Series 945 User’s Manual TOTAL CUSTOMER SATISFACTION 3 Year Warranty 1/4 DIN Microprocessor-Based Auto-tuning Control Watlow Controls 1241 Bundy Blvd., P.O. Box 5580, Winona, Minnesota USA 55987-5580, Phone: 507/454-5300, Fax: 507/452-4507 0600-0017-0000 Rev A August, 1994 Supersedes without change: W945-MA40-9432 $10.00 Made in the U.S.A.
Contents Starting Out Page Item Chapter 1 3 Starting Out With The Watlow Series 945 3 General Description 4 4 4 5 5 6 7 8 9 10 11 Chapter 2 How To Install And Wire The Series 945 Installation Procedure Dimensional Information Wiring the Series 945 Sensor Installation Guidelines Input Wiring Output 1 Wiring Output 2 Wiring Alarm Wiring Retransmit Wiring System Wiring Examples Chapter 3 12 How To Use The Keys And Displays 12 Series 945 Keys and Displays Chapter 4 13 How To Setup The Series 945 13 How to Set
Chapter 1 Starting Out Starting Out The Watlow Series 945, A Microprocessor-Based Control Single Input Type J, K, T, N, R, S, B, C or Pt2 Thermocouple, RTD or Process Dual Outputs PID or ON/OFF, User Selectable Output 1 Heat or Cool Output 2 Heat, Cool or None Remote Set Point Input 0-5VDC or 4-20mA Dual Alarms Figure 1 Series 945 Input and Output Overview Retransmit Output (Up to 10 Slaves) Process RS-422A, RS423A (RS-232C compatible), or EIA-485 Optional Computer Interface Output 1 Auto-tuning (He
Installation Chapter 2 How to Install and Wire the Series 945 1. Make a panel cutout per the dimensions given below. Your panel thickness can be from 0.06" to 0.25" (1.52 to 6.35 mm). 3.62" to 3.65" sq. (92 to 92.25 mm) Figure 2 Series 945 Panel Cutout and Unit Dimensions 0.92" (23 mm) Panel Cutout 6.0" (152 mm) 3.6" ± 0.015" (90 mm ± 0.381) 3.8" sq. (97 mm) 3.63" X 3.63" (92.08 X 92.08 mm) Bezel 0.17" sq. Dimension (4 mm) 2.
Power Wiring How to Wire the Series 945 The Series 945 wiring is illustrated by model number option. Check the terminal designation sticker on the control and compare your model number to those shown here and also the model number breakdown on the inside back cover of this manual. Series 945 internal circuits appear "inside" the line drawing of the 945, while connections and terminal designations appear "outside" the line drawing. All outputs are referenced to a de-energized state.
Input Wiring Figure 7 Thermocouple Input Wiring Thermocouple Input 945A - 1 _ 945A - 2 _ 945A - 3 _ 945A - 4 _ _ _ _ _ _ - _ 000 _ - _ 000 _ - _ 000 _ - _ 000 7 9 + - (-) = Red RTD, 2 or 3 Wire Jumper #5 to #6 for 2 Wire RTD Figure 8 2 or 3 wire RTD Input Wiring. 945A - 2 _ _ _ - _ 000 945A - 3 _ _ _ - _ 000 4 4 5 6 5 6 These input connections are also used in conjunction with T/C and RTD sensor types when using the remote set point input.
Output 1 Wiring Output 1 - Solid State Relay With Contact Suppression 945A - _ Figure 11 Solid State Relay With Contact Suppression B _ _ - _ 000 Suppression 17 N.O. External Load 18 COM. L2 L1 Fuse Off state state impedance: impedance: 20K 31MΩmax. max. Off Figure 12 Switched DC (Open Collector) Output 1 - Switched DC Output (Open Collector) NOTE: Minimum load resistance is 500 . Available current is 22mA maximum. Typical voltage drop across a 1K load is 12 to 19 volts.
Output 1 & 2 Wiring Output 1 - Process, 0 - 5VDC 945A - _ H _ _ - _ 000 Figure 15 Process, 0 - 5VDC + 17 + - 18 - External Load Load impedance: 10KΩ min. Figure 16 Solid State Relay Without Contact Suppression Output 1 - Solid State Relay Without Contact Suppression 945A - _ K _ _ - _ 000 Solid State Relay, Form A, 0.5 Amp 17 N.O. External Load 18 COM.
Output 2 & Alarms Output 2 - Mechanical Relay, 6 Amp, Form A 945A - _ _ D _ - _ 000 External Load Suppression 14 N.O. L2 15 COM. Figure 19 6 Amp Mechanical Relay L1 Fuse Off state impedance: 20KΩ min. Output 2 - Solid State Relay Without Contact Suppression 945A - _ _ K _ - _ 000 Solid State Relay, Form A, 0.5 Amp Fuse 14 N.O. L1 15 COM. NOTE: This output is supplied with an arc suppression snubber across the output terminals.
Alarm/Retransmit Mechanical Relay, 6 Amp, Form A or B/0 - 5VDC Retransmit Figure 23 Alarm/Retransmit Option 3 Wiring. - 945A- _ _ _ 3 - _ 000 External Load + NOTE: This output is supplied with an arc suppression snubber across the output terminals. High impedance loads may remain energized even though the output device is turned OFF. 24 25 26 + Fuse 27 L1 Load L2 Load impedance: 10KΩ min. for 0-5VDC. Relay offstate impedance: 20KΩ.
Wiring Example WARNING: All wiring and fusing must conform to the National Electric Code NFPA70 and to any locally applicable codes. Contact your local board for additional information. Failure to observe NEC safety guidelines could result in injury to personnel. ç CAUTION: Watlow mercury relays are designed to be used only with resistive loads.
Keys/Displays Chapter 3 How to Use the Keys and Displays Figure 28 Series 945 Keys and Displays. After 1 minute with no key activations, the control reverts to the process value in the upper display and the set point in the lower display. Upper Display Red, 0.56" (14 mm) high, seven segment, four digit LED display, indicating either process actual temperature, the operating parameter values, or an open sensor. When powering up, the Process display will be blank for 8 seconds. Lower Display Red 0.
Setup Chapter 4 How To Setup The Series 945 Setting up the Series 945 is a simple process. First configure the 945's features to your application in the Setup Menu, and then enter values in the Operating Menu. Use the MODE key to move through the menus and the UP/DOWN keys to select data. At this point, enter the Calibration menu by pressing the UP/DOWN keys simultaneously for 3 seconds.
Setup Menu = Parameter may or may not appear depending on control configuration. M Figure 31 The Setup Menu NOTE: The rL and rH parameters are used to scale the display for process inputs, and/or will scale the retransmit range for process output. rL and rH also limit the range of the set point.
Setup Input: Selects the sensor input type. Only those input types which are compatible with your unit will appear. See the model number information for your type. Range: J, K (appears as H), t, n, c, r, S, b, Pt2, rtd, rt.d, 0-5, 420 Default: J or r In Remote Set Point: Enables models with process input capability to accept a remote set point signal from another device. This parameter only appears if In = Thermocouple or RTD.
Setup AL1 LAt1 HYS3 Alarm 1: Determines whether the alarm type for Alarm 1 is process, deviation, or none. A process alarm is set at an absolute temperature. A deviation alarm follows or tracks the set point. This parameter only appears if your unit has alarms. Range: Pr, dE, no Default: Pr Latching 1: Selects whether Alarm 1 is latching or non-latching. Latching alarms must be cleared before the alarm output will reset. Non-latching automatically resets the alarm output when the condition clears.
Setup Setup Menu Use this page as a master copy for configuring your Series 945. Do not enter any values here; make photocopies instead. Table 2 Setup Menu Prompts and Descriptions. Parameter Range Factory Default LOC 0-3 0 In J, K (appears as H), t, n, c, Pt2, r, S, b, rtd, rt.d, 0-5, 420 J or r rSP OFF, 0-5, 420 OFF In = T/C or RTD dEC 0, 0.0, or 0.00 0 In = 0-5 or 420 C_F C or F F In = T/C or RTD rL rL to rH Input dependent. rH rH to rL Input dependent.
Operation Operation Menu In the Operation menu, the 945 operates as a digital set point control. All outputs are turned OFF when set point is set to OFF. = Parameter may not appear depending on control configuration NOTE: = Only appears if your unit has communications. See the Series 945 data communications manual for more information. The upper display will always return to the process value after 1 minute without key strokes.
Operation Reset/Integral1: A reset (integral) control action for Output 1 or Output 2 automatically eliminating offset, or "droop," between set point and actual process temperature. Will not appear if your unit does not have a secondary output. rE1/It1: Will not appear if Pb1 = 0. rE2/It2: Will not appear if Pb2 = 0, Ot2 = no, or Ot2 is the same configuration as Ot1. Either reset (rE) or integral (It) will appear depending on how the dFL parameter is set in the Calibration menu. See Appendix II.
Operation AUt L-r Table 3 Operation Menu Prompts and Descriptions. Parameters Auto-Tune: Initiates auto-tune for Output 1. This parameter appears if Ot 1 =ht. Range: 0 = off, 1 = slow, 2 = medium, 3 = fast Default: 0 Local-Remote: Selects a local or remote set point for the Series 945. This parameter only appears if the LOC parameter = 0, 1 or 2, and rSP = 0-5 or 420. If L-r = r, the remote set point will be displayed in place of the internal set point.
Tuning Chapter 5 How to Tune and Operate Auto-tuning Auto-tuning applies to Output 1, heating only. The auto-tuning procedure operates on a thermal response value — slow, medium, or fast. Use the slow thermal response when your process does not reach set point too rapidly, or if it usually does not exceed set point a lot. A fast thermal response produces a rapid temperature change over a short period of time.
Tuning To start auto-tuning: 1. Press the MODE key until the AUt parameter appears in the data display. 2. Select a thermal response value using the UP/DOWN keys, 1=slow, 2=medium, and 3=fast. A thermal response value of 2 satisfactorily tunes most thermal systems. 3. Press the MODE key. While the control is in the tuning mode, the lower display alternately displays the normal information and the prompt At. The time between alternations is 1 second. 4.
Tuning/Operation 5. Rate/Derivative Adjustment: Increase rA/dE to 1.00 minute. Raise set point by 20° to 30°F, or 11° to 17°C, observe the system's approach to set point. If the load temperature overshoots set point, increase rA/dE to 2.00 minutes. Next raise set point by 20 to 30°F, or 11 to 17°C and watch the approach to the new set point. If you increase rA/dE too much, approach to set point will be very sluggish.
Alarm Outputs Changing the Position of an Alarm Jumper 1. Remove power from the control. Turn the front panel screw 90° counterclockwise. 2. Grip the front panel bezel and pull it straight out from the control case. The control chassis will come out of the case as you pull the bezel. 3. Set the jumper to the position you want. See below for jumper location. 4. Return the control chassis to the case. Be sure you have it oriented correctly. Press firmly, but gently, to seat the chassis.
Alarms Using Alarms The Series 945 has two alarm types, Process or 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. A Deviation alarm alerts the operator when the process strays too far from set point. The operator can enter independent high and low alarm settings. The reference for the deviation alarm is the set point.
Error Codes Error Code Messages ç Four dashes, "- - - -", in the upper display indicate a Series 945 error. The error code is visible in the lower display. NOTE: An alarm display will be masked by an error condition or when the control is in the Calibration or Setup Menus. ç WARNING: Electrical noise or a noise event, vibration or excess environmental moisture or temperature may cause Series 945 errors to occur. If the cause of an error is not otherwise apparent, check for these.
Error Codes Error Code Actions • Error codes Er 1, Er 2, Er 3, Er 6, or Er 7 will result in these conditions: • If operator access is LOC 0 or 1… …and the control was in AUTO 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 945 switches into manual operation at the last automatic power level (bumpless transfer). If the control was in manual operation, it remains there.
Noise Guidelines Appendix 1 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 crossover-fired (randomly-fired or phase angle-fired devices). • All welding machinery and heavy current carrying conductors.
Noise • Twisted pair wire should be used any time control circuit signals must travel over two feet, or when they are bundled in parallel with other wires. • Select the size or gauge of wire by calculating the maximum circuit current and choose the gauge meeting that requirement. Using larger wire sizes than required generally increases the likelihood of electrostatic (capacitance) coupling of noise. • Eliminate ground loops in the entire control system.
Wiring Guide • "Islatrols" and other similar power line filters are designed to carry the power for the control circuit and "buffer" the control circuit from A.C. line noise. Devices like the Islatrol use media (electromagnetic filtering) other than electric circuits to filter out electrical noise. Take care in matching the power capabilities of the filter with power demands of the circuit. Keep line filters as close to the control as possible to minimize the area for interference pick up.
Noise Guidelines Line Filtering Configurations For Controls These three diagrams show filter configurations for removing input power noise. Choose the one best suited for your system. For very dirty or critical applications use a microcomputer-regulated power supply or Uninterruptable Power Supply (U.P.S.). Don't fasten common mode line filters or filters with metal cases to metal at ground potential. This prevents ground loops and maintains filter effectiveness.
Calibration Appendix 2 Calibration Before attempting to calibrate, make sure you have the proper equipment called for in each procedure. Entering the Calibration Menu Enter the Calibration Menu to change the configuration of the dFL (default language) parameter. Several parameters are dependent on the dFL parameter, they are listed below. It is a good idea to change this parameter, if necessary, before entering the Setup menu.
Calibration Upon entering the calibration menu, the top display window indicates CAL. The upper display continues to indicate CAL (with the exception of calibration of the 420mA 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 control uses the lower display to prompt the user as to what the input should be.
Calibration Calibration Menu ( ) YES to calibrate, No skips to display test. tCL ( ) Input 0.00mV for low thermocouple input. tCH ( ) Input 50.00mV (16.035 for r, S or b units) for high thermocouple input. tC ( ) Connect a "J" T/C compensator, with inputs shorted. T/C units only. rLO ( ) Connect the JIS RTD low resistance per model number. rHI ( ) Connect the JIS RTD high resistance per model number. O U ( ) Set the voltage source to 0.000 volts.
T/C and RTD Calibration Thermocouple Field Calibration Procedure Equipment Required: • • Type "J" or "R" Reference Compensator with reference junction at 32°F/0°C, OR Type "J" or "R" Thermocouple Calibrator set at 32°F/0°C. Precision millivolt source, 0-50mV min. range, 0.01mV resolution. Setup And Calibration 1. Connect the AC line voltage L1, L2, and ground to the proper terminals. 2. Connect the millivolt source to Terminal #9 (-) and Terminal #7 (+) on the Series 945 terminal strip.
0-5V/4-20mA Input 0 - 5 Volt Input Field Calibration Procedure Equipment Required: • Precision voltage source 0-5 volt minimum range with 0.001 volt resolution. Setup And Calibration NOTE: Before calibration on an installed control, make sure all data and parameters are documented. See Setup and Operation Tables, Pages 18 and 20. IMPORTANT: When the MANUAL LED is ON the unit is automatically calibrating. Your sequence is VERY important.
0-5 or 0-10 Volt/0-20 or 4-20mA Output 0 - 5 or 0-10 Volt Output Field Calibration Procedure Equipment Needed: • 20KΩ, 1/4 watt, 10% resistor • 4 1/2 digit digital multimeter. Setup and Calibration 1. Connect the AC line voltage L1, L2, and ground to the proper terminals. 2. Connect the multimeter across the 20KΩ resistor to Terminal #17 (+) and #16 (-) for 05Volt and 0-10Volt units on the Series 945 terminal strip. Use regular 20-24 gauge wire. 3. Apply power and allow warm up for 15 minutes.
0-5V/4-20mA Retransmit 0 - 5 Volt Retransmit Field Calibration Procedure Equipment Required: • 20KΩ, 1/4 watt, 10% resistor. • 4 1/2 digit Digital Multimeter. Setup and Calibration 1. Connect the AC line voltage L1, L2, and ground to the proper terminals of the 945. 2. Connect the multimeter across the 20KΩ resistor to Terminal #25 Positive and #24 Negative on the Series 945 terminal strip. Use regular 20 - 24 gauge wire. 3. Apply power to the unit and allow it to warm up for 15 minutes.
Glossary, A-J Alarm: A condition, generated by a controller, indicating that the process has exceeded or dropped below a predetermined alarm set point. Alarm Silence: Disables the alarm relay output. Anti-reset: Control feature that inhibits automatic reset action outside the proportional band. Also known as "reset windup inhibit." Automatic prompts: Data entry points where a microprocessor-based control "prompts" or asks the operator/programmer for information input.
Glossary, D-P Glossary, O-Z ON/OFF control: Control of temperature about a set point by turning the output full ON below set point and full OFF above set point in the heat mode. Open loop: System with no sensory feedback. Output: Action in response to difference between set point and process variable. Overshoot: Condition where temperature exceeds set point due to initial power up or process changes. Parameter: A physical property whose value determines the response of an electronic control to given inputs.
Index A Alarms, 25 Jumper Selection, 24 Parameter, 19 Wiring, 9 Appendix, 26 AUTO/MAN key, 12 Automatic Operation, 12, 23 Auto-tuning, 21 B Bumpless transfer, 23, 27 C Calibration, 32 - 38 Combination Differential Filter, 31 Common Mode Filter Wiring, 31 D DC Output 1, 7 DC Output 2, 8 Default Parameters, Operation, 20, Table 3 Setup, 17, Table 2 DIP Switch, How to Set, 13 Differential Mode Filter Wiring, 31 Dimensions, 4 Displays, 12 DOWN key, 12 E Error Codes, 26 F, G General Description, 3 Glossary, 40 G
Specifications (1359) Control Mode • Single or dual set point, non-ramping. • Single input, dual outputs, dual alarms. • Optional retransmit of set point or process variable. • Control outputs: User selectable as: Heat, Heat/Heat, Heat/Cool, Cool, Cool/Cool, Cool/Heat. • Outputs independent, or related via deadband for Heat/Cool. • ON/OFF: Determined by the HYSX parameter for Outputs 1 and 2. • Proportional band: 0 to 999°F/0 to 555°C/0 to 999 U or 0 to 999.9% of span. Reset: 0.00 to 9.
(1360) 1/4 DIN, single input, dual output dual alarms, dual digital displays. 94 5A Model No. 000 Inputs Type 1 = Type J, K, T, N, C, PT 2 thermocouple 2 = Type J, K, T, N, C, PT 2 thermocouple, RTD 1°, 4-20mA, 0-5VDC 3 = Type J, K, T, N, C, PT 2 thermocouple, RTD 0.1°, 4-20mA, 0-5VDC 4 = Type R, S, B thermocouple #1 Output Type B = Solid State Relay, Form A, 0.
Watlow Series 945 User's Manual Blvd.
