Using This Retrofit Guide This document is best viewed with Adobe Reader 6.0. To obtain the latest version of Adobe Reader, visit http://www.adobe.com Specification sheets on Watlow product may be obtained at http://www.watlow.com/literature/specsheets/ User Manuals on Watlow product may be obtained at http://www.watlow.com/literature/prodtechinfo/ Additional information on other Watlow products may be obtained by visiting http://www.watlow.
Abbreviation & Terminology (as used in this document) 0.5 – 0.5 amperes of current switching capability 2A – 2 amperes of current switching capability 5A - 5 amperes of current switching capability 10A – 10 amperes of current switching capability 15A – 15 amperes of current switching capability 12-24 – Supply voltage can be between 12 to 24 Volts 100-240 – Supply voltage can be between 100 to 240 Volts 100 ohm DIN – refers to 100-ohm platinum RTD that has a DIN curve.
Integral – the set point in integral (on board) to the controller. JIS – Joint Industrial Standards, a set of technical, scientific and dimensional standards developed in Japan. RTD sensors with the JIS curve change resistance at a rate of 0.00396 ohms/ohms/C. Line Voltage – the voltage required powering the electronics of the controller. Low Limit - device will deactivate output on a temperature drop below set point.
VTB Sw DC – Variable Time Base Switched Direct Current, a time proportioning DC output where the cycle time is variable.
These notes are used to signify areas of concern in changing to a retrofit choice. These notes are also printed at the end of the retrofit listing. Note 1: Retrofit controller requires a substitution of a 100 Ohm RTD sensor for the thermistor. Note 2: Mounting and dimensions of retrofit controller are different. Verify that sufficient panel space and depth is available. Note 3: Retrofit controller outputs are different. Add external interposing mechanical or solid state relay if applicable.
Series 922 Line Voltage Input Control Mode Action Output Set Point Mounting 922A-1BB0-A000 115/230 VAC RTD/RTD Progammable Progammable Dual 0.5A SSR/0.5A SSR Profiling 1/4 DIN F4DH-KKKK-01RG 6 922A-1BB0-B000 115/230 VAC RTD/RTD Progammable Progammable Dual 0.5A SSR/0.5A SSR Profiling 1/4 DIN F4DH-KKKK-01RG 6, 16 922A-1BB0-C000 115/230 VAC RTD/RTD Progammable Progammable Dual 0.5A SSR/0.
Series 922 Line Voltage Input Control Mode Action 922A-5CC0-C000 115/230 VAC T t/c/T t/c Progammable Progammable Dual Sw dc/Sw dc Profiling 1/4 DIN F4DH-CCCC-01RG 115/230 VAC T t/c/T t/c Progammable Progammable Dual 4-20MA/0.5A SSR Profiling 1/4 DIN F4DH-FKFK-01RG 6 922A-5FB0-B000 115/230 VAC T t/c/T t/c Progammable Progammable Dual 4-20MA/0.5A SSR Profiling 1/4 DIN F4DH-FKFK-01RG 6, 16 922A-5FB0-C000 115/230 VAC T t/c/T t/c Progammable Progammable Dual 4-20MA/0.
Series 922 Line Voltage Input Control Mode Action Output Set Point Mounting 922A-ABB0-B000 115/230 VAC J t/c/Proc Progammable Progammable Dual 0.5A SSR/0.5A SSR Profiling 1/4 DIN F4DH-KKKK-01RG 6, 16 115/230 VAC J t/c/Proc Progammable Progammable Dual 0.5A SSR/0.
Series 922 User's Manual Microprocessor-Based Ramping Control Watlow Controls Watlow Controls, 1241 Bundy Blvd., P.O. Box 5580, Winona, MN 55987-5580, Phone: 507/454-5300, Fax: 507/452-4507 W922-XUMN Rev C00 April 1996 Supersedes: W922-MA50-9246 $10.00 Made in the U.S.A.
Use The Manual First… This manual will make your job easier. Reading it and applying the information is a good way to become familiar with the Series 922. Here's an overview: Starting Out Introduction, Chapter 1. Front Panel Keys and Displays, Chapter 2. Running a Program Sample Program, Chapter 3. Install/Wire Installation and Wiring, Chapter 4. Tune How to Tune, Chapter 5. Programming How to Program, Chapter 6. Alarms How to Use Alarms, Chapter 7.
Contents Table of Contents Page Item 7 7 8 8 9 9 10 11 Starting out with the Watlow Series 922 - Chapter 1 "Read Me First" Packing List Put Your Control to Work —Three Steps How to Open the 922 How to Set the DIP Switches Changing the Position of a DIP Switch Overview of the Three Operating Modes Starting Out 12 12 13 13 How to Use the Keys and Displays - Chapter 2 Front Panel Information Actual and Alphanumeric Display Area Keyboard Area Front Panel 14 14 15 15 16 17 17 18 18 19 20 Learning the S
Contents Tuning Programming Alarms Appendix Terminology Quick Reference 4 Page Item 36 36 36 37 How to Tune the Series 922 - Chapter 5 Recommended Tuning Reference Using a Chart Recorder Tuning 38 38 38 38 38 39 39 40 41 42 42 45 57 How to Program the Series 922 - Chapter 6 Write Out Your Program Select the Proper DIP Switch Settings Event Input Remote Hold Input Event Outputs Guaranteed Soak The Four JUMPLOOP Types JUMPLOOP Rules to Follow Programming in General SYSTEM Menu SETUP Menu PROGRAM
Contents Figures Page Item Figures 7 9 10 11 12 13 13 20 25 25 25 26 27 27 27 28 29 30 30 31 31 32 32 32 33 33 33 34 34 35 39 42 45 57 64 64 65 Series 922 Input and Output Overview How to Open the Series 922 DIP Switch Location and Orientation Overview of the Series 922 Series 922 Front Panel Information Actual and Alphanumeric Display Front Panel Information Keyboard Front Panel Information RUN Key Flow Diagram Differential Mode Filter Diagram Common Mode Filter Combination Differential- Common Mode Fi
Contents Tables Page Item Table 10 16 17 18 18 19 24 43 46 58 74 DIP Switch Selection Series 922 Ramp and Soak Program Editing Your Program, Steps 4-7 Adding the AUTOSTART Step LINKing to Another File The WAITFOR Step Noise Suppression Device Ratings SYSTEM Prompts and Description SETUP Prompts and Description PROGRAM Prompts and Description RTD Parameter Settings Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Page Item Chart 62 Master Step Chart Chart 1
Starting Out Chapter 1 Starting out with the Watlow Series 922, A 2-Channel Ramping Control Dual PID or ON/OFF Outputs/Channel Dual Inputs: RTD, T/C or Process Value Event Input Remote Hold Input 8 Auxiliary Outputs RS-422A or RS-423A (RS-232C Compatible) Optional Computer Interface or 2 Auxiliary Outputs "Read Me First.
Starting Out The Series 922 is a dual channel PID controller. You may input individual sets of PID parameters for each output. This includes rate, reset, proportional band and cycle time. By setting the proportional band(s) to zero, the Series 922 becomes a simple ON/OFF control, with a 3°F or 1.7°C switching differential. Two of the Series 922's auxiliary outputs may be alarms or events. An event is an ON/OFF auxiliary output relay signal.
Opening How to Open the 922 Before going further, open the Series 922 and pull the control chassis from its case. Here's how: The control chassis fastens to the case with a single screw located on the lower front panel. See Figure 2. Turn the screw counterclockwise to loosen it. Three or four strip connector plugs, in the rear of the control chassis, feed power and signals through the back of the casing to the triple terminal strip. These plugs will let go as you pull.
DIP Switches A007- 1727 Board Figure 3 DIP Switch Location and Orientation. DIP Switches Control Chassis - Top View Table 1 DIP Switch Selection. DIP SW# ON 1 2 WARNING: Doing a cold start will cause all SETUP parameters and files to be lost. DO NOT put DIP switch #1 in the ON position unless all userprogrammed information is to be cleared. SPCLFUNC parameters define the personality of your Series 922.
922 Overview Overview of the Three Operating Modes Before getting into the details of the Series 922's keys and displays, take a look at Figure 5 showing the three different modes. After you feel comfortable with the names of the modes and their functions, go ahead to learn the keys and displays.
Keys / Displays Chapter 2 How to Use the Keys and Displays This chapter will show you the Series 922 front panel, and the function of each display, key and LED. Figures 6 and 7 explain the 922 front panel. Front Panel Information Use Figures 6 and 7 to assist you in learning the locations and functions of the front panel components. Use the following figures to learn the nature and function of the Series 922's keys and displays.
Actual and Alphanumeric Display Area Keys / Displays °F LED Indicates the value in the ACTUAL display is temperature in degrees Fahrenheit. ACTUAL Display Shows the actual value of the process variable for Channel 1 in four digits. When both °C and °F LEDs are OFF, the 922 is displaying Process Variable Units (PVUs). °C LED Indicates the value in the ACTUAL display is temperature in degrees Celsius.
Sample Program Chapter 3 Learning the Series 922 A Sample Program in Action This chapter will guide you through an easy sample program for the Series 922. You can quickly grasp the necessary terms and concepts by entering values and then observing this exercise. If you feel that your knowledge of ramping controllers does not require a sample program to learn the Series 922, skip this chapter.
Sample Program Enter Real Time First, set the Series 922's "real time-of-day, 24-hour clock. Remember that the MODE key is used to step through the menus. The UP/DOWN keys are used to select parameters and values, and remain flashing until you press the ENTER key. 1. Press the MODE key until the SETUP menu appears. Press the ENTER key. 2. At ACCESS, select (0) with the UP/DOWN keys. Press ENTER. This is the calibration (CALIB) menu. 3. Press the MODE key until HOUR appears in the alphanumeric display.
Sample Program Skip Step 3 if you do not have an external event board connected. 3. Continue through the menu with the MODE key until you see AUX1. Use the UP/DOWN keys to enter AUX1 as an event (EV) and press ENTER. Do the same for AUX2. Default is AL (Alarm). 4. Continue through the SPCLFUNC menu until you see GS (Guaranteed Soak). Enter a value of (0); press ENTER. This parameter defaults to 0. 5. Press the MODE key to move to the RETURN parameter. Press ENTER to return to SYSTEM.
Sample Program Running Your Program 1. Return to SYSTEM using the ENTER key at the RETURN prompt. Press the RUN/HOLD key. 2. The 922 asks what FILE? to run. Enter (1) if it is not already entered. 3. The 922 asks what step you would like to start on. Again, press (1) if it is not already there, and press ENTER. The 922 quickly shows the step type and jumps to Step 1; the RUN LED is lit. After each step is completed, the next step the 922 performs appears.
Sample Program Adding AUTOSTART and LINKing Files The Series 922 gives you the capability to link files together. The LINK step allows you to link the last step of a profile to the first step of another profile. We are going to edit the program again by adding a LINK step at the end of the profile. First, we must create another file. If you try to run your program with a LINK that goes to a nonexisting file, you will receive ER2 0036. This error means "no file found.
Sample Program The WAITFOR Step The last step type we will work with is the WAITFOR step. This is a test step. It compares a specified temperature with the process temperature, or a specified event state with the event input, before continuing the program. It can also wait for a programmed time to elapse before continuing on with the program. After the test is successful, the program continues with the next sequential step. Events cannot be programmed in this step; they maintain their previous state.
Sample Program Running Your Series 922 To run your Series 922, you must be at one of the three main level operating parameter menus, SYSTEM, PROGRAM, or SETUP. Press the RUN/HOLD key. The Series 922 asks what file you want to run, and asks what step to begin with. After entering the file and step number, your program begins, and the RUN LED is lit. While in the RUN mode, you can only view the current file and step. To stop a running program, press the RUN/HOLD key.
Install/Wire Chapter 4 How to Install and Wire the Series 922 This chapter tells you how to install the Series 922. All mounting and wiring information is right here. Because Watlow controls are thoroughly tested, and "burned in" before leaving the factory, the Series 922 is ready to install when you receive it. But before you begin working or cutting holes in panels, read through this chapter to gain an understanding of the entire installation. Consider sensor installation carefully.
Install/Wire Contact Gordon at: 5710 Kenosha St., Box 500 Richmond, IL 60071 Phone: 815/678-2211 Excessive lead length in a two-wire RTD sensor can create indication errors. To combat this, use a three wire sensor in long lead applications. RTD - The Dry Bulb Installation We suggest you mount the dry bulb RTD at a location in your process or system where it reads an average temperature. Air flow past this sensor should be moderate. The sensor should be thermally insulated from the sensor mounting.
Definitions Wiring Guide Ground Loop - A condition created when two or more paths for electricity are created in a ground line, or when one or more paths are created in a shield. Earth Ground - The starting point for safety and computer grounds. It is usually a copper rod driven into the earth. Safety Ground - A ground line run with electrical power wiring to protect personnel. Computer Ground - A ground line for the ground connections to computers or microprocessor-based systems.
Wiring Guide How to Check for Ground Loops To check for ground loops, disconnect the ground wire at the ground termination. Measure the resistance from the wire to the point where it was connected. The ohmmeter should read a high ohm value. If you have a low ohm value across this gap, there is at least one ground loop present in your system. Also, check for continuity; your reading should be "open". If you do find continuity, you must now begin looking for the ground loops.
Wiring Guide Line Filtering Configurations for Controls These three diagrams show you filter configurations for removing input power noise. Choose the one best suited for your system if you are unsure which one to use. For very "dirty" or critical application -use microcomputer-regulated power supply or Uninterruptable Power Supply (U.P.S.) D.M. Line Filter L1 L2 Line Control Load Ground Figure 9 Differential Mode Filter Diagram Shield NOTE: Keep filters 12 inches or less from the control.
Installation Installation Information The Series 922 mounts in a panel cutout with two brackets. These brackets hold the case against the front panel. The Series 922 behind-panel dimensions are 3.56 in. (9.05mm) high by 3.56 in. (9.05mm) wide by 6.0 in. (15.24mm) deep. Figure 12 shows the dimensions of the front panel bezel. The 922 weighs 2.75 lbs. (1.25Kg).
Install / Wire 7.8" (197 mm) DB9 Communications Connector 6.0" (152 mm) 0.92" (23 mm) Bezel 3.0" (76 mm) Mounting Bracket 1.75" (45 mm) 3.56 "± 0.015" (90 mm ± 0.381) Event Output Ribbon Connector Figure 13 Series 922 Dimensions (side view) Alarm/Event Terminal Strip 8.0" (203 mm) 7.5" (191 mm) 0.25" (6 mm) 1.3" (33 mm) 0.36" (9 mm) Figure 14 External Event/ Alarm Board Dimensions 4.0" (102 mm) 3.5" (89 mm) Power Terminal Strip Four 0.
Wire Power Series 922 Power Wiring WARNING: To avoid potential electric shock, use National Electric Code safety pracChassis tices when wiring & GND connecting this unit to a power source and to electrical sensors or periphGreen eral devices. GND Wire Figure 16 Series 922 Power Wiring Diagram. WARNING: To avoid electric shock, connect the chassis ground terminal to "Earth Ground.
Wire Input How to Wire the Series 922 This section has all the information you need to complete a good wiring job on the Series 922 and your system. Please read the Safety Information in the narrow column on the outside of each page. You will find internal circuits on the left in the following diagrams, and external circuits on the right. In addition, input and output options are listed by model number. Refer to the unit sticker on your control to be sure that you are wiring from the corresponding diagram.
Wire Input Input Options "2" & "7", Terminals 1 - 8 Figure 18 Input Options "2" & "7", RTD/Process, Wiring Diagram. NOTE: For a twowire RTD - Channel 1:Use Terminals 6 and 7 for RTD, and jumper Terminal 8 to Terminal 7.
Wire Input Input Option "4", Terminals 1 - 8 Model # 922A - 1 2 3 4 _ _ 0 - _ 000 Retransmit Common Retransmit Output Process + + Chart Recorder (Optional) 0 - 5V, 4 - 20mA input 4 5 6 Channel 2 Process - 0 - 5V, 4 - 20mA input Process + 0 - 5V, 4 - 20mA input 4 - 20mA Sensor 7 8 Figure 20 Input Option "4" Dual Process, Wiring Diagram. Process - Channel 1 0 - 5V, 4 - 20mA input NOTE1: Jumper terminal 4 to 5 only when using 4-20mA input for Channel 2.
Wire Output Output Option "BB", Dual Solid State Relay Model # 922A - Figure 22 Dual S.S. Relay Output, Option "BB", Wiring Diagram. _ BB _ - _ 000 9 Output 1 LOAD 10 Channel 1 11 Output 2 LOAD 12 13 Output 3 LOAD 14 Channel 2 15 Output 4 LOAD 16 L2 (Neutral) L1 (Hot) Output Option "CC", Solid State Switch Figure 23 Solid State Switch, Option "CC", Wiring Diagram.
Use the following figures to learn the connections and wiring of the External Event/Alarm Board. Refer to Page 27 for dimension and mounting information. Event Board Figure 25 External Event/ Alarm Board Information. Figure 26 Figure 28a & 28b Figure 27 Control Power L2 Control Power L2 L1 GND L1 GND Earth Ground Earth Ground L2B L2B L1B L1B L1A L1A L2A L2A N.C. N.C. 115 VAC Figure 26 External Board Control Power Wiring.
Event Board Event Output Option "B" and "K", Solid State Relay 0.5A @ 24V~ (VAC) Min., 253V~ (VAC) Max. NOTE: Check model number for appropriate diagram. Model #A007-1732-XXKX Without RC Suppression. Minimum OFF-state impedance 31M . Model #A007-1732-XXBX With RC Suppression. Minimum OFF-state impedance 20K .
Wiring Example Single Phase 120VAC Application WARNING: Install High or low temperature limit control protection in systems where an overtemperature or undertemperature fault condition could present a fire hazard or other hazard. Failure to install temperature limit control protection where a potential hazard exists could result in damage to equipment and property, and injury to personnel.
Tuning Programming Chapter 5 How to Tune the Series 922 This chapter will explain tuning the 922 to the system it controls. Recommended Tuning Reference There are a number of quality references on the art of tuning electronic controllers to the systems they control. If you are not an instrument technician qualified to tune thermal systems, we suggest that you obtain and become familiar with the reference below before attempting to tune your system.
Tuning Tuning For optimum control performance, tune the 922 to the thermal system. The tuning settings here are meant for a broad spectrum of applications; your system may have somewhat different requirements. Refer to the key flow charts, diagrams and definitions on Pages 42 - 61 for prompt location and description. Repeat this tuning procedure for both Channel 1 and 2. NOTE: When tuning in the Heat mode, use PID prompts followed by H. When tuning in the Cool mode, use PID prompts followed by C. 1.
Programming Chapter 6 How To Program The Series 922 This chapter enables you to setup the Series 922 quickly and easily. It explains why it's a good idea to write out your parameter values. Chapter 6 also shows you flow diagrams of the programming process. Write Out Your Program The Watlow Series 922 controls temperature for a specific heating and/or cooling process. Your setup parameter values, when they're entered, give the Series 922 orders for the work you want it to perform.
Events/ GS Event Outputs Another feature of the Series 922 is its capability for up to eight event outputs via an external event output board. You have the option of ordering your 922 without events, or adding an external board for two or eight outputs. An "event output" is simply a pre-programmed ON/OFF event per program step. The event may turn any number of peripheral devices ON or OFF to assist you in controlling your process, system or environment.
Jumploops The Four JUMPLOOP Types The Series 922 gives you the capability to perform four basic jumploop types in your programming. The backward jump, forward jump, nested loops, and intertwining loops. These are only definitions of the four loops. The Series 922 has very few rules concerning loops in your program. Backward Jump The Backward jump is the most common jump. A backward jump will force you to a step already performed. The Jump Step (JS) must be less than the current step.
Jumploops Nested Loop A "Nested" loop is a jump loop within a loop. You are forced to a step either forwards or backwards from your present location. When nested loops are performed, they cannot break across other loops. Your JC can be from 0 - 100 with 0 being an infinite looping.
SYSTEM Menu The next pages will show you each of the Series 922 menus and their prompts and values. Each section, SYSTEM, SETUP, and PROGRAM, has a menu graphic with a table of values, followed by prompt definitions. Don't write in the tables and charts here, but make copies to document your control. Prompt definitions are also listed in the glossary. Programming in General Programming the Series 922 is easy as 1 - 2 - 3: 1. Use the MODE key to select the alphanumeric display prompt you want. 2.
Table 8 SYSTEM Prompts and Description SYSTEM Menu Make photocopies, keep original clean. SYSTEM Prompt Description Range SP1 Monitor/Enter CH 1 Fixed Set Point value. SP2 Monitor/Enter CH 2 Fixed Set Point value. Dependent on "TYP" under SPCLFUNC. Displays CH 2 actual process variable. Dependent on "TYP" under SPCLFUNC. Monitor/Enter the Event Output 1 status. Dependent on AUX1 = EV & output board. Monitor/Enter the Event Output 2 status. Dependent on AUX2 = EV & output board.
SYSTEM Menu EV1 ( ) EV2 ( ) EV3 ( ) EV4 ( ) EV5 ( ) EV6 ( ) EV7 ( ) EV8 ( ) This auxiliary output can be an alarm or event. Events may be changed ON or OFF in the HOLD mode. EV2 will only appear when AUX2 = EV, under the SPCLFUNC menu, and when the external event output board is connected, or when TYP = "T" or "P" and an external event board is connected. Range: OFF or ON Default: OFF These auxiliary outputs are events. Events may be turned ON or OFF in the HOLD mode.
SETUP Menu SETUP Menu While in the HOLD mode, press the MODE key until you see SETUP, press ENTER. These parameters are to setup the personality of your Series 922. Using the MODE to progress through the prompts, use the UP/ DOWN keys to select parameters and values and press ENTER. Select each ACCESS number. Follow that parameter sequence to enter values. You must return to SYSTEM before you can continue to the next ACCESS number.
SETUP Menu Table 9 SETUP Prompts and Description. Make photocopies, keep original clean. SETUP Prompt Description Range ACCESS = (0) CALIB To enter CALIB parameters use ACCESS (0) and ENTER. TI XX:XX Read only. Displays the Real Time. HH:MM HOUR Enter the hours to display the system time-of-day clock. MIN Enter the minutes to display the system time-of-day clock. CAL1 Enter the Calibration Offset value for Channel 1. CAL2 Enter the Calibration Offset value for Channel 2. Dependent on TYP parameter.
SETUP Menu Table 9 continued Prompt Description Range Default Your Settings ACCESS = (1) PID Continued To enter PID parameters, use ACCESS (1) & press ENTER. CH2 PB2H Enter the Channel 2 Proportional Band value, Heating. Dependent on TYP parameter. RS2H Enter the Channel 2 Reset value, Heating. Not displayed if PB2H = 0. Dependent on TYP parameter. RT2H Enter the Channel 2 Rate value, Heating. Not displayed if PB2H = 0. Dependent on TYP parameter. CT2H Enter the Channel 2 Cycle Time value, Heating.
NOTE: Changing these parameter values will default other parameters and clear all files. See Page 53 & 54 for details. SETUP Menu Table 9 continued Prompt Make photocopies, keep original clean. Description Range Default Your Settings ACCESS = (5) SPCLFUNC To enter SPCLFUNC parameter, use ACCESS (5) and press ENTER. C/F/U Enter the unit of measure code. (Celcius/Fahrenheit/Units) C/F/U F Not displayed if DIP Switch #2 is ON. TYP Enter actual process display to be shown.
Shaded parameters may not appear on your control. They are dependent on your control configuration. SETUP Menu One of three main level operating menus. From the SETUP menu, you can set up or change system-operating parameters such as real time, high/low range, alarm types, alarm points, PID settings and communications. You must select each ACCESS number to create the personality of your Series 922.
SETUP Menu A2L The low process alarm or low deviation alarm for Output 2 of the Series 922. Displayed only when AUX2 = AL and an external event board is present. ALTYP2 parameter selects a process or deviation alarm. This parameter will not appear if TYP, under the SPCLFUNC menu, is set to "T" (Temperature for Channel 1 only) or "P" (Process for Channel 1 only). Process Range: R2L to R2H (R2L -10% to R2H +10%) Process Default: R2L (R2L -10%) Deviation Range: -R2H (or -555°C / -55.5°C / -999°F/U / -99.
SETUP Menu DB1 ( ) PB1C ( RS1C ) ( ) RT1C ( ) CT1C ( ) RB1C ( ) RETURN PID CH2 ( ) PB2H ( ) The area for Channel 1 where no heating or cooling takes place in a heat/cool proportional control. Range: -36 to 36°F / -20 to 20°C / -20 to 20 Units; -3.6°F / -2.0 to 2.0°C / -2.0 to 2.0 Units. Default: 0 A temperature band expressed in degrees within which a temperature controller proportioning function is active for Channel 1 cooling. Range: 0 to 900°F / 0 to 500°C / 0 to 500 Units; 0.0 to 90.
SETUP Menu RS2H ( ) RT2H ( ) CH2H ( ) RB2H ( ) DB2 ( ) PB2C ( ) RS2C ( ) RS2C ( ) 52 A reset (integral) heating control action for Channel 2 that automatically eliminates offset, or "droop", between point and actual process temperature in a proportional control. Expressed by repeats per minute. This parameter will not appear if PB2H is set to 0, or if "T" or "P" have been selected in TYP under the SPCLFUNC parameter. Range: 0.00 to 5.00 repeats/minute Default: 0.
SETUP Menu The cooling cycle time for Channel 2 expressed in seconds for a controller to complete one ON/OFF cycle. Time between successive turn ons. This parameter will not appear if: Your Series 922 has a 4-20ma output and OUT2 under the SPCLFUNC menu is set to CLHT, PB2C is set to 0, or "T" or "P" (Channel 1 only) in the TYP parameter under the SPCLFUNC menu has been selected.
SETUP Menu 54 TYP ( ) OUT1 ( ) OUT2 ( ) R1L ( ) R1H ( ) R2L ( ) R2H ( ) Allows the operator to configure the unit to the type of actual process display to be shown. This also affects the number of channels. This parameter will not appear if DIP Switch #2 is ON. Changing this parameter defaults all parameters and clears all files.
SETUP Menu This parameter determines whether Auxiliary Output 1 will be an alarm or event output for the Series 922. This parameter will not appear if the 2 event or 8 event output board is not connected, or DIP Switch #2 is ON. Range: Alpha Display Auxiliary Output 1's Function AUX1 AL Alarm Output defined for Event 1 AUX1 EV Event Output defined for Event 1 Default: AL This parameter determines whether Auxiliary Output 2 will be an alarm or event output for the Series 922.
SETUP Menu ANLG ( ) SCALE ( ) COM ( ) BAUD ( ) COM ID ( ) LOCK ( ) CLR FILE RETURN 56 Allows the operator to select which parameter the analog retransmit signal represents. For a chart recorder output, select C1 or C2. For a remote set point signal (to slave controls) select SP1 or SP2. C2 and SP2 will not appear if the TYP parameter is T or P. See SCALE parameter below for further explanation.
PROGRAM Menu PROGRAM Menu From the Program menu, you can create your files. There can be up to ten profiles, consisting of a total of 99 steps. You can only choose one step type per step. Graphics Key = MODE Key = ENTER Key = UP/DOWN Key M NOTE: Shaded parameters may not appear on your control. These parameters are dependent on how your control is configured. See Pages 58 61 for more information. E NOTE: The Series 922 leaves the factory programmed for a warm start.
PROGRAM Menu Table 10 PROGRAM Prompts and Description. Make photocopies, keep original clean. PROGRAM Prompt Description Range FILE? STEP Current system file to edit. Select step number to view or edit. Press MODE for step-type prompt. To change step-type use the increment/decrement key and press ENTER.
Shaded parameters may not appear on your control. They are dependent on your control configuration. PROGRAM Menu One of three main level operating menus. From the SETUP menu, you can enter or view step type, program loops, wait for conditions, set points, auxiliary (event) outputs ON/OFF, and step duration. Program F ILE? ( ) STEP ( ) Represents the current SYSTEM file of the Series 922 to be edited or reviewed.
PROGRAM Menu PROGRAM Menu Programming EV3 ( ) EV4 ( ) EV5 ( ) EV6 ( ) EV7 ( ) EV8 ( ) RETURN JUMPLOOP JS ( ) JC ( ) RETURN WAITFOR 60 W1 ( ) W2 ( ) WHR ( ) WMN ( ) SETPOINT step is executed. These events only appear when the 8 output event board is connected to the Series 922. Range: OFF or ON Default: Unprogrammed OFF = Event OFF ON = Event ON From RETURN, you can go back to the SYSTEM prompt by pressing the ENTER key, or return to FILE? by pressing the MODE key.
PROGRAM Menu WE ( ) RETURN AUTOSTART DAY ( ) HOUR ( ) MIN ( ) A wait for event input represented by a switch closure or opening, at which the 922 continues the program This is not a voltage or current input. Range: OPEN or CLSE Default: Unprogrammed From RETURN, you can go back to the SYSTEM prompt by pressing the ENTER key, or return to FILE? by pressing MODE. One of six step types under the PROGRAM menu of the Series 922 that can be programmed to automatically start at a determined real time.
Master Step Chart Programming Chart 1 - Master Step chart Step # √ Step Type SETPOINT Make photocopies, keep original clean.
Alarms Chapter 7 How To Use the Series 922 Alarms One of the most versatile features of the Watlow Series 922 is its capability for alarms. The alarms can be automatic signals for process error or temperature related event-type actions in your system. NOTE: If your unit does not have an external output board, or it's not connected, this section does not apply to your unit. To use the alarms to their fullest extent, you need to understand what they are and what they will do.
Alarms Alarm Types There are two Alarm Types for each alarm. ALTYP1 and ALTYP2 are the prompts for Alarm 1 and Alarm 2, respectively. The choices are: Process alarm (P), or Deviation alarm (D). For review, a "process" type alarm is one that is set at a fixed degree distance, either positive or negative, from the mean 0°C or 0°F. A "deviation" type alarm is always a fixed degree distance, positive or negative, from Set Point (SP).
Alarms The Operating Band Now we need to set the alarm limits. In doing so, you'll define an "operating band" where you want system temperature (or your controlled variable) to be "OK" and alarm-free. By selecting an alarm type (ALTYP), and then the alarm limits (AXL, AXH), you define the Operating Band. The extreme limits of the Operating Band are defined by the 922's high and low ranges, RXL and RXH. Alarm Limits You can set up alarm bands with the two available alarms.
Alarms AH 2 AH 1 A1H Temp New SP1 SP1 Figure 37 Alarm Limits for Alarms 1 and 2 with "Deviation" Type Alarm (ALTYP=D, ALTYP=D) AL 1 A1L AL 2 Actual 0°C Time Time NOTE: Only Channel 1 is shown here. Alarm Function, Latching or Non-Latching Alarm function is either "latching" or "non-latching." Latching is a means of "saving" indication of an alarm event for the operator to clear manually.
Alarms Clearing An Alarm Message You can clear a latched alarm when the ACTUAL display value returns to within the operating band. You do not need to clear, indeed, you cannot clear, a non-latching alarm. A non-latching alarm clears itself as soon as the ACTUAL display value returns to within the operating band. There is a 3°F switching differential. An Alarm And The State Of The Alarm Relay Simply stated, a flashing alarm on the 922 alphanumeric display indicates the state of the alarm relay contacts.
Specifications Specifications Appendix Control Mode • • • • • • Microprocessor-based, user selectable modes. Dual inputs, dual control outputs per channel. 8 event outputs/1 event input/1 remote hold input. 99 step programmer with up to 10 profiles. Control outputs: User selectable as: Heat/Cool, Cool/Heat. • Outputs independent, or related via deadband for Heat/Cool. • ON/OFF: 3°F or 1.7°C switching hysteresis or 0.3°F or 0.17°C for 0.1° Units .
Output - Control Per Channel (Single or Dual) • • • Solid state relay, 0.5A @ 24VAC min. 264 VAC max., opto-isolated, zero cross switching. Solid state switch, 20mA @ 20VDC max, open collector switch-to-ground. 4-20mA into 600Ω load maximum. Specifications Output/Input - Auxiliary • • • • External, plug-in module. Solid state relays, 2 or 8 ea., 0.5A @ 24VAC min. 264 VAC max. Auxiliary supply: 21 to 33VDC, 25mA maximum.
Ordering 922 A 0 000 Series 922 = Dual channel microprocessor-based, dual input, quad output, ramping controller, 99 steps, 1/4 DIN. Input 1 2 3 4 5 6 7 8 9 A B = = = = = = = = = = = Dual RTD 1° RTD 1° and process Type T thermocouple and process Dual process Dual Type T thermocouple Dual RTD 0.1° RTD 0.1° and process Dual Type K thermocouple Dual Type J thermocouple Type K thermocouple and process Type J thermocouple and process Output Per Channel BB = Dual solid state relay, Form A, 0.
T/C Calibration Thermocouple Field Calibration Procedure Equipment Required • • • • Type "J", "K", or "T" (depending on model number) Reference Compensator with reference junction at 0°C/32°F AND Precision Millivolt Source. OR Type "J", "K", or "T" thermocouple calibrator. 4-1/2 digit Digital Voltmeter (DVM). Can be used with either configuration above. Setup and Calibration k NOTE: Before calibration on an installed control, make sure all data and parameters are documented. 1.
T/C Calibration 5. Press the MODE key until DAS6 XXXX appears on the alphanumeric display. Use the UP/DOWN keys to adjust the alphanumeric display to match the reading on the DVM. Once the two readings match, press the ENTER key. 6. Press the MODE key until CH1Z XXXX appears on the alphanumeric display for Channel 1 [CH2Z XXXX for Channel 2]. Enter 0.00 millivolts from the millivolt source to the reference compensator, or set the t/c calibrator to 0°C/32°F.
RTD Calibration RTD Field Calibration Procedure Equipment Required • • 100Ω precision decade resistance box with 0.01 ohms resolution. 4-1/2 digit, digital voltmeter (DVM). Setup and Calibration NOTE: Before calibration on an installed control, make sure all data and parameters are documented. 1. Connect the precision decade box to #6, #7, and #8 of the Series 922 terminal strip for Channel 1 as shown on Figure 39. For Channel 2 connect the precision decade box to #3, #4, and #5 of the terminal strip.
RTD Calibration precision decade box to the correct RTD setting from Table 11 that corresponds to the type of 922 unit you have. Allow 10 seconds for settling, press the ENTER key. 7. Press the MODE key until CH1G XXXX for Channel 1 appears on the alphanumeric display [CH2G XXXX for Channel 2]. Set the precision decade box to the correct RTD setting from Table 11 that corresponds to the type of 922 unit you have. Allow 10 seconds for settling and then press the ENTER key.
Process Field Calibration Procedure Process Equipment Required • • 4-1/2 digit, digital voltmeter (DVM). Precision voltage/current source. Setup and Calibration NOTE: Before calibration on an installed control, make sure all data and parameters are documented. Figure 40 Voltage/Current Source to Series 922 Connection Diagram 1. Connect the voltage/current source to #6 Positive and #8 Negative on the Series 922 terminal strip for Channel 1 [#4 Positive and #5 Negative for Channel 2]. See Figure 40.
Glossary, A - B Glossary This glossary includes general thermal system control terms. ACCESS( ): In the SETUP menu of the Series 922, an ACCESS number (0, 1, 3, 5) must be selected to enter the personality of your Series 922 into the CALIB, PID, DIAGNOS, and SPCLFUNC. Any other number will return to SYSTEM. Actual Display data: Displayed information which gives the operator/programmer real or "actual" data, i.e., actual process temperature. See "Programmed display data.
BAUD: Represents the baud rate (1200, 2400, 4800, 9600) that serial communications will be running at. This parameter will not appear under ACCESS (5) of the SPCLFUNC menu if your Series 922 does not have communications. CAL1, CAL2: An offset of the process variable for Channel 1 or Channel 2. This number is added to the value that the system derives. The final result is used for the set point as well as a front panel indication.
Glossary, D - H Default parameters: The parameters, or programmed instructions, which are permanently stored in microprocessor software to provide a data base. DIP Switch: A Dual In-line Package switch. DIN: Deutsche Industrial Norms, a widely-recognized German standard for engineering units. Display capability: In a digital indicating instrument, the entire span that can be indicated if fully utilized. Droop: The difference in temperature between set point and stabilized process temperature.
Hunting: Oscillation or fluctuation of process temperature between set point and process variable. Hysterisis: In ON/OFF control, the temperature change necessary to change the output from full ON to full OFF. Input: Process variable information being supplied to the instrument. Integral: Control action that automatically eliminates offset, or "droop", between set point and actual process temperature. Also reset. Isolation: Electrical separation of sensor from high voltage circuitry.
Glossary, O - R OUT: Select an output type. Action in response to the difference between set point and process variable. Output: Action in response to difference between set point and process variable. Overshoot: Condition whereby temperature exceeds set point due to initial power up or process changes. PB1C/PB2C: A proportional temperature band for Channel 1 or Channel 2 expressed in degrees within which a temperature controller proportioning function is active for cooling expressed in degrees.
RB1H/RB2H: A thermal control band for heating in Channel 1 or Channel 2 that defines where the rate (derivative) function begins. RS1C/RS2C: Reset (integral) cooling control action for Channel 1 or Channel 2 that automatically eliminates offset, or "droop", between set point and actual process temperature in a proportional control. Expressed in repeats per minute.
Glossary, S - Z SYSTEM: One of three main level operating parameters. From the SYSTEM menu, you can generate a non-ramping set point (fixed), manipulate Events 1 through 8, clear error codes and latching alarms, and monitor Channel 2's actual temperature and the external input. Switching sensitivity: In ON/OFF controls, the temperature change necessary to change the output form full ON to full OFF (3° or °F in the Series 922.
Index A Accessories, 70 Actual and Alphanumeric Display Area, 13, Fig. 6 Alarms, Clearing, 67 Function, 66 Limits, 65 Types, 64 AUTOSTART Step Type, 18 B Backward Jump, 40 C Calibration, 71 Chart Recorder, 36, 56 Clean Input Power, The Do's and Don'ts, 23 Combination Differential Filter, 25, Fig. 11 Common Mode Filter Wiring, 25, Fig. 10 D Decade Resistance Box-to-Series 922 Connection Diagram, 73, Fig. 41 Default Parameters, 43, 46-48, 58 Differential Mode Filter Wiring, 25, Fig.
Index R Read Me First, 7 Reference Compensator-to-Series 922 Connection Diagram, 71, Fig. 40 Returns, 85 RTD Parameter Settings, 74, Table 11 RTD Sensor Wiring, Dual, 29, Fig. 17 RTD/Process, 30, Fig. 18 Running Your Series 922, 20, Fig. 8 S Sample Program, Chapter 3, 14 Sensor, Installation, 21, 29 Wiring, 29 Series 922 Input and Output Overview, 7, Fig. 1 SETUP, 45 Shipping Claims, 86 Specifications, 68 SS Relay Output Wiring, 31, Fig. 22 SS Switch Output Wiring, 31, Fig.
Warranty Warranty Information The Watlow Series 922 is warranted to be free of defects in material and workmanship for 36 months after delivery to the first purchaser for use, providing that the units have not been misapplied. Since Watlow has no control over their use, and sometimes misuse, we cannot guarantee against failure.
Shipping Shipping Claims When you receive your Watlow control, examine the package for any signs of external damage it may have sustained enroute. If there is apparent damage either outside the box or to its contents, make a claim with the shipper immediately. Save the original shipping carton and the packing material. Watlow Controls Watlow Controls is a division of Watlow Electric Manufacturing Company of St. Louis, Missouri.
Series 922 Error Codes/Alarms ER1 Error Codes and Actions ER2 Error Codes and Actions 1 2 3 4 1 5 6 7 8 9 10 11 12 14 15 18 Internal RAM failure. Contact factory. External RAM failure. Contact factory. Bad battery error. Contact factory. Channel 1 A/D conversion error; check sensor or contact factory. Channel 2 A/D conversion error; check sensor or contact factory. Ground A/D conversion error; contact factory. High reference A/D conversion error, contact factory. Channel 1 interpolation/overrange.
Series 922 Response to Error Codes Clearing an Error Code To clear an Error Code from the alphanumeric display, first correct the problem, then return to the SYSTEM menu. Use the UP/DOWN keys to reach the ER1 or ER2 parameter and press ENTER. Press ENTER or transmit a 0. If the code returns, or if the 922 replies to a data communicated "? ER1" or "? ER2" query with the same code, the problem still exists. Refer to the Series 922 manual.
Series 922 Quick Reference Main Menu M E SYSTEM To SYSTEM Menu PROGRAM To PROGRAM Menu SETUP To SETUP Menu SYSTEM Menu M E SYSTEM SP1 ( ) SP2 ( ) EV1 ( ) EV2 ( ) EV3 ( ) EV4 ( ) EV5 ( ) EV6 ( ) EV7 ( ) EV8 ( ) ER1 ( ) ER2 ( ) C2 EI CLR ALARM RETURN To SYSTEM M F ILE? ( ) ( ) STEP PROGRAM Menu E PROGRAM PROGRAM SETPOINT JUMPLOOP AUTOSTART WAITFOR SP1 ( ) JS ( ) W1 ( ) DAY ( ) SP2 ( ) JC ( ) W2 ( ) HOUR ( ) HOUR ( ) RETURN
Notes 90 WATLOW Series 922 User's Manual Appendix
Notes Appendix WATLOW Series 922 User's Manual 91
Watlow Series 922 User's Manual Watlow Controls, 1241 Bundy Blvd., P.O.
