment to eliminate the differ ence between the indicated value and the actual process value CE A manufacturer s mark that demonstrates compli ance with European Union EU laws governing prod ucts sold in Europe CE compliant Compliant with the essential require ments of European directives pertaining to safety and or electromagnetic compatibility closed loop A control
60. p between set point and actual process tem perature See reset automatic integral control I A form of temperature control The of PID See integral isolation Electrical separation of sensor from high volt age circuitry Allows use of grounded or ungrounded sensing element J K JIS See Joint Industrial Standards 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 junction The point where two dissimilar metal conduc tors join to form a thermocouple junction cold Connection point between thermocouple metals and the electronic instrument See reference junction junction reference The junction in a thermocouple cir cuit held at a stable known temperature cold junction Standard reference temperature is 32 F 0 C L limit or limit control A highly reliable discrete safety device redundant to the primary controller that monitors and limits the temperature of the process or a point in the process When temperature exceeds or falls below the limit set point the limit controller interrupts power through the load circuit A limit control can protect equip ment and people when it is correctly installed with its own power supply power lines switch and sensor manual mode A selectable mode that has no automati
61. por tant for protecting your equipment and performance Be especially careful to read and follow all cautions that apply to your application A bold text WARNING safety alert appears with information that is impor tant for protecting you others and equipment from damage Pay very close attention to all warnings that apply to your application The safety alert symbol an exclamation point in a triangle precedes a general CAUTION or WARNING statement The electrical hazard symbol A 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 con figuration information for each step of the setup to verify that your selections are consistent with your applications If the problem persists after checking the above you can get technical assistance from your local Watlow representa tive or by dialing 507 454 5300 An applications engineer will discuss your application with you Please have the following information available when calling Complete model number e All configuration information e User s Manual e Diagnostic Menu readings Your Feedback Your comments or suggestions on this manual are welcome please send them to Technical Writer Watlow Controls 1241 Bundy Blvd P O Box 5580 Winona MN 55987 5580 Phone 507 454 5300 F ax 507 452 4507 The Series 93 User s Ma
62. r conditions are met the Series 93 switches to manual operation at the last automatic power level The bumpless transfer conditions are the process has stabilized within a 5 power level for at least two minutes prior to sensor break provided the power level is less than 75 e If 1 00 is set to 3 or 4 the Series 93 switches into manual operation at 0 power outputs disabled When transferring from auto to manual operation the controller output s remains stable bumpless smooth transition When transferring from manual to automatic operation the controller output s may change significantly In manual operation the output value appears in the lower display in automatic operation the set point appears gt D a e o D 5 Watlow Series 93 Tuning and Operating 5 3 gt Lo o o Y oO TS 1 E Ev A Lo Using Alarms NOTE When the alarm output is de energized the N O contact is open in the alarm condition The N C contact is closed in the alarm condition Figure 5 4 Clearing an Alarm The Series 93 has two alarm types process and deviation A process alarm sets an absolute temperature When the process exceeds that absolute temperature limit an alarm occurs The process alarm set points may be independently set high and low Under the Setup Menu select the type of alarm output with the parameter sets a process alarm with an alar
63. ration it is not meant to clear values Calibration Menu Calibration Menu 3 a ue rn CA O co co Input 0 00mV for low input Input 50 00mV for high input Connect a Type J ambient compensator with inputs shorted Set the low resistance to 44 019 Set the high resitance to 255 420 Set the voltage source to 0 000 volts Set the voltage source to 5 000 volts Set the current source to 4 00mA 8 O r na lt lt CI PU UN UN O co co un CI O E co co Nu O C3 Set the current source to 20 00mA L D co Enter 4 20mA output calibration value for 4mA AY D C3 Enter 4 20mA output calibration value for 20mA a UN tr Figure A 4 Resi ores factory calibration values Test display Calibration Select SI integral derivative proportional band in of span C Parameters or US rate reset proportional band in degrees or units F a un Ay a W m Before attempting to calibrate make sure you have the proper equipment called for in each procedure The Series 93 is calibrated and tested before leaving the factory A 4 Appendix Watlow Series 93 Thermocouple Field Calibration Procedure Equipment Required NOTE Before calibrating an installed controller make sure all data and parameters are documented See the Setup and Operation Tables in Chapter Four Type J
64. resent is in its alarm state indicator light lit The upper display reads The lower display indicates the error code if the Infinity key is pressed e To clear a corrected error e Press the Advance key or turn the controller off and on Er Y and _ 5 jresult in these conditions e The controller is in automatic operation with both outputs off e The alarm output if present are in their alarm state de energized with the indicator lit The upper display indicates the process value The lower display indicates the error code All keys are inactive All Setup Menu parameters return to default values The above conditions occur regardless of the value of _ OC or the presence of the Setup or Calibration Menus e To clear a corrected error e Turn the controller off and on gt Lo o gt o Y oO TS 1 E Ev A Lo 5 6 Tuning and Operating Watlow Series 93 A Appendix Noise and Installation Guidelines For wiring guidelines refer tothelEEE Standard No 518 1982 available from IEEE Inc 345 East 47th Street New York NY 10017 Noise Sources Switches and relay contacts operating inductive loads such as motors coils solenoids and relays etc Thyristors or other semiconductor devices which are not zero crossover fired randoml y fired or phase angle fired devices All welding machinery and heavy current carrying conductors Fluorescent and neon
65. resistive load 5A 30V dc 3 Minimum contact current 100mA 5V dc e Switched dc signal provides a non isolated minimum turn on volt age of 3V dc into a minimum 500 load maximum on voltage not greater than 12V dc into an infinite load 4 20mA reverse or direct acting non isolated 0 to 8004 load Solid state relay3 Form A 0 5A 24V ac min 264V ac max opto isolated burst fire switched without contact suppres sion Off state output impedance is 31MQ Output 2 Heat Cool or Alarm e Electromechanical relay Form C 5A 120 240V ac maxi mum without contact suppression rated resistive load 5A 30V dc 3 Minimum contact current 100mA 5V dc e Switched dc signal provides a non isolated minimum turn on volt age of 3V dc into a minimum 500 load maximum on voltage not greater than 12V dc into an infinite load Solid state relay3 Form A 0 5A 24V ac min 264V ac max opto isolated burst fire switched without contact suppres sion Off state output impedance is 31MQ Alarm output can be latching or non latching and process or devi ation with separate high and low values Alarm silencing inhibit on power up for deviation alarms only Output Configurations Output 1 User selectable as on off P PI PD PID heat or cool action e Adjustable switching differential 1 to 55 C 1 to 99 F e Proportional band 0 off or O to 555 C 1 to 999 F or 0 0 to 999
66. ression Wiring 2 8b Switched DC Output 2 Wiring oo eeeeeteteteteteteteeeeees 2 8 System Wiring Example sesser 2 9 Wiring Note Sci nent iaa 2 10 Series 93 Keys and Displays n se 3 1 DIP Switch Location and Orientation oo ee 41a Input DIP SWitCheS vico 4 1b Entering the Setup Menu seeren 4 2a The Setup Menu oe eecccsseesseteeseseetetsesnetetstetenetetenens 4 2b The Operation Menu cecceeeeeeeeteeseseetetetseeteteteeetens 4 6 Autotuning at a 200 F Set Point seei 5 1 Clearing an Alarm oo ceceecsceseeeteseeteteeeeeseseseeeseseaeeeaenees 5 4 Error Code Message cociciciciciccoconncncnnonananonononananononancncnni 5 5 Entering the Calibration Menu oo cesta A 3 Calibration Menus ar innnenenenensdnenns A4 Tables oconccccncncnononenconnanonenconencanoncnnonesanss Page Input Rangos siei re ia 4 5a Setup Menu Prompts and Descriptions 4 5b Operation Menu Prompts and Descriptions 4 7 Quick Reference Sheet sissies A 17 A 18 Watlow Series 93 Table of Contents Meet the Series 93 Team AL CUSDMER SATISFACTION y We stand behind our product and are committed to your total satisfaction Pictured below are some of the people at Watlow who have worked hard to bring you one of the finest industrial temperature controllers available today Included in the photo are members of the development team and representa tives from our core manufacturing and customer service areas Front Linda Florin
67. ries 93 4 3 Setup 9 SJ X C Un m m Se tr Mm 5 AE V Toa a FE D re Range High Selects the high limit of the operating range Also used to scale the high end of the process input 5 0V dc and 20mA represent Range High for a process input The process input is linearly scaled between __r Jand __rH See the model number and specification information in the Appendix for your range val ues or refer tothe following table Range Sensor range high to Default High limit of sensor type for a thermocouple or RTD 9999 for process input Output 1 Selects the action for the primary output in response to the difference between set point and process variable Select heat for reverse acting or select cool for direct acting Range REC CU Default Hysteresis Control Selects the switching hysteresis for Output 1 and 2 when you select O on off under the parameter and issetto Con Range 1 to 55 0 1 to 5 5 0 01 to 0 55 C 1 to 99 0 1 to 9 9 0 01 to 0 99 F Default 2 0 2 0 02 C 3 0 3 0 03 F Output 2 Selects the output action for the secondary output Range on Control mode opposite Output 1 heat or cool Process alarm with alarm message displayed Process alarm with no alarm message displayed _dEA Deviation alarm with alarm message displayed C dE Deviation alarm with no alarm message displayed no None Default Hysteresis Alarm Selects the switching hysteresis
68. roller Chapters Three Four and Five A WARNING To avoid lis damage to property and equipment and or injury or loss of life use National Electric Code NEC standard wiring prac Figure 2 5c 4 20mA Process 2 Wire Transmitters tices to install and operate the Series 93 Failure to do so could result in such dam O age and or injury or i death A s O 1 2 400 DIP Switch Orientation NOTE When an external device with a non isolated circuit com mon is connected to the 4 20mA or dc out put you must use an isolated or unground ed thermocouple A CAUTION Process input does not have sensor break protec tion Outputs can remain full on Transmitter Watlow Series 93 Install and Wire 2 5 5j D a pat 2 o NOTE Successful installation requires four steps Choose the controller s hardware configuration and model number Appendix e Choose a sensor Chapter Two and Appendix Install and wire the controller Chapter Two Configure the con troller Chapters Three Four and Five A WARNING To avoid dam age to property and equipment and or injury or loss of life use National Electric Code NEC standard wiring practices to install and operate the Series 93 Failure to do so could result in such damage and or injury or death NOTE Switching inductive loads relay coils solenoids etc with the mechanical relay
69. rs are C integral derivative and proportional band in of span Or select 5 parameters which include displaying F rate reset and proportional band in degrees or units Once the information has been properly established and maintained for at least 5 to 10 seconds the Advance key may then be used to display the next prompt After the final input is established press the Advance key twice to return the controller to the configuration menu at the top of the parameter list Watlow Series 93 Appendix A 3 2s TD rT 2 oa lt Restoring Factory Calibration The parameter restores the factory calibration values to the Series 93 If you calibrate your controller incorrectly you have the option to default to the original values Once you leave the menu the values are entered 1 Press the 0Up arrow 9 Down arrow keys simultaneously for three seconds TheLOC parameter appears in the lower display Continue holding the OU p arrow Down arrow keys until the lower display reads CAL 2 Press the QUp arrow key until appears in the upper display 3 O Advance through the Calibration Menu until appears in the lower display 4 Press the OUp arrow key until appears in the upper display 5 Press the Advance key and the Series 93 advances to test the displays 6 To conclude wait 60 seconds or press the Advance key to reach the next prompt or to exit fromthe CAL menu This procedure is used only to restore calib
70. s caused by a change in the process variable PV that decreases over the time of the derivative TD The TD is in units of seconds Deutsche Industrial Norm DIN A set of technical scientific and dimensional standards developed in Germany Many DIN standards have worldwide recogni tion deviation alarm See alarm deviation DIN See Deutsche Industrial Norm direct action An output control action in which an increase in the process variable causes an increase in the output Cooling applications usually use direct action display capability In an instrument with digital display the entire possible span of a particular parameter or value droop In proportional controllers the difference between set point and actual value after the system sta bilizes 2s TD rT e lt duty cycle The percentage of a cycle time in which the output is on Watlow Series 93 Appendix A 9 F G Form A A single pole single throw relay that uses only the normally open NO and common contacts These contacts close when the relay coil is energized They open 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 H 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 off set or droo
71. s degrees from the value of the input signal 5 2 Tuning and Operating Watlow Series 93 NOTE A process input does not have sensor break protection or bump less transfer Outputs selected as reverse acting will be full on if a sensor break occurs Manual and Automatic Operation To change from auto to manual operation press the O Infinity key twice Manual operation provides open loop control of the outputs from a range of 100 full cooling to 100 full heating power The Series 93 allows a negative output value only when is set to _ Con Automatic operation provides closed loop on off or PID control When the operator transfers from a closed loop to an open loop the Series 93 retains the power level from the closed loop control referred to as bumpless transfer When the Series 93 returns to closed loop con trol it restores the previous set point temperature The percent indicator light indicates auto or manual operation When the percent indicator light is on the control is in manual operation and displays the percent power value in the lower display When the percent indicator light is off it is in automatic operation Press the O Infinity key to flash the percent indicator light Press the O Infinity key again to complete the manual automatic change When a sensor opens the Series 93 switches from automatic to manual operation if OO issetto0 lor 2 If L C is set to 0 1 or 2 and the bumpless transfe
72. s to change from Auto to Manual or vice versa While in Manual mode percent power is in the lower display Press both keys simultaneously for three seconds to enter the Setup Menu The _L OC parameter appears Continue pressing both keys to enter the Calibration Menu Alarms A process alarm sets an absolute temperature When the process exceeds that absolute temperature limit an alarm occurs The process alarm set points may be independently set high and low Under the Setup Menu select the type of alarm output with the parameter sets a process alarm with alarm mes sage displayed sets a process alarm with no alarm mes sage displayed A deviation alarm alerts the operator when the process strays too far from the set point The operator can enter independent high and low alarm settings The reference for the deviation alarm is the set point Any change in set point causes a corresponding shift in the deviation alarm sets a deviation alarm with alarm message displayed sets a deviation alarm with no alarm message displayed Example If your set point is 100 F and a deviation alarm is set to 7 F as the high limit and 5 F as the low limit 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 To clear an alarm e First correct the alarm condition then Ifthe alarm is latching Clear it manually press th
73. sjor 5 1 O0 to 9 99 minutes Default 0 0 Cycle Time 1 and 2 Time for a controller to complete one time proportioned cycle for Output 1 or Output 2 expressed in seconds _ 1 Will not appear if Pb 7 is set to O or Output 1 is 4 20mA CE 2 Will not appear if is set to O or is not set to Con 4 6 Setup Watlow Series 93 If a mechanical relay or contactor is switching power to the load a longer cycle time may be desirable to minimize wear on the mechanical compo nents Typical life of a mechanical relay is 100 000 cycles Range 0 1 to 999 9 seconds Default 5 0 seconds Alarm Low Represents the low process alarm or low deviation alarm This para meter will not appear if Gt 2J is set tonoor Con Range if Jtejissetto dem or gE 999to0 Default 999 Rangeif Gt ejissettol Pr Ajor _ Pre rijtol_AH I Default Alarm High Represents the high process alarm or high deviation alarm This parameter will not appear if Gt Jissetto nojor Con Range if Otejissetto dem or dgEj Oto999 Default 999 Range if Gte issetto PrAjor Pr ALG Jtol H Default H Calibration Offset Adds or subtracts degrees from the input signal Range 100 C to 100 C 180 F to 180 F 180 units to 180 units or 10 0 C to 10 0 C 18 0 F to 18 0 F Default 0 Autotune Initiates an autotune Range 0 is set to off 1 is set to slow 2 is set to medium 3 is set to fast E
74. ssume no electrostatic shielding when using the shield as a signal return If you must do this use triaxial cable electrostatically shielded coaxial cable a TD te T oa 2 lt Watlow Series 93 Appendix A 1 e Usetwisted pair wire any time controller circuit signals must travel more than two feet or when you bundle them in parallel with other wires e Select the size or gauge of wire by calculating the maximum circuit current and choosing the gauge meeting that requirement Using greatly larger wire sizes than required generally increases the likelihood of electrostatic capacitance coupling of noise e Eliminate ground loops in the entire controller system Y ou can spot the obvious loops by studying the as built wiring diagram There are also not so obvious ground loops resulting from connecting internal circuit com mons in the manufacturer s equipment Donot daisy chain ac power or return lines or output signal or return lines to multiple controller circuits Use a direct line from the power source to each input requiring ac power Avoid paralleling L1 power lead and L2 return lead to load power solenoids contactors and controller circuits If an application uses L 1 power lead to switch a load L2 return lead has the same switched signal and could couple unwanted noise into a con troller circuit e Tieall ground terminals together with one lead usually green wire tied to ground at one poin
75. switched dc or solid state relay output options requires use of 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 Output 1 Wiring Figure 2 6a Mechanical Relay Without Contact Suppression 93 1D 00 _ 100mA 5V dc Form C 5A Minimum load cur O O rent ES oe g rr 8 NC Fuse ES 9 COM A Li 10 NO Customer supplied Quencharc Figure 2 6b Solid state Relay Without Contact Suppression 93 1K__ 00__ 0 5A ac loads only al OS pal Customer supplied Quencharc L2 External Load Fuse L1 2 6 Install and Wire Watlow Series 93 NOTE Successful installa tion requires four steps Choose the con troller s hardware configuration and model number Appendix Choose a sensor Chapter Two and Appendix Install and wire the controller Chapter Two e Configure the controller Chapters Three Four and Five NOTE When an external device with a non isolated circuit com mon is connected to the 4 20mA or dc output you must use an isolated or un grounded thermo couple Figure 2 7a Switched DC 93 1C_ 00 _ unregulated l et i i g g External Li Figure 2 7b 4 20mA Process 93 1F__ 00__ Maximum load impedance 8000 re 0 EN o S S uN
76. system that uses a sensor to measure a process variable and makes decisions based on that input cold junction See junction cold cold junction compensation Electronic means to compensate for the effective temperature at the cold junction compensation ambient The ability of an instrument to adjust for changes in the temperature of the environ ment and correct the readings Sensors are most accu rate when maintained at a constant ambient tempera ture When temperature changes output drifts control action The response of the control output rela tive to the error between the process variable and the set point For reverse action usually heating as the process decreases below the set point the output increases For direct action usually cooling as the process increases above the set point the output increases cycle time The time required for a controller to com plete one on off on cycle It is usually expressed in sec onds D E 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 derivative control D The last term in the PID control algorithm Action that anticipates the rate of change of the process and compensates to minimize overshoot and undershoot Derivative control is an instantaneous change of the control output in the same direction as the proportional error This i
77. t Don t connect the ground to the controller case if the controller is in a grounded enclosure preventing ground loops e Donot confuse chassis grounds safety ground with controller circuit com mons or with ac supply L2 return or neutral line Each return system wiring must be separate Absolutely never use chassis ground safety as a conductor to return circuit current Eliminating Noise e Use snubbers QUENCHARC P N 0804 0147 0000 to filter out noise generated by relays relay contacts solenoids motors etc A snubber is a simple filter device using a 0 1uf 600 volt non polarized capacitor in series with a 100Q 1 2 watt resistor The device can be used on ac or dc circuits to effectively dampen noise at its source Refer to output wiring in Chapter Two for proper Quencharc installation e Theultimate protection is an uninterruptable power supply This sens es the ac power line when the line fluctuates a battery powered 60Hz inverted circuit takes over supplying power within one half to one cycle of the acline A 2 Appendix Watlow Series 93 Calibration Figure A 3 Entering the Calibration Menu NOTE Calibration values will not be retained unless you are in the MANUAL mode Do not enter the MAN UAL mode until you are at the correct input parameters NOTE While in the Calibra tion Menu the con troller output s go off and the alarm output if present is on Before attempting t
78. t parameters Chapter Four 5 At the 0 00 parameter set the voltage source to 0 000 volts Allow at least 10 seconds to stabilize Press the O Advance key 6 At the 5 00 parameter set the voltage source to 5 000V dc Allow at least 10 seconds to stabilize The controller leaves the _ AL mode if 1 minute passes between key acti vations Press the O Infinity key twice to exit the manual mode To conclude the 0 5 volt calibration press the Infinity key twice then press the Advance key to reach the next prompt or to exit from the CAL menu 4 20mA Input Field Calibration Procedure Equipment Required e Precision current source 0 20mA minimum range with 0 01mA resolution Setup and Calibration 1 Connect the ac line voltage L1 and L2 to the proper terminals on the Series 93 2 Connect the current source to Terminal 2 and 5 on the Series 93 terminal strip tor light is on the Use regular 20 24 gauge wire Make surethe DIP switch is set for process input see controller is auto Chapter Four matically calibrating 3 Apply power to the controller and allow it to warm up for 15 minutes After warm up NOTE When the indica Your sequence is put the controller in the _ AL menu See Figure A 3 Select YES Press the VERY important Advance key until 4is displayed Always move to the 4 Press the Infinity key twice to enter the manual mode The controller is calibrating next parameter when the indicator light
79. tallation Guidelines ono Al Noise Sources ceca A 1 Decreasing Noise Sensitivity ceeeeeeeeteees A 1 Eliminating Noise 00 0 eeeseseeseeseteereseseneeeteneeeees A 2 Entering the Calibration Menu oo A 3 Restoring Factory Calibration ooo A4 Calibration Menu o cccceeceeeteteteteteteteteteteteteteteeees A4 Calibration Procedures c cecceetetetetetetetetetetetee A5 TO Specifications Model Number Information ssssscsccscceceece A 13 IA hay annee AAR Ent re A 14 Declaration of Conformity A 15 Quick Reference nur A 17 Figures and Tables Figure iio di ge enced dunes Page Series 93 Input and Output Overview oo eee 1 1 Series 93 Multiple Panel Cutout Dimensions s s s 2 1a Series 93 Dimensions c oociccinnccinnnnnncncnnncncnananananananinos 2 1b Mounting Case Side View oooococicinicciciococcnincocannnos 2 2a Mounting Collariin 2 2b Case Rear View and IP65 NEMA 4X Seal Example 2 2c Power Wii an end 2 3 Thermocouple Sensor Input Wiring teen 2 4a 2 or 3 wire RTD Sensor Input Wiring nesses 2 4b 0 5V dc Process Sensor Input Wiring 2 5a 4 20mA Process Sensor Input Wiring Output 1 Mechanical Relay Wiring 2 68 Output 1 Solid state Relay w o Suppression Wiring 2 6b Switched DC Output 1 Wiring occcicnnnnnnnnnnnnccncannn 2 7a 4 20MA Process Wiring oo eeesesseeeseeeeeeeseeteeeeseeeees 2 7b Output 2 Mechanical Relay Wiring essees 2 8a Output 2 Solid state Relay w o Supp
80. ty prac tices when wiring and connecting this unit to a power source and to elec trical sensors or peripher al devices Failure to do so could result in injury or death A WARNING Install high or low temperature limit control protection in sys tems where an over tem perature fault condition could present a fire haz ard or other hazard Failure to install temper ature limit control protec tion where a potential hazard exists could result in damage to equipment property and injury to per sonnel WARNING All wiring and fusing must conform to the National Electric Code NFPA70 Contact your local board for additional information Failure to observe NEC safety guidelines could result in injury to personnel or damage to property 5j D a pat 2 o Figure 2 10 Wiring Notes 2 10 Install and Wire Watlow Series 93 How to Use the Key and Displays After 60 seconds with no key presses the controller reverts to the default display the process value in the upper display and the set point in the lower display Upper Display Indicates the process value actual temperature operating parameter values or an open sensor When powering up the Process display will be blank for five seconds e To set to blank set Lower Display Indicates to in the Setup the set point output value Menu parameters for data in the upper display or error and alarm codes e To set to blan
81. vert an analog to digital signal Make sure the parameter Setup Menu matches your sensor and the DIP switches are set accordingly gt D a e o D 5 Watlow Series 93 Tuning and Operating 5 5 Error Code Actions e E r C Erb Er result in these conditions e If LOC Lock is set to 0 Lor 2 and the controller was in automatic operation when the error occurred it goes into manual power operation If the output power is less than 75 power and a lt 5 change in power occurred within the last two minutes the Series 93 switches into manual operation at the last automatic power level bumpless transfer If the controller was in manual operation it remains there Press the Infinity key twice to see the error code The alarm output if present is in its alarm state indicator lit The upper display reads The lower display indicates the error code if the Infinity Key is pressed twice If the controller was operating with stable output values when the error oc curred it continues to operate at those levels on a power basis If output values were not stable the control outputs go to 0 power off If _ QC Lock is set to 3 or 4 The controller remains in automatic operation and the outputs turn off The lnfinity and 6 Advance keys are inactive The QU p arrow Down arrow keys may be pressed si multaneously to enter the Setup Menu The alarm out put if p
82. warranty back cover wiring 2 3 wiring example 2 9 A 14 Appendix Watlow Series 93 Declaration of Conformity CE 97 Series 93 WATLOW CONTROLS 1241 Bundy Boulevard Winona Minnesota 55987 USA Declares that the following product Designation Series 93 Model Number s 93 A or B A or B 1 C D F or K AC Dork 0 or 1 Any four letters or numbers Control Installation Category Il Polution Degree Il Rated Voltage 100 to 240V or 24 Rated Frequency 50 60 Hz Rated Power Consumption 6VA maximum Meets the essential requirements of the following European Union Directive s using the relevant section s of the normalized standards and related documents shown 89 336 EEC Electromagnetic Compatibility Directive EN 50082 2 1995 EMC Generic immunity standard Part 2 Industrial environment EN 61000 3 2 1995 Limits for harmonic current EN 61000 3 3 1995 Limitations of voltage fluctuatuions and flicker EN 61000 4 2 1995 Electrostatic discharge EN 61000 4 4 1995 Electrical fast transients EN 61000 4 3 1996 Radiated immunity EN 61000 4 6 1996 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 Group 1 Class A EN 61000 3 2 1995 Limits for harmonic current emissions EN 61000 3

Watlow Electric 93 User's Manual

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