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PM temperature & process controller user`s manual Rev. J 11.23 MB

1. A Output Point 7 Control Loop GEE Analog Input Menu iP Input Point 8 449 Heat Algorithm to o PB Output Point 8 CA9 Cool Algorithm Analog Input Input Point 9 CCc Cool Output Curve SEA Sensor Type Output Point 9 Et Un Tru Tune Enable L n Linearization P ID Input Point 10 Ebnd Tru Tune Band r EL RTD Leads oP 10 Output Point 10 E9n Tru Tune Gain Un E Units Pur ES ae eaa re S L o Scale Low eltier Delay Gh Scale High ee cEn Remote Set Point Enable cL o Range Low Process Value cE d Uter Ful een ype r h Range High Function L s ila E m ras PEE Process Error Enable Pressure Units 1 pu or Failure PEL Process Error Low Bunt Altitude Units PA Manual Power EC Thermistor Curve bPc Barometric Pressure LJE poe rs n od er Resistance Range Filter L dt Open Loop Detec ime F L Filter Eda L d d Open Loop Detect Deviation Er Error Latching SEE Digital Input Output Menu EE Funpacti n dE C Display Precision to rc SC Ramp Scale 5 5 A Sensor Backup Digi r r tj Ramp Rate gital Input Output L SP Low Set Point Chor lo dar Direction hSP High Set Point Linearization Menu LEu udin SPL o Set Point Open Limit Low E Hue Eo Function Ph _ Set Point Open Limit High Linearization F Function Instance Fa Function of E Control Un E Units o t b Time Base Output Menu P Input Point 1 o L o Low Power Scale
2. EM 4 19 75 mm 0 62 in 1 52 mm 100 33 mm 0 06 in 3 95 in i Er RN i anu i ma KD GS D 54 86 mm D 53 34 mm 2 16 in D 2 10 in Q S O00 8 Y Sj Y SL 10 16 mm ka 0 40 in 30 73 mm 1 21 in 101 60 mm e 0n ooo 1 8 DIN PM9 Horizontal Recommended Panel Spacing 92 3 mm m e 635 imm 45 mm 1 in Panel thickness 0 060 in 1 53 mm 21 6 mm to 0 375 in 9 52 mm 0 85 in JE 6 ME 0 85 in Watlow EZ ZONE PM Integrated Controller e 18 e Chapter 2 Install and Wire 1 4 DIN PM4 Dimensions 100 33 3 95 SN 100 33 3 95 j Y Y 1 4 DIN PM4 Recommended Panel Spacing uU 1575 62 n 152 06 _ OH CH CH Ci CH Gd CH CH Ci 12 70 ps 50 3073 1 21 100 84 3 97 21 6 85 Panel thickness 060 1 53 to 375 9 52 216 gt 85 Watlow EZ ZONE PM Integrated Controller w 19 we Chapter 2 Install and Wire Installation Retention Collar 1 Make the panel cutout using the mounting tem plate dimensions in this chapter Insert the case
3. 1 1 I I Lo I L ng ye I Output n I 1 0 to 100 1 Heat i Analog Input 1 Source A Heat Power 1 Cool Power I Control Loop 1 voee li ieee 0 to 100 I Temperature Outputn I I v A I lop KA I I I 1 Source A I I i Analog Input 2 SourceB Output o o 1 PV Function Sop 8a 7 1 Om A 1 Outputn I 0 to 100 I L Heat L 1 Source A Heat Power 1 L Cool Power I I Control L 2 Cool I ontrol Loop I hs 0 to 100 LI i Humidity Outputn Example 8 Vaisala Requirements Two analog inputs and the enhanced software option are required and at least two outputs adjusts the con trolled temperature and humidity processes Overview Vaisala Model HMM 30C Solid state Relative Humid ity Sensor is supported with the Vaisala configuration Analog Input 1 is used to measure temperature and Analog Input 2 must be a process input connected to a Vaisala sensor The controller provides temperature compensation for the Vaisala sensor The humidify and dehumidify outputs are disabled when Analog Input 1 temperature falls below 40 F 40 C or goes above 320 F 160 C When function is set for Vaisala the PV Function output equals the calculated relative humid ity compensated by the sensor on Analog Input 1
4. Dicclalinczonlneo6dl Watlow EZ ZONE PM Integrated Controller e 31 Chapter 2 Install and Wire Warning N N Use National Electric NEC or other country specific standard wiring and safety practices when wiring and connecting this controller to a power source and to electrical sensors or pe ripheral devices Failure to do so may result in damage to equipment and property and or injury or loss of life Note Maximum wire size termination and torque rating 0 0507 to 3 30 mm 30 to 12 AWG single wire termination or two 1 31 mm 16 AWG e 0 8 Nm 7 0 Ib in torque Note Adjacent terminals may be labeled differently depending on the model number Note To prevent damage to the control ler do not connect wires to unused terminals Note Maintain electrical isolation between analog input 1 digital input outputs switched dc open collector outputs and process outputs to prevent ground loops Note The control output common terminal and the digital common terminal are referenced to different voltages and must remain isolated Note This Equipment is suitable for use in CLASS I DIVISION 2 Groups A B C and D or Non Hazardous locations only Temperature Code T4A Warning A Explosion Hazard Substitution of component may impair suitability for CLASS I DIVISION 2 Warning A Explosion Hazard Do not disconnect while the circu
5. Lockout Security 5L oC amp cLoC Lockout Level 0 3 a 5 Home Page Y Y Y YI xY X Operations Page N N Yop Yo Setup Page NIN N N Y Y Profile Page NININ Y Y Y Factory Page Custom Menu NIN N N N Diagnostic Menu N Y Y Y Y Y Calibration Menu N N N N N Lockout Menu IL o C U NEN Y Y Y Y LoC PJ N EMI Y Y Y Y PRBS E NIYIYIYI Y Y rLoC NS NC IPS ENS EE Stol Y Y Y Y Y Y The following examples show how the Lockout Menu parameters may be used in applications 1 You can lock out access to the Operations Page but allow an operator access to the Profile Menu by changing the default Profile Page and Opera tions Page security levels Change Lock Opera tions Page to 3 and Lock Profiling Page to 2 If Set Lockout Security is set to 2 or higher and the Read Lockout Security is set to 2 the Profiling Page and Home Pages can be accessed and all writable param eters can be written to Pages with security levels greater than 2 will be locked out inaccessible 2 IfSet Lockout Security is set to 0 and Read Lockout Security is set to 5 all pages will be accessible however changes will not be allowed on any pages or menus with one exception Set Lockout Security can be changed to a higher level 3 The operator wants to read all the menus and not allow any parameters to be changed In the Factory Page Lockout Menu set Read Lockout Security to 5 and Set
6. B5 D6 D5 Switched DC Wiring Example Using switched dc outputs common switched dc switched dc Digital Output Update rate 10 Hz Output voltage 24V Current limit Output 5 24 mA maximum Current limit Output 6 10 mA maximum driving single pole DIN A MITE Capable of driving a 3 pole DIN A MITE Open circuit voltage 22 to 32V de PM __ 2 4 switched dc outputs a uL Ch D6 B5 Internal Circuitry DO 5 6 VDC Htr 1 Htr 2 Digital Output 7 12 Slot E B7 D7 D8 D9 D10 D11 D12 Z7 Collector out Collector out e Maximum switched volt Common Collector out e Collector out Collector out Collector out Supply Do not connect outputs PM 4 6 8 __ _ _ C D _ e Maximum output sink Total sink current for all age is 32V dc Internal supply provides a constant power out put of 750mW current per output is 1 5A external class 2 or outputs not to exceed 8A in parallel Open Collector Outputs B7 Common SELV supply required Saftey Extra Low Voltage Internal Circuitry Watlow EZ ZO
7. c uh Output 1 ontroller none switched dc open collector 5A mechanical relay form C process Analog Input 1 none Thermocouple RTD 1000 Optional YA OED A SS Po omy Ramp Soak max 4 1kQ Thermistor 5kO 10kO 20kO files 40 steps 40kQ Process V mV mA or 1k Potentiometer none 15A NO ARC m Output 2 5A mechanical relay form A or 0 5A SSR form A Slots A Optional Modbus Digital Input or Output 5 amp 6 Address 1 247 optional none switch volts dc EZ Key Programmable Event EIA 485 Communication Standard Bus optional Modbus RTU Digital Output or Input 5 amp 6 optional none switched dc Standard Bus Zone Address 1 16 Supervisory amp Power Board Output 3 none switched dc open collector 5A mechanical relay form C process V mA or 0 5A SSR form A Limit Controller Board optional Analog Input 2 none CT Thermocouple RTD 100 gt O 1kQ Thermistor 5kO 10kQ 20kQ 40kQ Process V mV mA or 1k Potentiometer Output 4 5A mechanical relay form A If Limit this output must Output Functions off heat cool alarm retransmit duplex event off heat cool alarm event off heat cool alarm event off heat cool alarm retransmit duplex or event Note Number of inputs and outputs and various combinati
8. 21 6 mm 0 85 in 21 6 mm 0 85 in Watlow EZ ZONE PM Integrated Controller 46 Chapter 2 Install and Wire 1 8 DIN PM8 Vertical Dimensions 53 34 mm Fit 2 10 in A TANN 100 33 mm 3 95 in 000 54 86 mm 2 16 in 15 75 mm 0 62 in 1 52 mm 0 06 in 9 I ELE LTITIT I I Ld 1 45 4 0 8 1 6666699 peeeeee S 10 16 mm Ew 0 40 in 30 73 mm 1 21 in Lr oon 1 8 DIN PM8 Vertical Recommended Panel Spacing 45 2 mm x 101 60 mm 1 78 in F 92 3 mm 3 635 in J Y Panel thickness 0 060 in 1 53 mm 21 6 mm to 0 375 in 9 52 mm 0 85 in i 21 6 mm 0 85 in Watlow EZ ZONE PM Integrated Controller e 17 Chapter 2 Install and Wire 1 8 DIN PM9 Horizontal Dimensions
9. w power common EZ ZONE PM PLC Power Supply i a EZ ZONE RM use ud LE LT LED pai LL pai pai mt 4 ma pmd pai LL ET pat CH pa pai pmi Sa power 98 LI 9o Power 4 a rj cel com Lr L CA A Jo A ICB ul I B5 i Tbe z Slot C Bs oeoooeoeo 8285988US5 dHHEHHHHH Ej 5 b s ima power 4 rr power w common common A mm e B FETA B t Watlow EZ ZONE PM Integrated Controller e 38 o Chapter 2 Install and Wire Warning A N Use National Electric NEC or other country specific standard wiring and safety practices when wiring and connecting this controller to a power source and to electrical sensors or pe ripheral devices Failure to do so may result in damage to equipment and property and or injury or loss of life Note Maximum wire size termination and torque rating 0 0507 to 3 30 mm 30 to 12 AWG single wire termination or two 1 31 mm 16 AWG e 0 8 Nm 7 0 Ib in torque Note Adjacent terminals may be labeled differently depending on the model number Note To prevent damage to the control ler do not connect wires to unused terminals Note Mai
10. I I Gg I 6 L I eo 1 I Or VO I I Output n I I 0 to 100 1 E IELL Em J Heat I i Analog Input 1 Source A Heat Power i l Cool Power I Control Loop 1 ee ly D 0 to 100 L Temperature Output n l I 1 Ny by 1 lon Ue l I i N i Source A I I I i Analog Input 2 Source B Output O I PV Function A i Oy Oo I 2 2o I Output n l I 0 to 100 I L Heat l I Source A Heat Power I L Cool Power L k Control L 2 TI ontrol Loop eh 0 to 100 I i Humidity Outputn Example 9 Motorized Valve Control A typical scenario where a motorized valve is used is to regulate the flow of fluid which in turn impacts the loop process value A valve is opend or closed by closing con tacts to drive the value in the intended direction Motor ized Valves come in a number of configurations Some valves have a position feedback mechanism that allows the control to measure the valve s position via an internal potentiometer called slide wire The controller can measure the potentiometer resistance to determine the initial valve position on power up This method may not be desirable for three reasons 1 It requires a second input on the controller to mea sure valve position 2 The controller and the valve are more expensive 3 Additional wiring is required for the slide wire feed back Other valves take an analog signal and have a local ized control mechanism that regulates the valve posi tio
11. 1 o zn T m D D e D D RS x2 ry Po x Wy Watlow EZ ZONE PM Integrated Controller e 94 o Chapter 8 Factory Page Parameter Name Description Custom Parameter 1 to 20 Select the parameters that will appear in the Home Page The Parameter 1 value will appear in the upper display of the Home Page It cannot be changed with the Up and Down Keys in the Home Page The Parameter 2 value will appear in the lower display in the Home Page It can be changed with the Up and Down Keys if the parameter is a writable one Scroll through the other Home Page parameters with the Advance Key e Custom 1 to 20 Instance ID Select which instance of the parameter will be selected Security Setting Operations Page Change the security level of the Operations Page Security Setting Profiling Page Change the security lev el of the Profiling Page Security Setting Password Enable Turn security features on or off Factory Page Default None Guaranteed Soak De ion 1 Value Guaranteed Soak De ion 2 Value Profile Action Request Profile Start Idle Set Point TRU TUNE Enable Ramp Rate Cool Hysteresis Cool Proportional Heat Hysteresis Heat Proportional Dead Band Time Derivative Time Integral Cool Power Heat Power User Control Mode Autotune Open Loop Set Point Active Set Point Active Process Value Set Po
12. Power Supply 5 to 32 VDC Collector Outputs B7 T Common F m use u An example fuse is Bussmann AGC 1 1 2 E D7 Diode wo m i D8 E k Relay VDC Y A D9 C 4 D10 D11 m D12 mn 27 Supply Internal Circuitry Watlow EZ ZONE PM Integrated Controller e 29 Chapter 2 Install and Wire Warning N N Use National Electric NEC or other country specific standard wiring and safety practices when wiring and connecting this controller to a power source and to electrical sensors or pe ripheral devices Failure to do so may result in damage to equipment and property and or injury or loss of life Note Maximum wire size termination and torque rating 0 0507 to 3 30 mm 30 to 12 AWG single wire termination or two 1 31 mm 16 AWG e 0 8 Nm 7 0 Ib in torque Note Adjacent terminals may be labeled differently depending on the model number Note To prevent damage to the control ler do not connect wires to unused terminals Note Maintain electrical isolation between analog input 1 digital input outputs switched dc open collector outputs and process outputs to prevent ground loops Note The control output common terminal and the digital common terminal are referenced to different voltages and must remain isolated Note This Equipment is suitable for use in CLASS I DIVISION 2 Groups A B C and D or No
13. Alarm silencing is active Alarm blocking is active Alarm is set to incorrect output Alarm is set to incorrect source Alarm set point is incorrect Alarm is set to incorrect type Sensor improperly wired or open ncorrect setting of sensor type Calibration corrupt Temperature is less than alarm set point Alarm is set to latching and an alarm occurred in the past ncorrect alarm set point ncorrect alarm source Temperature is greater than alarm set point Alarm is set to latching and an alarm occurred in the past ncorrect alarm set point ncorrect alarm source Sensor improperly wired or open ncorrect setting of sensor type Calibration corrupt Sensor input is out of limit set point range Limit set point is incorrect Digital input function is incorrect Sensor improperly wired or open ncorrect setting of sensor type Calibration corrupt Temperature is less than limit set point Limit outputs latch and require reset ncorrect alarm set point Reset alarm when process is within range or disable latching Set output to correct alarm source instance Set alarm source to correct input in stance Correct cause of sensor input out of alarm range Set alarm set point to correct trip point Set alarm to correct type process de viation or power Set digital input function and source instance Disable alarm silencing if required Di
14. 0 0 to 9 999 000 F or units 0 0 to 5 555 000 C Instance 1 Map 1 Map2 2192 2672 Instance 2 Map 1 Map2 2272 2752 Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only CIP Class Instance Attribute hex dec Ox6B 107 1to2 OxB 11 0x97 151 1to2 0x16 22 0x97 151 1to2 0x17 23 0x97 151 1to2 0x18 24 Ox6B 107 1to2 OxE 14 Ox6B 107 1to2 OxF 15 0x6B 107 1to2 0x11 17 I J Param eter ID 7011 8039 8040 8041 7014 7015 7017 float RWES uint RWES uint RWES float RWES uint RWES uint RWES float RWES Watlow EZ ZONE PM Integrated Controller 73 Chapter 6 Setup Page Setup Page Parameter Name Description Default Control Loop 1 to 2 Low Set Point Set the minimum value of the closed loop set point range 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C 1 999 F or units 1 128 C Control Loop 1 to 2 High Set Point Set the maximum value of the closed loop set point range 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C 1 999 F or units 1 128 C Control Loop 1 to 2 100 to 100 Set Point Open Limit Low Set the minimum value of the open loop set point range Control Loop 1 to 4 Set Point Open Limit High Set the maximum value of t
15. 1 8th unit load on EIA 485 bus Communications instance 2 Slot B PM 6 _ _ 6 Slot E PM 4 8 9 ot E P _ 6 Profibus Terminal EIA TIA 485 Name eee ase mics Note Maintain electrical isolation between analog input 1 digital input outputs switched dc open collector outputs and process outputs to prevent ground loops mim 3 3 m Note The control output common terminal and the digital common terminal are referenced to different voltages and must remain isolated Note This Equipment is suitable for use in Profibus DP LED Indicators Viewing the unit from the front and then looking on top of the RUI GTW two bi color LEDs can be seen where only the front one is used Definition fol lows Closest to the Front CLASS I DIVISION 2 Groups A B Indicator LED Description C and D or Non Hazardous locations 7 only Temperature Code T4A Red Profibus network not detected Red Indicates that the Profibus card is waiting for data Warning A Flashing exchange Explosion Hazard Substitution of Green Data exchange mode component may impair suitability for CLASS I DIVISION 2 Warning A Explosion Hazard Do not disconnect while the circuit is live or unless the area is known to be free of ignitable concentrations of flammable sub stances Watlow EZ ZONE PM Integrated Controller 37 Chapter 2 Install and Wire Warning A N Use
16. Adjacent terminals may be labeled differently depending on the model number Note To prevent damage to the control ler do not connect wires to unused terminals Note Maintain electrical isolation between analog input 1 digital input outputs switched dc open collector outputs and process outputs to prevent ground loops Note The control output common terminal and the digital common terminal are referenced to different voltages and must remain isolated Note This Equipment is suitable for use in CLASS I DIVISION 2 Groups A B C and D or Non Hazardous locations only Temperature Code T4A Warning AN Explosion Hazard Substitution of component may impair suitability for CLASS I DIVISION 2 Warning A Explosion Hazard Do not disconnect while the circuit is live or unless the area is known to be free of ignitable concentrations of flammable sub stances Digital Input 7 12 Common DC Input DC Input DC Input DC Input DC Input DC Input Supply Input 1 2 Thermocouple lt Slot E B7 01 D7 D8 D9 LI D10 T T D11LT 1 D1211 z7 LI Slot A B Digital Input Event Conditions Dry Contact Input inactive when gt 100KQ Input active when lt 500 Voltage Input inactive when lt 2V Input active when gt 3V Voltage Input e Six user
17. CIP Class Instance Attribute hex dec Param eter ID amp Read Profibus Index Ox6B 107 1to2 0x15 21 Ox6B 107 1to2 0x16 22 0x97 151 1to2 1 0x97 151 1to2 0x14 20 0x97 151 1to2 0x15 21 Ox6B 107 1to2 Ox6B 107 1to2 0x97 151 Watlow EZ ZONE PM Integrated Controller e 52 o Chapter 5 Operations Page Parameter name Description Control Loop 1 to 2 Heat Hysteresis Set the control switch ing hysteresis for on off control This determines how far into the on region the process value needs to move before the output turns on Control Loop 1 to 2 Cool Proportional Band Set the PID proportional band for the cool out puts Control Loop 1 to 2 Cool Hysteresis Set the control switch ing hysteresis for on off control This determines how far into the on region the process value needs to move before the output turns on Control Loop 1 to 2 Time Integral Set the PID integral for the outputs Control Loop 1 to 2 Time Derivative Set the PID derivative time for the outputs Control Loop 1 to 2 Dead Band Set the offset to the proportional band With a negative value both heating and cooling outputs are active when the process value is near the set point A positive value keeps heating and cooling outputs from fighting each other Control Loop 1 to 2 Open Loop Set Point Set a fixed level of out put power when in
18. Each of the menus in the Factory Page and each of the pages except the Factory Page has a security level assigned to it You can change the read and write access to these menus and pages by using the parameters in the Lockout Menu Factory Page Lockout Menu There are five parameters in the Lockout Menu Factory Page Lock Operations Page sets the security level for the Operations Page default 2 Note The Home and Setup Page lockout levels are fixed and cannot be changed Lock Profiling Page sets the security level for the Profiling Page default 3 e Password Security Enable P A S5 will turn on or off the Password security feature default off Read Lockout Security determines which pages can be accessed The user can access the se lected level and all lower levels default 5 e Set Lockout Security determines which pa rameters within accessible pages can be written to The user can write to the selected level and all lower levels default 5 The table below represents the various levels of lock out for the Set Lockout Security prompt and the Read Lockout Security prompt The Set Lockout has 6 lev els 0 5 of security where the Read Lockout has 5 1 5 Therefore level 0 applies to Set Lockout only Y equates to yes can write read where N equates to no cannot write read The colored cells simply dif ferentiate one level from the next
19. Motorized Valve Control Lb Q 9 UM Cor O 0 e y 2o ls lt 47 c Sex Sy E hs Son CDS ue 1 ny hay 7 Uo y Output n Special Function INS Close Lr Output 1 Analog Input 1 Source A Heat Power H Source Function A 1 1 Open H Special Function Control Loop 1 Special Output Function 1 Output 2 Output n Watlow EZ ZONE PM Integrated Controller e 121 Chapter 10 Applications Chapter 11 Appendix Troubleshooting Alarms Errors and Control Issues Alarm won t clear or Alarm will not clear or reset Alarm won t occur Alarm Error Alarm Low Alarm High Error Input Limit won t clear or reset Limit Error L 4L I Limit Low with keypad or digital input Alarm will not activate output Alarm state cannot be deter mined due to lack of sensor input Sensor input below low alarm set point Sensor input above high alarm set point Sensor does not provide a valid signal to controller Limit will not clear or reset with keypad or digital input Limit state cannot be deter mined due to lack of sensor input limit will trip Sensor input below low limit set point Alarm latching is active Alarm set to incorrect output Alarm is set to incorrect source Sensor input is out of alarm set point range Alarm set point is incorrect Alarm is set to incorrect type Digital input function is incorrect
20. Process Value A C P u will be displayed on top and Parameter PAr in the bottom Using the Up or Down Q arrow keys will allow for a customized se lection of choice There are twenty positions available that can be customized Modifying the Display Pairs The Home Page being a customized list of as many as 20 parameters can be configured in pairs of up to 10 via the Display Pairs prompt found in the Diagnostic Menu Factory Page The listing in the table that follows is what one may typically find in the Home Page as defaults based on control ler part numbers It is important to note that some of the prompts shown may not appear simply because the feature is not being used or is turned off As an example the prompt shown in position 7 loop 1 and position 12 loop 2 Pr will not appear unless the Cool algorithm C A 8 is turned on in the Setup Page under the Loop menu If the ninth digit of the part number is C J Lor M eer C J L M the Display Pairs prompt will default to 2 otherwise it will be equal to one As stated above the user can define pairs of prompts to appear on the display every time the Ad vance key is pushed The first pair will always be as defined in the Custom Menu and as stated will default factory settings to the Active Process Value loop 1 AEP ul and the Active Set Point loop 1 RC S P If two channels are present the first 2 pairs will be the same in that the first pair will r
21. SSR Error View the cause of the most recent load fault Current 1 Heater Error View the cause of the most recent load fault monitored by the cur rent transformer Current 1 Error Status View the cause of the most recent load fault Math 1 Source Value A View the value of Source A or Linearization 1 Math 1 Source Value B View the value of Source B or Linearization 2 Math 1 Source Value E Disables Process Devia tion scale when on Math 1 Offset Set an offset to be ap plied to this function s output Math 1 Output Value View the value of this function s output Math 1 Math Output Error View reported cause for math malfunction be read with other interfaces Operations Page non E None 61 Shr t Shorted 127 oP En Open 65 non E None 61 h 9h High 37 Lob uU Low 53 None 61 Fail 32 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C oF F Off 62 on On 63 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C None 61 Open 65 Shorted 127 Measurement error 140 Bad calibration data 139 Ambient error 9 RTD error 14 Fail 32 Math error 1423 Not sourced 246 Stale 1617 Can t process 1659 Available with PM4 PM8 and PM9 models only Modbus Relati
22. erator must take into account the input impedance of the device to be retransmitted to and the required signal type either voltage or milliamps Typically applications might use the retransmit option to record one of the variables with a chart re corder or to generate a set point for other controls in a multi zone application Outputs 1 and 3 can be ordered as process out puts Select retransmit as the Output Func tion Setup Page Output Menu Set the out put to volts or milliamps with Output Type o S Select the signal to retransmit with Retransmit Source _ 5r Range High Output Scale Range Low Scale Low Retransmit Source Scale High Set the range of the process output with Scale Low and Scale High 54 Scale the re transmit source to the process output with Range Low and Range High r h l When the retransmit source is at the Range Low value the retransmit output will be at its Scale Low value When the retransmit source is at the Range High value the retransmit output will be at its Scale High value Cool Output Curve A nonlinear output curve may improve performance when the response of the output device is nonlinear If a cool output uses one of the nonlinear curves a PID calculation yields a lower actual output level than a linear output would provide These output curves are used in plastics extruder applications curve 1 for oil cooled extruders and curve 2 for water cooled extru
23. 0 5A SSR form A Output 3 none switched dc open collector 5A mechanical relay form C process or 0 5A SSR form A T Communications Modbus RTU TCP DeviceNet EtherNet IP Profibus Communications Board Slots E Optional ES utput none 15A NO ARC switched dc 5A mechanical relay form A or 0 5A SSR form A If limit this output must be limit EIA 485 Communication Standard Bus optional Modbus RTU Power Supply None Limit reset Idle set point Tune TRU TUNE Alarm clear request Silence alarm Manual auto mode Control mode Remote set point enable Lock keypad Force alarm Loop amp alarms off Profile disable Profile hold resume Profile start Profile start stop Restore user settings Event inputs Math 100 to 240Vac 20 to 28 Vac or 12 to 40Vdc EZ Key 1 amp 2 Programmable Functions gt Digital Input or Output 5 amp 6 optional Programmable Functions Note Modbus Address 1 247 Standard Bus Zone Address 1 16 Supervisory amp Power Board Slot C Output Function off heat cool retransmit alarm duplex or event off heat cool gt alarm or event off heat cool retransmit alarm duplex or event off heat cool alarm event or limit Digital Outp
24. Available EZ ZONE Devices When complete the software will display all of the available devices found on the network as shown be low Scan Network for EZ ZONE device When the EZ ZONE device that you want to configure appears in the list select it and click Next Available EZ ZONE Devices PM6B2EH 1AAAAAA PM8B2CH 3CCHAAA STCL B2MC BPAA STCL B2MP EPAA RMFEF CCVA A44A EZ Zone PM EZ ZONE PM EZ Zone ST EZ ZONE ST E7 7nana RM Repeat Scan e Watlow EZ ZONE PM Integrated Controller Chapter 9 Features In the previous screen shot the PM is shown high lighted to bring greater clarity to the control in focus Any EZ ZONE device on the network will appear in this window and would be available for the purpose of configuration or monitoring After clicking on the control of choice simply click the next button once again The next screen appears below Watlow EZ ZONE CONFIGURATOR more clarity for the area of focus by not displaying unwanted menus and parameters Once the focus is brought to an individual parameter single click of mouse as is the case for Analog Input 1 in the left column all that can be setup related to that param eter will appear in the center column The grayed out fields in the center column simply mean that this Edit Device Settings On Line Configuring Model Number PMGR4CJ ALEJAAA Parameters are set in the device as you edit them Click Next to see more parameters or clic
25. Chapter 5 Operations Page Operations Page CIP Parameter name Modbus gass Profibus Param Description RAEO ACE Instance Index eter ID dress Attribute hex dec Limit 1 1 999 000 to 9 999 000 F Instance 1 0x70 112 39 12004 float Lh S High Set Point or units Map1 Map2 1 RWES Set the high process 1 128 000 to 5 537 000 C 686 726 4 value that will trigger the limit Limit 1 Off 62 Instance 1 0x70 112 12006 uint Limit State None 61 Mapi1 Map2 1 Clear limit once limit Limit High 51 690 730 6 condition is cleared Limit Low 52 Error 225 Limit 1 Clear 0 Instance 1 0x70 112 12001 Juint Limit Clear Request No Change 255 Map1 Map2 1 W Clear limit once limit 680 720 1 condition is cleared Monitor 1 to 2 oF F Off 62 Instance 1 0x97 151 C MA Control Mode Active AUE o Auto 10 Map1 Map2 1to2 View the current control Manual 54 1882 2362 2 mode Instance 2 Map1 Map2 1952 2432 Monitor 1 to 2 0 0 to 100 0 Heat Power View the current heat output level Monitor 1 to 2 100 0 to 0 0 Cool Power View the current cool output level Instance 1 0x97 151 Map1 Map2 1to2 1904 2384 OxD 13 Instance 2 Map1 Map2 1974 2454 Instance 1 0x97 151 Map1 Map2 1to2 1906 2386 OxE 14 Instance 2 Map1 Map2 1976 2456 2172 2652 7 Instance 2 Map1 Map2 2252 2732 Instance 1 0x68 104 Map1 Map2 1to2 402 402 0x16 22 Instance 2 Map1 Map2 482 492 Instance 1 Ox6B 107 Map1 Ma
26. Class arameter Name B Param n o ded Range Default tive Instance ID Attribute hex dec Special Output 1 1to2 Instance 1 0x87 135 185 35004 Source Instance B Map 2 1 Set the instance of the 4 function selected above Special Output 1 100 00 to 100 0096 Instance 1 0x87 135 186 35018 Power On Level A Map 1 Map2 ai Compressor 1 power on 3874 0x12 18 Instance 1 0x87 135 187 35019 Map 1 Map2 1 3876 0x13 19 Instance 1 0x87 135 188 35020 Map 1 Map2 il 3878 0x14 20 level Special Output 1 100 00 to 100 00 Power Off Level A Compressor 1 power off level Special Output 1 100 00 to 100 00 Power On Level B Compressor 2 power on level Special Output 1 0 to 9 999 seconds Minimum On Time At a minimum stay on specified amount of time Instance 1 0x87 135 190 35022 Map 1 Map2 il 3882 0x16 22 Instance 1 0x87 135 191 35023 Map 1 Map2 1 3884 0x17 23 Instance 1 0x87 135 35024 Map 2 al 0x18 24 Special Output 1 1 0 to 100 0 2 Instance 1 0x87 135 35025 Dead Band Map 2 1 Output power needs to 3888 0x19 25 change by specified level prior to turning on Function Key LEu Function Key 1 to 2 h 9h High 37 Instance 1 Ox6E 110 137 LEv Level Lob Low 53 Map 1 Map2 1 to 2 The Function Key will 1320 1560 1 always power up in the Instance 2 low state Map 1 Map2 Pressing the Function 1340 1580 Key will toggle the se lected
27. Silence Alarms edge red 108 Alarm Reset edge triggered 6 PL of Lock Keypad level triggered 217 uS r c Restore User Settings edge triggered 227 Offset to next instance Map 1 amp Map 2 equals 20 Llc Limit Reset edge trig gered 82 Instance 1 Ox6E 110 Map 1 Map2 1326 4 Offset to next instance Map 1 amp Map 2 equals 20 0x70 19 10003 10004 uint RWES Instance 1 Map 1 Map2 688 728 both Both 13 A 9h High 37 Lobu Low 53 Watlow EZ ZONE PM Integrated Controller 70 Chapter 6 Setup Page Setup Page CIP Class Instance Attribute hex dec Limit 1 0 001 to 9 999 000 F or units Instance 1 0x70 112 Hysteresis 0 001 to 5 555 000 C Map1 Map2 Set the hysteresis for the i 682 722 2 limit function This de termines how far into the safe range the process value must move before the limit can be cleared E Limit 1 1 999 000 to 9 999 000 9 999 000 Instance 1 0x70 112 42 Set Point Limit High Map 1 Map2 1 696 736 9 1 999 000 Instance 1 0x70 112 Map 1 Map2 1 698 738 0x0A 10 Modbus Rela tive Address Param eter ID Parameter Name Description Default 12002 float RWES 12009 float RWES Limit 1 Set Point Limit Low Set the low end of the limit set point range 1 999 000 to 9 999 000 12010 float RWES uint RWES Set the high end of the limit set point range Instance 1 0x70 11
28. Step Type Parameters Instance 1 0x79 121 21015 uint Wait For Process Instance Map2 1to40 RWE Select which analog input Wait 2598 4528 OxOF 15 For Process will use Offset to next instance Map 1 equals 50 Map 2 equals 100 Step Type Parameters 1 999 000 to 9 999 000 F or Instance 1 0x79 121 21011 float Wait For Process Value units i Map1 Map2 1to40 RWE Wait for process value on ana 1 128 000 to 5 537 000 C i 2590 4520 OxOB 11 log input 1 before proceeding in profile Offset to next instance Map 1 equals 50 Map 2 equals 100 Step Type Parameters Off 62 Instance 1 0x79 121 21009 uint Wait Event 5 12 On 63 Mapi Map2 1to10 RWE Select the event state that must None 61 2586 4516 9 DI 5 Event 1 Offset to next be satisfied during this step DI 6 Event 2 instance Map EZ Key 1 Event 3 1 equals 50 EZ Key 2 Event 4 Map 2 equals DI 7 12 represent Events 5 100 through 10 respectively Select the event state that must None 61 2588 4518 OxA 10 be satisfied during this step Digital input 5 provides the Offset to next state of Event 1 and digital instance Map input 6 provides the state of 1 equals 50 Event 2 Map 2 equals 100 Note R Read Some values will be rounded off to fit in the four character display Full values can be read with other Write interfaces F eius Watlow EZ ZONE PM Integrated Controller e 92 Chapter 7 Profiling Page LJE Step Type
29. 0 to 20 mA 100 Q input impedance 0 to 10V dc 20 kQ input impedance 0 to 50 mV dc 20 kO input impedance S1 R1 T1 S1 6 Input 2 PM IGRIL S2 R2 T2 S2 x S S PM 4 8 and 9 only HR amperes volts Input 1 2 Potentiometer Slot A B e Use a 1 KQ potentiometer Input 1 PM _ C R B ___ ______ S1 R1 T1 S1 R1 Input 2 PM C R L ___ SY R1 T1 S1 R1 PM 4 8 and 9 only cw S cow t Input 1 2 Thermistor Slot A B gt 20 MO input impedance 3 microampere open sensor detection SI R1 Input 1 PM Input 2 PM J N E J P M _ S2 R2 amp Input 2 Current Transformer Slot B Input range is 0 to 50 mA 100 input impedance response time 1 second maximum accuracy 1 mA typical T2 PM___ _ T _____ S2 current transformer part number 16 0246 Watlow EZ ZONE PM Integrated Controller e 27 Chapter 2 Install and Wire Warning A N Use National Electric NEC or other country specific standard wiring and safety practices when wiring and connecting this controller to a power source and to electrical sensors
30. 0x76 118 lor3 OxA 10 0x76 118 lor3 OxB 11 lor3 0x76 118 lor3 0x0D 13 0x76 118 lor3 OxOE 14 i li 0x76 118 102 H Param eter ID 18004 18009 18010 18011 18012 18013 18014 Watlow EZ ZONE PM Integrated Controller Chapter 6 Setup Page Parameter Name Description Output Process 1 or 3 Calibration Offset Set an offset value for a process output units ALP Alarm Menu A ty Alarm 1 to 4 Type Select whether the alarm trigger is a fixed value or will track the set point oF F Off 62 Alarm 1 to 4 Source Function A Select what will trigger this alarm 73 Setup Page Default 1 999 000 to 9 999 000 F or 1 110 555 to 5 555 000 C PAL Process Alarm 76 dEAL Deviation Alarm 24 _ Analog Input 142 PL Jc Power Control Loop Pu Process Value 241 Lnr Linearization 238 CUr Current 22 Alarm 1 to 2 Source Instance A Set the instance of the function selected above Alarm 1 to 4 Hysteresis Set the hysteresis for an alarm This determines how far into the safe region the process value needs to move before the alarm can be cleared 0 001 to 5 555 000 C Alarm 1 to 4 Logic Select what the output condition will be during the alarm state Note ALC Close On Alarm 17 AL o Open On Alarm 66 0 001 to 9 999 000 F or units Close On Alarm Some values will
31. 109 9007 Latching Latching 49 Latching Map 1 Map 2 1to4 Turn alarm latching on 1492 1892 7 or off A latched alarm has to be turned off by Offset to next the user instance Map 9008 9006 9016 9021 Watlow EZ ZONE PM Integrated Controller e 78 e Chapter 6 Setup Page 1 equals 50 for Map 2 equals 60 Alarm 1 to 4 oF F Off 62 Blocking St Startup 88 Select when an alarm SEPE Set Point 85 will be blocked After Both 13 startup and or after the set point changes the alarm will be blocked until the process value enters the normal range Instance 1 0x6D 109 Map1 Map2 1 to 4 1494 1894 8 Offset to next instance Map 1 equals 50 for Map 2 equals 60 Instance 1 0x6D 109 Map 1 Map2 1 to 4 1510 1910 0x10 16 Alarm 1 to 4 Off 62 Display On 63 Display an alarm mes sage when an alarm is active Offset to next instance Map 1 equals 50 for Map 2 equals 60 Alarm 1 to 4 0 to 9 999 seconds Delay Set the span of time that the alarm will be delayed after the process value exceeds the alarm set point Instance 1 0x6D 109 Map 1 Map2 1to4 1520 1920 0x15 21 Offset to next instance Map 1 equals 50 for Map 2 equals 60 Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Alarm 1 to 4 oF F Off 62 Off Instance 1 0x6D 109 29 Silencing On 63 Map1 Map2 1to4 Turn alarm silencing on
32. B E 4JIP Fixed Address Part 4 84 87 98 IP Address Mode 86 97 IP Fixed Subnet Part 1 87 IP Fixed Subnet Part 2 87 Oo IP Fixed Subnet Part 3 87 IP Fixed Subnet Part 4 87 Jump Count Remaining 59 Open Loop Detect Devia on 73 Open Loop Detect Enable iPS 1 LPS 8 1P 5 J IP Fixed Subnet Part 3 87 53 B54 Open Loop Detect Time 73 JJ Limit Hysteresis 71 L E I Limit Error 1 41 Limit High 1 41 L 9 Limit Menu 50 70 Linearization 62 L L 5 Limit Low Set Point 50 112 P Lock Profiling Page 95 96 97 112 Linearization Menu 48 64 Security Setting Menu 95 96 97 Locked Access Level 96 Lock Operations Page 95 LooP Control Loop Menu 71 LooP Loop Menu 52 1 Loop Open Error 41 LPo Loop Open Error 1 o r2 41 I Loop Reversed Error 41 l Loop Reversed Er orior2 41 L 5d Limit Sides 70 PAA n Manual Power 73 PAAE Math Menu 56 79 P 15 E Modbus TCP Enable 88 P n Minutes 59 P n Minutes 89 f 1oa Monitor Menu 51 Watlow EZ ZONE PM Integrated Controller e 132 Chapter 11 Appendix 3 3 c Electrical Measurement 98 02 Non volatile Save 85 Calibration Offset 77 Output Control 68 75 Output Function 101 PV Offset 49 Minimum Off Time 81 Output High Power Scale 9 75 Output Low Power
33. C and D or non hazardous locations only Temperature Code T4A UL reviewed to Standard No CSA C22 2 No 213 M1987 Cana dian Hazardous locations PM6 CSA C22 2 No 24 File 158031 Class 4813 02 1 16 DIN CSA Approved Controller User selectable heat cool on off P PI PD PID or alarm action not valid for limit controllers e Auto tune with TRU TUNE adaptive control algorithm Control sampling rates input 10Hz outputs 10Hz Profile Ramp Soak Real Time Clock and Bat tery Back up Accuracy typical x30PPM at 77 F 25 C 30 100 PPM at 4 to 149 F 20 to 65 C Battery type lithium recycle properly Battery typical life three cumulative years of unpowered life at 77 F 25 C Isolated Serial Communications EIA232 485 Modbus RTU EtherNet IP DeviceNet ODVA certified Modbus TCP Profibus DP Wiring Termination Touch Safe Terminals Input power and controller output terminals are touch safe re movable 12 to 22 AWG Universal Input Thermocouple grounded or ungrounded sensors gt 20MO input impedance e 3pA open sensor detection e Max of 2KO source resistance RTD 2 or 3 wire platinum 1000 and 10000 0 C calibration to DIN curve 0 003850 0 C Process 0 20mA 1000 or 0 10V dc 20kO input imped ance Voltage Input Ranges Accuracy 10mV 1 LSD at standard conditions Temperature stability 100 PPM C maximum Milliamp Input Rang
34. If set to Yes all values written to the control will be saved in EE PROM Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only 17029 17030 17031 17041 17042 24009 24010 Instance 1 0x96 150 199 17050 Map 1 Map2 1 2510 2990 6 IlN i Instance 2 96 150 198 17051 Map 1 Map2 2 2514 2994 8 number is a D or 1 other wise 2 Er Watlow EZ ZONE PM Integrated Controller e 88 e Chapter 6 Setup Page Parameter Name Description Real Time Clock Hours Real Time Clock Minutes Real Time Clock Day of Week Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Setup Page C Sun Sunday 1565 Monday 1559 Eu E Tuesday 1560 Wednesday 1561 Thursday 1562 Fr Friday 1563 SAE Saturday 1564 Available with PM4 PM8 and PM9 models only CIP Modbus Rela Class P tive Instance x em Address Attribute Index ceun hex dec Instance 1 88 136 Map 2 1 3 Instance 1 88 136 Map 2 1 4 Instance 1 88 136 Map1 Map2 1 4002 2 Watlow EZ ZONE PM Integrated Controller 89 Chapter 6 Setup Page Chapter 7 Profiling Page Navigating the Profiling Page Note Some of these menus and parameters may not appear depending on the controller s options See
35. Map 1 Map2 3574 Instance 2 Map 2 Instance 1 Map 1 Map2 3594 Instance 2 Map 2 Instance 1 Map 1 Map2 3576 Instance 2 Map 1 Map2 3646 Instance 1 Map 1 Map2 3597 Instance 2 Map 1 Map2 3667 Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only CIP Class Instance Attribute hex dec 0x68 104 1 to 2 0x1A 26 0x86 134 1 to 2 5 0x86 134 1 to 2 0x29 41 0x86 134 1to2 8 0x86 134 1to2 0x12 18 0x86 134 1to2 9 0x86 134 1to2 0x13 19 H Param eter ID 4026 34005 34029 34008 34018 34009 34019 Watlow EZ ZONE PM Integrated Controller e 64 e Chapter 6 Setup Page Note Parameter Name Description Linearization 1 to 2 Input Point 3 Set the value that will be mapped to output 3 Linearization 1 to 2 Output Point 3 Set the value that will be mapped to input 3 Linearization 1 to 2 Input Point 4 Set the value that will be mapped to output 4 Linearization 1 to 2 Output Point 4 Set the value that will be mapped to input 4 Linearization 1 to 2 Input Point 5 Set the value that will be mapped to output 5 Linearization 1 to 2 Output Point 5 Set the value that will be mapped to input 5 Linearization 1 to 2 Input Point 6 Set the value that will be mapped to output 6 Lineariz
36. Map2 1346 1586 60 Hz Instance 1 Map 1 Map2 886 1006 Full values can be read Default None 61 Profile Start Step Profile Start Stop level triggered 208 Pc of Profile Start Number edge triggered 196 PHoL Profile Hold Resume level triggered 207 d 15 Profile Disable level triggered 206 TRU TUNE Dis evel triggered 219 Control Outputs Off triggered 90 Manual Auto Mode level triggered 54 tUnE Tune edge triggered 98 dL E Idle Set Point Enable level triggered 107 AL Force Alarm level triggered 218 figF Alarm Outputs amp Control Loop Off level trig gered 220 Silence Alarms edge triggered 108 LP Alarm Reset edge triggered 6 P L o C Lock Keypad level triggered 217 uS r c Restore User Settings edge triggered 227 LP Limit Reset edge trig gered 82 50 Hz 3 Available with PM4 PM8 and PM9 models only 0x69 105 1 5 0x6A 106 1 4 CIP Class Instance Attribute hex dec Ox6E 110 1to2 3 0x96 110 1to2 4 W Write E EE PROM S User Set Watlow EZ ZONE PM Integrated Controller Chapter 6 Setup Page Parameter Name Description Global Ramping Type Global Profile Type Set the profile startup to be based on a set point or a process value Global Guaranteed Soak En able Enables the guaranteed soak deviation function in profiles Global Guaranteed Soak De
37. Pee Tee 0 to 100 1 Outputn When function is set for Ratio the PV Function output equals Source A as a ratio to Source B Control loop 1 will control Analog Input 1 to Closed Loop Set Point 1 Example 5 Differential Requirements Two analog inputs and the enhanced software option are required and at least one output adjusts the con trolled part of the process Overview Differential control maintains one process at a differ ence to another process Differential N oy Ky Op Ue Analog Input 1 Source A Analog Input 2 Source B Output PV Function So vo 056 2 Output n 0 to 100 Heat Source A Heat Power Cool Power Control Loop 1 Cool ON Cop 0 to 100 Output n When function is set for Differential the PV Function output equals Source A minus Source B Control loop 1 will control Analog Input 1 difference to Analog Input 2 based on Closed Loop Set Point 1 Example 6 Cascade Requirements Two inputs and the enhanced software option are re quired and at least one output adjusts the controlled part of the process Overview Cascade control can handle a difficult process with minimal overshoot while reaching the set point quick ly This minimizes damage to system components and allows for over sizing heaters for optimal heat up rates Heater life is also extended by reducing thermal cycling of
38. Process V mV mA or 1k Potentiometer None Idle set point Tune Alarm clear request Force alarm Silence alarm Manual auto mode Control outputs off Remote set point enable Lock keypad TRU TUNE disable Loop amp alarms off Profile disable Profile hold resume Profile start Profile start stop Restore user settings Event inputs Digital Input or Output 5 amp 6 optional none switch volts dc EZ Key Programmable Event RUI EZ ZONE EIA 485 Communication Controllers PLC PC Standard Bus or HMI optional Modbus RTU Analog Input 2 none CT Thermocouple RTD 100 Input Sensor gt Q 1kQ Thermistor 5kO 10kQ 20kQ 40kQ Process V mV mA or 1k Potentiometer Note PID Controller Optional Ramp Soak max 4 files 40 steps Slots A Optional Address 1 247 Standard Bus Zone Address 1 16 Supervisory amp Power Board Auxillary Input optional Output 1 none switched dc open collector 5A mechanical relay form C process V mA or 0 5A SSR form A Output 2 none 15A NO ARC switched dc 5A mechanical relay form A or 0 5A SSR form A Digital Output or Input 5 amp 6 optional none switched dc Output 3 none switched dc open collector 5A mechanical relay form C process V m
39. Sensor Backup Requirements Two analog inputs and the enhanced software option are required and at least one output adjusts the con trolled part of the process Overview The Sensor Backup feature controls a process based on a primary sensor on Analog Input 1 If this sensor fails then the process is controlled based on the sec ondary sensor on Analog Input 2 When function is set for Sensor Backup the PV Func tion output equals Source A if sensor of Analog Input 1 Sensor Backup 1 1 1 Analog Input 1 Source A 1 Analog Input 2 Source B Output li o 1 PV Function S v Aso i nn A i 7 Output n 1 0 to 100 1 Heat 1 Source A Heat Power i Cool Power Control Loop 1 So SSSR 0 to 100 Output n reading is valid or Source B if sensor reading is invalid Control loop 1 will control the valid Analog Input sensor to Closed Loop Set Point 1 Example 3 Square Root Requirements One analog input and the enhanced software option are required and at least one output adjusts the con trolled part of the process Overview Calculates the square root value of the sensor connect ed to Analog Input 1 When function is set for Square Root the PV Function output equals square root value of Source A Control loop 1 will control Analog Input 1 to Closed Loop Set Point 1 Square Root 1 E 1 N
40. Wet Bulb Dry Bulb 1369 bA Sensor Backup 1201 Ratio 1374 Differential 1373 Square Root 1380 Pressure to Altitude Instance 1 Map 1 Map2 3334 Instance 2 Map 2 Pounds per Square 1671 P8 S c Pascal 1674 Atmosphere 1675 Millibar 1672 Torr 1673 Kilofeet 1677 Instance 1 Feet 1676 Map 1 Map2 3336 Instance 2 Map 1 Map2 3406 Instance 1 Map 1 Map2 3338 Instance 2 Map 2 10 0 to 16 0 Instance 1 Map 1 Map2 3330 Instance 2 Map 2 0 0 to 60 0 seconds Instance 1 Map 1 Map2 1000 1120 DEPE Output 68 L on Input Dry Contact 44 n Input Voltage 193 Offset to next instance Map 1 amp Map 2 equals 30 Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only CIP Class Instance Attribute Index hex dec 123 26021 uint RWES 26028 26029 Ox7E 126 1to2 0x15 21 uint RWES Ox7E 126 1to2 0x1C 28 uint RWES Ox7E 126 1to2 Ox1D 29 Ox7E 126 1to2 Ox1E 30 Ox7E 126 1to2 Ox1A 26 26026 float RWES 0x6A 106 5 to 12 1 26030 float RWES Pressure Altitude calculation is based on the International Standard Atmosphere 1976 Watlow EZ ZONE PM Integrated Controller 67 Chapter 6 Setup Page Dis play Fa Fn Note Parameter Name Description D
41. goods must be be in new condition in the original boxes and they must be returned within 120 days of receipt A 20 per cent restocking charge is applied for all returned stock controls and accessories If the unit is unrepairable you will receive a letter of explanation and be given the option to have the unit returned to you at your expense or to have us scrap the unit Watlow reserves the right to charge for no trouble found NTF returns The EZ ZONE PM User s Manual is copyrighted by Watlow Winona Inc March 2010 with all rights reserved EZ ZONE PM is covered by U S Patent Numbers 6005577 D553095 D553096 D553097 D560175 D55766 and OTHER PATENTS PENDING Table of Contents Chapter 1 Overview llli eee 4 Standard Features and Benefits 000000 cece eee 4 Optional Features and Benefits llle 4 A Conceptual View of the PM liliis 6 Getting Started Quickly llli lessen 7 Chapter 2 Install and Wire 0 0 0 ccc cee ee 16 DIMENSIONS s sa endcr eevee doneeddigaewoeeePiee eee nn 16 Installation l l 20 WING cut tmr ok hien E Rae PAECRRER RPG ERE 22 Chapter 3 Keys and Displays llle 40 Attention CodeS once pe RR Pe rp RERX D REA 41 Chapter 4 Home Page 00 c cece ee I 43 Conventions Used in the Menu Pages 0c cece eeee 45 Chapter 5 Operations Page 0 ccc eee 47 Analog Input Menli i z
42. is 16 mm 0 630 in or less and the distance from the front of the bottom half and the panel is 13 3 mm 0 5265 in or less Removing the Mounted Controller from Its Case 1 From the controller s face pull out the tabs on each side until you hear it click Grab the unit above and below the face and pull forward Pull out the tab on each side until you hear it click 2 Grab the unit above and below the face with two hands and pull the unit out On the PM4 8 9 con trols slide a screwdriver under the pry tabs and turn J N Warning This equipment is suitable for use in class 1 div 2 Groups A B C and D or Non Hazardous loca tions only Temperature Code T4A WARNING EXPLOSION HAZARD Substitu tion of component may impair suitability for class 1 div 2 e WARNING EXPLOSION HAZARD Do not disconnect equipment unless power has been switched off or the area is known to be nonhaz ardous Returning the Controller to its Case 1 Ensure that the orientation of the controller is correct and slide it back into the housing Note The controller is keyed so if it feels that it will not Watlow EZ ZONE PM Integrated Controller lt 90 Chapter 2 Install and Wire slide back in do not force it Check the orientation again and reinsert after correcting Warning 2 Using your thumbs push on either side of the con 3 2 All electrical power to the controller and controlled troller until both latche
43. or b off heat cool gt alarm or event PID Controller Limit or Current Transformer Sense Output 3 none switched dc open collector 5A mechanical relay form C process or 0 5A SSR form A off heat cool retransmit alarm duplex or event CT Output 4 none 15A NO ARC switched dc off heat cool Slots B 5A mechanical relay form A or ig pu es or Optional 0 5A SSR form A If limit this output must be limit Modbus Address 1 247 Digital Output or Input 5 amp 6 gt Off heat cool optional none switched dc alarm or event Standard Bus Zone Address 16 LEDs Z Oym State em Channel Supervisory amp 172 gt Indicates Zone Power Board Address amp Channel 3 4 Indicates I O 5 6 d Status Dn 5 Slot C Number of inputs and outputs and various combinations of the same will vary depending upon part number see ordering matrix for more detail Watlow EZ ZONE PM Integrated Controller 12 Chapter 1 Overview EZ ZONE PM Integrated Model 1 8 and 1 4 DIN System Diagram With 6 Digital 1 0 slot D Without Communications slot E Input Function Output Function PID Output 1 Controller none switched dc open collector 5A mechanical relay form C process V mA or 0 5A SSR form A off heat cool gt alarm retransmit d
44. or units 1 128 000 to 5 537 000 C 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C Available with PM4 PM8 and PM9 models only CIP Modbus Class Relative Ad Instance dress Attribute hex dec Instance 1 0x86 134 34028 uint Map 1 Map2 1 to 2 R 3614 0x1C 28 Instance 2 Map 1 Map2 3684 Instance 1 0x7E 126 26016 float Map 1 Map2 1 to 2 R 3310 0x10 16 Instance 2 Map 1 Map2 3380 Instance 1 Ox7E 126 26017 float Map1 Map2 1to2 R 3312 0x11 17 Instance 2 Map 1 Map2 3382 Instance 1 0x7E 126 26023 float Map1 Map2 1to2 RWES 3324 0x17 23 Instance 2 Map 2 Instance 1 0x7E 126 26022 Map 1 Map2 1 to 2 3322 0x16 22 Instance 2 Map 2 Profibus Param eter ID amp Read Watlow EZ ZONE PM Integrated Controller Chapter 5 Operations Page Parameter name Description Process Value 1 to 2 Output Error View reported cause for Process output malfunc tion Digital Output 5 to 6 Output State View the state of this output Digital Output 7 to 12 Output State View the state of this output Digital Input 5 to 6 Event Status View this event input state Digital Input 7 to 12 Event Status View this event input state EZ Key s 1 to 2 Event Status View this event input state Emp Limit Menu Limit 1 Low Set Point Set the low process value that will trigger the limit Note Op
45. or units or 1 128 000 to 5 537 000 C units 150 0 C Offset to next instance Map 1 equals 50 Offset to next instance Map 2 equals 60 Startup 88 None 61 Blocked 12 Alarm low 8 Alarm high 7 Error 28 Instance 1 Map1 Map2 1496 1896 Offset to next instance Map1 50 Map 2 60 Instance 1 Map1 Map2 1502 1902 no No 59 YES Yes 106 Offset to next instance Map1 1 equals 50 Map 2 equals 60 Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only CIP Class Instance Attribute hex dec Ox6C 108 1 0x30 48 Param eter ID amp Read 8030 uint R 8031 uint W 9002 float RWES 9001 float RWES 9009 uint R 9012 uint R Profibus Index 0x6C 108 1 0x31 49 0x6D 109 1to4 OxC 12 Watlow EZ ZONE PM Integrated Controller 54 o Chapter 5 Operations Page Parameter name Description Alarm 1 to 4 Clear Request Write to this register to clear an alarm Alarm 1 to 4 Silence Request Write to this register to silence an alarm Alarm 1 to 4 Silenced Write to this register to silence an alarm Alarm 1 to 4 Latched Write to this register to silence an alarm Operations Page Clear 0 No Change 255 Silence 1010 Yes 106 No 59 Yes 106 No 59 Relative Ad Instance
46. set point Adjust the derivative with Time Derivative Operations Page Loop Menu Reduced Overshoot Set Point Proportional Band Proportional Band x 2 Heating Slows Temperature Dead Band In a PID application the dead bands above and below the set point can save an application s energy and wear by maintaining process temperature within ac ceptable ranges Proportional action ceases when the process value is within the dead band Integral action continues to bring the process temperature to the set point Using a positive dead band value keeps the two systems from fighting each other 4 Cool ouput Set Point Heafoutput Active Temperature Positive Dead Band gt Time When the dead band value is zero the heat ing output activates when the temperature drops be low the set point and the cooling output switches on when the temperature exceeds the set point 4 Cool output Set Point Heafou ut Active Temperature Zero Dead Band Time When the dead band value is a negative val ue both heating and cooling outputs are active when the temperature is near the set point 4 Temperature Negative Dead Band gt Time Adjust the dead band with Dead Band __ gb Operations Page Loop Menu Watlow EZ ZONE PM Integrated Controller e 107 Chapter 9 Features Variable Time Base Variable time base is the preferred method for
47. 1 Map 1 Map2 1504 1904 Offset to next instance Map1 1 equals 50 Map 2 equals 60 Instance 1 Map 1 Map2 1506 1906 Offset to next instance Map1 1 equals 50 Map 2 equals 60 Instance 1 Map 1 Map2 1500 1900 Offset to next instance Map1 1 equals 50 Map 2 equals 60 Instance 1 Map 1 Map2 1498 1898 Offset to next instance Map1 1 equals 50 Map 2 equals 60 CIP Class Instance Attribute hex dec OxE 14 0x6D 109 1to4 OxOB 11 0x6D 109 1to4 0x0A 10 Curr oPEc Current Menu Current 1 1 999 000 to 9 999 000 Instance 1 0x 73 115 High Set Point Map 1 Map2 1 Set the current value 1134 1374 8 that will trigger a high heater error state Current 1 1 999 000 to 9 999 000 Instance 1 0x73 115 Low Set Point Map 1 Map2 1 Set the current value 1136 1376 9 that will trigger a low heater error state Current 1 1 999 000 to 9 999 000 Instance 1 0x73 115 Read Map 1 Map2 1 View the most recent 1120 1360 1 current value monitored by the current trans former Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only Watlow EZ ZONE PM Integrated Controller e 55 e Chapter 5 Operations Page C Er Note Some values will be rounded off to fit in the four character display Full values can Parameter name Description Current 1
48. 1 999 000 to 9 999 000 F Instance 1 0x86 134 34006 float Offset or units Map 1 Map2 1 to 2 RWES Set an offset to be ap 1 128 000 to 5 537 000 C 3570 6 plied to this function s Instance 2 Analog Input 1 to 2 1 999 000 to 9 999 000 F Instance 1 0x68 104 Process Value or units Map 1 Map 2 1 to 2 View the process value 1 128 000 to 5 537 000 C 360 360 1 Instance 2 Map 1 Map 2 440 450 C Er Analog Input 1 to 2 None 61 Instance 1 0x68 104 1 i Er Error Status Open 65 ap 1 Map 2 1 to2 View the cause of the Fail 82 62 362 2 most recent error If Shorted 127 Instance 2 the message is i Measurement Er or Er 12 this 40 parameter will display j Bad Calibration the cause of the input 139 error Ambient Error 9 c RTD Error 141 N Sr c Not Sourced 246 408 Analog Input 1 to 2 1 999 000 to 9 999 000 F 0x68 104 i CA Calibration Offset or units 1to2 Offset the input reading 1 110 555 to 5 555 000 C 0xC 12 to compensate for lead wire resistance or other factors that cause the in put reading to vary from the actual process value Birak output Map 2 Linearization 1 to 2 1 999 000 to 9 999 000 F Instance 1 0x86 134 34007 Output Value or units Map 1 Map2 1 to 2 View the value of this 1 128 000 to 5 537 000 C 3572 7 function s output Instance 2 Map1 Map2 3642 Note Some values will be rounded off to fit in the four character display Full values can
49. 1 Set Point and produce a remote set point to Control Loop 2 based on the math scaling Control Loop 2 will control Analog Input 2 to the scaled value from the Math Function interpreted as a remote set point Example 7 Wet Bulb Dry Bulb Requirements Two analog inputs and the enhanced software option are required and at least and at least outputs adjusts the controlled part of the processes Overview Wet Bulb Dry Bulb is a configuration where a dry bulb connected to Analog Input 1 measures temperature on Analog Input 1 A wet bulb sensor that is maintained with moisture has air moved over the sensor As mois ture evaporates from the wet bulb the temperature drops wet bulb input on Analog Input 2 in combi nation with the dry bulb temperature senses relative humidity The controller calculates the temperature difference between the two sensors to determine per cent relative humidity The humidify and dehumidify outputs are disabled when Analog Input 1 temperature falls below 32 F 0 C or goes above 212 F 100 C When function is set for Wet Bulb Dry Bulb the PV Function output equals calculated humidity Control loop 1 will control Analog Input 1 to Closed Loop Set Point 1 Control loop 2 will control Analog Input 2 to Closed Loop Set Point 2 Watlow EZ ZONE PM Integrated Controller e 119 Chapter 10 Applications Wet Bulb Dry Bulb
50. 3 X3 W3 Y3 PM __ __ C Switched DC E lg common 7 Iw dc O re 24V e a dc Q bohosctonlctesncond Open Collector common dc Power Supply O Q Q Load Output 1 3 Mechanical Relay Form C SlotA B e 5 A at 240V ac or 30V de normally open L_ maximum resistive load common K 20 mA at 24V minimum load 125 VA pilot duty at 120 240V ac 25 VA at 24V ac 100 000 cycles at rated load Output does not supply power for use with ac or dc See Quencharc note Output 1 LLK1 J1 normally closed J PM E _ Output 3 L3 K3 J3 PM __ E L oe K common J normally open normally closed Output 1 3 Universal Process 0 to 20 mA into 800 Q maxi Slot A B mum load Volt or currents e 0 to 10V dc into 1 kQ mini Voli mum load G scalable euren output supplies power cannot use voltage and current outputs at same time Output may be used as re transmit or control Output 1 F1 G1 H1 PM F _ Output 3 F3 G3 H3 PM __ F ___ Oto 10V HF negative Its Watlow EZ ZO
51. 4 to 20 mA input the scale low value would be 4 00 mA and the scale high value would be 20 00 mA Commonly used scale ranges are 0 to 20 mA 4 to 20 mA 0 to 5V 1 to 5V and 0 to 10V You can create a scale range representing other units for special applications You can reverse scales from high values to low values for analog input sig nals that have a reversed action For example if 50 psi causes a 4 mA signal and 10 psi causes a 20 mA signal Scale low and high low values do not have to match the bounds of the measurement range These along with range low and high provide for process scaling and can include values not measureable by the control ler Regardless of scaling values the measured value will be constrained by the electrical measurements of the hardware Select the low and high values with Scale Low and Scale High _ h Select the displayed range with Range Low and Range High Setup Page Analog Input Menu Range High and Range Low With a process input you must choose a value to rep resent the low and high ends of the current or voltage range Choosing these values allows the controller s display to be scaled into the actual working units of measurement For example the analog input from a humidity transmitter could represent 0 to 100 per cent relative humidity as a process signal of 4 to 20 mA Low scale would be set to 0 to represent 4 mA and high scale set to 100 to represent 20 mA The in dicatio
52. 5to12 1002 1122 2 Offset to next instance Map 1 amp Map 2 equals 30 Instance 1 0x6A 106 Map 1 Map2 5to12 1004 1124 3 Offset to next instance Map 1 amp Map 2 equals 30 Instance 1 0x6A 106 Map 1 Map2 5to12 1016 1136 9 Offset to next instance Map 1 amp Map 2 equals 30 Watlow EZ ZONE PM Integrated Controller 68 o Chapter 6 Setup Page Setup Page CIP Modbus Rela Class Parameter Name Param DEA Range Default tive Instance cir ID Address Attribute hex dec 6010 float RWES 10001 uint RW 10001 uint RW Digital Output 5 to 12 0 0 to 100 0 Instance 1 0x6A 106 High Power Scale Map 1 Map2 5to12 The power output will 1018 1138 OxA 10 never be greater than the value specified and Offset to next will represent the value instance Map at which output scaling 1 amp Map 2 stops equals 30 Digital Input 5 to 6 h 9h High 37 i Instance 1 Ox6E 110 137 Level Low 53 Map1 Map2 1to2 Select which action will 1320 1560 1 be interpreted as a true state Offset to next instance Map 1 amp Map 2 equals 20 Digital Input 7 to 12 High 37 i Instance 1 Ox6E 110 Level Lob Low 53 Map1 Map2 5to12 Select which action will 1640 1 be interpreted as a true state Offset to next instance Map 2 equals 20 Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available wi
53. 62 Motorized Valve Compressor Control None 61 Power Control Loop GSEnA SFn A Special Output 1 Source Function A Set the type of function that will be used for this Source Heat Power Control Loop 160 Cool Power Control 161 Special Output 1 Source Instance A Set the instance of the function selected above S A S A SFab SFn b Special Output 1 Source Function B Set the type of function that will be used for this source None 61 PL Jc Power Control Loop 73 amp P c Heat Power Control Loop 160 Cool Power Control Loop 161 Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only CIP Class Instance Attribute hex dec Instance 1 0x7D 125 Map 2 1 0x18 24 Instance 1 0x7D 125 Map 2 1 0x19 25 0x7D 125 Map 2 1 3052 Instance 1 Map 1 Ox1B 27 Instance 1 0x7D 125 Map 2 1 Ox1C 28 Instance 1 0x7D 125 Map 1 Map2 1 3050 Ox1A 26 1 0 1 0 ff 1 Modbus Rela Default tive Address O Instance 1 0x87 135 Map 1 Map2 1 3856 9 None Instance 1 0x87 135 Map 1 Map2 1 3840 1 Instance 1 0x87 135 Map 2 1 3 None Instance 1 0x87 135 Map 1 Map2 1 3842 2 Watlow EZ ZONE PM Integrated Controller Chapter 6 Setup Page Setup Page CIP P Modbus Rela
54. 99 Power input ac or dc CC Standard Bus or Modbus RTU EIA 485 common Standard Bus or Modbus CA Standard Bus or Modbus RTU EIA 485 T R PM 1 CB Standard Bus or Modbus RTU EIA 485 T R CF Standard Bus EIA 485 common PM A D 2 3 5 _ CD Standard Bus EIA 485 T R CE Standard Bus EIA 485 T R B5 Digital input output common PM 2 D6 Digital input or output 6 PM 4 D5 Digital input or output 5 Back View Back View Slot Orientation 1 8 Slot Orientation DIN Vertical PM8 1 8 DIN Horizontal PM9 Watlow EZ ZONE PM Integrated Controller e 23 e Chapter 2 Install and Wire Back View Back View Slot Orientation Slot Orientation 1 4 DIN Horizontal PM4 1 16 DIN PM6 Note Slot B above can also be configured with a communications card PM Integrated Isolation Block Low voltage Isolation 42V peak Safety Isolation 2300V ac Watlow EZ ZONE PM Integrated Controller e 24 e Chapter 2 Install and Wire Warning AN A Use National Electric NEC or other country specific standard wiring and safety practices when wiring and connecting this controller to a power source and to electrical sensors or pe ripheral devices Failure to do so may result in damage to equipment and property and or injury or loss of life Note Maximum wire size termination and torque rating 0 0507 to 3 30 mm 30 to 12 AWG single wire termination or two 1 31 mm 16 AWG e 0 8 Nm 7 0 Ib in torque Note Adjacent termina
55. Bus network uses EIA 485 as the interface Most PCs today would require a USB to EIA 485 converter However some PCs may still be equipped with EIA 232 ports therefore an EIA 232 to EIA 485 converter would be required As can be seen in the above screen shot the software provides the user with the option of downloading a previously saved configuration as well as the ability to create a configuration off line to download later The screen shots that follow will take the user on line After clicking the next button above it is necessary to define the communications port on the PC to use amp Watlow EZ ZONE CONFIGURA Select a Communications Port If you don t know which communications port on your computer is connected to the EZ ZONE device EZ ZONE CONFIGURATOR can search for you With which Communications Port do you want to communicate Advanced en The available options allow the user to select Try them all or to use a specific known communications port After installation of your converter if you are not sure which communications port was allocated select Try them all and then click next The screen to follow shows that the software is scanning for devices on the network and that progress is being made e Watlow EZ ZONE CONFIGURA L Scan Network for EZ ZONE device When the EZ ZONE device that you want to configure appears in the list select it and click Next Came Help
56. Capabilities e Easily handle complex process problems such as cascade ratio differential square root motorized valve control without slidewire feedback wet bulb dry bulb and compressor control Full featured Alarms e Improves operator recognition of system faults Control of auxiliary devices Ten Point Linearization Curve e Improves sensor accuracy Remote Set Point Operation e Supports efficient set point manipulation via a master control or PLC Retransmit Output e Supports industry needs for product process re cording Profile Capability e Preprogrammed process control e Ramp and soak programming with four files and 40 total steps Watlow EZ ZONE PM Integrated Controller Chapter 1 Overview A Conceptual View of the PM The flexibility of the PM s software and hardware al lows a large range of configurations Acquiring a bet ter understanding of the controller s overall function ality and capabilities while at the same time plan ning out how the controller can be used will deliver maximum effectiveness in your application It is useful to think of the controller in terms of functions there are internal and external functions An input and an output would be considered external functions where the PID calculation or a logic func tion would be an internal function Information flows from an input function to an internal function to an output function when the controller is properly con figured A
57. Chapter 5 Operations Page Parameter name Description Control Loop 1 to 2 Loop Error Open Loop detect devia tion has been exceeded Control Loop 1 to 2 Clear Loop Error Current state of limit output Alarm 1 to 4 Low Set Point If Alarm Type Setup Page Alarm Menu is set to process set the process value that will trigger a low alarm deviation set the span of units from the closed loop set point that will trigger a low alarm A negative set point rep resents a value below closed loop set point A positive set point rep resents a value above closed loop set point Alarm 1 to 4 High Set Point If Alarm Type Setup Page Alarm Menu is set to process set the process value that will trigger a high alarm deviation set the span of units from the closed loop set point that will trigger a high alarm Alarm 1 to 4 State Current state of alarm A Lo Ahi Alarm 1 to 4 Clearable Current state of alarm Note Operations Page Modbus Relative Ad dress None 61 Open Loop 1274 Reversed Sensor 1275 Instance 1 Map 1 Map2 1798 Clear 129 Ignore 204 Instance 1 Map 1 Map2 1800 Instance 1 Map 1 Map2 1482 1882 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C Offset to next instance Map 1 equals 50 Offset to next instance Map 2 equals 60 Instance 1 Map 1 Map2 1480 1880 1 999 000 to 9 999 000 F 300 0 F
58. Factory Page 94 pages and menus 41 Profiling Page 90 Setup Page 47 60 No arc Relay 104 Non volatile Save 61 O on off control 106 Open Loop Detect Deviation 73 Open Loop Detect Enable 73 Open Loop Detection 111 Open Loop Detect Time 73 Open Loop Set Point 53 Operations Page 47 ordering information Watlow EZ ZONE PM Integrated Controller integrated controller models 131 output activity lights 40 output configuration 105 Output Function 75 Output Menu 74 Output Point 1 60 Output Point 2 60 Output Point 3 60 Output Point 4 60 Output Point 5 60 Output Point 6 60 Output Point 7 60 Output Point 8 60 Output Point 9 60 Output Point 10 60 output power scaling 105 outputs 6 Output State 50 Output Type 75 P P3T armor sealing system 4 Parameter 1 to 20 95 Parity 85 Part Number 97 Password 97 Peltier Delay 60 72 percent units indicator light 40 Power Off Level A 61 Power On Level A 61 Power Out Time 61 83 Pressure Units 60 process alarms 110 Process Error Enable 63 Process Error Low 63 Process Value 48 60 67 Process Value Active 51 Process Value Menu 49 Profibus Address Lock 86 Profibus DP 37 46 Profibus Node Address 86 profile activity light 40 Profile Status Menu 58 Profile Type 83 Profiling Page 90 profiling parameters 90 programming the Home Page 100 proportional control plus integral PI control 107 plus integral plus derivative PID control 107 Protocol 84 Public Key 96 Q R Ramp Act
59. Force alarm TRU TUNE disable Loop amp alarms off Profile disable Modbus TE Git Bett ead Profile hold resume Digital Input or Output 5 amp 6 optional Address 1 247 Digital Output or Input 5 amp 6 alam or eveni Profile start Programmable Functions optional none switched dc Profile start stop Restore user settings Event inputs Math EZ Key 1 amp 2 Standard Bus Programmable Functions RE E P dap LEDs Output Statis pane Channel TTA Indicates Zone RUI EZ ZONE EIA 485 Communication 2 Pi Controllers PLC PC Standard Bus Supervisory amp Address amp Channel or HMI optional Modbus RTU Power Board 3 4 Indicates I O 5 6 P Status d 100 to 240Vac Packs SUT a 20 to 28 Vac or 12 to 40Vde Sone nS Note Number of inputs and outputs and various combinations of the same will vary depending upon part number see ordering matrix for more detail Watlow EZ ZONE PM Integrated Controller e 13 Chapter 1 Overview EZ ZONE PM Integrated Model 1 8 and 1 4 DIN with CT System Diagram Without 6 Digital 1 0 slot D Without Communications slot E Input Output Function Function PID Output 1 Controller none switched dc open collector 5A mechanical relay form C process or 0 5A SSR form A off heat cool retransmit alarm duplex or event Analog Input 1 none Thermocouple RTD 1000 _ 1KQ Thermistor 5kO 10kQ 20kQ 40kQ Process V
60. Function Source Function E Source Instance E Input Scale Low Input Scale High Output Range Low Output Range High Filter m 3 n 3 em i D r o A c ra Ll a E Special Output Function Menu F n Function Source Function A Source Instance A Source Function B Source Instance B Power On Level A Power Off Level A Power On Level B Power Off Level B Minimum On Time Minimum Off Time Valve Travel Time Dead Band 3 0 n 3 o Oro o o Da dD oo oo Oma ojo o 2 fr o frm fr fr a e FUn SEE Function Key Menu I to F Un Function Key LE Level Fa Digital Input Function Instance o o r ve E Global Menu r3 F F m e 3 Fr Le Y D Pr uc o to un Pm to Un Q LO wn Q M u e o o rr EN 3 m Q Pu o 3 em F3 m D 3 e Oo 4 wn e er c Un un Cz Ser corm Display Units AC Line Frequency Ramping Type Profile type Guaranteed Soak Enable Guaranteed Soak Devia tion 1 Guaranteed Soak Devia tion 2 Source instance A Source instance B Power Out Time Communications LED Act ion Zone Action Channel Action Display Pairs Menu Display Timer User Save Use
61. High Set the maximum value of the retransmit value range in process units When the retransmit source is at this value the retransmit output will be at its Scale High value Output Process 1 or 3 Low Power Scale The power output will never be less than the value specified and will represent the value at which power scaling begins Output Process 1 or 3 High Power Scale The power output will never be greater than the value specified and will represent the value at which power scaling stops with other interfaces Setup Page 100 0 to 100 0 100 0 to 100 0 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C 9 999 0 F or units 5 537 0 C 0 0 to 100 0 0 to 100 Available with PM4 PM8 and PM9 models only Full values can be read Modbus Rela tive Address Instance 1 Map 1 Map2 726 846 Instance 3 Map 1 Map2 806 926 Instance 1 Map 1 Map2 736 856 Instance 3 Map 1 Map2 816 936 Instance 1 Map 1 Map2 738 858 Instance 3 Map 1 Map2 818 938 Instance 1 Map 1 Map2 740 860 Instance 3 Map 1 Map2 820 940 Instance 1 Map 1 Map2 742 862 Instance 2 Map 1 Map2 822 942 Instance 1 Map 1 Map2 744 864 Instance 2 Map 1 Map2 824 944 Instance 1 Map 1 Map2 746 866 Instance 2 Map 1 Map2 826 946 CIP Class Instance Attribute hex dec 0x76 118 lor3 4 0x76 118 lor3 9
62. Input Point 8 60 Input Point 9 60 Input Point 10 60 inputs 6 Input Sensor Type 101 installation 20 Instance 82 Integrate 71 IP Address Mode 86 97 IP Fixed Address Part 1 86 97 IP Fixed Address Part 2 86 97 IP Fixed Address Part 3 86 97 IP Fixed Address Part 4 84 87 98 IP Fixed Address Part 5 87 IP Fixed Address Part 6 87 IP Fixed Subnet Part 1 87 IP Fixed Subnet Part 2 87 88 IP Fixed Subnet Part 3 87 IP Fixed Subnet Part 4 87 J Jump Count 93 Jump Count Remaining 59 Jump Step 93 K keys 40 L Latching 78 111 Level 81 Watlow EZ ZONE PM Integrated Controller 134 Chapter 11 Appendix Limit Menu 50 70 Linearization 60 62 Linearization Menu 48 64 Locked Access Level 96 Lock Operations Page 112 Lockout Menu 112 Lock Profiling Page 112 Logic 77 Loop Menu 52 Low Power Scale 68 75 low range 103 low scale 103 Low Set Point Alarm 54 110 Current 55 111 Limit 50 Loop 74 103 Manual Control Indicator Light 106 manual open loop control 105 manual tuning 100 Math 61 Math Menu 56 79 Message Action 41 message display 41 Minimum Off Time 61 Minimum On Time 61 Minutes 91 92 Modbus Default Assembly Structure 80 119 126 Modbus Programmable Memory Blocks 125 Modbus Register Mapping 61 Modbus TCP 34 Modbus TCP Enable 88 Modbus Using Programmable Memory Blocks 114 Modbus Word Order 85 Monitor Menu 51 Motorized Valve Control 110 120 N navigating
63. Integrated Controller e 125 Chapter 11 Appendix Modbus Default Assembly Structure 80 119 Assembly Definition Assembly Definition Addresses Assembly Working Registers Assembly Working Default Pointers Addresses Default Pointers Registers Registers 80 amp 81 Registers 240 amp 241 Registers 100 amp 101 Registers 260 amp 261 Pointer 21 360 amp 361 Analog Input 1 Proces Value o Value of Pointer 21 Registers 82 amp 83 Pointer 22 362 amp 363 Registers 242 amp 243 Analog Input 1 Error Status Value of Pointer 22 Registers 84 amp 85 Pointer 23 440 amp 441 Analog Input 2 Proces Value n Registers 244 amp 245 Value of Pointer 23 Registers 86 amp 87 Pointer 24 442 amp 443 Registers 246 amp 247 Analog Input 2 Error Status Value of Pointer 24 Registers 88 amp 89 Pointer 25 1496 amp 1497 Alarm 1 State Registers 248 amp 249 Value of Pointer 25 Registers 90 amp 91 Pointer 26 1546 amp 1547 Alarm 2 State Registers 250 amp 251 Value of Pointer 26 Registers 92 amp 93 Pointer 27 1596 amp 1597 Alarm 3 State Registers 252 amp 253 Value of Pointer 27 Registers 94 amp 95 Pointer 28 1646 amp 1647 Alarm 4 State Registers 2
64. Profiling Page 0 ccc ee ee 90 Profiling Mani zs ig ides adhd did ed DRE Dh bb wanes d 91 Chapter 8 Factory Page 0 cece eee ee eee 94 CUSTOM isses e ob Res ERR bees cbuge ace esaaeeneeeeege 95 POC ei TU eer 95 Unlock MENU 1e gre bhp ee RET RETE ERE re Reyes 96 Diagnostics Ment coni ihr CRURA reor Rehd en 97 Calibration Merl err ux RE RE ERR RI RO RES 98 Chapter 9 Features llli 99 Saving and Restoring User Settings 0 0c cece ee 100 Tuning the PID Parameters 0 0 00 cece eee eens 100 INPUTS aces arra ber aongwasueed donee dul v ae tewan warded 102 Anc ETE 104 Control M thi ds prse RR Rx RT RE eR 105 Y EM CM TI eae dak oe aa Reka Lm 110 Open Loop Detection 0 ccc cece cece eee eens 111 Programming the EZ Key S 0 00 cc cece eee eee eee 111 Using Password Security 113 Modbus Using Programmable Memory Blocks 114 CIP Communications Capabilities 0 0 0 0 ee eee 114 Software Configuration 115 Chapter 10 Applications 0 0 ccc cee eee ees 118 Example 1 Single Loop Control 00005 118 Example 2 Sensor Backup 0 cece eee eee 118 Example 3 Square Root 00c eee eee eee 118 Watlow EZ ZONE PM Integrated Controller e2e Table of Contents Table of Contents cont Example 4 Ratio llis 118 Example 5 Differential llle 119 Example 6
65. Supervisory amp 422572 Indicates Zone Power Board Address amp Channel 3 4 RUI EZ ZONE EIA 485 Communication i Controllers PLC PC Standard Bus 5 6 a nes id or HMI optional Modbus RTU 7 8 100 to 240Vac Fowersuppiy AEE 20 to 28 Vac or 12 to 40Vdc Slot C Note Number of inputs and outputs and various combinations of the same will vary depending upon part number see ordering matrix for more detail Watlow EZ ZONE PM Integrated Controller e 14 Chapter 1 Overview EZ ZONE PM Integrated Model 1 8 and 1 4 DIN System Diagram Without 6 Digital 1 0 slot D With Communications slot E Input Function Input Sensor I v RUI EZ ZONE Controllers PLC PC or HMI a pM none Thermocouple RTD 1000 1kQ Thermistor 5kO 10kO 20kO 40kQ Process V mV mA or 1k Potentiometer none CT Thermocouple RTD 100 Input Sensor O 1kQ Thermistor 5kQ 10kQ 20kQ 40kQ Process V mV mA or 1k Potentiometer Analog Input 1 PID Controller Optional Ramp Soak max 4 files 40 steps Slots A Optional yO i ud Analog Input 2 PID Controller Limit or Current Transformer Sense CT Slots B Optional Output 1 none switched dc open collector 5A mechanical relay form C process or 0 5A SSR form A N none 15A NO ARC switched dc 5A mechanical relay form A or Output 2
66. Zone Address Profile hold resume EZ Key 1 16 Profile start Profile start stop Restore user settings Event inputs Programmable Event Supervisory amp Power Board RUI EZ ZONE Controllers PLC P or HMI EIA 485 Communication Standard Bus optional Modbus RTU Slot C Current Output 3 Transformer none switched dc open collector 5A Board mechanical relay form C process optional V mA or 0 5A SSR form A off heat cool alarm retransmit duplex event Output 4 none 15A NO ARC switched dc off heat cool 5A mechanical relay form A or g elem weni 0 5A SSR form A Current m Analog Input 2 Transformer Current Transformer Output Status 44 one 1 2 __ Indicates Zone Address 3 4 Indicates I O 5 6 Status Note Number of inputs and outputs and various combinations of the same will vary depending upon part number see ordering matrix for more detail Current Monitoring detects heater current flow provides an alarm indication of a failed load issue Watlow EZ ZONE PM Integrated Controller e e Chapter 1 Overview EZ ZONE PM Integrated Model 1 16 DIN System Diagram With Auxillary Input Without Communications Card Slot B Input Functions Analog Input 1 none Thermocouple RTD 1000 Input Sensor gt 1kQ Thermistor 5KQ 10kQ 20kQ 40kQ
67. as a digital input by toggling the function assigned to it in the Digital Input Function parameter in the Function Key Menu Setup Page Internal Functions Functions use input signals to calculate a value A function may be as simple as reading a digital input to set a state to true or false or reading a tempera ture to set an alarm state to on or off Or it could compare the temperature of a process to the set point and calculate the optimal power for a heater To set up an internal function it s important to tell it what source or instance to use For example an alarm may be set to respond to either analog in put 1 or 2 instance 1 or 2 respectively Output Functions Outputs can perform various functions or actions in response to information provided by a function such as operating a heater driving a compressor turning a light on or off unlocking a door etc Assign an output to a Function in the Output Menu or Digital Input Output Menu Then select which instance of that function will drive the select ed output For example you might assign an output to respond to alarm 4 instance 4 or to retransmit the value of analog input 2 instance 2 You can assign more than one output to respond to a single instance of a function For example alarm 2 could be used to trigger a light connected to output 1 and a siren connected to digital output 5 Input Events and Output Events Input and output events are intern
68. assembly into the panel cutout 2 While pressing the case assembly firmly against the panel slide the mounting collar over the back of the controller If the installation does not require a NEMA 4X seal simply slide together until the gasket is compressed Place the blade of a screw driver in any of the corner of the mounting collar assembly Slide the mounting collar over the back of the controller 3 Fora NEMA 4X UL50 IP66 seal alternately place and push the blade of a screwdriver against each of the the four corners of the mounting col lar assembly Apply pressure to the face of the controller while pushing with the screwdriver Don t be afraid to apply enough pressure to prop erly install the controller The seal system is compressed more by mating the mounting collar tighter to the front panel see pictures above If you can move the case assembly back and forth in the cutout you do not have a proper seal The tabs on each side of the mounting collar have 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 time Note There is a graduated measurement difference be tween the up per and lower half of the display to the panel In order to meet the seal requirements mentioned above ensure that the distance from the front of the top half of the display to the panel
69. be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only Modbus Rela tive Address Instance 1 Map 1 Map2 732 852 Instance 2 Map 1 Map2 812 932 Instance 1 Map 1 Map2 1508 1908 Offset to next instance Map 1 amp Map 2 equals 60 Instance 1 Map 1 Map2 1512 1912 Offset to next instance Map 1 amp Map 2 equals 60 Instance 1 Map 1 Map2 1514 1914 Instance 2 Map 1 Map2 1564 1974 Instance 1 Map 1 Map2 1484 1884 Offset to next instance Map 1 equals 50 for Map 2 equals 60 Instance 1 Map 1 Map2 1488 1888 Offset to next instance Map 1 equals 50 for Map 2 equals 60 CIP Class Instance Attribute hex dec 0x76 118 lor3 7 Param eter ID 0x6D 109 1to4 OxF 15 0x6D 109 1to4 0x11 17 0x6D 109 1to2 0x12 18 0x6D 109 1to4 3 0x6D 109 1to4 5 Watlow EZ ZONE PM Integrated Controller e 77 Chapter 6 Setup Page Setup Page CIP Modbus Rela Class Parameter Name X Param DOS Range Default tive Instance p Address Attribute hex dec Alarm 1 to 4 bot hj Both 13 Both Instance 1 0x6D 109 9004 Sides h 9h High 37 Mapi1 Map2 1to4 Select which side or sides L o 5 J Low 53 1486 1886 4 will trigger this alarm Offset to next instance Map 1 equals 50 for Map 2 equals 60 Alarm 1 to 4 Non Latching 60 Non Instance 1 0x6D
70. configurable digital in puts outputs per slot Dry Contact Slot E DIO 7 12 PM 4 6 8 ___ C D ____ Input 1 PM C R B Input 2 PM __ 2K Q maximum source resistance gt 20 MQ input impedance 3 microampere open sensor detection Thermocouples are polarity sensitive The negative lead usually red must be connected to S1 To reduce errors the extension wire for thermocouples must be of the same alloy as the thermocouple C R L S2 R2 PM 4 8 and 9 only Input 1 2 RTD Slot A B Slot A B S2 e platinum 100 and 1 000 Q 0 C calibration to DIN curve 0 00385 0 0 C e 20 Q total lead resistance RTD excitation current of 0 09 mA typical Each ohm of lead resistance may affect the reading by 0 03 C For 3 wire RTDs the S1 lead usually white must be con nected to R1 E T For best accuracy use a 3 wire RTD to compensate for lead 8 ss length resistance All three lead wires must have the same S IR R resistance Bem 2 Input 1 PM_ C R B ___ _______ S RD TISYRI wre Input 2 PM C R L S2 R2 T2 S2 R2 PM 4 8 and 9 only Watlow EZ ZONE PM Integrated Controller e 26 e Chapter 2 Install and Wire Warning AN A Use National Electric NEC or other country specific standard wiring and safety practices
71. devices Watlow EZ ZONE PM Integrated Controller 39 Chapter 2 Install and Wire Chapter 3 Keys and Displays Upper Display In the Home Page displays the process value otherwise displays the value of the parameter in the lower display Zone Display Temperature Units 1 8 DIN PM8 Horizontal WATLOW Indicates whether the temperature is displayed in Fahrenheit or Cel sius EZ ZONE9 Percent Units Indicates the controller zone 1 to 9 zones 1 to 9 A zone 10 E zone 14 b 2 zone 11 F zone 15 C zone 12 h zone 16 d zone 13 Lower Display 1234E2 A 567 8 EZ Lights when the controller is dis playing values as a percentage or when the open loop set point is dis played 1 16 PM6 DIN EZ ZONE Output Activity Number LEDs indicate activity of outputs A flashing light indicates Indicates the set point or output power value during operation or the param eter whose value appears in the upper display ee EZ Key s p di This key can be programmed to do various tasks such as starting a pro file Channel Display Indicates the channel for any given EZ ZONE module Available with the PM4 8 and 9 only Advance Key Advances through para meter prompts N output activity din cm Profile Activity Lights when a profile is running Flashes when a profile is paused 1 8 DIN PM9 Ver
72. fin Manual Fixed sets output power to Manual Power setting 33 USE c User sets output pow er to last open loop set point the user entered 100 Note 0 to 100 CIP Class Instance Attribute hex dec 0x97 151 1to2 0x11 17 Modbus Rela tive Address Instance 1 Map 1 Map2 1912 2392 Instance 2 Map 1 Map2 1982 2462 0x97 151 1to2 0x12 18 Instance 1 Map 1 Map2 1914 2394 Instance 2 Map 1 Map2 1984 2464 0x97 151 1to2 0x13 19 Instance 1 Map 1 Map2 1916 2396 Instance 2 Map 1 Map2 1986 2466 0x97 151 1to2 0x1C 28 Instance 1 Map 1 Map2 1934 2414 Instance 2 Map 1 Map2 2004 2484 Ox6B 107 1to2 OxC 12 Instance 1 Map 1 Map2 2182 2662 Instance 2 Map 1 Map2 2262 2742 Instance 1 Map 1 Map2 2184 2664 Instance 2 Map 1 Map2 2264 2744 Ox6B 107 1to2 OxD 13 Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only Watlow EZ ZONE PM Integrated Controller 72 Chapter 6 Setup Page Parameter Name Description Control Loop 1 to 2 Manual Power Set the manual output power level that will take effect if an input error failure occurs while User Failure Action is set to Manual Fixed Control Loop 1 to 2 Open Loop Detect En able Turn on the open loop detect feature to monitor a closed loop operation for the appropriate re
73. iun seats Rhe bare eie 48 Linearization Meriili een rm RR RR RR ERES 48 Process Value Menu esser n eer b c oes 49 Digital Input Output Menu 0 0 cee RR 50 Limit Meri eieiei a aia eda eee ee ea EE 50 Monitor Menus 2 22222 arbre POI RLPRerpsfIc heseerg ken 51 Control Loop Menu 0 ccc cece eee eens 52 DA ule 54 Current Menlo dh Rh edd antra vage a por lo RRA 55 Math MB cuoco es Ete eye REREREI XX ei cky dew ew MAREA 56 Special Output Function Menu 0 sese 57 Profile Status Menu 0 0 0 eee eee 58 Chapter 6 Setup Page 1 0 0 ccc ee eee 60 Analog Input Men 2e e rb RT RES 62 Linearization Men ions ete obe EL Reka otek 64 Process Value Menu ir aa aa aaa ee 67 Digital Input Output Menu 0 eee eee 67 Lir Meri owns sehen ey a e town ee eebowew ARES 70 Control LOOP Mam sus set De bee d eite 71 Watlow EZ ZONE PM Integrated Controller ele Table of Contents Table of Contents cont Output Menu 0 0 00 IR n 74 Alarm Metus scere RR RREETPBpE betes bode a eee 77 Current MENU s gare eRe Aah ae Relates oboe wee ed 79 Math M fillz roe x FEET EE REPE E RES 79 Special Output Function Menu 00 cece eee eee 80 FUNCTION KEY cies sc tetro xtd aoc Soc a ciens 81 Global MGM is ceri ERE Rr ety Pes ear eien Due 82 Communications Menu 000000 cece eee ee 84 Real Time Clock Menu 0 0c cee eee eee e eee 89 Chapter 7
74. loads See Quencharc note Output 2 L2 K2 PM Kl Output 4 L4 K4 PM __ K 1 Amp SSR Derating Curve 14 1 0 94 0 8 07 g a 0 6 o o 2 0 5 E 3 04 x E 0 3 D 0 2 0 1 0 20 10 0 10 20 30 40 50 60 70 Ambient Temperatue C Watlow EZ ZONE PM Integrated Controller Chapter 2 Install and Wire Warning AN A Use National Electric NEC or other country specific standard wiring and safety practices when wiring and connecting this controller to a power source and to electrical sensors or pe ripheral devices Failure to do so may result in damage to equipment and property and or injury or loss of life Note Maximum wire size termination and torque rating 0 0507 to 3 30 mm 30 to 12 AWG single wire termination or two 1 31 mm 16 AWG e 0 8 Nm 7 0 Ib in torque Note Adjacent terminals may be labeled differently depending on the model number Note To prevent damage to the control ler do not connect wires to unused terminals Note Maintain electrical isolation between analog input 1 digital input outputs switched dc open collector outputs and process outputs to prevent ground loops Note The control output common terminal and the digital common terminal are referenced to different voltages and must remain isolated Note This Equipment is suitab
75. long lag time Curve A represents a single loop control system with PID parameters that allow a maximum heat up rate Too much energy is introduced and the set point is overshot In most systems with long lag time the process value may never settle out to an ac ceptable error Curve C represents a single control system tuned to minimize overshoot This results in unacceptable heat up rates taking hours to reach the final value Curve B shows a cascade system that Watlow EZ ZONE PM Integrated Controller 108 Chapter 9 Features limits the energy introduced into the system allow ing an optimal heat up rate with minimal overshoot Cascade control uses two control loops outer and inner to control the process The outer loop analog input 2 monitors the process or part temperature which is then compared to the set point The result of the comparison the error signal is acted on by the PID settings in the cascade outer loop which then generates a power level for the outer loop The set point for the inner loop is determined by the outer loop power level The inner loop Analog Input 2 monitors the energy source heating and cooling which is compared to the inner loop set point gener ated by the outer loop The result of the comparison the error signal is acted on by the PID settings in the cascade inner loop which generates an output power level between 100 to 100 If the power level is positive the heat will b
76. model number information in the Appendix for more information If there is only one instance of a menu no sub menus will appear The Profiling Page allows you to enter your ramp and soak profile information To go to the Profiling Page from the Home Page press the Advance Key 6 for three seconds until appears in the lower display and the profile number appears in the upper display Press the Up or Down key to change to another profile e Press the Advance Key to move to the selected profile s first step Press the Up or Down Q keys to move through the steps Press the Advance Key to move through the selected step s settings Press the Up or Down Q keys to change the step s settings Press the Infinity Key at any time to return to the step number prompt Press the Infinity Key again to return to the profile number prompt From any point press and hold the Infinity Key for two seconds to return to the Home Page Note Changes made to profile parameters in the Profiling Pages will be saved and will also have an immediate impact on the running profile Some parameters in the Profile Status Menu can be changed for the currently running profile but should only be changed by knowledgeable personnel and with cau tion Changing parameters via the Profile Status Menu will not change the stored profile but will have an immediate im pact on the profile that is running Note How to Start a Profile A
77. nr m c E D c Cc o c em c c e fu o o C C C Uu C F3 e 3 fr e 3 fr Pu Watlow EZ ZONE PM Integrated Controller e 90 Chapter 7 Profiling Page Profiling Page CIP Modbus Class Default Relative Ad Instance dress Attribute hex dec Parameter Name Description 1 to 10 profile 1 11 to 20 profile 2 21 to 30 profile 3 31 to 40 profile 4 Unused Step 50 Unused Instance 1 0x79 121 21001 uint Select a step type End 27 Map1 Map2 1to40 RWE Note Jump Loop 116 2570 4500 1 When configuring the Wait For Time 1543 profile type there will be Wait For Both 210 Offset to next a Time prompt 1 Wait For Process 209 instance Map as delivered from the fac Wait For Event 144 1 equals 50 tory default If rate is Soak 87 Map 2 equals desired navigate to the Time 143 100 Setup Page and then the Rate 81 Global Menu where Ramping Type can be changed Step Type Parameters 1 999 000 to 9 999 000 F or Instance 1 0x79 121 21002 float Target Set Point loop 1 units Map1 Map2 1to40 RWE Select the set point for this step 1 128 to 5 537 000 C 2572 4502 2 Offset to next instance Map 1 equals 50 Map 2 equals 100 Step Type Parameters 1 999 000 to 9 999 000 F or Instance 1 0x79 121 21028 float Target Set Point loop 2 units Map1 Map2 1to40 RWE Selec
78. o 3 o o D d D o m 7o o 0 0 2 2 Ru D o rr Q rr Ru D tr uc o O C 3 fr o c D c D 2t m 3 m c 2 JJ o als o ro r o 1 o 1 o Watlow EZ ZONE PM Integrated Controller D M By 1 nr 3 tr uc o oe ae U anna m ea LO 5 AN ee LO An m 3 e n 3 e nr P3 rr e m Lo 34a nr m fr a3 n fr nre 3 nre 3 djs c m zm pono fk N N 00 Thermistor Resistance ange 63 Ramp Rate 73 108 Ramp Scale 73 108 RTD Leads 62 Ramping Type 83 Sensor Backup Enable 103 Software Build 97 Seconds 59 Sensor Type 62 101 103 Source Function A 77 Source Function A 80 Source Function B 80 Source Function E 79 Scale High 62 76 103 Event Input Source Instance 83 Source Instance A 80 Event Input Source Instance 83 Source Instance B 81 Source Instance 79 Scale Low 62 76 103 Set Lockout Security 96 2 Serial Number 97 Special Output Function enu 57 rofile Start Step 70 Profile Start Step 70 Active Step 58 Active Step Type 58 Source Value 1 57 Source Value A 49 Source Value 2 57 Source Value B 49 Source Value E 56 User Tune Aggressive
79. parameter is only used with PID control but can be set anytime Output Digital 1 to 4 Time Base Set the time base for fixed time base control Output Digital 1 to 4 Low Power Scale The power output will never be less than the value specified and will represent the value at which output scaling begins Output Digital 1 to 4 High Power Scale The power output will never be greater than the value specified and will represent the value at which output scaling stops Output Process 1 or 3 Type Select whether the pro cess output will operate in volts or milliamps Output Process 1 or 3 Function Set the type of func tion that will drive this output r Sr Output Process 1 or 3 Retransmit Source Select the value that will be retransmitted Note Setup Page Default FES Fixed Time Base 34 ut b Variable Time Base 108 0 1 to 60 0 seconds solid state 0 1 sec relay or switched dc SSR amp 5 0 to 60 0 seconds mechani sw dc cal relay or no arc power 20 0 sec control mech relay no arc 0 0 to 100 0 0 0 to 100 0 vole Volts 104 PTA Milliamps 112 Off 62 Duplex 212 Cool 20 Heat 36 Retransmit 213 Profile Event Out B Profile Event Out A Alarm 6 Analog Input 142 Set Point 85 Current 22 Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available wi
80. produce a mixture with specified physical properties e Maintaining correct air and fuel mixture to com bustion Output 1 mixed paint flow transmitter flow transmitter controlled flow of pigment uncontrolled flow of Y unmixed paint A motorized A valve Watlow EZ ZONE PM Integrated Controller 109 Chapter 9 Features Duplex Control Certain systems require that a single process output control both heating and cooling outputs A PM con trol with a process output can function as two sepa rate outputs With a 4 to 20mA output the heating output for instance will operate from 12 to 20mA 0 to 100 and the cooling outputs will operate from 12 to 4mA 0 to 100 In some cases this type of output is required by the device such as a three way valve that opens one way with a 12 to 20mA signal and opens the other way with a 4 to 12mA signal This feature reduces the overall system cost by using a single output to act as two outputs Fluid Sample Container temperature transmitter cold water Motorized Valve Control A motorized valve is used is to regulate the flow of fluid which in turn impacts the loop process value A valve is opened or closed by closing contacts to drive the value in the intended direction This feature is configured by selecting Motorized Valve as the func tion in the Setup Page Special Output Function menu
81. single PM controller can carry out several functions at the same time for instance closed loop control monitoring for several different alarm situ ations performing logical operations and operating switched devices such as lights and motors Each process needs to be thought out carefully and the controller s various functions set up properly Input Functions The inputs provide the information that any given programmed procedure can act upon In a simple form this information may come from an operator pushing a button or as part of a more complex pro cedure it may represent a remote set point being re ceived from another controller Each analog input typically uses a thermocouple thermistor or RTD to read the temperature of some thing It can also read volts current or resistance al lowing it to use various devices to read humidity air pressure operator inputs and others values The set tings in the Analog Input Menu Setup Page for each analog input must be configured to match the device connected to that input Each digital input reads whether a device is ac tive or inactive A PM with digital input output DIO hardware can include up to eight DIO each of which can be used as either an input or an output Each DIO must be configured to function as either an in put or output with the Direction parameter in the Digital Input Output Menu Setup Page The Function or EZ Key on the front panel of the PM also operates
82. solid state or mechanical relay Current transformer load wire associ ated to wrong output Defective current transformer or con troller Noisy electrical lines Unable to access SEE GPE FCEY or Pr oF menus or particular prompts in Home Page Menus inaccessible Security set to incorrect level Digital input set to lockout keypad Custom parameters incorrect EZ Key s don t work EZ Key s does not activate EZ Key function incorrect required function EZ Key function instance not incor rect Keypad malfunction Perform autotune or manually tune system Set control mode appropriately Open vs Closed Loop Set control set point in appropriate control mode and check source of set point remote idle profile closed loop open loop Verify output function is correct heat or cool Correct sensor wiring red wire nega tive Verify and correct wiring Replace heater Replace or repair power controller Replace or repair controller Replace or repair controller Check that the load current is proper Correct cause of overcurrent and or en sure current trip set point is correct Check that the load current is proper Correct cause of undercurrent and or ensure current trip set point is correct Replace relay Replace relay Route load wire through current transformer from correct output and go to the Source Output In stance parameter Setup Pa
83. to q oP I Output Point 1 o h 1 High Power Scale Output 1P 2 Input Point 2 t Pn Fa Function as ENE nee 2 SEE Limit Menu iene Instance 3 Input Poin L5d Si oP 3 Output Point 3 EI Dos RN o t b Time Base iE Input Point 4 PLh Set Point Limit High oLo cedi id Pies oP Output Point 4 PLL Set Point Limit Low oh cud A E 1P5 Input Point 5 LE Limit Integrate of PE Output 1 3 process oP 5 Output Point 5 ot JJ Type 1P6 Input Point 6 LooP Fana Function oP 5 Output Point 6 GEE Control Loop Menu F Function Instance P 1 Input Point 7 I to S L o Scale Low Available with PM4 PM8 and PM9 models only Watlow EZ ZONE PM Integrated Controller e 60 e Chapter 6 Setup Page Sh Scale High e Lo Range Low Range High Low Power Scale oho High Power Scale o C A Calibration Offset D c Ha ALIA Alarm I to AL PT Alarm At J Type Source Function A Source Instance A Hysteresis Logic Sides Latching Blocking Silencing Display Delay E un zo x D in m go PN c Ra r to Bi zo P m zB io r Ra a wn o zB Q r urrent Menu Sides Read Enable Detection Threshold Input Current Scaling Heater Current Offset Output Source Instance c m rr 2s QO r3 3 U r3 a ir a m o n WN 73 gt m 3o cr er E S th Menu
84. viation 1 Set the value of the de viation band that will be used in all profile step types The process value must enter the deviation band before the step can proceed Global Guaranteed Soak De viation 2 Set the value of the de viation band that will be used in all profile step types The process value must enter the deviation band before the step can proceed Global Source Instance A Set the digital source for WE1 Global Source Instance B Set the digital source for WE2 Global Power Out Time If profile is running and power is lost profile will resume where it left off provided time set has not expired pri or to power restoration Note Some values will be rounded off to fit in the four character display with other interfaces Setup Page Default Range r ALE Rate 81 t i Time 143 SEPE Set Point 85 Pr o Process 75 oF F Off 62 on On 63 0 0 to 9 999 000 F or units 0 0 to 5 555 000 C 0 0 to 9 999 000 F or units 0 0 to 5 555 000 C 0 to 9999 seconds Available with PM4 PM8 and PM9 models only Full values can be read Modbus Rela tive Address Instance 1 Map 1 Map2 4414 Instance 1 Map 1 Map2 2534 4354 Instance 1 Map 1 Map2 2530 4350 Instance 1 Map 1 Map2 2532 4352 Instance 1 Map 2 Instance 1 Map 2 Instance 1 Map 2 Instance 1 Map 2 CIP Class Instance Attribute Index hex dec 0x7A 122 1 26 38 0x7A
85. viewing this document electronically and have a connection to the internet simply click on the link below and download the soft ware from the Watlow web site free of charge http www watlow com products software zone_config cfm Once the software is installed double click on the EZ ZONE Configurator icon placed on your desktop dur ing the installation process If you cannot find the icon follow the steps below to run the software 1 Move your mouse to the Start button 2 Place the mouse over All Programs 3 Navigate to the Watlow folder and then the sub folder EZ ZONE Configurator 4 Click on EZ ZONE Configurator to run The first screen that will appear is shown below 24 Welcome to the EZ ZONE CONFIGURATOR This program makes it easy for you to configure any of your EZ ZONE products Choose one of these options Ed Configure a device while communicating with it C Create or edit a configuration file to download late E C Download a configuration file in to a device and click Next to begin configuring an EZ ZONE device Version 3 0 31 2006 WatlowElectric and Manufacturina Comoanv AIl riahts Cmes Hep Get Updates i mm If the PC is already physically connected to the EZ ZONE PM control click the next button to go on line Note When establishing communications from PC to the EZ ZONE PM control an interface converter will be required The Standard
86. when wiring and connecting this controller to a power source and to electrical sensors or pe ripheral devices Failure to do so may result in damage to equipment and property and or injury or loss of life Note Maximum wire size termination and torque rating 0 0507 to 3 30 mm 30 to 12 AWG single wire termination or two 1 31 mm 16 AWG e 0 8 Nm 7 0 Ib in torque Note Adjacent terminals may be labeled differently depending on the model number Note To prevent damage to the control ler do not connect wires to unused terminals Note Maintain electrical isolation between analog input 1 digital input outputs switched dc open collector outputs and process outputs to prevent ground loops Note The control output common terminal and the digital common terminal are referenced to different voltages and must remain isolated Note This Equipment is suitable for use in CLASS I DIVISION 2 Groups A B C and D or Non Hazardous locations only Temperature Code T4A Warning AN Explosion Hazard Substitution of component may impair suitability for CLASS I DIVISION 2 Warning AN Explosion Hazard Do not disconnect while the circuit is live or unless the area is known to be free of ignitable concentrations of flammable sub stances Input 1 2 Process Slot A B Slot A B scalable Input 1 PM _ C R B
87. 0 Mbps ethernet E6 m switch Both Modbus TCP unused 5 6 green receive and EtherNet IP are unused 4 white amp blue unused available on the network Communications instance move pg unused 2 transmit E2 receive Slot B transmit E1 transmit E2 PM 6 ____ 8 ____ Note EtherNet IP and Modbus TCP communica PMI 4 8 9 __ _ _ tions to connect with a 10 100 switch 3 ___ When changing the fixed IP address cycle module power for new address to take effect Ethernet LED Indicators Viewing the control from the front and then looking on top four LEDs can be seen aligned vertically front to back The LEDs are identified accordingly closest to the front reflects the Network Net Status Module Mod Status is next Activity status follows and lastly the LED closest to the rear of the con trol reflects the Link status Watlow EZ ZONE PM Integrated Controller amp 3A Chapter 2 Install and Wire Note Warning AN A Use National Electric NEC or other country specific standard wiring and safety practices when wiring and not used Network Status When using Modbus TCP the Network Status and Module Status LEDs are connecting this controller to a power source and to electrical sensors or pe ripheral devices Failure to do so may result in damage to equipment and property and or injury or loss of life Indicator State Steady Off Summary Not powered no IP
88. 0x17 23 0x86 134 1to2 OxE 14 Param eter ID 34010 R Read W Write E EE PROM S User Set Watlow EZ ZONE PM Integrated Controller Chapter 6 Setup Page Setup Page CIP Modbus Rela Class Parameter Name Lu t Description Range Default tive Instance Address Attribute hex dec Linearization 1 to 2 1 999 000 to 9 999 000 Instance 1 0x86 134 Output Point 7 Map1 Map2 1 to2 Set the value that will be 3606 0x18 24 mapped to input 7 Instance 2 Map 1 Map2 3676 Linearization 1 to 2 1 999 000 to 9 999 000 7 0 Instance 1 0x86 134 Input Point 8 Map 1 Map2 1 to 2 Set the value that will be 3588 OxF 15 mapped to output 8 Instance 2 0 Map 1 Map2 T 3658 Linearization 1 to 2 1 999 000 to 9 999 000 7 Instance 1 0x86 134 Output Point 8 Map1 Map2 1 to 2 Set the value that will be 3608 0x19 25 mapped to input 8 Instance 2 Map 1 Map2 3678 Linearization 1 to 2 1 999 000 to 9 999 000 Input Point 9 Set the value that will be mapped to output 9 Instance 1 0x86 134 Map 1 Map2 1 to 2 3590 0x10 16 Instance 2 Map 1 Map2 3660 Linearization 1 to 2 1 999 000 to 9 999 000 Input Point 10 Set the value that will be mapped to output 10 Instance 1 0x86 134 Map 1 Map2 1 to 2 3592 0x11 17 Instance 2 Map 1 Map2 3662 Linearization 1 to 2 1 999 000 to 9 999 000 Output Point 10 Set the value that will b
89. 1 1848 2318 OxOA 10 Security Setting 1to5 Locked Access Level Determines user level menu visibility when security is enabled See Features section under Password Security Security Setting Off Rolling Password nj On When power is cycled a new Public Key will be displayed Security Setting 10 to 999 User Password Used to acquire access to menus made avail able through the Locked Access Level setting Security Setting 10 to 999 Administrator Pass word Used to acquire full ac cess to all menus Security Setting Customer Specific Public Key If Rolling Password turned on generates a random number when power is cycled If Roll ing Password is off fixed number will be displayed Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces If there is only one instance of a menu no submenus will appear Watlow EZ ZONE PM Integrated Controller e 96 o Chapter 8 Factory Page Factory Page 1999 to 9999 0 to 2 147 483 647 Parameter Name Description Default Security Setting Password Number returned from calculation found in Features section under Password Security Diagnostics Menu j Diagnostics Part Number Display this controller s part number Diagnostics Software Revision Display this control ler s firmware revision number Diagnostics Software Build Num ber Display the firmware build nu
90. 122 1 8 Ox7A 122 1 6 Ox7A 122 1 7 Ox7A 122 1 0x29 41 0x7A 122 1l Ox1A 26 7A 122 1 Ox1B 27 7A 122 1 0x49 73 Watlow EZ ZONE PM Integrated Controller 83 o Chapter 6 Setup Page Setup Page CIP Modbus Rela Class Parameter Name koil t Description Range Default tive Instance Address Attribute Index hex dec Global Comm port 2 1189 Instance 1 0x6A 103 Communications LED Comm port 1 1190 Map 1 Map2 1 Action Comm port 1 and 2 1856 2326 OxOE 14 Turns comms LED on or off for selected comms Off 62 ports Global Off 62 Instance 1 0x6A 103 Zone On 63 Map 2 1 Turns Zone LED on or Ox1A 26 off based on selection Global Off 62 Instance 1 0x6A 103 Channel On 63 Map 2 1 Turns Channel LED on Ox1B 27 or off based on selection Global Instance 1 0x6A 103 Display Pairs Map 2 1 Defines the number of Ox1C 28 Display Pairs Global Instance 1 0x6A 103 Display Time Map 1 Map2 1 Time delay in toggling 2356 Ox1D 29 between channel 1 and channel 2 Global User Set 1 101 Instance 1 0x 101 User Settings Save User Set 2 102 Map1 Map 1 Save all of this control None 61 26 26 OxE 14 ler s settings to the selected set Global Factory 31 Instance 1 0x65 User Restore Settings None 61 Map1 Map2 101 Replace all of this con User Set 1 101 24 24 1 troller s settings with User Set 2 102 OxD 13 another set Communica
91. 1490 1890 6 to allow the user to dis able this alarm Offset to next instance Map 1 equals 50 for Map 2 equals 60 i Available with PM4 PM8 and PM9 models only Setup Page Parameter Name Description Current Menu Current 1 oF F Off 62 Sides b 19h High 37 Select which side or sides L o 5 UJ Low 53 will be monitored both Both 13 3 to 59 0 to 9 999 000 9 999 000 to 9 999 000 Map 1 1128 Current 1 Read Enable Display under over range current Map 1 1126 Current 1 Detection Threshold For factory adjustment only Map 1 1142 Current 1 Scaling Adjust scaling to match the transformer s high range Map 1 1162 Current 1 Current Offset Calibrate the current reading with an offset value Map 1 1140 Current 1 Output Source In stance Select which output in stance the current trans former will monitor Map 1 1156 oF F Off 62 Function PSC Process Scale 1371 Set the operator that will dS C Deviation Scale 1372 be applied to the sources non t None 61 FUn Function Key 1001 d o Digital I O 1142 Map 1 Source Function E Set the type of function that will be used for this Source Math 1 Source Instance Set the instance of the function selected above Map 1 Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available wi
92. 2 Map 2 1 Limit 12008 Integrate In a limit state the con troller will turn off the outputs terminate an active profile and freeze PID and TRU TUNE calculations no No 59 YES Yes 106 Map 1 694 734 8 Control Loop Menu 0x97 151 1to2 Control Loop 1 to 2 oFF Off 62 Instance 1 Note Heat Algorithm Set the heat control method Control Loop 1 to 2 Cool Algorithm Set the cool control method Control Loop 1 to 2 Cool Output Curve Select a cool output curve to change the responsiveness of the system Control Loop 1 to 2 TRU TUNE Enable Enable or disable the TRU TUNE adap tive tuning feature P d PID 71 On Off 64 oF F Off 62 P d PID 71 onoF On Off 64 Off 62 Non linear Curve 1 214 C r b Non linear Curve 2 215 No 59 Yes 106 Map 1 Map2 1884 2364 Instance 2 Map 1 Map2 1954 2434 Off Instance 1 Map 1 Map2 1886 2366 Instance 2 Map 1 Map2 1956 2436 Instance 1 Map 1 Map2 1888 2368 Instance 2 Map 1 1958 Map 2 2438 Instance 1 Map 1 Map2 1910 2390 Instance 2 Map 1 1980 Map 2 2460 Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only 0x97 151 0x97 151 0x97 151 0x10 16 Watlow EZ ZONE PM Integrated Controller Chapter 6 Setup Page Setup Page m Parameter Name Des
93. 4 7 12 X1 X3 common Any switched dc output can use Switched dc open collector this common output 1 PM _ C _ RE W1 W3 dc open collector output 3 PM C L Y1 Y3 de W2 WA dc Switched dc Y2 Y4 dc output 2 PM C1 22 ws output 4 PM _ C __ F1 F3 voltage or current Universal Process G1 G3 voltage output 1 PM F E H1 H3 current output 3 PM ___ F L1 L3 normally open Mechanical Relay 5 A Form C K1 K3 common output 1 PM El J1 J3 normally closed output 3 PM _ E L2 L4 normally open NO ARC 15 A Form A K2 K4 common output 2 PM ____H ___ R ___ L2 L4 normally open Mechanical Relay 5 A Form A K2 K4 common output 2 PM ____ J o output 4 PM _ J Li L2 L3 L4 normally open Solid state Relay 0 5 A Form A K1 K2 K3 K4 common output 1 PM _ K _ _ output 2 PM _ K ___ output 3 PM _ __ K output 4 PM _ K B7 Common Digital Outputs D7 switched dc open collector output PMI4 8 9 IG D D8 switched dc open collector output D9 switched dc open collector output D10 switched dc open collector output D11 switched dc open collector output D12 switched dc open collector output Z7 Supply Slot A Slot B Slot D Slot E Output 4 PM4 PM8 and PM9 only Watlow EZ ZONE PM Integrated Controller e 22 e Chapter 2 Install and Wire Communications Terminal Function Configuration CB CB
94. 54 amp 256 Value of Pointer 28 Registers 96 amp 97 Pointer 29 1328 amp 1329 Digital Input 5 Status Registers 256 amp 257 Value of Pointer 29 Registers 98 amp 99 Pointer 30 1348 amp 1349 Digital Input 6 Status Registers 258 amp 259 Value of Pointer 30 Pointer 31 1882 amp 1883 Control Mode Active Value of Pointer 31 Registers 102 amp 103 Pointer 32 1904 amp 1905 Heat Power Registers 262 amp 263 Value of Pointer 32 Registers 104 amp 105 Pointer 33 1906 amp 1907 Cool Power Registers 264 amp 265 Value of Pointer 33 Registers 106 amp 107 Pointer 34 690 amp 691 Limit State Registers 266 amp 267 Value of Pointer 34 Registers 108 amp 109 Pointer 35 2520 amp 2521 Profile Start Registers 268 amp 269 Value of Pointer 35 Registers 110 amp 111 Pointer 36 2540 amp 2541 Profile Action Request Registers 270 amp 271 Value of Pointer 36 Registers 112 amp 113 Pointer 37 2524 amp 2525 Active File Registers 272 amp 273 Value of Pointer 37 Registers 114 amp 115 Pointer 38 2526 amp 2527 Active Step Registers 274 amp 275 Value of Pointer 38 Reg
95. 64 default Home Page parameters 40 43 deviation alarms 110 Differential Control 109 Digital Input Function 82 Digital Input Output Menu 50 67 dimensions 16 17 18 19 Direction 67 Display 78 Display Pairs 61 84 displays 40 Display Time 84 Display Units 82 88 Down Key 40 duplex 104 Duplex Control 110 E Electrical Gain 102 Electrical Input Offset 98 Electrical Input Slope 98 Electrical Measurement 98 102 Electrical Offset 102 Electrical Output Offset 98 Electrical Output Slope 98 Electrical Slope 102 End Set Point Value 93 EtherNet IP 34 Ethernet IP Enable 88 Event Output 1 and 2 93 EZ Key 111 F Factory Page 94 Filter Time 63 102 filter time constant 102 Function 60 101 Function Instance 68 70 Function Key Menu 111 G Global Menu 82 Setup Page 47 60 Guaranteed Soak Devia tion 61 Guaranteed Soak Deviation 83 Guaranteed Soak Enable 61 83 H Heat Algorithm 71 106 Heater Error 56 111 Heat Hysteresis 53 106 Heat Power 51 100 Heat Proportional Band 52 100 107 High Power Scale 69 75 high range 103 high scale 103 High Set Point Alarm 54 55 110 Current 55 111 Loop 74 103 Home Page 43 Hours 91 Hysteresis 71 77 110 l Idle Set Point 52 Input Error Failure 72 105 Input Error Latching 63 106 Input Error Status 48 input events 6 Input Point 1 60 Input Point 2 60 Input Point 3 60 Input Point 4 60 Input Point 5 60 Input Point 6 60 Input Point 7 60
96. 94 5656 between 7 a m and 5 p m Central Standard Time CST Ask for for an Applications Engineer Please have the following information available when calling Complete model number e All configuration information User s Manual Factory Page Return Material Authorization RMA 1 Call Watlow Customer Service 507 454 5300 for a Return Material Authorization RMA number before returning any item for repair If you do not know why the product failed contact an Application Engineer or Product Manager All RMA s require e Ship to address e Bill to address Contact name e Phone number e Method of return shipment Your P O number Detailed description of the problem ny special instructions Name and phone number of person returning the product Prior approval and an RMA number from the Customer Service Department is required when returning any product for credit repair or evaluation Make sure the RMA number is on the outside of the carton and on all paperwork returned Ship on a Freight Prepaid basis After we receive your return we will examine it and try to verify the reason for returning it In cases of manufacturing defect we will enter a repair order replacement order or issue credit for material returned In cases of customer mis use we will provide repair costs and request a purchase order to proceed with the repair work To return products that are not defective
97. A or 0 5A SSR form A Output 4 none 15A NO ARC switched dc 5A mechanical relay form A or 0 5A SSR form A Output Status 12 3 4 5 6 Zone Address ES Output Functions off heat cool alarm retransmit duplex event off heat cool alarm event off heat cool alarm event off heat cool alarm retransmit duplex event off heat cool alarm event Indicates Zone Address Indicates I O Number of inputs and outputs and various combinations of the same will vary depending upon part number see ordering matrix for more detail Remote Set Point Operation Status e Supports efficient set point manipulation from a remote device such as a master control or PLC Watlow EZ ZONE PM Integrated Controller Chapter 1 Overview EZ ZONE PM Integrated Model 1 16 DIN With Limit System Diagram Input Functions Input Sensor gt None Limit reset Idle set point Tune Alarm clear request Force alarm Silence alarm Manual auto mode Control outputs off Remote set point enable Lock keypad TRU TUNE disable Loop amp alarms off Profile disable Profile hold resume Profile start Profile start stop Restore user settings Event inputs RUI EZ ZONE Controllers PLC PC or HMI Input Sensor Integrated PID a Without Communications Card Slot B
98. A new feature in EZ ZONE PM products will al low set point changes while the control is autotun ing this includes while running a profile or ramping When the auto tune is initially started it will use the current set point and will disregard all set point changes until the tuning process is complete Once complete the controller will then use the new set point This is why it is a good idea to enter the active set point before initiating an autotune Autotuning calculates the optimum heating and or cooling PID parameter settings based on the sys tem s response Autotuning can be enabled whether or not TUNE TUNE is enabled The PID settings generated by the autotune will be used until the au totune feature is rerun the PID values are manually adjusted or TRU TUNE is enabled To initiate an autotune set Autotune Request Operations Page Loop Menu to YES You should not autotune while a profile is running If the autotune cannot be completed in 60 minutes the autotune will time out and the original settings will take effect The lower display will flash between and the set point while the autotuning is underway The temperature must cross the Autotune Set Point five times to complete the autotuning process Once com plete the controller controls at the normal set point using the new parameters Select a set point for the tune with Autotune Set Point The Autotune Set Point is expressed as a per cent of the C
99. Cascade 0000 eens 119 Example 7 Wet Bulb Dry Bulb 0005 119 Example 8 Vaisala illie 120 Example 9 Motorized Valve Control 05 120 Chapter 11 Appendix 00 000 ee 122 Troubleshooting Alarms Errors and Control Issues 122 Modbus Programmable Memory Blocks 125 CIP Implicit O to T Originator to Target Assembly Structure 127 CIP Implicit T to O Target to Originator Assembly Structure 127 Spacifications v cur 2 hd a Ma EE REESE HER RE EE 128 Ordering Information for PM Integrated Controller Models 131 WNC cT 132 How to Reach US 22 esce eroe ter PIER Rer 138 Watlow EZ ZONE PM Integrated Controller 3 Table of Contents Chapter 1 Overview The EZ ZONE PM takes the pain out of solving your thermal loop requirements Watlow s EZ ZONE PM controllers offer options to reduce system complexity and the cost of control loop ownership You can order the EZ ZONE PM as a PID controller or an over under limit controller or you can combine both functions in the PM Integrat ed Limit Controller You now have the option to in tegrate a high amperage power controller output an over under limit controller and a high performance PID controller all in space saving panel mount packages You can also select from a number of se rial communications options to help you manage sys tem performance It just got a w
100. EZ ZONE PM User s Manual PFIN N ad f wanow ILE NM gi Cs Integrated Controller Models TOTAL 3 YearWarranty id WATLOW 1241 Bundy Boulevard Winona Minnesota USA 55987 Registered Company Phone 1 507 454 5300 Fax 1 507 452 4507 http www watlow com Winona Minnesota USA 0600 0059 0000 Rev J Made in the U S A March 2010 Safety Information We use note caution and warning symbols through out this book to draw your attention to important operational and safety information A NOTE marks a short message to alert you to an important detail A CAUTION safety alert appears with informa tion that is important for protecting your equip ment and performance Be especially careful to read and follow all cautions that apply to your application A WARNING safety alert appears with infor mation that is important for protecting you others and equipment from damage Pay very close attention to all warnings that apply to your application The electrical hazard symbol A a lightning bolt in a triangle precedes an electric shock hazard CAUTION or WARNING safety statement Symbol Explanation CAUTION Warning or Hazard that needs further explanation than label on unit can provide Consult users manual for further information ESD Sensitive product use proper grounding and handling tech niques when installing or servic ing product Unit protected by double re
101. Germany Tel 49 0 7253 9400 0 Fax 49 0 7253 9400 900 Email info watlow de Website www watlow de Watlow Italy S r l Viale Italia 52 54 20094 Corsico MI Italy Tel 39 024588841 Fax 39 0245869954 Email italyinfo watlow com Website www watlow it Watlow Ib rica S L U C Marte 12 Posterior Local 9 E 28850 Torrej n de Ardoz Madrid Spain T 34 91 675 12 92 F 34 91 648 73 80 Email info watlow es Website www watlow es Watlow UK Ltd Linby Industrial Estate Linby Nottingham NG15 8AA United Kingdom Telephone 0 115 964 0777 Fax 0 115 964 0071 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 Watlow Korea Co Ltd 1406 E amp C Dream Tower 46 Yangpyeongdong 3ga Yeongdeungpo gu Seoul 150 103 Republic of Korea Tel 82 2 2628 5770 Website www watlow co kr Fax 82 2 2628 5771 Watlow Malaysia Sdn Bhd No 14 3 Jalan 2 114 Kuchai Business Centre Jalan Kuchai Lama 58200 Kuala Lumpur Fax 61 3 9330 3566 Website www watlow com Watlow Electric Manufacturing Shanghai Company 1118 Fangyuan Road Anting Industrial Park Jiading Shanghai PRC 201203 People s Republic of China Tel 86 21 39509510 Fax 86 21 5080 0906 Email info watlow cn Website www watlow cn TRO Zy NTAEXEt S T 101 0047 RRABF AR TIRE 1 14 4 FURIE L gl SEO FE Tel 03 3518 6630 Fax 03 3518 6632 Email inf
102. Integrated Controller 116 Chapter 9 Features Lastly when the configuration is complete click the Finish button at the bottom right of the previous screen shot The screen that follows this action can be seen below Watlow EZ ZONE CONFIGURA f O X Finish Configuring a Device On Line Congratulations you have updated the settings in the device If you save these settings in a file on this computer you can load the file in to a device or edit the file again later Choose one of these options C Save the configuration in a file and start over C Exit and do not save the changes in a file and click Finich Gees tee xe i Although the PM control now contains the configu ration because the previous discussion focused on doing the configuration on line it is suggested that after the configuration process is completed that the user save this file on the PC for future use If for some reason someone inadvertently changed a set ting without understanding the impact it would be easy and perhaps faster to download a saved configu ration back to the control versus trying to figure out what was changed Of course there is an option to exit without saving a copy to the local hard drive After selecting Save above click the Finish button once again The screen below will than appear Authorname Smith Joel Save Date 27Jan 2010 Comment Enter a comment here that will help yo
103. Lockout Security to 0 4 The operator wants to read and write to the Watlow EZ ZONE PM Integrated Controller 112 Chapter 9 Features Home Page and Profiling Page and lock all other pages and menus In the Factory Page Lockout Menu set Read Lockout Security to 2 and Set Lockout Security to 2 In the Factory Page Lockout Menu set Lock Operations Page to 3 and Lock Profiling Page to 2 5 The operator wants to read the Operations Page Setup Page Profiling Page Diagnostics Menu Lock Menu Calibration Menu and Cus tom Menus The operator also wants to read and write to the Home Page In the Factory Page Lockout Menu set Read Lockout Security to 1 and Set Lockout Security to 5 In the Factory Page Lockout Menu set Lock Operations Page to 2 and Lock Profiling Page to 3 Using Password Security It is sometimes desirable to apply a higher level of security to the control where a limited number of menus are visible and not providing access to others without a security password Without the appropri ate password those menus will remain inaccessible If Password Enabled P A 5 in the Factory Page under the Menu is set to on an overriding Password Security will be in effect When in ef fect the only Pages that a User without a password has visibility to are defined in the Locked Access Level L o C L prompt On the other hand a User with a password would have visibility restricted by the Read
104. Lockout Security r L o C As an example with Password Enabled and the Locked Access Level LoC L set to 1 and oL oC is set to 3 the avail able Pages for a User without a password would be limited to the Home and Factory Pages locked level 1 If the User password is entered all pages would be accessible with the exception of the Setup Page as de fined by level 3 access How to Enable Password Security Go to the Factory Page by holding down the Infinity key and the Advance key for approximately six seconds Once there push the Down Q key one time to get to the menu Again push the Advance key until the Password Enabled P A 5 prompt is visible Lastly push either the up or down key to turn it on Once on 4 new prompts will appear 1 Lo C L Locked Access Level 1 to 5 correspond ing to the lockout table above 2 co LL Rolling Password will change the Cus tomer Code every time power is cycled 3 PA 5 u User Password which is needed for a Us er to acquire access to the control 4 PR 5 8 Administrator Password which is need ed to acquire administrative access to the control The Administrator can either change the User and or the Administrator password or leave them in the de fault state Once Password Security is enabled they will no longer be visible to anyone other than the Administrator As can be seen in the formula that follows either the User or Administrator will need to k
105. Modbus RTU EIA 485 T R Modbus RTU 232 485 Communications CA CA Modbus RTU EIA 485 T R Slot B PM6 21AAA ___ CC CC Modbus RTU EIA 485 common Slot E PM 4 8 9 __ _ I 2 CB CB Modbus RTU EIA 485 T R CA CA Modbus RTU EIA 485 T R C5 C5 Modbus RTU EIA 232 common C3 C3 Modbus RTU EIA 232 to DB9 pin 2 C2 C2 Modbus RTU EIA 232 to DB9 pin 3 V V DeviceNet power DeviceNet Communications CH CH Positive side of DeviceNet bus Slot B PM6___ _ 5J AAA___ SH SH Shield interconnect Slot E PM 4 8 9 5 CL CL Negative side of DeviceNet bus V V DeviceNet power return E8 E8 EtherNet IP and Modbus TCP unused Ethernet 10 100 supporting EtherNet IP E7 E7 EtherNet IP and Modbus TCP unused and Modbus TCP E6 E6 EtherNet IP and Modbus TCP receive Slot B PM6___ _ 3 AAA___ E5 E5 EtherNet IP and Modbus TCP unused Slot E PM 4 8 9 3 E4 E4 EtherNet IP and Modbus TCP unused E3 E3 EtherNet IP and Modbus TCP receive E2 E2 EtherNet IP and Modbus TCP transmit El E1 EtherNet IP and Modbus TCP transmit VP VP Voltage Potential Profibus Communications B B EIA 485 T R Slot B PM6____ 6J AAA___ A A EIA 485 T R Slot E PM 4 8 9 ____ 6J AAAAAA DG DG Digital ground common trB trB Termination resistor B B B EIA 485 T R A A EIA 485 T R trA trA Termination resistor A Slot A Slot B Slot D Slot E Terminal Definitions for Slot C Slot C Terminal Function Configuration 98 Power input ac or dc all
106. NE Band Setup Page Loop Menu to set the range above and below the set point in which adaptive tuning will be active Adjust this parameter only in the unlikely event that the controller is unable to stabilize at the set point with TRU TUNE Band set to auto 0 This may occur with very fast processes In that case set TRU TUNE Band to a large value such as 100 Use TRU TUNE Gain Setup Page Loop Menu to adjust the responsiveness of the adap tive tuning calculations Six settings range from 1 with the most aggressive response and most poten tial overshoot highest gain to 6 with the least ag gressive response and least potential for overshoot lowest gain The default setting 3 is recommended for loops with thermocouple feedback and moderate response and overshoot potential Before Tuning Before autotuning the controller hardware must be installed correctly and these basic configuration pa rameters must be set e Sensor Type Setup Page Analog Input Menu and scaling if required e Function Setup Page Output Menu and scaling if required How to Autotune a Loop 1 Enter the desired set point or one that is in the middle of the expected range of set points that you want to tune for 2 Enable TRU TUNE 3 Initiate an autotune See Autotuning in this chapter When autotuning is complete the PID parameters should provide good control As long as the loop is in the adaptive control
107. NE PM Integrated Controller e 30 Chapter 2 Install and Wire Warning A N Use National Electric NEC or other country specific standard wiring and safety practices when wiring and connecting this controller to a power source and to electrical sensors or pe ripheral devices Failure to do so may result in damage to equipment and property and or injury or loss of life Note Maximum wire size termination and torque rating 0 0507 to 3 30 mm 30 to 12 AWG single wire termination or two 1 31 mm 16 AWG e 0 8 Nm 7 0 Ib in torque Note Adjacent terminals may be labeled differently depending on the model number Note To prevent damage to the control ler do not connect wires to unused terminals Note Maintain electrical isolation between analog input 1 digital input outputs switched dc open collector outputs and process outputs to prevent ground loops Note The control output common terminal and the digital common terminal are referenced to different voltages and must remain isolated Note This Equipment is suitable for use in CLASS I DIVISION 2 Groups A B C and D or Non Hazardous locations only Temperature Code T4A Warning A Explosion Hazard Substitution of component may impair suitability for CLASS I DIVISION 2 Warning A Explosion Hazard Do not disconnect while the circuit is live or unless the area is known to be free of ignitable concentrations of flamm
108. NE PM Integrated Controller Chapter 2 Install and Wire Warning AN A Use National Electric NEC or other country specific standard wiring and safety practices when wiring and connecting this controller to a power source and to electrical sensors or pe ripheral devices Failure to do so may result in damage to equipment and property and or injury or loss of life Note Maximum wire size termination and torque rating 0 0507 to 3 30 mm 30 to 12 AWG single wire termination or two 1 31 mm 16 AWG e 0 8 Nm 7 0 Ib in torque Note Adjacent terminals may be labeled differently depending on the model number Note To prevent damage to the control ler do not connect wires to unused terminals Note Maintain electrical isolation between analog input 1 digital input outputs switched dc open collector outputs and process outputs to prevent ground loops Note The control output common terminal and the digital common terminal are referenced to different voltages and must remain isolated Note This Equipment is suitable for use in CLASS I DIVISION 2 Groups A B C and D or Non Hazardous locations only Temperature Code T4A Warning A Explosion Hazard Substitution of component may impair suitability for CLASS I DIVISION 2 Warning A Explosion Hazard Do not disconnect while the circuit is live or unless the area is known to be free of ignitable concentrations of flammable sub
109. National Electric NEC or other country specific standard wiring and safety practices when wiring and connecting this controller to a power source and to electrical sensors or pe ripheral devices Failure to do so may result in damage to equipment and property and or injury or loss of life Note Maximum wire size termination and torque rating 0 0507 to 3 30 mm 30 to 12 AWG single wire termination or two 1 31 mm 16 AWG e 0 8 Nm 7 0 Ib in torque Note Adjacent terminals may be labeled differently depending on the model number Note To prevent damage to the control ler do not connect wires to unused terminals Note Maintain electrical isolation between analog input 1 digital input outputs switched dc open collector outputs and process outputs to prevent ground loops Note The control output common terminal and the digital common terminal are referenced to different voltages and must remain isolated Note This Equipment is suitable for use in CLASS I DIVISION 2 Groups A B C and D or Non Hazardous locations only Temperature Code T4A Warning AN Explosion Hazard Substitution of component may impair suitability for CLASS I DIVISION 2 Warning AN Explosion Hazard Do not disconnect while the circuit is live or unless the area is known to be free of ignitable concentrations of flammable sub stances Wiring a Serial EIA 485 Network Do not route network wires with p
110. O assembly is called the Device Status and cannot be changed However the 20 members that follow it are user configurable See Appendix CIP Implicit O to T Originator to Target Assembly Structure and CIP Implicit T to O Target to Originator Assembly Structure To change any given member of either assembly simply write the new class instance and attribute to the member location of choice As an example if it were desired to change the 14 member of the O to T assembly from the default parameter Heat Propor tional Band to Limit Clear Request see Operations Page Limit Menu write the value of 0x70 0x01 and 0x01 Class Instance and Attribute respectively to 0x77 0x01 and OxOE Once executed writing a value of zero to this member will reset a limit assuming the condition that caused it is no longer present Note The maximum number of implicit input output members using DeviceNet cannot exceed 200 Note The maximum number of implicit input output members using EtherNet IP cannot exceed 100 Watlow EZ ZONE PM Integrated Controller 114 Chapter 9 Features Software Configuration Using EZ ZONE Configurator Software To enable a user to configure the PM control using a personal computer PC Watlow has provided free software for your use If you have not yet obtained a copy of this software insert the CD Controller Sup port Tools into your CD drive and install the soft ware Alternatively if you are
111. Output 1 and 2 Hardware Options Output 1 Output 2 CA Switched dc open collector None CH Switched dc open collector NO ARC 15 A power control CC Switched dc open collector Switched dc CJ Switched dc open collector Mechanical relay 5 A form A CK Switched dc open collector Solid state relay 0 5 A form A EA Mechanical relay 5 A form None EH Mechanical relay 5 A form NO ARC 15 A power control EC Mechanical relay 5 A form C Switched dc EJ Mechanical relay 5 A form C Mechanical relay 5 A form A EK Mechanical relay 5 A form C Solid state relay 0 5 A form A FA Universal process None FC Universal process Switched dc cannot use variable time base FJ Universal process Mechanical relay 5 A form A cannot use variable time base FK Universal process Solid state relay 0 5 A form A cannot use variable time base AK None Solid state relay 0 5 A form A KH Solid state relay 0 5 A form A NO ARC 15 A power control KK Solid state relay 0 5 A form A Solid state relay 0 5 A form A Communications Options or Additional Digital I O None 6 Digital I O Not available with PM6 6 Digital I O and EIA 485 Modbus RTU Not available with PM6 EIA 485 Modbus RTU9 Modbus RTU 232 485 EtherNet IP Modbus TCP DeviceNet Profibus DP Standard Bus EIA 485 always included all models Auxilliary Control Functions None 2nd PID Channel with Universal Input Not available on PM6 2nd PID Channel with Thermistor Input Not available
112. Page To go to the Setup Page from the Home Page press press the Up or Down Q key to select and then both the Up O and Down Q keys for six seconds press the Advance Key to enter will appear in the upper display and e Press the Up O or Down Q key to move through will appear in the lower display available menu prompts e Press the Up O or Down Q key to view available Press the Infinity Key to move backwards menus On the following pages top level menus through the levels parameter to submenu sub are identified with a yellow background color menu to menu menu to Home Page Press the Advance Key to enter the menu of Press and hold the Infinity Key for two seconds choice to return to the Home Page e If a submenu exists more than one instance Note Some of these menus and parameters may not appear depending on the controller s options See model number information in the Appendix for more information If there is only one instance of a menu no sub menus will appear Note Some of the listed parameters may not be visible Parameter visibility is dependent upon controller part number
113. Parameters Off 62 Instance 1 0x79 121 21010 uint WE 2 Wait Event 5 12 On 63 Mapi1 Map2 1to40 RWE Profiling Page Parameter Name Description d Every Day 1567 Week days 1566 Sunday 1565 Monday 1559 Tuesday 1560 Wednesday 1561 Thursday 1562 Friday 1563 SAE Saturday 1564 0 to 9 999 Control Mode set to Off 62 Hold last closed loop set point in the profile 47 USE User reverts to previ ous set point 100 Step Type Parameters Day of Week Step Type Parameters Jump Step Select a step to jump to Step Type Parameters Jump Count Set the number of jumps A val ue of 0 creates an infinite loop Loops can be nested four deep Step Type Parameters End Type Select what the controller will do when this profile ends oF F Off 62 on On 63 Step Type Parameters Profile Event Output A Select whether Event Output 1 or 2 is on or off during this step Off 62 Profile Event Output B On 63 Select whether Event Output 1 or 2 is on or off during this step Note Default i I ee will be rounded off to fit in the four character display Full values can be read with other Modbus Relative Ad dress Instance 1 Map 1 CIP Class Instance Attribute hex dec 0x79 121 1 to 40 0x29 41 Map 2 4580 Offset to next instance Map 2 equals 100 Instance 1 Map 1 2592 0x79 121 1 to 40 OxC 12 Map 2 4522 Offset t
114. Read the value of Electrical Measurement Factory Page Calibration Menu for that input Calculate the offset value by subtracting this val ue from the low source signal Set Electrical Input Offset Factory Page Calibration Menu for this input to the offset val ue 5 Check the Electrical Measurement to see whether it now matches the signal If it doesn t match ad just Electrical Offset again Apply the high source signal to the input Mea sure the signal to ensure it is accurate Read the value of Electrical Measurement for that input Calculate the gain value by dividing the low source signal by this value Set Electrical Slope Factory Page Cali bration Menu for this input to the calculated gain value 10 Check the Electrical Measurement to see wheth er it now matches the signal If it doesn t match adjust Electrical Slope again Set Electrical Offset to 0 and Electrical Slope to 1 to restore factory calibration 6 8 9 Follow these steps for an RTD input 1 Measure the low source resistance to ensure it is accurate Connect the low source resistance to the input you are calibrating Read the value of Electrical Measurement PAu Factory Page Calibration Menu for that input Calculate the offset value by subtracting this val ue from the low source resistance Set Electrical Input Offset Factory Page Calibration Menu for this input to the offset val ue Check the Electric
115. Scale 8 75 Minimum On Time 81 Open Loop Set Point 53 Output Point 2 64 Output Point 3 65 Output Point 4 65 Output Point 5 65 Output Point 6 65 Output Point 7 66 Output Point 8 66 Output Point 9 66 Output Point 10 66 Output Time Base 68 75 Output Menu 74 Output Type 75 Output Value 1 57 Output Value 2 57 Output Value 56 Profibus Node Address 86 Administrator Password 96 Password Enable 95 Password 97 User Password 96 Peltier Delay 72 Process Error Enable 63 Process Error Low 63 Part Number 97 Power Off Level A 81 Power Off level B 81 Power On LevelA 81 Power On Level B 81 Power Out Time 61 Profile Status Menu 58 Profile Type 83 Pressure Units 67 Process Value Menu 67 Process Value Active 51 Remote Enable 52 104 Software Revision 97 Range High 63 76 103 Range Low 62 76 103 Read Lockout Security 96 12 Rolling Password 96 Ramp Action 73 108 Ramping 41 Ramping 1 or 2 41 J C Rx o o 74 nr o hy 3 Oo mt fr o N fr o a o oo Oo 3 fr o o o Lo fu o Oo EN o Aa lt o Oo uU o 0 o o O J o 0 Co o O Es o o 1 o rr D rr o Pr Lc 9 C o C fu Jr C Lo Ru o e o 3o D 7o o 70 20 e o 0 20 o r Ec D m
116. Source Function A is selected for either Heat or Cool Power then entering the Valve Travel Time and Deadband Lastly program the outputs which will open and close the valve The algorithm will calculate Dead Time which is the minimum on time that the valve will travel once it is turned on in either the closed or open direction Dead Time Valve Dead Band 100 Valve Travel Time Gas Furnace N BB E Output 1 Close y Valve Actuator SS Temperature Sensor Si d Output 2 Open Gas Flow Note See Chapter 10 for application examples Alarms Alarms are activated when the output level process value or temperature leaves a defined range A user can configure how and when an alarm is triggered what action it takes and whether it turns off auto matically when the alarm condition is over Configure alarm outputs in the Setup Page before setting alarm set points Alarms do not have to be assigned to an output Alarms can be monitored and controlled through the front panel or by using software Process and Deviation Alarms A process alarm uses one or two absolute set points to define an alarm condition A deviation alarm uses one or two set points that are defined relative to the control set point High and low alarm set points are calculated by adding or subtracting offset values from the control set point If the set point changes the window defined by the alarm set points automatically mo
117. a universal process output out put 2 cannot use variable time base fixed time base only When output 3 is configured as a univer sal process output 4 cannot use variable time base fixed time base only Single Set Point Ramping Ramping protects materials and systems that can not tolerate rapid temperature changes The value of the ramp rate is the maximum degrees per minute or hour that the system temperature can change Select Ramp Action Setup Page Loop Menu ramping not active ramp at startup ramp at a set point change ramp at startup or when the set point changes Select whether the rate is in degrees per minute or degrees per hour with Ramp Scale _r 5C Set the ramping rate with Ramp Rate Setup Page Loop Menu Set Point Temperature Temperature reaches Set Point quickly Te Heating System without Ramping Set Point degrees Temperature per minute Temperature ramps to Set Point at a set rate Time Heating System with Ramping Cascade Control The PM PM4 8 9 can be configured for Cascade control with enhanced firmware Cascade control is a control strategy in which one control loop provides the set point for another loop It allows the process or part temperature to be reached quickly while mini mizing overshoot Cascade is used to optimize the performance of thermal systems with long lag times The graph to the right illustrates a thermal system with a
118. able sub stances Quencharc Note Switching pilot duty inductive loads relay coils solenoids etc with the mechanical relay solid state relay or open collector output options requires use of an R C sup pressor Output 1 3 Solid State Relay Form A Slot A B normally open L mum resistive load common K opto isolated without contact suppression maximum off state leakage of 105 microamperes output does not supply power Do not use on dc loads See Quencharc note Output 1 L1 K1 PM IK Output 3 L3 K3 PM__ __ K _ 1 Amp SSR Derating Curve 0 5 A at 20 to 264V ac maxi 20 VA 120 240V ac pilot duty NN p ea1y bunejedQ ayes 20 10 0 Ambient Temperatue C a a TIT TITTITT 10 20 30 40 50 TT 70 Output 2 4 Switched DC Slot A B 10 mA DC maximum supply cur rent short circuit limited to 50 mA e 22 to 32V dc open circuit volt age dc e use dc and dc to drive external W solid state relay deri DIN A MITE compatible single pole up to 2 in series none in parallel Output 2 W2 Y2 PM C Output 4 W4 Y4 PM ___ C _ lt common dc
119. action 1 5 5 20 Special Output 1 0 to 9 999 seconds 20 Minimum Off Time At a minimum stay off specified amount of time Special Output 1 10 to 9 999 seconds 120 Valve Travel Time The amount of time it takes the valve to fully open and then fully close Special Output 1 100 00 to 100 00 Instance 1 0x87 135 189 35021 Power Off Level B Map 2 T Compressor 1 power off 0x15 21 level Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only Watlow EZ ZONE PM Integrated Controller e 81 o Chapter 6 Setup Page Parameter Name Description Function Key 1 to 2 Digital Input Function Program the EZ Key to trigger an action Functions respond to a level state change or an edge level change Function Key 1 to 2 Instance Select which instance the EZ Key will affect If only one instance is avail able any selection will affect it Select which scale to use for temperature ACLE AC LF AC Line Frequency Set the frequency to the applied ac line power source Note Some values will be rounded off to fit in the four character display with other interfaces F F 30 C C 15 60 60 Hz 4 Setup Page Modbus Rela tive Address None Instance 1 Map 1 Map2 1324 1564 Instance 2 Map 1 Map2 1344 1584 Instance 1 Map 1 Map2 1326 1566 Instance 2 Map 1
120. address Requirement If the device does not have an IP address or is powered off the network status indicator shall be steady off Note Maximum wire size termination and torque rating Flashing Green No connections If the device has no established connections but has obtained an IP address the network status indicator shall be flashing green 0 0507 to 3 30 mm 30 to 12 AWG If the device has at least one established connec Single wire termination or two 1 31 Steady Green Connected tion even to the Message Router the network mm 16 AWG status indicator shall be steady green e 0 8 Nm 7 0 Ib in torque If one or more of the connections in which this Note C device is the target has timed out the network Adjacent terminals may be labeled Flashing Red onnecrion status indicator shall be flashing red This shall differently depending on the model simeon be left only if all timed out connections are rees number tablished or if the device is reset Note If the device has detected that its IP address is To prevent damage to the control Steady Red Duplicate IP already in use the network status indicator shall ler do not connect wires to unused be steady red terminals Note Maintain electrical isolation between Flashing Green Red Self test While the device is performing its power up test ing the network status indicator shall be flash ing green red an
121. al Measurement to see whether it now matches the resistance If it doesn t match adjust Electrical Offset again Measure the high source resistance to ensure it is accurate Connect the high source resistance to the input Read the value of Electrical Measurement for that input Calculate the gain value by dividing the low source signal by this value Set Electrical Slope Factory Page Cali bration Menu for this input to the calculated gain value 10 Check the Electrical Measurement to see wheth er it now matches the signal If it doesn t match adjust Electrical Slope again Set Electrical Offset to 0 and Electrical Slope to 1 to restore factory calibration Filter Time Constant Filtering smoothes an input signal by applying a first order filter time constant to the signal Filter ing the displayed value makes it easier to monitor Filtering the signal may improve the performance of PID control in a noisy or very dynamic system Adjust the filter time interval with Filter Time Setup Page Analog Input Menu Example With a filter value of 0 5 seconds if the process input Watlow EZ ZONE PM Integrated Controller 102 Chapter 9 Features value instantly changes from 0 to 100 and remained at 100 the display will indicate 100 after five time con stants of the filter value or 2 5 seconds 4 Unfiltered Input Signal Temperature Filtered Input Signal Temperature Tim
122. al states that are used exclusively by profiles The source of an event input can come from a real world digital input or an output from another function Likewise event out puts may control a physical output such as an output function block or be used as an input to another func tion Watlow EZ ZONE PM Integrated Controller Chapter 1 Overview Getting Started Quickly The PM control has a page and menu structure that is listed below along with a brief description of its purpose Once received a user would want to setup their control prior to op eration As an example define the input type and set the output cycle time Setup Page Push and hold the up and down keys O OQ for 6 seconds to enter See the Setup Page for further information After setting up the control to reflect your equipment the Op erations Page would be used to monitor or change runtime settings As an example the user may want to see how much time is left in a profile step or perhaps change the limit high set point Operations Page Push and hold the up and down keys O OQ for 3 seconds to enter See the Operations Page for further infor mation For the most part the Factory Page has no bearing on the con trol when running A user may want to en able password protec tion view the control part number or perhaps create a custom Home Page Factory Page Push and hold the In finity and the green Adv
123. alog input 1 digital input outputs switched dc open collector outputs and process outputs to prevent ground loops Note The control output common terminal and the digital common terminal are referenced to different voltages and must remain isolated Note This Equipment is suitable for use in CLASS I DIVISION 2 Groups A B C and D or Non Hazardous locations only Temperature Code T4A Warning A Explosion Hazard Substitution of Module Status Indicator State Steady Off Steady Green Flashing Green Sy Svea asec Flashing Red component may impair suitability for CLASS I DIVISION 2 Warning N Steady Red Explosion Hazard Do not disconnect while the circuit is live or unless the area is known to be free of ignitable concentrations of flammable sub Module Status cont Device operational Standby Minor fault Major fault Requirement If no power is supplied to the device the mod ule status indicator shall be steady off Requirement If the device is operating correctly the module status indicator shall be steady green If the device has not been configured the module status indicator shall be flashing green If the device has detected a recoverable minor fault the module status indicator shall be flashing red NOTE An incorrect or inconsistent configura tion would be considered a minor fault If the device has detected a non recoverable major fault the module s
124. ance 1 Map 1 Map2 728 848 Instance 3 Map 1 Map2 808 928 Instance 1 Map 1 Map2 730 850 Instance 3 Map 1 Map2 810 930 CIP Class Instance 104 1 to 2 0x15 21 0x68 104 1to2 Ox0A 10 0x68 104 1to2 OxB 11 Watlow EZ ZONE PM Integrated Controller 98 Chapter 8 Factory Page Chapter 9 Features Saving and Restoring User Settings 0 0 00 ee eee 100 Tuning the PID Parameters 000 c ee eee eee eee 100 Autotuning with TRU TUNE 2 0 0 ec cece cece e eee ees 101 NPWS cocearoten Bevel nE Eor EERE ENGS ee ado ex Dawes 102 Calibration OffSL e eu roni Dub hr eire deh wes 102 GAN DATION ep 102 Filter Time Constant 102 Sensor Selection 103 Sensot BACKUP ancene turpe xt be tue one eed bine de eet 103 Scale High and Scale Low 0 ccc cece eee eee ees 103 Range High and Range Low 0 cece eee eee eee 103 Receiving a Remote Set Point 0 cece eee eee 103 Ten Point Linearization 0 0 cee eee 104 MIDI Er 104 BIO PEE tice ithe Rid En a A adak 104 NO ARC Relay 0 0 00 c cece cece RH eee ees 104 Retransmitting a Process Value or Set Point 104 Cool Output Curve 0 eee eee eee ees 105 Control Methods 0 0 0 cee ee eee 105 Output Configuration 0 eee eee ee 105 Auto closed loop and Manual open loop Control 105 ON OF Control 22010 c eeecdiwre bas ecsadieeeoonsndtedeae
125. ance keys for 6 seconds to enter See the Factory Page for fur ther information Pushing the green Advance key will al low the user to see and change such parameters as the control mode en able autotune and idle set point to name a few Home Page The control is at the Home Page when ini tially powered up If equipped with this feature a user would want to go here to con figure a profile Profile Page Push and hold the the green Advance key for 6 seconds to enter See the Profile Page for fur ther information The default PM loop configuration out of the box is shown below Analog Input functions set to thermocouple type J Heat algorithm set for PID Cool set to off Output 1 set to Heat Control mode set to Auto e Set point set to 75 F If you are using the input type shown above simply connect your input and output devices to the control Power up the control and push the up arrow O on the face of the control to change the set point from the default value of 75 F to the desired value As the Set Point increases above the Process Value output 1 will come on and it will now begin driving your out put device The PV function as shown in the graphic below is only available with PM4 8 9 models Note The output cycle time will have a bearing on the life of mechanical relay outputs and can be differ ent based on the type of output ordered The output cycle ti
126. at R float R Modbus Relative Ad dress Profibus Param Instance 1 Map1 Map2 2520 4340 RW Instance 1 Ox7A 122 Map1 Map2 1 2526 4346 4 Instance 1 Ox7A 122 Map1 Map2 1 2544 4364 OxD 13 JL Jump Loop 116 CL oC Wait For Time 1543 b Ub o Wait For Both 210 b UP c Wait For Process 209 Wait For Event Soak 87 Time 143 Rate 81 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C Instance 1 Ox7A 122 Map1 Map2 1 2542 4362 OxC 12 Instance 1 0x7A 122 Map 2 1 0x30 48 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C Instance 1 Map1 Map2 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C Instance 1 Map1 Map2 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only Watlow EZ ZONE PM Integrated Controller 58 o USEP Unused Step 50 f Chapter 5 Operations Page Parameter name Description Profile Status Hours Step time remaing in hours Profile Status Minutes Step time remaing in minutes Profile Status Seconds Step time remaing in seconds Profile Status Active Event Output 1 View or change the event output states Profile Status Active Event Output 2 View or change the event output states Profile Statu
127. at Hysteresis PSP2 Produced Set Point 2 L S4 Source Value A CP Cool Proportional Band hour Hours Remaining Sub Source Value B ChY Cool Hysteresis 7 n Minutes Remaining Offset t J Time Integral GEC Seconds Remaining Output Value t d Time Derivative Ent I Active Event Output 1 db Dead Band Ent 2 Active Event Output 2 oPE c Digital Input Output Menu o 5P Open Loop Set Point JC Jump Count Remaining to ALIA Available with PM4 8 and 9 only with Digital Input Output Alarm Menu gth digit of part number equal to C or _da 5 Output State C Ito q J AND with 12th digit equal to C E R Event Sat ALP Alm D ML IL o Low Set Poin LPT Ah High Set Point o PE r Limit Menu Low Set Point oPEr Current Menu LL 5 5 High Set Point Ch High Set Point CL o Low Set Point oPE Monitor Menu E ur aia C Pto Er Error Watlow EZ ZONE PM Integrated Controller e 47 e Chapter 5 Operations Page Operations Page CIP Parameter name Modbus glass Profibus Param Description Belen Insane Index eter ID dress Attribute hex dec 4001 float R 4002 uint R 4012 float RWES Linearization Menu Sul Linearization 1 to 2 1 999 000 to 9 999 000 F 0x86 134 34004 float Source Value A or units 1to2 R View the value of Source 1 128 000 to 5 537 000 C 4 A Source A of Lineariza tion 1 is connected to a Analog Input 1 Source A of Lineariza tion 2 is connected to Analog Input 2 Linearization 1 to 2
128. ating action Switches on at startup Time The cooling action switches on when the process temperature rises above the set point plus the hysteresis cem Hysteresis The cooling action switches on at startup The cooling action switches off when the process temperature drops below the set point Process Temperature Set Point Temperature gt Time Some processes need to maintain a temperature or process value closer to the set point than on off con trol can provide Proportional control provides closer control by adjusting the output when the temperature or process value is within a proportional band When the value is in the band the controller adjusts the output based on how close the process value is to the set point The closer the process value is to the set point the lower the output power This is similar to backing off on the gas pedal of a car as you approach a stop sign It keeps the temperature or process value from swinging as widely as it would with simple on off control However when the system settles down the temperature or process value tends to droop short of the set point With proportional control the output power level equals set point minus process value divided by the proportional band value In an application with one output assigned to heating and another assigned to cooling each will have a separate proportional parameter The heating parameter takes e
129. ation 1 to 2 Output Point 6 Set the value that will be mapped to input 6 Linearization 1 to 2 Input Point 7 Set the value that will be mapped to output 7 1 999 000 to 9 999 000 1 999 000 to 9 999 000 1 999 000 to 9 999 000 1 999 000 to 9 999 000 1 999 000 to 9 999 000 1 999 000 to 9 999 000 1 999 000 to 9 999 000 1 999 000 to 9 999 000 1 999 000 to 9 999 000 Setup Page Modbus Rela tive Address Default eo Instance 1 Map 1 Map2 3578 Instance 2 Map 1 Map2 3648 Instance 1 Map 1 Map2 3598 Instance 2 Map 2 Instance 1 Map 1 Map2 3581 Instance 2 Map 2 Instance 1 Map 1 Map2 3600 Instance 2 Map 2 Instance 1 Map 1 Map2 3582 Instance 2 Map 2 Instance 1 Map 1 Map2 3602 Instance 2 Map 1 Map2 3672 Instance 1 Map 1 Map2 3584 Instance 2 Map 1 Map2 3654 Instance 1 Map 1 Map2 3604 Instance 2 Map 2 Instance 1 Map 1 Map2 3586 Instance 2 Map 2 Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only CIP Class Instance Attribute hex dec 0x86 134 1to2 OxA 10 0x86 134 1to2 0x14 20 0x86 134 1to2 OxB 11 0x86 134 1to2 0x15 21 0x86 134 1to2 OxC 12 0x86 134 1to2 0x16 22 0x86 134 1to2 OxD 13 0x86 134 1to2
130. ation Inc EtherNet IP is a trademark of ControlNet International Ltd used under license by Open DeviceNet Vendor Association Inc ODVA ULO is a registered trademark of Underwriters Laboratories Inc DeviceNet is a trademark of Open DeviceNet Vendors Associatlon Note These specifications are subject to change without prior notice Watlow EZ ZONE PM Integrated Controller e 130 e Chapter 11 Appendix Ordering Information for PM Integrated Controller Models Controller PM EZ ZONE Integrated Controller Models LI LI TRU TUNE49 Adaptive Tune red green 7 segment displays Package Size 4 Panel Mount 1 4 DIN 6 Panel Mount 116 DIN 8 Panel Mount 1 8 DIN Vertical 9 Panel Mount 1 8 DIN Horizontal Primary Function C PID Controller with Universal Input R PID Controller with Universal Input and Profiling Ramp and Soak B PID Controller with Universal Input and Profiling Ramp and Soak and Battery Backup with Real Time Clock PID Controller with Thermistor Input PID Controller with Thermistor Input and Profiling Ramp and Soak PID Controller with Thermistor Input and Profiling Ramp and Soak and Battery Backup with Real Time Clock S Custom Firmware Options B and E are not available with PM6 Power Supply Digital Input Output 1 100 to 240V ac 2 100 to 240V ac plus 2 Digital I O points 3 15 to 36V dc and 24V ac 4 15 to 36V dc and 24V ac plus 2 Digital I O points E zc
131. atus Action Request Profile Status Active Step View the currently run ning step Profile Status Active Step Type View the currently run ning step type Profile Status Target Set Point Loop 1 View or change the tar get set point of the cur rent step Profile Status Target Set Point Loop 2 View or change the tar get set point of the cur rent step Profile Status Produced Set Point 1 Display the current set point even if the profile is ramping Profile Status Produced Set Point 2 Display the current set point even if the profile is ramping 3 REA Uu D Note Operations Page CIP Class Instance Attribute hex dec Available with PM8 9 only Some parameters in the Profile Status Menu can be changed for the currently running profile but should only be changed by knowledge able personnel and with caution Changing parameters via the Pro file Status Menu will not change the stored profile but will have an immediate impact on the profile that is running Changes made to profile parameters in the Profiling Pages will be saved and will also have an immediate impact on the running profile 1 to 40 1 Ox7A 122 204 22001 1 1 nonE None 61 Instance 1 Ox7A 122 205 22011 uint SEE P Step Start 89 Map1 Map 2 1 RW 22004 uint R Terminate 148 2540 4360 OxB 11 22013 uint R Resume 147 22012 float RW PRUS Pause 146 float RW Pr oF Profile 77 flo
132. be read with other interfaces Available with PM4 PM8 and PM9 models only Watlow EZ ZONE PM Integrated Controller e 48 e Chapter 5 Operations Page Parameter name Description Linearization 1 to 2 Output Error View reported cause for Linearization output malfunction By Process Value Menu Process Value 1 to 2 SvA Source Value A View the value of Source A Linearization 1 is con nected to Source A of Process Value 1 Linearization 2 is con nected to Source A of Process Value 2 Sub Process Value 1 to 2 Svb Source Value B View the value of Source B Linearization 2 is con nected to Source B of Process Value 1 Linearization 1 is con nected to Source B of Process Value 2 oF St Process Value 1 to 2 oFSt Offset Set an offset to be ap plied to this function s output Process Value 1 to 2 o v Output Value View the value of this function block s output Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Operations Page None 61 Open 65 Shorted 127 Measurement error 140 Bad calibration data 139 Ambient error 9 RTD error 14 Fail 32 Math error 1423 Not sourced 246 Stale 1617 Can t process 1659 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C 1 999 000 to 9 999 000 F
133. c Profibus Address Lock 86 A o n b Implicit Output Assembly 88 A S d Alarm Sides 78 A S Alarm Silencing 78 111 AE SP Autotune Set Point 52 100 Attention 41 43 111 Alarm Type 77 110 Altitude Units 67 AUE Autotune 52 100 b P Barometric Pressure 67 Cool Algorithm 71 106 CAL Calibration Menu 98 Cool Output Curve 71 105 Current Error 41 56 111 Current Error 41 Display Units 82 88 Channel 84 Current High Set Point 55 11 Cool Hysteresis 53 106 Communications LED Activ ity 84 CL o Current Low Set Point 55 11 Wait for Time 91 Control Mode 52 Control Mode Active 51 Public Key 96 Communications Menu 84 89 91 95 C P b Cool Proportional Band 53 00 107 Cool Power 51 100 Closed Loop Set Point 52 CSP CSP Closed Loop Working Set P oint 51 CU Current Read 55 Q d m Q m Qa o oi Q 3 j Q Cc o 1 o fr m m Um Tm zB m m 9 o n rr rn rr fu m A N 3 3 Co a LO a 1 a en a gt uc m o a o 1 m 3B Current Menu 55 79 Cu
134. can be read with other interfaces the speed of the serial network 17014 17015 Communications 2 no No 59 DeviceNet Quick YES Yes 106 17016 Connect Enable Watlow EZ ZONE PM Integrated Controller e 86 e Chapter 6 Setup Page LM Available with PM4 PM8 and PM9 models only Setup Page Ez e escription Communications 2 0 to 255 IP Fixed Address Part 4 Set the IP address of this module Each device on the network must have a unique address Communications 2 0 to 255 IP Fixed Address Part 6 Set the IP address of this module Each device on the network must have a unique address Communications 2 0 to 255 IP Fixed Subnet Part 1 Set the IP subnet mask for this module 1 255 55 Communications 2 0 to 255 2 IP Fixed Subnet Part 2 Set the IP subnet mask for this module Communications 2 0 to 255 IP Fixed Subnet Part 3 Set the IP subnet mask for this module Communications 2 0 to 255 IP Fixed Subnet Part 4 Set the IP subnet mask for this module Communications 2 0 to 255 IP Fixed Subnet Part 6 Set the IP subnet mask for this module Communications 2 0 to 255 Fixed IP Gateway Part 1 Communications 2 0 to 255 Fixed IP Gateway Part 2 Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only Modbus Rela Communications 2 0 to 255 IP Fi
135. circuit 20mA Digital output update rate 10Hz Output voltage 24V current limit Output 6 10mA max Output 5 3 pole DIN A MITE 9 or 24mA max 6 Digital Input Output Option 6 DIO Digital input or output Update rate 10Hz Watlow EZ ZONE PM Integrated Controller 129 Switched DC Output voltage 12 to 24V dc controller automatically ad justs based on current draw Max supply current source 40mA at 20V dc and 80mA 12V dc Max lowstate2V Open Collector Max switched voltage is 32V dc Max switched current per output is 1 5A Max switched current for all 6 outputs is 8A Output Hardware e Switched dc 22 to 32V dc 930mA output 1 and 3 10mA for output 2 and 4 e Switched dc open collector 30V dc max 100mA max cur rent sink Solid state relay SSR FormA 0 5A 24V ac min 264V ac max opto isolated without contact suppression 20 VA 120 240V ac pilot duty Electromechanical relay FormC 5A 24 to 240V ac or 30V dc max resistive load 100 000 cycles at rated load 125 VA pilot duty at 120 240V ac 25 VA at 24V ac e Electromechanical relay FormA 5A 24 to 240V ac or 30V dc max resistive load 100 000 cycles at rated load 125 VA pi lot duty at 120 240V ac 25 VA at 24V ac NO ARC relay FormA 15A 24 to 240V ac noV dc resis tive load 2 million cycles at rated load Universal process retransmit Output
136. con trolling a resistive load providing a very short time base for longer heater life Unlike phase angle firing variable time base switching does not limit the cur rent and voltage applied to the heater With variable time base outputs the PID algo rithm calculates an output between 0 and 100 but the output is distributed in groupings of three ac line cycles For each group of three ac line cycles the controller decides whether the power should be on or off There is no fixed cycle time since the decision is made for each group of cycles When used in conjunc tion with a zero cross burst fire device such as a solid state power controller switching is done only at the zero cross of the ac line which helps reduce elec trical noise RFI Variable time base should be used with solid state power 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 relays inductive loads or heaters with unusual resis tance characteristics The combination of variable time base output and a solid state relay can inexpensively approach the ef fect of analog phase angle fired control Select the AC Line Frequency ACL F Setup Page Global Menu 50 or 60 Hz 100 percent output 10 ON 0 OFF 50 percent output 3 ON 3 OFF 66 percent output 6 ON 3 OFF Note When output 1 is
137. cription Control Loop 1 to 2 TRU TUNE Band Set the range centered on the set point within which TRU TUNE will be in effect Use this function only if the con troller is unable to adap tive tune automatically Control Loop 1 to 2 TRU TUNE Gain Select the responsiveness of the TRU TUNE adaptive tuning calcula tions More responsive ness may increase over shoot Control Loop 1 to 2 Autotune Aggressive ness Select the aggressiveness of the autotuning calcu lations Und Under damped 99 Cr t Critical damped 21 Over damped 69 Control Loop 1 to 2 Peltier Delay Set a value that will cause a delay when switching from heat mode to cool mode 0 0 to 5 0 seconds Control Loop 1 to 2 User Failure Action Select what the control ler outputs will do when the user switches control to manual mode oFF to 0 bPL 5 Bumpless maintains same output power if it was less than 7596 and stable otherwise 0 14 fi n Manual Fixed sets output power to Manual Power setting 33 USE User sets output pow er to last open loop set point the user entered 100 Off sets output power 62 FAiL Control Loop 1 to 2 Input Error Failure Select what the control ler outputs will do when an input error switches control to manual mode of Fj Off sets output power 62 Bumpless maintains output power if it was less than 75 and stable otherwise 0 14
138. d 106 Proportional plus Integral PI Control 0008 107 Proportional plus Integral plus Derivative PID Control 107 Dead Bald cea eee Ra eae adie ie WERT RE 107 Variable Time Base iv asser re RR doe 108 Single Set Point Ramping 0 00 cece eee eee eee 108 Cascade Conti x eee penser Eee wed we Rem Mie 108 Compressor Control scrise rns eee eee eens 109 Differential Control 0 0 cece cee IIR 109 Ratio Control 0 cc eee I 109 Duplex Control 22 aa tee brem RR P RR emen 110 Motorized Valve Control 110 ILI PEMEX eE 110 Process and Deviation Alarms 0 0 00 ccc cece eee ee 110 Alarm Set POINTS ei se iem ree a RR ee deans 110 Alarm Hysteresis 2 0 0 0 cece cette ee 110 Alarm Latchifig usos iet Re RR E RR des 111 Alarm Silencing 0 0 0 ccc cece cece enna 111 Alarm BIOCKING s semp rer ERR ERR a weed wed 111 Open Loop Detection llle 111 Programming the EZ Key S 0 00 cece eller 111 Using Password Security 0 00 cc eee eee eee eee 113 Modbus Using Programmable Memory Blocks 114 CIP Communications Capabilities 000ee 114 Software Configuration 0 0 0 cee eee 115 Watlow EZ ZONE PM Integrated Controller e 99 o Chapter 9 Features Saving and Restoring User Settings Recording setup and operations parameter settings for future reference is very important If you uninten tionall
139. de 1 Operations Page Monitor Menu Heat Power 1 Operations Page Monitor Menu Process Value 2 erations Page Monitor Menu value Limit Status o 70 om tn Autotune 1 dle 1 10 User Control Mode 2 7 11 Heat Power 2 12 Cool Power 2 Operations Page Monitor Menu Autotune 2 Operations Page Loop Menu se 14 dle 2 Operations Page Loop Menu imit Set Point Low i Operations Page Limit Menu Limit Set Point High 7 Operations Page Limit Menu Start Profile ction Request O ren Ol E Cool Power 1 i Operations Page Monitor Menu gt o D v 2 None 2 59 1 9 m ov e lojl ja loa Note Numbers within parenthesis indicates the instance Watlow EZ ZONE PM Integrated Controller e 44 e Chapter 4 Home Page Conventions Used in the Menu Pages To better understand the menu pages that follow review the naming conventions used When encoun tered throughout this document the word default implies as shipped from the factory Each page Op erations Setup Profile and Factory and their associ ated menus have identical headers defined below Header Name Visually displayed infor Display mation from the control Describes the function of Parameter Name the given parameter Defines options available for this prompt i e min max values numerical yes no etc further ex planation below Default Values as delivered from the facto
140. ders 100 80 60 Actual Output Power 40 20 PID Calculation Select a nonlinear cool output curve with Cool Out put Curve Setup Menu Loop Menu Control Methods Output Configuration Each controller output can be configured as a heat output a cool output an alarm output or deactivat ed No dependency limitations have been placed on the available combinations The outputs can be con figured in any combination For instance all three could be set to cool Heat and cool outputs use the set point and Oper ations parameters to determine the output value All heat and cool outputs use the same set point value Heat and cool each have their own set of control pa rameters All heat outputs use the same set of heat control parameters and all cool outputs use the same set of cool output parameters Each alarm output has 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 manual mode Auto mode allows the con troller to decide whether to perform closed loop con trol or to follow the settings of Input Error Failure Setup Page Loop Menu The manual mode only allows open loop control The EZ ZONE PM controller is normally used in the auto mode The manual mode is usually only used for specialty appli cations or for troubleshooti
141. e Sensor Selection You need to configure the controller to match the in put device which is normally a thermocouple RTD or process transmitter Select the sensor type with Sensor Type Setup Page Analog Input Menu Sensor Backup Sensor backup maintains closed loop control after an input failure by switching control to input 2 The sen sor backup feature is only available in an EZ ZONE PM Integrated Limit or Remote Set Point controller Turn sensor backup on or off with Sensor Backup Enable Setup Page Analog Input 1 Set Point Low Limit and High Limit The controller constrains the set point to a value be tween a set point low limit and a set point high limit Set the set point limits with Low Set Point and High Set Point Setup Page Loop Menu There are two sets of set point low and high lim its one for a closed loop set point another for an open loop set point 4 High Limit of selected functional range EN Range High Range between High Limit of Sensor and Range Low Set Point High E Set Point Range must be between Range High and Range Low Set Point EN Range Low Range between Low Limit of Sensor and Range High Gas Pressure Low Limit of selected functional range Scale High and Scale Low When an analog input is selected as process voltage or process current input you must choose the value of voltage or current to be the low and high ends For example when using a
142. e mapped to input 10 Instance 1 0x86 134 Map 1 Map2 1to2 3612 0x1B 27 Instance 2 Map 1 Map2 3682 Linearization 1 to 2 1 999 000 to 9 999 000 Instance 1 0x86 134 Output Point 9 Map 1 Map2 1 to 2 Set the value that will be 3610 Ox1A 26 mapped to input 9 Instance 2 Map 2 Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only Watlow EZ ZONE PM Integrated Controller e 66 e Chapter 6 Setup Page Parameter Name Description Process Value 1 to 2 Function Set the function that will be applied to the source or sources Note Differential and Ratio not available using instance 2 Process Value 1 to 2 Pressure Units Set the units that will be applied to the source Process Value 1 to 2 Altitude Units Set the units that will be applied to the source A unt Process Value 1 to 2 Barometric Pressure Set the units that will be applied to the source Process Value 1 to 2 Filter Filtering smooths out the output signal of this function block Increase the time to increase fil tering Digital Input Output 5 to 12 Direction Set this function to oper ate as an input or output Note Setup Page Modbus Rela tive Address Default Instance 1 Map 1 Map2 3320 Instance 2 Map 2 Off 62 Vaisala RH Compen sation 1648 Ldb
143. e calculation defined below 7b or 8b for either the User or Administrator 5 Enter the result of the calculation in the upper display play by using the Up O and Down Q arrow keys or use EZ ZONE Confgurator Software 6 Exit the Factory Page by pushing and holding the Infinity key for two seconds Formulas used by the User and the Administrator to calculate the Password follows Passwords equal 7 User a If Rolling Password r o L L is Off Password P855 equals User Password P A 5 Watlow EZ ZONE PM Integrated Controller e 113 Chapter 9 Features b If Rolling Password r oL is On Password PASS equals P R5 x code Mod 929 70 8 Administrator a If Rolling Password r oL L is Off Password P4855 equals User Password P A 5 A b If Rolling Password m oL L is On Password PASS equals P A S A x code Mod 997 1000 Differences Between a User Without Password User With Password and Administrator User without a password is restricted by the Locked Access Level L o L A User with a password is restricted by the Read Lockout Security c L o C never having ac cess to the Lock Menu Lol An Administrator is restricted according to the Read Lockout Security c L o C however the Ad ministrator has access to the Lock Menu where the Read Lockout can be changed Modbus Using Programmable Memory Blocks When using the Modbus protocol the PM cont
144. e on if the power level is negative the cool will come on Power from the en ergy sources are supplied by the outputs of choice A Curve A PID Set Point Curve B Cascade Curve C Single control Temperature Time Cascade see aaa ee a eee eel anal el See She ee ind alarm 1 2 1 Outer Loop B2 Arig os Be hy Ry i Oy Co Con os Soy s Me 1 1 Power gt Source A k Input 1 gt SourceA Closed Loop SP gt Source B 1 Process Part Control Loop1 PID gio Source E Output i 1 i cascade disable Math Function 1 hom om momo m tV m G m 6o mwo wo cm om om ooo momomo momo momo momo moo momo m B AW eee HENCE ILLE E a Inner Loop 100 Range Low 1 1 100 Range High 1 1 1 1 1 1 Remote SP Oto 100 Heat Output f I L gt Source B Heat Power i 1 1 Input 2 gt Source A Cool Power obl OUIDR i o gt Cool Output i Energy Source Control Loop 2 PID 0 to 100 id 1 1 Math Function output equals Source A when Source E is False Source E disables cascade when True and Math Function output equals PID Loop 1 Closed Loop Set Point Compressor Control The PM PM4 8 9 can be configured for Compres sor control with enhanced firmware The compressor control can save wear on a compressor and prevent it from locking up from short cycling A bypass valve operated by a control ou
145. e on the network must have a unique address 0 to 255 1 IP Actual Address Part 6 Actual IP address of this module Each device on the network must have a unique address Parameter Name Description Diagnostics Diagnostics Diagnostics CEAL Calibration Menu Calibration 1 to 2 Electrical Measure ment Read the raw electrical 3 4e38 to 3 4e38 value for this input in the units corresponding to the Sensor Type Set up Page Analog Input Menu setting Calibration 1 to 2 Electrical Input Offset Change this value to calibrate the low end of the input range 1 999 000 to 9 999 000 Calibration 1 to 2 Electrical Input Slope Adjust this value to calibrate the slope of the input value 1 999 000 to 9 999 000 Calibration 1 or 3 Electrical Output Offset Change this value to calibrate the low end of the output range Calibration 1 or 3 Electrical Output Slope Adjust this value to calibrate the slope of the output value 1 999 000 to 9 999 000 1 999 000 to 9 999 000 Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces If there is only one instance of a menu no submenus will appear Modbus Relative Ad Instance 1 Map 1 Map2 400 400 Instance 2 Map 1 Map2 480 490 Instance 1 Map 1 Map2 378 378 Instance 2 Map 1 Map2 458 468 Instance 1 Map 1 Map2 380 380 Instance 2 Map 1 Map2 460 470 Inst
146. ensor Type TC Linearization J z RTD Leads 2 gt Units Process Scale Low fo Scale High po 8 8 8 F Range Low D F Range High ps9 F Process Error Enable n Process Error Low Value oo Filter 05 nowt Eror Lachin o Parameter Hel Configure the Inputs Set the controller parameters to match the sensors attached to the inputs In Sensor Type set the analog sensor type to match the device wired to this input If a thermocouple is wired to this input set TC Linearization to match the thermocouple s type If an RTD is wired to this input set RTD Leads to match the number of leads on the RTD In Units set the type of units the sensor will measure 004005 v Sensor Backup or Range Not Applicable Copy Settings does not apply for the type of sensor selected As an example notice that when RTD is selected TC Lin earization does not apply and is therefore grayed out To speed up the process of configuration notice that at the bottom of the center column there is an op tion to copy settings If Analog Input 1 and 2 are the same type of sensor click on Copy Settings where a copy from to copy to dialog box will appear allowing for quick duplication of all settings Notice too that by clicking on any of those items in the center column that context sensitive help will ap pear for that particular item in the right hand col umn Watlow EZ ZONE PM
147. eplace fuse Reset breaker Close interlock switch Reset limit Correct wiring issue Apply correct voltage check part number Set unique addresses on network Match protocol between devices Match baud rate between devices Match parity between devices Correct wiring issue Check settings or replace converter Set correct communication port Correct software setup to match con troller Route communications wires away from power wires e Place 120 Q resistor across EIA 485 on last controller Chapter 11 Appendix Process is unstable or never e Controller not tuned correctly reaches set point Process doesn t con trol to set point Control mode is incorrectly set Control set point is incorrect Controller output incorrectly pro grammed Temperature runway Process value continues to increase or decrease past set point Thermocouple reverse wired Controller output wired incorrectly Short in heater Power controller connection to con troller defective Controller output defective Controller defective Sensor input over driven Controller displays internal malfunction message at power up Device Error Heater Error hEr Heater Error Current through load is above current trip set point Current through load is below current trip set point Shorted solid state or mechanical relay Load current incorrect CEr Current Error Open
148. epresent channel 1 Active Process Value and Active Set Point and the second being the same for channel 2 If an other pair is created where the Display Pairs prompt is equal to 3 using the default prompts when the Advance key is pushed two times from the Home Page the upper display will reflect the current control mode and the bottom display would show the output power When configuring the Custom Menu to your liking it should be noted that if 2 change able writable prompts are displayed in a Pair i e Control Mode on top and Idle Set Point on the bot tom only the lower display Idle Set Point can be changed The display can be configured to scroll by go ing to the Factory Page under the Diagnostic Menu and changing the Display Time dt prompt to something greater than 0 If set to 2 the display will scroll every 2 seconds from channel 1 to 2 Gf present and then through all of the custom pairs that are configured Watlow EZ ZONE PM Integrated Controller od us Chapter 4 Home Page Possible Home Page Defaults Dependent on Part Number Op Op Home Page Denice Parameter Page and Menu Active Process Value 1 sabes Operations Page Monitor Menu Mm erations Page Monitor Menu Active Set Point 1 Numerical IF 9th digit of PN is equal to __ IA C J R P T ____ Active Process Value 2 Operations Page Monitor Menu Closed Loop Set Point 2 2 Operations Page Monitor Menu User Control Mo
149. er As an example look in the Operations Page for the Process Value Find the column identified in the header as Modbus and notice that it lists register 360 Because this parameter is a float it is actually represented by registers 360 low order bytes and 361 high order bytes Because the Modbus specifi Watlow EZ ZONE PM Integrated Controller e 45 o Chapter 4 Home Page cation does not dictate which register should be high or low order Watlow provides the user the ability to swap this order Setup Page Co Menu from the default low high L oh to high low h Lo Note With the release of firmware revision 7 00 and above new functions where introduced into this product line With the introduction of these new functions there was a reorganization of Modbus registers Notice in the column identified as Mod bus the reference to Map 1 and Map 2 registers for each of the various parameters If the new func tions namely Math Linearization Process Value Real Time Clock and the Special Output Function are to be used than use Map 2 Modbus registers If the new functions of this product line are not to be used Map 1 legacy PM controls Modbus reg isters will be sufficient The Modbus register map ping can be changed in the Setup Page un der the Menu This setting will apply across the control It should also be noted that some of the cells in the Modbus column contain wording pertaining to an off set Sev
150. eral parameters in the control contain more than one instance such as profiles 4 alarms 4 analog inputs 2 etc The Modbus register shown always represents instance one Take for an example the Alarm Silence parameter found in the Setup Page under the Alarm menu Instance one of Map 1 is shown as address 1490 and 50 is identified as the offset to the next instance If there was a desire to read or write to instance 3 simply add 100 to 1490 to find its address in this case the instance 3 address for Alarm Silence is 1590 The Modbus communications instance can be either 1 or 2 depending on the part number Instance 1 PM 1 Instance 2 PM 2 To learn more about the Modbus protocol point your browser to http www modbus org Common Industrial Protocol CIP DeviceNet amp Ethernet IP Both DeviceNet and EtherNet IP use open object based programming tools and use the same address ing scheme In the following menu pages notice the column header identified as CIP There you will find the Class Instance and Attribute in hexadecimal decimal in parenthesis which makes up the address ing for both protocols The CIP communications instance will always be in stance 2 Data Types Used with CIP Signed 16 bit integer Signed 32 bits long Float IEEE 754 32 bit ASCII 8 bits per character Signed 8 bits byte To learn more about the DeviceNet and EtherNet IP protocol point your browser to h
151. erations Page None 61 Open 65 Shorted 127 Measurement error 140 Bad calibration data 139 Ambient error 9 RTD error 14 Fail 32 Math error 1423 Not sourced 246 Stale 1617 Can t process 1659 Off 62 On 63 oF F Off 62 on On 63 iB c E Inactive 41 AcE Active 5 ic E Inactive 41 C AcEe Active 5 Inactive 41 AcE Active 5 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only Modbus Relative Ad dress Instance 1 Map 1 Map2 3332 Instance 2 Map 2 Instance 1 Map 1 Map2 1012 1132 Offset to next instance equals 30 Instance 1 Map 1 Map2 1132 Offset to next instance equals 30 Instance 1 Map 1 Map2 1328 1568 Offset to next instance equals 20 Instance 1 Map 1 Map2 1648 Offset to next instance equals 20 Instance 1 Map 1 Map2 1368 1608 Instance 2 Map 1 Map2 1628 Instance 1 Map 1 684 724 Map 2 0x70 112 tf CIP Class Instance Attribute hex dec 0x86 134 1to2 Ox1B 27 Profibus Index Param eter ID amp Read 26027 uint R 0x6A 106 5 to 6 7 0x6A 106 7 to 12 a Ox6E 110 1to2 5 Ox6E 110 5 to 10 5 Ox6E 110 3 to 4 5 Watlow EZ ZONE PM Integrated Controller 50
152. es Accuracy 20pA 1 LSD at standard conditions Temperature stability 100 PPM C maximum Resolution Input Ranges 0 to 10V 200 pV nominal 0 to 20 mA 0 5 mA nominal e Potentiometer 0 to 1 2000 eInverse scaling Input Type 3 as Fans o 150 Dec x 3 9 Fass o mo Pec eo o mo pec 0 0 i E a ca Po as Dog gt essa 0 zs Dog wen ex 0 1 Dog Pa s o o av vas som e 10 vars EBENEN mAmps 0 02 2 x mAmps A ES E Potentiometer 1 1000 Ohms 1K range x f o x 8 f o 3s i s f o T m o 9 T rem o o _ Watlow EZ ZONE PM Integrated Controller Chapter 11 Appendix opening Hange cont Potentiometer 1K range Thermis Thermis tor 10K Thermis Thermis 0 to 40KQ 0 to 20K9 0 to 10KQ 0 to 5KQ e 2 252K0 and 10KO base at 77 F 25 C e Linearization curves built in e Third party Thermistor compatibility requirements Alph p Beta THERM Tech 25C niques 2 252K 2 2K3A Current Measurement Accepts 0 50mA signal user programmable range Displayed operating range and resolution can be scaled and are user programmable Requires optional current transformer 2 Digital Input Output Option 2 DIO Digital input update rate 10Hz DC voltage e Max input 36V 3mA Min high state 3V at 0 25mA Max low state 2V Dry contact e Min open resistance 10KO Max closed resistance 500 Max short
153. es Failure to do so may result in damage to equipment and property and or injury or loss of life Note Maximum wire size termination and torque rating 0 0507 to 3 30 mm 30 to 12 AWG single wire termination or two 1 31 mm 16 AWG e 0 8 Nm 7 0 Ib in torque Note Adjacent terminals may be labeled differently depending on the model number Note To prevent damage to the control ler do not connect wires to unused terminals Note Maintain electrical isolation between analog input 1 digital input outputs switched dc open collector outputs and process outputs to prevent ground loops Note The control output common terminal and the digital common terminal are referenced to different voltages and must remain isolated Note This Equipment is suitable for use in CLASS I DIVISION 2 Groups A B C and D or Non Hazardous locations only Temperature Code T4A Warning A Explosion Hazard Substitution of component may impair suitability for CLASS DIVISION 2 Warning A Explosion Hazard Do not disconnect while the circuit is live or unless the area is known to be free of ignitable concentrations of flammable sub stances EIA 232 485 Modbus RTU Communications Slot B E Wire T R to the A termi Do not connect more than 485 TR CB nal of the EIA 485 port one EZ ZONE PM control 485 T R o p e Wire T R to the B termi ler on an EIA 232 netw
154. ess Switched dc cannot use variable time base FJ Universal Process Mechanical relay 5 A form A cannot use variable time base FK Universal Process Solid state relay 0 5 A form A cannot use variable time base KH Solid state relay 0 5 A form A NO ARC 15 A power control KK Solid state relay 0 5 A form A Solid state relay 0 5 A form A With Communications Options 2 6 option AA must be ordered with PM6 above Output options CH EH and KH not available with PM6 Additional Options A Standard C Enhanced firmware including Compressor Control Cascade Ratio Differential Square root Motorized Valve Control without feedback Not available with PM6 Custom Options AA Standard EZ ZONE face plate 12 Class 1 Div 2 Not available with Integrated Limit Controller or mechanical relay outputs Watlow EZ ZONE PM Integrated Controller e 131 Chapter 11 Appendix Index Abt Alarm Blocking 78 111 ACL E AC Line Frequency 82 Alarm Delay 78 Alarm Display 78 Alarm High Set Point 54 10 Alarm Hysteresis 77 110 Analog Input Menu 48 62 Implicit Input Assembly 88 A unb A 5 Alarm Source Instance 77 AL R Alarm Latching 78 111 ALE CALE FARLEY i Alarm Error 1 to 4 41 AL 8 Alarm Logic 77 BL NACA ALAZ ALAY Alarm High 1 to 4 41 ALL HACC ALL 3 RL L 4 Alarm Low 1 to 4 41 RLfP 1 Alarm Menu 54 77 AL o Alarm Low Set Point 54 10 AL o
155. et point 43 Chapter 11 Appendix Channel 84 chattering output 106 chemical compatibility 21 CIP Communications Capabilities 114 CIP Implicit O to T Originator to Target Assembly Structure 114 127 CIP Implicit T to O Target to Origi nator Assembly Structure 127 Closed Loop Set Point 52 Closed Loop Working Set Point 51 communications activity light 40 Communications Menu 84 89 91 95 Setup Page 47 60 Compressor Control 109 Control 68 75 Control Loop Menu 71 control methods 105 Control Mode 52 106 Control Mode Active 51 Control Module Menus Factory Page Calibration Menu 98 Security Setting Menu 95 96 97 Operations Page Alarm Menu 54 Analog Input Menu 48 Current Menu 55 Digital Input Output Menu 50 Limit Menu 50 Linearization Menu 48 Loop Menu 52 Math Menu 56 Monitor Menu 51 Process Value Menu 49 Profile Status Menu 58 Special Output Function Menu 57 Setup Page Alarm Menu 77 Analog Input Menu 62 Communications Menu 84 89 91 95 Control Loop Menu 71 Current Menu 79 Digital Input Output Menu 67 Global Menu 82 Limit Menu 70 Linearization Menu 64 Math Menu 79 Output Menu 74 Process Value 67 Cool Algorithm 71 106 Cool Hysteresis 53 106 cool output curve 105 Cool Output Curve 71 105 Cool Power 51 100 Cool Proportional Band 53 100 107 Current Error 56 111 Current Menu 55 79 current sensing 111 Current Sensing 111 D Data Map 85 Date of Manufacture 97 Dead Band 53 107 Decimal 63
156. ffect when the process temperature is lower than the set point and the cooling param eter takes effect when the process temperature is higher than the set point Watlow EZ ZONE PM Integrated Controller 106 Chapter 9 Features Adjust the proportional band with Heat Pro portional Band or Cool Proportional Band Operations Page Loop Menu 4 Set Point T UIS Proportional Band Droop Temperature Time Proportional plus Integral PI Control The droop caused by proportional control can be cor rected by adding integral reset control When the system settles down the integral value is tuned to bring the temperature or process value closer to the set point Integral determines the speed of the cor rection but this may increase the overshoot at start up or when the set point is changed Too much inte gral action will make the system unstable Integral is cleared when the process value is outside of the proportional band Adjust the integral with Time Integral Operations Page Loop 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 change in the temperature or process value Too much derivative rate will make the system sluggish Derivative action is active only when the process value is within twice the proportional value from the
157. file 1 To go to the Setup Page from the Home Page press both the Up O and Down Q keys for six sec onds will appear in the upper display and will appear in the lower display 2 Press the Up Key O until appears in the upper display and will appear in the lower display 3 Press the Advance Key until Digital Input Lev el appears in the lower display Use an arrow key to specify the state of the key high or low when the controller is powered up Functions will toggle with each press of the EZ Key such as Profile Start Stop 4 Press the Advance Key The lower display will show Digital Function Fa Press the Up or Down Q key to scroll through the functions that can be assigned to the EZ Key When Profile Start Stop appears in the upper display and appears in the lower display press the Advance Key once to select that function and move to the Function Instance parameter 5 Press the Up O or Down O key to scroll to the profile that you want the EZ Key to control 6 The instance tells the controller which of the numbered functions should be acted upon For profiles there are 4 instances Press the Infinity Key once to return to the submenu twice to return to the main menu or three times to re turn to the Home Page Using Lockout to Hide Pages and Menus If unintentional changes to parameter settings might raise safety concerns or lead to downtime your can use the lockout feature to make them more secure
158. fter defining the profile follow the steps below to run the profile 1 From the Home Page push the Advance Key repeatedly until Profile Start appears in the lower display 2 Use the Up or Down Q 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 takes you to Profile Action PAC 1 where you can select the appropriate action e non E No action Pr of Begin execution from first step of the specified profile number whether it exists or not PA Pause the currently running profile rt Resume running the profile from the previously paused step e End End the profile SE EP Begin running the profile from the spec ified step number T EEPROM will cause premature EEPROM failure The EE PROM is rated for 1 000 000 writes To disable EEPROM writes go to the Setup Page and then the menu Proceed to the prompt and set it to no for 1 2 or both Some of the listed parameters may not be visible Parameter visibility is dependent upon controller part number Profiling Parameters PT to P9 C Ato 5E YP Step Type t SP I Target Set Point Loop 1 t SP 2 Target Set Point Loop 2 hor Hours P ia Minutes Seconds Rate Wait For Process Instance Wait For Process 1 Wait For Event 1 Wait for Event 2 Day of Week Jump Step Jump Count End Type Event 1 Event 2 5 7n
159. g 0 0507 to 3 30 mm 30 to 12 AWG single wire termination or two 1 31 mm 16 AWG e 0 8 Nm 7 0 Ib in torque Note Adjacent terminals may be labeled differently depending on the model number Note To prevent damage to the control ler do not connect wires to unused terminals Profibus DP Communications Slot B amp E 5Vdc Voltage Potential VP 485 T R ius 485 T R A Digital ground DG Termination resistor B eee trB 485 T R B 485 T R Termination resistor A tA Wire T R to the A termi nal of the EIA 485 port Wire T R to the B termi nal of the EIA 485 port Wire Digital Ground to the common terminal of the EIA 485 port Do not route network wires with power wires Connect network wires in daisy chain fashion when con necting multiple devices in a network A termination resistor should be used if this con trol is the last one on the network If using a 150 Q cable Wat low provides internal termi nation Place a jumper across pins trB and B and trA and A If external termination is to be used with a 150 Q cable place a 390 Q resis tor across pins VP and B a 220 resistor across pins B and A and lastly place a 390 resistor across pins DG and A Do not connect more than 32 EZ ZONE PM control lers on any given segment Maximum EIA 485 network length 1 200 meters 4 000 feet
160. ge Current Menu to select the output that is driv ing the load Replace or repair sensor or controller Route wires appropriately check for loose connections add line filters Check settings in Factory Page Enter appropriate password in Ut of setting in Factory Page Change state of digital input Change custom parameters in Factory Page Verify EZ Key function in Setup Menu Check that the function instance is correct Replace or repair controller Watlow EZ ZONE PM Integrated Controller e 124 e Chapter 11 Appendix Modbus Programmable Memory Blocks Assembly Definition Addresses and Assembly Working Addresses 200 amp 201 240 amp 241 202 amp 203 242 amp 243 204 amp 205 244 amp 245 206 amp 207 246 amp 247 208 amp 209 248 amp 249 210 amp 211 250 amp 251 DIP2IS219 252 amp 253 214 amp 215 254 amp 255 216 amp 217 256 amp 257 218 amp 219 256 amp 259 220 amp 221 260 amp 261 222 amp 223 262 amp 263 224 amp 225 264 amp 265 226 amp 227 266 amp 267 228 amp 229 268 amp 269 230 amp 231 270 amp 271 232 amp 233 DIR Ea OMB 234 amp 235 274 amp 275 236 amp 237 276 amp 277 238 amp 239 278 amp 279 Assembly Definition Assembly Definition Addresses Assembly Working Addresses Assembl
161. he open loop set point 100 to 100 Output Digital 1 to 4 Function Select what function will drive this output Off 62 Limit 126 Profile Event Out B Fn Profile Event Out A Special Function Out 1533 Special Function Out 1532 Cool 20 Heat 36 Alarm 6 Output Digital 1 to 4 Function Instance Set the instance of the function selected above Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only Modbus Rela tive Address Instance 1 Map 1 Map2 2164 2644 Instance 2 Map 1 Map2 2244 2724 Instance 1 Map 1 Map2 2166 2646 Instance 2 Map 1 Map2 2246 2726 Instance 1 Map 1 Map2 2168 2649 Instance 2 Map 1 Map2 2248 2728 Instance 1 Map 1 Map2 2170 2650 Instance 2 Map 1 Map2 2250 2730 Instance 1 Map 1 Map2 888 1008 Offset to next instance Map 1 amp Map 2 equals 30 Instance 1 Map 1 Map2 890 1010 Offset to next instance Map 1 amp Map 2 equals 30 CIP Class Instance Attribute hex dec Ox6B 107 1to2 3 Ox6B 107 1to2 4 Ox6B 107 1to2 5 Ox6B 107 1to2 6 0x6A 106 83 6005 uint 1to4 RWES 5 0x6A 106 84 6006 uint 1to4 RWES 6 Watlow EZ ZONE PM Integrated Controller e 74 Chapter 6 Setup Page Parameter Name Description Output Digital 1 to 4 Control Set the output control type This
162. hole lot easier to solve the thermal requirements of your system Because the EZ ZONE PM controllers are highly scalable you only pay for what you need So if you are looking for a PID con troller an over under limit controller or an integrat ed controller the EZ ZONE PM is the answer Standard Features and Benefits Advanced PID Control Algorithm e TRU TUNE Adaptive tune provides tighter con trol for demanding applications Auto Tune for fast efficient start ups EZ ZONE configuration communications and software e Saves time and improves the reliability of control ler set up FM Approved Over under Limit with Auxiliary Outputs ncreases user and equipment safety for over under temperature conditions To meet agency requirements output 4 is the fixed limit output Other outputs can be config ured to mirror the limit output 4 Parameter Save amp Restore Memory Reduces service calls and down time Agency approvals UL Listed CSA CE RoHS W E E E FM SEMI F47 0200 Class 1 Div 2 rat ing on selected models Assures prompt product acceptance Reduces end product documentation costs EZ Key s Programmable EZ Key enables simple one touch operation of repetitive user activities Programmable Menu System Reduces set up time and increases operator effi ciency Three year warranty Demonstrates Watlow s reliability and product support Touch safe Package e P2X increased safety for ins
163. hout Communications slot E Input Function l gt 1kQ Thermistor 5kO 10kO 20kQ 40kQ Process V mV mA or 1k Input Sensor l Q 1kQ Thermistor 5kQ 10kO 20kQ 40kQ Process V mV mA None Limit reset Idle set point Tune Alarm clear request Silence alarm Manual auto mode Control mode Remote set point enable Lock keypad Force alarm TRU TUNE disable Loop amp alarms off Profile disable Profile hold resume Profile start Profile start stop Restore user settings Event inputs Math RUI EZ ZONE Controllers PLC PCie_ or HMI Power Supply Analog Input 1 none Thermocouple RTD 100Q Potentiometer Analog Input 2 none CT Thermocouple RTD 100 or 1k Potentiometer EZ Key 1 amp 2 Programmable Functions Digital Input or Output 5 amp 6 optional Programmable Functions Y EIA 485 Communication Standard Bus optional Modbus RTU 100 to 240Vac 20 to 28 Vac or 12 to 40Vdc Note PID Controller Optional Ramp Soak max 4 files 40 steps Slots A Optional process or 0 5A S Output 1 none switched dc open collector 5A mechanical relay form C Output Function off heat cool retransmit alarm duplex or event SR form A Output 2 0 5A SSR form A none 15A NO ARC switched dc 5A mechanical relay form A
164. igital Output 5 to 12 Function Select what function will drive this output Digital Output 5 to 12 Function Instance Set the instance of the function selected above Digital Output 5 to 12 Control Set the output control type This parameter is only used with PID control but can be set anytime Digital Output 5 to 12 Time Base Set the time base for fixed time base control Digital Output 5 to 12 Low Power Scale The power output will never be less than the value specified and will represent the value at which output scaling begins Setup Page Default Off Off 62 Limit 126 Profile Event Out B Profile Event Out A 1533 1532 Cool Power Control 161 Heat Power Control Loop 160 Alarm 6 Fixed Time Base 34 Variable Time Base 103 0 1 for Fast and Bi Direc tional outputs 5 0 for Slow outputs to 60 0 0 to 100 0 Special Function Out Special Function Out Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only CIP Class Instance Attribute hex dec Instance 1 0x6A 106 Map 1 Map2 5to12 1008 1128 5 Modbus Rela tive Address Offset to next instance Map 1 amp Map 2 equals 30 Instance 1 0x6A 106 Map 1 Map2 5to12 1010 1130 6 Offset to next instance Map 1 amp Map 2 equals 30 Instance 1 0x6A 106 Map1 Map2
165. in forced insulation for shock hazard prevention Do not throw in trash use proper recycling techniques or consult manufacturer for proper disposal cC PC Enclosure made of Polycarbonate material Use proper recycling techniques or consult manufac turer for proper disposal Unit can be powered with either alternating current ac voltage or direct current dc voltage Unit is a Listed device per Un derwriters Laboratories It has been evaluated to United States and Canadian requirements for Process Control Equipment UL 61010 and CSA C22 2 No 61010 File E185611 QUYX QUYX7 See www ul com c US 93RL PROCESS CONTROL EQUIPMENT Unit is a Listed device per Un derwriters Laboratories It has been evaluated to United States and Canadian requirements for Hazardous Locations Class 1 Division II Groups A B C and D ANSI ISA 12 12 01 2007 File E184390 QUZW QUZW7 See www ul com Wu 2s81 LISTED PROC CONT EQ FOR HAZARDOUS LOCATIONS CE APPROVED SR DeviceNet CO ORMAMCE TESTED EtherNet IP conformance tested Unit is compliant with European Union directives See Declaration of Conformity for further details on Directives and Standards used for Compliance Unit has been reviewed and ap proved by Factory Mutual as a Temperature Limit Device per FM Class 3545 standard See www fmglobal com Unit has been reviewed and ap proved by CSA International for
166. int Custom Menu Alarm Hysteresis Alarm High Set Point Alarm Low Set Point User Restore Set Display Units Input Calibration Offset P Process Current Read Limit Low Set Point Limit High Set Point Limit Hysteresis Some values will be rounded off to fit in the four character display Full values can be read with other interfaces If there is only one instance of a menu no submenus will appear Modbus Relative Ad dress Instance 1 Map 1 1832 2302 Instance 1 Map 1 1844 2314 Map 2 Map 2 CIP Class Instance Attribute hex dec Param eter ID 14005 uint RWES 14003 uint RWES uint RWE uint RWE uint RWE Chapter 8 Factory Page Factory Page CIP Parameter Name Modbus Class Description Range Default Relative Ad Instance dress Attribute hex dec Security Setting 1to5 5 Read Lock Set the read security clearance level The user can access the selected level and all lower levels If the Set Lockout Secu rity level is higher than the Read Lockout Secu rity the Read Lockout Security level takes priority Security Setting 0 to 5 5 Instance 1 0x67 103 Write Security Map 1 Map2 1 Set the write security 1844 2314 OxOB 11 clearance level The user can access the selected level and all lower levels If the Set Lockout Secu rity level is higher than the Read Lockout Secu rity the Read Lockout Security level takes priority Instance 1 0x67 103 Map 1 Map2
167. interfaces PROM S User Available with PM4 PM8 and PM9 models only or Watlow EZ ZONE PM Integrated Controller e 63 o Chapter 6 Setup Page Parameter Name Description Analog Input 1 to 2 Sensor Backup Enable Enable sensor backup Fr Linearization 1 to 2 Fn Function Set how this function will linearize Source A which is Analog Input 1 Source A of Linearization 2 is Analog Input 2 n iE U Linearization 1 to 2 Set the units of Source A or Analog Input 1 Source A of Linearization 2 is Analog Input 2 Linearization 1 to 2 Input Point 1 Set the value that will be mapped to output 1 Linearization 1 to 2 Output Point 1 Set the value that will be mapped to input 1 Linearization 1 to 2 Input Point 2 Set the value that will be mapped to output 2 Linearization 1 to 2 Output Point 2 Set the value that will be mapped to input 2 Note oF F Off 62 on On 63 Off 62 inte Interpolated 1482 1 999 000 to 9 999 000 1 999 000 to 9 999 000 1 999 000 to 9 999 000 1 999 000 to 9 999 000 Setup Page Modbus Rela Default tive Address Off Instance 1 Map 1 Map2 410 410 Instance 2 Map 1 Map2 490 500 Instance 1 Map 1 Map2 3568 Instance 2 Map 2 Instance 1 Map 1 Map2 3616 Instance 2 Map 2 Source 1539 Relative Humidty Process 75 Power 73 Relative Temperature Absolute Temperature non E None 61 Instance 1
168. ion Temperature control Installation Category II Pollution degree 2 IP66 Rated Voltage and Frequency 100 to 240 V ac 50 60 Hz or 15 to 36 V dc 24 V ac 50 60 Hz Rated Power Consumption 10 VA maximum PM3 PM6 Models 14 VA maximum PM8 PM9 PM4 Models Meets the essential requirements of the following European Union Directives by using the relevant standards show below to indicate compliance 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 EN 61000 4 2 1996 A1 A2 Electrostatic Discharge Immunity EN 61000 4 3 2006 Radiated Field Immunity 10V M 80 1000 MHz 3 V M 1 4 2 7 GHz EN 61000 4 4 2004 Electrical Fast Transient Burst Immunity EN 61000 4 5 2006 Surge Immunity EN 61000 4 6 1996 A1 A2 A3 Conducted Immunity EN 61000 4 11 2004 Voltage Dips Short Interruptions and Voltage Variations Immunity EN 61000 3 2 2006 Harmonic Current Emissions EN 61000 3 3 2005 Voltage Fluctuations and Flicker SEMI F47 2000 Specification for Semiconductor Sag Immunity Figure R1 1 For mechanical relay loads cycle time may need to be extended up to 160 seconds to meet flicker requirements depending on load switched and source impedance 2006 95 EC Low Voltage Directive EN 61010 1 2001 Safety Requirements of electrical equipment for measurement control and laboratory use Part 1 General requireme
169. ion 73 Ramp Rate 73 108 Ramp Scale 73 108 e 135 Range High 63 76 103 Range Low 62 76 103 Ratio Control 109 Read 55 111 Read Lockout Security 112 Real Time Clock 61 receiving a remote set point 103 Remote Enable 52 104 restoring user settings 100 retransmit 104 Retransmit Source 75 Rolling Password 96 RTD Leads 62 S saving user settings 100 Scale High 62 76 103 Scale Low 62 76 103 Seconds 92 secure settings 112 113 Security Setting 95 96 97 sensor backup 103 Sensor Backup Enable 103 sensor selection 103 Sensor Type 62 101 103 Serial Number 97 Set Lockout Security 112 set point high limit 103 Set Point High Limit Open Loop 74 set point low limit 103 Set Point Low Limit Open Loop 74 Setup Page 60 Sides Alarm 78 Limit 70 Silencing 78 111 single set point ramping 108 Software Build 97 Software Configuration 115 Software Revision 97 Source 77 Source Function A 61 Source Function E 61 Source Instance A 61 Source Instance E 61 Special Output Function Menu 57 System Security 113 T Target Set Point 91 temperature units indicator lights 40 Ten Point Linearization 104 Thermistor 62 Time Base 68 75 Time Derivative 53 100 107 Time Integral 53 100 107 TRU TUNE Band 72 101 TRU TUNE Enable 71 101 TRU TUNE Gain 72 101 tuning the PID parameters 100 Chapter 11 Appendix Type 77 110 U Up Key 40 upper display 40 User Failure Action 72 User Password 96 User Res
170. isters 116 amp 117 Pointer 39 2528 amp 2529 Active Set Point Registers 276 amp 277 Value of Pointer 39 Registers 118 amp 119 Pointer 40 2536 amp 2537 Step Time Remaining Registers 278 amp 279 Value of Pointer 40 Watlow EZ ZONE PM Integrated Controller 126 Chapter 11 Appendix CIP Implicit O to T Originator to Target Assembly Structure CIP Implicit Assembly REAL REAL REAL REAL REA REAL REAL REAL REAL 10 REAL CIP Implicit T to O Target to Originator Assembly Structure CIP Implicit Assembly 1 Cawetbechanged Binary Deve Siaus me om 2 0x77 0x02 0x07 INT Analog Input 1 Analog Input Value 0x66 0x01 0x01 REAL 3 0x77 0x02 0x02 DINT __ Analog Input 1 Input Error _0x68 0x01 0x02 REAL a 0x77 0x02 0x03 DINT Analog Input 2 Analog Input Value s 0x77 0x02 0x08 DINT Analog Input 2 Input Error 0x77 0x02 0x05 Alarm 1 Alarm State 0x77 0x02 0x06 Alarm 2 Alarm State 0x77 0x02 0x07 Alarm 3 Alarm State O co mli x77 0x02 0x08 Alarm 4 Alarm State 0x77 0x02 0x09 Event Status 0x77 0x02 Ox0A Event Status 0x77 0x02 OxOB Control Mode Active 13 0x77 0x02 0x0C Heat Power 4 0x77 0x02 OxOD Cool Power 15 0x77 0x02 OxOE Limit State 6 0x77 0x02 OxOF Profile Start N pas 17 0x77 0x02 0x10 Profile Action Request Current Pr
171. it control acti vated Wiring error ncorrect voltage to controller Address parameter incorrect ncorrect protocol selected Baud rate incorrect Parity incorrect Wiring error EIA 485 converter issue ncorrect computer or PLC communi cations port ncorrect software setup Wires routed with power cables Termination resistor may be required 123 Check cause of over temperature Clear limit Establish correct limit set point Set correct Open Loop Detect Time for application Set correct Open Loop Deviation value for application Determine cause of open thermal loop misplaced sensors load failure loss of power to load etc Deactivate Open Loop Detect feature Set correct Open Loop Detect Time for application Set correct Open Loop Deviation value for application Set output function correctly Wire thermocouple correctly red wire is negative Disable ramping feature if not re quired Wait until autotune completes or dis able autotune feature Set digital input to function other than autotune if desired Set output function correctly Set control mode appropriately Open vs Closed Loop 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 controller model for ap plication urn on power R
172. it is live or unless the area is known to be free of ignitable concentrations of flammable sub stances Output 2 4 NO ARC Relay Form A normally open common Slot A B H r HE 15 A at 85 to 264V ac resis tive load only 2 000 000 cycle rating for no arc circuit 100 mA minimum load 2mA maximum off state leakage Do not use on dc loads Output does not supply power Output 2 L2 K2 PM H Output 4 L4 K4 PM 4 8 9 s Output 2 4 Mechanical Relay Form A normally open common Slot A B H r HE e 5 A at 240V ac or 30V dc maximum resistive load 20 mA at 24V minimum load 125 VA pilot duty 120 240V ac 25 VA at 24V ac 100 000 cycles at rated load Output does not supply power for use with ac or dc See Quencharc note Output 2 L2 K2 PM __ J 4 Output 4 L4 K4 PM __ J _ Output 2 4 Solid State Relay Form A normally open common Slot A B Amps RMS 0 5 A at 20 to 264V ac maxi mum resistive load 20 VA 120 240V ac pilot duty opto isolated without contact suppression maximum off state leakage of 105 microamperes Output does not supply power Do not use on dc
173. it will Instance 2 trigger an input error Map 1 Map2 500 510 Analog Input 1 to 2 Curve A 1451 Instance 1 0x68 104 Thermistor Curve Curve B 1452 Map 1 Map2 1 to 2 Select a curve to apply to Curve C 1453 434 434 20x6 38 the thermistor input Custom 180 Instance 2 Map 1 Map2 514 524 Analog Input 1 to 2 5K 1448 Instance 1 0x68 104 Resistance Range 10K 1360 Map 1 Map2 1 to 2 Set the maximum resis 20K 1361 432 432 0x25 37 tance of the thermistor 40K 1449 Instance 2 input Map 1 Map2 512 522 Analog Input 1 to 2 0 0 to 60 0 seconds Instance 1 0x68 104 Filter Map 1 Map2 1 to 2 Filtering smooths out the 386 386 OxE 14 process signal to both the Instance 2 display and the input Map 1 Map2 Increase the time to in 466 476 crease filtering Analog Input 1 to 2 oF F Off 62 Instance 1 0x68 104 Error Latching on On 63 Map1 Map2 1to2 Turn input error latching 414 414 Ox1C 28 on or off If latching is on Instance 2 errors must be manually Map 1 Map2 cleared 494 504 Analog Input 1 to 2 C Q Whole 105 Instance 1 0x68 104 Display Precision 80 Tenths 94 Map 1 Map2 1to2 Set the precision of the 808 Hundredths 40 398 398 0x14 20 displayed value B800 Thousandths 96 Instance 2 Map 1 Map2 478 488 amp e n et Note R Read Some values will be rounded off to fit in the four character display Full values can be read W Write i d E EE with other
174. k a Menu in the tree to view and edit its settings Click Finish to save and exit Parameter Menus Analog Input Analog Input 1 Analog Input 2 Digital 1 0 Digital 1 0 5 Digital 1 0 6 E Limit Limit 1 Control Loop Control Loop 1 Output Output 1 Output 2 Output 3 Output 4 El Alarm Alam 1 Alarm 2 Alam 3 Alam 4 Function Key Function Key 1 2i Global Global 1 Communications Communications 1 Operations Analog Input 4 Cancel In the screen shot above notice that the device part number is clearly displayed at the top of the page green highlight added for emphasis When multiple EZ ZONE devices are on the network it is important that the part number be noted prior to configuring so as to avoid making unwanted configuration changes to another control Display Precision Whole Help Looking closely at the left hand column Parameter Menus notice that it displays all of the available menus and associated parameters within the control The menu structure as laid out within this software follows Setup Operations Factory Profile Navigating from one menu to the next is easy and clearly visible Simply slide the scroll bar up or down to display the menu and parameter of choice As an alternative clicking on the negative symbol next to Setup will collapse the Setup Menu where the Op erations Menu will appear next and perhaps deliver Parameters Setup Analog Input 1 S
175. lay The upper display will display for manual mode Use the Up O or Down O keys to select AUE o The automatic set point value will be recalled from the last automatic operation Changes take effect after three seconds or imme diately upon pressing either the Advance Key or the Infinity Key On Off Control On off control switches the output either full on or full off depending on the input set point and hys teresis values The hysteresis value indicates the amount the process value must deviate from the set point to 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 er to the set point but the output would switch on and off more frequently and may result in the output chattering On off control can be selected with Heat Algorithm or Cool Algorithm Setup Page Loop Menu On off hysteresis can be set with Heat Hysteresis or Cool Hysteresis Operations Page Loop Menu Note Input Error Failure Mode does not function in on off control mode The output goes off 4 The heating action switches off when the process temperature rises above the set point x Set Point NS Process Temperature Temperature Hysteresis The heating action switches on when the process temperature drops below the set point minus the hysteresis The he
176. le for use in CLASS I DIVISION 2 Groups A B C and D or Non Hazardous locations only Temperature Code T4A Warning A Explosion Hazard Substitution of component may impair suitability for CLASS I DIVISION 2 Warning A Explosion Hazard Do not disconnect while the circuit is live or unless the area is known to be free of ignitable concentrations of flammable sub stances Quencharc Wiring Example In this example the Quencharc circuit Watlow 1 partit 0804 0147 0000 is used to protect PM internal circuitry from the counter electro magnetic force from the inductive user load when de engergized It is recommended that this or an equivalent Quencharc be used when connecting inductive loads to PM outputs User Load L DOD Quencharc Standard Bus EIA 485 Communications Slot C CD CE C F common TJR T R Wire T R to the A terminal of the EIA 485 port Wire T R to the B terminal of the EIA 485 port Wire common to the common terminal of 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 120 Q termination resistor may be required across T R and T R placed on the last PM 4 6 8 9 ___ _ controller on the network Do not connect more
177. losed Loop Set Point If you need to adjust the tuning procedure s ag gressiveness use Autotune Aggressiveness Setup Page Loop Menu Select Under Damped Undr to bring the process value to the set point quickly Select over damped to bring the pro cess value to the set point with minimal overshoot Select critical damped to balance a rapid re sponse with minimal overshoot Process Set Point Autotune begins Autotune complete ES Autotune Set Point 90 percent of Process Set Point Temperature Manual Tuning In some applications the autotune process may not provide PID parameters for the process characteris tics you desire If that is the case you may want to tune the controller manually 1 Apply power to the controller and establish a set point typically used in your process 2 Goto the Operations Page Loop Menu and set Heat Proportional Band and or Cool Pro portional Band to 5 Set Time Integral to 0 Set Time Derivative to 0 3 When the system stabilizes watch the process value If it fluctuates increase the Heat Propor tional Band or Cool Proportional Band value in 3 to 5 increments until it stabilizes allowing time for the system to settle between adjustments 4 When the process has stabilized watch Heat Power or Cool Power Operations Page Monitor Menu It should be stable 2 At Watlow EZ ZONE PM Integrated Controller 100 Chapter 9 Features this point the pr
178. ls may be labeled differently depending on the model number Note To prevent damage to the control ler do not connect wires to unused terminals Note Maintain electrical isolation between analog input 1 digital input outputs switched dc open collector outputs and process outputs to prevent ground loops Note The control output common terminal and the digital common terminal are referenced to different voltages and must remain isolated Note This Equipment is suitable for use in CLASS I DIVISION 2 Groups A B C and D or Non Hazardous locations only Temperature Code T4A Warning A Explosion Hazard Substitution of component may impair suitability for CLASS I DIVISION 2 Warning A Explosion Hazard Do not disconnect while the circuit is live or unless the area is known to be free of ignitable concentrations of flammable sub stances Warning A Explosion Hazard Dry contact closure Digital Inputs shall not be used in Class Division 2 Hazardous Locations unless switch used is approved for this ap plication Low Power Slot C power m 98 fuse 99 power Minimum Maximum Ratings 12 to 40V dc 20 to 28V ac Semi Sig F47 47 to 63 Hz 14VA maximum power consumption PM4 8 and 9 10VA maximum power consumption PM6 PM 3 4 High Power Slot C power m 98 fuse power 99
179. m e Minimum Maximum Ratings e 85 to 264V ac e 100 to 240V ac Semi Sig F47 e 47 to 63 Hz e 14VA maximum power consumption PMA 8 and 9 10VA maximum power consumption PM6 PM 1 2 Digital Input 5 6 198 99 CF CD CE common DC input DC Input Slot C B5 D6 D5 Digital Input Update rate 10 Hz Dry contact or dc voltage DC Voltage Input not to exceed 36V at 3 mA e Input active when gt 3V 0 25 mA Input inactive when 2V Dry Contact Input inactive when gt 500 0 e Input active when lt 100 Q e maximum short circuit 13 mA PM I24 Voltage Input B Sun E Y Cy E D Watlow EZ ZONE PM Integrated Controller s 25 o Chapter 2 Install and Wire Warning A N Use National Electric NEC or other country specific standard wiring and safety practices when wiring and connecting this controller to a power source and to electrical sensors or pe ripheral devices Failure to do so may result in damage to equipment and property and or injury or loss of life Note Maximum wire size termination and torque rating 0 0507 to 3 30 mm 30 to 12 AWG single wire termination or two 1 31 mm 16 AWG e 0 8 Nm 7 0 Ib in torque Note
180. mV mA or 1k Optional Potentiometer Ramp Soak max 4 files 40 steps IN Output 2 lt none 15A NO ARC switched dc off heat cool 5A mechanical relay form A or J gt alarm or event Slots A 0 5A SSR form A Optional EN Current Transformer gumus ff heat none switched dc open collector Cui lieu COC t t alarm Sense toD 5A mechanical relay form C duplex Pe event process or 0 5A SSR form A Analog Input 2 Current gt Current Transformer Transformer Slots B utput Optional none 15A NO ARC switched d off heat cool hone 5A mechanical relay form A or i aug event e Idle set point 0 5A SSR form A Tune If limit this output Alarm clear request must be limit Silence alarm Manual auto mode Control mode Remote set point enable Lock keypad Ls EZ Key DN Programmable Functions Modbus Force alarm 8 Address 1 247 TRU TUNE disable TE Loop amp alarms off Digital Output or Input 5 amp 6 ot heat cool Profile disable Digital Input or Output 5 amp 6 optional optional none switched de prea ete Profile hold resume Programmable Functions Profile start Standard Bus Profile start stop Zone Address Restore user settings 1 16 Event inputs LEDs Math vui pdt Channel
181. man ual open loop mode Note Operations Page 0 001 to 9 999 000 F or units 1 110 555 to 5 555 000 C 0 001 to 9 999 000 F or units 1 110 555 to 5 555 000 C 0 001 to 9 999 000 F or units 1 110 555 to 5 555 000 C 0 to 9 999 seconds per repeat 0 to 9 999 seconds 1 000 0 to 1 000 0 F or units 556 to 556 C 100 to 100 heat and cool 0 to 100 heat only 100 to 0 cool only Modbus Relative Ad dress Instance 1 Map 1 Map2 1900 2380 Instance 2 Map 1 Map2 1970 2450 Instance 1 Map 1 Map2 1892 2370 Instance 2 Map 1 Map2 1962 2442 Instance 1 Map 1 Map2 1902 2382 Instance 2 Map 1 Map2 1972 2522 Instance 1 Map 1 Map2 1894 2374 Instance 2 Map 1 Map2 1964 2444 0 0 seconds Instance 1 Map 1 Map2 1896 2376 Instance 2 Map 1 Map2 1966 2446 Instance 1 Map 1 Map2 1898 2378 Instance 2 Map 1 Map2 1968 2448 Instance 1 Map 1 Map2 2162 2642 Instance 2 Map 1 Map2 2242 2722 Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only CIP Class Instance Attribute hex dec 0x97 151 1 to 2 OxB 11 0x97 151 1 to 2 7 0x97 151 1 to 2 OxC 12 0x97 151 1to2 8 0x97 151 1to2 9 0x97 151 1to2 OxA 10 Ox6B 107 Param eter ID amp Read 8010 float Profibus Watlow EZ ZONE PM Integrated Controller
182. mber Diagnostics Serial Number Display the serial num ber 0 to 2 147 483 647 Diagnostics Date of Manufacture Display the date code 0 to 2 147 483 647 Diagnostics IP Address Mode Actual address mode DHCP or Fixed dh CP DHCP 1281 Fixed Address 1284 DA Diagnostics IP Actual Address Part 1 Actual IP address of this module Each device on the network must have a unique address cyn ps 5 Diagnostics IP Actual Address Part 2 Actual IP address of this module Each device on the network must have a unique address Diagnostics IP Actual Address Part 3 Actual IP address of this module Each device on the network must have a unique address cyn tU 5 Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces If there is only one instance of a menu no submenus will appear Modbus Relative Ad Instance 1 Map 2 8 CI P Class Param Instance ter ID Attribute Index dec 3022 hex 0x65 101 1 Ox11 10 1 string RWE string R dint R 17 0x65 string 1 RWE Watlow EZ ZONE PM Integrated Controller e 97 e Chapter 8 Factory Page Factory Page aes 0 to 255 1 IP Actual Address Part 4 Actual IP address of this module Each device on the network must have a unique address 0 to 255 1 IP Actual Address Part 5 Actual IP address of this module Each devic
183. me can be changed in the Setup Page under the Output Menu EZ ZONE PM Default Configuration Input Process Output Function Value ED Function Controller Analog Input 1 Heat Heat Input Sensor P Output 1 puts Thermocouple Type J Me nm E Loop 1 oft Watlow EZ ZONE PM Integrated Controller Chapter 1 Overview EZ ZONE PM Integrated Model 1 16 DIN System Diagram With a Current Transformer Without Communications Card Slot B Input Output Functions PID Ginna Functions goto none switched dc open collector 5A PRIUS dee Analog Input 1 TS ME Mud DUE VOIE USE Ramp Soak max 4 none Thermocouple RTD 1000 Input Sensor gt 1kQ Thermistor 5kO 10kO 20kQ 40kQ Process V mV mA or 1k Potentiometer files 40 steps Output 2 none 15A NO ARC switched dc 2 off heat cool None Slot A 5A mechanical relay form A or alarm event Idle set point Optional 0 5A SSR form A Tune Alarm clear request Force alarm Silence alarm Manual auto mode Control outputs off fe us Remote set point ete sin Digital Input or Output 5 amp 6 Saale Lock ki d i i EE Pook Ke pda n P optional none switch volts dc Digital Output or Input 5 amp 6 off heat cool Loop amp alarms off Standard Bus optional none switched dc i Profile disable
184. mode TRU TUNE continu ously tunes to provide the best possible PID control for the process A WARNING During autotuning the controller sets the out put to 100 percent and attempts to drive the Process Value toward the set point Enter a set point and heat and cool power limits that are within the safe operating limits of your system Watlow EZ ZONE PM Integrated Controller e 101 Chapter 9 Features Inputs Calibration Offset Calibration offset allows a device to compensate for an inaccurate sensor lead resistance or other factors that affect the input value A positive offset increases the input value and a negative offset decreases the input value The input offset value can be viewed or changed with Calibration Offset Operations Page Analog Input Menu Negative Calibration Offset will compensate for the difference between the Sensor Reading and the Actual Temperature Temperature Reading from Sensor Temperature Actual Process Temperature Time Calibration To calibrate an analog input you will need to provide two electrical signals or resistance loads near the ex tremes of the range that the application is likely to utilize See recommended values below fmillismps nomma 20 000 Follow these steps for a thermocouple or pro cess input 1 Apply the low source signal to the input you are calibrating Measure the signal to ensure it is ac curate
185. mp E E Watlow EZ ZONE PM Integrated Controller 85 o Chapter 6 Setup Page Setup Page CIP Modbus Rela Class Parameter Name Param eccrine Range Default tive Instance aa iD Address Attribute Index hex dec Communications 2 125 125 kb 1351 125 17053 Baud Rate DeviceNet 258 250 kb 1352 Set the DeviceNet speed _50 500 kb 1353 for this gateway s com munications to match 17061 E 17012 B Allows for immediate communication with the Scanner upon power up Communications 2 0 to 126 Profibus Node Address Set the Profibus address for this control Communications 2 no No 59 Profibus Address Lock YES Yes 106 When set to yes will not allow address to be changed using software Can be changed from front panel Communications 2 DHCP 1281 IP Address Mode F Rid d Fixed Address 1284 Select DHCP to let a DHCP server assign an address to this module Communications 2 0 to 255 IP Fixed Address Part 1 Set the IP address of this module Each device on the network must have a unique address Communications 2 0 to 255 IP Fixed Address Part 2 Set the IP address of this module Each device on the network must have a unique address Communications 2 0 to 255 IP Fixed Address Part 8 Set the IP address of this module Each device on the network must have a unique address Note Some values will be rounded off to fit in the four character display Full values
186. n These are typically more expensive valves because of the control mechanism built in plus it requires an analog signal which is not always available The actual valve position is not critical because it is a part of a closed loop control The Motorized Valve control algorithm is designed to work with another type of valve This algorithm pro vides two discrete signals one to open the valve and an other to close the valve The algorithm turns on off the appropriate signal for an appropriate amount of time to approximate the valve position This works when the valve is inside a closed control loop because when the valve is not in the correct position the PID algorithm will adjust the valve further open or close as needed These valves have travel limit switches which deac tivates the motor once the valve is fully open or fully closed so the controller can not cause the valve to over travel and burn out the motor or the motor is built so it can not overheat at max locked rotor amperes To use the motorized feature the user programs the Special Output Function to Motorized Valve Then the Source Function A is selected to either Heat or Cool Power and Source Instance A is set to match the control loop typically 1 Next the user enters the amount of time in seconds that the valve requires power to go from a closed state to an open state The user enters the dead band in percent PID power to prevent the valve from excessive cycling Large
187. n Hazardous locations only Temperature Code T4A Warning A Explosion Hazard Substitution of component may impair suitability for CLASS I DIVISION 2 Warning A Explosion Hazard Do not disconnect while the circuit is live or unless the area is known to be free of ignitable concentrations of flammable sub stances Quencharc Note Switching pilot duty inductive loads relay coils solenoids etc with the mechanical relay solid state relay or open collector output options requires use of an R C sup pressor Output 1 3 Switched DC Open Collector SlotA B Switched DC cemmon ix e 30 mA dc maximum supply cur dc open collector W rent dc Y e Short circuit limited to 50 mA e 22 to 32V dc open circuit volt age e Use dc and dc to drive exter nal solid state relay e DIN A MITE compatible e Single pole up to 4 in parallel or 4 in series 2 pole up to 2 in parallel or 2 in series e 3 pole up to 2 in series Open Collector 100 mA maximum output cur rent sink 30V dc maximum supply volt age Any switched dc output can use the common terminal Use an external power supply to control a dc load with the load positive to the positive of the power supply the load negative to the open collector and com mon to the power supply nega tive Output 1 X1 W1 Y1 PM___ C _ Output
188. n on the display would then represent percent humidity and range from 0 to 100 percent with an input of 4 to 20 mA Select the low and high values with Range Low and Range High Setup Page Analog Input Menu Receiving a Remote Set Point The remote set point feature allows the controller to use a thermocouple RTD 1 k potentiometer or process signal at input 2 to establish the set point which allows its set point to be manipulated by an external source A common application would use one ramping controller with a set point retransmit out put to ramp multiple controllers using the remote set point Or you could use an analog output from a PLC to send set point values to an EZ ZONE PM The controller must have two process inputs to use the remote set point feature You may select between local and remote set points at the front panel with an event input from a remote computer using the communications fea ture or from an external switch using an event input Make sure all input and output impedances are com patible Watlow EZ ZONE PM Integrated Controller e 103 gt Chapter 9 Features Switch to the remote set point with Remote En able Operations Page Loop Menu Select whether the remote set point controls an open or closed loop set point with Remote Set Point Type ct S Assign the function of switching to a remote set point to a digital input with Digital Input Function F n Setup Page Digital Inp
189. ness User Tune Aggressiveness TRU TUNE Band 72 TRU TUNE Band 101 Thermistor Curve 63 Time Derivative 53 100 07 TRU TUNE Gain 72 01 Time Integral 53 100 107 TRU TUNE Enable 71 01 Valve Travel Time 81 Tuning 41 EUng Tuning 1 or 2 41 User Failure Action 72 User Restore Set 84 100 User Save Set 84 100 Wait Event 2 92 e 133 Zone 84 A AC Line Frequency 82 108 Active Event Output 1 or 2 59 Active Step 58 Active Step Type 58 adaptive tuning 101 Address Modbus 85 Address Standard Bus 84 85 88 Administrator Password 96 Advance Key 40 agency approvals 4 alarm blocking 111 Alarm Menu 54 77 alarms 108 Blocking 78 111 deviation 110 Display 78 Hysteresis 77 110 Latching 78 111 Logic 77 process 110 set points 110 Sides 78 Silencing 78 111 Source 77 Type 77 Altitude Units 60 Analog Input Menu 48 62 Assembly Definition Addresses 125 Assembly Definition Addresses 114 Assembly Definition Addresses and Assembly Working Addresses 125 Assembly Working Addresses 114 125 Attention Codes 41 43 auto closed loop control 105 Autotune 100 Autotune Aggressiveness 72 Autotune Request 52 Autotune Set Point 52 100 autotuning 100 101 autotuning with TRU TUNE 101 B Barometric Pressure 60 Baud Rate 85 Blocking 78 111 bumpless transfer 105 C calibrating an analog input 102 Calibration Menu 98 Calibration Offset 48 77 102 103 Cascade Control 108 changing the s
190. ng Manual mode is open loop control that allows the user to directly set the power level to the controller s output load No adjustments of the output power level occur based on temperature or set point in this mode In auto mode the controller monitors the input to determine if closed loop control is possible The con troller checks to make certain a functioning sensor is providing a valid input signal If a valid input signal is present the controller will perform closed loop con trol Closed loop control uses a process sensor to de termine the difference between the process value and the set point Then the controller applies power to a control output load to reduce that difference If a valid input signal is not present the control ler will indicate an input error message in the upper display and in the lower display and respond to the failure according to the setting of Input Error Failure FA L You can configure the controller to perform a bumpless transfer b PL 5 switch power to output a preset fixed level 784 or turn the out put power off Bumpless transfer will allow the controller to transfer to the manual mode using the last power value calculated in the auto mode if the process had stabilized at a 5 percent output power level for the time interval of Time Integral Operations Page Watlow EZ ZONE PM Integrated Controller e 105 Chapter 9 Features Loop prior to sensor failure and that p
191. now what those passwords are to acquire a higher level of access to the control Back out of this menu by pushing the Infinity key Once out of the menu the Password Security will be enabled How to Acquire Access to the Control To acquire access to any inaccessible Pages or Menus go to the Factory Page and enter the UL oC menu Once there follow the steps below Note If Password Security Password Enabled PA 5 is On is enabled the two prompts mentioned below in the first step will not be visible If unknown call the individual or company that originally set up the control 1 Acquire either the User Password P 45 u or the Administrator Password PA 5 8 2 Push the Advance key one time where the Code Cod E prompt will be visible Note a If the the Rolling Password is off push the Ad vance key one more time where the Password P amp S55 prompt will be displayed Proceed to either step 7a or 8a Pushing the Up O or Down O arrow keys enter either the User or Adminis trator Password Once entered push and hold the Infinity key for two seconds to return to the Home Page b If the Rolling Password r ol L was turned on proceed on through steps 3 9 3 Assuming the Code Co d prompt Public Key is still visible on the face of the control simply push the Advance key to proceed to the Password P A 5 5 prompt If not find your way back to the Factory Page as described above 4 Execute th
192. nt values Communications 1 Data Map If set to 1 the control will use PM legacy mapping If set to 2 the control will use new mapping to accommodate new func tions Communications 1 Non volatile Save If set to Yes all values written to the control will be saved in EE PROM Communications 2 DeviceNet Node Ad dress Set the DeviceNet ad dress for this gateway Note Setup Page 9 600 188 19 200 189 38 400 190 non None 61 Eu En Even 191 odd Odd 192 F Fahrenheit 30 C Celsius 15 Loh Low High 1331 h L o High Low 1330 YES Yes 106 no No 59 Default 9 600 Low High Instance 1 1 if gth digit of part number isa Dor 1 other wise 2 Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only Modbus Rela tive Address Instance 1 Map 1 2482 Map 2 2962 Instance 1 Map 1 2484 Map 2 2964 Instance 1 Map 1 2486 Map 2 2966 Instance 1 Map 1 2490 Map 1 2488 Map 2 2970 Map 2 2968 Instance 1 Map 1 2494 Map 2 2974 CIP Class Instance Attribute Index hex dec 0x96 150 il 2 0x96 150 I 3 0x96 150 17003 1 4 0x96 150 17050 1 6 0x96 150 17043 1 5 Param eter ID 17007 17002 B 0x96 150 17051 I 8 17052 8 amp 8 E Z Is tj EE E tj E a
193. ntain electrical isolation between analog input 1 digital input outputs switched dc open collector outputs and process outputs to prevent ground loops Note The control output common terminal and the digital common terminal are referenced to different voltages and must remain isolated Note This Equipment is suitable for use in CLASS I DIVISION 2 Groups A B C and D or Non Hazardous locations only Temperature Code T4A Warning A Explosion Hazard Substitution of component may impair suitability for CLASS I DIVISION 2 Warning A Explosion Hazard Do not disconnect while the circuit is live or unless the area is known to be free of ignitable concentrations of flammable sub stances Connecting a Computer to PM Controls Using B amp B 485 to USB Converter asn EZ Configurator AC f a Model 485TB 2W 8 BAB electronics GND 0847 0326 0000 PC Software Protocol Standard Bus Address 1 WATLOW EZ ZONE Address 2 WATLOW EZ ZONE g 2 g gt o o o0 0 co E coo o foa Data format mal E Co 38 400 baud 8 data bits nat q z no parity jma 1 start bit nt mj m Coy En 1 stop bit R PM6 A A PM6____ A___A__ Use twisted pair wires such as Cat 5 cabling Do not route with power carrying conductors Daisy chain wire up to 16 EZ ZONE
194. nts Compliant with 2002 95 EC RoHS Directive Per 2002 96 EC W E E E Directive Please Recycle Properly Raymond D Feller III Winona Minnesota USA Name of Authorized Representative Place of Issue General Manager June 2009 Title of Authorized Representative Date of Issue CE DOC EZ ZONE PM 06 09 Watlow EZ ZONE PM Integrated Controller e 137 e Chapter 11 Appendix How to Reach Us Corporate Headquarters Watlow Electric Manufacturing Company 12001 Lackland Road St Louis MO 63146 Sales 1 800 WATLOW2 Manufacturing Support 1 800 4WATLOW Email info watlow com Website www watlow com From outside the USA and Canada Tel 1 314 878 4600 Fax 1 314 878 6814 Latin America Watlow de M xico S A de C V Av Fundici n No 5 Col Parques Industriales Quer taro Qro CP 76130 Mexico Tel 52 442 217 6235 Fax 52 442 217 6403 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 Europe Watlow France Tour d Asni res 4 Avenue Laurent C ly 92600 Asni res sur Seine France T l 33 0 1 41 32 79 70 T l copie 33 0 1 47 33 36 57 Email info watlow fr Website www watlow fr Watlow GmbH Postfach 11 65 Lauchwasenstr 1 D 76709 Kronau
195. o next instance Map 1 equals 50 Map 2 equals 100 Instance 1 Map 1 2594 0x79 121 1 to 40 OxD 13 Map 2 4524 Offset to next instance Map 1 equals 50 Map 2 equals 100 Instance 1 Map 1 2596 0x79 121 1 to 40 OxE 14 Map 2 4526 Offset to next instance Map 1 equals 50 Map 2 equals 100 Instance 1 Map 1 2582 0x79 121 Map 2 1 to 40 4512 7 Offset to next instance Map 1 equals 50 Map 2 equals 100 Instance 1 Map 1 2584 0x79 121 Map 2 1 to 40 4514 8 Offset to next instance Map 1 equals 50 Map 2 equals 100 R Read W Write E EEPROM S User Set Watlow EZ ZONE PM Integrated Controller 93 o Chapter 7 Profiling Page Chapter 8 Factory Page Navigating the Factory Page To go to the Factory Page from the Home Page press the Up O or Down Q key to select and then press and hold both the Advance and Infinity press the Advance Key to enter keys for six seconds Press the Up O or Down Q key to move through e Press the Up O or Down Q key to view available available menu prompts menus On the following pages top level menus Press the Infinity Key to move backwards are identified with a yellow background color through the levels parameter to submenu sub Press the Advance Key to enter the menu of menu to menu menu to Home Page choice Press and hold the Infinity Key for two seconds f a submenu exis
196. ocess temperature should also be stable but it will have stabilized before reach ing the set point The difference between the set point and actual process value can be eliminated with Integral 5 Start with an Integral value of 6 000 and allow 10 minutes for the process temperature to reach the set point If it has not reduce the setting by half and wait another 10 minutes Continue re ducing the setting by half every 10 minutes until the process value equals the set point If the pro cess becomes unstable the Integral value is too small Increase the value until the process stabi lizes 6 Increase Derivative to 0 1 Then increase the set point by 11 to 17 C Monitor the system s ap proach to the set point If the process value over shoots the set point increase Derivative to 0 2 Increase the set point by 11 to 17 C and watch the approach to the new set point If you increase Derivative too much the approach to the set point will be very sluggish Repeat as necessary until the system rises to the new set point with out overshoot or sluggishness For additional information about autotune and PID control see related features in this chapter Autotuning with TRU TUNE The TRU TUNE adaptive algorithm will optimize the controller s PID values to improve control of dy namic processes TRU TUNE monitors the Process Value and adjusts the control parameters automati cally to keep your process at set point du
197. of Pointer 5 Value of Pointer 15 Registers 70 amp 71 Registers 230 amp 231 Registers 50 amp 51 Registers 210 amp 211 Pointer 16 1894 amp 1895 Time Integral Value of Pointer 16 Pointer 6 1530 amp 1531 Alarm 2 High Set Point Value of Pointer 6 Registers 232 amp 233 Registers 72 amp 73 Registers 52 amp 53 8 Pointer 7 1532 amp 1533 Alarm 2 Low Set Point Registers 212 amp 213 Pointer 17 1896 amp 1897 Time Derivative Value of Pointer 17 Value of Pointer 7 Registers 74 amp 75 Registers 234 amp 235 Registers 54 amp 55 Registers 214 amp 215 Pointer 18 1900 amp 1901 7 ii Vali f Pointer 18 Pointer 8 1580 amp 1581 Value of Pointer 8 Heat Hysteresis alue of Pointer Alarm 3 High Set Point SSS Registers 76 amp 77 Registers 236 amp 237 Registers 56 amp 57 Pointer 9 1582 amp 1583 Alarm 3 Low Set Point Registers 216 amp 217 Pointer 19 1902 amp 1903 Cool Hysteresis Value of Pointer 19 Value of Pointer 9 Registers 78 amp 79 Registers 238 amp 239 Registers 58 amp 59 Pointer 10 1630 amp 1631 Alarm 4 High Set Point Registers 218 amp 219 Pointer 20 1898 amp 1899 Deadband Value of Pointer 20 Value of Pointer 10 Watlow EZ ZONE PM
198. ofile Current Step Watlow EZ ZONE PM Integrated Controller e 127 e Chapter 11 Appendix Specifications LineVoltage Power Minimum Maximum Ratings e 85 to 264V ac 47 to 63Hz 20 to 28V ac 47 to 63Hz 12 to 40V dc 14VA maximum power consumption PM8 amp 9 e 10VAmaximum power consumption PM6 Data retention upon power failure via non volatile memory Compliant with SEMIF47 0200 FigureR1 1 voltage sag require ments 24V ac or higher Environment 0 to 149 F 18 to 65 C operating temperature e 40 to 185 F 40to85 C storage temperature 0 to 90 RH non condensing Accuracy Calibration accuracy and sensor conformity 0 1 of span 1 C the calibrated ambient 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 3 C Accuracy span 1000 F 540 C min Temperature stability 0 1 F F 0 1 C C rise in ambient max Agency Approvals e UL Listed to UL 61010 1 File E185611 UL Reviewed to CSA C22 2 No 61010 1 04 e UL 50 Type 4X NEMA 4X indoor locations IP66 front panel seal indoor use only FM Class 3545 File 3029084 temperature limit switches CE See Declaration of Conformity RoHS and W E E E complaint ODVA EtherNet IP and DeviceNet Compliance e UL Listed to ANSI ISA 12 12 01 2007 File E184390 This equipment is suitable for use in Class 1 Div 2 Groups A B
199. ogether and the relay remains in the on state The Watlow no arc relay is a hybrid relay It uses a mechanical relay for the current load and a triac solid state switch to carry the turn on and turn off currents No arc relays extend the life of the relay more than two million cycles at the rated full load current Although a no arc relay has significant life advan tages a few precautions must be followed for accept able usage Do not use hybrid relays for limit contactors A limit or safety device must provide a positive mechanical break on all hot legs simultaneously dc loads with hybrid relays The triacs used for arc suppression will turn off only with ac line voltage hybrid switches to drive any inductive loads such as relay coils transformers or solenoids cycle times less than five seconds on hybrid switches on loads that exceed 264V ac through relay on loads that exceed 15 amperes load on loads less than 100 mA no arc relays in series with other no arc relays Retransmitting a Process Value or Set Point The retransmit feature allows a process output to provide an analog signal that represents the set point or process value The signal may serve as a remote set point for another controller or as an input for a chart recorder documenting system performance over time In choosing the type of retransmit signal the op Watlow EZ ZONE PM Integrated Controller 104 Chapter 9 Features
200. oj watlow com Watlow Japan Ltd 1 14 4 Uchikanda Chiyoda Ku Tokyo 101 0047 Japan Tel 81 3 3518 6630 Fax 81 3 3518 6632 Email infoj watlow com Website www watlow co jp Website www watlow co jp Malaysia Tel 60 3 7980 7741 Fax 60 3 7980 7739 Risse SKA Ra 80143 Sith Bi s 52 5 E 981899 10 2 iad 07 2885168 E 07 2885568 Watlow Electric Taiwan Corporation 10F 1 No 189 Chi Shen 2nd Road Kaohsiung 80143 Taiwan Tel 886 7 2885168 Fax 886 7 2885568 Your Authorized Watlow Distributor 1a CUSTOMER SATISFACTION ha Watlow EZ ZONE PM Integrated Controller 138 Chapter 11 Appendix
201. on Ky i on e _ Analog Input 1 Source A Output 7 s PV Function SS Sy b Cao ng 7 Output n O to 100 Heat Source A Heat Power Cool Power Cool Control Loop 1 0 to 100 Output n Example 4 Ratio Requirements Two analog inputs and the enhanced software option are required and at least one output adjusts the con trolled part of the process Overview The Ratio feature allows control of one process as a ratio of another process This is especially useful in applications that mix two materials whether steam paint or food ingredients Analog Input 1 monitors the controlled part of the process Analog Input 2 of the controller measures the part of the process that is ei ther uncontrolled or controlled by another device The part of the process controlled will be maintained at a level equal to the quantity measured at input 2 mul tiplied by the ratio term set by the user as Closed Set Point 1 Watlow EZ ZONE PM Integrated Controller e 118 Chapter 10 Applications Ratio i 1 oy Ky k i Op Ue L 1 Analog Input 1 controlled Source A L Analog Input 2 Source B Output uncontrolled i PV Function Sp ng Ap 1 d Output n i 0 to 100 Heat T i Source A Heat Power 1 i Cool Power Control Loop 1 Cool i
202. on PM6 Auxillary 2nd input Universal Input Auxillary 2nd input Thermistor Input Current Transformer Input The following options are Not Valid for outputs 3 amp 4 FA FC FJ and FK Integrated Limit Controller with Universal Input Valid options for outputs 3 amp 4 CJ EJ or AJ only Integrated Limit Controller with Thermistor Input Valid options for outputs 3 amp 4 CJ EJ or AJ only PM6 When ordering Communications Options 2 6 option A must be ordered above PM6 Auxillary 2nd input can be configured for remote set point or back up sensor PM4 8 and 9 Auxillary input can be configured for remote set point back up sensor ratio differential or wet bulb dry bulb input anwe gar Znana Output 3 and 4 Hardware Options Output 3 Output 4 AA None None AJ None Mechanical relay 5 A form A AK None Solid state relay 0 5 A form A CA Switched dc open collector None CC Switched dc open collector Switched dc CH Switched dc open collector NO ARC 15 A power control CJ Switched dc open collector Mechanical relay 5 A form A CK Switched dc open collector Solid state relay 0 5 A form A EA Mechanical relay 5 A form None EC Mechanical relay 5 A form C Switched dc EH Mechanical relay 5 A form NO ARC 15 A power control EJ Mechanical relay 5 A form C Mechanical relay 5 A form A EK Mechanical relay 5 A form C Solid state relay 0 5 A form A FA Universal Process None FC Universal Proc
203. one to activate the alarm output function again An active message such as an alarm message will cause the display to toggle between the normal settings and the active message in the upper display and in the lower display Push the Advance Key 9 to display in the upper display and the message source in the lower display Use the Up O and Down Q keys to scroll through possible responses such as Clear or Silence 5 L Then push the Advance or Infinity key to execute the action See the Keys and Displays chapter and the Home Page chapter for more details Turn alarm silencing on or off with Silencing Setup Page Alarm Menu Alarm Blocking Alarm blocking allows a system to warm up after it has been started up With alarm blocking on an alarm is not triggered when the process tempera ture is initially lower than the alarm low set point or higher than the alarm high set point The process temperature has to enter the normal operating range beyond the hysteresis zone to activate the alarm function If the EZ ZONE PM has an output that is func tioning as a deviation alarm the alarm is blocked when the set point is changed until the process value re enters the normal operating range Turn alarm blocking on or off with Blocking Setup Page Alarm Menu Current Sensing Open heater circuit detection Current Error Operations Page Current Menu detects an open load circuit if no current is flowing thr
204. ons of the same will vary depending upon part number see ordering matrix for more detail be Limit Output Status ones 1 2 gt Indicates Zone Address 3 4 Indicates I O 5 6 Status nd Limit Controller Reduces panel space Reduces installation costs Increases dependability with backup control sensor operation Increases user and equipment safety for over under temperature conditions Reduces wiring time and termination complexity compared to connecting separate products Watlow EZ ZONE PM Integrated Controller e 10 Chapter 1 Overview Input Functions Input Sensor gt EZ ZONE PM Integrated Model 1 16 DIN System Diagram with Expanded Communications Slot B None Idle set point Tune Alarm clear request Force alarm Silence alarm Manual auto mode Control outputs off Remote set point enable Lock keypad TRU TUNE disable Loop amp alarms off Profile disable Profile hold resume Profile start Profile start stop Restore user settings Event inputs Analog Input 1 none CT Thermocouple RTD 100 Q 1kQ Thermistor 5kO 10kO 20kQ 40kQ Process V mV mA or 1k Potentiometer Digital Input or Output 5 amp 6 optional none switch volts dc EZ Key Programmable Event lei RUI EZ ZONE Controllers PLC PC or HMI a ii EIA 485 Communication Standard Bu
205. or pe ripheral devices Failure to do so may result in damage to equipment and property and or injury or loss of life Note Maximum wire size termination and torque rating 0 0507 to 3 30 mm 30 to 12 AWG single wire termination or two 1 31 mm 16 AWG e 0 8 Nm 7 0 Ib in torque Note Adjacent terminals may be labeled differently depending on the model number Note To prevent damage to the control ler do not connect wires to unused terminals Note Maintain electrical isolation between analog input 1 digital input outputs switched dc open collector outputs and process outputs to prevent ground loops Note The control output common terminal and the digital common terminal are referenced to different voltages and must remain isolated Note This Equipment is suitable for use in CLASS I DIVISION 2 Groups A B C and D or Non Hazardous locations only Temperature Code T4A Warning A Explosion Hazard Substitution of component may impair suitability for CLASS I DIVISION 2 Warning A Explosion Hazard Do not disconnect while the circuit is live or unless the area is known to be free of ignitable concentrations of flammable sub stances Quencharc Note Switching pilot duty inductive loads relay coils solenoids etc with the mechanical relay solid state relay or open collector output options requires use of an R C sup pressor Digital Output 5 6 Slot C
206. ork dab common nal of the EIA 485 port Do not connect more than CC e Wire common to the com 16 EZ ZONE controllers on A TURO OB mon terminal of the EIA a Standard Bus EIA 485 485 TRICA 485 port network 232 common Do not route network wires Maximum number of EZ C5 with power wires Connect ZONE controllers on a 292 TX to DB9 pR 2 RD o3 live wires in daisy Modbus network is 247 232 RD to DB9 pin 3 TY o chain fashion when con maximum EIA 232 network necting multiple devices in length 15 meters 50 feet a network maximum EIA 485 network e A termination resistor may length 1 200 meters 4 000 be required Place a 120 0 feet resistor across T R and e 1 8th unit load on EIA 485 T R of last controller on bus network Communications instance 2 Do not wire to both the Slot B EIA 485 and the EIA 232 PM I6 2 pins at the same time Two EIA 485 terminals of 1 T R are provided to assist Slot E in daisy chain wiring PM 489 _ 2 ___ Modbus IDA EIA TIA 485 Terminal Name o A Watlow Terminal Function Label EtherNet IP and Modbus TCP Communications Slot B E RJ 45 T568B wire Do not route network unused Eg pin color wires with power wires Connect one Ethernet EZ 8 brown unused cable per controller to receive 7 unused a 10 10
207. ote The control output common terminal and the digital common terminal are referenced to different voltages and must remain isolated Note This Equipment is suitable for use in CLASS I DIVISION 2 Groups A B C and D or Non Hazardous locations only Temperature Code T4A Warning AN Explosion Hazard Substitution of component may impair suitability for CLASS I DIVISION 2 Warning A Explosion Hazard Do not disconnect while the circuit is live or unless the area is known to be free of ignitable concentrations of flammable sub stances Green Link speed 100 Mbit If the device is communicating at 100 Mbit the link LED will be green Activity Status Indicator State Flashing Green If the MAC detects activity the LED will be Detects activity flashing green Red If the MAC detects a collision the LED will Link speed 10Mbit ber d DeviceNet Communications Slot B E V CH shield SH CAN_L CL V V CAN_H V positive side of Devi jo E L4 negative side of Devi y v DeviceNet power return Communications instance 2 Slot B PM 6 5 ___ Slot E PM 4 8 9 5 ND DeviceNet LED Indicators Viewing the control from the front and then looking on top two LEDs can be seen aligned vertically front to back The LED closest to the front i
208. ough the current transformer when the output is active and the load is supposed to be on Shorted heater circuit detection Current Error detects a shorted load circuit if cur rent is flowing through the current transformer when the output is inactive and the load is supposed to be off Set the current detect set points with High Set Point and Low Set Point Operations Page Current Menu View the current level and most recent faults with Read Current Error Operations Page Cur rent Menu and Heater Error Operations Page Current Menu Open Loop Detection When Open Loop Detection is enabled L g E the controller will look for the power output to be at 100 Once there the control will then begin to mon itor the Open Loop Detect Deviation L dg as it relates to the value entered for the Open Loop Detect Time L d E If the specified time period expires and the deviation does not occur an Open Loop Error will be triggered Once the Open Loop Error condi tion exists the control mode will go off Note All prompts identified in this section can be found in the Loop Menu of the Setup Page Programming the EZ Key s You can program the EZ Key either in the Setup Menu or with configuration software such as EZ ZONE Configurator using a personal computer The following examples show how to program the Watlow EZ ZONE PM Integrated Controller e 111 Chapter 9 Features EZ Key to start and stop a pro
209. ow er wires Connect network wires in daisy chain fashion when connecting multiple devices in a network A termination resistor may be re quired Place a 120 Q resistor across A network using Watlow s Standard Bus and an RUI Gateway EZ ZONE ST ST__ BorF _M_ sal L 9q sa T1 3900 aoLri power power common EZ ZONE PM RUI Gateway EZKB A T R and T R of the last controller on a network Only one protocol per port is avail able at a time either Modbus RTU or Standard Bus Power Supply Ed EZ ZONE RM Pte PE I1 pad ru o Lr pat 4 fo Ern pa ELT if D E uu Tu m pu CHI TI B a So t a ssi Er OT Lr 99 4 pad ITTICA A UT A A B CD CE p8 B5 ae Del 1 lot i D5 eeeooo 223888385 HHHHEHHHH 8 3 l f E power T common common jor Pert Lobo 8 4 B I E B A network with all devices configured using Modbus RTU EZ ZONE ST ST__ BorF _M_ TODOOD Of o o m OO power
210. ower level is less than 75 percent 4 Set Point Actual Temperature Sea Break Temperature 100 40 Power 4 2 minutes Locks in N Output Power SS Re Output 0 Power Time Input Error Latching Setup Page Ana log Input Menu determines the controller s response once a valid input signal returns to the controller If latching is on then the controller will continue to indicate an input error until the error is cleared To clear a latched alarm press the Advance Key then the Up Key O If latching is off the controller will automatically clear the input error and return to reading the tem perature If the controller was in the auto mode when the input error occurred it will resume closed loop control If the controller was in manual mode when the error occurred the controller will remain in open loop control gt The Manual Control Indicator Light is on when the controller is operating in manual mode You can easily switch between modes if the Con trol Mode parameter is selected to appear in the Home Page To transfer to manual mode from auto mode press the Advance Key until appears in the lower display The upper display will display for auto mode Use the Up or Down Q keys to select PAn The manual set point value will be recalled from the last manual operation To transfer to auto mode from manual mode press the Advance Key until appears in the lower disp
211. p2 372 368 Instance 2 Map 1 Map2 452 462 Process Instance 1 Map 1 Map2 442 Instance 2 Map 2 Instance 1 Map 1 Map2 388 388 Instance 2 Map 1 Map2 468 478 20 0 Instance 1 Map 1 Map2 390 390 Instance 2 Map 1 Map2 470 480 Instance 1 Map 1 Map2 392 392 Instance 2 Map 1 472 Map 2 482 Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only CIP Class Instance Attribute hex dec 0x68 104 1 to 2 5 0x68 104 1 to 2 6 0x68 104 1to2 7 0x68 104 1 to 2 Ox2A 42 0x68 104 1to2 OxF 15 0x68 104 1 to 2 0x10 16 0x68 104 1 to 2 0x11 17 Watlow EZ ZONE PM Integrated Controller Chapter 6 Setup Page Setup Page CIP Modbus Rela Class tive Instance Address Parameter Name Description hex dec Analog Input 1 to 2 Instance 1 0x68 104 Range High Map 1 Map2 1 to 2 Set the high range for 394 394 0x12 18 this function block s Instance 2 output Map 1 Map2 474 484 Analog Input 1 to 2 oF Fj Off 62 Instance 1 0x68 104 Process Error Enable Lobu Low 53 Map 1 Map2 1to2 Turn the Process Error 418 388 Ox1E 30 Low feature on or off Instance 2 Map 1 Map2 498 508 Analog Input 1 to 2 100 0 to 1 000 0 Instance 1 0x68 104 Process Error Low Map 1 Map2 1 to 2 Tf the process value drops 420 420 Ox1F 3D below this value
212. p2 1to2 2172 2652 7 Instance 2 Map1 Map2 2252 2732 Set Point 1 128 000 to 5 537 000 C View the set point cur rently in effect Monitor 1 to 2 1 999 000 to 9 999 000 F Process Value Active or units View the current filtered 1 128 000 to 5 537 000 C process value using the control input Monitor 1 to 2 1 999 000 to 9 999 000 F Set Point Active or units Read the current active 1 128 000 to 5 537 000 C set point Monitor 1 to 2 1 999 000 to 9 999 000 F Instance 1 Ox6B 107 Closed Loop Working or units Map1 Map2 1to2 Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only Watlow EZ ZONE PM Integrated Controller e 51 e Chapter 5 Operations Page Note Parameter name Description Control Loop 1 to 2 Remote Enable Enable this loop to switch control to the re mote set point Control Loop 1 to 2 Remote Set Point Type Enable this loop to switch control to the re mote set point Control Loop 1 to 2 Control Mode Select the method that this loop will use to control Control Loop 1 to 2 Autotune Set Point Set the set point that the autotune will use as a percentage of the cur rent set point Control Loop 1 to 2 Autotune Request Start an autotune While the autotune is active the Home Page will display RE E or E unc When the autotune is complete
213. put can func tion as two separate outputs With a 4 to 20mA output the heating output will operate from 12 to 20mA 0 to 100 percent and the cooling output will operate from 12 to 4mA 0 to 100 percent In some cases this type of output is required by the device that the EZ ZONE PM controls such as a three way valve that opens one way with a 12 to 20mA signal and opens the other way with a 4 to 12mA signal This feature reduces the overall system cost by using a single output to act as two outputs Outputs 1 and 3 can be ordered as process out puts Select duplex as the Output Function Setup Page Output Menu Set the output to volts or milliamps with Output Type o Jj Set the range of the process output with Scale Low and Scale High h 4 NO ARC Relay A no arc relay provides a significant improvement in the life of the output relay over conventional relays Conventional mechanical relays have an expected 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 action produces un avoidable electrical arcing causing metal to transfer from one contact to the other The arcing conditions continue on each subsequent contact opening until over time the resistance through the contacts in creases causing the contacts to increase in tempera ture Eventually the contacts will weld t
214. r Restore Communications Menu D to C On Communications PLoL dS RU aS o a D dD r L 73 a c zo 3 3 Ay 0 D x ru zo N m zo a i z any wn rec a Protocol Standard Bus Address Baud Rate Parity Modbus Word Order IP Address Mode IP Fixed Address Part 1 IP Fixed Address Part 2 IP Fixed Address Part 3 IP Fixed Address Part 4 IP Fixed Address Part 5 IP Fixed Address Part 6 IP Fixed Subnet Part 1 IP Fixed Subnet Part 2 IP Fixed Subnet Part 3 IP Fixed Subnet Part 4 IP Fixed Subnet Part 5 IP Fixed Subnet Part 6 IP Fixed Gateway Part 1 IP Fixed Gateway Part 2 IP Fixed Gateway Part 3 IP Fixed Gateway Part 4 IP Fixed Gateway Part 5 IP Fixed Gateway Part 6 Modbus TCP Enable EtherNet IP Enable Implicit Output Assembly Size a Implicit Input Assembly Size Display Units Data Map Non volatile Save E SEE Real Time Clock hoUc Hour P 1 n Minute dob J Day of Week Available with PM4 PM8 and PM9 models only Watlow EZ ZONE PM Integrated Controller ebt ou Chapter 6 Setup Page Parameter Name Description 2 m a og Input Menu Analog Input 1 to 2 Sensor Type Set the analog sensor type to match the device wired to this inpu
215. r numbers reduce activity on the valve and small er numbers improve controllability Select a value that compromises on these two competing goals Lastly assign an output to Special Output Function 1 that is wired to close the valve Assign an output to Spe cial Output Function 2 that is wired to open the valve Typically these two outputs are normally open mechan ical relays but solid state relays or switch DC outputs may be programmed in the same manner Watlow EZ ZONE PM Integrated Controller Chapter 10 Applications Definitions Current Position is an approximation of the valve s position as it relates to a power level 0 100 where 0 is fully closed and 100 is fully open Dead Time is the minimum on time that the valve will travel once it is turned on in either the closed or open direction Dead Time Valve Dead Band 100 Valve Travel Time On Time is the amount of time the valve needs to be turned on either open or close to eliminate the error between the estimated valve position and the desired power level A positive On Time value indicates the need to open the valve while a negative value indi cates the need to close the valve On Time Input 1 Value Current Position 100 Valve Travel Time When power is applied to the controller the valve is closed and time is set to 0 Special Output Function 1 is the close signal to the valve Special Output Function 2 is the open signal to the valve
216. r units 1 128 000 to 5 537 000 C 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C None 61 Open 65 Shorted 127 Measurement error 140 Bad calibration data 139 Ambient error 9 RTD error 14 Fail 32 Math error 1423 Not sourced 246 Stale 1617 Can t process 1659 None 61 Open 65 Shorted 127 Measurement error 140 Bad calibration data 139 Ambient error 9 RTD error 14 Fail 32 Math error 1423 Not sourced 246 Stale 1617 Can t process 1659 Modbus Relative Ad dress Instance 1 Map 2 Instance 1 Map 2 Instance 1 Map 2 Instance 1 Map 2 Instance 1 Map 2 Instance 1 Map 2 CIP Class Profibus Param Instance Index eter ID Attribute hex dec 0x87 135 1 7 35007 float R 35008 float R 35010 float R 35012 float R 35011 uint R 35013 uint R 0x87 135 i 8 0x87 135 1 OxA 10 0x87 135 1 OxC 12 0x87 135 1 0x0D 13 Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only 0x87 135 1 OxOB 11 Watlow EZ ZONE PM Integrated Controller e 57 Chapter 5 Operations Page Parameter name Description PSEA Profile Status Menu Profile Menu appears if PM _ R B N E Profile Status Profile Start Select step to act upon LO nr 4 Profile St
217. range selectable 0 to 10V dc into a min 1 0000 load 0 to 20mA into max 8000 load Resolution dc ranges 2 5mV nominal mA ranges 5 pA nominal Calibration Accuracy de ranges 15 mV mA ranges 30 pA Temperature Stability 100 ppm C Operator Interface Dual 4 digit 7 segment LED displays Advance infinity up and down keys plus optional programmable EZ KEY s depending on model size Typical display update rate 1Hz RESET key substituted for infinity on all models including the limit control Width Height Display Character Height up 11 43 mm 0 450 in middle 9 53 mm 0 375 in low 7 62 mm 0 300 in up 10 80 mm 0 425 53 3 mm in 2 10 in low 6 98 mm 0 275 in top 11 4 mm 0 450 in middle 9 53 mm 0 3775 in bottom 7 62 mm 0 300 in 100 8 mm 3 97 in 100 3 mm 3 95 in 100 3 mm 3 95 in 101 6 mm 4 00 in 53 3 mm 2 10 in 101 6 mm 4 00 in 100 3 mm 2 10 in 53 9 mm 1 22 in Chapter 11 Appendix Width Height Display Character Height top 11 4 mm 0 450 in 101 6 mm 53 3 mm 100 3 mm middle 9 53 mm 4 00 in 2 10 in 3 95 in 0 375 in bottom 7 62 mm 0 300 in Weight 1 4 DIN PM4 1 8 DIN PM8 amp 9 e Controller 331 g 11 7 oz Controller 284 g 10 oz 1 16 DIN PM6 User Manual Controller 186 g 6 6 oz User manual 284 86 g 10 1 oz Modbus is a trademark of AEG Schneider Autom
218. ring set point and load changes When the controller is in 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 off control The preferred and quickest method for tuning a loop is to establish initial control settings and contin ue with the adaptive mode to fine tune the settings Setting a controller s control mode to tune starts this two step tuning process See Autotuning in this chapter This predictive tune determines initial rough settings for the PID parameters Then the loop automatically switches to the adaptive mode which fine tunes the PID parameters Once the Process Value has been at set point for a suitable period about 30 minutes for a fast process to roughly two hours for a slower process and if no further tuning of the PID parameters is desired or needed TRU TUNE may be turned off However keeping the controller in the adaptive mode allows it to automatically adjust to load changes and compen sate for differing control characteristics at various set points for processes that are not entirely linear Once the PID parameters have been set by the TRU TUNE adaptive algorithm the process if shut down for any reason can be restarted in the adaptive control mode Turn TRU TUNE on or off with TRU TUNE Enable Setup Page Loop Menu Use TRU TU
219. rol fea tures a block of addresses that can be configured by the user to provide direct access to a list of 40 user configured parameters This allows the user easy ac cess to this customized list by reading from or writ ing to a contiguous block of registers To acquire a better understanding of the tables found in the back of this manual See Appendix Modbus Programmable Memory Blocks please read through the text below which defines the column headers used Assembly Definition Addresses Fixed addresses used to define the parameter that will be stored in the Working Addresses which may also be referred to as a pointer The value stored in these addresses will reflect point to the Modbus address of a parameter within the ST control Assembly Working Addresses Fixed addresses directly related to their associ ated Assembly Definition Addresses i e As sembly Working Addresses 200 amp 201 will as sume the parameter pointed to by Assembly Defi nition Addresses 40 amp 41 When the Modbus address of a target parameter is stored in an Assembly Definition Address its cor responding working address will return that param eter s actual value If it s a writable parameter writ ing to its working register will change the param eter s actual value As an example Modbus register 360 contains the Analog Input 1 Process Value See Operations Page Analog Input Menu If the value 360 is loaded into A
220. rs When not in pairs the parameter prompt will appear in the lower display and the parameter value will appear in the upper display You can use the Up O and Down Q keys to change the value of writable parameters just as you would in any other menu If Control Mode is set to Auto the Process Value is in the upper display and the Closed Loop Set Point read write is in the lower display If a profile is running the process value is in the upper display and the Target Set Point read only is in the lower display If Control Mode is set to Manu al the Process Value is in the upper display and the output power level read write is in the lower display If Control Mode is set to Off the Process Value is in the upper display and read only is in the lower display If a sensor failure has occurred J is in the upper display and the output power level read write is in the lower display Changing the Set Point You can change the set point by using the Up O or Down Q keys when a profile is not running Modifying the Home Page To modify the Home Page proceed to the Factory Menu by pushing and holding the Advance 9 key and the Infinity key for approximately six seconds Upon entering the Factory Page the first menu will be the Custom Menu u S E Once there push the Advance key where the lower display will show Cu St and the upper display will show Again push the Advance button where the prompt for the
221. rticular selection Range selections can be made simply by writing the enumerated value of choice using any of the available communications protocols As an exam ple turn to the Setup Page and look at the Analog Input A menu and then the Sensor Type SEn prompt To turn the sensor off using Modbus sim ply write the value of 62 off to register 400369 and send that value to the control Communication Protocols When using a communications protocol in conjunc tion with the EZ ZONE PM there are two possible ports instances used Port 1 or instance 1 is always dedicated to Standard Bus communications This same instance can also be used for Modbus RTU if ordered Depending on the controller part number port 2 instance 2 can be used with Modbus CIP and Profibus For further information read through the remainder of this section Modbus RTU amp TCP Protocols All Modbus registers are 16 bits and as displayed in this manual are relative addresses actual Some legacy software packages limit available Modbus reg isters to 40001 to 49999 5 digits Many applications today require access to all available Modbus regis ters which range from 400001 to 465535 6 digits Watlow controls support 6 digit Modbus registers For parameters listed as float notice that only one low order of the two registers is listed this is true throughout this document By default the low order word contains the two low bytes of the 32 bit param et
222. ry Identifies unique param eters using either the Modbus RTU or Modbus TCP protocols further ex planation below Range Modbus Relative Ad dress Identifies unique param eters using either the De viceNet or EtherNet IP protocol further explana tion below CIP Common Indus trial Protocol Identifies unique param eters using Profibus DP protocol further explana tion below Profibus Index Identifies unique param eters used with other soft ware such as LabVIEW Unsigned 16 bit integer Signed 32 bit long string ASCII 8 bits per character float IEEE 754 32 bit RWES Readable Writable EEPROM saved User Set saved Parameter ID uint dint Data Type R W Display Visual information from the control is displayed to the observer using a fairly standard 7 segment dis play Due to the use of this technology several char acters displayed need some interpretation see the list below ll e ll e n J T fu j T ho e o Il I gt cji uj elt e Il Mir e rr ll ele TY Il c2 WIE i EI uc i all A i C I lt 3 i z m I Ico 3 Il B Il fu e Il Nix mas ms gine ia fo I Jg 7 I gt Range Within this column notice that on occasion there will be numbers found within parenthesis This number represents the enumerated value for that pa
223. s Note Some of these menus and parameters may not appear depending on the controller s options See model number information in the Appendix for more information If there is only one instance of a menu no sub menus will appear Note Some of the listed parameters may not be visible Parameter visibility is dependent upon controller part number hEr Heater Error oPE c Analog Input Menu ron Mode Active TIAE 1 to _hP Heat Power Analog Input CP r Cool Power oPEr LOHN A n Process Value CSP Closed Loop Working Set Output Value Er Error Status Point eu Pp Calibration Offset Process Value Active SoFl Lac Lao oPE Special Output Function oPE Linearization Menu o PE c Control Loop Menu gu T Output Value L4 to 4 to e PSEA Lar Linearization Loop oPEr Profile Status Menu Su Source Value A r E n Remote Enable St r Profile Start oF SE Offset Crn Control Mode PAC Action Request Output Value AE SP Autotune Set Point St P Active Step x RUE Autotune Request EJP Active Step Type CSP Closed Loop Set Point E SP I Target Set Point Loop 1 loPEr Process Value Menu 1d 5 Idle Set Point ESPZ Target Set Point Loop 2 1 to hP b Heat Proportional Band ACSP Produced Set Point 1 Process Value h h J He
224. s Jump Count Remain ing View the jump counts remaining for the cur rent loop In a profile with nested loops this may not indicate the actual jump counts re maining Profile Status Profile State Read currentProfile state Profile Status Current File Indicates current file be ing executed Operations Page Modbus Relative Ad dress Instance 1 Map 2 4494 Map 1 Instance 1 Map 2 4492 Map 1 Instance 1 Map 2 Instance 1 Map 1 2546 oF F Off 62 On 63 Instance 1 Map 1 2548 of F Off 62 on On 63 0 to 9 999 Instance 1 Map 1 2538 Off 62 Running 149 Pause 146 Instance 1 Map 1 2522 Instance 1 Map 1 2524 Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only Map 2 4366 Map 2 4368 Map 2 4358 Map 2 4342 Map 2 4344 CIP Class Instance Attribute hex dec 0x7A 122 1 Ox4E 78 Profibus Index Param eter ID amp Read 22078 22077 22076 22014 22015 22010 22002 22003 Ox7A 122 1 Ox4D 77 0x7A 122 1 0x4C 76 0x7A 122 1 OxE 14 Ox7A 122 1 OxF 15 Ox7A 122 1 2 Ox7A 122 1 3 w 5d w 5E E 5 E Es E a5 z zB z z Ox7A 122 1 OxA 10 Watlow EZ ZONE PM Integrated Controller e 59 o Chapter 5 Operations Page 6 Chapter 6 Setup Page Navigating the Setup
225. s optional Modbus RTU Communications EIA 232 485 Modbus RTU TCP EtherNet IP DeviceNet Profibus Note PID Controller Optional Ramp Soak max 4 files 40 steps Slot A Optional Output 1 none switched dc open collector 5A mechanical relay form C process V mA or 0 5A SSR form A Modbus Address 1 247 Standard Bus Zone Address 1 16 Supervisory amp Power Board Slot C Communications Board Output 2 none 15A NO ARC switched dc 5A mechanical relay form A or 0 5A SSR form A Digital Output or Input 5 amp 6 optional none switched dc Zone Output Status Address Output Functions off heat cool alarm retransmit duplex event off heat cool alarm event off heat cool alarm event Indicates Zone Address 12 3 4 5 6 Number of inputs and outputs and various combinations of the same will vary depending upon part number see ordering matrix for more detail Indicates I O Status Serial Communication Capabilities e Supports network connectivity to a PC or PLC e Available in a wide range of protocol choices including Modbus RTU EtherNet IP Modbus TCP Watlow EZ ZONE PM Integrated Controller e 11 Chapter 1 Overview EZ ZONE PM Integrated Model 1 8 and 1 4 DIN System Diagram Without 6 Digital 1 0 slot D Wit
226. s click circuits must be disconnected before removing the controller from the front panel or disconnecting Chemical Compatibility other wiring Failure to follow these instructions may cause an electrical shock and or sparks that could cause an explosion in class 1 div 2 hazardous locations This product is compatible with acids weak alkalis alcohols gamma radiation and ultraviolet radiation This product is not compatible with strong alkalis organic solvents fuels aromatic hydrocarbons chlo rinated hydrocarbons esters and keytones Watlow EZ ZONE PM Integrated Controller e 21 Chapter 2 Install and Wire Wiring Slot A Slot B Slot D Slot E Inputs Terminal Function Configuration 1 2 7 12 T1 WV S2 RTD or current Universal Thermistor Input S1 S2 S3 RTD thermocouple current or volts input 1 all configurations potentiometer wiper thermistor input 2 PM R L R1 R2 S1 RTD thermocouple or volts thermistor 102 mA ac Current Transformer 82 mA ac PM___ T B7 Common Digital Inputs D7 digital input or output PMI4 8 9 C D D8 digital input or output D9 digital input or output D10 digital input or output D11 digital input or output D12 digital input or output Z7 Supply Outputs Terminal Function Configuration 1 2 3
227. s identified as the network Net LED where the one next to it would be identified as the module Mod LED Network Status Indicator LED Description The device is not online and has not completed the duplicate MAC ID test Off yet The device may not be powered The device is online and has connections in the established state allcated Green to a Master Failed communication device The device has detected an error that has Red rendered it incapable of communicating on the network duplicate MAC ID or Bus off The device is online but no connection has been allocated or an explicit Flashing Green connection has timed out Flashing Red A poll connection has timed out Module Status Indicator LED Description Off No power is applied to the device Flashing Green Red The device is performing a self test Flashing Red Major Recoverable Fault Red Major Unrecoverable Fault Green The device is operating normally Watlow EZ ZONE PM Integrated Controller e 36 e Chapter 2 Install and Wire Warning AN A Use National Electric NEC or other country specific standard wiring and safety practices when wiring and connecting this controller to a power source and to electrical sensors or pe ripheral devices Failure to do so may result in damage to equipment and property and or injury or loss of life Note Maximum wire size termination and torque ratin
228. sable alarm blocking if required Set output to correct alarm source instance Set alarm source to correct input in stance Set alarm set point to correct trip point Set alarm to correct type process de viation or power Correct wiring or replace sensor Match setting to sensor used Check calibration of controller Check cause of under temperature Clear latched alarm Establish correct alarm set point Set alarm source to proper setting Check cause of over temperature Clear latched alarm Establish correct alarm set point Set alarm source to proper setting Correct wiring or replace sensor Match setting to sensor used Check calibration of controller Correct cause of sensor input out of limit range Set limit set point to correct trip point Set digital input function and source instance Correct wiring or replace sensor Match setting to sensor used Check calibration of controller Check cause of under temperature Clear limit Establish correct limit set point Watlow EZ ZONE PM Integrated Controller 122 Chapter 11 Appendix Limit High Sensor input above high limit set point Open Loop Detect is active and the process value did not deviate by a user select ed value in a user specified period with PID power at 100 L Poe Loop Open Error Open Loop Detect is active and the process value is headed in the wrong direc tion when the ou
229. sed It can only be deactivated by the user An active message such as an alarm message will cause the display to toggle between the normal settings and the active message in the upper display and in the lower display Push the Advance Key to display in the upper display and the message source in the lower display Use the Up O or Down Q keys to scroll through possible responses such as Clear or Silence 5 L Then push the Advance or Infinity key to execute the action See the Keys and Displays chapter and the Home Page chapter for more details An alarm that is not latched self clearing will deactivate automatically when the alarm condition has passed Turn alarm latching on or off with Latching Setup Page Alarm Menu The alarm state begins when the temperature A teaches the Alarm High Set Point Alarm High Set Point V Alarm Hysteresis Normal Operating Range The alarm state continues until the temperature drops to the Alarm High Set Point minus the hysteresis A latching alarm could be turned off by Temperature Process Temperature A the operator at this point A non latching alarm would turn off automatically re Alarm Low Set Point gt Time Alarm Silencing If alarm silencing is on the operator can disable the alarm output while the controller is in an alarm state The process value or temperature has to enter the normal operating range beyond the hysteresis z
230. sponse Control Loop 1 to 2 Open Loop Detect Time The Open Loop Detect Deviation value must oc cur for this time period to trigger an open loop error Control Loop 1 to 2 Open Loop Detect De viation The value entered repre sents the Process Value deviation that must occur to trigger an open loop error Control Loop 1 to 2 Ramp Action Select when the control ler s set point will ramp to the defined end set point Control Loop 1 to 2 Ramp Scale Select the scale of the ramp rate Control Loop 1 to 2 Ramp Rate Set the rate for the set point ramp Set the time units for the rate with the Ramp Scale param eter Note Setup Page Range Default Set Point Open Loop Limit Low to Set Point Open Loop Limit High Setup Page Modbus Rela tive Address Instance 1 Map 1 Map2 2180 2660 Instance 2 Map 1 Map2 2260 2740 Instance 1 Map 1 Map2 1922 2402 Instance 2 Map 1 Map2 1992 2472 no No 59 JE 5 Yes 106 0 to 3 600 seconds Instance 1 Map 1 Map2 1924 2404 Instance 2 Map 1 Map2 1994 2474 1 999 000 to 9 999 000 F or units 1 110 555 to 5 555 000 C Instance 1 Map 1 Map2 1926 2406 Instance 2 Map 1 Map2 1996 2476 Off 62 Startup 88 Set Point Change Instance 1 Map 1 Map2 2186 2666 Instance 2 Map 1 Map2 2266 2746 oFF Str StPt 1647 both Both 13 Hours 39 Minutes 57 Instance 1 Map 1 Map2 2188 2668 Instance 2 Map 1 Map2 2268 2748
231. ssembly Definition Address 91 the process value sensed by analog input 1 will also be stored in Mod bus registers 250 and 251 Note that by default this parameter is also stored in working registers 240 and 241 as well The table See Appendix Modbus Programmable Memory Blocks identified as Assembly Definition Addresses and Assembly Working Addresses reflects the assemblies and their associated addresses CIP Communications Capabilities CIP Communications Methodology There are two ways in which CIP can be used with the PM control 1 PM control ordered with an Ethernet card 2 RUI GTW equipped with a Ethernet card Reading or writing when using CIP can be accom plished via explicit and or implicit communications Explicit communications usually requires the use of a message instruction but there are other ways to do this as well Implicit communications is also com monly referred to as polled communications When using implicit communications there is an I O assem bly that would be read or written to the assemblies are embedded into the PM firmware Watlow refers to these assemblies as the T to O Target to Origina tor and the O to T Originator to Target assemblies where the Target is always the PM and the Origina tor is the PLC or master on the network The O to T assembly is made up of 20 32 bit members that are user configurable where the T to O assembly consists of 21 32 bit members The first member of the T to
232. stances Quencharc Note Switching pilot duty inductive loads relay coils solenoids etc with the mechanical relay solid state relay or open collector output options requires use of an R C sup pressor Switched DC Wiring Example Using DO 7 12 Collector Outputs B7 Common E 1 2 3 AN O N WY YY D7 an A E e n AO we p e V r DI e mnfis D10 DC90 60C0 0000 E D11 Cons Mara Oo GD Gm D12 f O AN E NM Y w 4 5 6 Internal Circuitry Sob Note As a switched DC output this output is a constant current output delivering 750 mW current limited to 400 mA The internal supply does have a maxi mum open circuit voltage of 22 VDC and minimum open circuit voltage of 19 VDC Pin Z7 is shared to all digital outputs This type of output is meant to drive solid state relays not mechanical relays As an open collector output use an external power supply with the negative wired to B7 the positive to the coil of a pilot mechanical relay and the other side 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 reversed wired across the relay coil to prevent damage to the internal transistor Open Collector Wiring Example Using DO 7 12
233. stom Menu 43 Date of Manufacture 97 Dead Band 53 107 Decimal 63 64 Digital Input Output Menu 0 67 Direction 67 Digital Output State 50 Day of Week 89 Display Pairs 61 84 Display Time 84 Ethernet IP Enable 88 Event Input Status 50 Electrical Input Offset 98 02 Electrical Input Slope 98 02 Electrical Output Offset 98 Active Event Output 1 59 Event Output 2 93 Error Input 1 or 2 Input Error Failure 72 105 Digital Output Function Instance 68 70 Output Function Instance 4 76 Filter 63 Function 67 Output Function 74 75 Function Key Menu 81 Global Menu 82 Guaranteed Soak Deviation Co Guaranteed Soak Deviation 83 Guaranteed Soak Deviation 83 Guaranteed Soak Enable Co Guaranteed Soak Enable Heat Algorithm 71 106 Heater Error 41 56 111 Heater Error 41 Heat Hysteresis 53 106 Hours 89 00 107 Heat Power 51 100 Calibration Offset 48 02 103 Idle Set Point 52 Input Error Latching 63 k r Input Error Status 48 P I Input Point 1 64 P 2 Input Point 2 64 Heat Proportional Band 52 o N 3 Input Point 3 65 4 Input Point 4 65 Input Point 5 64 65 Input Point 6 65 7 Input Point 7 65 8 Input Point 8 66 q Input Point 9 66 B Input Point 10 66 IP Fixed Address Part 1 86 PF 2 IP Fixed Address Part 2 86 o N PF 3 IP Fixed Address Part 3 86 o N
234. such as Clear or Silence 5L Then push the Advance amp or Infinity key to exe cute the action See the Home Page for further infor mation on the Attention Codes Default Appears If Display Parameter Name Setting Description Attention An active message will cause the display to toggle between the normal settings and the active message in the upper display and in the lower display Your response will depend on the message and the controller set tings Some messages such as Ramping and Tuning indicate that a process is underway If the message was generated by a latched alarm or limit condition the message can be cleared when the condition no longer exists If an alarm has silencing enabled it can be silenced Push the Advance Key to dis play in the upper display and the message source such as Lah 1 in the lower display Use the Up and Down Q keys to scroll through possible responses such as Clear or Silence S L Then push the Advance 9 or Infinity key to execute the action Alternatively rather than scrolling through all mes sages simply push the Infinity button to generate a clear ALL I ALLO ALL 3 ALLY Alarm Error 1 to 4 L al I Limit Low 1 L h I Limit High 1 L E I Limit Error 1 CEr I Current Error hEr I Heater Error ALE I ALE ALEJ Alarm Eri Error Input 1 or 2 t
235. t Note There is no open sensor detection for process inputs Analog Input 1 to 2 Linearization Set the linearization to match the thermocouple wired to this input Analog Input 1 to 2 RTD Leads Set to match the num ber of leads on the RTD wired to this input 4h Em m Analog Input 1 to 2 Units Set the type of units the sensor will measure Analog Input 1 to 2 Scale Low Set the low scale for pro cess inputs This value in millivolts volts or mil liamps will correspond to the Range Low output of this function block n H e Analog Input 1 to 2 Scale High Set the high scale for process inputs This value in millivolts volts or milliamps will corre spond to the Range High output of this function block Analog Input 1 to 2 Range Low Set the low range for this function block s output Note Setup Page Off 62 Thermocouple 95 Millivolts 56 Volts dc 104 Milliamps dc 112 RTD 100 113 RTD 1 000 Q 114 Potentiometer 1 kQ Thermistor 229 K 48 a N 68 _ R 80 _5 8 84 T 93 AE P Absolute Temperature 1540 r hj Relative Humidity 1538 Process 75 PL uc Power 73 100 0 to 1 000 0 100 0 to 1 000 0 1 999 000 to 9 999 000 Modbus Rela tive Address Default Instance 1 Map 1 Map2 368 368 Instance 2 Map 1 Map2 448 458 J Instance 1 Map 1 Map2 370 370 Instance 2 Map 1 Map2 450 460 Instance 1 Map 1 Ma
236. t the set point for this step 1 128 to 5 537 000 C 4554 Ox1C 28 Offset to next instance Map 2 equals 100 Step Type Parameters Instance 1 0x79 121 21003 uint Hours Mapi1 Map2 1to40 RWE Select the hours plus Minutes 2574 4504 3 and Seconds for a timed step Offset to next instance Map 1 equals 50 Map 2 equals 100 Step Type Parameters Instance 1 0x79 121 21004 uint Minutes Map1 Map2 1to40 RWE Select the minutes plus Hours 2576 4506 4 and Seconds for a timed step Offset to next instance Map 1 equals 50 Map 2 equals 100 Note R Read Some values will be rounded off to fit in the four character display Full values can be read with other we Write interfaces ae Watlow EZ ZONE PM Integrated Controller e 91 Chapter 7 Profiling Page Profiling Page CIP Parameter Name odes CEE Param DP Range Default Relative Ad Instance eter ID dress Attribute hex dec Step Type Parameters 0 to 59 Instance 1 0x79 121 21005 uint Seconds Map 2 1to 40 RWE Select the seconds plus Hours 2578 4508 5 and Minutes for a timed step Offset to next instance Map 1 equals 50 Map 2 equals 100 Step Type Parameters 0 to 9 999 000 F or units per Instance 1 0x79 121 21006 float Rate minute Map1 Map2 1to40 RWE Select the rate for ramping in 0 to 5 555 000 C per minute 2580 4510 6 degrees or units per minute Offset to next instance Map 1 equals 50 Map 2 equals 100
237. tallers and operators P3T Armor Sealing System e NEMA 4X and IP66 offers water and dust resis tance can be cleaned and washed down indoor use only Backed up by UL 50 independent certification to NEMA 4X specification Removable cage clamp wiring connectors e Reliable wiring reduced service calls e Simplified installation Heat Cool Operation Provides application flexibility with accurate tem perature and process control Optional Features and Benefits High amperage Power Control Output Drives 15 amp resistive loads directly Reduces component count e Saves panel space and simplifies wiring e Reduces the cost of ownership Integrated PID and Limit Controller Reduces wiring time and termination complexity compared to connecting discrete products Decreases required panel space Lowers installation costs ncreases user ad equipment safety for over under temperature conditions Current Monitoring Detects heater current flow and provides alarm indication of a failed output device or heater load Serial Communications Capabilities Provides a wide range of protocol choices includ ing Modbus RTU EtherNet IP DeviceNet Modbus TCP and Profibus DP e Supports network connectivity to a PC or PLC Watlow EZ ZONE PM Integrated Controller Chapter 1 Overview Dual Channel Controller e For selected models provides two PID controllers in one space saving package Enhanced Control
238. tatus indicator shall be steady red While the device is performing its power up stances Steady Off Flashing Green Red Self test testing the module status indicator shall be flashing green red Link Status Indicator State Summary Requirement Not powered unknown link speed If the device cannot determine link speed or power is off the network status indicator shall be steady off Red Link speed 10 Mbit If the device is communicating at 10 Mbit the link LED will be red Watlow EZ ZONE PM Integrated Controller e 35 e Chapter 2 Install and Wire Warning Jn A Use National Electric NEC or other country specific standard wiring and safety practices when wiring and connecting this controller to a power source and to electrical sensors or pe ripheral devices Failure to do so may result in damage to equipment and property and or injury or loss of life Note Maximum wire size termination and torque rating 0 0507 to 3 30 mm 30 to 12 AWG single wire termination or two 1 31 mm 16 AWG e 0 8 Nm 7 0 Ib in torque Note Adjacent terminals may be labeled differently depending on the model number Note To prevent damage to the control ler do not connect wires to unused terminals Note Maintain electrical isolation between analog input 1 digital input outputs switched dc open collector outputs and process outputs to prevent ground loops N
239. th PM4 PM8 and PM9 models only Watlow EZ ZONE PM Integrated Controller e 69 e Chapter 6 Setup Page Parameter Name Description Digital Input 5 to 12 Fn Action Function Select the function that will be triggered by a true state for Digital In puts 5 through 12 L_F 4 Digital Input 5 to 12 Function Instance Select which Digital In put will be triggered by a true state Fam Limit Menu L Sd Limit 1 Sides Select which side or sides of the process value will be monitored Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only Setup Page Range Default None 61 Profile Start Step CIP Class Instance Attribute hex dec Instance 1 Ox6E 110 Map 1 Map2 5to12 1324 1564 3 Modbus Rela tive Address Param eter ID Profile Start Stop level triggered 208 Pr oF Profile Start Number edge triggered 196 P oL Profile Hold Resume level triggered 207 Pd 5 Profile Disable level triggered 206 TRU TUNE Dis able level triggered 219 oF F Control Outputs Off level triggered 90 PAn Manual Auto Mode level triggered 54 E UnE Tune edge triggered 98 idl E Idle Set Point Enable level triggered 107 FAL Force Alarm level triggered 218 BoF Alarm Outputs amp Control Loop Off level trig gered 220
240. th PM4 PM8 and PM9 models only Modbus Rela Default tive Address Instance 1 Map 2 1368 Instance 1 Map 2 1366 Instance 1 Map 2 1382 Instance 1 Map 2 1402 Instance 1 Map 2 1380 Instance 1 Map 2 1396 Instance 1 Map 2 Instance 1 Map 2 3008 Instance 1 Map 2 3018 CIP Class Instance Attribute hex dec 0x73 115 I 5 0x73 115 1 4 0x73 115 1 OxC 12 0x73 115 1 0x16 22 0x73 115 1 OxB 11 0x73 115 1 0x18 19 0x7D 125 il 0x15 21 0x7D 125 1 5 0x7D 125 1 OxA 10 a l Param eter ID 128 25021 25010 R Read W Write E EE PROM S User Set Watlow EZ ZONE PM Integrated Controller e 79 Chapter 6 Setup Page Setup Page Parameter Name Description Math 1 Scale Low This value will corre spond to Output Range Low 1 999 000 to 9 999 000 Math 1 Scale High This value will corre spond to Output Range High 1 999 000 to 9 999 000 Math 1 Range Low This value will corre spond to Input Scale Low Math 1 Range High This value will cor respond to Input Scale High Math 1 Filter Filtering smooths out the output signal of this function block Increase the time to increase fil tering 1 999 000 to 9 999 000 1 999 000 to 9 999 000 0 0 to 60 0 seconds Special Output 1 Function Set the function to match the device it will operate Off
241. th PM4 PM8 and PM9 models only Modbus Rela tive Address Instance 1 Map 1 Map2 882 1002 Offset to next instance Map 1 amp Map 2 equals 30 Instance 1 Map 1 Map2 884 1004 Offset to next instance Map 1 amp Map 2 equals 30 Instance 1 Map 1 Map2 896 1016 Offset to next instance Map 1 amp Map 2 equals 30 Instance 1 Map 1 Map2 898 1018 Offset to next instance Map 1 amp Map 2 equals 30 Instance 1 Map 1 Map2 720 840 Instance 3 Map 1 Map2 800 920 Instance 1 Map 1 Map2 722 842 Instance 3 Map 1 Map2 802 922 Instance 1 Map 1 Map2 724 844 Instance 3 Map 1 Map2 804 924 CIP Class Instance Attribute hex dec 0x6A 106 1to4 2 0x6A 106 1to4 3 0x6A 106 1to4 9 0x6A 106 0x76 118 0x76 118 lor3 0x76 118 lor3 Chapter 6 Setup Page Note Some values will be rounded off to fit in the four character display Parameter Name Description Output Process 1 or 3 Function Instance Set the instance of the function selected above Output Process 1 or 3 Scale Low Set the minimum value of the output range Output Process 1 or 3 Scale High Set the maximum value of the output range Output Process 1 or 3 Range Low Set the minimum value of the retransmit value range in process units When the retransmit source is at this value the retransmit output will be at its Scale Low value Output Process 1 or 3 Range
242. than 16 EZ ZONE PM controllers on a network maximum network length 1 200 meters 4 000 feet 1 8th unit load on EIA 485 bus All models include Standard Bus communications instance 1 Modbus RTU or Standard Bus EIA 485 Communications Slot C CC CA CB common TJR T R Wire T R to the A terminal of the EIA 485 port Wire T R to the B terminal of the EIA 485 port Wire common to the common terminal of 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 120 Q resistor across T R and T R of last controller on network Only one protocol per port is available at a time either Mod bus RTU or Standard Bus Do not connect more than 16 EZ ZONE controllers on a Stan dard Bus network Maximum number of EZ ZONE controllers on a Modbus net work is 247 maximum network length 1 200 meters 4 000 feet 1 8th unit load on EIA 485 bus Communications instance 1 PM 46 89 1 Watlow EZ ZONE PM Integrated Controller Chapter 2 Install and Wire Warning N N Use National Electric NEC or other country specific standard wiring and safety practices when wiring and connecting this controller to a power source and to electrical sensors or pe ripheral devic
243. the message will clear auto matically Control Loop 1 to 2 Closed Loop Set Point Set the set point that the controller will auto matically control to Control Loop 1 to 2 Idle Set Point Set a closed loop set point that can be trig gered by an event state Control Loop 1 to 2 Heat Proportional Band Set the PID proportional band for the heat out puts Operations Page no No 59 YES Yes 106 But oj Auto 10 P188 Manual 54 oF F Off 62 RUE o Auto 10 P184 Manual 54 50 0 to 200 096 ng No 59 Yes 106 Low Set Point to High Set Point Setup Page Low Set Point to High Set Point Setup Page 0 001 to 9 999 000 F or units 1 110 555 to 5 555 000 C Modbus Relative Ad dress Instance 1 Map1 Map2 2200 2680 Instance 2 Map1 Map2 2280 2760 Instance 1 Map1 Map2 2202 2682 Instance 2 Map1 Map2 2282 2762 Instance 1 Map1 Map2 1880 2360 Instance 2 Map1 Map2 1950 2430 Instance 1 Map1 Map2 1918 2398 Instance 2 Map1 Map2 1988 2468 Instance 1 Map1 Map2 1920 2400 Instance 2 Map1 Map2 1990 2470 Instance 1 Map1 Map2 2160 2640 Instance 2 Map1 Map2 2240 2720 Instance 1 Map1 Map2 2176 2656 Instance 2 Map1 Map2 2197 2736 Instance 1 Map1 Map2 1890 2370 Instance 2 Map1 Map2 1960 2440 Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only
244. the heater Systems with long lag times be tween the energy source heater steam etc and the measured process value cannot be controlled accurately or efficiently with a single control loop because a lot of energy can build up before a response is detected This can cause the system to overshoot the set point which could damage the heater product or heat transfer me Math Function Cascade i12 c rwr Eum ee ee ee 9 1 Outer Loop es Kop y Sl S 5 A 2 i o 4 AN Cy ap Vo KCN i 1 Uiig tip h o D PD Kip 1 i 72 O n 95 n 95 By 1 1 Li MN PT ttt 1 Process Sensor Power Source A 1 Analog Input 1 SourceA Closed Loop SP Source B Control Loop 1 dio 4 Source E Output i I I I I 1 1 I I I I I i Inner Loop Sen 1 100 Range Low amp Ore 1 1 100 Range High K Outputn LI I 1 Remote SP 0 to 100 Heat i Source B Heat Power i Analog Input 2 Source A Cool Power i Energy Source Control Loop 2 0 to 100 Cool 1 Output n LI dium such as a heat transfer fluid When function is set for Process or Deviation Scale the Math Function output equals Source A scaled by Range Low and Range High when Source E is False Source E disables cascade when True and Math Func tion output equals Control Loop 1 Closed Loop Set Point Control Loop 1 will control Analog Input 1 to Closed Loop
245. tical WATLOW Communications Activity EZ ZONE Flashes when another device is communicating with this control ler Up and Down Keys O O In the Home Page adjusts the set point in the lower display In other pages changes the upper dis play to a higher or lower value or changes a parameter selection Infinity Key Press to back up one level or press and hold for two seconds to return to the Home Page From the Home Page clears alarms and errors if clearable Watlow EZ ZONE PM Integrated Controller e 40 e Chapter 3 Keys and Displays Responding to a Displayed Message Attention Codes An active message see Home Page for listing will cause the display to toggle between the normal set tings and the active message in the upper display and Attention in the lower display Your response will depend on the message and the controller settings Some messages such as Ramp ing and Tuning indicate that a process is underway If the message was generated by a latched alarm or limit condition the message can be cleared when the condition no longer exists by simply pushing the In finity key or alternatively by following the steps below If an alarm has silencing enabled it can also be silenced Push the Advance Key to display Ignore in the upper display and the message source such as Limit High in the lower display Use the Up O and Down Q keys to scroll through possible responses
246. tions 1 GE d Standard Bus 1286 Modbus Instance 1 0x96 150 Protocol P 1o d Modbus RTU 1057 Map 1 Map2 1 Set the protocol of this 2492 2972 7 m um oo controller to the protocol that this network is us ing _ AdS Communications 1 Instance 1 0x96 150 Ad S Address Standard Bus Map1 Map2 1 Set the network address 2480 2960 1 of this controller Each device on the network must have a unique ad dress The Zone Display on the front panel will display this number Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Available with PM4 PM8 and PM9 models only Watlow EZ ZONE PM Integrated Controller e 84 e Chapter 6 Setup Page Parameter Name Description Communications 1 or 2 Address Modbus Set the network address of this controller Each device on the network must have a unique ad dress Communications 1 or 2 Baud Rate Modbus Set the speed of this con troller s communications to match the speed of the serial network Communications Parity Modbus 1 or 2 Set the parity of this con troller to match the par ity of the serial network Communications 1 Display Units Select whether this com munications channel will display in Celsius or Fahrenheit Note Applies to Modbus only Communications 1 or 2 Modbus Word Order Select the word order of the two 16 bit words in the floating poi
247. tore Set 84 100 User Save Set 84 100 User Tune Aggressiveness 100 Using EZ ZONE Configurator Software 115 using the software 112 V Valve Travel Time 61 variable time base 108 W Wait Event 1 and 2 92 93 Wait For Process Instance 92 Wait For Time 91 weight 130 wiring digital input or output 5 25 26 digital input or output 6 26 EIA 232 485 Modbus RTU communications 34 high power 25 input 1 process 27 input 1 RTD 26 input 1 thermocouple 26 input 2 current transformer 27 input 2 thermocouple 27 low power 25 Modbus RTU or standard bus EIA 485 communications 33 output 1 mechanical relay form C 30 output 1 switched dc open collector 28 output 1 universal process 30 output 2 mechanical relay form A 32 output 2 no arc relay form A 32 output 2 solid state relay form A 32 output 2 switched DC open collector 31 standard bus EIA 485 communications 33 X Y Z zone display 40 Watlow EZ ZONE PM Integrated Controller 136 Chapter 11 Appendix Declaration of Conformity Series EZ ZONE PM C C WATLOW an ISO 9001 approved facility since 1996 1241 Bundy Blvd Winona MN 55987 USA Declares that the following product Designation Series EZ ZONE PM Panel Mount Model Numbers PM 3 6 8 9 or 4 Any Letter or number 1 2 3 or 4 A C E F or K A C H J or K Any letter or number Any letter or number A C E F or K A C H J or K Any three letters or numbers Classificat
248. tput is activated based on devia tion value and user selected value LPr i LPre Loop Reversed Error Controller is ramping to new set point Ramping 1 Ramping 2 EUN I Autotuning 1 Controller is autotuning the EUN Autotuning 2 control loop No heat cool action Output does not activate load No display indication or LED illumination No Display Cannot establish serial com munications with the con troller No Serial Communi cation Watlow EZ ZONE PM Integrated Controller Temperature is greater than limit set point Limit outputs latch and require reset ncorrect alarm set point Setting of Open Loop Detect Time incorrect Setting of Open Loop Detect Devia tion incorrect Thermal loop is open Open Loop Detect function not re quired but activated Setting of Open Loop Detect Time incorrect Setting of Open Loop Detect Devia tion incorrect Output programmed for incorrect function Thermocouple sensor wired in reverse polarity Ramping feature is activated User started the autotune function Digital input is set to start autotune Output function is incorrectly set Control mode is incorrectly set Output is incorrectly wired Load power or fuse is open Control set point is incorrect ncorrect controller model for applica tion Power to controller is off Fuse open Breaker tripped Safety interlock switch open Separate system lim
249. tput regulates how the pro cess is cooled while another output switches the com pressor on and off The compressor will not turn on until the output power exceeds the Compressor On Power for a time longer than the Compressor On Delay The compressor will not turn off until the out put power exceeds the Compressor Off Power for a time longer than the Compressor Off Delay Power Heat 100 295 Compressor 2 P Off Power 0 DES Compressor On Power Cool 100 Time In Seconds On Compressor On Delay 45 Seconds Compressor Pr6880T ott Compressor Off Delay 20 Seconds Differential Control The PM PM4 8 9 can be configured for Differential Control with enhanced firmware After configuring the appropriate inputs and their associated internal functions Differential Control allows the PM to drive an output based on the difference between those ana log inputs ambient air temperature glass temperature sensor d ERAI SW Ou glass _heater Ratio Control The PM PM4 8 9 can be configured for Ratio control with enhanced firmware especially useful in applica tions that mix materials Ratio control is commonly used to ensure that two or more flows are kept at the same ratio even if the flows are changing Applications of ratio control e Blending two or more flows to produce a mixture with specified composition e Blending two or more flows to
250. ts more than one instance to return to the Home Page Note Some of these menus and parameters may not appear depending on the controller s options See model number information in the Appendix for more information If there is only one instance of a menu no sub menus will appear Note Some of the listed parameters may not be visible Parameter visibility is dependent upon controller part number CUSE IP Actual Address Part 4 Custom Setup Menu IP Actual Address Part 5 to IP Actual Address Part 6 CUSE Custom Setup CCAD PA Parameter FCt 9 Calibration Menu d Instance ID C lto CAL Calibration Security Setting Menu P1 Electrical Measurement Security Setting Electrical Input Offset LoCo Operations Page Electrical Input Slope LoCP Profiling Page Electrical Output Offset PB85SE Password Enabled EL 5 Electrical Output Slope rLoC Read Lock Lol Write Security LoL Locked Access Level coll Rolling Password PR S u User Password PASA Administrator Password C r3 r7 rro tc e Un c urity Setting Menu Public Key Password F3 o a m o 7o Un WN Qo m Fr 9 to y Diagnostics Menu d A 9 Diagnostics Pa Part Number r Eu Firmware Revision bL d Software Build Number Serial Number Date of Manufacture IP Actual Address Mode IP Actual Address Part 1 IP Actual Address Part 2 IP Actual Address Part 3 3
251. ttp www odva org Profibus DP To accomodate for Profibus DP addressing the follow ing menus contain a column identified as Profibus Index Data types used in conjunction with Profibus DP can be found in the table below The Profibus communications instance will always be instance 2 Unsigned 16 bit Integer Signed 16 bit Integer Signed 32 bit Integer REAL Float IEEE 754 32 bit CHAR ASCII 8 bits per character BYTE To learn more about the Profibus DP protocol point your browser to http www profibus org Watlow EZ ZONE PM Integrated Controller 46 e Chapter 4 Home Page Chapter 5 Operations Page Navigating the Operations Page To go to the Operations Page from the Home Page the Up or Down Q key to select and then press press both the Up O and Down Q keys for three sec the Advance Key 5 to enter onds will appear in the upper display and Press the Up O or Down O key to move through will appear in the lower display available menu prompts Press the Up O or Down Q key to view available Press the Infinity Key to move backwards menus On the following pages top level menus are through the levels parameter to submenu sub identified with a yellow background color menu to menu menu to Home Page Press the Advance Key to enter the menu of Press and hold the Infinity Key for two seconds choice to return to the Home Page e If a submenu exists more than one instance pres
252. u recognize when this configuration file pe be used Controller PMGRACJ ALEJAAA 00 My Computer On WINLL3A2343 File name My Network Saveastype EZ ZONE Configuration Files wcf When saving the configuration note the location where the file will be placed Saved in and enter the file name File name as well The default path for saved files follows Program Files Watlow EZ ZONE CONFIGURA TOR Saved Configurations The user can save the file to any folder of choice Watlow EZ ZONE PM Integrated Controller e 117 e Chapter 9 Features Chapter 10 Applications With the release of version 7 00 firmware several new functions were added to the EZ ZONE PM family of controls This chapter contains some sample applica tions using these new functions Example 1 Single Loop Control Requirements One input is required and at least one output adjusts the controlled part of the process Overview Controls one process value to a user entered Closed Loop Set Point based on an control algorithm Control loop 1 will control Analog Input 1 to Closed Single Loop Control 1 O 1 1 Zog Coo Sey 1 1 EN 1 1 Weg eg Xing 1 m Outputn f ote 100 f Heat i Analog Input 1 Source A Heat Powe id i Cool Power un i 00 i Control Loop 1 0 to 100 l I I Output n Rei eee sy es a E E ee eee ee Loop Set Point 1 Example 2
253. un Tuning 1 or 2 cP i Ramping 1 or 2 LPo i Loop Open Error 1 or 2 LPr i Loop Reversed Error 1 or 2 an alarm or er Low 1 to 4 ror message is AL h I ALAC ALAJ ALARY Alarm active High 1 to 4 Watlow EZ ZONE PM Integrated Controller e dX Chapter 3 Keys and Displays Navigating the EZ ZONE PM Integrated Controller EZ ZONE EZ ZONE o o 3 SEE Factory Page from Home Page Press both the Advance and Infinity keys for six seconds Watlow EZ ZONE PM Integrated Controller e 42 e Chapter 3 Keys and Displays Chapter 4 Home Page Default Home Page Parameters Watlow s patented user defined menu system im proves operational efficiency The user defined Home Page provides you with a shortcut to monitor or change the parameter values that you use most of ten The default Home Page is shown on the follow ing page When a parameter normally located in the Setup Page or Operations Page is placed in the Home Page it is accessible through both If you change a parameter in the Home Page it is automatically changed in its original page If you change a param eter in its original page it is automatically changed in the Home Page The Attention parameter appears only if there is an active message An example of an active message could be a Current Error C I or it could be for information only like Autotune taking place Use the Advance Key to step through the other paramete
254. uplex or event Analog Input 1 none Thermocouple RTD 1000 Input Sensor 1kQ Thermistor 5kO 10kQ 20kQ 40kQ Process V mV mA or 1k Potentiometer Optional Ramp Soak max 4 files 40 steps Output 2 none 15A NO ARC switched dc off heat cool Slots A 5A mechanical relay form A or alarmjoreveni Optional 0 5A SSR form A X c Output 3 PID ontroller none switched dc open collector 5A off heat cool Limit or mechanical relay form C process BIST Current Trans y By duplex or event Analog Input 2 V mA or 0 5A SSR form A Lee fs Ua former Sense none CT Thermocouple RTD 100 CT m QO 1kQ Thermistor 5kO 10kO 20kQ 40kQ Process V mV mA or 1k Potentiometer Output 4 none 15A NO ARC switched dc off heat cool _ Slots B 5A mechanical relay form A or alarm eventiarlimit Optional 0 5A SSR form A If limit this output must be limit None 6 Digital Limit reset Inputs QUEUE Idle set point Tem off heat cool Tune Digital Input or Output 7 12 optional Digital Output or Input 7 12 alarm or event Alarm clear request Programmable Functions optional none switched dc Silence alarm Manual auto mode Slot D Control mode Optional Remote set point Optional enable Lock keypad
255. use as Temperature Indicating Regulating Equipment per CSA C22 2 No 24 See www csa inter national org Unit has been reviewed and ap proved by ODVA for compliance with DeviceNet communications protocol See www odva org Unit has been reviewed and ap proved by ODVA for compliance with Ethernet IP communications protocol See www odva org Warranty The EZ ZONE PM is manufactured by ISO 9001 registered processes and is backed by a three year warranty to the first purchaser for use provid ing that the units have not been misapplied Since Watlow has no control over their use and some times misuse we cannot guarantee against failure Watlow s obligations hereunder at Watlow s option are limited to replacement repair or refund of pur chase price and 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 purchaser must use Watlow parts to maintain all listed ratings Technical Assistance If you encounter a problem with your Watlow control ler review your configuration information to verify that your selections are consistent with your applica tion inputs outputs alarms limits etc If the prob lem persists you can get technical assistance from your local Watlow representative see back cover by e mailing your questions to wintechsupport watlow com or by dialing 1 507 4
256. ut or Input 5 amp 6 optional none switched dc off heat cool alarm or event i Number of inputs and outputs and various combinations of the same will vary depending upon part number see ordering matrix for more detail LEDs Dupuis VELIE channel 122 Indicates Zone Address amp Channel 3 4 Indicates I O gt 5 6 Status 7 8 Watlow EZ ZONE PM Integrated Controller e 45 e Chapter 1 Overview YN CE joy Chapter 2 Install and Wire Dimensions 1 16 DIN PM6 15 8 mm 0 62 in 101 6 mm 4 00 in _ IP I ilo B sijal rie aa 2 C ej h Oo e Ciao Side TE ry C 5 Cc 5 Z ig C y gt az ri c gt gt 0 j 51 2 mm t gt c 5 fm _ 2 02 in C D F 2 C 2 2 By a fp el J Top 2 10 in 53 3 mm 2 10 in E m i L J 53 3 mm x x E ur ms ULT eL aT vs LI ur pm wl 1 NN nO T T1 s TT sz CLL art e Iw 1 16 DIN PM6 Recommended Panel Spacing 45 2 mm 1 78 in Back 45 2 mm 1 78 in panel thickness 1 53 to 9 52 mm 0 060 to 0 375
257. ut Menu Assign the function of switching to a remote set point to the EZ Key with Digital Input Function F a Setup Page Function Key Menu Ten Point Linearization The linearization function allows a user to re linear ize a value read from an analog input There are 10 data points used to compensate for differences be tween the sensor value read input point and the de sired value output point Multiple data points enable compensation for non linear differences between the sensor readings and target process values over the thermal or process system operating range Sensor reading differences can be caused by sensor place ment tolerances an inaccurate sensor or lead resis tance The user specifies the unit of measurement and then each data point by entering an input point value and a corresponding output point value Each data point must be incrementally higher than the previous point The linerization function will interpolate data points linearly in between specified data points A Jee Input Point 10 9 a sc Reading fom Sensor D Vu without Linearization aw g Actual Value ga 3 ae 2 i P S Saa cp E 2 d Offset Zone E Input Point 1 i o E Reading from Sensor with Linearization Displayed Value Output Point 1 No Offset Time Duplex Certain systems require that a single process output control both heating and cooling outputs An EZ ZONE PM controller with a process out
258. ve Ad dress Instance 1 Map1 Map2 1160 1400 Instance 1 Map1 Map2 1124 1364 Instance 1 Map1 Map2 1160 1400 Instance 1 Map 2 Instance 1 Map 2 Instance 1 Map1 Map2 3038 Instance 1 Map 1 Map2 3044 Instance 1 Map 2 Instance 1 Map 2 CIP Class Instance Attribute hex dec 0x73 115 1 2 0x73 115 1 3 0x73 115 1 21 0x7D 125 1 0x10 16 0x7D 125 1 0x11 17 0x7D 125 1 0x14 20 0x7D 125 1 0x17 23 Profibus Index 0x7D 125 1 0x16 22 0x7D 125 1 Ox1D 29 Watlow EZ ZONE PM Integrated Controller 56 Chapter 5 Operations Page Parameter name Description Special Output Func tion 1 Source Value 1 View the value of Source A which is connected to Loop Power 1 Special Output Func tion 1 Source Value 2 View the value of Source B which is connected to Loop Power 2 Special Output Func tion 1 Output Value 1 View the value of this function s Output 1 Special Output Func tion 1 Output Value 2 View the value of this function s Output 2 Special Output Func tion 1 Output Error 1 View reported cause for output malfunction Special Output Func tion 1 Output Error 2 View reported cause for output malfunction Operations Page 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C 1 999 000 to 9 999 000 F o
259. ves with it Select the alarm type with Type Setup Page Alarm Menu Alarm Set Points The alarm high set point defines the process value or temperature that will trigger a high side alarm The alarm low set point defines the temperature that will trigger a low side alarm For deviation alarms a negative set point represents a value below closed loop set point positive set point represents a value above closed loop set point View or change alarm set points with Low Set Point and High Set Point Operations Page Alarm Menu Alarm Hysteresis An alarm state is triggered when the process 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 zone inside each alarm set point This zone is defined by adding the hysteresis value to the alarm low set point or subtracting the hysteresis value from the alarm high set point View or change alarm hysteresis with Hysteresis Setup Page Alarm Menu High Side Alarm Range Alarm High Set Point y Alarm Hysteresis Normal Operating Range Temperature 4 Alarm Hysteresis Alarm Low Set Point Low Side Alarm Range Be Time Alarm Set Points and Hysteresis Watlow EZ ZONE PM Integrated Controller 110 Chapter 9 Features Alarm Latching A latched alarm will remain active after the alarm condition has pas
260. xed Address Part 5 Set the IP address of this module Each device on the network must have a unique address Communications 2 0 to 255 IP Fixed Subnet Part 5 Set the IP subnet mask for this module Instance gS Attribute Index eienn hex dec 17017 17018 17019 17025 17026 17027 Watlow EZ ZONE PM Integrated Controller e 87 Chapter 6 Setup Page Parameter Name Description Communications 2 Setup Page CIP Modbus Rela Class Parum Range Default tive Instance ter ID Address Attribute Index hex dec 0 to 255 17028 Fixed IP Gateway Part 3 Communications 2 0 to 255 Fixed IP Gateway Part 4 0 to 255 Fixed IP Gateway Part 5 0 to 255 Fixed IP Gateway Part 6 Communications 2 Communications 2 YES Yes 106 no No 59 Communications 2 Modbus TCP Enable Activate Modbus TCP C 9E S Yes 106 no No 59 Communications 2 EtherNet IP Enable Activate Ethernet IP Communications 2 Implicit Output Assem bly Size Communications 2 Implicit Input Assem bly Size Communications 2 Display Units Select which scale to use for temperature passed over communications port 2 F 30 C C 15 Communications 2 Data Map If set to 1 the control will use PM legacy mapping If set to 2 the control will use new mapping to accommodate new func tions Yes 106 No 59 Communications 2 Non volatile Save
261. y Working Default Pointers Addresses Default Pointers Addresses Registers 40 amp 41 Registers 220 amp 221 Pointer 1 1880 amp 1881 Loop Control Mode Registers 200 amp 201 Registers 60 amp 61 Pointer 11 1632 amp 1633 Alarm 4 Low Set Point Value of Pointer 1 Value of Pointer 11 Registers 202 amp 203 Registers 62 amp 63 Registers 222 amp 223 Pointer 12 2540 amp 2541 Profile Action Request Registers 42 amp 43 Pointer 2 2160 amp 2161 Closed Loop Set Point Value of Pointer 2 Value of Pointer 12 Registers 204 amp 205 7 Registers 64 amp 65 Registers 224 amp 225 Pointer 13 2520 amp 2521 Profile Start Registers 44 amp 45 Pointer 3 2162 amp 2163 Value of Pointer 13 Open Loop Set Point Value of Pointer 3 Registers 206 amp 207 Registers 66 amp 67 Registers 226 amp 227 Pointer 14 1890 amp 1891 Heat Proportional Band Registers 46 amp 47 Value of Pointer 14 SSS Registers 228 amp 229 Pointer 4 1480 amp 1481 Alarm 1 High Set Point Value of Pointer 4 Registers 68 amp 69 Registers 48 amp 49 Registers 208 amp 209 Pointer 15 1892 amp 1893 Cool Proportional Band Pointer 5 1482 amp 1483 Alarm 1 Low Set Point Value
262. y change these you will need to program the correct settings back into the controller to return the equipment to operational condition After you program the controller and verify prop er operation use User Save Set Setup Page Global Menu to save the settings into either of two files in a special section of memory If the settings in the controller are altered and you want to return the controller to the saved values use User Restore Set US c c Setup Page Global Menu to recall one of the saved settings A digital input or the Function Key can also be configured to restore parameters Note Only perform the above procedure when you are sure that all the correct settings are programmed into the controller Saving the settings overwrites any previously saved collection of settings Be sure to document all the controller settings Tuning the PID Parameters Autotuning When an autotune is performed on the EZ ZONE PM the set point is used to calculate the tuning set point For example if the active set point is 200 and Autotune Set Point Operations Page Loop Menu is 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 controllers causes the autotune function to restart where with the EZ ZONE PM changing the set point after an autotune has been started has no af fect

PM temperature & process controller user`s manual Rev. J 11.23 MB

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PM temperature &amp; process controller user`s manual Rev. J 11.23 MB

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PM temperature & process controller user`s manual Rev. J 11.23 MB