Series 92

User's Manual

TOTAL
CUSTOMER
DIN Rail Mount SATISFACTION
3 Year Warranty

Limit or Temperature
Control
ISO 9001

Registered Company
Winona, Minnesota USA

Watlow Controls
Watlow Controls, 1241 Bundy Blvd., P.O. Box 5580, Winona, MN 55987-5580, Phone: 507/454-5300, Fax: 507/452-4507

0600-0020-0000 Rev. B (1291) $10.00

March 1998 Made in the U.S.A.
Supersedes: W092-MA10-9311
Printed on Recycled Paper
WATLOW Series 92 User's Manual 1
 General Description
The Watlow Series 92 is a DIN rail-mounted (DIN EN • Lead resistance effect for type J, K, or T thermo-
50022) analog control. If a DIN rail is not available, the couple input: 200 of lead resistance will cause
Series 92 can be mounted using two screws. The less than 1°F error. Refer to the lead wire
control mode is ON/OFF, limit or PI. The input for the manufacturer's specification on ohms per double
Series 92 is a single Type J, K or T thermocouple, or foot for type and gauge of wire.
DIN curve RTD sensor input. For the output device, Output
choose from an electromechanical relay, switched DC • Electromechanical relay, Form C, 5A @ 120/
voltage (open collector), solid state relay, or an optional 240VAC. Minimum offstate impedance is 20K .
variable burst-fired output. Variable burst-fired is only Warranted to 100,000 cycles.
available with the PI version, and can be used with DC • Solid State Relay, Form A, 0.5A @ 24 VAC mini-
input solid state relays. Set point options include a mum, 264 VAC maximum, opto-coupled, zero-
remote or integral setpot assembly. crossed switching. Minimum off state impedance
is 20K for output "B", and 31M for output "K".
Specifications • Open collector, switched DC signal provides a
minimum turn ON voltage of 3VDC into a minimum
Control Mode
500 load; maximum ON voltage not greater than
• Heat or cool, factory selectable.
32VDC into an infinite load.
ON/OFF
• Variable time base, open collector, switched DC,
• Switching hysteresis: Typically 3°F/1.7°C
Form A signal provides a minimum turn ON voltage
PI: Time proportional with automatic reset
of 3VDC into a minimum 500 load; maximum ON
• Proportional band adjust: Typically 5 to 50°F/2.8 to
voltage not greater than 32VDC into an infinite load.
27.8°C
Available for PI control only.
• Cycle time, fixed: Typically 6 seconds
Accuracy
• Automatic reset, fixed: Typically 0.25 repeats/minute
• Calibration accuracy and sensor conformity:
Limit
± 1% of span maximum, at 77°F ± 5°F (25°C ± 3°C)
• Latching
ambient and rated line voltage.
• High or low, factory selectable
• Setpoint Accuracy: < ± 3% of range.
• Internal reset switch and/or customer supplied
• Temperature stability: Typically ± 5µV / °F ambient
remote reset switch. Automatic reset on power loss.
for thermocouple. Typically < 1°F from 32 to 130°F
Operator Interface
for RTD.
• LED indication of limit condition or status of load.
• Voltage stability: ± 0.01% of span / % of rated line
• Setpot.
voltage.
• Dial scale calibrated to compensate for sensor
Agency Approvals
non-linearities.
• UL, CSA and FM pending.
• Dual °F & °C scales.
• Patent pending.
• Remote or integral.
Terminals
Input
• Captive screw, cage clamp connection. 0.155"
• Thermocouple or RTD available.
(4mm) maximum diameter screwdriver blade.
• Thermocouple may be isolated or grounded.
22 - 12 maximum wire gauge
• Thermocouple, automatic cold junction compensation.
Power
• RTD input 2 or 3 wire, platinum 100 @ 0°C cali-
• Factory selectable.
brated for #3850 (DIN): 0.003850 / °C. Contact
• 120VAC: 85 to 132VAC, 50/60 Hz.
Watlow for #3916 (JIS) 0.003916 / °C)curve.
• 208/240VAC: 175 to 264VAC, 50/60 Hz.
• T/C and RTD sensor break protection de-energizes
• 6VA power consumption.
output to protect system.
Operating Environment
• Sensor and ranges available:
• 30 to 140°F/0 to 60°C.
Thermocouple
• 0 to 90% RH, non-condensing.
J1: J t/c 32 to 600°F or 0 to 315°C
• Storage Environment: -40 to 158°F/-40 to 70°C.
J2: J t/c 32 to 1382°F or 0 to 750°C
Weight
K1: K t/c 32 to 2282°F or 0 to 1250°C
• Control: 0.75 lb (0.34kg)
T1: T t/c -328 to 662°F or -200 to 350°C
• Setpot: 0.20 lb (0.09kg)
RTD
P1: -328 to 1112°F or -200 to 600°C

2 WATLOW Series 92 User's Manual

Limit Ordering Information
9 2 3 D 0 0 0

Line Voltage
A = 120VAC
B = 208/240VAC
Control Type
3 = Limit
Control Mode
1 = High (heat)
2 = Low (cool)
Output
D = Electromechanical relay, Form C, 5A
(Warranted to 100,000 cycles)
Input and Range See Page 2 for ranges
Separate Remote
Set Point Assembly
A006-0 _ _ _
J1 = J t/c 515
J2 = J t/c 516
K1 = K t/c 517
T1 = T t/c 518
P1 = RTD 519
Setpot
0 = Integral
1 = Remote* (order setpot separately, see above)

On/Off PI
9 2 1 0 0 0 9 2 2 0 0 0

Line Voltage Line Voltage

A = 120VAC A = 120VAC
B = 208/240VAC B = 208/240VAC
Control Type Control Type
1 = ON/OFF control 2 = PI control
Control Mode
1 = Heat Control Mode
2 = Cool 1 = Heat
Output 2 = Cool
B = Solid state relay, Form A, 0.5A Output
C = Switched DC, open collector, non-isolated B = Solid state relay, Form A, 0.5A
D = Electromechanical relay, Form C, 5A C = Switched DC, open collector,
(Warranted to 100,000 cycles) non-isolated
K = Solid state relay, Form A, 0.5A, D = Electromechanical relay, Form C, 5A
without contact suppression (Warranted to 100,000 cycles)
Input and Range See Page 2 for ranges K = Solid state relay, Form A, 0.5A
without contact suppression
Separate Remote V = Variable time base, open collector, non-
Set Point Assembly isolated Only available in heat mode.
A006-0 _ _ _ Input and Range See Page 2 for ranges
J1 = J t/c 515
J2 = J t/c 516 Separate Remote
K1 = K t/c 517 Set Point Assembly
T1 = T t/c 518 A006-0 _ _ _
P1 = RTD 519 J1 = J t/c 515
J2 = J t/c 516
Setpot K1 = K t/c 517
0 = Integral T1 = T t/c 518
1 = Remote* (order setpot separately, see above) P1 = RTD 519
Setpot
0 = Integral
1 = Remote* (order setpot separately, see above)

WATLOW Series 92 User's Manual 3

 3.89" 2.28"
(99 mm)
Installation 3.72"
0.33"
(8 mm)
(58 mm)
1.62"
0.18"
(5 mm)
(95 mm) (41 mm)

1 2 3 4 5 6 7 8 9

4.45"
700 800
300
500
(113 mm)
500
1000
200
1100
600
300
4.10"
100
700
(104 mm)
100 1300
0 C 750
F
TYPE J T/C 3.75"
LOAD
(95 mm)

35mm X 7.5mm SERIES 92 BAND

Rail is not included

in the assembly
10 11 12 13 14 15 16 17

Release Lever

Figure 1 - Series 92 Dimensions

DIN-Rail Mounting the Series 92

Mounting Removing 1. Place the Series 92 upper mounting clip on the top edge
of the DIN rail. See Figure 2.
2. Press down firmly on the top front edge of the Series 92,
see Figure 2 Mounting for location. The control "snaps"
securely onto the rail. If the control does not snap on,
check to see if the DIN rail is bent. The DIN rail specifica-
tion is DIN EN 50022, 35 mm X 7.5 mm. Minimum
Panel clipping distance is 1.37" (34.8mm), the maximum is
DIN Rail 1.39" (35.3mm).
Upper
Mounting
Clip Removing the Series 92 from the DIN-Rail
1. Place your fingers on the release lever located at the
Lower base of the Series 92. See Figure 2 Removing.
Mounting
Release Clip 2. While gently pressing on the top of the case, above
Lever Terminals 1 - 9 (see Figure 2 inset), pull forward on the
release lever.
Snap Action

Figure 2 - Series 92 Side View Mounting Mounting the Series 92

1. Using the control as a location template, mark both
mounting holes.
2. Drill two 0.19" (5 mm) diameter holes in desired panel
location See Figure 1.
0.11" Dia.
(3 mm) Tap drill size for Screw/thread size
4 mounting holes #29 - 0.136 dia. #8-32
3.3 mm M4 x 0.7

Installing the Remote Setpot Assembly

2.25"
(57 mm) 1. Drill a 2.25" (57 mm) diameter hole (or use a 2.25", or
2.375" punch) at desired remote setpot assembly loca-
tion. See Figure 3.
2. Using the dial scale as a location template, center and
0.75" mark all four mounting holes on the dial scale with a
(19.05mm) center punch.
2.69" sq.
(68 mm) 3. For a bolted dial scale assembly, drill four 0.125" (3 mm)
1.4" diameter clearance holes. If you are using a screw
3.00" sq.
(36 mm)
(76 mm) assembly, use a tap drill.
Figure 3 - Setpot Dimensions Tap drill size for Screw/thread size
#43 - 0.089 dia. #4-40
4 WATLOW Series 92 User's Manual #42 - 0.093 dia. #4-48
 WARNING:
Line Voltage
To avoid potential electric shock, use National Electric
Code safety practices when wiring and connecting this
unit to a power source and to electrical sensors or
peripheral devices.

All wiring and fusing must conform to the National

Electric Code and to any locally applicable codes also.
Fuse
L1

L2

92AX - XXXX - X0XX

1 2 3 4 5 6 7 8 9 120VAC

and

92BX - XXXX - X0XX

208/240VAC

Figure 4 - 120 and 240VAC Power Wiring

(determined by your model number)

92X3 - XXXX - X0XX 92XX - XXXX - 10XX

(Reset Switch (Remote Setpot)
customer supplied)
10 11 12 13 14 15 16 17

N.O.
Green P3
Momentary Remote
Reset Switch Black P2
Setpot
Red P1 Assembly

Figure 5 - Reset Switch and Remote Setpot Wiring

(determined by your model number)
WATLOW Series 92 User's Manual 5
 Input Wiring

NOTE:
When an external device with a non-
isolated circuit common is connected 92XX - XXJ1 - X0XX
to the DC (open collector) output, you
must use an isolated or ungrounded 92XX - XXJ2 - X0XX
thermocouple.
92XX - XXK1 - X0XX

10 11 12 13 14 15 16 17 92XX - XXT1 - X0XX

+ - Red
k
Figure 6 - Thermocouple Wiring

92XX - XXP1 - X0XX 92XX - XXP1 - X0XX

2 Wire RTD 3 Wire RTD

k NOTE:
Jumper Terminals 11 and 12
for a 2 wire RTD.

10 11 12 13 14 15 16 17 10 11 12 13 14 15 16 17

S3

S2
S2

S1
S1

Figure 7 - RTD Wiring

NOTE:
Long lead lengths create electrical resistance. There will be approximately +2°C input error for every 1Ωof lead
length resistance, when using a two wire RTD. That resistance, when added to the resistance of the RTD element,
can result in erroneous input to the instrument. To overcome this problem, use a three wire 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.)

6 WATLOW Series 92 User's Manual

 Output Wiring
92XX - XBXX - X000 92XX - XCXX - X000
L2
92XX - XVXX - X000
External
Load -
External
Load
L1 +
N.O. COM Fuse

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9

NOTE:
Contact suppression
is not recommended
for high impedance
loads such as AC
input SSR's.

Figure 8 - Solid State Relay with Figure 9 - Switched DC, Open Collector OR
Contact Suppression, Variable Time Base, Zero Cross
Form A, 0.5A Non-Isolated

92XX - XDXX - X000 92XX - XKXX - X000

L2
L2
External
N.O. External
Load
Load

COM L1 L1
Fuse N.O. COM Fuse
N.C.

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9

Figure 10 - Electromechanical Relay with Figure 11 - Solid State Relay without

Contact Suppression Contact Suppression,
Form C, 5A Form A, 0.5A

WATLOW Series 92 User's Manual 7

 System Wiring Example

L1
120 VAC
L2

Earth Ground High temp. light

High Limit
Coil Mechanical
Contactor
Fuse

11 12 SSR-240-10G-DC1
DC Input 92A3-1DJ1-0000
Out Limit Control
SSR
1 2
4 3
3 (+) In
9 +
Heater
5 (-) 10 -
13 14

Red 965A-3CA0-0000 10 11
+ -
Rear View
Optional
Process Sensor Limit Sensor Normally Open
Momentary Switch

çWARNING: The
Series 92 Temperature
Limit Switch should be
120VAC
mounted in an incon- L1 L2
spicuous location to
discourage unautho- 11 12
1
rized changes to the 1 3 2

set point. Only ap- 2

4 (+)
3
Series 965
965A-3CA0-0000
proved and appropriate 3 5 (-) 5 Temperature control
personnel should have
the authority to change 9 10
the set point on the 4
6 7
limit switch. Failure to 3-32VDC
comply with these In SSR-240-10G-DC1
(+) (-) DC Input Solid State Relay
recommendations 1 CR-1
could result in damage 5
1 8 9
Out
10
Heater
2
24-240VAC
to equipment and
property, and injury to
personnel. 6
11
1 2
1 2
7 12 13 Series 92
8 13 14 92A3-1DJ1-0000
Limit Control
9 (+) 14 10
10 (-) 15 11 3
11 1CR
4 16 2
12
1 17 5
13 R
18 2
Hi Temp. Light

Figure 12 - Series 92 System Wiring Examples

8 WATLOW Series 92 User's Manual

 Tuning
(cont.)
Tuning Procedure for PI Controls

92X2 - XXXX - X0XX

Proportional Band Adjustment:
Rotate the proportional band pot CCW 1/4 turn and
Initial Settings: observe system stability. Repeat until the process
• Proportional band: 5 to 50°F/2.8 to 27.8°C temperature begins to hunt (becomes unstable). When
Maximum proportional band is clockwise (CW), hunting is observed, rotate the pot CW, in small
minimum (CCW). Located on the front of the increments, until the system becomes stable. Some
control labeled "Band." systems may be stable enough to allow minimum
proportional band (maximum CCW).
• Cycle time, fixed. Typically 6 seconds.
Proportional
• Automatic reset, fixed. Typically 0.25 repeats/ Band
minute
Reduced Overshoot
Set point
Energize the system and allow the process tempera-
ture to stabilize. When the system is stable, the load
will cycle at a constant rate. Droop
Temperature

After an adjustment is made, the system may become Time

unstable. Allow sufficient time for the system to
stabilize before making another adjustment. Figure 13 - PI Adjustment Graph

Variable Time Base

92X2 - XVXX - X0XX

When the time base varies upon load demand, this is

considered variable time base. The ON and OFF time
is proportional to the command signal, but the time
base changes according to the demand. At 50% it's NOTE:
three AC cycles ON and three AC cycles OFF. The variable time base option is only
available with the PI control type.
Zero cross SSR's must be used. If you are using
random fired SSR's, the Series 92 will not provide zero
cross output.

Figure 14 - Variable Time Base Example

WATLOW Series 92 User's Manual 9

 Glossary
1. Automatic Reset (Integral) - Used in proportional 8. Switching Sensitivity or Differential - The output
control systems to automatically pick up any system will de-energize when the actual temperature
droop. This action may be adjustable or fixed, and reaches the set point temperature. The switching
adjusts the output level to obtain agreement be- sensitivity or differential is the drop in temperature
tween actual process temperature and controller set required to re-energize the output.
point.
9. Temperature Droop - Phenomenon that occurs in
2. Automatic Reset on Power Loss - The limit a proportional control system without reset. As the
control does not recognize the power outage as a proportional band is increased, the average process
limit condition. When power is restored, the output temperature may drop to a point that is not the set
will energize automatically as long as a temperature point temperature. This action takes place even
limit condition does not exist. though the load has stabilized.

3. Anti Reset - Inhibits reset action when the actual 10. Temperature Oscillation or Hunting - Occurs
process temperature is outside the proportional when the proportional band is too narrow or the
band. system is upset by some outside source. The
actual process temperature is not controlled within
4. Cycle Time - Time interval between consecutive the proportional band on its extreme temperature
turn ons. excursions.

5. Manual Reset or Offset - Adjustment used in Load temperature may never stabilize. Control is
control systems to offset any temperature droop either full ON or full OFF, not within the proportional
and obtain agreement between actual process band.
temperature and controller set point.
11. Variable Time Base - When the time base varies
6. ON/OFF - The output is turned full ON below set upon load demand. The Series 92 at 50% power
point and stays turned on until the process tem- level passes three AC cycles on and three AC
perature reaches set point, then the controller turns cycles off.
the output full OFF. At this point, depending on the
design of the thermal system, the process tempera- 12. Zero Switching - Load is activated only during the
ture overshoots the set point temperature by some time period that the sine wave is going through
degree. As the load cools down below set point (an zero. This eliminates RFI and EMI radiation
amount equal to the switching sensitivity or differen- (applies to solid state outputs only).
tial) the output is once again turned full ON.
13. or - Musical Notes are used to alert you to
7. Proportional Band - In a straight time proportional
control system when the actual process tempera- important details.
ture is below set point and outside the proportional
band limit, 100% power is applied to the load.
14. - The Warning symbol ((lightning bolt)
When the actual process temperature is above set alerts you to a "WARNING", a safety hazard which
point and outside the proportional band limit, 0% could affect you and the equipment.
power is applied to the load.

When the actual process temperature is within the 15. - The Caution symbol (exclamation
proportional band, the controller will proportion the point) alerts you to a "CAUTION", a safety or
amount of power applied to the load, 0 to 100%. functional hazard which could affect your equipment
or its performance.

10 WATLOW Series 92 User's Manual

 Troubleshooting Chart
Problem Probable Cause Action

Poor temperature The proportional band is not Adjust the proportional band per Tuning.
control. adjusted properly. See Page 9.
The load will 1. An open sensor. Repair or replace.
not turn ON.
2. The load circuit is open. Check the fuses, circuit breakers, load,
and wiring. See Line Voltage, Page 5..
3. The AC input is not connected or Check the AC input connections. If not
is connected improperly. present or proper, connect per Line Voltage.
See Page 5.
4. A faulty unit. Contact the factory.
The load will 1. The polarity is reversed on the T/C. Connect per Input Wiring. See Page 6,
not turn OFF. Figure 6.
2. A faulty unit. Remove power to the control and the control
from the system. Apply power to the system
with the control removed. If the load turns
OFF, return the control to the factory. If the
load remains ON, there are other problems in
the system that must be resolved. Consult
the factory.
The unit is not con- The unit is out of calibration Contact Watlow for an RMA number, and
trolling to set point. return unit to the factory to be calibrated.

material. A 20 percent restocking charge is

Returns applied for all returned stock controls and
accessories.
1. Call Watlow Customer Service, 507/454-5300, for
a Return Material Authorization (RMA) number 5. If the unit is unrepairable, it will be returned to you
before returning any item for repair. We need this with a letter of explanation. Repair costs will not
information: exceed 50 percent of the original cost.
• Ship-to address • Bill-to address
• Contact name • Phone number Warranty
• Ship via • P.O. number
• Symptions and/or special instructions The Watlow Series 92 is warranted to be free of
• Name and phone number of person returning defects in material and workmanship for 36 months
the material. after delivery to the first purchaser for use, providing
that the units have not been misapplied.
2. Prior approval and an RMA number is needed
when returning any unused product for credit. Since Watlow has no control over their use, and
Make sure the RMA number is on the outside of sometimes misuse, we cannot guarantee against
the carton, and on all paperwork returned. Ship failure. Watlow's obligations hereunder, at Watlow's
on a Freight Prepaid basis. option, are limited to replacement, repair, or refund of
purchase price, any parts which upon examination
3. After we receive your return, we will examine it prove to be defective within the warranty period
and determine the cause for your action. specified. This warranty does not apply to damage
resulting from transportation, alteration, misuse or
4. In cases of manufacturing defect, we will enter a abuse. This excludes mechanical relays which are
repair order, replacement order, or issue credit for warranted to 100,000 cycles.
WATLOW Series 92 User's Manual 11
 Watlow Series 92 User's Manual
Watlow Controls, 1241 Bundy Blvd., P.O. Box 5580, Winona, MN 55987-5580, 507/454-5300, Fax: 507/452-4507

12 WATLOW Series 92 User's Manual

 Series 92
Addendum

ç WARNING: The Series 92 Temperature Limit Switch should be

mounted in an inconspicuous location to discourage unauthorized changes to
the set point. Only approved and appropriate personnel should have the
authority to change the set point on the limit switch. Failure to comply with
these recommendations could result in damage to equipment and property, and
injury to personnel.

Watlow Controls
1241 Bundy Blvd., P.O. Box 5580
Winona, MN 55987-5580
(1264) Phone: 507-454-5300, Fax: 507-452-4507

Addendum to 0600-0020-0000 Rev A WATLOW Series 92 User’s Manual 8a

January, 1998