WW Faceplate 00 Faceplate 1/4 DIN Digital | Temperature Controller C Data Sheet Sheet) WWATLOW Watlow Winona Ine., 1241 Bundy Blvd., Winona, MN $5987 507/454-5900, Fax: 507/452-4507 W908-DA10-8736 ‘September, 1987 ‘Supersedes: WwMattCST Teye n ‘The Watlow Series 808 is a 1/4 DIN digital indicating temperature control. The control features a plug-in ‘design to facittate installation and service. The control ode is PID, with user accessible adjustment to all parameters. Input options include the selection of thermocouple ranges, RTD ranges, or electrical voltage or current inputs. There are many output options to select from including mechanical relay and solid state output. switching devices. Front panel accessible adjustments include the push- {o-set assembly for the main set point, and proportional band adjustments. The front face plate is available in {wo styles, gray with white bars, or black with white lettering. Bee osy Control Mode + PID: Proportional with auto reset and rte (integral and derivative). + Proportional band: lo to 100°F/FC (810 30°F/C for 0.4°RTD range), front panel adjust. + Reset: 0.05005 repeats per minute, intemal adjust. Rate: 005 minutes, internal adjust. + Cycletime: 21030 seconds, intomal adjust. Operatorintertace + 1/2" LEDs displaying process input value and, ‘when setpot knob is depressed, primary set point value. *+ LED indication of output energized (load light). Input + Thermocouple, RTD, and electrical process input available. Refer to the note on Page 5 conceming thermocouples. + Automatic cold junction compensation for thermocouple. + RTD input 2 0r3 wire, platinum, 100 ohms @ 0°C calibrated for either of two curves: #3916: 0.003916 O/C. ‘#3850 (DIN): 0.003850. Q/0"C, + Electrical process input: 4-20mA and 0-5VDC. User selectable decimal point enable. 1002 input impedance for 4-20mA. MV set point input, (rom programmer or another Control), 5 mvidigit for3 digit ranges and 2 mvidigit for 4 digi ranges. + Sensor break protection de-energizes output to Protect system. Display will indicate open sensor. Diat Digit Upscale: EEE OFL Downscale: - - - 000 2. WATLOW Series 806 Data Sheet + Nosensor break protection is provided when the 0-5V inputis used, (Electrical process #701) since Visa valid input. Output Control + Relay 10A , SPDT Plugin: 104@ 120VAC, 5A @ 240VAC, 108 @ 28VDC, 1/3 HP @ 120 or 240VAC, 345VA pilot duty @ 120 or 240VAC, See Figure 1. + Triac, 1A @ 240VAC zero-crossed switching SOmA min oad. Resistive ratings only. + Triac, 15A @ 240VAC zoro-crossed switching 100mA min oad. Resistive ratings only. + 4-20 mA/1-5VDC, 0-20mA/0-5VDC. + Load impedance for voltage output; SK ‘minimum, + Load impedance for current; 6000 maximum, Indication + Linearized MV output corresponding to input signal, Smwidigit for 3 digit ranges. 2muidigit for 4 digit ranges. ‘Accuracy * Calibration Accuracy: 40.25% of span at 77°F 45°F ambient & rated line voltage + 1%. + Linearization Accuracy: 40.25% of span, +4 digit at 77°F 35°F ambient & rated line voltage +1%. + MV Signal VO: +-0.25% of span. + Accuracy Span: 1000°F or §40°C minimum, + Temperature Stability: #2uV°F ambient. + Voltage Stability: +0.01% or span % of rated ine. Agency Approval + UL recognized, File #£43684, UL 873. + InUL applications, relay output version is rated 10A@120VAC for ambient temperature up to 10°F. Over 100°F, the rating decreases linearly to 6A @ 130°F. See Figure 1, Terminals + #6 screw on barter strip, Power + 115/230VAC+ 10%, 50/60Hz, + 6VApower consumpiion. Operating Environment + 30 to 190°F/0 10 55°C. + 00.90% RH, non-condensing, Dimensions * Heigh + Width: + Behind pane! depth with 154 triae: + Weight:© Series 808 = moom> feet 00 = 101 108 109 120 ya 80 Oe 129 610 ett 612 618 lee Maximum ‘Allowable ‘Ambient Temperatur Control! Digital indicating closed loop control with PID; T/C, RTD, or electrical input; interface capability; 1/4 DIN. Output — Relay 10A, SPOT. Triac, 14. Triac, 154. 4:20mA/-SVDC 0-20mA0-5VDC. Controt Mode. Heat ‘Coo! (only with output A or D) Input & Range — ~ RTD #291699 to 00°F #91699 to 540°C #3916 to 299.9°F #9916 tw 399.90, 3850 ‘909°F #3850 540°C #3850 399.9°F #9850 399.9°C J 9° to 00°F J 0 10 1600°F J ot ‘850°C kK OF tl 9090 K Oe al 2500°F T 990 00°F K 0 0 1970°C Electrical 4-20 mA/0-SVDC Omer 999 00 999 Faceplate ———— Gray, with white bars Black, with white lettering S4:0(120°F) S0-C(122°F) areirr) aecit"F) 40°C(106°F) (eo Rolated Devices + Extender #Z100-0421-0000 to facitate installation tuning. + Relay, 10A, Plug-in: #0003-0073-0000. + Triac, 1A: #0802-0217-0000. + Tiiac, 1SA: #0802-0404-0000. or 10A Relay Derating 4 5 6 7 8 9 1 Load Current (Amperes) Figure 1 - Temperature Derating Curve for 10A Relay (when used in UL applications) WATLOW Sots 808 Data Shoot 304 mal 0.470, (17.45) 0687 (141.61mm) 5575 Figure 2- Standard Case (0156(3.96mm)D1A a =| c1'17mm) 5 | 200 ‘ (73.66mm) pos J a a zen i a fe (24a) aE > ee a le (124.179) Ps] nn 4800} Case Outing of ont of Controller (96.52mm) 3.80050. Ng Clearance Hole - Mount with(3.5mm %12.7mm) 6-32NC. (e2mm+.8) 3.62 4.63 c ‘(73.66mm) Panel cutout for le 5 a (645m) 2.900 compression mounting 075 [— (91.440) 3.600 Alternate panel cutot Figure 4- Mounting Requirements 4 WATLOW Series 208 Data Shoet is ser xV2in. pan head ‘crows and STD nut platos or (3.5mm) 6-32NC nuts (Clearance Hole- 0.187 (4.75me) [889mm 0.350Input- Terminals 9 through 16 Wire your unit according to the figures showing the correct input and output. For models with Electrical Process Input (Range #701) see Page 9. Thermocouple Input } Terminal Designations 2.16.) re naieed | san ©0008 0000 a Pee i 13, Set point (+) out 14, Programmer (+) in 15. Signal conditioner (+) out Figure 5- Thermocouple Input 16. Circuitcommon For programmer input referto Pages 7 & 8, Figures 11, 12, and 13. 2 note: \ ‘Toure se an leoleed or ungrounded thernacuiple program cult commen ant lanl or ‘arin ground, Extension wire for thermocouples must be othe sare lloy asthe thermocouple salt it srrors. sa Platinum RTD Input Terminal Designations O8FOGOGO 9.81 10. Not used 11. $2 12. Not used Figure 6- RTO Input (2 wire) 12. Setpoint (s)out 14 Programme (ein A 418, Signal condtioner (+) out 18. Circuit common, $3 For programmer input refer to Pages 7 & 8, Si Figures 11, 12, and 14. OOOO OOOO Fi v0 Long lead lengths create electrical resistance. There will be approximat resistance, when using a two wire RTD. That resistance, when added to the resistance of the RTD elom ‘erroneous Input to the instrument. To overcome this problem, use a throe wire RTD sensor, which compensates for lead length resistance. When extension wire Is used for a three wire RTD, al three extension wires must have the same ‘olectrical resistance. (Le, same gauge, copper stranded). Figure 7 - RTD input (3 wire) WATLOW Series 608 Data Shoot 5‘Terminal Designations een © ware enon deietararcama tec Temas”) See HS | ct Sra rage i foyecomonts emma ce 120 aeihegenes3 mae om dent of line vokage) eacee fuse " , Figure 8-808A Relay Output Not used . Not used . T1 NO, Solid State |. T2~ Output - Gate (for external trac) AC line common, L2 115Vline, L1 230V ine, L1 Triac Internally oO ® canon Terminal 5, Gate (for external trac) Is for Internal use only. Any external wiring to terminal 5 may damage the control. Consult the factory before using terminal 5. Select 118 or 2Q0VAC (Indepen- | U2 (NEUTRAL)—LLOA Line voltage (field selectable) Lt, 290 VAC Select Li, 115 VAC 1.) 115 VAC (pins 6& 7) dent oftine vottage) | — L1 (HOT) Figure 9- 8088 & 808C 1 & 15ATriac Output 6 WATLOW Sories 608 Data Shoet 2.) 290 VAC (pins 6& 8) 12, Common o>© 1.47. Voltage 22+ ow 3. - “| Current 44+ Ou) 5. Notused Process out 8. AC line common, 2 a 7. 118V ine, Lt 8. J vorage —) Lizovac | §. L1, 115 VAC L2, Common Wiring (cont. voltage (field selectable) ‘Select 4.)115 VAC (pins 6 & 7) 2.) 290 VAC (pins 6 & 8) 2 You must jumper current output (Terminal to 4) using voltage output only. Figure 10-808D- 4/2GmA/1-5VDC & 808E-0-20mA/0-5VDC 2 Note: Remove appropriate internal jumper wire if you Programmer Input are using the programmer input. ‘See Pages 8 and 9, Figures 13, 14, or 17. 000060686 Figure 11 - Remote set point (wiprogrammer) Bom Micro Pro 2000 Micro Pro 2000) Figure 12- Local/remote set point (w/programmer) JI wore: Use dry circuit for SW1 (SW1 customer supplied) WATLOW Setios 608 Data Sheot 7a * Jumper Locations ® caution: ‘hse [unre re sldre onto te pine eutboard, They must be > Temoveduen using apogee epuorihe soul a akcton sorely ‘3 Digit Display A Digit Display _ L oy Mee aeae, ‘A007-1233-W55, ‘A007-1215-W34 Figure 13- Thermocouple Unit Digit Display ADigit Display ; oy. bee eae, ‘8007-1143-W25 ‘n007-1602-W1 Figure 14-RTD Unit } 8 WATLOW Sorios 8608 Data ShootCc ‘Taree dimensional drawing ‘of Range #701 removable jumper block positioning. Figure 15 - Decimal Display Jumper Positioning Electrical Process Input Electrical Process Input Terminal Designations, ' Desig 9. 4-20mA, (+) in 10. Notused 41. in 12, Notused 13, Sot point (+) out | 14, Programmer (+) in 15, Signal conditioner (+) 0-SVDC| 16. Circuitcommon ‘Touse the Electrical Process Input, you must set jumper W1 for decimal display or no decimal display, and you must set Jumper W2 for 4-20mA input or 0-SVDG input. Figure 16 shows you how to place the jumpers. Figure 17 shows you where its jumpers are. Decimal Display 4-20mA Input (@-5VDC input Decimal Display: Meet oomperWt | i ‘Jumper Installed No Decimal Display: Install Jumper W2 Remove Jumper Wt ‘Jumper Removed Jumper (Gave Cap) Installed Figure 16- Electrical Process Input r ol For 0-SVDC input, you we_| Romove Jumper W2 hi Jumper Removed __ (Gave Cap) ‘oO L \ou A007-1599-W1 ‘A007-1598-W1 Decimal Programmable Removable jumper block Removable jumper block Soldered in Figure 17 - Electrical Process Range #701 Jumper Locations WATLOW Sori 808 Data Shoot 9ecole e) 2 Wore: Anpotsare on the upperboard, Platinum RTD Input Equipment Required: ‘A. 1000 decade resistance box. B. Digital voltmeter (DVM). ©. Extender board may be used for ease of servicing, Watlow P/N Z100-0421-0000, Procedure: 1 Connect decade resistance box to input terminals 9 and 11, with 11 jumperedto 16. Connect digital voltmeter to terminals 15 (+) and 16 (-). Install contro into extender board, it ‘one is in possession. Connect powerto the control, Let the control stabilize before calibration begins Set the decade box to, Loohms. Adjust SC Lo pot for. ‘SC_Lovolts onthe digital voltmeter. Adjust the Zero pot for Lo Temp onthe display of the control, Set the decadp box to Hiohms. Adjust SC Hipot for volts on the digital voltmeter. Adjust the FS pot for Hi Temp on the display of the control. Repeat steps 2 and 3 until all of the readings are correct with no further adjustment necessary. ‘Check the midpoint of the temperature range. Table 1 - RTD Input Calibration Values Range Millivoltvs. Temperature f ~ L Mid Mid Hi sc Ohms tom | ofme tot }-100_-99- _999°F _#3916 | 9 | 199.370 | 294,919. 495 | | {01 992enerG soar ~98 08 7800 [Sev | 108 __0,0- 399,9°F #3916 436,590 | 103 ov | : poise | as a {gsrs00- La. 18500. S009 ep ease [poor 12300" Sone —¥5000 Besson 780 10 WATLOW Series 208 Data Sheet ®)eager Tre Tel aactercrs eccd ‘Thermocouple Input Equipment Required: 1. Precision milvot source. 2 Digital voltmeter (DVM). 3. Type. reference compensator with reference junction at 32°F/0°C. 4. Extenderboard may be used for ease of sevicing, Watlow P/N Z100-0421-0000. Procedure: 1. Connect millivlt source to reference compensator and compensator leads to T/C inputs, terminals 9 (+) and 11 (-). Connect digital voltmeter to terminals 15 (+) and 16 (-). Install control into extender board, if ‘one is in possession. Connect power to the control. Let the control stabilize before calibration begins. 2. Sethe milivolt source to 4a 2..L0 mV. Adjust SC Lo pot for SC Lovolts on the digital voltmeter. Adjust the Zero pat for Lo Tempon the display of the control. ick supe Himv. Adjust the SC Hipot for ‘SC Hivolts on the digital Adjust the FS pot for HiTemp on the display ofthe control. 4, Repeat steps 2 and 3 unti all of the readings are correct with no further adjustment necessary. 3. Sethe voltmet 5. Check the midpoint of the temperature range. Table 2- T/C Input Calibration Values Millivott vs. Temperature Lo so Md Mid Hi Code mV LoPot mV Temp | mv 606. 202mv|___100v 29.1amv| 700° | _54.13mV. ‘608__0- 1600°F_ "J" | .000mv|osav. 23.3amV| 800° |” 50.05mV. = 050°F 00} .85mV| 400" | 42.26mV. [10 0-s99°F “=| “o00mv| oo0v | o* | “20.64mv | s00° |" 40.88mv_| | 611 = 2500°F _*k"| | ogav | 32°_|"26,96mv | 1250° | 54.85mv_| 612_-59-_ 600° = 618 _0- 1970°F “teov | 9° | 6.647mv{ 900° | 15.77mVv ‘roov | 50° | 29.13mv| 700° | 54.1amVv WATLOW Series 808 Data Shoot 11rd 1. Proportional Band - Ina straight time proportional control system when the actual process temperature is below set point and outside the proportional band limit, 100% power is applied to the load. ‘When the actual process temperature is above set point and outside the proportional band limit, 0% Powers applied to the load. ‘When the actual process temperature is within the proportional band, the controller will proportion the amount of powerto the load, Oto 100%, 2. Temperature Droop - Phenomenon that occurs ina proportional control system without reset. As the Proportional bandis increased, the average process temperature may drop to a point that is not the set Point temperature. This action takes place even though the load temperature has stabilized. 3. Automatic Reset (Integral) - Used in proportional control systems to automatically pick up any system droop. Normally this action is adjustable and adjusts the time for reset to oblain agreement between actual process temperature and controller set point. 4. Rate (Derivative) - Action that anticipates the rate of actual process temperature rise and automatically wien the proportional band to prevent overshoot. Retums the proportional bandto the stalio adjustment When the set point temperature is stable within the static band boundaries. 5. Temperature Oscillation or Hunting - Occurs when the proportional band is too narrow or the systemis Upset by some outside source. The actual load temperature is not controlled within the proportional band onits extreme temperature excursions, Load temperature may neverstabilize. Control is ether full ON or full OFF, not within the proportional oO band 6. Zero Switching - Loads activated only during the time period that the sine wave is going through zero. This eliminates RF and EMI radiation. (Applies to solid stale outputs only.) 7. Cycle Time - The rate at which the controller samples load temperature. Ata setting of 2 seconds, 25%. Power is required to maintain load tempeature at set point, power willbe applied for 1/2 Second every 2 seconds, 8. Anti Reset - Inhibits reset action when the actual process temperature is outside the proportional band. 9. 2 or FI -Musicatnotesarousedte alert youto important details 10. D -teswopsignatens you to a "WARNING equipment, "a safety hazard which could affect you and the 11, > -the deercrossing sign ales youto a “CAUTION, a safely or functional hazard which could affect your equipment or its performance. 12. WATLOW Series 608 Data SheetTuning Procedure for PID Controls Set point ‘Temperature Time Figure 18- Adjustment Graph P initia Seting 41. Cycle time: 2 seconds; tum maximum counter-clockwise; CCW. 2. Proportional band: Turn maximum clockwise; CW. 3. Rate: 0; tum maximum CCW. 4, Reset: 0.05 repeats/minutes; turn maximum CW. Energize the system and allow the process temperature to stabilize. When the systemis stable, the load light will cycle at a constant rate Proportional Band Adjustment: Rotate the proportional band pot CCW 1/4 tun and observe system stability. Repeat untilthe process. temperature begins to hunt (becomes unstable). When hunting is observed, rotate pot slowly CW until the system becomes stable. Some systems may be stable enough to allow minimum proportional band (maximum CCW), Rate Adjustment: ‘The rate adjustment controls overshoot as load temperature approaches set point temperature by limiting the rate of change of load temperature. Rotate the rate pot 1/4 turn CW. Change the set point temperature 20 to ‘80°F /°C and observe the approach to set point, Ifthe load temperature overshoots, repeat the procedure until optimum approach to set points achieved. If the rate potis advanced too far, the system will be overdamped and approach to set point willbe very sluggish. Reset Adjustment: The reset adjustment controls the time required to drive the error signalto zero. Aslow setting (0.05 repeats/mins.) requires long periods of time for the load temperature to reach set point. Ifthe reset time is set too fast (0.5 repeats/ mins.) the system may become unstable and oscillate about set point temperature. ‘To adjust reset time, rotate the reset pot 1/4 turn CCW and observe stability. Continue adjusting CCW until the system becomes unstable. Rotale CW very slowly to regain stability. Cycle Tim Cycle time is the time base used in proportioning powerto the load. At a setting of 2 seconds, if 25% poweris required to maintain load temperature at set point, power willbe applied for 0.5 second every 2 seconds. At 10 second cycle time, power would be applied for 2.5 seconds every 10 seconds. Best control is always achieved with faster cycle times. However, if a mechanical contactor or a solenoid is used to switch power to the load, slower cycle times may be desirable to minimize the wear on the mechanical ‘components. CF note: storie pots are located onthe ower board. JY nore: Forease of adjusting, order extender board - Watlow PIN 100-042-0000. WATLOW Series 808 Data Sheot 13MSs ket Problem Cause ‘No display The A.C. inputis not connected or is connected improperly. 6&7, Figures 8-10. Check the A.C. input connections. lot present or correct, connect per Wiring outputs. See Pages tpresent and correct, return the Litto the factory. The display indicates | 1. Anopen thermocouple or RTD. Repair or replace, | EEE or OFL — ap 2, Fora2wireRTD- Ajumperisnotbeing | Connect per Wiring inputs. Used between S2 and $3. See Page 5, Figure 6. Adisplay error The sensoris connected improperly. ‘Check the sensor location, con- Repair or replace the sonsor a required. The Indicator is functioning room temperature. The indicator is functioning approximately 0°C/32°F. nections, and the sensing element. ‘A. Thermocouple - Place a jumper wire across the T/C terminals, correct if the display indicates 4B. RTD- Place a 100 ohm resis across the sensor terminals. properly ithe display indicates is istor Poor temperature control The control parameters are not adjusted properly, time and the manual reset per Tuning. See Page 13. ‘Adjust the proportional band, cycle ‘The loadwill not tum ON The load will not tum OFF Cannot control the unitwith an extemal programmer 1. Anopen thermocouple or RTD. 2. The load circuits open. 3. Ataulty unit. 1. The polarity is reversed on the TIC. 2. Ashortcircuit between T1 and T2. The intemal jumper wires are not removed. Repair or replace. and the load. Return the unit to the factory. Connect per the Wiring inputs. See Page 5, Figure 5, resistance from T1 to T2 (Pins. (0802-0217-0000 fora 1A triac. | Order PIN 0802-0404-0000 for at5Atriac, depending on your unit. See Figures 13,14, or 17. ‘Check the fuses, circuit breakers With the power OFF, measure the ititis short circuited, order PIN Remove the proper jumper wires Jumper Locations, Pages 8 or 9, 3 & f ==) 14 WATLOW Series 808 Data ShootCc ‘The Watlow Series 808 is warranted to be free of defects in material and workmanship for 18 months after delivery to the first purchaser for use, providing that the units have not been misapplied. Since Watlow has no control over their use, and sometimes misuse, we cannot guarantee against failure. Watlow’s obligations hereunder, at Watlow’s option, are limited to replacement, repair, or refund of purchase price, any 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. ‘The following procedure applies for any products returned to the factory: 1. You must call Watlow Customer Service, 507/454-5900, for a Return Material Authorization (RMA) number before retuning any fem forrepai. We need this information: + Shipto address + Billto address * Contactname + Phone number + Ship via + Your P.O. number + Symptoms and/or special insructions + Name and phone number of person returning the material ‘We willnot 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 willbe retumed. Ship on a Freight Prepaid basis. 2. 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 forall returned stock controls and accessories. 3. Afterwe receive your return, we will examine itto determine the cause for your action. 4. Incases of manufacturing defect, we will enter a repair order, replacement order or issue credit for material. 5. {tthe unit is unrepairable, we will return itto you with a letter of explanation. Repair costs will not exceed 50 percent of the original cost. WATLOW Series 808 Data Sheot 15