Despatch Watlow 1500 Control User manual

P/N 260786
Rev. 8/96
E-87
U.S. $45.00
Instruction Manual for the
Despatch/Watlow 1500 Control

Copyright © October 24, 2001 by Despatch Industries
Notice
Users of this equipment must comply with operating procedures and training of
operation personnel as required by the Occupational Safety and Health Act (OSHA)
of 1970, Section 6 and relevant safety standards, as well as other safety rules and
regulations of state and local governments. Refer to the relevant safety standards
in OSHA and National Fire Protection Association (NFPA), section 86 of 1990.
Caution
Setup and maintenance of the equipment should be performed by qualified
personnel who are experienced in handling all facets of this type of system.
Improper setup and operation of this equipment could cause an explosion that may
result in equipment damage, personal injury or possible death.
Dear Customer,
Thank you for choosing Despatch Industries. We appreciate the
opportunity to work with you and to meet your heat processing
needs. We believe that you have selected the finest equipment
available in the heat processing industry.
At Despatch, our service does not end after the purchase and
delivery of our equipment. For this reason we have created the
Service Products Division within Despatch. The Service Products
Division features our Response Center for customer service. The
Response Center will direct and track your service call to ensure
satisfaction.
Whenever you need service or replacement parts, contact the
Response Center at 1-800-473-7373: FAX [phone].
Thank you for choosing Despatch.
Sincerely,
Despatch Industries

Despatch/Watlow 1500 Control Instruction Manual Page i
NOTE:
Read the entire
INTRODUCTION and
THEORY OF OPERATION
before operating the control.
WARNING:
Failure to head warnings in
this instruction manual and
on the oven could result in
death, personal injury or
property damage.
PREFACE
This manual is your guide to the Watlow 1500 control. It is
organized to give you the information you need quickly and
easily.
The INTRODUCTION section provides an overview of the
control.
The THEORY OF OPERATION section details the function
and operation of the control.
The INSTRUCTIONS section provides directions on
unpacking, installing, operating and maintaining the control.
The APPENDIX section contains Special Instructions for
operating the control instrument and a Troubleshooting
Table.
An efficient way to learn about the control would be to
read the manual while working with the control. This will
give you practical hands-on experience with information in
the manual and the control.
While reading this manual, if a term or section of
information is not fully understood, look up that item in the
appropriate section to familiarize yourself with that item.
Then go back and reread that section again. Information
skipped, not understood or misunderstood could create the
possibility of operating the equipment in an unsafe manner.
This can cause damage to the oven or personnel, or reduce
the efficiency of the equipment.

Page ii Despatch/Watlow 1500 Control Instruction Manual

Despatch/Watlow 1500 Control Instruction Manual Page iii
Table of Contents
PREFACE ............................................................i
Table of Contents .................................................iii
List of Figures ....................................................iv
List of Tables .....................................................iv
INTRODUCTION ..................................................... 1
INSTRUCTIONS ...................................................... 3
Operating ........................................................ 3
Watlow 1500 Control ............................................... 4
Manual Set Point Controller ....................................... 6
Guarded Access Programming ..................................... 8
Setting the Clock ............................................. 9
GA0001 and 0002 PID Tuning ................................. 10
GA0000 Alarms ............................................. 10
GA0006 Setting Options ...................................... 11
ECOSPHERE/16000 Series Guarded Access Chart ................ 12
LPB Series Guarded Access Chart .............................. 13
Profile Mode .................................................. 14
Change Data Mode ............................................ 14
Halt Conditions ................................................ 14
Blank Step ................................................... 15
Set Point Step ................................................. 15
Creating Files/Profiles .......................................... 16
Wait Steps ................................................... 20
Next Step .................................................... 21
Recycle Option ................................................ 21
Write Your Program ............................................ 22
WORKSHEETS ..................................................... 23
Programming Work Sheet .......................................... 23
Sample HAST Profile for LPB Chambers ............................ 24
Procedure for Programming HAST Profile ........................... 25
HAST Chamber Programming Instructions and Definitions .............. 31
Ecosphere Sample Program ...................................... 32
Ecosphere Sample Profile Worksheet .............................. 33
Clearing a Program ............................................ 34
Tuning/Programming Worksheet ..................................... 35
Guarded Access Chart .......................................... 35
Warm/Cold Start ................................................. 36
Changing the Position of a Switch ................................. 37

Page iv Despatch/Watlow 1500 Control Instruction Manual
List of Figures
Figure 1 illustrates the Watlow 1500 installed on the Series 16000 environmental
chamber control panel. ............................................. 4
Figure 2 DIP Switch Location and Orientation .............................. 36
List of Tables
Table 1 Watlow 1500 Displays ........................................... 4
Table 2 Watlow 1500 Keys .............................................. 5
Table 3 Watlow 1500 LEDs ............................................. 5
Table 4 GA0001 and 0002 PID Tuning Parameters .......................... 10
Table 5 GA0000 Alarms ............................................... 10
Table 6 Setting Options ............................................... 11
Table 7 Set Point Step Programming Detail ................................ 19
Table 8 Wait Steps ................................................... 20
Table 9 Despatch Sample Program ...................................... 32
Table 10 DIP Switch Selection .......................................... 37

Despatch/Watlow 1500 Control Instruction Manual Page 1
NOTE:
Your control has already
been configured at
Despatch. Use this manual
as a guide to typical settings.
CAUTION:
Before making changes to
your control, consult with
Despatch Industries Product
Service at 1-800-473-7373.
INTRODUCTION
This INTRODUCTION section provides an overview of the
Watlow 1500 controller. The microprocessor based
controller is capable of measuring, displaying and
controlling temperature and humidity from a variety of
inputs.
The controller is easy to use. Control functions, alarm
settings and other parameters are easily entered through
the front keypad. Limited data can be protected from
unauthorized changes with its guarded access mode
security system. Battery back-up protects against data
loss during AC power outages.
In this application the controller has been factory
configured to control temperature and humidity conditions
in your Despatch chamber. Under normal conditions, you
should not have to reprogram this controller. We have,
however, included reprogramming instructions in this
manual to help guide you through that process if it should
become necessary.

Page 2 Despatch/Watlow 1500 Control Instruction Manual

Despatch/Watlow 1500 Control Instruction Manual Page 3
NOTE:
Your control has already
been configured at
Despatch. Use this manual
as a guide to typical settings.
CAUTION:
Before making changes to
your control, consult with
Despatch Industries Product
Service at 1-800-473-7373.
INSTRUCTIONS
Operating
To start the controller, start the oven fans. When you
start the fans the following sequence will automatically
take place.
1. The controller will power up.
2. The controller MNTR DATA LED will light up and the
alarm indicator A1 will be flashing in the FUNCTION
display. Alarm A1 is an indication of power loss.
3. Clear the alarm by pressing the clear button on the
Watlow 1500.
4. The actual temperature and humidity will be shown in
the ACTUAL display located at the top of the control.
Press the SEL key to toggle between temperature
and humidity. Temperature will be displayed on
Channel 1. Humidity will be displayed on Channel 2.

Page 4 Despatch/Watlow 1500 Control Instruction Manual
Figure 1 illustrates the Watlow 1500 installed on the Series 16000
environmental chamber control panel.
Display Description
Actual Shows the actual process conditions (dry bulb temp if CH-1 LED is on, RH% if
CH-2 is on.
Event Shows current status of all events. Lowest significant event is left justified
[instead of right justified as when events are shown in data display].
Step Shows which step the programmer is currently pointed to.
Function Describes the function or type of data being displayed in the data display.
Data Shows current value for the function being viewed. This display is effected by
the scroll up and down keys.
Table 1 Watlow 1500 Displays
Watlow 1500 Control
The Watlow Series 1500 is a versatile microprocessor-
based control; powerful, yet simple to learn.

Despatch/Watlow 1500 Control Instruction Manual Page 5
Key Description
CH SEL Selects either channel 1 or channel 2 for the ACTUAL display.
CLEAR Clears alarm codes from the FUNCTION display in the monitor data mode.
Clears the step in the STEP display in the change data mode when the unit
is in the halt condition. Clears all 51 programmed steps when the unit is in
the halt condition, and in the guarded access area of the change parameter
mode.
RE-START Returns the controller to the initial program step only in the program halt
condition.
RUN/HALT Starts or stops the program. The processor will resume a program where it
was interrupted, unless the RESTART key was pressed, or the step number
or set point data at the current step was changed during the halt condition.
MODE Selects either the monitor data, change data or change parameter mode.
FCTN The FUNCTION key steps through the prompts in each of the three modes.
ENTER Enters the selected data or next step operations in the change data and
change parameter modes.
Increases and decreases the value in the DATA display. A light touch
changes the value by one. Holding the key down causes the DATA display
to increase rapidly.
Table 2 Watlow 1500 Keys
LED Description
CH-1 CH-2 Indicates the channel in the ACTUAL display.
EEFIndicates the value in the ACTUAL display is temperature in EF.
EECIndicates the value in the ACTUAL display is temperature in EC.
%RH Indicates the value in the ACTUAL display is per cent relative humidity.
PROG END Indicates that the processor has reached the end of the program.
PROG HALT Indicates that the processor is in the halt condition. This may be caused by
pressing the RUN/HALT key or by a blank step in the program. Flashing
indicates that the processor is in remote-hold condition.
MNTR
DATA Indicates the processor is in the monitor data mode. While in this mode the Watlow 1500 is used as a set point controller or a process profiler.
CHG DATA Indicates the processor is in the change data mode.
CHG PARA Indicates the processor is in the change parameter mode.
TIME Indicates that the FUNCTION and DATA displays are showing time.
Table 3 Watlow 1500 LEDs
Watlow 1500 Control (Cont.)

Page 6 Despatch/Watlow 1500 Control Instruction Manual
Manual Set Point Controller
Use the following procedure to enter a dry bulb temperature,
RH%, or change auxiliary event status when the MNTR
DATA LED is on.
1. Press the RUN/HALT key so the PROG HALT LED
lights up.
2. Press the RESTART key.
3. Enter the dry bulb temperature.
a. Press the FCTN key until C1 is signaled in the
FUNCTION display.
b. Update the dry bulb temperature by using up/down
arrow keys.
c. Press enter when the desired set point is signaled in
the data display.
Your set point is now in effect.
If the set point shown in the DATA display is higher than
the value shown in the ACTUAL display for CH-1, then
the heat LED near the Watlow 1500 should be on.
If the set point in the DATA display is lower than the
value in the ACTUAL display for CH-1, then the cool
LED should be on.

Despatch/Watlow 1500 Control Instruction Manual Page 7
NOTE:
In the DATA display the right
most character for Event 11
is shown as 0001.
Manual Set Point Controller (Cont.)
4. Enter the %RH. The humidity event must be off when
outside of the range 4EC to 98EC. Humidity beyond
these extremes can result in equipment damage. If a
dry air system and an electronic humidity sensor are
installed in lieu of a wet bulb sensor, the optional dry
air event may be outside the range of 4EC to 98EC.
a. Press the FCTN key. C2 is shown.
b. Update the %RH temperature by using the up/down
keys.
c. Press enter when DATA display shows your desired
set point.
5. Change the auxiliary events.
a. Press the FCTN key. E1 is displayed.
b. Turn the auxiliary event on or off.
1 = on
0 = off
Try varying set points and events and watch how each
effects the output LEDs.

Page 8 Despatch/Watlow 1500 Control Instruction Manual
Guarded Access Programming
The Guarded Access parameters control the process limits.
the three GA parameter loops are restricted to operators by
special codes. The Guarded Access codes prevent
inexperienced or unauthorized operators from changing the
parameters.
You must select one of the following:
GA = 0000 To set CH-1 and CH-2 alarm limits
GA = 0001* To set CH-1 PID tune parameters
GA = 0002* To set CH-2 PID tune parameters
GA = 0006 To set set point scroll limits, optional
lockout and option recycle
*If GA = 0001 and 0002 will not work, try GA code 0005
for both channel parameters.
Use the following sequence to alter the GA prompts:
1. Follow the steps for “SETTING THE CLOCK.”
2. Select a GA code with the >key and the ?key.
3. Press ENTER. The prompt appears in the DATA
display.
4. Press the FCTN key. The next prompt in the loop
appears in the DATA display.

Despatch/Watlow 1500 Control Instruction Manual Page 9
Setting the Clock
1. Press the MODE key to select the Change Parameter
(CHG PARA) mode. The TIME LED will be ON. The
FUNCTION and DATA displays will show the real time
of day.
2. Press FCTN to produce the time prompt, HR, in the
FUNCTION display.
3. Enter the real time of day, beginning with hours. The
CHG PARA programming prompts are listed below in
the order they appear.
a. Enter the real time of day (24 hour basis) by
selecting the hour with the >key and the ?key.
b. Press ENTER to enter the hour into the program.
The prompt MN will appear when you press ENTER.
c. Select correct minutes and seconds.
After setting the real time the FUNCTION prompt should
display a GA. This is guarded access.

Page 10 Despatch/Watlow 1500 Control Instruction Manual
Parameter FUNCTION
Display Description
Proportional
Band Pb
Reset RS
Rate RT
Rate Band Rb Rate band defines where the rate function will occur. The
rate band will occur at one to seven times the proportional
band. With a 0 entry, rate is always in effect.
Cycle Time CT
Dead Band db The dead band defines an area on either side of set point
where no switching action will occur.
Calibration
Offset CA Calibration offset enables you to offset the input value from -10Eto 10EC or EF.
Table 4 GA0001 and 0002 PID Tuning Parameters
Parameters FUNCTION
Display Description
Upper Process Type Alarm UP If you do not want this alarm, set to highest
value.
Lower Process Type Alarm LP If you do not want this alarm, set to lowest value.
Upper Deviation Type
Alarm Ud If you do not want this alarm, set to highest value.
Lower Deviation Type
Alarm lD If you do not want this alarm, set to lowest value.
Table 5 GA0000 Alarms
GA0001 and 0002 PID Tuning
Prompts appear for CH-1 with Code 0001, and then repeat
for CH-2 with Code 0002. Except for CA, these parameters
pertain directly to tuning your control to the system.
GA0000 Alarms
Prompts appear for CH-1, then repeat for CH-2. Refer to
the Watlow User's Manual for details.
Sequence repeats for Channel 2 and then leaves the
guarded area, returning to real time.

Despatch/Watlow 1500 Control Instruction Manual Page 11
Parameter FUNCTION
Display Description
CH-1 Upper Set Point Limit U1
CH-1 Lower Set Point Limit L1
CH-2 Upper Set Point Limit U2
CH-2 Low Set Point Limit L2
Front Panel Keyboard
Lockout LC Enter:
C1 to lock the entire front panel,
C0 to unlock it.
Recycle RC Select:
C1 to activate the recycle option (begin
again at Step #1 after completing a
profile),
C0 to deactivate the recycle option.
Temp-Temp, 2-channel
temperature control TT This prompt will not appear on thermocou- ple units. Select:
C0000 for Temp-RH control
C0001 or Temp-Temp control.
RS-422 Address for the
1500 Ad This prompt appears only on units with data communications. It applies only for an
RS-422 interface. Each device on the net-
work must have its own address.
Table 6 Setting Options
GA0006 Setting Options
These parameters are high and low display and scroll limits,
and for some units, two channel control type and device
address.
Sequence then leaves the guarded area, returning to real
time.

Page 12 Despatch/Watlow 1500 Control Instruction Manual
ECOSPHERE/16000 Series Guarded Access Chart
Make a copy of this chart to document the Series 1500
Guarded Access for each program you use.
Program #_____ System _______ Programmer ________ Date__________
GA Code Ch Pmpt Parameter Typical ECOSPHERE Setting Your Settings
0000 C1 UP Ch-1 Upper Process Alarm 180
C1 LP Ch-1 Lower Process Alarm -75
C1 Ud Ch-1 Upper Deviation Alarm 538
C1 Ld Ch-1 Lower Deviation Alarm -538
C2 UP Ch-2 Upper Process Alarm 101
C2 LP Ch-2 Lower Process Alarm -001
C2 Ud Ch-2 Upper Deviation Alarm 101
C2 Ld Ch-2 Lower Deviation Alarm -101
0001 1 Pb Ch-1 Prop. Band 0009
1RS Ch-1 Reset 0010
1RT Ch-1 Rate 0000
1Rb Ch-1 Rate Band 0001
1CT Ch-1 Cycle Time 0003
1 db Ch-1 Dead Band 0001
1CA Ch-1 Calibration Adjust. 0000
Dual
PID 1C Pb Ch-1 Prop. Band 0009
1C RS Ch-1 Reset 0002
1C RT Ch-1 Rate 0001
1C Rb Ch-1 Rate Band 0001
1C CT Ch-1 Cycle Time 0007
0002 2 Pb Ch-2 Prop. Band 0020
2RS Ch-2 Reset 0010
2RT Ch-2 Rate 0050
2Rb Ch-2 Rate Band 0003
2CT Ch-2 Cycle Time 0002
2 db Ch-2 Dead Band -0001
2CA Ch-2 Calibration Adjust. 0000
Dual
PID 2C Pb Ch-2 Prop. Band 0020
2C RS Ch-2 Reset 0006
2C RT Ch-2 Rate 0001
2C Rb Ch-2 Rate Band -0001
2C CT Ch-2 Cycle Time 0005
0006 U1 Ch-1 Upper Set Point Limit 177
L1 Ch-1 Lower Set Point Limit -73
U2 Ch-2 Upper Set Point Limit 100
L2 Ch-2 Lower Set Point Limit 000
RC Recycle: ON = 1, OFF = 0 0
TT T-RH = 0000, T-T = 0001 0
Ad Address number RS-422 0
LC Keyboard Lock 0

Despatch/Watlow 1500 Control Instruction Manual Page 13
LPB Series Guarded Access Chart
Make a copy of this chart to document the Series 1500
Guarded Access for each program you use.
Program #_____ System _______ Programmer ________ Date__________
GA Code Ch Pmpt Parameter Typical HASP Settings Your Settings
0000 C1 UP Ch-1 Upper Process Alarm 170
C1 LP Ch-1 Lower Process Alarm 0
C1 Ud Ch-1 Upper Deviation Alarm 538
C1 Ld Ch-1 Lower Deviation Alarm -538
C2 UP Ch-2 Upper Process Alarm 101
C2 LP Ch-2 Lower Process Alarm -001
C2 Ud Ch-2 Upper Deviation Alarm 101
C2 Ld Ch-2 Lower Deviation Alarm -101
0005 RC Recycle 0000
C1 Pb Ch-1 Prop. Band 0003
C1 RS Ch-1 Reset 0005
C1 RT Ch-1 Rate 0001
C1 Rb Ch-1 Rate Band 0001
C1 CT Ch-1 Cycle Time 0001
C1 db Ch-1 Dead Band 0000
C1 CA Ch-1 Calibration Adjust. 0000
C2 Pb Ch-2 Prop. Band 0005
C2 RS Ch-2 Reset 0002
C2 RT Ch-2 Rate 0005
C2 Rb Ch-2 Rate Band 0001
C2 CT Ch-2 Cycle Time 0001
C2 db Ch-2 Dead Band 0000
C2 CA Ch-2 Calibration Adjust. 0000
0006 U1 Ch-1 Upper Set Point Limit 166
L1 Ch-1 Lower Set Point Limit 0
U2 Ch-2 Upper Set Point Limit 100
L2 Ch-2 Lower Set Point Limit 000
RC Recycle: ON = 1, OFF = 0 0
TT T-RH = 0000, T-T = 0001 0
Ad Address number RS-422 0

Page 14 Despatch/Watlow 1500 Control Instruction Manual
Profile Mode
This section of the manual provides details on programming
the Watlow 1500 in the Change Data (CHG DATA) mode,
the Change Parameters (CHG PARA) mode and Guarded
Access. Refer to the Watlow 1500 manual for more details.
Change Data Mode
When the Watlow CHG DATA LED is lit, the processor is in
the change data mode. While in this mode, the
programming steps can be entered into the processor.
There are three step types:
CSet Point (SP)
CJump Loop (JL)
CWait (WT)
Halt Conditions
The Watlow 1500 can HALT in three ways, when the:
Cprocessor encounters a Blank Step in the program,
CRUN/HALT key is pressed while the program is
running,
Cremote hold input is shorted.
While in the HALT condition, the Watlow 1500 actively
maintains set points and event output conditions which
existed at the time the processor was halted.
If you do not want the hot or humid conditions to be retained
at the end of a programmed halt, add a step just before the
Blank Step [End of Program] to establish stand-by set points
near ambient with all Event Outputs OFF.