Watlow 97 series User Manual Download Page 1

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WO97-XUMN Rev A

Made in the U.S.A.

July 1997

$15.00

User’s Manual

User Levels:

• New User ....................................................... go to page 1.1
• Experienced User .......................................... go to page 2.1
• Expert User .................................................... go to page 2.1

Installers:

• Installation ...................................................... go to page 2.1
• Wiring .............................................................go to page 3.1

Watlow Controls

1241 Bundy Blvd., P.O. Box 5580, Winona, Minnesota USA 55987-5580, Phone: (507) 454-5300, Fax: (507) 452-4507

Registered Company

Winona, Minnesota USA

ISO 9001

Series 97

Summary of Contents for 97 series

Page 1: ...1 1 Experienced User go to page 2 1 Expert User go to page 2 1 Installers Installation go to page 2 1 Wiring go to page 3 1 Watlow Controls 1241 Bundy Blvd P O Box 5580 Winona Minnesota USA 55987 5580...

Page 2: ...the Trouble shooting Table in the Appendix and review all of your configuration informa tion to verify that your selections are consistent with your application inputs outputs alarms limits etc If th...

Page 3: ...ures and Tables Inputs and outputs 1 1 Multiple panel cutout dimensions 2 1 Installing the controller 2 2a Gap dimensions 2 2b Removing the controller 2 3 Isolation blocks 3 2 Power wiring 3 3 Wiring...

Page 4: ...ave worked hard to bring you one of the finest industrial temperature controllers available today Included in the photo are members of the development team production team and representatives from our...

Page 5: ...to thermal applications to limit over temperature conditions The Series 97 controller provides safety assurance against instances where a high temperature runaway condition could occur from a shorted...

Page 6: ...our explains the keys displays and software navigation Chapter Five explains features such as alarms and control methods Chapter Six lists parameter descriptions ranges Modbus numbers and other inform...

Page 7: ...mounting use Greenlee punch number 60020 and die number 60021 or hand hydraulic unit kit number 7306 all available from Grainger Panel Cutout Panel Thickness 0 06 to 0 38 1 5 to 9 7 mm 1 77 to 1 79 4...

Page 8: ...ar and slide it over the controller making certain that one cantilever is pointing up and one is pointing down also With one hand holding the con troller and the other hand using a 2 Phillips screw dr...

Page 9: ...ntil the end of the screw is flush or past the end of the can tilevers see the figure below 2 After the screws have been loosened hold the controller with one hand while squeezing the two screws toget...

Page 10: ...Notes 2 4 Installation Watlow Series 97...

Page 11: ...Installation Guidelines 3 3 Wiring Example 3 4 Wiring Notes 3 5 Input 1 3 6 Input 2 3 6 Output 1 Limit Output Wiring 3 7 Output 2 Alarm Output Wiring 3 8 Output 3 Alarm Wiring 3 9 Output 4 3 10 EIA Co...

Page 12: ...ted for the model number on the controller and described in this manual indicating a customized hardware setup Input to output Isolation The Series 97 uses optical and transformer isolation between th...

Page 13: ...wire RTD A three wire RTD sensor overcomes this problem All three wires must have the same electrical resistance i e same gauge same length multi stranded or solid same metal 10 8 1 2 3 4 5 6 7 13 14...

Page 14: ...temperature light coil 9 Heater DIN a mite DA1C 1624 C000 L2 L1 T1 T2 10 8 1 2 3 4 5 6 7 13 14 15 11 12 16 17 18 19 20 21 9 10 8 1 2 3 4 5 6 7 13 14 15 11 12 16 17 18 19 20 21 9 1 3 14 15 17 9 16 WARN...

Page 15: ...ng example in this chapter Figure 3 5 Wiring notes L1 L2 power 9 8 WARNING To avoid damage to property and equipment and or injury of loss of life use National Electric Code NEC standard wiring practi...

Page 16: ...20 21 9 6 7 NOTE Successful installation requires five steps Choose the controller s hardware configuration and model number Appendix Choose a sensor Chapters 3 and 6 and Appendix Install the control...

Page 17: ...sensor Chapters 3 and 6 and Appendix Install the controller Chapter 2 Wire the controller Chapter 3 and Configure the controller Chapters 4 5 and 6 WARNING To avoid damage to property and equipment an...

Page 18: ...ternal Load COM N C L2 L1 16 17 18 18 used for D outputs only N O customer supplied Quencharc NOTE Successful installation requires five steps Choose the controller s hardware configuration and model...

Page 19: ...and 6 and Appendix Install the controller Chapter 2 Wire the controller Chapter 3 and Configure the controller Chapters 4 5 and 6 NOTE Switching inductive loads relay coils solenoids etc with the mech...

Page 20: ...2 L1 19 20 21 N O customer supplied Quencharc NOTE Successful installation requires five steps Choose the controller s hardware configuration and model number Appendix Choose a sensor Chapters 3 and 6...

Page 21: ...esult in such damage and or injury or death Figure 3 11a EIA 232 to EIA 485 Conversion B B Converter B B Electronics Manufacturing Company 815 433 5100 CMC Converter CMC Connecticut Micro Computer Inc...

Page 22: ...3 12 Wiring Watlow Series 97 Notes...

Page 23: ...Chapter Four Navigation and Software Keys and Displays 4 2 Navigation 4 3 Software Map 4 4 Task Charts 4 6 Watlow Series 97 Navigation 4 1 4...

Page 24: ...hanges the upper display to a lower value or down through a list of values Moves from menu to menu in a page Up Key Changes the upper display to a higher value or up through a list of values Moves fro...

Page 25: ...alues in the upper To go backward through the parameter list press and together Press or to select a value either alpha or numeric Press to set the value and go to the next parameter 2 3 4 LIMIT 97 1...

Page 26: ...w A2hi Alarm 2 High A3Lo Alarm 3 Low A3hi Alarm 3 High A4Lo Alarm 4 Low A4hi Alarm 4 High Mon Monitor Menu OPEr ALM Alarm Menu OPEr 97 Process Value safe Home Page Limit Status 97 Process Value Safe L...

Page 27: ...age Ldsp Lower Display Lo S Lower Display User Safe Message Lo L Lower Display User Limit Message SEt Setup Page C F C or F Err Input Error Latching InP2 Input 2 Menu SEt Out1 Output 1 Menu SEt Out2 O...

Page 28: ...e chosen value is displayed 5 Set a value and go on to the next parameter E In In 2 Values appear in the upper display when the parameter is in the lower display Up arrow key until you reach the desir...

Page 29: ...Sensor Selection 5 5 Range Low and Range High 5 5 Event Input 5 6 Retransmitting the process value 5 7 Alarms Alarm Set Points 5 8 Alarm Hysteresis 5 8 Process or Deviation Alarms 5 9 Alarm Latching...

Page 30: ...away condition could occur from a shorted input sensor or an output device that could fail in a closed position A limit condition is latched and therefore requires operator intervention to clear it Th...

Page 31: ...ve offset increases the input value and a negative offset decreases the input value The input 1 offset value can be viewed or changed with Calibration Offset 1 CAL1 Limit Menu Figure 5 3 Calibration o...

Page 32: ...ltering the displayed value makes it easier to monitor View or change the input 1 time filter with Filter Time Constant 1 Ftr1 Input 1 Menu A positive value affects only the viewed values A negative v...

Page 33: ...controller constrains the set point to a value between range high and range low Range high cannot be set higher than the sensor high limit or lower than range low Range low cannot be set lower than t...

Page 34: ...nonE Events will not affect the system Lrst Clear Limit LOC Lock out key board ALr Clear an alarm Use Event Condition E cn Input 2 Menu to select what condition will trigger an event Lo Low generates...

Page 35: ..._ M _ _ _ _ The temperature of the limit process value is being recorded on a chart recorder The oven temperature range stays between 600 to 900 F The chart recorder requires a 4 20mA sig nal Set Aout...

Page 36: ...rocess alarm set points for output 2 can be viewed or changed with Alarm 2 High A2hi and Alarm 2 Low A2Lo Alarm Menu Alarm Hysteresis Alarm hysteresis is a zone inside each alarm set point This zone i...

Page 37: ...larm condition has passed Alarm 2 Latching LAt2 Output 2 Menu allows you to view or change whether the out put 2 alarm will latch Figure 5 9 Alarm latching Normal Operating Range Alarm High Set Point...

Page 38: ...an alarm state The process temperature has to enter the normal operating range beyond the hysteresis zone in order to activate the alarm output function Alarm Silencing 2 SiL2 Output 2 Menu allows yo...

Page 39: ...t bit To view or change controller settings with a personal computer you need to run software that uses the Modbus RTU protocol to read or write to registers in the controller These reg isters contain...

Page 40: ...5 12 Features Watlow Series 97 Notes...

Page 41: ...9 Output 2 Menu 6 9 Output 3 Menu 6 11 Output 4 Menu 6 12 Display Menu 6 14 Global Menu 6 16 Factory Page 6 17 Lockout Menu 6 17 Diagnostics Menu 6 17 Input Calibration Menu 6 20 Output Calibration Me...

Page 42: ...C D D C Analog Output Low A lo C D D C Analog Output Offset ACAL C D D C Alarm Hysteresis 2 3 4 hys2 3 4 C D D C Latching 2 3 4 Lat2 3 4 Alarm Silencing 2 3 4 Sil2 3 4 Alarm Active Sides 2 3 4 Sid2 3...

Page 43: ...Lower Display Monitor the processes determined by the Upper Display UdSP and Lower Display LdSp parameters Display Menu Display Parameter Range Default Modbus Conditions for Address Parameters to App...

Page 44: ...Output 2 Output 2 Menu is set to AL and Operations Page Mode Lockout Menu is not set to hide 106 r nonE 0 Lo 1 hi 2 AL 2 Alarm 2 Status Monitor alarm 2 status Active if Operations Page Mode Lockout M...

Page 45: ...set to AL Alarm Alarm Active Sides 2 Output 2 Menu is not set to hi Output 2 is present 97 _ _ _ D _ _ _ _ _ _ or 97 _ _ _ K_ _ _ _ _ _ and Operations Page Mode Lockout Menu is not set to hide 321 r...

Page 46: ...and Operations Page Mode Lockout Menu is not set to hide none Process low limit of selected sensor range Process low limit of selected sensor range to Alarm 4 High 1 A4Lo Alarm 4 Low Sets the low alar...

Page 47: ...ermocouple 0 RTD RTD 1 Sen1 Sensor Type 1 Sets the input hardware type of input 1 Inp1 Input 1 Menu set Setup Page Active if Setup Page Lock Lockout Menu is not set to hide InP1 InP1 Input 1 Inp2 Inpu...

Page 48: ...s the position of the decimal point for input readings Active if Setup Page Lock Lockout Menu is not set to hide 603 r w rh 1 Range High 1 Sets the input range high This setting is the highest value t...

Page 49: ...L fall 3 E cn Event Condition Selects the condition to trigger an event Active if input 2 hardware is present 97 _1 _ _ _ _ _ _ _ _ _ or Input 2 Input 2 Menu is set to E in Event Input and Setup Page...

Page 50: ...Selects which side or sides the alarm setpoints can be programmed for Active if Output 2 Output 2 Menu is set to AL Alarm and Setup Page Lock Lockout Menu is not set to hide 722 r w no no no action 0...

Page 51: ...Output 3 Output 3 Menu is set to AL Alarm and Setup Page Lock Lockout Menu is not set to hide 738 r w no no no action 0 Yes latching enabled 1 Lat3 Latching 3 Enables Alarm 3 Latching Active if Outpu...

Page 52: ...ock Lockout Menu is not set to hide none 3 1 to 9999 hys4 Alarm Hysteresis 4 Sets the switching hysteresis for the alarm output This defines a band on the inside of the alarm set point When the proces...

Page 53: ..._ _ _ _ and Setup Page Lock Lockout Menu is not set to hide none 4 20 4 20 4 20 mA 0 20 0 20 mA 0 5 0 5V dc 1 5 1 5V dc 0 10 0 10V dc Prc4 Process 4 Type Sets process 4 out put type Active if Output...

Page 54: ...r user message 1 L hi high limit set point 3 L Lo low limit set point 2 UdSP Upper Display Selects the value that will appear in the upper display Alarm messages will toggle in the upper display if ou...

Page 55: ...1 backwards C 32 backwards c 33 y 34 0 35 1 36 2 37 3 38 4 39 5 40 6 41 7 42 8 43 9 44 blank 45 46 47 1 48 li 49 il 50 ll 51 i 52 l 53 l 54 UP L Upper Display User Limit Message Select four characters...

Page 56: ...ay User Limit Message Selects four characters for the user message to appear while the unit is in a limit condition Active if Lower Display LdSP is set to USEr 1406 r w 1407 r w 1408 r w 1409 r w char...

Page 57: ...Active Always 1301 r w chng hide hide 0 chng change 1 read read 2 Oper Operations Page Mode Lock Sets the Operations Page lockout level LOC Lockout Menu Fcty Factory Page Active Always cin1 LOC Locko...

Page 58: ...eLy relay 1 OTY1 Output 1 Hardware Reads the output 1 hardware type Active Always 4 r none 0 00 to 99 99 reu Software Revision Reads software revision number Active Always 3 r none 0 to 9999 Soft Soft...

Page 59: ...s the ambient temperature in 0 1 degrees Fahrenheit Active Always 1707 r none 0 0 to 99 9 hres High Resolution Displays high resolution input value Active Always 1513 r w OFF OFF turn off cyclical dis...

Page 60: ...1603 w no no no 0 yes yes 3 tc32 Thermocouple Calibration 32 Stores 32 degrees F type J calibration Active if Calibration Lock Lockout Menu is not set to hide 1603 w no no no 0 yes yes 1 tc00 Thermoc...

Page 61: ..._ _ _ _ M _ _ _ _ and Calibration Lock Lockout Menu is not set to hide 1621 w 1 00 0 00 to 99 99 4 1 Output Calibration 4 1V Enter the output value in volts as measured Active if Output 4 is process...

Page 62: ...NOTE For more information about how parameter settings affect the controller s operation see Chapter Five Features Notes 6 22 Parameters Watlow Series 97 Notes...

Page 63: ...nd Errors A 2 Modbus RTU A 4 Modbus Address Chart A 10 Calibrating the Series 97 A 11 Glossary A 14 Specifications A 18 Ordering Information A 20 Index A 21 Prompt Index A 23 Parameter Setup Order A 2...

Page 64: ...not be calibrated Err3 Over Sensor Range Power may be incorrect Err4 Overflow Ambient temperature may be too hot or too cold The open loop detect shows a broken sensor The calibration offset paramete...

Page 65: ...r is 32 to 149 F 0 to 65 C Check sensor function The Open Loop Detect parameter indicates it may be broken Check the Calibration Offset parameter value set it to a lower level Configure output as an a...

Page 66: ...nformation for writing a software application that uses Modbus Writing a Modbus Application You need to code messages in eight bit bytes with no parity bit one stop bit 8 n 1 Negative parameter values...

Page 67: ...or 0x04 starting register high byte starting register low byte number of registers high byte 0x00 number of registers low byte CRC low byte CRC high byte Packet returned by controller nn 03 nn nn nn...

Page 68: ...ontroller will echo back the command An attempt to write to a read only parameter returns an illegal data address error 0x02 Packet sent to controller nn 06 nnnn nn nn nnnn controller address one byte...

Page 69: ...rned by controller nn 10 nn nn 00 01 nn nn controller address one byte write to multiple registers command 0x10 starting register high byte starting register low byte number of registers to write high...

Page 70: ...nn nn controller address one byte command 0x80 exception code 0x01 or 0x02 or 0x03 CRC low byte CRC high byte Messages with the wrong format timing or CRC are ignored A read command sent to an inacti...

Page 71: ...gned char end_of_packet unsigned int crc unsigned char bit_count unsigned char char_ptr Start at the beginning of the packet char_ptr start_of_packet Initialize CRC crc 0xffff Loop through the entire...

Page 72: ...735 734 Output 3 40738 737 Alarm Hysteresis 3 40739 738 Latching 3 40740 739 Silencing 3 40741 740 Alarm Active Sides 3 40742 741 Alarm Logic 3 40743 742 Alarm Annunciation 3 40902 901 C or F 41061 10...

Page 73: ...tory Calibration rSt Calibration 1 Menu or revert to the default parameter range value with Default Settings dFLt Calibration 1 Menu Figure A 11 The Calibration Menus Factory Page Fcty Factory Page rS...

Page 74: ...n and short the input wires When using a type J calibrator set it to simulate 32 F 0 C Allow 10 seconds for the controller to stabilize Set Thermocouple Calibration 32 tc32 Input Calibration Menu to y...

Page 75: ...lue and move to the next prompt 4 At Output Calibration 4 20mA 4 20 Output Calibration Menu enter the reading from the volt ammeter The unit should stabilize within one second Repeat until the ammeter...

Page 76: ...ot Derivative control is an instantaneous change of the control output in the same direction as the proportional error This is caused by a change in the process variable PV that decreases over the tim...

Page 77: ...dividual Modbus capable device on a network NEMA 4X A NEMA specification for determining resistance to moisture infiltration This rating certifies the controller as washable and corrosion resistant on...

Page 78: ...ize power outage as a limit condition When power is restored the output is re energized automatically as long as the temperature is within limits manual reset 1 A feature on a limit control that requi...

Page 79: ...f a two wire loop The loop has an external power supply The transmitter acts as a variable resistor with respect to its input signal Transmitters are desirable when long lead or extension wires produc...

Page 80: ...Up Arrow Down Arrow Reset tactile keys Standard Conditions For Specifications Ambient temperature 77 F 25 C 3 C rated line voltage 50 to 60Hz 0 to 90 RH non condensing 15 minute warm up Universal Inpu...

Page 81: ...to 12 AWG Power 100 240V ac 10 15 50 60Hz 5 24 28V ac or V dc 10 15 50 60Hz 5 5 5 VA maximum power consumption Data retention upon power failure via nonvolatile memory Operating Environment 32 to 149...

Page 82: ...d dc output open collector D Electromechanical relay Form C 2A without RC suppression K 0 5A solid state relay without RC suppression Output 3 A None D Electromechanical relay Form C 2A without RC sup...

Page 83: ...RC algorithm A 9 D Date of Manufacture 6 17 Decimal 1 6 8 Default Settings 6 20 Diagnostics Menu 6 17 6 19 Digital event wiring 3 6 Display Menu 6 14 6 16 E EIA Conversion 3 11 Errors troubleshooting...

Page 84: ...retransmit 5 7 RTD Calibration 15 6 20 RTD Calibration 380 6 20 RTD input wiring 3 3 3 6 S safety information inside front cover sensor installlation 3 3 selection 5 5 Sensor Type 1 6 7 Serial Number...

Page 85: ...nput 2 Hardware Enabled 6 18 L Lat2 Latching 2 6 10 Lat3 Latching 3 6 11 Lat4 Latching 4 6 12 LdSp Lower Display 6 16 lead Lead Resistance Calibration 6 20 L9c2 Alarm Logic 2 6 10 L9c3 Alarm Logic 3 6...

Page 86: ...A 24 Appendix Watlow Series 97 Notes...

Page 87: ...A lo C D D C Analog Output Offset ACAL C D D C Alarm Hysteresis 2 3 4 hys2 3 4 C D D C Latching 2 3 4 Lat2 3 4 Alarm Silencing 2 3 4 Sil2 3 4 Alarm Active Sides 2 3 4 Sid2 3 4 Alarm Logic 2 3 4 Lgc2...

Page 88: ...ay_____________ Lo S Lower Display User Safe Message________ Lo L Lower Display User Limit Message________ GLbL Global Menu SEt Setup Page C F C or F ___________________ Err Input Error Latching _____...

Page 89: ...ship 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 a...

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