Series 93 User’s Manual 1/16 DIN Microprocessor-Based Auto-tuning Control 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 2.
NOTE: Details of a “Note” appear here in the narrow margin on the left side of each page. çCAUTION: Details of a “Caution” 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 to important operational and safety information. A bold text “NOTE” marks a short message in the margin to alert you to an important detail.
TC Table of Contents Chapter 1: Overview ......................................................... 1.1 General Description ................................................ 1.1 Chapter 2: Install And Wire The Series 93 .................... 2.1 Panel Cutout ............................................................2.1 Dimensions ..............................................................2.1 Installation Procedure ..............................................2.1 Wiring the Series 93 .....................
Meet the Series 93 Team TOTAL CUSTOMER SATISFACTION 3 Year Warranty 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 representatives from our core manufacturing and customer service areas.
Overview of the Series 93 Overview 1 ;; ;; ;; ;; Single Input Type J, K, T, N or S Thermocouple, RTD or Process Dual Control OutputPID or on-off, User Selectable Output 1 Heat or Cool 93 Figure 1.1 Series 93 Input and Output Overview. Output 2 Heat, Cool, Alarm or None General Description Welcome to the Watlow Series 93, a 1/16 DIN microprocessor-based temperature controller. The 93 has a single input which accepts type J, K, T, N or S thermocouple, RTD or process input.
Notes Overview 1.
2 Install and Wire the Series 93 NOTE: Install and Wire For rapid mounting, use Greenlee 1/16 DIN punch, die, draw stud, part number 5073941.7. NOTE: Measurements between panel cutouts are the minimum recommended. Figure 2.1a Series 93 Multiple Panel Cutout Dimensions. Figure 2.1bSeries 93 Dimensions. Installation procedure Bold print denotes requirement for IP65 (NEMA 4X) seal. Follow this procedure to mount the Watlow Series 93 temperature controller: 1.
0 to 0.483 mm space (0 to 0.019 in.) Panel Ridges Figure 2.2a - Bezel Tabs Mounting Case Side View. Mounting Collar External Gasket Install and Wire Teeth Figure 2.2b Mounting Collar Cross Section with offset teeth. ç 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 equipment. 3.
Wiring the Series 93 WARNING: To avoid electric shock, use National Electric Code (NEC) safety practices when wiring and connecting this unit to a power source and to electrical sensors or peripheral devices. Failure to do so could result in injury or death. The Series 93 wiring is illustrated by model number option. Check the unit sticker on the controller and compare your model number to those shown here and also the model number breakdown in the Appendix of this manual.
∫ç Install and Wire WARNING: To avoid electric shock and damage to property and equipment, use National Electric Code (NEC) safety practices when wiring and connecting this unit to a power source and to electrical sensors or peripheral devices. Failure to do so could result in injury or death. Sensor Installation Guidelines We suggest you mount the sensor at a location in your process or system where it reads an average temperature.
NOTE: Successful installation requires four steps: Figure 2.5a – 0-5VÎ (dc) Process Input impedance: 10kΩ • Choose the controller’s hardware configuration and model number (Appendix); • Install and wire the controller (Chapter Two); • Configure the controller (Chapters Three, Four and Five). Install and Wire • Choose a sensor (Chapter Two and Appendix); Figure 2.
NOTE: Successful installation requires four steps: • Choose the controller’s hardware configuration and model number (Appendix); • Choose a sensor (Chapter Two and Appendix); Install and Wire • Install and wire the controller (Chapter Two); Output 1 Wiring Figure 2.6a – Mechanical Relay Without Contact Suppression 93_ _- 1 D _ _- 00 _ _ Form C, 5A Minimum load current: 100mA @ 5VÎ (dc) • Configure the controller (Chapters Three, Four and Five).
Successful installation requires four steps: Figure 2.7a – Switched DC 93_ _- 1 C _ _- 00 _ _ • Choose the controller’s hardware configuration and model number (Appendix); • Choose a sensor (Chapter Two and Appendix); • Install and wire the controller (Chapter Two); • Configure the controller (Chapters Three, Four and Five). NOTE: 9 + 10 - External Load Install and Wire NOTE: Figure 2.
NOTE: Successful installation requires four steps: • Choose the controller’s hardware configuration and model number (Appendix); • Choose a sensor (Chapter Two and Appendix); Install and Wire • Install and wire the controller (Chapter Two); Output 2 Wiring Figure 2.8a – Mechanical Relay Without Contact Suppression 93_ _- 1 _ D _ - 00_ _ Form C, 5A Minimum load current: 100mA @ 5VÎ (dc) Fuse 6 COM NC 1 L1 7 NO • Configure the controller (Chapters Three, Four and Five).
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.
∫ç Install and Wire WARNING: To avoid electric shock and damage to property and equipment, use National Electric Code (NEC) safety practices when wiring and connecting this unit to a power source and to electrical sensors or peripheral devices. Failure to do so could result in injury or death. Wiring Notes Sketch in your application on this page or a copy of it. See the wiring example in this chapter.
3 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. 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 Downarrow Keys: Increases or decreases the value of the displayed parameter. • Press lightly to increase or decrease the value by one.
Notes Keys and Displays 3.
4 How to Set Up the Series 93 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 [``In] 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 Up-arrow/Down-arrow keys to select data. Before entering information in the Setup Menu, set the [`dFL] parameter.
Entering the Setup Menu 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 ¿Up-arrow and ¯Down-arrow keys simultaneously for 3 seconds. The lower display shows the [`LOC] Lock parameter, and the upper display shows its current level. All keys are inactive until you release both keys. You can reach the Lock parameter from anywhere. 93 93 Figure 4.
Setup Parameters Shaded parameters may not appear, depending on the controller’s configuration and model number. [`LOC} NOTE: Set the [`LOC] parameter value as the final step in programming the Series 93 controller to prevent locking yourself out of the Operation and Setup Menu during initial programming. çCAUTION: A process input does not have sensor break protection or bumpless transfer.
{``rh} Range High: Selects the high limit of the operating range. Also used to scale the high end of the process input. 5.0VÎ (dc) and 20mA represent Range High [``rh] for a process input. The process input is linearly scaled between [``rL] and [``rH]. See the model number and specification information in the Appendix for your range values, or refer to the following table. Range: Sensor range high to [``rL] Default: High limit of sensor type for a thermocouple or RTD. 9999 for process input.
[`P`L] Power Limiting: The power limiting function in % power for heat only. Power Limiting will function if [`pb1] is set to [```0]. Range: Dependent on output type. 0 to100 Default: 100 {`dSP} Display: Selects which displays are active or viewable. Five seconds after selected, the appropriate display goes blank. Press ‰Advance, ¿Up-arrow or ¯Downarrow to override this feature and cause the current value to be displayed for 5 seconds.
Figure 4.6 The Operation Menu. Operation Menu ‰ NOTE: The upper display will always return to the process value after 1 minute without key strokes. NOTE: Shaded parameters may not appear, depending on the controller’s configuration and model number.
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 components. Typical life of a mechanical relay is 100,000 cycles. Range: 0.1 to 999.9 seconds Default: 5.0 seconds {`ALO} Alarm Low: Represents the low process alarm or low deviation alarm. This parameter will not appear if [`Ot2] is set to no or [`Con].
Notes Setup 4.
5 How to Tune and Operate the Series 93 Autotuning (Heat and/or Cool) The Series 93 can automatically tune the PID parameters to fit the characteristics of your particular thermal system. Set the [`HSC] parameter under the Setup Menu to 2°C/3°F before autotuning your controller. The autotuning procedure operates on a thermal response value — slow, medium, or fast.
4. When tuning is complete, the displays return to their previous state and [`AUt] reverts to 0. The Series 93 installs appropriate PID tuning parameters and saves them in the non-volatile memory. 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 components. Typical life of a mechanical relay is 100,000 cycles.
Manual and Automatic Operation To change from auto to manual operation, press the ˆInfinity 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 [`Ot2] is set to [`Con]. Automatic operation provides closedloop on-off or PID control.
Using Alarms The Series 93 has two alarm types, process and deviation. 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. 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 [`Ot2] parameter.
Alarm Silencing is available with the deviation alarm and has two uses: When [`SIL] is selected as "on," the operator must manually disable the alarm by pressing the ˆInfinity 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 [`Ot2] is set to [`dEA]) shows an alarm condition until the process value is within the “safe” region of the deviation alarm band.
Error Code Actions • [`Er2], [`Er6], [`Er7] result in these conditions: • If [`LOC] Lock is set to 0, 1 or 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 <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.
A Appendix Noise and Installation Guidelines For wiring guidelines, refer to the IEEE 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 crossoverfired (randomly-fired or phase angle-fired devices). • All welding machinery and heavy current carrying conductors.
• Use twisted pair wire any time controller circuit signals must travel more than two feet, or when you bundle them in parallel with other wires. • 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. • Eliminate ground loops in the entire controller system.
Calibration Before attempting to 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 controller to go through its auto calibration. The Calibration Menu can only be entered from the [`LOC] Lock parameter in the Setup Menu.
Restoring Factory Calibration The [`rSt] 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 [`CAL] menu, the values are entered. 1. Press the ¿Up-arrow/¯Down-arrow keys simultaneously for three seconds. The LOC parameter appears in the lower display. Continue holding the ¿Up-arrow/¯Down-arrow keys until the lower display reads [`CAL]. 2.
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" 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 Setup And Calibration 1. Connect the ac line voltage L1 and L2 to the proper terminals. 2.
0-5 Volt Input Field Calibration Procedure Equipment Required • Precision dc voltage source 0-5 volt minimum range with 0.001 volt resolution. Setup and Calibration 1. Connect the ac line voltage L1 and L2 to the proper terminals on the Series 93. NOTE: Before calibrating an installed controller, make sure all data and parameters are documented. See the Setup and Operation Tables in Chapter Four . 2. Connect the voltage/current source to Terminal 3 (+) and 5 (-) on the Series 93 terminal strip.
4-20mA Output Field Calibration Procedure Equipment Required: • 300Ω, 1/2 watt 10% resistor. • 4 - 1/2 digit Digital Multimeter. NOTE: Before calibrating an installed controller, make sure all data and parameters are documented. See the Setup and Operation Tables in Chapter Four. Setup And Calibration 1. Connect the ac line voltage L1 and L2 to the proper terminals of the Series 93. See Chapter Two. Set the multimeter to measure current. 2.
Notes Appendix A.
Glossary compensate for the effective temperature at the cold junction. A compensation, ambient The ability of an instrument to adjust for changes in the temperature of the environment and correct the readings. Sensors are most accurate when maintained at a constant ambient temperature. When temperature changes, output drifts. alarm, deviation Warns that a process has exceeded or fallen below a certain range around the set point.
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.
PID Proportional, integral, derivative. A control mode with three functions: proportional action dampens the system response, integral corrects for droop, and derivative prevents overshoot and undershoot. increase in the process variable causes a decrease in the output. Heating applications usually use reverse action. RTD See resistance temperature detector. process variable The parameter that is controlled or measured.
• Solid-state relay3, Form A, 0.5A @ 24V~ (ac) min., 264V~ (ac) max., opto-isolated burst fire switched, without contact suppression. Off-state output impedance is 31MΩ. • Alarm output can be latching or non-latching, and process or deviation with separate high and low values. Alarm silencing (inhibit) on power up (for deviation alarms only).
Series 93 Model Number Information Ordering Information (1068) 93 _ _ - 1 _ _ _ - 0 0_ _ 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 = With CE Output 1 C = Switched dc output, non-isolated D = Electromechanical relay, Form C, 5A, without contact suppression1, 3 F = Process, 4-20mA (dc), non-isolated K = Solid-state relay, Form A, 0.
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 J-K Keys 3.1 B-C calibration A.3 Calibration Menu A.4 Calibration Offset 4.7 Celsius-Fahrenheit 4.3 clearing an alarm 5.4 Cycle Time 4.6 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 D default parameters Operation 4.6-4.7 Setup 4.3-4.5 Derivative 4.
Declaration of Conformity 97 WATLOW CONTROLS 1241 Bundy Boulevard Winona, Minnesota 55987 USA Declares that the following product: English Designation: Series 93 Model Number(s): 93(A or B) (A or B) - 1 (C D F or K) (A C D or K) (0 or 1) - (Any four letters or numbers) Classification: Control, Installation Category II, Polution Degree II 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
Notes Appendix A.
Series 93 Quick Reference Keys and Displays 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 [`Ot2] parameter. [`PrA] sets a process alarm with alarm message displayed. [``Pr] sets a process alarm with no alarm message displayed.
Parameter Setup Menu Value Range Factory Default Appears If: 0 [```J] DIP switch-selectable. [`dEC] 0-4 [```J], [```H], [```t], [```n], [```S][`rtd], [`r†d], [`0-5], [`420] 0, 0.0, 0.00 [`C_F] [```C] or [```F] Dependent on [`dFL] [``rL] [``rL] to [``rh] Input dependent.
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 manufactured totally in-house, in the U.S.A. Watlow products include electric heaters, sensors, controls and switching devices.
How to Reach Us TOTAL CUSTOMER SATISFACTION Contact 3 Year Warranty Your Authorized Watlow Distributor is: 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. • or Phone: 507/454-5300. • Fax: 507/452-4507. • For technical support, ask for an Applications Engineer. • To place an order, ask for Customer Service.
