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Series 988
User’s Manual
Includes 986, 987, 988 and 989
1/8 DIN Microprocessor-Based Temperature/Process Controller
User Levels:
• New User........................... go to Introduction
9 6
• Experienced User................... go to page 4.1
Installers:
• Set-up..................................... go to page 1.1
TOTAL
• Wiring & Installation................ go to page 2.1
3 Y ear Warranty
ISO 9001
Registered Company
Winona, Minnesota USA
Watlow Controls
1241 Bundy Blvd., P.O. Box 5580, Wino
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a.TOC.wc 5/14/1999 8:57 AM Page 1 Table of Contents Introduction to the Watlow Series 988 Chapter 6 Controllers The Factory Menus ii Using this Manual 6.1 Navigating the Factory Menus ii Document Every Step 6.2 Panel Lockout Menu iii Notes, Cautions and Warnings 6.7 Diagnostics Menu iii Technical Assistance 6.13 Calibration Menu iii We Value Your Feedback Chapter 7 Chapter 1 Tuning, Manual Operation, Hardware Setup Alarms and Error Codes 1.1 Dip Switch Locations and Functions 7.1 Auto-tuning
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C0-intro.wc 5/14/1999 8:57 AM Page i Introduction to the Watlow Series 988 Controllers Figure Int.1 - The Series 988 Controllers. Watlow’s Series 988 controllers set a new standard in the controller indus- try by packing an impressive array of features into an 1/8-DIN package. No other controller offers the flexibility, compact size and durability of the Series 988. It can control a wide variety of temperature and process appli- cations, with a broad range of input and output options that a
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C0-intro.wc 5/14/1999 8:57 AM Page ii Introduction Using this Manual This manual provides the information you will need to install and operate a Series 988 controller. If you need information about Series 988 configurations and model num- bers, refer to the Appendix of this manual or, for more detailed informa- tion, to Optimizing Your Process System with the Series 988 Controller: An Application Guide for the Watlow Series 988 Family. If your Series 988 controller will be used for data comm
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C0-intro.wc 5/14/1999 8:57 AM Page iii Introduction Notes, Cautions and Warnings 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. A bold text “CAUTION” safety alert appears with information that is important for protecting your equipment and performance. Be especially careful to read and follow all cautions that apply
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C1.wc 5/14/1999 8:42 AM Page 1.1 Chapter 1 Hardware Setup DIP Switch Locations and Functions The Watlow Series 988 has at least one and as many as six dual in-line package (DIP) switches inside the controller, depending on the model number. They allow users to configure the controller for a variety of input sensors, to provide power for external signal conditioners or to lockout front panel access to some functions. To set any DIP switch: • Remove the controller from the case by pressing fir
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C1.wc 5/14/1999 8:42 AM Page 1.2 DIP Switches 1. Set the input DIP Input 2 DIP switches to match the sensors you are using ON in your application. Input 1 DIP Only controllers with model number 98_ _- ON ÷ 2_ _ _-_ _ _ _ or 98_ _- _2_ _-_ _ _ _ have an NOTE: input DIP switch. Controller Chassis The Input 2 DIP Rear View switch is mounted upside down. Input 1 Input 2 (98 _ _-2_ _ _-_ _ _ _)(98 _ _-_2_ _-_ _ _ _) ÷ NOTE: › 12 3 Only controllers O N › with the indicated RTD (100 Ω) model numbers
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C1.wc 5/14/1999 8:42 AM Page 1.3 DIP Switches 2. Set DIP switches for Output 1 Option Board outputs equipped with on off Output 2 an external signal con- Option Board and DIP ditioner power supply. Output 4 off on Option Board and DIP Only controllers with Output 3 model number 98_ _-_ Option Board and DIP off on _ _T-_ _ _ _, 98_ _-_ _ _ _-T_ _ _ or 98_ _-_ _ _ ÷ _-_T_ _ have an exter- NOTE: nal signal conditioner Controller Chassis For other voltages power supply. Top View (986 & 988) or
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C1.wc 5/14/1999 8:42 AM Page 1.4 DIP Switches 4. The lockout DIP switch hides the Setup Menus (Input, Output, Global and CAUTION: Communications) and the The lockout DIP Factory Menus (Panel switch makes the Setup and Factory Lockout, Diagnostics and menus unavailable. Calibration). All units have Configure all the a lockout DIP switch. Setup and Factory menus before lock- ing them out. Failure to do so could result in dam- age to equipment in the event of a setup error. 12 12 O O N N › › n
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C2.wc 5/14/1999 8:44 AM Page 2.1 Chapter 2 Installation and Wiring WATL W ÷ 4.03" NOTE: (102mm) Space panel PROCESS cutouts at least 1.66 WATL W inches (42.2mm) DSPY MODE 4.03" apart. L1 L2 L3 L4 (102mm) 2.18" PROCESS DEV (55 mm) DISPLAY % OUT DEV AUTO % OUT MAN AUTO MAN SERIES 989 L1 L2 L3 L4 MODE ÷ SERIES 988 NOTE: 2.18" Adjustable mount- (55 mm) ing brackets can be side-mounted. Adjustable Panel Mounting Bracket Panel Cutout ÷ Maximum Panel Thickness NOTE: 0.38" (9.65mm) Holes can be cut i
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C2.wc 5/14/1999 8:44 AM Page 2.2 Installation Installing the Series 988 Installing and mounting requires access to the back of the panel. 1. Make a panel cutout using the panel cutout dimensions from the previ- ous page. 2. To remove the controller chassis from its case, press in firmly on the two tabs on one side or the top of the bezel until they unsnap, then unsnap the two tabs on the opposite side or the bottom. Pull the chassis out of ÷ the case by gently rocking it. NOTE: 3. Slide the
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C2.wc 5/14/1999 8:44 AM Page 2.3 Installation the mounting collar over the back of the control. 4. Loosen the mounting bracket screws enough to allow for the mounting collar and panel thickness. Place each mounting bracket into the mounting slots (head of the screw facing the back of the controller). Push each bracket backward then down to secure it to the control case. To guarantee a proper NEMA 4X seal, Series 986 and 988 units (vertical) must have the mounting brackets located on either si
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C2.wc 5/14/1999 8:44 AM Page 2.4 Wiring Wiring the Series 988 º WARNING: Wiring options depend on the model number and DIP switch settings. To avoid potential Check the terminal designation stickers on either side of the controller electric shock, use and compare your model number to those shown here and with the model National Electric number breakdown on the inside back cover of this manual. Code (NEC) safety practices when Input-to-output Isolation wiring and connect- ing this unit to a po
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C2.wc 5/14/1999 8:44 AM Page 2.5 Wiring Sensor Installation Guidelines Maintain isolation between input 1 and input 2 to prevent a ground loop. A ground loop may cause incorrect readings, dashes across the upper dis- CAUTION: play or the display of error codes. The Series 988 will not function with Thermocouple input: Extension wire for thermocouples must be of the two grounded ther- same alloy as the thermocouple itself to limit errors. mocouple inputs. Avoid using a Using grounded thermoc
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C2.wc 5/14/1999 8:44 AM Page 2.6 Wiring Example º WARNING: To avoid potential electric shock, use L1 National Electric 120V (ac) L2 Code (NEC) safety high-temperature earth ground light practices when wiring and connect- high-limit mechanical coil ing this unit to a fuse contactor power source and 21 22 11 to electrical sen- 12 (+) 15 SSR-240-10A-DC1 sors or peripheral 92A3-1DJ1-0000 (-) 13 limit control out dc input devices. Failure to SSR 12 do so could result 43 in injury or death. in h
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C2.wc 5/14/1999 8:44 AM Page 2.7 Wiring Notes L1 L2 earth ground 11 21 22 power WARNING: To avoid damage to property and equip- ment, and/or injury of loss of life, use National Electric Code (NEC) stan- dard wiring prac- tices to install and operate the Series 988. Failure to do so could result in such damage, and/or injury or death. ÷ NOTE: Sketch in your application on this page or a copy of it. See wiring exam- ples in this chapter and in the Appen- dix. Figure 2.7 - Wiring notes. Ins
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C2.wc 5/14/1999 8:44 AM Page 2.8 Input 1 Wiring Figure 2.8a — Thermocouple or 0-50mV (high impedance) ÷ NOTE: Thermocouple only Successful installa- 98 _ _ - 1 _ _ _ - _ _ _ _ (no DIP switches) tion requires five steps: Universal signal conditioner • Model number and 9 12 3 12 3 O O 98 _ _ - 2 _ _ _ - _ _ _ _ N N software choice 10 › › (Appendix); J, K, T, N, C, E, D, Pt2, R, S, B 9 • DIP switch set- Input impedance: 20MΩ 0-50mV DIP Settings DIP Settings 10 tings (Chapter 1); 0-50mV • Sensor
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C2.wc 5/14/1999 8:44 AM Page 2.9 Input 2 Wiring Figure 2.9a — Thermocouple or 0-50mV (high impedance) NOTE: Successful installa- Thermocouple only tion requires five 98 _ _ - _ 1 _ _ - _ _ _ _ (no DIP switches) steps: • Model number and Universal signal conditioner software choice › › 98 _ _ - _ 2 _ _ - _ _ _ _ 19 (Appendix); 20 • DIP switch set- 0-50mV R, S, B J, K, T, N, C, E, D, Pt2, tings (Chapter 1); Input impedance: 20MΩ 19 DIP Settings 0-50mV DIP Settings • Sensor match 20 (Chapter 2
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C2.wc 5/14/1999 8:44 AM Page 2.10 Input 2 Wiring NOTE: Figure 2.10a — Slidewire Feedback or Potentiometer Input See Chapter 8 for information on slidewire feedback. 98 _ _ - _ 3 _ _ - _ _ _ _ 18 CCW 19 Wiper 20 CW ÷ NOTE: A process output Figure 2.10b — Current Transformer Input cannot be installed on output 1 when 98 _ _ - _ 4 _ _ - _ _ _ _ using a current transformer input. The current transformer must be purchased separately. Watlow current transformer part number 16-0246 (up to 50 amps).
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C2.wc 5/14/1999 8:44 AM Page 2.11 Event Input 1 Wiring Figure 2.11a — Digital Event Input 1 NOTE: Successful installa- tion requires five Available on all units. OPTO steps: ISOLATOR • Model number and open 14-36Vë (dc) Event Input 1 off software choice closed 0-3Vë (dc) Event Input 1 on (Appendix); 4.99KΩ .01μf • DIP switch set- 750Ω tings (Chapter 1); +24Vë (dc) 23 24 • Sensor match +- 10KΩ 4.99KΩ (Chapter 2 and Appendix); Internal Circuitry • Sensor installation (Chapter 2); and 23 24 •
