Watlow F4T User Manual Download Page 7

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Watlow F4T Install & Troubleshooting

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Chapter 1 Overview

Document Overview and Purpose

The purpose of this document is to assist the installer in providing necessary information to

mount, wire and power up the F4T controller. This document also provides information to as-

sist in the process of diagnosing problems which might occur during or after the installation

process.

Summary of Contents for F4T

Page 1: ...uide Registered Company Winona Minnesota USA ISO 9001 TOTAL 3Y earWarranty CUSTOMER SATISFACTION F4T Controller Installation and Troubleshooting 1241 Bundy Boulevard Winona Minnesota USA 55987 Phone 1 507 454 5300 Fax 1 507 452 4507 http www watlow com F4T cfm ...

Page 2: ...unit can provide Consult QSG for further infor mation AVERTISSEMENT mise en garde ou danger qui demande plus de précisions que l information sur l étiquette de l unité Consultez le manuel de l utilisateur pour plus d informations Unit can be powered with either alternating current ac voltage or direct current dc voltage ESD Sensitive product use proper grounding and handling tech niques when insta...

Page 3: ...Software Systems Limited All rights reserved 2008 2014 Crank Software Inc All rights reserved Watlow and TRU TUNE are registered trademarks of Watlow Electric Manufacturing Company UL is a registered trademark of Underwriter s Laboratories Incorporated Modbus is a registered trademark of Schneider Automation Incorporated Vaisala is a registered trademark of Vaisala OY Corporation Microsoft and Win...

Page 4: ... Buttons 26 DHCP Connection 28 Fixed IP Connection 28 Starting Composer Software 29 Verifying Pluggable Flex Module Installation Using Composer 29 Chapter 4 Calibration 31 Calibrating the F4T 31 Required Equipment When Performing Calibration 31 Calibration of Analog Inputs 32 Using Composer Software to Calibrate Analog Inputs 33 Using the User Interface to Calibrate Analog Inputs 33 Chapter 5 Trou...

Page 5: ...k on the link be low to find your document of choice http www watlow com F4T cfm For the Application Guide click here http www watlow com common catalogs files appguide pdf Your Comments are Appreciated In an effort to continually improve our technical literature and ensuring that we are pro viding information that is useful to you we would very much appreciate your comments and suggestions Please...

Page 6: ...ed Ship on a Freight Prepaid basis 3 After we receive your return we will examine it and try to verify the reason for return ing it 4 In cases of manufacturing defect we will enter a repair order replacement order or issue credit for material returned In cases of customer misuse we will provide repair costs and request a purchase order to proceed with the repair work 5 To return products that are ...

Page 7: ...e The purpose of this document is to assist the installer in providing necessary information to mount wire and power up the F4T controller This document also provides information to as sist in the process of diagnosing problems which might occur during or after the installation process ...

Page 8: ...h mount options 3 Ensure that incoming power is off and connect to the base power supply connector see section Wiring the F4T Base 4 Make note of any I O module slot dependencies installing each one into an appropriate base slot see graphic entitled F4T Slot Dependencies under Flex Module Installation 5 Connect the wires from each field device to the associated I O module connector see section Wir...

Page 9: ...against each of the the four corners of the retention collar assem bly Apply pressure to the face of the control ler while pushing with the screwdriver Don t be afraid to apply enough pressure to properly install the controller The seal system is com pressed more by mating the retention collar tighter to the front panel If you can move the case assembly back and forth in the cutout you do not have...

Page 10: ... based on panel material into mounting panel per supplier recom mendations PEM Standoffs PEM P N S0 632 6 Z1 S0S 632 6 S0A 632 6 S04 632 6 Material Steel Zinc Plated Stainless Steel Aluminum Hardened Stainless Steel 3 Mount flush mount bracket to back panel with 6 6 32 screws 4 Insert the controller through the panel and bracket and lock it in place with the reten tion collar as described above 5 ...

Page 11: ...Watlow F4T Install Troubleshooting 8 Chapter 2 Install and Wire Dimensions cont ...

Page 12: ... une source d alimentation et aux capteurs électriques ou aux équipements périphériques Tout manque ment à cette règle pourrait provoquer des dégâts sur l équipement et le matériel et ou des blessures personnelles ou des décès 98 99 Power input ac or dc Power input ac or dc CX CY CZ Inter module Bus A Inter module Bus B Inter module Bus Common GND Functional earth ground Digital Inputs Outputs Swi...

Page 13: ...e of the assembly right below the con nector black label as seen in the graphic to the right Flex Module Installation Some Flex Modules require that they be installed in specific slots within the base As an example if a communications card is to be installed it must be placed in slot 6 Slot 6 can receive and accept any card however it is the only slot that allows for a communication card see table...

Page 14: ...ing removed and installed into the wrong slot affix the slot number labels as directed in step 4 above to each module as shown in the graphic below white circle and each removable screw ter minal block Wiring the Modules Prior to wiring any of the I O modules described in this document it is recommended that the warnings and notes listed below be reviewed CAUTION ç To prevent damage to the control...

Page 15: ...ots have slot caps installed Note Maximum wire size and torque for screw terminations 0 0507 to 3 30 mm2 30 to 12 AWG single wire termination or two 1 31 mm2 16 AWG 0 57 Nm 5 0 lb in torque Input Connections Thermocouple FM M L A L U Y _ _ A A _ _ _ S1 R1 Grounded or ungrounded sensors greater than 20MΩ input imped ance 2kΩ source resistance max 3 microampere open sensor detection Thermocouples ar...

Page 16: ...6 24 26 17 26 41 62 28 66 17 Note 3 wire RTD s self compensate for lead wire resistance up to 10 Ω of wire resistance RTD High Density FMHA RAAA A _ _ _ 2 wire RTD S1 R1 S2 R2 S3 R3 S4 R4 Platinum 100 and 1 000 Ω 32 F 0 C calibration to DIN curve 0 00385 Ω Ω C RTD excitation current of 0 09 mA typical Each ohm of lead resistance may affect the reading by 2 55 C for a 100 ohm platinum sensor or 0 2...

Page 17: ... S4 R4 Amps S1 R1 S2 R2 S3 R3 S4 R4 0 to 20 mA 100 Ω input impedance 0 to 10VÎ dc 20 kΩ input impedance 0 to 50 mVÎ dc 20 MΩ input impedance Scalable Potentiometer FM M L A L U _ _ A A _ _ _ S_ R_ CW CCW Potentiometer 0 to 1 200Ω Potentiometer High Density FMHA RAAA A _ _ _ S_ R_ S_ R_ S_ R_ S_ R_ CW CCW CW CCW CW CCW CW CCW Potentiometer 0 to 1 200Ω ...

Page 18: ...n coefficients A B and C from thermistor manufacturer corresponding to the terms of the Steinhart Hart equation 1 T A Bln R C ln R 3 Thermistor High Density FMHA PAAA A _ _ _ S1 R1 S2 R2 S3 R3 S4 R4 20 MΩ input impedance 0 to 40kΩ 0 to 20kΩ 0 to 10kΩ 0 to 5kΩ 2 252kΩ and 10kΩ base at 77 F 25 C Drive current is 109 μA as a constant current source User selectable curves for Alpha Technics BetaTHERM ...

Page 19: ...Vdc Digital Input High Density FMHA CAAA A _ _ _ Common DC Input B1 D1 D2 D3 D4 D5 D6 Z1 Supply DC Input DC Input DC Input DC Input DC Input Internal Voltage Max input 36V at 3mA Input inactive when 2V Input active when 3V at 0 25mA Dry contact Input inactive when 500Ω Input active when 100Ω Max short circuit 13mA Voltage Input Dry Contact common D_ Z_ Vdc Current Transformer FMMA C _ _ A A _ _ _ ...

Page 20: ...ent CT Ratio R 1000 1 Is IpT R 50mA ISC Ip full scale 50mA R T CSI Output N Is Current in secondary of current transformer Ip Current in primary of current transformer T Number of turns through the primary of the transformer R Number of turns in the secondary of the current transformer Turns ratio assuming one primary turn ISC Input Scaling parameter found in Current function block CSI Current Out...

Page 21: ... at 122 F 50 C 85 to 264VÅ ac resistive load only see derating curve 2 000 000 cycle rating for rated load 100 mA minimum load 2 mA maximum off state leakage Do not use on dc loads Output does not supply power Do not drive another relay or solenoid with this output type See Quencharc note page 12 L2 K2 Solid State Relay Form A FMMA _ KKA A _ _ _ normally open common L1 K1 normally open common L2 K...

Page 22: ...te page 12 L3 K3 L1 K1 L2 K2 L4 K4 normally open common normally open common normally open common normally open common Dual Solid State Relays Form A High Density FMHA KAAA A _ _ _ normally open common L1 L1 normally open common K1 K1 normally open common normally open common L2 L2 K2 K2 10 A at 20 to 264VÅ ac maximum resis tive load 10A per output at 240VÅ ac max 20A per card at 122 F 50 C Opto i...

Page 23: ... not supply power Do not use on dc loads N O COM N O wiring shared common between each set of outputs See table below for maximum current out put K3 L3 L4 Normally Open Normally Open Common K1 L1 L2 Normally Open Normally Open Common Not Used Not Used Quad 2 Amp SSR Derating Curve All Outputs 100 Duty Cycle Amps per Each SSR Ambient Temperature o C 0 4 0 15 10 5 20 0 6 0 8 1 0 1 2 1 4 1 6 1 8 25 3...

Page 24: ...Form C FM M L A _ E _ A A _ _ _ normally open normally closed common L1 K1 J1 5 A at 240VÅ ac or 30VÎ dc maxi mum resistive load Requires a minimum load of 20 mA at 24V 125 VA pilot duty at 120 240VÅ ac 25 VA at 24VÅ ac 100 000 cycles at rated load Output does not supply power For use with ac or dc See Quencharc note page 12 normally open common normally closed L1 K1 J1 Universal Process FMMA _ F ...

Page 25: ...A _ _ _ dc dc W2 Y2 Switched DC Output 1 30 mA dc maximum supply current Output 2 10 mA dc maximum supply current Short circuit limited to 50 mA 22 to 32VÎ dc open circuit voltage Use dc and dc to drive exter nal solid state relay DIN A MITE compatible Open Collector Output 1 only 100 mA maximum output cur rent sink 30VÎ dc maximum supply voltage Any switched dc output can use the common terminal ...

Page 26: ... required Total sink current for all outputs not to exceed 8A Do not connect outputs in parallel Safety Extra Low Voltage Switched DC User selectable voltage 5VÎ dc at 130mA or 19 to 22VÎ dc at 80mA Open Collector Outputs B1 Z1 D6 D5 D4 D3 D2 D1 24Vdc Switched DC Outputs B1 Z1 D6 D5 D4 D3 D2 D1 5Vdc 24Vdc User Selectable Voltage Digital Output Switched DC Wiring Example Note As a switched DC outpu...

Page 27: ...e of the coil wired to D_ Each open collector output can sink 1 5 A with the total for all open collector outputs not exceeding 8 amperes Ensure that a kickback diode is reverse wired across the relay coil to prevent damage to the internal transistor Digital Output Open Collector Wiring Example 32Vdc Open Collector Outputs Internal Circuitry Power Supply 5 to 32 V dc Relay Common Diode Fuse An exa...

Page 28: ...mination resistor may be required Place a 120 Ω resis tor across T R and T R of last controller on network Do not wire to both the EIA 485 and the EIA 232 pins at the same time Two EIA 485 terminals of T R are provided to assist in daisy chain wiring Do not connect more than one controller on an EIA 232 network Do not connect more than 16 controllers on a Standard Bus EIA 485 network Maximum numbe...

Page 29: ...mp as shown above Control mode Auto as shown above Process Value input connected to the PV receiver of the loop function block Set Point which represents the desired value to be maintained by the controller PWR output power levels for heat and cool if both are configured Output Actions allows a user to monitor the on off status of user defined inputs or outputs Menu as shown below will provide acc...

Page 30: ...x xx xx xx xx Will be different and unique for each controller MAC address is a manufacturer supplied address for the network interface card Display Units F Fahrenheit C Celsius Modbus TCP Enable Yes No Modbus is an industrially hardened field bus protocol used for communications from the controller to other devices on the network Modbus Word Order High Low Modbus allows a user to select the word ...

Page 31: ...his To connect using Fixed IP changing PC IP address 1 Connect Ethernet cables from F4T RJ45 connector to PC Ethernet port 2 On the PC navigate to the control panel and click on Network and Sharing Center 3 Click on Change adapter settings 4 Double click on the Local Area Connection the Ethernet port where cable is connected icon 5 Click the Properties button 6 Double click on Internet Protocol Ve...

Page 32: ...ck the Start button and then type composer exe in the search box to find the execut able 2 Double click on the file composer exe Note If experiencing difficulties installing or using Composer software prior to contacting Watlow technical support be prepared to send the user log file to the tech support team This text file can be found here C Users username AppData Roaming Watlow EZ Zone Composer L...

Page 33: ...utton will be of the most significance The red exclamation will always take prece dence Symbol Description The expected module has been detected No module has been detected in a slot the controller expects to be empty A module has been detected in a slot the controller expects to be empty The controller expects a module but that module is missing or a different module has been detected ...

Page 34: ...m within Composer software or while viewing the input from the front panel Operations menu shifts the readings across the entire displayed range by the offset value Use this pa rameter to compensate for sensor error or sensor placement error Typically this value is set to zero Required Equipment When Performing Calibration Obtain a precision source for millivolts volts milliamperes or resistance d...

Page 35: ...signals from the analog input will act on the high and low signals applied in this procedure Note When calibrating a Universal Input configured as a 3 wire RTD ensure that the calibrated source is connected across R and both T and S inputs Note If the user exits this procedure at any point by clicking cancel or simply navigating away to another screen the previous calibration for the selected inpu...

Page 36: ...lick on Calibrate 5 Select the appropriate Module and Input and then click on Perform Field Calibration 6 Follow instructions on the screen Using the User Interface to Calibrate Analog Inputs To calibrate from the F4T front panel 1 Push the Menu Service and Calibration buttons in that order 2 Select the desired module and input and then push Perform Field Calibration 3 Follow instructions on the s...

Page 37: ...larm set point to correct trip point Set alarm to correct type process deviation or power Set digital input func tion and source instance Alarm won t occur Alarm will not acti vate output Alarm silencing is active Alarm blocking is active Alarm is set to incorrect output Alarm is set to incorrect source Alarm set point is incor rect Alarm is set to incorrect type Disable alarm silencing if require...

Page 38: ...roller Sensor improperly wired or open Incorrect setting of sen sor type Calibration corrupt Correct wiring or re place sensor Match setting to sensor used Check calibration of controller Limit won t clear or reset Limit will not clear or reset with key pad or digital input Sensor input is out of limit set point range Limit set point is incor rect Digital input function is incorrect Correct cause ...

Page 39: ...s load failure loss of power to load etc Deactivate Open Loop Detect feature Loop Reversed Error Open Loop Detect is active and the pro cess value is headed in the wrong di rection when the output is activated based on deviation value and user se lected value Setting of Open Loop Detect Time incorrect Setting of Open Loop De tect Deviation incorrect Output programmed for incorrect function Thermoc...

Page 40: ...mode appro priately Open vs Closed Loop Set heat cool algorithim to on off or PID Correct output wiring Correct fault in system Set control set point in appropriate control mode and check source of set point remote idle profile closed loop open loop Obtain correct control ler model for applica tion No Display No display indica tion Power to controller is off Fuse open Breaker tripped Safety interl...

Page 41: ...m power wires Place 120 Ω resistor across EIA 485 on last controller Process doesn t con trol to set point Process is unstable or never reaches set point Controller not tuned cor rectly Control mode is incor rectly set Control set point is incor rect Perform autotune or manually tune system Set control mode appro priately Open vs Closed Loop Set control set point in appropriate control mode and ch...

Page 42: ...al relay Current transformer load wire associated to wrong output Defective current trans former or controller Noisy electrical lines Replace relay Replace relay Route load wire through current transformer from correct output select the output that is driving the load Replace or repair sensor or controller Route wires appropri ately check for loose connections add line filters Menus inac cessible ...

Page 43: ...ery is 0830 0858 0000 Identifying the battery location 1 Orient the controller as shown in the picture below 2 Notice that the battery compartment is located just below the two USB Removing the old battery 1 Ensure all power is off to the F4T 2 Insert a small screwdriver into the hole provided on the side of the controller as shown below 3 Place screwdriver into the bottom of the white battery hol...

Page 44: ...y perpendicular to the plastic housing 3 Turn and secure the battery so that it sits under the tabs located on the top of the holder 4 Insert the holder into the controller housing with the positive side of the battery ori ented to the left as shown below Note If the battery is fully discharged it may be dis posed of in normal municipal waste Because there will always be some residual metals remai...

Page 45: ...d sensor conformity 0 1 of span 1 C the calibrated ambi ent temperature and rated line voltage Types R S B 0 2 Type T below 50 C 0 2 Calibration ambient temperature 77 5 F 25 C 3 C Accuracy span 1000 F 540 C min Temperature stability 0 1 F F 0 1 C C rise in ambient maximum Agency Approvals UL Listed to UL 61010 File E185611 QUYX CSA 22 2 14 File 158031 FM Class 3545 configurations with limit modul...

Page 46: ...10 years at 77 F 25 C Isolated Communications EIA232 485 Modbus RTU Ethernet Modbus TCP Standard bus protocol via USB for configuration profile and data log file transfers USB Device Port Version USB 2 0 full speed Connector USB Mini Type B 5 position Recognized as a mass storage device serial communications Driver for Microsoft Windows 7 and Windows 8 USB Host Port Total of 2 available Version US...

Page 47: ...ial subtraction ratio divide add multiply absolute difference min max square root sample and hold Process Value 8 total Off sensor backup average crossover wet dry bulb switch over differential subtrac tion ratio divide add multiply absolute difference min max square root Special Output Function 4 total Compressor turns on off compressor for one or two loops cool and dehumidify with single compres...

Page 48: ...andard Yes 6 24 to 28Vac or Vdc Right angle standard No 7 24 to 28Vac or Vdc Front screw Yes 8 24 to 28Vac or Vdc Front screw No Profiles and Function Blocks Profiles Function Blocks None 40 Profiles Battery Backup and Real Time Clock Basic Set Set 1 Set 2 A X X B X X C X X D X X E X X F X X Documentation Accent Bar Replacement Connector Custom Documentation Decorated Brush Aluminium Accent Bar DV...

Page 49: ... Input Ranges Accuracy 20µA 1 LSD at standard conditions Temperature stability 100 PPM C maximum Resolution Input Ranges 0 to 10V 200 µV nominal 0 to 20 mA 0 5 mA nominal Potentiometer 0 to 1 200Ω Inverse scaling Input Type Max Error 25 Deg C Accuracy Range Low Accuracy Range High Units J 1 75 0 750 Deg C K 2 45 200 1250 Deg C T 200 to 350 1 55 200 350 Deg C N 2 25 0 1250 Deg C E 2 10 200 900 Deg ...

Page 50: ...00 ohms Resistance 10K range 0 10000 ohms Resistance 20K range 0 20000 ohms Resistance 40K range 0 40000 ohms 1 Thermistor Input Input Type Max Error 25 Deg C Accuracy Range Low Accuracy Range High Units Thermistor 5K range 5 0 5000 Ohms Thermistor 10K range 10 0 10000 Ohms Thermistor 20K range 20 0 20000 Ohms Thermistor 40K range 40 0 40000 Ohms 0 to 40KΩ 0 to 20KΩ 0 to 10KΩ 0 to 5KΩ 2 252KΩ and ...

Page 51: ...cal Requires optional current transformer Watlow part number 16 0246 Switched DC Output Switched dc 22 to 32VÎ dc 30mA per output 40mA per pair option CC Open Collector Output Switched dc open collector 32VÎ dc max 100mA max current sink Solid State Relay Output Form A 1A at 50 F 10 C to 0 5A at 149 F 65 C 0 5A at 24VÅ ac min 264VÅ ac max opto isolated without contact suppression 20VA pilot duty a...

Page 52: ... A AK None SSR Form A 0 5A CA Switched dc open collector None CH Switched dc open collector NO ARC 12A power control CC Switched dc open collector Switched dc CJ Switched dc open collector Mechanical relay 5A Form A CK Switched dc open collector SSR Form A 0 5A EA Mechanical relay 5A Form C None EH Mechanical relay 5A Form C NO ARC 12A power control EC Mechanical relay 5A Form C Switched dc EJ Mec...

Page 53: ... with thermistor input None Mechanical relay 5A Form A None YEB Limit control with temperature input None Mechanical relay 5A Form C Single digital input limit reset Flex Modules High Density I O Specifications 4 Universal Inputs Thermocouple grounded or ungrounded sensors 20MΩ input impedance Max of 2KΩ source resistance RTD 2 or 3 wire platinum 100Ω and 1000Ω 32 F 0 C calibration to DIN curve 0 ...

Page 54: ...2315 Deg C D 3 32 0 2315 Deg C F PTII 2 34 0 1343 Deg C RTD 100 ohm 2 00 200 800 Deg C RTD 1000 ohm 2 00 200 800 Deg C mV 0 05 0 50 mV Volts 0 01 0 10 Volts mAdc 0 02 2 20 mAmps DC mAac 5 50 50 mAmps AC Potentiometer 1K range 1 0 1000 Ohms Operating Range Input Type Range Low Range High J 210 C 1200 C K 270 C 1371 C T 270 C 400 C N 270 C 1300 C E 270 C 1000 C R 50 C 1767 C S 50 C 1767 C B 50 C 181...

Page 55: ...zation curves built in Third party Thermistor compatibility requirements Base R 25C Alpha Techniques Beta THERM YSI 2 252K Curve A 2 2K3A 004 10K Curve A 10K3A 016 10K Curve C 10K4A 006 3 Universal Process Retransmit Outputs Universal process retransmit Output range selectable 0 to 10V Î dc into a min 4 000Ω load 0 to 20mA into max 400Ω load Resolution dc ranges 2 5mV nominal resolution mA ranges ...

Page 56: ... max See table for max current per output 50 VA pilot duty at 120 240 VÅ ac 6 Digital Input Output Option 6 DIO Digital input update rate 10Hz DC voltage Max input 36V 3mA Min high state 3V at 0 25mA Max low state 2V Dry contact Min open resistance 10KΩ Max closed resistance 50Ω Max short circuit 13mA Digital output update rate 10Hz User selectable Switched DC output 5VÎ dc at 130mA or 19 to 22VÎ ...

Page 57: ...n Flex Module Communications Ordering Information Part Number Module ID Type Future Option Comm Option Future Option Future Options Custom Options and Connectors d Custom Options Firmware Overlay Preset Parameters Locked Code FM C A 2 A A Communication Option 2 Modbus RTU 232 485 Custom Options and Connectors A Right angle screw connector standard F Front screw connector d Custom Options Firmware ...

Page 58: ...unity Group 1 Class A1 Emissions EN 61000 4 2 2009 Electrostatic Discharge Immunity EN 61000 4 3 2010 Radiated Field Immunity EN 61000 4 4 2012 Electrical Fast Transient Burst Immunity EN 61000 4 5 2006 Surge Immunity EN 61000 4 6 2009 Conducted Immunity EN 61000 4 11 2004 Voltage Dips Short Interruptions and Voltage Variations Immunity EN 61000 3 2 2009 Harmonic Current Emissions EN 61000 3 32 20...

Page 59: ...of themselves it is only when installed in a Watlow EZ ZONE CC or F4T Base enclosure that they have useful function Modules were tested as part of these systems for compliance with the following directives 2004 108 EC Electromagnetic Compatibility Directive EN 61326 1 2006 Electrical equipment for measurement control and laboratory use EMC requirements Industrial Immunity Class B Emissions 2006 95...

Page 60: ...l 44 115 964 0777 Fax 44 115 964 0071 Asia and Pacific Watlow Singapore Pte Ltd 16 Ayer Rajah Crescent 06 03 04 Singapore 139965 Tel 65 6773 9488 Fax 65 6778 0323 Email info watlow com sg Website www watlow com sg Watlow Australia Pty Ltd 4 57 Sharps Road Tullamarine VIC 3043 Australia Tel 61 3 9335 6449 Fax 61 3 9330 3566 Website www watlow com Watlow Electric Manufacturing Company Shanghai Co Lt...

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