Watlow Integrated Controller Rev C EZ-ZONE PM User Manual Download

Page: 1 / 80

0600-0059-0000 Rev. C

Made in the U.S.A.

March 2008

$15.00

User’s Manual

Registered Company

Winona, Minnesota USA

ISO 9001

TOTAL

3 Year Warranty

CUS

CUST

MER

ATISF

TISFA

ACTI

CTIO

EZ-ZONE

Integrated Controller Models

1241 Bundy Boulevard., Winona, Minnesota USA 55987

Phone: +1 (507) 454-5300, Fax: +1 (507) 452-4507 http://www.watlow.com

Summary of Contents for Integrated Controller Rev C EZ-ZONE PM

Page 1: ...ered Company Winona Minnesota USA ISO 9001 ISO 9001 TOTAL 3 Year Warranty CUS CUST TO OM MER ER S SA ATISF TISFA ACTI CTIO ON N EZ ZONE PM Integrated Controller Models 1241 Bundy Boulevard Winona Minn...

Page 2: ...ive see back cover by e mailing your questions to wintechsupport watlow com or by dialing 1 507 494 5656 between 7 a m and 5 p m Central Standard Time CST Ask for for an Applications Engineer Please h...

Page 3: ...s and Displays 24 Attention Codes 24 Chapter 4 Home Page 26 Chapter 5 Operations Page 28 Chapter 6 Setup Page 33 Chapter 7 Profiling Page 45 Chapter 8 Factory Page 49 Chapter 9 Features 53 Chapter 10...

Page 4: ...tly Reduces component count Saves panel space and simplifies wiring Reduces the cost of ownership EZ ZONE configuration communications and software Saves time and improves the reliability of control l...

Page 5: ...in the Digital Input Function parameter in the Function Key Menu Setup Page Functions Functions use input signals to calculate a value A function may be as simple as reading a digital input to set a...

Page 6: ...nsmit off heat cool alarm event EZ Key programmable event Digital Output or Input 5 optional none switched dc Digital Output or Input 6 optional none switched dc off heat cool alarm event off heat coo...

Page 7: ...or Input 5 optional none switched dc Digital Output or Input 6 optional none switched dc off heat cool alarm event off heat cool alarm event Network remote user interface personal computer programmab...

Page 8: ...l alarm event Network remote user interface personal computer programmable logic controller human machine interface EIA 485 Communications Standard Bus Modbus RTU optional Limit Controller Board optio...

Page 9: ...ol alarm event off heat cool alarm event Network remote user interface personal computer programmable logic controller human machine interface EIA 485 Communications Standard Bus Modbus RTU optional C...

Page 10: ...2 S2 R2 98 99 CF CD CE B5 D6 D5 15 8 mm 0 62 in 101 6 mm 4 00 in 53 3 mm 2 10 in 53 3 mm 2 10 in 51 2 mm 2 02 in Side Front Top Back Chapter 2 Install and Wire 2 Dimensions 21 6 mm 0 85 in 45 2 mm 1 7...

Page 11: ...e teeth that latch into the ridges on the sides of the controller Each tooth is staggered at a different depth from the front so that only one of the tabs on each side is locked onto the ridges at a t...

Page 12: ...til both latches click Chemical Compatibility This product is compatible with acids weak alkalis alcohols gamma radiation and ultraviolet radiation This product is not compatible with strong alkalis o...

Page 13: ..._ K A _ _ Communications CB CA CC CB CA C5 C3 C2 Modbus RTU EIA 485 T R Modbus RTU EIA 485 T R Modbus RTU EIA 485 common Modbus RTU EIA 485 T R Modbus RTU EIA 485 T R Modbus RTU EIA 232 common Modbus...

Page 14: ..._ _ _ _ _ _ A _ _ Terminal Definitions for Slot C Slot A Slot B Slot C or Output 1 Output 2 Input 1 Output 3 Output 4 Input 2 Power 485 Comms Dig I O 5 6 Communications Slot B Controller Power Supply...

Page 15: ...g F47 47 to 63 Hz 10VA maximum power consumption PM6 _ 3 or 4 _ _ _ _ _ _ A _ _ High Power power power 98 99 CF CD CE B5 D6 D5 Slot C fuse 85 to 264V ac 100 to 240V ac Semi Sig F47 47 to 63 Hz 10VA ma...

Page 16: ...couple L1 K1 J1 L2 K2 T1 S1 R1 Slot A 20 maximum source resistance 20 M input impedance 3 microampere open sensor detection Thermocouples are polarity sensitive The negative lead usually red must be c...

Page 17: ...le L3 K3 J3 L4 K4 T2 S2 R2 Slot B 20 maximum source resistance 20 M input impedance 3 microampere open sensor detection Thermocouples are polarity sensitive The negative lead usually red must be conne...

Page 18: ...ntly depend ing on the model number Note To prevent damage to the controller do not connect wires to unused terminals Note Maintain electrical isolation between analog input 1 digi tal input outputs s...

Page 19: ...3 pole up to 2 in series Open Collector 100 mA maximum output cur rent sink 30V dc maximum supply voltage Any switched dc output can use the common terminal Use an external power supply to control a...

Page 20: ...f 105 microamperes output does not supply power Do not use on dc loads See Quencharc note PM6 _ _ K _ _ _ _ _ A _ _ Internal Circuitry common normally open Solid state Relay L1 K1 Output 2 Switched DC...

Page 21: ...uitry common normally open Solid state Relay L2 K2 Output 3 Switched DC Open Collector dc common X3 W3 Y3 L4 K4 T2 S2 R2 Slot B dc open collector Switched DC 30 mA dc maximum supply current short circ...

Page 22: ...ntrol PM6 _ _ _ _ _ _ F _ A _ _ Note If output 3 is a universal process output output 4 cannot function as a variable time base output Output 3 Solid state Relay Form A normally open common L3 K3 L4 K...

Page 23: ...ote Maintain electrical isolation between analog input 1 digi tal input outputs switched dc open collector outputs and process outputs to prevent ground loops Note The control output common terminal a...

Page 24: ...the EIA 485 port Do not route network wires with power wires Connect net work wires in daisy chain fash ion when connecting multiple devices in a network A termination resistor may be required Place a...

Page 25: ...98 99 CC CA CB B5 D6 D5 power supply fuse A network using Watlow s Standard Bus and an RUI Gateway A network using Modbus RTU Wiring a Serial EIA 485 Network Do not route network wires with pow er wir...

Page 26: ...le is paused Communications Activity Flashes when another device is communicating with this controller Up and Down Keys In the Home Page adjusts the set point in the lower dis play In other pages chan...

Page 27: ...ONE Ai oper WATLOW EZ ZONE Operations Page from Home Page Press both the Up and Down keys for three seconds 70 72 WATLOW EZ ZONE Ai Set WATLOW EZ ZONE Setup Page from Home Page Press both the Up and D...

Page 28: ...active message could be a reported error for ex ample C Er1 Current Error or it could be for in formation only for example tUN1 Autotuning Use the Advance Key to step through the other parameters The...

Page 29: ...hrough possible responses such as Clear CLr or Silence SiL Then push the Advance or Infinity key to execute the action AL L1 AL L2 AL L3 AL L4 Alarm Low 1 to 4 AL h1 AL h2 AL h3 AL h4 Alarm High 1 to...

Page 30: ...gital I O 6 Submenu Same as above LiM oPEr LL S Lh S Limit Menu Limit Low Set Point Limit High Set Point Mon oPEr C MA h Pr C Pr C SP Pu A Monitor Menu Control Mode Active Heat Power Cool Power Closed...

Page 31: ...lways Ei S Ei S Digital Input 5 or 6 Event Input Status View this event input state iACt Inactive ACt Active always LiM oPEr Limit Menu menu appears if PM6 _ _ _ _ _ L _ _ AAA LL S LL S Limit Low Set...

Page 32: ...s 24 0 C always h Pb h Pb Loop Heat Proportional Band Set the PID proportional band for the heat outputs 0 001 to 9 999 000 F or units 1 110 555 to 5 555 000 C 25 0 F or units 14 0 C Heat Algorithm Se...

Page 33: ...s Setup Page is not set to Low CUrr oPEr Current Menu menu appears if PM6 _ _ _ _ T _ _ A _ _ Note To use the current sensing feature Time Base Setup Page Output Menu must be set to 0 7 seconds or mor...

Page 34: ...0 to 9 999 000 F or units 1 128 000 to 5 537 000 C 0 0 F or units 18 0 C always S ti S ti Profile Status Step Time Remaining View or change the time remaining for the current step Step is displayed in...

Page 35: ...nge Low Range High Output Low Power Scale Output High Power Scale Calibration Offset Output Function Fi o Ct o tb o Lo o hi Output Function Instance Output Control Output Time Base Output Low Power Sc...

Page 36: ...the thermo couple wired to this input b B C C d D E E F F J J H K n N r R S S t T J Sensor Type is set to Thermocouple Rt L rt L Input 1 or 2 RTD Leads Set to match the number of leads on the RTD wire...

Page 37: ...ction Select what function will drive this output oFF Off CooL Cool hEAt Heat ALM Alarm Ent Event Off Direction is set to Out put o Ct o Ct Digital Output 5 or 6 Control Set the output control type Th...

Page 38: ...e fea ture is available Fi Fi Digital Input 5 or 6 Function Instance Select which instance of the Event Func tion will be triggered by a true state 0 All Instances except pro files For example if Digi...

Page 39: ...within which TRU TUNE will be in ef fect Use this function only if the controller is unable to adaptive tune automatically 0 Auto 1 to 100 0 Cool Algorithm or Heat Algorithm is set to PID and TRU TUNE...

Page 40: ...ust devi ate from the set point to trigger an open loop error 1 999 000 to 9 999 000 F or units 1 110 555 to 5 555 000 C 10 0 F or units 6 0 C Open Loop Detect Enable is set to Yes rP rP Loop Ramp Act...

Page 41: ...20 00 10 00 a process output PM6 _ _ F _ _ _ _ _ A _ _ or PM6 _ _ _ _ _ F _ A _ _ r Lo r Lo Output 1 or 3 Range Low Set the minimum value of the retransmit value range in process units When the retran...

Page 42: ...control 0 1 sec SSR sw dc 20 0 sec mech relay no arc a time proportioned output solid state relay switched dc or mechanical relay and Control is set to Fixed Time Base o Lo o Lo Output 1 to 4 Low Pow...

Page 43: ...ormal range oFF Off Str Startup StPt Set Point both Both Off always A Si A Si Alarm 1 to 4 Silencing Turn alarm silencing on to allow the user to disable this alarm oFF Off on On Off always A dSP A dS...

Page 44: ...s able level AoF Alarm Outputs Control Loop Off level USr r Restore User Settings edge P diS Profile Disable level P hoL Profile Hold Resume level ProF Profile Start Number edge P StS Profile Start St...

Page 45: ...odel Ad M Ad M Communications 1 or 2 Address Modbus Set the network address of this controller Each device on the network must have a unique address 1 to 247 1 Protocol is set to Modbus Range depends...

Page 46: ...IP Fixed Subnet Part 4 Set the IP subnet mask for this controller 0 to 255 0 IP Address Mode is set to Fixed iP g1 ip g1 Communications 2 IP Fixed Gateway Part 1 Set the IP gateway address for this co...

Page 47: ...4 FiLE 31 P4 WE S tyP WE 1 WE 2 Ent1 Ent2 Pro le 4 Steps 31 to 40 Pro le 4 Wait For Event Wait Event 1 Wait Event 2 Event Output 1 Event Output 2 W Pr S tyP W Pi WPr Ent1 Ent2 Wait For Process Wait fo...

Page 48: ...ofile Start P St1 appears in the lower display 2 Use the Up or Down key to choose the file or step number within a profile where you want the profile to begin running 3 Press the Advance Key This take...

Page 49: ...r Process is satisfied this step ends 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C 0 0 F or units 18 0 C Step Type is set to Wait For Process WE 1 WE 1 or WE 2 WE 2 Step Type Parameters...

Page 50: ...input 5 WE 2 Wait Event 2 digital input 6 Ent1 Event Output 1 Ent2 Event Output 2 W Pr W Pr Step Types Wait For Process A Wait For Process Step will wait for the process value to match the Wait For P...

Page 51: ...Same as above LoC FCty LoC o LoC P rLoC SLoC Lockout Menu Lock Operations Page Lock Pro ling Page Read Lock Set Lock diAg FCty Pn rEu S bLd Sn dAtE USr r USr S iP A1 iP A4 C LEd Diagnostic Menu Part N...

Page 52: ...ti Time Integral td Time Derivative db Dead Band h Pb Heat Proportional Band h hy Heat Hysteresis C Pb Cool Proportional Band C hy Cool Hysteresis r rt Ramp Rate CU r Current Read t tUn TRU TUNE Enabl...

Page 53: ...Page 5 always diAg FCty Diagnostics Menu Pn Pn Diagnostics Menu Part Number Display this controller s part number always rEu rEu Diagnostics Menu Software Revision Display this controller s firmware...

Page 54: ...units cor responding to the Sensor Type Setup Page Analog Input Menu setting 1 999 000 to 9 999 000 always ELi o ELi o Calibration Menu 1 or 2 Electrical Input Offset Change this value to calibrate t...

Page 55: ...Remote Set Point 57 Outputs 58 Duplex 58 No arc Relay 58 Retransmitting a Process Value or Set Point 58 Cool Output Curve 59 Control Methods 59 Output Configuration 59 Auto closed loop and Manual open...

Page 56: ...set to 90 percent the autotune function utilizes 180 for tuning This is also how autotun ing works in previous Watlow Winona controllers In addition changing the active set point in previous controll...

Page 57: ...the adaptive control mode it determines the appropriate output signal and over time adjusts control param eters to optimize responsiveness and stability The TRU TUNE feature does not function for on...

Page 58: ...actory Page Calibration Menu for that input 3 Calculate the offset value by subtracting this val ue from the low source signal 4 Set Electrical Input Offset ELi o Factory Page Calibration Menu for thi...

Page 59: ...etween Low Limit of Sensor and Range High Set Point Low Set Point High Scale High and Scale Low When an analog input is selected as process voltage or process current input you must choose the value o...

Page 60: ...ted life of 100 000 cycles at the rated full load current The shorter life for conventional relays is due to the fact that when contacts open while current is flowing metal degradation occurs This act...

Page 61: ...its own set of configura tion parameters and set points allowing independent operation Auto closed loop and Manual open loop Control The controller has two basic modes of operation auto mode and manu...

Page 62: ...turn on the output Increasing the value de creases the number of times the output will cycle Decreasing hysteresis improves controllability With hysteresis set to 0 the process value would stay clos...

Page 63: ...op Menu Proportional plus Integral plus Derivative PID Control Use derivative rate control to minimize the over shoot in a PI controlled system Derivative rate ad justs the output based on the rate of...

Page 64: ...r controllers such as a solid state relay SSR or silicon controlled rectifier SCR power controller Do not use a variable time base output for control ling electromechanical relays mercury displacement...

Page 65: ...ess value reaches the alarm high or alarm low set point Alarm hysteresis defines how far the process must return into the normal operating range before the alarm can be cleared Alarm hysteresis is a z...

Page 66: ...urrent Error C Er Operations Page Cur rent Menu and Heater Error h Er Operations Page Current Menu Programming the EZ Key You can program the EZ Key either in the Setup Menu or with configuration soft...

Page 67: ...Profile Page and Opera tions Page security levels Change Lock Opera tions Page LoC o to 3 and Lock Profiling Page LoC P to 2 If Set Lockout Security SLoC is set to 2 or higher and the Read Lockout Sec...

Page 68: ...AL L4 Sensor input below low alarm set point Temperature is less than alarm set point Alarm is set to latching and an alarm occurred in the past Incorrect alarm set point Incorrect alarm source Check...

Page 69: ...tuning 1 Controller is autotuning the control loop User started the autotune function Digital input is set to start autotune Wait until autotune completes or dis able autotune feature Set digital inpu...

Page 70: ...the load current is proper Correct cause of overcurrent and or en sure current trip set point is correct Current through load is below current trip set point Check that the load current is proper Corr...

Page 71: ...rminals touch safe remov able 3 30 to 0 0507mm 12 to 30 AWG Wire strip length 7 6 mm 0 30 in Torque 0 8 Nm 7 0 lb in Universal Input Thermocouple grounded or ungrounded sensors 20 M input impedance Ma...

Page 72: ...ss Retransmit outputs range selectable 0 to 10 V dc into minimum 1 000 load 0 to 20 mA into maximum 800 load Operator Interface Dual 4 digit 7 segment LED displays Advance infinity up and down keys pl...

Page 73: ...one 1 EIA 485 Modbus RTU With options 2 or 3 order option AA for outputs 3 4 2 Modbus RTU 232 485 3 EtherNet IP Modbus TCP Auxilliary Control Functions With Communications Options 2 to 6 option A must...

Page 74: ...ailure 38 59 FiL Filter 35 Fi Digital Input Function In stance 36 Fi Function Key Instance 42 Fi Digital Output Function Instance 35 Fi Output Function Instance 39 40 Fn Digital Input Function 36 42 F...

Page 75: ...vent 2 47 W Pi Wait For Process Instance 47 W Pr Wait For Process 48 WPr Wait For Process 47 A accuracy 69 Active Event Output 1 or 2 32 Active Process Value Home Page 26 Active Set Point 32 Home Page...

Page 76: ...Part 2 51 IP Actual Address Part 3 52 IP Actual Address Part 4 52 IP Address Mode 43 IP Fixed Address Part 1 43 IP Fixed Address Part 2 43 IP Fixed Address Part 3 44 IP Fixed Address Part 4 44 IP Fixe...

Page 77: ...e 40 Source Output Instance 42 specifications 69 Step 46 Step Time Remaining 32 Step Type 46 T Target Set Point 46 temperature units indicator lights 24 Time 48 Time Base 35 40 Time Derivative 30 55 6...

Page 78: ...dustrial Immunity Class B Emissions EN 61000 4 2 1996 A1 A2 2001 Electrostatic Discharge Immunity EN 61000 4 3 2002 A1 A2 2005 Radiated Field Immunity EN 61000 4 4 2004 Electrical Fast Transient Burst...

Page 79: ......

Page 80: ...071 Email info watlow co uk Website www watlow co uk From outside The United Kingdom Tel 44 115 964 0777 Fax 44 115 964 0071 Asia and Pacific Watlow Singapore Pte Ltd 16 Ayer Rajah Crescent 06 03 04 S...

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