Watlow 965 Series User manual

Series 965
User's Manual
0600-0003-0000 Rev. C
July 1998
Supersedes: 0600-0003-0000 Rev. B
$10.00
Made in the U.S.A.
Printed on Recycled Paper
Watlow Controls, 1241 Bundy Blvd., P.O. Box 5580, Winona, MN 55987-5580, Phone: [phone], Fax: [phone]
WatlowControls
1/16 DIN
Microprocessor-Based
Auto-tuning Control
Registered Company
Winona, Minnesota USA
ISO 9001
96
TOTAL
3YearWarranty
CUSTOMER
SATISFACTION

WATLOW Series 965 User's Manual2
Starting Out
How to Use the Manual
About This Manual
How to Use this Manual
We have designed this user's manual to be a helpful guide to your new Series 965. The
headlines in the upper right and left corners indicate which tasks are explained on that
page.
Notes and Safety Information
We use notes, cautions and warnings throughout this book to draw your attention to
important information.
Notes are printed in bold in the margin to alert you to an important detail.
ç
A Caution symbol (an exclamation point in a triangle) appears with information that is
important to protect equipment and performance. Read and follow all cautions that apply
to your application.
Ó
A Warning symbol (a lightning bolt in a diamond) appears with information that is
important to protect people and equipment from damage. Pay very close attention to all
warnings that apply to your application.
Technical Assistance
If you encounter a problem with your Watlow controller, review all of your configuration
information for each step of the setup, to verify that your selections are consistent with
your applications.
If the problem persists after checking all the steps, call for technical assistance: Watlow
Controls at [phone], between 7:00 a.m. and 5:30 p.m. Central Standard Time.
Ask for an applications engineer. When you call, have the following information ready:
• the controller's model number ( the 12-digit number is printed on the top of the
stickers on each side of the controller's case and on the top or right side of the circuit
board);
• this user's manual;
• all configuration information;
• the Diagnostics Menu readings.
Warranty and Returns
For information about the warranty covering the Series 965, see page 37.
Comments and Suggestions
We welcome your comments and opinions about this user's manual and the Series 965.
Send them to the Technical Editor, Watlow Controls, 1241 Bundy Blvd., P.O. Box 5580,
Winona,MN55987-5580.Orcall(507)454-5300.Orfaxthemto(507)452-4507.(1459).
NOTE:
Details of a "Note"
appear here, in the
narrow box on the
outside of each
page.
ç
CAUTION:
Details of a "Cau-
tion" appear here, in
the narrow box on
the outside of each
page.
Ó
WARNING:
Details of a "Warn-
ing" appear here, in
the narrow box on
the outside of each
page.

Starting Out
3WATLOW Series 965 User's Manual
How to Use the Manual
Contents
Page Item
Chapter 1
4 Starting Out With The Watlow Series 965
4 General Description
Chapter 2
5 Install And Wire The Series 965
5 Panel Cutout
5 Dimensions
5 Installation Procedure
7 Wiring the Series 965
8 Sensor Installation Guidelines
8 Input Wiring
10 Output 1 Wiring
11 Alarm Wiring
12 System Wiring Example
Chapter 3
13 How To Use The Keys And Displays
13 Keys, Displays & LEDs
Chapter 4
14 How To Set Up The Series 965
14 Setting the Input Type DIP Switch
15 Entering Setup Menu
16 Setup Parameters
18 Setup Menu Table
19 Operation Parameters
20 Operation Menu Table
Chapter 5
21 How To Tune And Operate
21 Auto-tuning
22 Manual Tuning
23 Manual and Automatic Operation
24 Using Alarms
25 Error Code Messages
Appendix 1
27 Noise Sources
27 Decreasing Noise Sensitivity
28 Eliminating Noise
Appendix 2
29 Entering the Calibration Menu
30 Restoring Factory Calibration
30 Calibration Menu
31 Calibration Procedures
34 Glossary
36 Index
37 Warranty and Returns
38 Specifications
39 Model Number Information
40 Declaration of Conformity
41 Quick Reference
Figures & Tables
Page Figure Item
4 Series 965 Input & Output Overview 1
5 Multiple Panel Cutout Dimensions 2
5 Series 965 Dimensions 3
6 Mounting, Case Side View & Collar 4
6 Case, Rear View & NEMA 4X Seal Example 5
7 High Voltage Power Wiring 6
7 Low Voltage Power Wiring 7
8 Thermocouple Sensor Input Wiring 8
8 0-5VÎ(dc) Process Sensor Input Wiring 9
9 2- or 3-wire RTD Sensor Input Wiring 10
9 4-20mA Process Sensor Input Wiring 11
10 Switched DC Output Wiring 12
10 5A Mechanical Relay Wiring 13
10 4-20mA Process Wiring 14
10 0.5A Solid-state Relay w/o Suppression Wiring 15
11 Switched DC Output Wiring 16
11 5A Mechanical Relay Wiring 17
11 0.5A Solid-state Relay w/o Suppression Wiring 18
12 System Wiring Example 19
13 Series 965 Keys and Displays 20
14 DIP Switch Location & Orientation 21
15 Entering the Setup Menu 22
15 The Setup Menu 23
19 The Operation Menu 24
21 Auto-tuning at a 200°F Set Point 25
24 Alarm Display Examples 26
29 Entering the Calibration Menu 27
30 Calibration Menu 28
Tables
18 Input Ranges 1
18 Setup Menu Prompts/Description 2
20 Operation Menu Prompts/Description 3
41 Quick Reference Sheet (Perforated)

Starting Out
4Getting Started, Chapter 1
WATLOW Series 965 User's Manual
Starting Out
General Description
Welcome to the Watlow Series 965, a 1/16 DIN microprocessor-based tempera-
ture control. The 965 has a single input which accepts type J, K, T, N or S
thermocouple, RTD or process input.
With dual output, the primary can be heating or cooling while the secondary can
be a control output opposite the primary output (heat or cool), alarm or none.
Both outputs can be selected as either PID or on/off. PID settings include
proportional band, reset/integral, and rate/derivative. Setting the proportional
band to zero makes the Series 965 a simple on/off control with switching
differential selectable under the HSC parameter.
Special 965 features include the NEMA 4X rating, dual four digit displays in
either red or green, optional low volt power supply, auto-tuning for both heat
and cool outputs, ramp to set point for gradual warm-up of your thermal system,
and automatic/manual capability with bumpless transfer.
Operator-friendly features include automatic LED indicators to aid in monitoring
and setup, as well as a calibration offset at the front panel. The Watlow Series
965 automatically stores all information in a non-volatile memory.
Figure 1 -
Series 965 Input and
Output Overview
Single Input -
Type J, K, T, N or S
Thermocouple,
RTD or Process Output 1 -
Heat or Cool
Dual Control Output-
PID or on/off, User Selectable
Output 2 -
Heat, Cool, Alarm
or None
Output 1 or 2
Percent Power Auto-tuning
for Heat &
Cool PID
Settings
Chapter 1
Starting Out With The Watlow Series 965,
A Microprocessor-Based Control

Install and Wire, Chapter 2 5WATLOW Series 965 User's Manual
Installation
Chapter 2
Install and Wire the Series 965
Figure 2 -
Series 965
Multiple Panel
Cutout Dimensions
Installation Procedure
Follow this procedure to mount the Watlow Series 965 temperature control:
1. Make a panel cutout per the dimensions in Figure 2.
2. Remove the 965 chassis from its case. Holding each side of the bezel,
press in firmly on the side grips until the tabs release. Pull the chassis out
of the case and set aside for later installation.
3. Make sure the rounded side of the external case gasket is facing the panel
surface. Check to see that the gasket is not twisted, and is seated within
the case bezel flush with the panel. Place the case in the cutout you just
made. Make sure the gasket is between the panel cutout and the case
bezel. See Figure 4A.
NOTE:
Measurements
between panel
cutouts are the
minimum
recommended.
Figure 3 -
Series 965
Dimensions
2.1"
(53 mm)
Panel Cutout
Your Panel
Thickness
0.06" to 0.38"
(1.5 to 9.7 mm)
1.77" to 1.79"
(44.96mm to 45.47mm)
1.77" to 1.79"
(44.96mm
to 45.47mm)
0.38"
(9.65mm)
Minimum
0.85"
(20mm)
0.40"
(10mm) 1.21"
(
31mm
)
4.1"
(104mm)
4.7"
(119mm)
1.76"
(45mm)
NOTE: For rapid
mounting, use
Greenlee punch
#60020 and die
#60021, or hand
hydraulic unit, Kit
#7306. All available
from Grainger.

Install and Wire, Chapter 26WATLOW Series 965 User's Manual
Installation
NOTE:
To guarantee a
proper NEMA 4X
seal, make sure
the gasket
between the panel
and the rim of the
case is not twisted
and is seated
properly.
PRESS FIRMLY.
Figure 4 -
Mounting, Case Side
View & Collar Cross
Section
Figure 5 -
Case Rear View and
NEMA 4X Seal
Example
4B
0 to 0.019 space
(0 to 0.483 mm)
Bezel
Panel
External Gasket Mounting Collar
Ridges
Teeth
Tabs
4A
When removing the mounting collar, we suggest sliding a thin tool such as
a putty knife or screwdriver under all three tabs on each side at once and
pulling it back off the case.
5. Insert the control chassis into its case and press the bezel to seat it. Make
sure the inside gasket is also seated properly and not twisted. The hard-
ware installation is complete. Proceed to the wiring section from here.
4. While pressing the front of the case firmly against the panel, slide the
mounting collar over the back of the control. The tabs on the collar must
line up with the mounting ridges on the case for secure installation. See
Figure 4A again. Slide the collar firmly against the back of the panel getting
it as tight as possible. Make sure you cannot move the case within the
cutout; if you can you do not have a NEMA 4X seal.
Now let's make sure we have a tight seal. Use your thumb to lock the tabs
into place while pressing the case from side to side. Don't be afraid to apply
enough pressure to install the control. The tabs on each side of the collar
have teeth which latch into the ridges. See Figure 4B. Each tooth is stag-
gered at a different height, so only one of the tabs on each side are ever
locked into the ridges at any time.
Looking at Figure 5, you see that the tabs on one side of the collar corre-
spond with those on the opposite side. Make sure that the two correspond-
ing tabs are the only ones locked in the ridges at the same time. If the
matching tabs are not holding the case at the same time you will not have
a NEMA 4X seal. You can make a visual check, or use your finger nail to
pull out on each tab. Only one on each side is engaged, and they must
be corresponding as in Figure 5. The space between the bezel and
panel must be between 0 and 0.019" (0.48 mm).
NEMA 4X Seal Example.
Make sure that the two correspond-
ing tabs below are locked in the
ridges at the same time.
Mounting Collar
Cross Section
(notice the offset teeth
on each tab)

Install and Wire, Chapter 2 7
WATLOW Series 965 User's Manual
PowerWiring
Ó
WARNING:
To avoid potential
electric shock, use
National Electric
Code (NEC) safety
practices when
wiring and connect-
ing this unit to a
power source and to
electrical sensors or
peripheral devices.
NOTE:
Taking the unit out
of the case is not a
normal operating
condition and
should only be done
by a qualified
maintenance
installation techni-
cian. Power to the
case should be
disconnected before
removing or install-
ing the controller
into its case.
Figure 7 -
Low Voltage
Power Wiring
Figure 6 -
High Voltage
Power Wiring
How to Wire the Series 965
The Series 965 wiring is illustrated by model number option. Check the unit
sticker on the control and compare your model number to those shown here
and also the model number breakdown in the Appendix of this manual.
All outputs are referenced to a de-energized state. The final wiring figure is a
typical system example.
When you apply power without sensor inputs on the terminal strip, the Series
965 displays [----] in the upper display, and a [```0] in the lower display,
except for 0-5VÎ(dc) or 4-20mA process input units. Press the A/M key twice,
and [ER`7] is displayed for one second. This error indicates an open sensor or
A/D error. Remove power to the control and connect the sensor properly, see
pages 8 and 9. All wiring and fusing must conform to the National Electric Code
and to any locally applicable codes as well.
LowVoltage
Model # 965A - 3 1 - 00 .
Ó
WARNING:
If high voltage is
applied to the low
voltage unit,
irreversible damage
will occur.
12-24V‡(ac/dc)
HighVoltage
Model # 965A - 3 0 - 00 .
100 to 240 VÅ(ac),
nominal
(85 to 264 actual)
Ó

Install and Wire, Chapter 2
8WATLOW Series 965 User's Manual
Input Wiring
DIP Switch
Orientation
0-5VÎ(dc) Process Input
Figure 9 -
0-5VÎ(dc) Process
Sensor Input Wiring
Figure 8 -
Thermocouple
Sensor Input Wiring
Input impedance: 10KΩ
Thermocouple Input
Extension wire for thermocouples must be of the same alloy as the thermo-
couple itself to limit errors.
Sensor Installation Guidelines
We suggest you mount the sensor at a location in your process or system
where it reads an average temperature. Put the sensor as near as possible to
the material or space you want to control. Air flow past this sensor should be
moderate. The sensor should be thermally insulated from the sensor mounting.
See Chapter 4 for more information on DIP switch location and orientation.
DIP Switch
Orientation
ç
CAUTION:
Process input does
not have sensor
break protection.
Outputs can remain
full on.
T/C
+
-
3
5
V
+
-
3
5
dc
ç
NOTE:
When an external
device with a non-
isolated circuit
common is con-
nected to the 4-
20mA or dc output,
you must use an
isolated or un-
grounded thermo-
couple.

Install and Wire, Chapter 2 9
WATLOW Series 965 User's Manual
RTD, 2- or 3-wire
Input Wiring
DIP Switch
Orientation
4 - 20mA Process Input
DIP Switch
Orientation
Figure 11 -
4-20mA Process
Sensor Input Wiring
Figure 10 -
2- or 3-wire RTD
Sensor Input Wiring
Input impedance: 5Ω
There could be a + 2°F input error for every 1Ωof lead length resistance when
using a 2-wire RTD. That resistance, when added to the RTD element resis-
tance, will result in erroneous input to the instrument. To overcome this prob-
lem, use a 3-wire RTD sensor, which compensates for lead length resistance.
When extension wire is used for a 3-wire RTD, all wires must have the same
electrical resistance (i.e. same gauge, copper stranded, same length).
ç
CAUTION:
Process input does
not have sensor
break protection.
Outputs can remain
full on.
S1
S2
S3
2
3
5
3-wire RTD
S1
S2
S3
2
3
5
2-wire RTD
Jumper
Terminals
3 and 5.
+
-2
5
Idc
ç

Install and Wire, Chapter 2
10 WATLOW Series 965 User's Manual
Switched DC Output
Model # 965A - 3 C- 00 .
Output 1 Wiring
Figure 12 -
Switched dc Output
Wiring
Figure 15 -
0.5 Amp Solid-state
Relay Without
Contact Suppression
Wiring
Mechanical Relay Without Contact Suppression, Form C, 5 Amp
Model # 965A - 3 D- 00 .
External
Load
10
9
-
+
Figure 14 -
4-20mA Process
Wiring
Solid-state Relay Without Contact Suppression, 0.5 Amp
Model # 965A - 3 K- 00 .
External
Load
10
9
-
+
Maximum load
resistance:
800Ω
Process, 4-20mA
Model # 965A - 3 F- 00 .
NOTE:
Switching inductive
loads (relay coils,
solenoids, etc.) with
the mechanical
relay, switched dc or
solid-state relay
output options
requires using an
R.C. suppressor.
Watlow carries the
R.C suppressor
Quencharc brand
name, which is a
trademark of ITW
Pakron. Watlow Part
No. 0804-0147-0000.
Figure 13 -
5 Amp Mechanical
Relay Wiring
NOTE:
When an external
device with a non-
isolated circuit
common is connected
to the 4-20mA or
Switched dc output,
you must use an
isolated or un-
grounded thermo-
couple.
External
Load
10
9
NO
COM
8NC
Fuse
L1
L2
Customer Supplied
Quencharc
10
unregulated
V+
V—
9
Internal Circuitry
External
Load
10
SS1
SS1
8
Fuse L1
L2
Custommer Supplied
Quencharc