P/N 260786 Rev. 8/96 E-87 U.S. $45.
Notice Users of this equipment must comply with operating procedures and training of operation personnel as required by the Occupational Safety and Health Act (OSHA) of 1970, Section 6 and relevant safety standards, as well as other safety rules and regulations of state and local governments. Refer to the relevant safety standards in OSHA and National Fire Protection Association (NFPA), section 86 of 1990.
PREFACE This manual is your guide to the Watlow 1500 control. It is organized to give you the information you need quickly and easily. The INTRODUCTION section provides an overview of the control. The THEORY OF OPERATION section details the function and operation of the control. NOTE: Read the entire INTRODUCTION and The INSTRUCTIONS section provides directions on THEORY OF OPERATION unpacking, installing, operating and maintaining the control. before operating the control.
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Table of Contents PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Figures Figure 1 illustrates the Watlow 1500 installed on the Series 16000 environmental chamber control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Figure 2 DIP Switch Location and Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 List of Tables Table 1 Watlow 1500 Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Table 2 Watlow 1500 Keys . . . . . . . . . . . . . . . . .
INTRODUCTION This INTRODUCTION section provides an overview of the Watlow 1500 controller. The microprocessor based controller is capable of measuring, displaying and controlling temperature and humidity from a variety of inputs. The controller is easy to use. Control functions, alarm settings and other parameters are easily entered through the front keypad. Limited data can be protected from unauthorized changes with its guarded access mode security system.
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INSTRUCTIONS Operating To start the controller, start the oven fans. When you start the fans the following sequence will automatically take place. 1. The controller will power up. 2. The controller MNTR DATA LED will light up and the alarm indicator A1 will be flashing in the FUNCTION display. Alarm A1 is an indication of power loss. 3. Clear the alarm by pressing the clear button on the Watlow 1500. 4.
Watlow 1500 Control The Watlow Series 1500 is a versatile microprocessorbased control; powerful, yet simple to learn. Figure 1 illustrates the Watlow 1500 installed on the Series 16000 environmental chamber control panel. Table 1 Watlow 1500 Displays Display Description Actual Shows the actual process conditions (dry bulb temp if CH-1 LED is on, RH% if CH-2 is on. Event Shows current status of all events.
Watlow 1500 Control (Cont.) Table 2 Watlow 1500 Keys Key Description CH SEL Selects either channel 1 or channel 2 for the ACTUAL display. CLEAR Clears alarm codes from the FUNCTION display in the monitor data mode. Clears the step in the STEP display in the change data mode when the unit is in the halt condition. Clears all 51 programmed steps when the unit is in the halt condition, and in the guarded access area of the change parameter mode.
Manual Set Point Controller Use the following procedure to enter a dry bulb temperature, RH%, or change auxiliary event status when the MNTR DATA LED is on. 1. Press the RUN/HALT key so the PROG HALT LED lights up. 2. Press the RESTART key. 3. Enter the dry bulb temperature. a. Press the FCTN key until C1 is signaled in the FUNCTION display. b. Update the dry bulb temperature by using up/down arrow keys. c. Press enter when the desired set point is signaled in the data display.
Manual Set Point Controller (Cont.) 4. Enter the %RH. The humidity event must be off when outside of the range 4EC to 98EC. Humidity beyond these extremes can result in equipment damage. If a dry air system and an electronic humidity sensor are installed in lieu of a wet bulb sensor, the optional dry air event may be outside the range of 4EC to 98EC. NOTE: In the DATA display the right most character for Event 11 is shown as 0001. a. Press the FCTN key. C2 is shown. b.
Guarded Access Programming The Guarded Access parameters control the process limits. the three GA parameter loops are restricted to operators by special codes. The Guarded Access codes prevent inexperienced or unauthorized operators from changing the parameters.
Setting the Clock 1. Press the MODE key to select the Change Parameter (CHG PARA) mode. The TIME LED will be ON. The FUNCTION and DATA displays will show the real time of day. 2. Press FCTN to produce the time prompt, HR, in the FUNCTION display. 3. Enter the real time of day, beginning with hours. The CHG PARA programming prompts are listed below in the order they appear. a. Enter the real time of day (24 hour basis) by selecting the hour with the > key and the ? key. b.
GA0001 and 0002 PID Tuning Prompts appear for CH-1 with Code 0001, and then repeat for CH-2 with Code 0002. Except for CA, these parameters pertain directly to tuning your control to the system. Table 4 GA0001 and 0002 PID Tuning Parameters Parameter FUNCTION Display Description Proportional Band Pb Reset RS Rate RT Rate Band Rb Cycle Time CT Dead Band db The dead band defines an area on either side of set point where no switching action will occur.
GA0006 Setting Options These parameters are high and low display and scroll limits, and for some units, two channel control type and device address.
ECOSPHERE/16000 Series Guarded Access Chart Make a copy of this chart to document the Series 1500 Guarded Access for each program you use.
LPB Series Guarded Access Chart Make a copy of this chart to document the Series 1500 Guarded Access for each program you use.
Profile Mode This section of the manual provides details on programming the Watlow 1500 in the Change Data (CHG DATA) mode, the Change Parameters (CHG PARA) mode and Guarded Access. Refer to the Watlow 1500 manual for more details. Change Data Mode When the Watlow CHG DATA LED is lit, the processor is in the change data mode. While in this mode, the programming steps can be entered into the processor.
Blank Step Any unprogrammed step is first a Blank Step before information entered makes it a Set Point, Jump Loop or Wait Step. In normal programming, only the last step in the program remains a Blank Step. A Blank Step halts the processor. If, however, the RECYCLE option was selected in the CHG PARA mode, the program will return to Step #01 and repeat. When programming a HAST chamber, a Blank Step is not used.
Creating Files/Profiles See sections on “SAMPLE HAST PROFILE” and “PROCEDURE FOR PROGRAMMING HAST PROFILE” for LPB chambers. 1. Press the MODE key to select the CHANGE DATA mode. The FUNCTION display will indicate one of three submodes: • • • SP-Set Point, JL-Jump Loop, WT-Wait. 2. Press the FCTN key until SP appears in the function display. 3. Press the ENTER key. S1 will appear in the FUNCTION display and 0000 will appear in the DATA display. 4. Use the FCTN key to select the variable to edit.
Creating Files/Profiles (Cont.) 6. Enter set points for the JL (Jump Loop) submode. a. Use the > key and the ? key to enter the JS-Jump Step parameter. OR Use the FCTN key to advance to the next prompt without entering a value. b. Press the ENTER key. c. Use the > key and the ? key to enter the JC-Jump Count parameter. OR Use the FCTN key to advance to the next prompt without entering a value. d. Press the ENTER key. WT appears in the FUNCTION display.
Creating Files/Profiles (Cont.) 7. Enter the wait condition values for the WT (Wait) submode. a. Use the ENTER KEY. W1 appears in the FUNCTION window, indicating that a wait condition for the CH-1 set point can be entered. b. Use the > key and the ? key to enter the wait condition. OR Use the FCTN key to advance to the next prompt without entering a value. c. Press the ENTER key. W2 appears requesting a wait for CH-2 set point. d.
Creating Files/Profiles (Cont.) Table 7 Set Point Step Programming Detail Step FUNCTION Display Programming Procedure Channel 1 Set Point S1 1. 2. Select the Channel 1 set point. Press ENTER (or FCTN to leave blank). Channel 2 Set Point S2 1. 2. Select the Channel 2 set point. Press ENTER (or FCTN to leave blank). Channel 1 Event Outputs E1 1. Select a 1 or a 0 for each of the four available events (1 = ON, 0 = OFF).
Wait Steps The Wait (WT) submode allows the Watlow 1500 to wait for: C Channel 1 and/or Channel 2 actual process inputs, C the real time of day (not elapsed time as in set point steps). You can wait for one or two of these conditions, or all of them. If you don't need one wait condition, just press the FCTN key and the next Wait prompt will appear. By doing this the particular wait function will remain blank and be ignored.
Wait Steps (Cont.) The Wait Step does not allow the linear ramping path to reach the new conditions, as a Set Point Step does. To optimize control (reduce the overshoot and undershoot), a Wait Step uses the PID Parameters to satisfy the wait condition. In other words, select the step type which best matches your needs. Next Step The Next step (NX) step is used to select the program step. After the final prompt in each of the step types (SP, JL or WT), pressing ENTER advances the processor to NX.
Write Your Program The number of steps in the program may be as many as 51. We suggest that you write it out on copies of the charts in this section. This will enable you to program the Series 1500 quickly and without mistakes. This Programming Chart will provide you with a back-up copy of your entire program.
WORKSHEETS Programming Work Sheet Date Name Step No.
Sample HAST Profile for LPB Chambers Name Step No. SAMPLE JEDEC PROGRAM Set Point CH-1 CH-2 EC or EF % or E S1 S2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 20 70 W3(0001) 115 58 --120 58 W4(99.
Procedure for Programming HAST Profile 1. If power on, check HALT LED. If off, press RUN/HALT. 2. Press RESTART. 3. Press MODE until CHG PARA LED is lit. 4. Press FCTN until FUNCTION display reads GA. 5. Press UP arrow until DATA display stops at 2000. 6. Press DOWN arrow until display reads 1995, press enter key. 7. At Step 1 the display will read 01 SP (if Step 1 is clear), press enter.
Procedure for Programming HAST Profile (Cont.) 9. At Step 3 the display will read 03 SP, press enter. S1 is displayed, use arrow keys to 115, press enter S2 is displayed, use arrow keys to 58, press enter E1 is displayed, press FCTN E2 is displayed, use arrow keys to 0010, press enter HR is displayed, press FCTN MN is displayed, use arrow keys to 40, press enter SC is displayed, use arrow keys to 00, press enter TIME is displayed NX is displayed, use arrow keys to 0004, press enter 10.
Procedure for Programming HAST Profile (Cont.) 13. At Step 7 the display will read 07 SP, press enter. S1 is displayed, use arrow keys to 120, press enter S2 is displayed, use arrow keys to 58, press enter E1 is displayed, press FCTN E2 is displayed, press FCTN HR is displayed, press FCTN MN is displayed, use arrow keys to 10, press enter SC is displayed, use arrow keys to 00, press enter TIME is displayed NX is displayed, use arrow keys to 0008, press enter 14.
Procedure for Programming HAST Profile (Cont.) 16. At Step 10 the display will read 10 SP, press enter. S1 is displayed, use arrow keys to 120, press enter S2 is displayed, use arrow keys to 85, press enter E1 is displayed, press FCTN E2 is displayed, press FCTN HR is displayed, press FCTN MN is displayed, use arrow keys to 31, press enter SC is displayed, use arrow keys to 00, press enter TIME is displayed NX is displayed, use arrow keys to 0011, press enter 17.
Procedure for Programming HAST Profile (Cont.) 19. At Step 13 the display will read 13 SP, press enter. S1 is displayed, press FCTN S2 is displayed, press FCTN E1 is displayed, use arrow keys to 0011, press enter E2 is displayed, press FCTN HR is displayed, use arrow keys to 00, press enter MN is displayed, use arrow keys to 30, press enter SC is displayed, use arrow keys to 00, press enter TIME is displayed NX is displayed, use arrow keys to 0014, press enter 20. At Step 14 the display will read 14 SP.
Procedure for Programming HAST Profile (Cont.) 23. At Step 48 the display will read 48 SP, press FCTN until WT appears, press enter. Press FCTN until W4 is displayed, use arrow keys to 0102, press enter Press FCTN until NX is displayed, use arrow keys to 0049, press enter 24. At Step 49 the display will read 49 SP, press enter.
HAST Chamber Programming Instructions and Definitions C1 = Channel 1, Temperature (EC) C2 = Channel 2, Relative Humidity (%RH) SP = Set Points S1 = Set Temperature S2 = Set Relative Humidity E1 = Event 1: E2 = Event 2: WT = Wait Loop WE = Wait Event: JL JS JC 4 3 4 2 3 1 2 3 4 = = = = 2 1 > Power Devices 0 1 Off On > Cooling Fan 0 1 Off On > Nitrogen (optional) 0 1 Off On > Ramp/Test Light 0 1 On Off > Autofill 0 1 Off On > Heaters 0 1 Off On > Vent Solenoid 0 1 Open Closed
Ecosphere Sample Program The sample program on the following page is provided to demonstrate the function of the unit. It is pre-programmed in the factory and available for you to run upon installation of your chamber. If the program has been cleared somehow, you may wish to re-enter it as programming practice. Table 9 Despatch Sample Program Step Description 1 Set points of 25EC and 95% RH entered for S1 and S2. Event 1.1 is on. This enables the humidity control system.
Ecosphere Sample Profile Worksheet Date Program Name Step No.
Clearing a Program To clear an entire program, perform the following steps: 1. Press MODE key until CHG PARA LED lights. 2. Press FCTN key until GA shows in FUNCTION display. 3. Press the > key until DATA display shows 0006. 4. Press ENTER key. 5. Press the CLEAR key. 6. Press the RESTART key.
Tuning/Programming Worksheet Guarded Access Chart Make a copy of this chart to document the Series 1500 Guarded Access for each program you use.
Warm/Cold Start 1. A “Warm” start will save all programmed information in the memory. 2. A “Cold” start is a “Clean” startup condition. All MEMORY IS DELETED and the controller will return to default settings. 3. Upon completion of “Cold” start, return the control to “Warm” start, otherwise the control will return to the default settings after each power loss. 4. DIP Switch #6 determines a warm or cold start. Your controller leaves the factory programmed for a warm start.
Warm/Cold Start (Cont.) Table 10 DIP Switch Selection DIP Switch No. 1 2 3 4 5 6 7 8 FUNCTION ON OFF Auxiliary (Event) Output #4 for both Ch-1 Auxiliary (Event) Output #4 for both Ch-1 and Ch-2 are alarm outputs. and Ch-2 are event outputs. Alarms are latching (displayed until Alarms are non-latching (displayed only cleared manually). as long as the alarm condition exists). RTD Unit Only The Ch-2 sensor is an RTD sensor. The Ch-2 sensor is an RTD sensor.
