Watlow Electric Network Card SERIES 980 985 User Manual
Microprocessor-Based  
Auto-tuning Control  
User’s Manual)  
Watlow Controls, 1241 Bundy Blvd., P.O. 8ox 5580, Winona, MN 55987-5580, Phone: 507/454-5300, Fax: 507/452-4507  
$10.00  
W985-MA58-9307  
February, 1993  
Supersedes:  
Made in the U.S.A.  
Printed on Recycled Paper  
W985-MA70-9043  
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How to Use the Manual  
Reading it and applying the informa-  
This manua/ will make your job easier.  
First..  
An overview:  
tion is a good way to become familiar with the Series 980/985.  
Chapter 1, Page 4.  
Chapter 2, Page 6.  
Chapter 3, Page 22.  
Chapter 4, Page 24.  
Chapter 5, Page 29.  
StartingOut  
Install/Wire  
Front Panel  
Set Up  
Tuning  
Specifications, Page 34  
Cali bration  
Appendix  
Glossary  
Warranty  
Notes  
The user’s manual contains informational notes to alert you to important details.  
When you see a note icon, look for an explanation in the margin.  
NOTE:  
Details of a *‘Note**  
appear here, in the  
narrow box on the  
outside of each page.  
Safety Information  
This user‘s manual also has boldface safety information notes to protect both  
you and your equipment. Please be attentive to them. Here are explanations:  
CAUTION:  
Details of  
a
“Caution”  
appear here, in the  
narrow box on the  
outside of each page.  
The Caution symbol (exclamation point) in the wide text column alerts you to a  
“CAUTION,” a safety or functional hazard which could affectyour eguipment or  
its performance. A full explanation is in the narrow column on the outside of  
the page.  
WARNING:  
Details of a “Warning”  
appear here, in the  
narrow box on the  
outside of each page.  
The Warning symbol (lightning bolt) in the wide text column alerts you to a  
**WARNING,” a safety hazard which could affect you and the equipment. A full  
explanation is in the narrow column on the outside of the page.  
Your Feedback  
Your comments or suggestions on this manual are welcome, please send them  
to: Technical Writer, Watlow Winona, Inc., 1241 Bundy Blvd., Winona, MN  
55987, or phone 507-454-5300. The Watlow Series 9801985 User’s Manual  
and integral software are copyrighted by Watlow Winona, Inc.,  
rights reserved.  
©
1988, with all  
blrO293  
2
How to Use the Manual  
WATLOW Series 9801985 User’s Manual  
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Figures, Table, Charts  
Chapters  
page  
Figure  
Item  
page  
Item  
1
2
3
4
5
6
7
8
Input  
Series 980/985  
Differential Mode Filter Wiring  
Common Mode Fifter Wiring  
Combination filter Wiring  
Panel Cutout Dimensions  
Series 980/985 Dimensions  
115 VAC Power Wiring  
230 VAC Power Wiring  
Thermocouple Wimg Diagram  
Process Wiring Diagram  
&
Output Overview  
4
5
10  
10  
10  
Series 980/985  
Overview of the  
Chapter 1  
4
4
5
5
Starting Out With The Watlow Series 980/985  
General Description  
Putting Your Control To Work  
Overview of the Series 980/985 Menus  
12 Series 980/985  
12  
13  
13  
14  
14  
15  
15  
16  
16  
Chapter 2  
6
6
6
6
7
9
9
How To Install And Wire The Series 980/985  
System Planning  
Sensor Installation Guidelines  
Installation Guidelines For Preventing Noise  
Noise  
Checking For Ground Loops  
Noise Suppression Devices Available..  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
31  
32  
33  
34  
RTD (2 wire) Wiring Diagram  
RTD (3 wire) Wiring Diagram  
Solid State Relay, Output 1 Wiring  
DC Output 1 (Open Collector) Wiring  
10 Line Filtering Configurations For Controls  
l? 6 Amp Relay, Output 1 Wiring  
11  
How To Install The Series980/985  
13 How To Wire The Series980/985  
21 System Wiring Example  
17  
18  
18  
19  
19  
20  
20  
21  
O-lOVDC, Output 1 Wiring  
4-2OmA, Output 1 Wiring  
O-2OmA, Output  
1
Wiring  
0-5VDC, Output 1 Wiring  
Chapter 3  
S.S. Relay, Output 2 Wiring  
DC Output, Output 2 Wiring  
6A Mechanical Relay, Output 2 Wiring  
System Wiring Example  
22 How To Use The Keysand Displays  
22 Series 980/985 Displays  
-
&
Load LED’s  
Series 980/985 Keys  
23  
22 Series 980/985 Displays  
Chapter 4  
Series 980/985 Keys  
Entering the Set Up Menu  
24 The Set Up Menu  
27 The Operation Menu  
Alarm Display Examples  
Error Code Display Examples  
37 The Calibration Menu  
23  
24  
24 How To Set Up The Series 980/985  
24 Entering Set Up Menu  
25 Set Up Parameters  
26 Set Up Menu  
27 Operation Parameters  
28 Operation Menu  
-
31  
32  
Calibration Parameters  
38  
Chapter  
5
29 How To Tune And Operate  
-
Tables  
29 Tuning  
30 Tuning  
-
-
Manual  
Automatic  
1
2
9
39  
Noise Suppression Device Ratings  
RTD Settings  
31 Manual and Automatic Operation  
31 Using Alarms  
Charts  
How To Deal With Error Codes  
32  
1
2
3
26 Set Up Menu Prompts/Description  
26  
28  
Input Ranges  
Operation Menu Prompts/Description  
34 Appendix  
34 Specifications  
36 Model Number Information  
37 Calibration Menu  
38 Calibration Procedures  
38 Glossary  
41 Index  
42 Returns  
42 Shipping Claims  
43 Warranty  
43 Watlow Controls  
H o w to Use the Manual  
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Chapter  
1
Starting Out With The  
Watlow Series 9801985,  
A Microprocessor-Based Control  
Dual Outputs-  
PID or ON/OFF  
Single Input  
-
Type J, K, T, N or Pt2  
User Selectable  
Flgure  
1
-
Series 980/985 Input  
and Output Overview  
Heat, Cool or Alarm  
Output or 2  
1
Percent Power  
Output 1, Heating  
Auto-tuning  
General Description  
Welcome to the Watlow Series 980/985, a dual output, single input, micropro-  
cessor-based, 1/8 DIN, auto-tuning temperature control, featuring the Auto-  
matic/Manual capability with bumpless transfer. In the Auto mode, the control  
has closed loop control with sensory feedback, while the Manual mode has  
The 980/985 accepts  
open loop control with user defined output power level.  
a Type J, K, T, N, or Platinel2 thermocouple, RTD, or process input. The  
primary output is Heating or Cooling, while the secondary output can be Heat,  
Cool or Alarm.  
With the Series 980/985 you can select either PID or ON/OFF for Output 1 or  
Output 2. You may input a complete set of PID parameters for both outputs,  
and select automatic tuning for Output 1 from the front panel. This includes  
proportional band, reset, rate and cycle time. By setting either output’s propor-  
tional band to zero, the Series 9801985 becomes a simple ON/OFF control with  
a
3°F or 1.7°C switching differential, 0.3°F or 0.17°C for 0.1  
°
RTD.  
Operator-friendly features include automatic LED indicators to aid in monitoring  
and set-up, as well as a calibration offset at the front panel. The Watlow  
Series 980/985 automatically stores all information in a non-volatile memory.  
GettingStarted, Chapter  
1
4
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Putting Your Control To Work  
To put your Series 980/985 to work, we suggest the following steps:  
Read the User’s Manual.  
Plan your installation and wiring.  
Cut the panel mounting hole and install the control.  
Wire your Series 980/985 to the system.  
Start the system and tune the Series 980/985.  
Make final adjustments to the control parameters and record the data.  
That’s all there is to it.  
Overview of the Series 980/985 Menus  
Before getting into the details of installing and wiring the Series 980/985, take a  
look at Figure 2, and at the three different menus. “Setup”, “Operation”, and  
“Calibration”. After you feel comfortable with the names and their functions,  
move on to installation and wiring.  
Configure the 980/985’s features to your  
application. Establish levels of operator  
access, input type, units of measure, low and  
Figure 2  
Overview of the  
Series 980/985.  
-
Setup  
high range limits, and Output 2 configuration.  
Enter the set point and the PID tuning values  
and alarm set points here. Parameters for  
proportional band, reset, rate and cycle time for  
Operation  
Outputs 1 and 2; alarm low and high;dead-  
band: calibration offset and auto-tune  
are here also.  
Supply various input signals to the  
Series 980/985, and it performs auto-  
Calibration  
calibration. Calibration procedures  
should only be attempted with  
proper equipment and by qualified  
personnel.  
Where To Go From Here  
If your Series 980/985 is already installed and wired, go directly to “How to Use  
the Keys and Displays”, Chapter 3. If not, turn the page to Chapter 2, “How to  
Install and Wire the Series 980/985”, and proceed from there.  
Getting Started, Chapter 1  
WATLOW Series 980/985 User’s Manual  
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Chapter 2  
How to Install and Wire the  
Series 9801985  
SystemPlanning  
Thischaptertellsyouhowtoinstallthe Series 980/985.Allmountingand  
Because Watlow controls are thoroughly  
wiring information is right here.  
tested and "burned in" before leaving the factory, the Series 980/985 is ready  
to install when you receive it.  
But before you begin working, read through this chapter to gain an understand-  
ing of the entire installation. Consider sensor installation carefully. You’ll need  
to look at the noise reduction guidelines before making your panel cutout.  
SensorInstallationGuidelines  
We suggest that you mount the sensor at a location in your process or system  
Put the sensor as near as possible to  
where it reads an average temperature.  
the material or space that you want to control. Air flow past this sensor should  
be moderate. The sensor should be thermally insulated from the sensor  
mounting.  
Installation Guidelines For Preventing Noise  
For improved electrical noise immunity, install the Series 980/985 as far away  
as possible from motors, relays, and other similar noise generators.  
Do not run low power (sensor input) lines in the same bundle as AC power  
lines. Grouping these lines in the same bundle can create electrical noise  
interference which may result in error codes in the Series 980/985.  
The Culprit  
Most noise problems stem from wiring practices. They’re the major means of  
coupling noise from its sources to the control circuit The following information  
will tell you how to eliminate or decrease noise.  
An Information Resource  
Anoutstandingresource for information for wiring guidelines is the IEEE  
StandardNo. 518-1982 and is available from IEEE, Inc. 345 East 47th Street,  
New York, NY 10017.  
6
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Install and Wire, Chapter 2  
Noise Sources  
Switchesandrelay contacts operatinginductiveloadssuchas motor,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.  
Heavy current carrying conductors.  
Fluorescent and neon lights.  
How To Decrease Noise Sensitivity  
Physical separatlon and wire routing must be given careful consideration in  
planning the layout of the system. For example, A.C. power supply lines  
should be bundled together and physically kept separate from input signal  
lines(sensorlines).A12inchminimumseparatlonisusuallyeffective Keep  
.
all switched output signal lines (high power level) separate from input signal  
lines (sensor lines). Cross other wiring at 90° angles whenever crossing lines  
is unavoidable.  
Another important practice is to look at the system layout and identify electri-  
cal noise sources such as solenoids, relay contacts, motors, etc., and where  
they are physically located. Then route the wire bundles and cables as far  
Don’t mount relays or switching  
away as possiblefrom these noisesources.  
devices close to a microprocessor control. Don’t have phase angle-fired  
devices in the same electrical enclosure or on the same power line with the  
control.  
Shielded cables should be used for all low power signal lines to protect from  
magnetic and electrostatic coupling of noise. Some simple pointers are:  
• Whenever possible, low level signal lines should be run unbroken from  
signal source to the control circuit.  
• Connect the shield to the control circuit common at the control end only.  
Never leave the shield unconnected at both ends. Never connect both  
shield ends to a common or ground.  
• If the shield is broken at some termination point and then continued on, the  
shield must be connected to maintainshieldcontinuity.  
• If the shield is used as a signal return, no electrostatic shieldlng should be  
assumed. If this must be done, use a triaxed cable (electrostatically  
shielded coaxial cable).  
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.  
The size or gauge of wire should be selected by calculating the maximum  
circuit current and choosing the gauge meeting that requirement. Using  
greatly larger wire sizes than required generally will increase the likelihood of  
electrostatic (capacitance) coupling of noise.  
Install and Wire, Chapter 2  
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7
• Groundloops must be eliminated in the entire control system. There are  
obvious loops which can be spotted by studying the"as-built" wiring diagram.  
There are also the not-so-obvious ground loops that result from the technique  
of connecting internal circuit commons in the manufacturer's equipment. An  
example of this would be if a control circuit is designed to work with a  
groundedsensorinput.  
• Do not daisy chain A.C. power (or return) lines, or output signal (or return)  
Use a direct line from the power source to  
lines to multiple control circuits.  
eachinputrequiring A.C.power.Avoidparalleling L1 (power lead) and L2  
ts. If L1  
(return lead) to load power solenoids, contactors, and control circui  
(power lead) is used to switch a load, L2 (return lead) willhave the same  
switched signal and could couple unwanted noise into a control circuit.  
• Grounding the chassis of each piece of equipment in the system is very  
important. The simple practice of connecting each individuai chassis to the  
overall equipment chassis immediately adjacent to that piece, and then tie all  
the major chassis ground terminals together with one lead (usually green  
Don’tconnectgroundto  
wire) to ground at one single point will work best.  
the control case if the control is mounted in grounded enclosure (prevent  
ground loops).  
• Do not confuse chassis grounds (safety ground) with control circuit commons  
Each return system  
or with AC. supply lines L2 (return or neutral line).  
wiring must be kept separate. Be absolutely sure chassis ground (safety) is  
never used as a conductor to return circuit current  
How To Eliminate Noise  
• Use “snubbers” ("QUENCHARC™") to filter out noise generated by devices  
such as relays, relay contacts, solenoids, motors, etc. A snubber is a simple  
filter device using a 0.1µf, 600 volt, non-polarized capacitor in series with a  
100 ohm, 1/2 watt resistor. The device can be used on A.C. or D.C. circuits  
to effectively dampennoiseatitssource.  
• The general purpose Watlow snubber, described above, is 0804-0147-0000.  
For other ‘QUENCHARC” sizes contact  
PAKTRON  
P.O. Box 5438  
Lynchburg, VA24502  
Phone: 804-239-6941  
• Metal Oxide Varistor (MOV) can be used to limit voltage “spikes” that  
occur on the A.C. supply lines as a result of lightning strikes, switching large  
motors, etc. The MOV is available in several varieties and for 115 or 230  
volt lines. The device dissipates the voltage “spikes” to ground and in doing  
so repeatedly, deteriorates its ability to function. MOVs havealimitedlife.  
• Watlow stocks several MOVs. See Table 1.  
8
WATLOW Series 980/985 User's Manual  
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"Islatros" andother similarpowerlinefiltersaredesignedto carry thepower  
for the control circuit and “buffer” the control circuit from A.C. line noise.  
Devices like the lslatrol use media (electromagnetic filtering) other than  
electric circuits to filter out electrical noise. Take care in matching the power  
Keep line filters as  
capabilities of the filter with power demands of the circuit.  
close to the control as possible to minimize the area for interference pick up.  
lslatrols are availablefrom:  
Control Concepts Corporation  
328 Water Street  
P.O. Box 1360  
Blnghamton, NY 139O2-1360  
Phone: 607/724-2464  
I
I
I
-
-
-
101 (1A,l20VAC)  
105 (5A, 120VAC)  
115 (15A, 120VAC)  
I
I
-
202 (2.5A, 208/240VAC)  
- 207 (7.5A, 208/240VAC)  
The ultimate protection is an “uninterruptable” power supply. This 'senses'  
the A.C. power line; when the line fluctuates, a battery powered 6OHz in-  
verted circuit takes over, supplying power within one-half to one cycle of the  
A.C. line; very expensive.  
How To Check For Ground Loops  
To check for ground loops, disconnect the ground wire at the ground termina-  
tion. 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.  
Or check for continuity; your reading should be "open”. Ifyoudofind continu-  
ity, you must now begin looking for the ground loops. Begin disconnecting  
grounds in the system one at a time, checking for continuity after each discon-  
nection. When continuity reads "open” you have eliminated the ground loop(s).  
Also, as you reconnect grounds, keep making the continuity test. It is possible  
to reconnect a ground loop.  
Noise Suppression Devices Available From Watlow  
Watlow Controls stocks a few key noise suppression parts. You may order  
these by calling your localWatlowdistributor.  
Item  
Electrical Ratlngs  
25OV, 3 Amp  
Part Number  
Common Mode Line Filter  
0804-0196-0000  
Table  
NoiseSuppressIon  
Device Ratings  
1
-
Differential Mode Line Filter  
Refer to the lslatrol listing above.  
Metal Oxide Varistor  
15OV, 80 Joule  
13OV,38 Joule  
275V, 75 Joule  
275V, 140 Joule  
0802-0273-0000  
0802-0304-0000  
0802-0266-0000  
0802-0405-0000  
MOV  
MOV  
MOV  
Install and Wire, Chapter 2  
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9
Line Filtering Configurations For Controls  
These three diagrams show you filter configurations for removing input power  
For very dirty or critical  
noise. Choose the one best suited for your system.  
applications use microcomputer-regulatedpowersupplyor Uninterruptable  
Don’t fasten common mode line filters or filters with  
-
a
Power Supply(U.P.S.)  
metal cases to metal that is at ground potential. This prevents ground loops  
and maintains filter effectiveness.  
Figure  
Differential Mode  
Filter  
3
-
Wiring  
D.M. Line Filter  
Ll  
.
Control  
NOTE: Keep filters  
12 inches or less  
from the control.  
Minimize the line  
distance where  
nolse can be re-  
introduced to  
control.  
Common Mode Filter  
Wiring  
C.M. Line Filter  
Control  
2
I
NOTE: To prevent  
ground loops do not  
fasten common  
mode line filters or  
filters with metal  
cases to metal that  
is at ground poten-  
tlal. Doing so will  
reduce filter effec-  
tiveness.  
Figure  
Combination  
Differential/  
5
-
Control  
Ground  
Common Mode Filter  
Wiring  
10 WATLOW Series 980/985 User's Manual  
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How to Install the Series 980/985  
Figures 6,7 and 8 provide the Series 980/985’s panelcutoutanddimensions.  
Do not, however, make your panel cutout until you are sure that you are  
placing the control in the best location. Read the noise guidelines at the  
beginning of this chapter before installing and wiring the Series 980/985.  
Figure 6 shows you the  
1. Place the panel cutout in the desired location.  
panel cutout dimensions.  
Push  
2.  
Toinstall, carefully insert the Series 980/985 intothepanelcutout.  
the unit in until the bezel is seated securely against the panel.  
NOTE:  
Removing the Series  
980/985 chassis  
from its case may  
make mounting  
easier.  
3.  
Included with your control are two adjustable mounting brackets; one for the  
Installingthemounting  
top and one for the bottom of the control case.  
brackets requires access to the back side of the panel.  
On the top and bottom of the case are a series of slots running the length of  
the case. The first two shorter slots are for attaching the mounting brack-  
ets. Figure 8 shows a side view with both mounting brackets.  
4.  
5.  
Loosen the mounting bracket screws with a Phillips screwdriver far enough  
to allow for the panel thickness.  
Make sure that each bracket is placed in the first two slots from the front of  
Refer  
the control, with the head of the screw facing the back of the control.  
to Figure 8 for screw and bracket placement.  
6.  
To attach, place the bracket into the slots (head of the screw facing the  
back of the control and push backward, securing the brackets to the control  
Do the same for the other side of the control.  
case.  
7. Make sure the Series 980/985 case is seated properly. Tighten the installa-  
tion screws firmly against the panel to secure the unit in place.  
8.  
To remove the unit from its enclosure, loosen the captive screw at the  
bottom of the 980/985’s front panel with a Phillips screwdriver.  
Pull the unit  
from its case.  
9.  
To release the mounting brackets, push the brackets forward and pull out to  
release them from the control case.  
Installand Wire, Chapter  
2
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11  
Panel Cutout  
Max.Panel  
Thickness  
0.50 (12.7mm)  
Figure 6  
-
Series 980/985  
Panel Cutout  
Dimensions  
3.82 +0.03  
-
0.00  
(92mm  
+
0.8)  
Load Power  
indicators  
.89  
(48.0 mm  
Figure 7  
-
Series 980/985  
Dimensions  
Panel  
‘Install and Wire, Chapter 2  
12 WATLOW Series 9801985 User’s Manual  
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How to Wire the Series 980/985  
The Series 980/985 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 back of this manual.  
Series 980/985 internal circuits appear “inside“ the line drawing of the 980/985,  
while connections and terminal designations appear “outside” the line drawing.  
All outputs are referenced to a de-energized state. The final wiring figure is a  
typical system example.  
All wiring and fusing should conform to the National Electric Code and to any  
locally applicable codes as well  
.
When you apply power without sensor inputs on the terminal strip, the Series  
in the Upper display, and a "O" in the Lower display.  
-
”
980/985 will display “-  
-
Press the AUTO/MANUAL key twice, and an ER 7 is displayed for one second.  
This error indicates an open sensor. Remove power to the control and connect  
the sensor properly, see Page 14.  
Figure 8  
-
115 VAC Power  
Wiring  
Jumper #4 to #6 and  
Jumper #5 to #7 for  
115 VAC operation  
L2  
Ground  
Earth  
CAUTION:  
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.  
Figure 9  
230 VAC Power  
Wiring  
-
Jumper #5 to # 6 for  
230 VAC operation  
Install and Wire Chapter  
2
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13  
“, “2”  
lnput Options “1  
Terminals 18 & 20  
&
“3”, Thermocouple Input  
Model  
#
98  
– A - 1 _ _ - 0-0000  
98_A-2 – –0-0000  
Figure 10  
Input Options “1”,  
*3’, Thermo-  
-
98_A-3- – –0-0000  
**2*  
&
couple Wiring  
Diagram.  
NOTE:  
You must use an isolated or ungrounded thermocouple if an external 4-20mA  
output device with a non-isolated circuit common is connected to the 4-20mA  
output.  
Extenslon wire for thermocouples must be of the same alloy as the thermocouple  
itself to limit errors.  
These input connections are used in conjunction with your units sensor  
type. (Thermocouple and RTD only)  
Input Options “2’  
Terminals 15 17  
&
“3”, Process or Remote Set Point Input  
-
Flgure 11  
-
Input Options "2"  
&
"3" Process Input  
Wlring Diagram.  
Model #98_A - 2 _ _ 0 - 0000  
98_A - 3 _ _ 0 - 0000  
0-5VDC 4-20mA INPUT  
NOTE:  
Input  
Voltage  
When using a4-  
2OmA process  
Input, the input  
impedance is  
2 4 9 o hm s  
16  
17  
Jumper Terminal 16  
to Terminal 17 when  
using a 4-20mA  
input.  
0-5VDC, 4-20mA INPUT  
.
NOTE:  
When using a process input such as O-5VDC or 4-2OmA, the rL and rH settings  
scale the display to match the measured range of the process signal. When using  
0-5VDC process input, the input impedance is 100K ohms.  
a
An example of this is: A pressure transducer operates over a range of 0  
delivering a 4-20mA output signal for this range. By setting rL=0 and rH  
-
300 PSI,  
300,  
=
the Series 980/985 is now displayed as a direct reading of pressure.  
14  
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Install and Wire, Chapter2  
Input Options “2”  
Terminals 12 14  
&
" 3 " RTD 2 Wire  
-
-
ModeI#98 _ A - 2 _ _0-0000  
98_A-3_ _0-0000  
Figure 12  
-
Input Options "2" &  
“3”, RTD (2 wire)  
Sensor Wiring.  
Jumper#l3to#l4  
Input Options “2”  
Terminals 12  
&
" 3 " RTD 3 Wire  
-
-
14  
Model# 98_A-2_ _ 0-0000  
98_A-3_ _0-0000  
Figure 13  
-
Input Options “2’  
‘*3”, RTD (3 wire)  
Sensor Wiring.  
&
.
.
.
.
.
.
-
NOTE:  
Long lead lengths create electrical resistance. There will be  
input error for every 1ohm of lead length resistance when using  
That resistance, when added to the resistance of the RTD element, can result in  
erroneous input to the instrument. To overcome this problem, use three wire  
a
1° approximate  
a
two wire RTD.  
a
RTD sensor, which compensates for lead length resistance. When extension wire  
is used for a three wire RTD, all three extension wires must have the same  
electrical resistance. (i.e. same gauge, copper stranded).  
Install and Wire, Chapter 2  
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15  
Output  
1
Option “B”, Solid State Relay  
ModeI# 98_A-_  
B
_0-0000  
Figure 14  
-
Solid State Relay,  
Output 1, Option“B”  
Wiring Diagram.  
Solid State  
Relay  
Solid State Relay  
Watlow's solid state relays change state at zero volts, which is *zero-cross switching.”  
They are also optically isolated, which means the output circuitry is energized by  
infrared light striking a photo-sensitive device. This results in virtual absence of electri-  
cally generated noise, pIus output to input electrical isolation. Off state impedance is  
2O K o h m minimum.  
Output 1 Option“C”, DC Output (Open Collector)  
Model# 98_A-_C_0-0000  
,
+
.
DCLoad  
3
Figure 15  
-
DC Output 1 (Open  
Collector), Option  
72” Wiring Diagram.  
Switched DC  
Watlow’s solid state switch isa low current DC output (open collector) used to switch an  
external power switching device such as anSSR or an electromechanical relay. The  
input specifications of the power switching device must those listed for the SS  
switch output. The power switching device must provide isolation between the SS  
switch output and load power since the SS switch output is a non-isolated output.  
Minimum load resistance is 5OO o h ms. Available current is minimum 9mA,22mA maximum.  
16  
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Install and Wire, Chapter  
2
Output 1 Option “D”, 6 Amp Mechanical Relay  
Model#98_A-_D _0-0000  
Figure 16  
-
Mechanical  
Relay  
6 Amp mechanical  
Relay, Output 1,  
Optlon “D” Wlrlng  
Diagram.  
Mechanical Relay  
The Electromechanical relay iS an electrical and mechanical  
with moving parts.  
When power is applied to the relay solenoid, Contact closure is Created through move-  
ment of the “Common” Contact of the relay. Off state impedance is2 O K o h m minimum.  
Output  
1
Option “E”, 0-I0 VDC  
Model# 98_A-_E _0-0000  
Figure 17  
-
0-10VDC, Output 1,  
Optlon "E" Wiring  
Diagram.  
Process Output,  
Proportional value determined by the Control to balance the sensor input and set point.  
This value will fall between 0-10VDC depending on your process output type.  
Install and Wire, Chapter  
2
WATLOW Series 980/985 User’s Manual  
17  
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Output 1 Option “F", 4-20mA  
Model# 98_A-_F _0-0000  
Figure 18  
-
4-2OmA, Output 1,  
Option "F" Wiring  
Diagram.  
Process Output  
Proportional value determined by the control to balance the sensor input and set point.  
This value will fall between4-20mA depending on your process output type.  
Output 1 Option “G”, O-20mA  
Model# 98_A-_G _0-0000  
Figure 19  
-
0-20mA, Output 1,  
Option “G” Wiring  
Diagram.  
Process Output  
Proportional value determined by the control to balance the sensor input and set point.  
This value will fall between 0-20mA depending on your process output type.  
18  
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InstallandWire, Chapter  
2
Output 1 Option “H”, O-5VDC  
Model# 98_A-_H _0-0000  
Figure 20  
-
O-5VDC, Output 1,  
Option "H" Wiring  
Diagram.  
Process Output  
Proportional value determined by the control to balance the sensor input and set point.  
This value will fall between O-5VDC dependlng on your process output type.  
Output 2 Option “B”, Solid State Relay  
B
0-0000  
Model# 98_A-  
- -  
Figure 21  
-
S.S. Relay,  
Output 2, Option "B"  
Wiring Diagram.  
Solid State Relay  
Watlow’s solid staterelays change state at zero volts, which is zero-cross switching.”  
They are also optically isolated, which means the output circuitry is energized by  
infrared light striking aphoto-sensitive device. This results in virtual absence of electri  
cally generated noise, plus output to input electrical isolation. Off state impedance is  
2 O K o h m s minimum.  
-
InstallandWire, Chapter  
2
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19  
Output 2 Option “C", DC Output (Open Collector)  
Model# 98_A-  
C 0-0000  
__  
Figure 22  
-
DC Output (Open  
Collector), output  
Option "C" Wiring  
Diagram.  
2
9
-
8 Heat, Cool  
+
or Alarm  
Switched DC  
Watlow’s solid state switch is a low current DC output (open collector) used to switch an  
external power switching device such as a SSR or an electromechanical relay. The input  
specifications of the power switching device must match those listed for the SS switch  
output. The power switching device must provide isolation between the SS switch  
output and load power since the SS switch output is a non-isolated output. Minimum  
load resistance is 5 0 0 ohms. Available current is9mA minimum and 22mAmaximum.  
Output 2 Option “D”,  
6
Amp Mechanical Relay  
Model# 98_A-  
D 0  
-
0000  
- -  
Figure 23  
-
6 Amp Mechanical  
Relay,  
Output 2, Option "D"  
Wiring Diagram.  
Mechanical  
Relay  
Mechanical Relay  
The electromechanical relay is an electrical and mechanical device with moving parts.  
When power is applied to the relay solenoid, contact closure is created through move-  
ment of the “common” contact of the relay. Off state impedance is 20K ohms minimum.  
20  
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InstaIl and Wire, Chapter 2  
WARNING:  
Install high or low temperature limit control protection in systems where an  
overtemperature 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.  
1
CAUTION:  
Do not jumper load power from the control power terminals. Doing so will cause  
your control to be more susceptible to electrical interference from loadswitching.  
See Noise Guidelines at the beginning of this chapter.  
Figure 24  
-
System Wiring  
Example  
115 Volt  
Control Power  
1
L2 L1  
Earth  
Ground  
A
A
Fuse  
2
CAUTION:  
1
With Watlow mercury relays, load  
must have a unity power factor.  
For RESISTIVE LOADS ONLY.  
NOTE  
All fuses must be selected for  
proper protection in a given  
application.  
Load  
Power  
Fuse  
HighLiiit  
Control Power  
120  
Ll L2  
Ll  
140A- 16XX- 6000  
Hi ghLimitControl  
Heat  
Load  
L2  
Ll  
Relay Contactor  
coilPower  
Limit Sensor  
Process Sensor  
Install and Wire, Chapter  
2
WATLOW Series 980/985Use'sManual  
21  
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Chapter 3  
How to Use the Keys and Displays  
Series 980/985 Displays and Load LED’s  
Upper Display  
Red, 0.3” high LED, seven segment, three or four  
digit display indicating either process actual tem-  
perature, the operating parameter values, or an  
open sensor.  
NOTE:  
The Upper display  
will always show  
the process value  
after 1 minute  
without key  
strokes.  
Lower Display  
Red 0.3” high LED, seven segment, three or  
four digit, display indicating the set point,  
output value, prompts for data in the upper  
display, or error and alarm codes.  
Figure 25  
-
Series 980/985  
Displays  
LOAD  
1
When lit, this LED  
tells you when  
Output 1 is ener-  
gized.  
Output 2 is ener-  
gized or the alarm is  
active.  
22  
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Keys and Displays, Chapter 3  
Series 980/985 Keys  
Figure 27  
-
Series 980/985 Keys  
MODE Key  
UP/DOWN keys  
Steps the control through the  
Operating menu; also, in the  
Auto mode, enters new data  
When pressed simultaneously for 3 sec-  
onds, the Setup Menu appears displaying  
the LOC parameter. From the LOC pa-  
rameter, press the UP/DOWN keys again  
and the Calibration Menu appears.  
selected less than  
5
seconds  
previously  
.
AUTO/MAN Key  
Pressed once, it clears any  
latched alarms. If the key is  
pressed again within  
5
seconds, the control toggles  
between the Auto and Manual  
mode. While in the Manual  
mode, percent power is  
always displayed in the lower  
display.  
Increases the value  
of the displayed  
parameter. A light  
touch increases the  
value by one.  
Holding the key  
down increases the  
display value at a  
rapid rate. New  
data is self entering  
Auto/Manual LED  
DOWN Key  
Lit when the control is in Manual opera-  
tion. Press the key twice to enter Auto  
operation. A blinking Auto/Manual LED  
indicates that pressing the Auto/Manual  
key toggles between Auto and Manual.  
After 5 seconds without pressing the  
Auto/Manual key, the LED stops blinking,  
and returns to its previous state.  
Decreases the value of the  
displayed parameter. A light  
touch decreases the value by  
one. Holding the key down  
decreases the displayed value  
at a rapid rate. New data is  
in  
5
seconds.  
self entering in seconds.  
5
Where To Go From -Here  
Now that you know how to read the keys and displays, continue to Chapter 4 to  
begin entering data and setting up your Series 980/985.  
KeysandDisplays, Chapter  
3
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23  
Chapter  
4
How To Setup The Series 9801985  
Setting up the Series 980/985 is a simple process. First configure the 980/  
985’s features to your application in the Setup Menu, and then enter values in  
the Operating Menu. Both tasks use the MODE key to move through the  
menus and the UP/DOWN keys to select data.  
NOTE:  
While in the Setup  
menu, all outputs  
are OFF.  
Entering the Setup Menu  
The Setup Menu displays the parameters that configure the Series 980/985’s  
features to your application.  
To enter the Setup Menu, press the UP and DOWN keys simultaneously for 3  
seconds. See Figure 27. The Lower display shows the LOC parameter, and  
the Upper display shows its current level. All keys are inactive until you release  
both keys. You can get to the LOC parameter from anywhere.  
Use the MODE key to cycle through the menu; use the UP/DOWN keys to  
select Setup data. You may not see all the parameters in this menu, depend-  
ing on the unit’s configuration and model number. After stepping through the  
Figure 27  
Entering the Setup  
Menu.  
-
under the Operation  
menu, you will return to the control set point parameter  
menu.  
Mode Key  
Figure 28  
-
The Setup Menu.  
Prompt appears or not according  
to control configuration.  
NOTE:  
When using a  
process input such  
as O-5VDC or  
4-2OmA, the rL and  
rH settings scale the  
display to match the  
measured range of  
the process signal.  
Control Set Point  
Setup, Chapter 4  
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24 WATLOW Series 980/985 User’s Manual  
Setup Parameters  
At the top of the menu, the Series 980/985 displays the user level of operation  
in the Upper display, and the LOC parameter in the Lower display. When  
pressing the MODE key, the value of the next parameter appears in the Upper  
display, and the parameter itself is in the Lower display.  
Lock: Selects the level of operator lock-out. This parameter’s range is from  
0
-
3. The default is 0. The levels of operator lock-out are defined as follows:  
LOC 0: All operating parameters may be viewed or changed. Manual operation  
is permitted.  
LOC 1: The set point and actual are the only visible parameters, the set point  
is adjustable in this level of lock-out. Manual operation is permitted.  
LOC 2: The set point and actual are the only visible parameters, set point is  
adjustable in this level of lock-out. Manual operation is not permitted.  
Bumpless transfer is defeated.  
LOC 3: The set point and actual are the only visible parameters, the set point is  
not adjustable in this level of lock-out. Manual operation is not  
permitted. Bumpless transfer is defeated.  
Input:  
Selects the sensor input type. This parameter’s range is J, K, t, n, Pt2,  
rtd, rt.d, 0-5, and 420. The default is Type “J”. Only those input types compat-  
ible with your unit appear. See the model number information for your type.  
Remote Set Point: Enables the Series 980/985 to accept a remote set point  
signal from another device. This parameter only appears on models 98XA-  
2XXX-0000 or 98XA-3XXX-0000 and if In  
=
Thermocouple or RTD input.  
Range: OFF, 05,420 Default: OFF  
Decimal: Selects the location of the decimal point for ail process related data.  
The range is 0, 0.0, or 0.00. The default is 0. This parameter only appears if  
the in parameter is 0-5 or 420.  
Celsius  
_
Fahrenheit: Selects the units of measure for the control. The range  
of this parameter is C or F. The default is F. This parameter only appears if the  
In parameter is J, K, t, n, Pt2, rtd, or rt.d.  
Range Low: Selects the low limit of the operating range. See the model  
number and specification information in the Appendix for your range values. For  
units with process input, it determines scaling of the remote set point input.  
0.0VDC and 4mA input are equal to Range Low(rL) of your input type. Set point  
is linearly scaled between rL and rH. See Chart 2 on Page 26.  
Range High: Selects the high limit of the operating range. See the model  
number and specification information in the Appendix for your range values. For  
units with process input, it determines scaling of the remote set point input. The  
5.OVDC and 2OmA input are equal to the Range High (rH) of your input type.  
Set point is linearly scaled between rL and rH. See Chart 2 on Page 26.  
Output 1: Selects the output action for the primary output. The range of this  
parameter is Ht (Heating) or CL (Cooling). Default is Ht.  
Output 2: Selects the output action for the secondary output. The range of this  
parameter is Ht (Heating), CL (Cooling), AL (Alarm) or no (None). Default is AL.  
Alarm Type: Selects the alarm type when Output 2 has been selected as an  
alarm. The range of this parameter is Pr (Process Alarm) or dE (Deviation  
Alarm). A process alarm is set at an absolute temperature to prevent over/  
underrange. Deviation tracks your process set point. The default is Pr. This  
only appears if the Ot2 parameter is AL.  
SetupChapter4  
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25  
Latching: Selects whether the output is latching or non-latching when Output 2  
is an alarm. Latching alarms must be cleared before the alarm output will reset.  
Non-latching automatically resets the alarm output when the condition clears.  
The range is LAt or nLA, default is nLA. This only appears if the Ot2  
=
AL.  
Silencing: Selects alarms silencing (alarm inhibit). Appears only when  
ALt dE. If LAt, press the Auto/Man key to reset the alarm output. If nLA, alarm  
=
automatically resets seconds after power is applied.  
5
RTD: Selects the RTD calibration curve. JIS  
=
0.003916 PC  
/
DIN =0.003850 °C.  
/
Chart 1-  
Setup Menu  
Prompts and  
Descriptions.  
Use this page as a master copy for configuring your Series 980/elects the low  
limit of the Operating range See the model number and specification informa-  
Setup Parameters  
Factory Default  
Value  
Range  
LOC  
In  
0-3  
0
J
J,  
K
(appears as H), t, n,  
Pt2, rtd, rt.d, 0-5,4-20  
Dependent on model number.  
rSP  
OFF, O-5,420  
OFF  
0
DEC  
0, 0.0, or 0.00  
Dependent on input type.  
F
C or F  
Will not appear if In  
C-F  
=
0-5 or 420.  
Input selection dependent.  
rL  
rLtorH  
Input selection dependent.  
rH  
rH to rL  
Ht  
AL  
Pr  
Otl  
ot2  
ALt  
Ht or CL  
Ht. CL, AL or no  
Pr or dE  
Dependent on Ot2  
=
AL.  
AL.  
nLA  
OFF  
JIS  
LAt  
SIL  
rtd  
LAt or nLA  
Dependent on Ot2  
=
OFF or On  
Appears if Ot2=AL&ALt=dE.  
JIS or din  
Appears if In  
=
rtd or rt.d.  
Sensor Range Low  
Sensor Range High  
999*F/750°C (3 digit)  
Input Type  
Chart 2-  
Input Ranges.  
J
32°F/0°C  
32°F/0°C  
1
382°F/750°C (4 digit)  
K
-328°F/-200°C  
2282°F/1250°C  
I
n
32°F/0°C  
2282°F/1 250°C  
2543°F/l395°C  
111 2°F/600°C  
Pt2  
32°F/O°C  
rtd  
(1°)  
-328°F/-200°C  
-99.9°F/-99.9°C  
-5.00/-50.0/-500  
.-5.00/-50.0/-500  
rt.d (0.1’)  
0-5 (VDC)  
420 (mA)  
392.0°F/200.0°C  
35.00/350.0/3500  
35.00/350.0/3500  
I
I
26WATLOW Series 980/985 User’s Manual  
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Setup, Chapter4  
Mode Key  
NOTE:  
The Upper display  
will always show the  
process value after 1  
minute without key  
strokes.  
Control Set Point  
=
Prompt appears or not according to control configuration.  
.
Figure 29  
-
The Operation Menu.  
Operation Parameters  
Set Point 2: Sets the operating set point for Output 2 when control mode is Ht/  
Ht or CL/CL. SP2 only appears when Ot1 and 0t2 are the same, and functions  
as an ON/OFF control.  
Proportional Band: Set the proportional bandwidth for each Output, adjustable  
from 0  
°
to 999°F or 0 to 555°C for ranges displayed in whole degrees, and 0 to  
0, the Series  
99.9°F or 0 to 55.5°C for ranges displayed in 0.1°. If set at Pb  
=
9801985 functions as a simple ON/OFF control with a 3°F or 1.7°C switching  
differential for ranges displayed in whole degrees, and 0.3°F or 0.17°C for  
ranges displayed in 0.1°  
.
The default is 25°F/13°C.  
If the input type is 0-5VDC or 4-20mA, the range of Pb1 is 0-999, 0-99.9 or O-  
9.99 (determined by the value of DEC). The switching differential is 0.03, 0.3 or  
3 units. Pb2 default is 0. Pb2 only appears with Ht/CL or CL/Ht operation.  
Reset: Enter Reset for Output 1 or 2, adjustable from 0.00 to 9.99 rpts/min.  
value of 2.00 rpts/min. corresponds to an integral time constant of 30 seconds.  
Selecting 0.00 no integral action. rE2 only appears with Ht/CL or CL/Ht  
operation. rA will not appear if Pb 0 respectively.  
A
=
X
X =  
Rate: Adjust Rate function for Output 1 or 2, from 0.00 to 9.99 minutes maxi-  
mum. Selecting 0.00 no derivative action. rA2 will only appear with Ht/CL or  
CL/Ht operation. rA X will not appear if Pb X 0 respectively.  
=
=
Cycle Time: Enter the Cycle Time for each Output, adjustable from 1 to 60  
seconds. The default will be 5 seconds. Ct1 will not appear if Output 1 is 4-20.  
CT2 only appears with Ht/CL or CL/Ht operation..  
27  
Setup, Chapter  
4
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Dead Band: Enter the Dead Band between the heating and cooling functions  
adjustable from 99°F/± 55°C. The default is 0°. Appears when Ot2 CL.  
±
=
Alarm Low: Represents the low process alarm or low deviation alarm.  
Displayed only when 0t2 parameter is AL.  
Alarm High: Represents the high process alarm or high deviation  
alarm. Displayed only when Ot2 parameter is AL.  
Calibration Offset. The range is ±99°F/±55°C. The default is 0°.  
Calibration Offset adds or subtracts degrees from the input signal.  
Auto-Tune.The range of this parameter is 0-3, off  
=
0, slow  
=
1,  
medium 2, and fast 3. A value other than 0 initiates the auto-tune.  
=
=
Local-Remote: Selects a local or remote set point for the Series 980/985.  
Local set point is adjustable directly from the 980/985, while remote can only  
be changed from an external device. The signal must be within O-5V or 4-  
20mA process input. This parameter appears if the LOC parameter  
=
0, 1 or 2,  
If L-r the remote set point is displayed in place of the  
=
and rSP  
internal set point.  
=
0-5 or 420.  
Chart 3  
-
Operation Menu  
Prompts and  
Descriptions.  
Use this page as a master copy for your Series 980/985. Operation Parameters.  
Do not enter any values here: make photocopies instead.  
1
Factory Default  
Same as primary set point.  
25°F/l3°C (3 or 4 digit)  
Range  
Value  
Operation Parameters  
SP2  
Pbl  
rL to rH  
0
to 999°F/0 to 555°C or  
0
to 99.9°F/0 to 55.5°C  
0=ON/OFF control  
with 3°F or 1.7°C  
switching differential.  
0.3°F or 0.17°C  
for 0.10 units.  
Same as Pb1 . Only appears if  
Ht/CL or CL/Ht operation.  
0.00 to 9.99 repeats/min.  
0°F/0°C (3 or 4 digit)  
0.00 repeats/min.  
0.00 repeats/min.  
Pb2  
rE1  
0.00  
=
No Reset Action  
Same as rE1. Only appears if  
Ht/CL or CL/Ht operation.  
rE2  
Will not appear if Pb2  
0.00 to 9.99 min.  
=
0.  
0.00 min.  
0.00 min.  
rA1  
0.00  
=
No Rate Action  
Same as rA1. Only appears  
if Ht/CL or CL/Ht operation.  
rA2  
Will not appear if Pb2  
=
0.  
-99°  
-999°  
rL  
99°  
999°  
rH  
AL0  
AHI  
-
-99° to  
(3 digit display)  
Deviation dE  
-999° to 0° (4 digit display)  
rL to AH1  
0° to 99° (3 digit display)  
0° to 999° (4 digit display)  
AL0 to  
Process Pr  
Deviation dE  
-
Process Pr  
5 seconds  
5 seconds  
Ctl  
Ct2  
1 to 60 seconds  
1 to 60 seconds  
Appears if Ht/CL or CL/Ht  
Will not appear if PB2 = 0  
±99°F/±55°C.  
db  
0
Appears if Ht/CL or CL/Ht  
±99°F/±55°C  
0-3  
CAL  
AUt  
0
0
Appears if Ot1  
L or r.  
Appears if rSP  
=
=
Ht.  
L-r  
0-5 or 420.  
28 WATLOW Series 980/985User’s Manual  
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Setup, Chapter 4  
Chapter  
5
How to Tune and Operate  
Tuning Automatic  
-
Auto-tuning: The Series 9801985 gives you the capability to automatically tune  
the PlD parameters to fit the characteristics of your particular thermal system.  
NOTE:  
Auto-tuningisonly  
possible in the heat  
mode. The cool  
The auto-tuning procedure operates on a thermal response value  
medium, or fast. A slow thermal response is used when the process tempera-  
A fast thermal  
slow,  
output remains off.  
ture is not met too rapidly, or greatly exceeds the set point value.  
response produces a rapid temperature change over a short period of time.  
Once the auto-tune sequence has begun, all PID values for both heat and cool  
are set to 0 and the control goes into an ON/OFF mode of control at 90% of the  
established set point. The displayed set point remains unchanged.  
Once the control has  
The cool output remains off for the duration of the tuning.  
finished “learning” the system, it returns to standard PID control with the heat  
PID values being automatically established as a result of the auto-tuning. The  
operator must then establish the cool PID values manually. Tuning is complete  
within 40 minutes. Any change of the set point, while in auto-tune, re-initiates  
the auto-tune procedure.  
To start auto-tuning:  
1. Press the MODE key until the AUt prompt appears in the data display.  
2. Select a thermal response value, 1=slow, 2=medium, and 3=fast, using  
the UP/DOWN keys. A thermal response value of  
most thermal systems.  
2
will satisfactorily tune  
3.  
4.  
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.  
When the process is complete, the displays return to their previous state  
and AUt reverts to 0. The appropriate PID tuning parameters are now  
installed, and retained in the non-volatile memory.  
To abort auto-tuning, the operator must reset the AUt parameter to 0. This  
leaves the unit in an ON/OFF heat control state in Auto operation at the dis-  
played set point. The auto-tuning process may also be aborted by pressing the  
AUTO/MANUAL key twice.  
In both cases, all PID values are set to 0.  
Tuning and Operating, Chapter  
5
WATLOW Series 980/985 User'sManual  
29  
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Tuning Manual  
-
For optimum control performance, tune the Series 985 to the thermal system  
The tuning settings here are meant for a broad spectrum of applications; your  
system may have somewhat different requirements.  
1. Apply power to the Series 965 and enter a set point. Begin with these  
1, rE1  
=
0.00, rA1  
=
0.00, Ct1  
=
5, CAL 0,  
=
Operation Parameters: Pbl  
=
AUt= 0.  
2. ProportionaI Band Adjustment (Output 1): Gradually increase Pb1 until  
the Upper display temperature stabilizes to a constant value. The process  
temperature will not be right on Set point because the initial reset value is  
0.00 repeats per minute.  
PB1 = 0; rE1 and rA1 are inoperative, and  
the 985 functions as a simple ON/OFF control with a 3°F or 1.7°C switching  
differential.)  
3. Reset Adjustment: Gradually increase rE1 until the upper display tem-  
perature begins to oscillate or “hunt”. Then slowly decrease rE1 until the  
Upper display stabilizes again near set point. NOTE: This is a slow proce-  
dure, taking from minutes to hours to obtain optimum value.  
Cycle Time Adjustment: Set Ct1 as required. Optimum system control is  
sometimes achieved with faster cycle times. However, if a mechanical  
contactor or solenoid is switching power to the load, a longer cycle time may  
be desirable to minimize wear on the mechanical components. Experiment  
until the cycle time is consistent with the quality of control you want.  
4.  
Rate Adjustment: lncrease rA1 to 1.00 min. Then 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 rA1 to 2.00 minutes.  
5.  
Then raise set point by 20 to 30°F, or 11 to 17°C and watch the approach to  
the new set point. If rA1 is advanced too far, approach to the set point will  
be very sluggish. Repeat as necessary until the system rises to the new set  
point without overshooting or approaching the set point too slowly.  
6. Calibration Offset Adjustment: You may want your system to control to a  
If so,  
temperature other than the value coming from the input sensor.  
measure the difference between that temperature, perhaps at another point  
in the system, and the process value showing in the Upper display. Then  
enter the amount of CAL offset you want. Calibration offset adds or sub-  
tracts degrees from the value of the input signal.  
Manual and Automatic Operation  
To change from manual to auto operation, press the AUTO/MAN key twice.  
Manual operation provides direct (time proportioned  
%
power) control of the  
outputs from -100% to 100%. A negative output value is allowed only with a Cl  
(Cool) selection on either Otl or 0t2. Automatic operation provides closed loop  
ON/OFF or PID control. When the operation transfers from a closed loop to an  
open loop, the 985 retains the power level from the closed loop control. When  
returning to the closed loop control,the previous set point temperature is  
restored.  
30  
WATLOW series 98O/985 User’s Manual  
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Tuning and Operating, Chapter  
Indication of Auto/Manual operation is the LED located on the AUTO/MAN key.  
When the LED is ON, the control is in the Manual operation, an alarm condition  
is present, and the output de-energizes. When the LED is OFF, the control is in  
AUTO operation and the alarm is energized. When the LED flashes, press the  
key again within five seconds to complete the change in operation. If the sensor  
is open and LOC  
=
0 or 1, the Series 985 switches to Manual operation (time  
proportioned power), if the output was stable before the break occurred.  
%
When transferring from auto to manual operation, the control output(s) will not  
change (“bumpless,” smooth transition). When transferring from manual to  
automatic operation, the control output(s) may change significantly. In manual,  
the output value (% power) appears in the lower display. In automatic operation,  
the set point appears.  
Using Alarms  
The Series 985 has two alarms types, Process or Deviation. A Process alarm  
sets an absolute temperature when the process exceeds that absolute tem-  
perature limit. The Process alarm points may be independently set high, low,  
or high/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. Any change in set point  
causes a corresponding shift in the deviation alarm. Example: If your set point  
is l OO° F, and you have a deviation alarm set at ±7°F as the high limit, and -5°F  
as the low limit, the high alarm will trip at 107°F, and the low alarm at 95°F. If  
you change the set point to 130°F, the alarms will follow the set point and trip at  
137°F and 125°F.  
Figure 31  
-
Alarm Display  
Examples  
Alarm Silencing for alarm output A1 is available with the deviation alarm. This  
overrides alarm A1 during power up. The non-latching mode automatically  
enables alarm output A1 on initial power up. In the latching mode, the operator  
must manually disable the alarm by pressing the AUTO/MAN key once. In both  
cases alarm silencing disables the A1 alarm output relay, but the A1 LED  
displays the alarm condition until the process value is within the “safe” region of  
the deviation alarm band. Once the process value crosses into the “safe”  
region, both a latching or a non-latching alarm is ready. Any future deviation  
outside this safe band triggers an alarm.  
Both Process and Deviation alarms can be latching or non-latching. The  
operator must manually reset a latching alarm before the alarm will reset. The  
operator must also remove the condition that created the alarm. When the  
operator removes the condition causing the alarm, a non-latching alarm auto-  
matically resets the alarm output.  
Press once  
Clear  
a latched  
and  
corrected  
alarm.  
-
Flashing ‘LO” or “HI” in the lower display indicates an alarm.  
The Lower display alternately displays information from the current parameter  
and the “LO” or “HI” alarm message at one second intervals. The alarm output  
(Output 2) is de-energized and the LOAD 2 LED is lit.  
To clear an alarm...  
l
The alarm condition must first be corrected...  
• If the alarm is latching...  
Clear manually; press the AUTO/MAN key once as soon as  
the process temperature is inside the alarm limit by3°F/l.7°C for 1°  
RTD units, and 0.3°F/0.17°C for 0.1° RTD units.  
WATLOW Series 980/985 User’s Manual 31  
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Tuning and Operating, Chapter  
5
•If the alarm is non-latching...  
The alarm will clear  
automatically as soon as the process  
temperature is inside the alarm limit by 3°F/l.7°C for 1° RTD units, or  
0.3°F/0.17°C for 0.1° RTD units.  
l
CAUTION:  
An alarm display will be masked by an error condition or when the  
control is in the Calibration or Set Up Menus.  
How To Deal With Error Codes  
Three dashes, “-  
-
-", in the upper display indicate  
a
Series 985 error.  
Press  
twice-  
Read  
~
l
If operator access is LOC 0 or  
1
.
.
.
error  
l
Press the AUTO/MAN key twice to see the error code for one  
second.  
•
•
If operator access is LOC 2 or 3...  
l
The error code is already in the lowerdisplay.  
Error code definitions and actions...  
Er Sensor overrange error  
1 -  
The sensor input is generating a value that is higher than that allowed for  
the range of this sensor, or the A/D circuitry is not functioning properly.  
Enter a valid input.  
Er  
2
-
Sensor underrange error  
The sensor input is generating a value that is lower than that allowed for  
the range of this sensor, or the A/D circuitry is not functioning properly.  
Enter a valid input.  
Figure 32  
-
Error Code Display  
Examples  
Er  
3
-
Ambient error  
Check the specification for the ambient temperature range.  
Er  
4
-
Configuration error  
The unit’s microprocessor is faulty; call the factory.  
NOTE:  
Er  
5
-
Non volatile checksum error  
Electrical noise or a  
noise event, vibra-  
tion or excess  
The nonvolatile memory checksum has discovered a checksum error.  
Unless a momentary power interruption occurred while the unit was  
storing data, the nonvolatile memory is bad. Call the factory.  
environmental  
moisture or tem-  
perature may cause  
Series 985 errors to  
occur. If the cause  
of an error is not  
otherwise apparent,  
check for these.  
Er  
7
-
A/D overflow error  
The A/D circuit is over- or under-range. An open or reversed polarity  
sensor is the most likely cause. Check the sensor; if it is connected and  
functioning properly, then call the factory.  
To clear a corrected error...  
l
Cycle power to the control.  
32  
WATLOW Series 980/985 User’s Manual  
Tuning and Operating, Chapter  
5
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Er 1, 2,  
3
&
7 Errors Control Outputs May Be ON  
-
If operator access is LOC 0 or 1 . . .  
. ..and the control was in AUTO operation when the error occurred, it will  
If the output power is less than  
go into MANUAL (% power) operation.  
70%±5% change within the last two minutes, the 985 will switch into  
Manual operation at the last Automatic power level. If the control was in  
(You must press the AUTO/  
MANUAL operation, it will remain there.  
MAN key twice to see the error code.) The alarm output (if present) will  
be in its alarm state (LED lit). The Upper display will read“-  
Lower display will indicate the error code.  
-
-“. The  
If the control was operating with stable output values when the error  
occurred, it will continue to operate at those levels on a power basis.  
%
If output values were not stable, the control outputs will go to 0% power  
(OFF).  
.
If operator access is LOC  
2
or 3. . .  
The control outputs will go  
The control will remain in AUTO operation.  
OFF. The AUTO/MAN and MODE keys are disabled. The UP/DOWN  
keys may be used together to enter the Set Up Menu. The alarm output  
(if present) will be in its alarm state (LED lit). The Upper display will read  
”
- - -“. The Lower display will indicate the error code.  
l
To clear a corrected error...  
lCycle power to the control.  
Er 4  
&
5
Errors Control Outputs Will Be OFF  
-
Error codes Er 4 and Er  
5
will result in these conditions:  
The control is in AUTO operation with both Outputs OFF.  
The alarm output (Output 2), if present, is in its alarm state (de-ener-  
gized with the LED lit).  
The Upper display will indicate the process value#.  
The Lower display will indicate the error code.  
All Keys are inactive.  
All Set Up Menu parameters are reset to default values. Calibration  
values 4AO and 2AO are set to default values. All other Calibration  
Menu values remain unchanged.  
These conditions will occur regardless of the value of LOC, or the pres-  
ence of the Set Up or Calibration Menus.  
To clear a corrected error. . .  
lCycle power to the control.  
lRecalibrate the 4-20mA output, if applicable (see the unit’s model #).  
TuningandOperating, Chapter  
5
WATLOW Series 9801985 User’s Manual  
33  
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Appendix  
Control Mode  
•
Single set point, non-ramping.  
l
l
Single input, dual outputs.  
Control outputs: User selectable as: Heat, Heat/Heat, Heat/Cool, Cool,  
Cool/Cool, Heat/Alarm, Cool/Alarm  
l
Outputs independent, or related via deadband for Heat/Cool.  
ON/OFF: 3°F or .7°C switching hysteresis or 0.3°F or 0.l7°C for  
0.10 Units  
PID parameters:  
l
1
.
l
Proportional band: 0 to 999°F/0 to 555°C(3 digit only)  
0 to 999°F/0 to 555°C or 0 to 99.9°F/0 to 55.5°C (3 or 4 digit)  
Reset: 0.00 to 9.99 repeats per minute.  
Rate: 0.00 to 9.99 minutes.  
Cycle time: 1 to 60 seconds.  
Deadband: ±99°F, ±99 units or ±55°C  
l
±9.9°F, ±9.9 units or ±5.5°C for 0.1 decimal units)  
Operator Interface  
l
Membrane front panel.  
l
l
l
Three or four digit 0.3” (8mm) LED diiplays.  
MODE, AUTO/MANUAL, UP, and DOWN keys.  
Dual digital displays.  
Input  
Thermocouple, RTD, and electrical process input.  
Automatic cold junction compensation for thermocouple.  
RTD input 2 or 3 wire, platinum, 100 ohm 0°C user selectable, calibrate  
@
to JIS curve #3916 (0.003916(0.003916ohm/ohm/°C or DIN curve #3850(0.003850ohm/ohm°C  
Sensor break protection de-energizes control output to protect system or  
selectable bumpless transfer to manual operation.  
Grounded or ungrounded sensors.  
°F/°C or process variable units are user selectable.  
Operating ranges user selectable.  
32 to 999°F or  
32 to 1382°F or  
0 to 750°C (3 Digit)  
0 to 750°C (4 Digit)  
Jt/c:  
Kt/c:  
-328 to 2282°F or -200 to 1250°C  
-328 to 662°F or -200 to 350°C  
T
t/c:  
N t/c:  
PT 2 (Platinel2) 32 to 2543°F or  
32 to 2282°F or  
0 t o 1250°C  
0 t o 1395°C  
1° RTD:  
0.1° RTD:  
0-5VDC:  
4-20mA:  
-328 to 1112°F or -200 to 600°C  
-99.9 to 392.0°F or -99.9 to 200.0°C  
-500 to 3500 units  
-500 to 3500 units  
34  
WATLOW Series 980/985 User’s Manual  
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Appendix  
Primary Output (Heating or Cooling)  
l
Solid state relay, 0.5A  
@
24VAC minimum, 253VAC maximum, opto-  
isolated, zero cross switching.  
Electromechanical relay, Form C, 6A  
@
115/230VAC, 6A  
@
28VDC,  
l
l
1/8 hp.  
@
115VAC 125VA  
@
115VAC. Warranted to 100,000 cycles.  
Open collector, switched DC signal provides a minimum turn ON voltage of  
3VDC into a minimum 500 ohm load, maximum ON voltage not greater than  
32VDC into an infinite load.  
4-20mA reverse acting into a 600 ohm maximum load.  
l
Secondary Output (Heat, Cool or Alarm)  
Solid state relay, 0.5A  
@
24VAC minimum, 253VAC maximum, opto-  
l
isolated, zero cross switching.  
Electromechanical relay, Form A, 6A  
.
l
@
115/230VAC, 6A  
@
28VDC,  
1/8 hp.  
@
115VAC, 125VA  
@
115VAC. Warranted to 100,000 cycles.  
Open collector, switched DC signal provides a minimum turn ON voltage of  
3VDC into a minimum 500 ohm load; maximum ON voltage not greater than  
32VDC into an infinite load.  
Accuracy  
l
Calibration Accuracy: ± 0.1% of span, ± 1 LSD,  
rated line voltage  
Accuracy Span: 1000°F or 540°C minimum.  
Temperature Stability: 0.1 °F/°F (0.1 °C/°C) change in ambient.  
Voltage Stability: ± 0.01% of span per percent of rated line voltage.  
77°F ± 5°F (25°C ±3°C) ambient  
&
±
10%.  
l
l
l
Agency Approvals  
l
UL recognized, File #E43684, UL873  
CSA file #LR30586  
l
Terminals  
l
#6 compression type screw terminals  
Power  
.
115/230VAC +1 0%, -15%, 50/60Hz,  
10VA maximum  
Data retention upon power failure via nonvolatile memory  
±
5%  
.
l
Operating Environment  
l
32 to 1 30°F/0 to 55°C.  
l
0 to 9O% RH, non-condensing.  
Dimensions  
(985 orientation) For 980 units, switch height and width measurements.  
l
H e i g h t :  
W i d t h :  
Overall depth:  
Behind panel depth:  
W e i g h t :  
3.8 in.  
1.9 in.  
6.3 in.  
6.0 in.  
0.9 lb.  
(96.5 mm)  
(48.0 mm)  
(160.5 mm)  
(152.5 mm)  
l
l
l
l
(0.4 kg)  
Appendix  
WATLOW Series 980/985 User’s Manual  
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35  
Series 980/985 Model Number Information  
The Series 980/985 Model Number, listed on your unit sticker, is defined below.  
Control  
Series 980/985  
=
Dual output,  
microprocessor-based  
I/8 DIN  
Mounting  
0
=
Horizontal  
Vertical  
5
=
,
Input  
=
=
1
2
Type J thermocouple (3 digit only)  
Type J, K, T, N, PT 2 thermocouple;  
RTD 1°, 420mA, 0-5VDC (4 digit)  
Type J, K, T, N, PT 2 thermocouple;  
=
3
RTD 0.1°  
,
4-20mA, 0-5VDC (4 digit)  
#1 output  
B
c
=
=
=
Solid state relay, Form A, 0.5A, RC suppression  
Switched DC, open collector, non-isolated  
Electromechanical relay, Form C, 6A  
(Warranted to 100,000 cycles)  
D
E
F
G
H
K
=
=
=
=
=
Process, 0-10VDC, non-isolated  
Process, 4-20mA, non-isolated  
Process, 0-20mA, non-isolated  
Process, 0-5VDC, non-isolated  
Solid state relay, Form A, 0.5A,  
without contact suppression  
#2 output  
Type  
A
B
c
=
=
=
=
None  
Solid state relay, Form A, 0.5A, RC suppressed  
Switched DC, open collector, non-isolated  
Electromechanical relay, Form A, 6A  
(Warranted to 100,000 cycles)  
D
K
=
=
Solid state relay, Form A, 0.5A  
without contact suppression  
Electromechanical relay, Form B, 6A  
(Warranted to 100,000 cycles)  
L
Front Panel  
00  
=
Standard  
xx  
=
Special label, consult Watlow representative  
36  
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Appendix  
Calibration Menu  
l
CAUTION:  
In the Calibration Menu, various input signals must be supplied in order for the  
control to go through its auto calibration. The calibration menu can only be  
entered from the LOC parameter in the Setup menu. Press the UP/DOWN  
keys simultaneously for 3 seconds 1 second). The CAL parameter appears.  
Incorrect calibration  
will affect the  
accuracy and should  
only be attempted  
with proper equip-  
ment and by quali-  
fied personnel.  
Figure 33  
-
Entering the  
Calibration Menu.  
NOTE:  
Calibration values  
are not retained  
unless you are In the  
MANUAL mode.  
Any inadvertent change in displayed data when pressing UP DOWN, is  
&
ignored. At the CAL parameter, press the AUTO/MANUAL key twice to enter  
the MANUAL mode. Calibration values are not retained unless in MANUAL  
mode.  
Upon entering the calibration menu, the top display window indicates CAL and  
keys are inactive until all keys are released.The upper display continues to  
indicate CAL (with the exception of calibration of the 4-20mA output) while the  
operator walks through the entire calibration parameter list. While calibrating  
the 4-20mA output, the upper display contains a numeric value that is 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.  
NOTE:  
While in the Calibra-  
tlon Menu, all  
outputs are OFF,  
except the 4-20mA  
output.  
Once the input has been properly established and maintained for at least 10  
seconds, the MODE key may then be used to display the next prompt. After  
the final input is established, another press of the MODE key returns the unit to  
the configuration menu at the top of the parameter list.  
Cal Restore  
If you make a mistake in calibrating your control, the rSt prompt at the end of  
the calibration menu restores the original factory calibration settings. Simply  
select yes and press the MODE key. The original factory calibration values are  
restored. Figure 34 on the next pages shows the calibration prompt.  
Appendix  
WATLOW Series 980l985User’s Manual  
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37  
Thermocouple, low end uncompensated. 0 mV  
Thermocouple, high end uncompensated. 50mV  
Thermocouple compensated value reference.  
RTD low end resistance, see Table 2 on Page 39.  
RTD high end resistance, see Table 2 on Page 39.  
Figure 34  
-
The Calibration  
Menu.  
Process input. 0V  
Process input. 5V  
Process input. 4mA  
Process input. 20mA  
Process output. 4mA  
4A0  
Process output. 20mA  
Restore factory calibration values. See Page 37.  
Factory use only.  
Factory use only.  
Field Calibration Procedure  
Thermocouple  
Equipment Required  
l
Type “J” Reference Compensator with reference junction at 320F/0°C, or  
Type “J” Thermocouple Calibrator set at 320F/0°C.  
Precision millivolt source, 0-50mV min. range, 0.01 mV resolution  
l
Setup And Calibration  
NOTE  
Connect the AC line voltage Ll to Terminal #4, L2 to Terminal #7, and  
Ground to Terminal #8. Jumper for correct line voltage. See Chapter 2.  
1.  
2.  
3.  
Before calibration  
on an installed  
control, make sure  
all data and  
parameters are  
documented. See  
Setup and Operation  
Charts, Pages 26  
and 28.  
Connect the millivolt source to Terminal#18 Negative and Terminal#20  
Positive on the 980/985 terminal strip. Use regular 20 24 gauge wire.  
-
Apply power to the unit and allow it to warm upfor 15 minutes. After  
warm-up put the unit in the CAL menu. See Figure 33 on Page 37.  
IMPORTANT:  
When the MANUAL LED is ON the unit is automatically calibrating. Your  
sequence is VERY important. Always move to the next prompt before  
changing the calibration equipment.  
4.  
5.  
6.  
7.  
Press the AUTO/MAN key twice to enter the MANUAL mode. The unit is  
calibrating when the MANUAL LED is ON.  
NOTE:  
At the “tcL” prompt, enter 0.00 millivolts from the millivolt source to the  
control. Allow at least 10 seconds to stabilize. Press the MODE key.  
Not all parameters  
will appear. They  
are dependent on  
your unit type.Use  
only the steps that  
apply to your unit.  
At the “tcH” prompt, enter 50.00 millivolts from the millivolt source to the  
9801985. Allow at least 10 seconds to stabilize. Press the MODE key.  
At the “tc” prompt, disconnect the millivoltsource, and connect the  
reference compensator orT/C calibrator to Terminal#18 Negative, and  
Terminal #20 Positive on the Series 980/985 terminal strip. Allow 10  
seconds for the control to stabilize. Press the AUTO/MAN key twice to  
exit the MANUAL mode. This pauses calibration to allow you to exit the  
CAL mode.  
38  
Appendix  
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RTD Field Calibration Procedure  
Equipment Required  
1K ohm precision decade resistance box with 0.01ohms resolution.  
l
Setup And Calibration  
NOTE  
Before calibration on an installed control, make sure all data and  
parameters are documented. See Setup and Operation Charts,  
Pages 26 and 28.  
1.  
Connect the AC line voltage L1 to Terminal #4, L2 to Terminal #7, and  
Ground to Terminal #8. Jumper for correct line voltage. See Chapter 2.  
NOTE:  
Not all parameters  
will appear. They  
are dependent on  
your unit type. Use  
only the steps that  
apply to your unit.  
2.  
Connect the decade resistance box to Terminal #12,13 and 14 on the  
Use regular 20 24 gauge wire of the same length and  
-
terminal strip.  
type.  
3.  
Apply power to the unit and allow it to warm up for 15 minutes. After  
warm-up put the unit in the CAL menu. See Figure 33 on Page 37.  
Press the MODE key until the rL0 prompt is displayed.  
IMPORTANT:  
When the MANUAL LED is ON the unit isautomatlcally calibrating. Your  
sequence is VERY important. Always move to the next prompt before  
changing the calibration equipment.  
4.  
5.  
Press the AUTO/MAN key twice to enter the MANUAL mode. The unit is  
calibrating when the MANUAL LED is ON.  
At the rL0 prompt, set the decade resistance box to the correct low  
setting- See the table below. Allow at least 10 seconds to stabilize.  
Press the MODE key.  
High  
1
Calibration  
Low  
Table 2-  
RTD Settings.  
985A-2XX0-0X00  
985A-3XX0-0X00  
317.33  
177.13  
1°  
0.1  
17.31  
59.57  
°
At the rHI prompt, set the decade resistance box to the correct high  
setting. Allow at least 10 seconds to stabilize. Press the AUTO/MAN key  
twice to exit the MANUAL mode. This pauses calibration to allow you to  
exit the CAL mode.  
6.  
Appendix  
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39  
0
-
5
Volt Field Calibration Procedure  
Equipment Required  
Precision voltage source 0-5 volt minimum range with 0.001 volt  
resolution.  
l
Setup And Calibration  
NOTE  
NOTE:  
Before calibration on an installed control, make sure all data and  
parameters are documented. See Setup and Operation Charts,  
Pages 26 and 28.  
Not all parameters  
will appear. They  
are dependent on  
your unit type. Use  
only the steps that  
apply to your unit.  
1. Connect the AC line voltage Ll to Terminal #14 L2 to Terminal #7, and  
,
Ground to Terminal #8. Jumper for correct line voltage. See Chapter 2.  
2.  
3.  
Connect the voltage/current source to Terminal #15 and #17 on the  
Series 980/985 terminal strip. Use regular 20 24 gauge wire.  
-
Apply power to the unit and allow it to warm up for 15 minutes. After  
warm-up put the unit in the CAL menu. See Figure 33 on Page 37.  
Press the MODE key until the OU prompt is displayed.  
IIMPORTANT:  
When the MANUAL LED Is ON the unit is automatically calibrating. Your  
sequence is VERY important. Always move to the next prompt before  
changing the calibration equipment.  
Press the AUTO/MAN key twice to enter the MANUAL mode. The unit is  
calibrating when the MANUAL LED is ON.  
4.  
5.  
6.  
At the OU prompt, set the voltage/current source to 0.00 volts. Allow at  
least 10 seconds to stabilize. Press the MODE key.  
At the 5U prompt, set the voltage/current source to 5.00 volts. Allow at  
least 10 seconds to stabilize. Press the AUTO/MAN key twice to exit the  
MANUAL mode. This pauses calibration to allow you to exit the CAL  
mode.  
40  
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Appendix  
4-20mA Input Field Calibration Procedure  
Equipment Required  
Precision current source 0-20mA minimum range with 0.01 mA  
resolution.  
l
Setup And Calibration  
NOTE:  
Not all parameters  
will appear. They  
are dependent on  
your unit type. Use  
only the steps that  
apply to yourunit.  
NOTE  
Before calibration on an installed control, make sure all data and  
parameters are documented. See Setup and Operation Charts,  
Pages 26 and 26.  
1.  
Connect the AC line voltage Ll to Terminal # 4 , L2 to Terminal #7, and  
Ground to Terminal #8. Jumper for correct line voltage. See Chapter 2.  
2.  
Connect the voltage/currentsource to Terminal #15 and #17. Jumper  
Terminal #16 to #1 7 on the Series 980/985 terminal strip. Use regular  
20 24 gauge wire.  
-
.
Apply power to the unit and allow it to warm up for 15 minutes. After  
warm-up put the unit in the CAL menu. See Figure 33 on Page 37.  
Press, the MODE key until the 4A prompt is displayed.  
IMPORTANT:  
When the MANUAL LED is ON the-unit is automatlcally calibratlng. Your  
sequence is VERY Important. Always move to the next prompt before  
changing the calibration equlpment.  
4.  
Press the AUTO/MAN key twice to enter the MANUAL mode. The unit is  
calibrating when the MANUAL LED is ON.  
5. At the 4A prompt, set the mA source to 4.00mA. Allow at least 10  
seconds to stabilize. Press the MODE key.  
6.  
At the 20A prompt, set the voltage/current source to 20.00mA. Allow at  
least 10 seconds to stabilize. Press the AUTO/MAN key twice to exit the  
MANUAL mode. This pauses calibration to allow you to exit the CAL  
mode.  
Appendix  
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41  
0-20/4-20mA Output Field Calibration Procedure  
Equipment Required  
NOTE  
l
l
470 ohm 1/2 watt 10% resistor.  
Not all parameters  
will appear. They  
are dependent on  
your unit type. Use  
only the steps that  
apply to your unit.  
4
-
1/2 digit Digital Multimeter.  
Setup And Calibration  
NOTE  
Before calibration on an installed control, make sure all data and  
parameters are documented. See Setup and Operation Charts,  
Pages 26 and 28.  
1.  
Connect the AC line voltage Ll  
the 980/985. See Chapter 2.  
,
L2, and ground to the proper terminals of  
2.  
Connect the multimeter in series with the 470 ohm resistor to Terminal #1 (+)  
and #3 (-) for 0-20mA units, on the Series 980/985 terminal strip. Use  
Terminal #I (+) and #2 (-) for 4-20mA units. Use regular 20  
wire.  
-
24 gauge  
Apply power to the unit and allow it to warm up for 15 minutes. After  
warm-up put the unit in the CAL menu. See Figure 33 on Page 37.  
Press the MODE key until the 4A0 prompt is displayed.  
3.  
IMPORTANT:  
When the MANUAL LED 's ON the unit is automatically calibrating. Your  
sequence is VERY important. Always move to the next prompt before  
changing the calibration equipment.  
4.  
Press the AUTO/MAN key twice to enter the MANUAL mode. The unit is  
calibrating when the MANUAL LED is ON.  
5.  
At the 4A0 prompt, the multimeter should read approximately 0mA for 0-  
20mA units and 4mA for 4-20mA units. Allow at least 10 seconds to  
stabilize.  
6.  
Use the UP/DOWN keys (reverse acting) to adjust the reading on the  
multimeter for 0.0mA ±0.1 OmA on 0-20mA units and 4.0mA+/-0.2mA on  
4-20mA units. Press the MODE key.  
7.  
8.  
At the 2AO prompt, the multimeter should read approximately 20mA.  
Allow at least 10 seconds to stabilize.  
Use the UP/DOWN keys (reverse acting) to adjust the reading on the  
multimeter for 20.0mA ±0.10mA on 0-20mA units and 20.0mA+/-0.2mA  
on 4-20mA units.  
9.  
Press the AUTO/MAN key twice to exit the MANUAL mode. This pauses  
calibration to exit the CAL mode.  
42  
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0-5/0-10 Volt Output Field Calibration Procedure  
Equipment Required  
NOTE:  
l
l
20K ohm, 1/4 watt, 10% resistor  
Not all parameters  
will appear. They  
are dependent on  
your unit type. Use  
only the steps that  
apply to your unit.  
4
-
1/2 digit Digital Multimeter.  
Setup And Calibration  
NOTE  
Before calibration on an installed control, make sure all data and  
parameters are documented. See Setup and Operation Charts,  
Pages 26 and 26.  
1.  
Connect the AC line voltage Ll  
the 980/985. See Chapter 2.  
,
L2, and ground to the proper terminals of  
2. Connect the multimeter across the 20K ohm resistor to Terminai #1 (+) and  
#3 (-) for 0-5VDC or 0-10VDC units, on the Series 980/985 terminal strip.  
Use regular 20 24 gauge wire.  
-
3.  
Apply power to the unit and allow it to warm up for 15 minutes. After  
warm-up put the unit in the CAL menu. See Figure 33 on Page 37.  
Press the MODE key until the 4A0 prompt is displayed.  
IMPORTANT:  
When the MANUAL LED is ON the unit is automatically calibrating. Your  
sequence is VERY important. Always move to the next prompt before  
changing the calibration equipment.  
4.  
5.  
6.  
7.  
Press the AUTO/MAN key twice to enter the MANUAL mode. The unit is  
calibrating when the MANUAL LED is ON.  
At the 4A0 prompt, the multimeter should read approximately 0.000V.  
Allow at least 10 seconds to stabilize.  
Use the UP/DOWN keys (reverse acting) to adjust the reading on the  
multimeter for 0.0V±0.10V  
.
Press the MODE key.  
At the 2AO prompt, the multimeter should read approximately 5.000V for  
0-5 volt units, or 1 0.000V for 0-10 volt units. Allow at least 10 seconds to  
stabilize.  
8.  
9.  
Use the UP/DOWN keys (reverse acting) to adjust the reading on the  
multimeter for 5.0V ±0.10V on 0-5V units and 10.0V+/-0.1 OV on 0-1 OV  
units.  
Press the AUTO/MAN key twice to exit the MANUAL mode. This pauses  
calibration to exit the CAL mode.  
Appendix  
WATLOW Series 980/985User’s Manual  
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43  
Droop: Difference in temperature between set  
point and stabilized process temperature.  
Alarm: A condition, generated by a controller,  
indicating that the process has exceeded or fallen  
below the set or limit point.  
Duty cycle: Percentage of “load ON time”  
relative to total cycle time.  
Anti-reset: Control feature that inhibits auto-  
matic reset action outside of the proportional  
band.  
Hysteresis: In ON/OFF control, the temperature  
change necessary to change the output from full  
ON to full OFF.  
Automatic prompts: Data entry points where a  
microprocessor-based control “prompts” or asks  
the operator/programmer for information input.  
Hunting: Oscillation or fluctuation of process  
temperature between set point and process  
variable.  
Bumpless transfer: Whentransferringfrom  
auto to manual operation, the control output(s)  
will not change (“bumpless,” smooth transition).  
input: Process variable information being sup-  
plied to the instrument.  
Closed loop: Control system that has a sensing  
device for process variable feedback.  
integral: Control action that automatically elimi-  
nates offset, or “droop”, between set point and  
actual process temperature. Also “reset.”  
Cold junction: Point of connection between  
thermocouple metals and the electronic instru-  
ment.  
Isolation: Electrical separation of sensor from  
high voltage circuitry. Allows for application of  
grounded or ungrounded sensing element.  
Coldjunction  
compensation: Electronic means used to  
compensate for the effect of temperature at the  
cold junction.  
JIS: Japanese Industrial Standards. Also Japa-  
nese Industrial Standards Committee (JISC).  
Establishes standards on equipment and compo-  
nents.  
Cycle time: The time necessary to complete a  
full ON-through-OFF period in a time proportion-  
ing control system.  
Offset: Adjustment to actual input temperature  
and to the temperature values the Series 985  
uses for display and control.  
Dead band: A temperature band between  
heating and cooling functions.  
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.  
Derivative: Anticipatory action that senses the  
rate of change of temperature, and compensates  
to minimize overshoot and undershoot. Also  
“rate.”  
I
Open loop: Control system with no sensory  
feedback. The Series 980/985 uses closed loop.  
Deviation: The difference between the value of  
the controlled variable and the value at which it is  
being controlled.  
Output: Action in response to difference between  
set point and process variable.  
Default parameters: The parameters, or pro-  
grammed instructions, which are permanently  
stored in microprocessor software to provide a  
data base.  
Overshoot: Condition where temperature  
exceeds setpoint due to initial power up or  
process changes.  
1
DIN: Deutsche Industrial Norms, a widely-  
recognized German standard for engineering  
units.  
P control: Proportioning control.  
Parameter: A physical property whose value  
determines the response of an electronic control  
to given inputs.  
Display capability: In a digital indicating instru-  
ment, the entire span that can be indicated if fully  
utilized.  
44  
WATLOW Series 980/985 User’s Manual  
Appendix  
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Switchingsensitivity: In ON/OFF control, the  
temperature change necessary to change the  
output from full ON to full OFF.  
PD control: Proportioning control with rate  
action.  
PI control: Proportioning control with auto-reset.  
Thermal System: A regulated environment  
consisting of a heat source, heat transfer me-  
dium, sensing device and a process variable  
control instrument.  
PID control: Proportioning control with auto-  
reset and rate.  
Process varlable: Thermal system element to  
be regulated, such as time, temperature, relative  
humidity, etc.  
Thermocouple: Temperature sensing device  
that is constructed of two dissimilar metals  
wherein a measurable, predictable voltage is  
generated corresponding to temperature.  
Programmed display data: Displayed informa-  
tion which gives the operator/programmer the  
“programmed” or intended process information,  
i.e., intended set point, intended alarm limit, etc.  
See “Actual displayed data.”  
Thermocouple break protection: Fail-safe  
operation that assures output shutdown upon an  
open thermocouple condition.  
Three mode control: Proportioning control with  
reset and rate.  
Proportlonal band: Span of temperature about  
the set point where time proportional control  
action takes place.  
Time Proportioning Control: Action which  
varies the amount of ON and OFF time when  
“close” to the set point, i.e., in the proportional  
band. This variance is proportional to the differ-  
ence between the set point and the actual  
process temperature. In other words, the amount  
of time the output relay is energized depends on  
the system temperature.  
Proportloning control: See Time Proportioning  
Control.  
Rate: Anticipatory action that senses the rate of  
change of temperature and compensates to  
minimize overshoot. Also “derivative.”  
Rate Band: A thermal control band that defines  
where the rate (derivative) function begins. A  
Watlow rate band occurs centered on set point at  
one or more times the width of the proportional  
band.  
Triac: Solid state switching device.  
Upper display data: Displayed information  
which gives the operator/programmer real or  
“actual” data, i.e., actual process temperature.  
See “Programmed display data.”  
Reference junction: Synonymous with cold  
junction. See “Cold junction.”  
Warm Start: Start-up condition where all program  
information is remembered by the instrument’s  
memory back-up protection.  
Reset: Control action that automatically elimi-  
nates offset, or “droop”, between set point and  
actual process temperature. Also “integral.”  
Zero switching: Action that provides output  
switching only at the zero voltage crossing points  
of the AC line.  
Reset windup inhibit: Synonymous with anti-  
reset. See “Anti-reset.”  
RTD: Resistance Temperature Detector. Resis-  
tive sensing device displaying resistance versus  
temperature characteristics. Displays positive  
temperature coefficient.  
Set point: Intended value of the process variable.  
Appendix  
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45  
K, L  
Keys, 23, Fig. 27  
A
Appendix, 34  
AUTO/MAN key, 23  
Automatic Operation, 23,31  
Auto-tuning, 30  
Line Filtering Configurations, 10  
Local-Remote Set Point, 25,28  
Lower Display, 22, Fig. 25  
’
B
Bumpless transfer, 31  
Manual Operation, 23, 31  
Mechanical Relay, 6 Amp,  
Output 1 Wiring, 17, Fig. 16  
Output 2 Wiring, 20, Fig. 23  
MODE key, 23  
C
Calibration, 38  
Combination Differential Filter, 10, Fig. 5  
Common Mode Fitter Wiring, 10, Fig 4  
D
Model Number, 36  
DCOutput 1, 16, Fig.16  
DC Output 2,20, Fig. 20  
Decrease Noise Sensitivity, How To, 7  
Default Parameters,  
N
Sources, 7  
Suppression Device  
&
Ratings, 9, Table 1  
Installation, 26, Chart 1  
Operation, 28, Chart 2  
Differential Mode Filter Wiring, 10, Fig.  
Dimensions,  
Control, 12, Fig. 7  
Panel Cutout, 12, Fig. 6  
Displays, 22  
3
Operating Chart and Default Parameters, 28  
Operation Parameters, 27  
Output 1 Wiring, 16  
Output 2 Wiring, 19  
overview of the Series 980/985, 5 Fig. 2  
DOWN key, 23  
P
E
Power Wiring, 13, Fig. 8,9  
Preventing Noise, Installation Guidelines, 6  
Process Calibration, 40  
Process Input, 14, Fig. 13  
Eliminate Noise, How To, 8  
Entering the Setup Menu, 24  
Error Codes, 32  
F,  
G
General Description, 4  
Glossary, 44  
Q, R  
Returns, 47  
Ground Loops,  
9
RTD Calibration, 39  
RTD Sensor Wiring, 15, Fig. 12  
-
13  
13  
H
How To,  
S
Deal with Alarms, 31  
Deal with Error Codes, 32  
Eliminate Noise, 8  
Install And Wire The Series 980/985  
Install The Series980/985,11  
Sensor Wiring 14  
-
15, Fig. 10  
-
Series 980/985 Input And Output Overview, 4, Fig. 1  
Setup Charts, 26,28  
Specifications, 34  
SS Relay,  
Output 1 Wiring, 16, Fig. 14  
Output 2 Wiring, 19, Fig. 21  
Steps To Put Your Control To Work, 5  
System, Planning, 6  
-
Chapter 2,6  
Setup The Series 980/985  
Tune And Operate Chapter 5,29  
Use The Keys And Displays Chapter 3,22  
-
Chapter 4.24  
-
-
Wire Power For The Series 980/985, 13  
Wire Input, 14  
Wire Output, 16  
Wiring Example, 21, Fig. 24  
I
Thermocouple Calibration, 38  
Thermocouple Sensor Wiring, 14, Fig. 10  
Tuning, 29  
Index, 46  
Information Resource, 6  
Inputs, 14  
Installation Guidelines for Preventing Noise, 6  
Setup Menu and Parameters, 24  
U, V,  
W
UP/DOWN keys, 23  
Upper Display, 22, Fig. 25  
Warranty, 47  
46  
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WATLOW Series 980/985 User’s Manual  
Index  
Warranty  
The Watlow Series 980/985 is warranted to be free of defects in material and  
workmanship for 36 months after delivery to the first purchaser for use, provid-  
ing that the units have not been misapplied. Since Watlow has no control over  
their use, and sometimes misuse, we cannot guarantee against failure. Wat-  
low’s obligations hereunder, at Watlow’s option, are limited to replacement,  
repair or refund of purchase price, and parts which upon examination prove to  
be defective within the warranty period specified. This warranty does not apply  
to damage resulting from transportation, alteration, misuse, or abuse.  
Returns  
We will not accept a return without an RMA number. The RMA number must  
appear on the outside of the carton and on all paperwork. Cartons without  
RMA numbers will be returned. Ship on a Freight Prepaid basis.  
1.  
You must call Watlow Customer Service, 507/454-5300, for a Return  
Material Authorization (RMA) number before returning any item for repair.  
We need this information:  
l
Contact name  
Your P.O. number  
l
Ship to address  
Phone number  
lBill to address  
Ship via  
l
l
l
lSymptoms and/or special instructions  
lName and phone number of person returning the material.  
You need prior approval and an RMA number from the Customer Service  
Department when you are returning an unused product for credit. Also, we  
must apply a 20 percent restocking charge for all returned stock controls  
and accessories.  
2.  
3. After we receive your return, we will examine it to determine the cause for  
your action.  
4. In cases of manufacturing defect, we will enter a repair order, replacement  
order or issue credit for material.  
5. If the unit is unrepairable, we will return it to you with a letter of explanation.  
Repair costs will not exceed 50 percent of the original cost.  
Watlow Controls  
Watlow Controls is a division of Watlow Electric Mfg. Co., St. Louis, MO, a  
manufacturer of industrial electric heating products, since 1922. Watlow begins  
with a full set of specifications and completes an industrial product that is  
manufactured totally in-house, in the U.S.A. Watlow products include electric  
heaters, sensors, controls and switching devices. The Winona operation has  
been designing solid state electronic control devices since 1962, and has  
earned the reputation as an excellent supplier to original equipment manufac-  
turers. These OEMs depend upon Watlow Controls to provide compatibly  
engineered controls which they can incorporate into their products withconfi-  
dence. Watlow Controls resides in a 100,000 square foot marketing, engineer-  
ing and manufacturing facility in Winona, Minnesota.  
Index  
47  
WATLOW Series 9801985 User’s Manual  
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